Massey University POST-GRAD Energy Conference Massey University POST-GRAD Energy Conference

Steve BroomeSteve Broome

Industrial Research LtdIndustrial Research Ltd

26 July 200626 July 2006

Alkaline Fuel Cell System Research

Alkaline Fuel Cell System Research

Contents of PresentationContents of Presentation

Ground RulesGround Rules About IRL and MeAbout IRL and Me Distributed Hydrogen EnergyDistributed Hydrogen Energy Alkaline Fuel CellsAlkaline Fuel Cells ElectrolysersElectrolysers Combined Power SystemsCombined Power Systems IRL’s Set-upIRL’s Set-up

Ground RulesGround RulesAny questions? Just ask!

About IRL and MeAbout IRL and Me

IRL ChristchurchIRL Christchurch– Industrial Research Ltd – Formerly the DSIR.Industrial Research Ltd – Formerly the DSIR.

– Chch site is full of research engineers.Chch site is full of research engineers.

– Wellington site is full of research scientists.Wellington site is full of research scientists.

MeMe– Chemical & Process Engineer from University of Canterbury.Chemical & Process Engineer from University of Canterbury.

– Masters with Fonterra and FRST – played with big toys.Masters with Fonterra and FRST – played with big toys.

– Spent two years in Timaru – the Ultimate O.E.!Spent two years in Timaru – the Ultimate O.E.!

Distributed Hydrogen EnergyDistributed Hydrogen Energy

Electrolyser

Electricity

Electricity

Reformer

Heat

Wind or wave power

Wood, coal or biomass

Ethanol or methanol

H2

H2

Alkaline Fuel Cell

Syngas

Methanol

H2Gasifier

How Alkaline Fuel Cells WorkHow Alkaline Fuel Cells Work

Exhaust air

Inlet H2Inlet air

Exhaust H2

30% KOH

ElectrolyteHeat

K+ OH-

Cathode Anode

Electricity

H2O

0.5 O2 + 2e- + H2O 2OH- H2 + 2OH- 2 H2O + 2e-

H2 + 0.5 O2 H2O + electricity + heat

N2

O2

Hercules and MinotaurIRL’s Experimental Alkaline Fuel Cells

Vapour separators before outlet

CO2 scrubberAir preheater & exhaust cooler

Baby cyclone for exhaust

Fuel Cell Stack

KOH Sump

Air inH2 in

Vapour separators before outlet

CO2 scrubberAir preheater & exhaust cooler

Vapour separator for exhaust

Fuel Cell Stack

KOH Sump

Air inH2 in

HerculesHercules DCI-1200 #004DCI-1200 #004

MinotaurMinotaur DCI-1200 #003DCI-1200 #003

Applications of AFCsApplications of AFCs

Space TravelSpace Travel– AFCs used on space shuttles since 1981.AFCs used on space shuttles since 1981.

– Developed by UTC Power.Developed by UTC Power.

– Carry 3x 12kW units.Carry 3x 12kW units.

– Use bottled HUse bottled H22 and O and O22..

– Over 90,000 hours of operation.Over 90,000 hours of operation.

– ““Over 70% efficient”Over 70% efficient”

Goal: Domestic Combined Heat & PowerGoal: Domestic Combined Heat & Power– Introduce whisper-quiet electricity and heat generator to NZ homes.Introduce whisper-quiet electricity and heat generator to NZ homes.

– Supply electricity to home or the grid.Supply electricity to home or the grid.

– Heating for domestic hot water,Heating for domestic hot water,

– Especially useful for remote areas & rural communities.Especially useful for remote areas & rural communities.

– Operating off conventional fuels & air – the challenge!Operating off conventional fuels & air – the challenge!

IRL Progress on AFCsIRL Progress on AFCs

PEM fuel cell (Proton Exchange Membrane)PEM fuel cell (Proton Exchange Membrane)– Testing of a ReliOn PEM fuel cell at US Antarctic Centre Testing of a ReliOn PEM fuel cell at US Antarctic Centre

during 2005-2006. during 2005-2006.

– Successful.Successful.

– Methanol Methanol Reformed to H Reformed to H22 Fed to fuel cell. Fed to fuel cell.

– Bottled HBottled H22 fed to fuel cell. fed to fuel cell.

Alkaline fuel cellAlkaline fuel cell– About to begin field trial of Zetek alkaline fuel cell at US About to begin field trial of Zetek alkaline fuel cell at US

Antarctic Centre.Antarctic Centre.

– Methanol Methanol Reformed to H Reformed to H22 Fed to fuel cell. Fed to fuel cell.

– Will build low-cost AFCs.Will build low-cost AFCs.

ElectrolysersElectrolysers

IRL Christchurch has one of these.IRL Christchurch has one of these. IRL Wellington is developing one of these.IRL Wellington is developing one of these.

Combined Cycle System– Totara Valley Hylink

Combined Cycle System– Totara Valley Hylink

– – Use wind energy to produce hydrogen in an electrolyser.Use wind energy to produce hydrogen in an electrolyser.

– – Hydrogen can be stored in a pipe and used on demand.Hydrogen can be stored in a pipe and used on demand.

– – It’s potentially cheaper to run a polymer pipe for hydrogen than an electrical cable.It’s potentially cheaper to run a polymer pipe for hydrogen than an electrical cable.

– – Experimental system has been set up in Christchurch.Experimental system has been set up in Christchurch.

– – A wind turbine has been installed at Totara Valley.A wind turbine has been installed at Totara Valley.

Fuel Cell ElectricityElectricity

H2

Electrolyser

O2

Totara Valley Pipe System – Christchurch style

Totara Valley Pipe System – Christchurch style

We have installed a medium density polymer pipe We have installed a medium density polymer pipe – Like the one planned for Totara Valley.Like the one planned for Totara Valley.

– 160 m long and 1 inch diameter.160 m long and 1 inch diameter.

– Box is filled with sand.Box is filled with sand.

– Holds hydrogen well at 4 bar gauge pressure.Holds hydrogen well at 4 bar gauge pressure.

– Electrolysed hydrogen stored in here.Electrolysed hydrogen stored in here.

– Run alkaline fuel cell off this hydrogen.Run alkaline fuel cell off this hydrogen.

– Peter Sudol working on this next week.Peter Sudol working on this next week.

Brainwave:Brainwave:

– Run HRun H22 and O and O22 pipes to power an alkaline fuel cell. pipes to power an alkaline fuel cell.

IRL’s Set-upIRL’s Set-up

Windmills Electrolyser

Bottled hydrogen

Methanol

Coal or biomass Syngas Hydrogen purifier

Alkaline Fuel Cell

Electricity & Heat

Reformer

H2

H2

H2 H2H2 Storage

SummarySummary

IRL is working on distributed hydrogen energy research and IRL is working on distributed hydrogen energy research and development.development.

Experiments and trials:Experiments and trials:– Alkaline fuel cells being tested.Alkaline fuel cells being tested.

– PEM electrolyser being powered off wind energy.PEM electrolyser being powered off wind energy.

– Alkaline electrolysers being developed by IRL.Alkaline electrolysers being developed by IRL.

– Electrolysed hydrogen being stored in a polymer pipe.Electrolysed hydrogen being stored in a polymer pipe.

– This is used to fuel an alkaline fuel cell.This is used to fuel an alkaline fuel cell.

Hylink will be installed at Totara Valley in 2006-2007.Hylink will be installed at Totara Valley in 2006-2007.