high differential pressure pem-based hydrogen generation for backup power and home fueling by: e....

High Differential Pressure PEM-Based Hydrogen Generation for Backup Power

and Home Fueling

By:

E. Anderson, S. Szymanski, and L. Dalton

NHA Hydrogen Conference & Expo Long Beach, CA

4 May 2010

NHA Hydrogen Conference & Expo 2010NHA Hydrogen Conference & Expo 2010

Presentation Outline

• Introduction to Proton

• Military Focus Areas in Contract Research

• Backup Power – “Silent Camp”

• Home Fueling

• Future Work

2

NHA Hydrogen Conference & Expo 2010

Proton Energy Systems• Manufacturer of Proton Exchange Membrane

(PEM) hydrogen generation products using electrolysis

• Founded in 1996

• Headquarters in Wallingford, Connecticut.

• ISO 9001:2008 registered

• Over 1,200 systems operating in 60 different countries.

3


PEM Cell Stacks Complete Systems

Proton Capabilities

• Complete product manufacturing & testing• Containerization and hydrogen storage solutions• Integration of electrolysis into RFC systems• Turnkey product installation• World-wide sales and service

Storage Solutions

Power Plants LaboratoriesHeat Treating Semiconductors Government

4


S Series

H Series

StableFlow

Hydrogen ControlSystems

TM

HOGEN Hydrogen GeneratorsTM

GC

Hydrogen ProductsCommercial Products Future Products

Fueling

Backup PowerRenewable EnergyStorage

Lab Gas Generators

5


R&D Focus and Agency Partners

Military Markets

• Submarine life support• Unmanned vehicles

– UAV– UUV

• Silent Camp– Back up power

• Military fueling needs– Fork lifts– Light duty vehicles

Commercial Markets

• Industrial• Vehicle fueling• Telecomm backup• Renewable energy storage

6


Forward Operating Bases:Problem Definition

• Logistics of moving fuel can limit combat OPS

• Operational issues with gen-sets operating at low capacity

• Renewable power: How to make it dispatchable and reliable?

• Low audible and thermal signatures needed at times

• Expeditionary forces have additional mobile requirements

7


Backup Power System Concept Using High Pressure Electrolyzer

8


CERL Silent Camp® Phase I Program

“Regenerative Fuel Cell” integratedinto CERL’s Silent Camp system concept

Tactical Generator

Power Management

High Pressure Electrolyzer Module

HydrogenStorage

Fuel Cell

General Camp Loads

Critical / Silent Loads

Electrical Electrical

ElectricalElectrical

Hydrogen

Electrical

Renewable Power

Electrical

• Based on low pressure S-series design

• 10 cell stack, 0.1 ft2 active area

• 10 SCFH (0.5 kg/day) hydrogen production rate

• 2,200 psig hydrogen pressure generation

9


Design &Development

Commercial Product

High Pressure Engineering Demo

Design &Development

Commercial Product

High Pressure Engineering Demo

CERL Silent Camp® Phase I Program

10

• Army/CERL installation for Silent Camp energy storage demo

• >1 year field data achieved


• Demonstrate 40 SCFH (2+ kg/day)• H2 Generation pressure of 2400 psig• Conduct cost reduction activities for

system design– Phase separation / drying– Power conversion

• Develop, build & test outdoor system for electrolyzer with cost reductions

• Integrate diesel gen-set, hydrogen storage, and fuel cell for system demo

• Follow-on phase:Integrate with renewables and ruggedize system

CERL Silent Camp® Phase 2 Program

11

NHA Hydrogen Conference & Expo 2010NHA Hydrogen Conference & Expo 2010 12

“Home Fueling” Product Requirements

• Small-scale generation• Safe system, easy to operate• ≥ 5,000 psi (350 bar) dispensing pressure• Potential integration with renewables• Simple, low cost• Small footprint• Applicable Codes & Standards

– ISO 22734-2, “Hydrogen Generators Using Water Electrolysis Process – Part 2: Residential Applications”


Proton’s System Approach to Small Distributed Fueling Applications

• High differential pressure, PEM electrolysis• Ambient pressure O2

• 1 to 2 kilograms per day production• Some storage needed for “reasonable” fill time

(e.g. not “fast fill”)• Leverage commercial platform and demonstrated high

pressure capability– 2,400 psi capability enabled by Silent Camp program

• Integrate with commercial boost compressor and modest storage for complete 5,000/10,000 psi fills.

• Further develop electrolysis capability to displace some/all mechanical compression


Proton’s Home Fueling Pathways

• H2 generation/compression

Current HOGEN® HP Electrolyzer

2,400 psi 2 kg/day Indoor

Next Gen HP Electrolyzer

2,400 psi 2 kg/day

Outdoor rated

FutureHP Electrolyzer

5,000 psi1-2 kg/day

No MechanicalCompression

Near TermHP Electrolyzer+ Compressor

10,000 psi2 kg/day

UAV Fueling5,000 psi<1 kg/day

Timeline 2009 2010 2011


Small Distributed Fueling System Concept

High pressure electrolyzerOutdoor rated

Single stage boostcompressor

Medium PressureStorage(2,400 psi)

Simpledispensinginterface

Packaged system boundary Vehicle Fill5 kg at up to

10,000 psi

15


UAV Fueling Concept

• H2 Production Rate: ≤ 94 g/hr

• Generation pressure: 10,000 psi

• H2 storage: 1.3 kg

• Service Rating: 14 KVA• Voltage: 240 VAC

16

3.68

4.01

3.33

HPEM

HP 4

0 O

UT

DO

OR

EL

ECT

RO

LY

SIS

UN

IT

COM PRESSOR

1.02

4.69

H 2 STORAGE

All dimensions in feet

6.43

4.69

HPEM HP 40OUTDOOR

2.50


COM PRESSOR

H 2 STORAGE 3.00

3.68

4.01

3.33

HPEM

HP 4

0 O

UT

DO

OR

EL

ECT

RO

LY

SIS

UN

IT

COM PRESSOR

1.02

4.69

H 2 STORAGE


6.43

4.69

HPEM HP 40OUTDOOR

2.50


COM PRESSOR

H 2 STORAGE 3.00

Conceptual Layout of High Pressure Electrolysis (Side View and Top

View) (Chiller and Dispenser not shown)


Home Fueling Trade Study Objectives

• Define critical requirements for PEM Electrolysis Home Fueling System – Technical

• Define hydrogen production capacity for a recharge time relevant to end-user

• Estimate electrical service and physical size

– Capital and operating cost– Codes and standards– Product safety– Operation and maintenance


5,000 psi High Pressure PEM System

H2 Product Output

O2 VENT

Water Pump

ElectrolyzerCell Stack

PressureRegulator

Oxygen/Water Separator

High PressureHydrogen/Water

Separator

Drain O

Vent

Water Input

O

DC Source

• Based on 2,400 psi platform

• Simple Balance-of-Plant• Higher differential

pressure stack development initiated

• Timeline to be driven by market need


Fueling Capacity - Scenarios

Scenarios: Weekly Driving Distance & Available Recharge Time

0

100

200

300

400

500

600

700

800

E F G H I J

Scenarios

Dri

vin

g D

ista

nce

(m

i)

0

20

40

60

80

100

120

Rec

har

ge

Tim

e (h

)

Single Vehicle Multi-Vehicle Single Vehicle Multi-Vehicle

19


Fueling Capacity - Estimates

Electrolysis-Based Home Fueler Hydrogen Generation Rate

0

2

4

6

8

10

12

14

50 60 70 80 90 100

Hydrogen Vehicle MPGGE

Gen

erat

ion

Rat

e (k

g/w

k)

3V

2V Hi

2V Lo

1V Hi

1V Med

1V Lo

20

Electrolysis-Based Home Fueler Electrical Service Rating

0

5

10

15

20

25

30

35

40

45

50 60 70 80 90 100

Hydrogen Vehicle MPGGE

Ele

ctri

cal

Ser

vice

(A

@ 2

20 V

AC

)

3V

2V Hi

2V Lo

1V Hi

1V Med

1V Lo


Conceptual Design


Summary & Future Work

• Commercial markets driving business success and sustainability

• Government support a key product area as well as a critical component to technology development

• Silent Camp pushing RFC Backup Power Concept• Next steps will renewables and ruggedness• High differential pressure enabling small fueling

opportunities for government and commercial markets• Continuing to push generation pressure to offset

mechanical compression

22


Thank you!

Contact Info:

Everett Anderson

[email protected]

www.protonenergy.com

Tel 203/678-2105

Acknowledgements:

Co-authors

Sponsors

23

high differential pressure pem-based hydrogen generation for backup power and home fueling by: e....

Documents

systemcerl silent camp

system demofollow

kgdayh2 generation pressure

backup power system

high pressure electrolyzer

low capacityrenewable

test outdoor system

operating bases