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Hydrogen generators for
energy storage and industrial applications
Water electrolysis state of affairs
Dr.ir. Jan Vaes, Technology Director, Hydrogenics On Site Generation
World of Energy Solutions, Stuttgart, October 10, 2016
2
Hydrogenics in Brief
Zero-emission Hydrogen Technology Provider
Onsite Generation Electrolysers
H2O + electricity H2 + ½ O2
Industrial Hydrogen Power-to-X
Power Systems Fuel Cell Modules
H2 + ½ O2 H2O + electricity
Stand-by Power Mobility Power
3
Hydrogenics
Alkaline technology
Recent evolutions
Energy storage applications
PEM technology
Evolving towards industrial market
Outlook
4
Industry “Workhorse” for Onsite Electrolysis
Hydrogenics HySTAT™ Alkaline Stack
“We offer high quality products that combine innovation, customer-
centric features with industrial design and robustness.”
5
48%
Global Hydrogen Market
Steam Methane reforming
Electrical power plants Food industry
OTHERS: cooling agent, hardening of oil, power generation, mobility
Production Storage / Transport / Distribution End-use (global market in 2010: +/- 43 Mtons
FCEV
Steam Methane Reforming
1%
Float glass Metallurgy Semi-conductors
INDUSTRY : protecting atmosphere (H2/N2), hardening of metals 6%
18%
3%
1%
30%
Crude oil cracking
Coal gasification
H2 by-product
Water electrolysis
Main data source: The Hydrogen Economy, M. Ball, 2009
NB: 5 % is merchant hydrogen (free market),
onsite production represents 95%
CHEMISTRY & REFINERIES: C, H, O, Amonia
50%
93%
43%
Fertilizers Refineries
AWE medium flow 10-200 Nm³/h
6
Over 500 Worldwide industrial systems alkaline systems ranging from 50 kW to 2.5 MW
Saudi Arabia: Powerplant Russia: Float Glass
Greece: Solar Industry
China: Merchant Gas
Romenia: Float Glass
Ukraine: Metallurgy
7
Alkaline Balance of Plant
Hydrogen purification system • De-Oxo • Mol-Sieve Dryer
Gas Separators
Cell Stack
Electrolyte cooling
Confidential. Cannot be distributed without Hydrogenics' approval.
Break tank for process water
recovery
Online purity measurement (Dew point and OTH)
HTO measurement (Alarm: 1.5 vol%
Shutdown: 1.75 vol%)
Demin water inlet Rinser
Coalescent Filter • Captures Moisture • Gas Cooling
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Continuous improvement of the Balance of Plant
Confidential. Cannot be distributed without Hydrogenics' approval.
Safety
updated HazOp
refined with key customers
sound safety philosophy – minimal user action
Health & Environment
no drain from process
no KOH carry-over
Quality
lifted gas separator vessels
• increased mass transport
• more performant cooling
remote I/O to instrumentation on skid
• ProfiSafe protocol implemented
• reduced installation time
supply side control of operation
• grid service capability
9
Grid service capability
10
Updated Cell stacks
Cell stack polymer choice optimization
Less hydraulic resistance in the stack – improved mass transport
10 -15% more cells per stack
Up to 50% higher current density demonstrated
x2.5 active area 2500 cm² (250 kW stack)
=> 120 Nm³/h unit in 40 ft. container
11
Hydrogen generation and Power-to-X routes
GAS GRID
Electrolysis H2 storage (optional)
POWER GRID
Power-to-Hydrogen
Power-to-Power
Wind turbine
Solar PV
CHP
Fuel cells
Methanation
Refuelling stations
Refineries
Chemical plants
Power-to-Gas
Hydrogen network Power network Gas network Liquid fuels network
SURPLUS OR LOW-COST
ELECTRICITY
Blending
O2 H2O
CO2
H2
Heat
Speciality chemicals
Ammonia
Power-to-Industry
Industry
Hydrogen Vehicles (FCEV)
Power-to-Mobility
Gas turbines
Low C02 fuels
Methanol
Power-to-Fuels
CNG
AWE
10-180
nm³/h
AWE
240
nm³/h
AWE
15-210
nm³/h
AWE
360 nm³/h
Avedøre, Denmark (2016)
BioCatProject
OBJECTIVES • Design, engineer, and construct a commercial-scale power-to-gas facility • Demonstrate capabilities to provide energy storage services to the Danish energy system. • Demonstrate capability and economic viability of oxygen and heat recycling in the on-site
wastewater operations • Biological methanation system to produce pipeline-grade renewable gas (CH4) • Feed CH4 into the gas distribution grid at 3.6 bar SOLUTION • 2x HySTAT™ 100 (Alkaline) with all peripherals to produce 100Nm³/h H2. • Power: 1MW More info: www.biocat-project.com
13
http://biocat-project.com/
Falkenhagen, Germany (2013)
Greening of Gas
OBJECTIVES • Demonstration of the Power-to-Gas process chain. • Optimize operational concept (fluctuating power from wind vs. changing gas feed). • Gain experience in technology and cost. • Feed H2 into the high-pressure transmission natural gas pipeline at 55bar (ONTRAS). SOLUTION • 6 x HySTAT™ 60 with all peripherals in 20Ft. housings to produce 360Nm³/h H2. • A 40 Ft container including 2 compressors to compress the hydrogen to 55barg. • Power: 2MW
Photo credits: Uniper Energy Storage GmbH
Raglan Mine, Nunavik (Northern Quebec, Canada)
PROJECT DESCRIPTION
• Nickel and Copper Mine
• Extreme tip of Northern Quebec, 400 km North of the tree line, average annual temp -10
degrees C (Permafrost 550 m deep)
•Hydrogen is used energy storage solution in combination with a wind turbine and reduce
diesel consumption
SOLUTION
•3.0 MW Arctic Wind Turbine
•1.8 MW diesel generator
•350 kW Electrolyser 1 x HySTAT TM 60
•200 kW HyPM Fuel Cell System
Puglia, Italy (2016, in commissioning)
INGRID (FP7 project) OBJECTIVES • Allow increased integration of RES into the grid using electrolysis and supply-demand balancing • Improvement of distribution operations through active/reactive power control for optimal voltage regulation and power quality •Hydrogen used for transport, industry, grid balancing and injection into the gas grid
SOLUTION •1 MW HySTAT™ electrolyser 40 ft, outdoor solution to produce 200 Nm³/h of hydrogen •120 kW fuel cell back-up system •39 MWh, 1.000 kg solid hydrogen storage system
More info: www.ingridproject.eu
17
Hydrogenics
Alkaline technology
Recent evolutions
Energy storage applications
PEM technology
Evolving towards industrial markets
Outlook
Thank you, Wikipedia Uploader !
Proton Exchange
Membrane
• Solid polymer electrolyte
• Deionized water feed
Polymer electrolyte technology
PEM stack development
1. Logan Energy = 45 Nm³/hr (Gladbeck)
2. HyBALANCE = 230 Nm³/Hr D unit (Oevel)
3. MethCo = 120 Nm³/hr (Oevel)
20
48%
Global Hydrogen Market
Steam Methane reforming
Electrical power plants Food industry
OTHERS: cooling agent, hardening of oil, power generation, mobility
Production Storage / Transport / Distribution End-use (global market in 2010: +/- 43 Mtons
FCEV
Steam Methane Reforming
1%
Float glass Metallurgy Semi-conductors
INDUSTRY : protecting atmosphere (H2/N2), hardening of metals 6%
18%
3%
1%
30%
Crude oil cracking
Coal gasification
H2 by-product
Water electrolysis
Main data source: The Hydrogen Economy, M. Ball, 2009
NB: 5 % is merchant hydrogen (free market),
onsite production represents 95%
CHEMISTRY & REFINERIES: C, H, O, Amonia
50%
93%
43%
Fertilizers Refineries
low flow PEM 1-5 Nm³/h
21
1.5 MW, MODEL 1500E Electrical Power Input 1.5 MW
Hydrogen Output 285 Nm3/h
Max. Operating Pressure 40 bar (g)
Dimensions L800xW550x1000mm
Certifications PED (97/23/EC)
1500E PEM stack launched in 2014
22
Hydrogen generation and Power-to-X routes
GAS GRID
Electrolysis H2 storage (optional)
POWER GRID
Power-to-Hydrogen
Power-to-Power
Wind turbine
Solar PV
CHP
Fuel cells
Methanation
Refuelling stations
Refineries
Chemical plants
Power-to-Gas
Hydrogen network Power network Gas network Liquid fuels network
SURPLUS OR LOW-COST
ELECTRICITY
Blending
O2 H2O
CO2
H2
Heat
Speciality chemicals
Ammonia
Power-to-Industry
Industry
Hydrogen Vehicles (FCEV)
Power-to-Mobility
Gas turbines
Low C02 fuels
Methanol
Power-to-Fuels
CNG
PEM
10-180
nm³/h
PEM
30 nm³/h PEM
120
nm³/h
Hybalance
100/ 230
nm³/h
PEM
285 nm³/h
Colruyt, Halle (Brussels, Belgium)
65 kg/day, 350 bar dispensing • Located at one of the warehouse of Colruyt, one of the biggest Belgian retail company
• Hydrogen is used to fill fork lift trucks, additionally it can refuel other vehicles
• The station has a 30 Nm³/h alkaline electrolyser, 50 kg storage and -20º chiller the
customer’s SAEJ 2601 refueling sequence.
• Funded by InterReg project (Waterstofregio Vlaanderen Zuid-Nederland)
• DON QUICHOTE - Extension - FCH JU (2015) - www.don-quichote.eu
• + 30 Nm³/h PEM electrolyser
• Electrochemical compressor HYET
• + 100 kW Fuel Cell
• Smart grid operation
WindGas Hamburg Reitbrook, Germany (2015)
1,5 MW Power to Gas
OBJECTIVES • Demonstration of the Power-to-Gas process chain. • Development of 1,5 MW PEM Electrolysis Stack and System • Optimize operational concept (fluctuating power from wind vs. changing gas feed). • Gain experience in technology and cost. • Feed H2 into the medium-pressure distribution natural gas pipeline at 30 bar. SOLUTION • 1x 1,5 MW PEM Electrolyser with all peripherals in 40Ft. housings for max 285 Nm³/h H2. • Power: 1,5 MW
•This 1,5 MW building block is now the foundation for multi MW P2G plants
Partners:
Sponsors: Coordinators:
More info: www.windgas-hamburg.com
Photo credits: Uniper Energy Storage GmbH
WindGas Hamburg Reitbrook, Germany (2015)
1,5 MW Power to Gas
OBJECTIVES • Demonstration of the Power-to-Gas process chain. • Development of 1,5 MW PEM Electrolysis Stack and System • Optimize operational concept (fluctuating power from wind vs. changing gas feed). • Gain experience in technology and cost. • Feed H2 into the medium-pressure distribution natural gas pipeline at 30 bar. SOLUTION • 1x 1,5 MW PEM Electrolyser with all peripherals in 40Ft. housings for max 285 Nm³/h H2. • Power: 1,5 MW
•This 1,5 MW building block is now the foundation for multi MW P2G plants
Partners:
Sponsors: Coordinators:
More info: www.windgas-hamburg.com
Hobro, Denmark (construction in 2017)
HyBalance Project
OBJECTIVES • validate the highly dynamic PEM electrolysis technology in a real industrial environment • provide grid balancing services on the Danish power market • validate innovative hydrogen delivery processes for fueling stations at high pressure • hydrogen is used by industrial customers and for clean transportation (refueling stations)
SOLUTION • 1x HyLYSER™ 230 (PEM, dual cell stack design) with all peripherals to produce 230 Nm³/h H2. • power: 1,2 MW This project receives financial support FCH-JU (GA No 671384) and ForskEL program, administered by Energinet.dk.
More info: www.hybalance.eu
Hybalance
1.2 MW dual stack unit
FAT December 2016, Oevel (B) Presentation to public
Lünen, Germany
MefCO2 project (Methanol Fuel from CO2)
OBJECTIVES • Increase efficiency and reduce emissions of STEAG’s coal fired power plant • Leverage existing carbon capture pilot plant (= CO2 source) owned by UDE SOLUTION • 1 MW PEM electrolyser for 200 Nm³/h of Hydrogen • EU Horizon 2020 research and innovation programme funding (SPIRE) • Flexible methanol synthesis. • Power: 1MW
Carbon capture unit
Photo credit: University of Duisburg-Essen
More info: http://www.spire2030.eu/mefco2/
10 MW System lay-out with major equipment
30
CO2 pollution is a kinetic problem
sunlight photosynthesis
plants algae
geological processes
fossil carbon reserves
mining
oil, coal and gas
refining
fuel
energy
low carbon
production
31
Hydrogenics
Alkaline technology
PEM technology
Outlook and conclusions
32
Outlook Power-to-Gas potential in GW scale
Publication Potential for water
electrolysis (P2G)
“Study of the requirement for electricity storage in Germany” Agora Energiewende
GER: 16 GW (2023), 80 GW (2033) and 130
GW (2050)
Commercialisation of Energy Storage in Europe Mc Kinsey, FCH-JU, 2014
GER: 170 GW by 2050 (all energy storage)
“Reduction of CO2 emissions by addition of hydrogen to natural
gas” by Haines, Polman and de Laat, in IEA Greenhouse Gas Control Technologies
Volume 1
UK: 23.5 GW of electrolysis in 2050
“Study of hydrogen and methanation as processes for capturing the
value of excess electricity” Report by ADEME GRTGaz and GRDF, France
FR: 1.2-1.4 GW of P2G plant in France by
2030 and up to 24 GW by 2050
“The role of power-to-gas in the future Dutch energy system” ECN and DNVGL for TKI Gas, 2014
HOL: 20 GW of installed P2G capacity if
deep CO2 emission reduction targets in the
energy system (-80% to -95% by 2050)
Effects of large-scale power to gas conversion on the power, gas
and carbon sectors and their interactions KULeuven, 2014
BE: 7 GW Power-to-Methane potential a
100% RES scenario
… …
33
Price of
Electricity
Equipment
Capex
H2 Energy
Produced
Grid
Services
Multiple Revenue Streams Operating Cost Capital
Renewable
Fuel or Gas
Premium
P2G Economic Drivers
Capacity
Factor
Business case for Power-to-Gas developers has six drivers
34
Conclusions
Both Alkaline and PEM remain on path for cost decrease • Volume scaling w/ increased supply chain development
• Improvements and rationalization of BOP • SHEQ driven
• Also reduces Total Cost of Ownership
• New materials in qualification • Lab -> prototype -> in use
Performance increase will help cost reduction • Current density increase
• Electrode development
• Cell stack development
• Process intensification need
• Process window widening • Membrane development
• High pressure operation
Positive business case ? • Combining revenues
35
O2
Renewable Generation
Electrolysis operation stabilizes the grid
Surplus converted
to Hydrogen gas
Hydrogen fuels vehicles
Gas is blended up to 10% Hydrogen in Natural Gas
Blended gas to be used for heat and power generation
O2
Thank you!
