presented: peter bouwman 12 october 2015 - phaedrus · presented: peter bouwman – 12th october...

PHAEDRUS: High Pressure Hydrogen All Electrochemical Decentralized Refueling Station

presented: Peter Bouwman – 12th October 2015

Website: www.phaedrus-project.eu Project grant No: 303418

Theme: [SP1-JTI-FCH.2011.1.8]

http://www.phaedrus-project.eu/




Partners in PHAEDRUS

HyET B.V. (coordinator)

ITM Power

H2 Logic A/S

Raufoss Fuel Systems AS

Daimler AG

Shell Global Solutions International B.V.

Bundesanstalt für Materialforschung und – prüfung (BAM)

Armines

Hochschule Esslingen

Uniresearch

12/10/2015


Hydrogen Refueling Stations (HRS)

12/10/2015

Status Quo: Hydrogen Refueling station are present, However…

We need To Do more, because:

• Limited Number of stations Install more HRS,

• Low Utilisation scalable to demand,

• No Standard configuration optimise configuration using

• Capital Intensive latest technologies, including

• OPEX are significant on-site H2 production

• Trucking in hydrogen is not always a long term solution


Optimising Configuration HRS

12/10/2015


Optimising Configuration HRS

12/10/2015

Scalable Design

Design for

200 kg/day

and…

Validate at

5 kg/day


Assumed HRS Fuelling Cycle at 200 kg/day

12/10/2015


PHAEDRUS Objective

12/10/2015

Objective of PHAEDRUS is to Research and Develop the feasibility of a scalable HRS station using new technology:

• Electrolyser: APEM and PEM

higher pressure operation & system design

• Compression: Electrochemical Hydrogen Compression Isothermic compression principle, No moving parts

• Dispensing: Cost Reduction Effective Pre-cooling, Compact system, Control strategy

• Hydrogen cost: Production, Compression, Refuelling 10€/kg

Delivering capacity matching demand

• Safety and compliance: SAE J2601, SAE 2799, PED, CEN/ISO


2D Layout of HRS Components

12/10/2015

Schematic representation how components fit together


Technical approach to electrolyser development

12/10/2015

Components

• Cell plates

• Catalysts structures

• Durability

System

• Balance of plant

• Control system

• Compliance

Prototype

• Full size cells

• High pressure

• Integration

Vision

• Fully integrated

• Green hydrogen

• Low cost


Technical approach to electrolyser development

12/10/2015

• Electrolysis enables on-site, green H2 production

• achieved a significant jump in terms of output H2 pressure and current density

• stack and electrolyser technology is modular, thus able to grow with demand as the project required

• The materials and processes enable manufacturability and cost effective offering


Principle of Electrochemical Compression

12/10/2015

Electrons move Protons Anode: H2 → 2 H+ + 2 e-

Cathode: 2 H+ + 2 e- → H2 pump rate: 2 e- ~ H2


ARMINES: Catalyst Development

12

Synthesis and characterizations of new eletrocatalysts based on platinated

carbon aerogels

Various textures of carbon aerogels and various methods of nanoparticles deposit

of platinum have been evaluated ex-situ and in-situ in MEAs

After grinding

Carbon aerogel

Micronic particles constituted of

nanostructured carbon aerogel

After Pt

deposit

Selection of the

best texture and

Pt deposition

method

200

nm

12/10/2015


Pressure Capability with bespoke membrane

Bespoke membrane tested on a small scale cell up to a pressure of 900 bar

900 bar pressure

achieved here

1000 bar record


451 bar

demonstrated

here, pressure

ratio > 1:40

Stack Testing in Progress

Stack is tested with increasing

output pressure to 451 bar


Stack is tested with increasing

output pressure on cathode

10 bar anode

up to 150 bar

output tested

here before

validation at ITM

Validation testing at HyET Laboratory

12/10/2015


5 kg/day MoHyTO vs. 200 kg/day Container

12/10/2015


Approach for development of dispenser

12/10/2015

• Compact design of skid

• Footprint reduction

• Refueling protocol applied in H2Station® products

• Expected continued R&D and product maturation

• EHC compressor follows production rate capacity

• Buffer tank configuration to match optimum situation


Multiple HRS configurations evaluated

12/10/2015

Base Compressor

Medium Pressure Storage

(up to 50 MPa)

High Pressure Storage

(up to 100 MPa)

Dispenser


(up to 100 MPa)

Base Compressor

On-site Electrolyser H2 supply up to 8 MPa

HRS 1 HRS 5 HRS 6

Base Compressor


(up to 100 MPa)

Booster Compressor


(up to 50 MPa)

Dispenser

18

HRS 6 was

recommended in order

to have a higher

hydrogen flow rate and

use standard

configuration

Traditional Mechanical Compressor


Sizing and Modelling in Matlab Simulink

12/10/2015

Influence of sizing was assessed by

• Medium pressure storage tank size:

• High pressure storage tank size :

19

EHC Base Compressor


(50 MPa)

Piston Booster Compressor


(100MPa)

Dispenser

1st step

dispensing

<50 MPa

2nd step

dispensing

> 50 MPa

Case A:

direct

refill

Case 1: 7.5 m3

Case 2: 10 m3

Case 3: 14.2 m3

Case B: (1 car) ~1 m3

Case C: (2 cars) ~1.5 m3

Case A: 0 m3



12/10/2015




20

EHC Base Compressor


(50 MPa)



(100MPa)

Dispenser

1st step

dispensing

<50 MPa

2nd step

dispensing

> 50 MPa

Case A:

direct

refill

Case 1: 7.5 m3

Case 2: 10 m3

Case 3: 14.2 m3



Case A: (none) 0 m3

Lowest CAPEX (1A)



12/10/2015




21

EHC Base Compressor


(50 MPa)



(100MPa)

Dispenser

1st step

dispensing

<50 MPa

2nd step

dispensing

> 50 MPa

Case A:

direct

refill

Case 1: 7.5 m3

Case 2: 10 m3

Case 3: 14.2 m3



Case A: (none) 0 m3

Lowest OPEX (3C)



12/10/2015




22

EHC Base Compressor


(50 MPa)



(100MPa)

Dispenser

1st step

dispensing

<50 MPa

2nd step

dispensing

> 50 MPa

Case A:

direct

refill

Case 1: 7.5 m3

Case 2: 10 m3

Case 3: 14.2 m3



Case A: (none) 0 m3

Lowest Combined

cost CAPEX + OPEX

(2C)


Relative Cost Distribution between Components

12/10/2015 23

EHC Base Compressor


(50 MPa)



(100MPa)

Dispenser

1st step

dispensing

<50 MPa

2nd step

dispensing

> 50 MPa

alternative

2nd step


Relative Cost Distribution between Components

CAPEX Cost per daily dispensed H2

around 10,000 €/kg is feasible! PHAEDRUS target set between 5 - 12 k€/kg, meeting specifications.

12.10.2015 24


Breakdown of Hydrogen Provision Cost Structure

12/10/2015

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

Hyd

rog

en

pro

vis

ion

co

sts

[€

/ k

g H

2]

Share of hydrogen provision costs 2015 [€/ kg H2]at maximum electricity density and 8,760 operating hours (total: 13.67 €/ kg H2)

BoP

HP storage

Booster compressor

MP storage

Base compressor

Electrolyser



12/10/2015

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

Hyd

rog

en

pro

vis

ion

co

sts

[€

/ k

g H

2]


BoP

HP storage

Booster compressor

MP storage

Base compressor

Electrolyser

intelligent use of the electrolyser

saves largest amount of OPEX

by exploiting optimal electricity tariffs

and balancing payments



12/10/2015

0.00

2.00

4.00

6.00

8.00

10.00

12.00

Hyd

rog

en

pro

vis

ion

co

sts

[€

/ k

g H

2]


BoP

HP storage

Booster compressor

MP storage

Base compressor

Electrolyser

intelligent use of the electrolyser

saves largest amount of OPEX

by exploiting optimal electricity tariffs

and balancing payments



12/10/2015

0.00

2.00

4.00

6.00

8.00

10.00

12.00

Hyd

rog

en

pro

vis

ion

co

sts

[€

/ k

g H

2]


BoP

HP storage

Booster compressor

MP storage

Base compressor

Electrolyser

• Costs depends on electricity

• No easy comparison with high variations in components /size

Future recommendation:

• make a better analysis before constructing the HRS, to know HOW to design effectively


Project Status

12/10/2015

Integration of components (HyET/ITM) is critical for FCH-JU, and was executed on the 29th + 30th of Sept 2015:

We have successfully field tested electrolyser + EHC at ITM

ITM Electrolyser

(5 kg/day)

HyET Electrochemical

Compressor (here 2 kg/day)


Project Status

12/10/2015

Integration of components (HyET/ITM) is critical for FCH-JU, and was executed on the 29th + 30th of Sept 2015:

We have successfully field tested electrolyser + EHC at ITM


Impact of PHAEDRUS

12/10/2015

Development of a model for the most energy efficient method of generating, compressing and dispensing hydrogen at 70MPa

Development of high pressure, high current density electrolyser stack & BoP

Optimisation of an electrochemical compressor and mobile MoHyTO system

Extensive durability data for developed components and systems

Successful integration and operation of a high pressure, high current density electrolyser module with an electrochemical compressor

Technology cost comparison and projection undertaken with Daimler

Validation of a new approach and required technology for decentralised H2 generation & refuelling

Electrochemical compressor needs to achieve higher TRL level but potential benefit and cost –down potential justifies continued its pursuit

Hydrogen cost target of €10/kg for 2020 assuming EHC achieves projected cost savings

Further collaboration between partners outside of the Phaedrus Project


Hydrogen around the Corner - roadmap

12/10/2015

For market growth, the final outcome should be:

• Hydrogen is made available to the customer at the same or lower cost as conventional fuels.

• Fuelling stations want to be able to sell hydrogen for that cost.

• This means the cost of production, compression and dispensing needs to be below the sales level to break even.

• Urban environment dictates: footprint requirements, noise reduction, high safety standards.

CAPEX/OPEX balance: serious CAPEX for installation now, but you need to look at the OPEX to make the business case work.


Thank You

12/10/15

THANK YOU


Thank you for your attention

Project manager: Anna Molinari E-mail: [email protected]

Project coordinator: Peter Bouwman E-mail: [email protected]

Program Officer: (Carlos Navas) Lionel Boillot Website: www.phaedrus-project.eu

mailto:[email protected]







Additional slides

12/10/2015


Hydrogen around the Corner - roadmap

12/10/2015

Roadmap for HRS:

• On-site hydrogen production has strong advantages

• electrolysis ,delivering some base pressure (80 bar here)

• potentially with reformate gas (and cleaning)

• storage buffers can be sized accordingly / optimum modelling

Now 50 kg/day is needed for HRS capacity, leading up to 200 kg/day and beyond.

electrochemical compressor could be combined with reformer as most cheap with potential to contribute to cleaning and process simplifications


Project overview

12/10/2015

CompressorSystem

Storage System

Trucked-in / piped hydrogen supply

Hydrogen Refueling Station

Pre-Cooling RefuelingControlSystem

HRS Integration Skid & packaging

Climate managementSafety control

Remote monitoringSite interfaces

H2 supply interfaces

Dispenser

Onsite ElectrolyserH2 outlet pressure: 200 bar

Current density : 1 => 3 A/cm2

Stack efficiency : 65% => 85% Energy consumption: ≤ 4.6 kWh/Nm3

System OPEX target: ≤ €5.2 kg *

Compressor: major innovations

HRS concept: major innovations

Storage System

Onsite Electrolyser: major innovations

Electrochemical compressionCompression: factor 5 – 40 upto 1,000 barEnergy consumption : < 4 kWh/kgCAPEX target: < €2,300/kg.day

Modular and scalable designFuelling capacity: 5kg/3min; up to 200 kg/daySAE J2601 and SAE 2799 compatibleHRS CAPEX/kg daily capacity: €5.000-€12.000


HRS Simulations tool exist (UASE)

12/10/2015

A software tool (using MATLAB/Simulink) has been developed to:

Analyze the different architectures and choose the optimum one

Simulate the operation of the complete hydrogen refueling station

Calculate the sizes of the components

Calculate the efficiencies of the components

Calculate CAPEX and OPEX

Hisham Ashkar, “Simulation sizing and analysis of high pressure hydrogen all electrochemical decentralised refuelling station”, SAE International (under peer review)

40

presented: peter bouwman 12 october 2015 - phaedrus · presented: peter bouwman – 12th october...

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