transformative renewable energy storage devices based on neutral water input 2010 update... ·...
TRANSCRIPT
Transformative Renewable Energy Storage Devices Based
on Neutral Water Inputp
E St S t U d tEnergy Storage Systems UpdateARPA-E GRIDS Kick-Off
4 November 20104 November 2010
Team
• Proton Energy SystemsD K th A PI– Dr. Kathy Ayers, PI
– Luke Dalton, System Lead– Chris Capuano Stack Lead– Chris Capuano, Stack Lead– Project Lead; Electrolysis Stack and System; Fuel
Cell System• Penn State University
– Prof. Mike Hickner– Prof. Chao-Yang Wang– Electrolysis and Fuel Cell Membrane Material;
Fuel Cell Stack2
Fuel Cell Stack
Proton Energy Systems• Manufacturer of Proton Exchange Membrane
(PEM) hydrogen generation products using electrolysis
• Founded in 1996• Founded in 1996
• Headquarters in Wallingford, Connecticut.
• ISO 9001:2008 registered
• Over 1,200 systems operating in 60 different countries
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Proton Capabilities and Applications
PEM Cell Stacks Complete Systems
• Complete product development, manufacturing & testing• Containerization and hydrogen storage solutions
Storage Solutions
• Containerization and hydrogen storage solutions• Integration of electrolysis into RFC systems• Turnkey product installationy p• World-wide sales and service
L b t iH t T ti S i d t GovernmentPower Plants LaboratoriesHeat Treating Semiconductors Government
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HOGEN® C Series• Maximum Capacity: 30 Nm3/h H2 (65 kg/day) (~200 kW input)• Commercial availability: Q1 2011
5X h d t t ith l 1 5X th f t i t• 5X hydrogen output with only 1.5X the foot print
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Next Steps in Scale Up• 70 Nm3/h • 150 kg/day• 400 kW input
2.202.252.30
0.6 SQFT 3 Cell (1032 amps, 425 psi, 50oC)
1.952.002.052.102.15
l Pot
entia
l (V)
1.751.801.851.90
0 1000 2000 3000 4000
Cel
l
Run Time (hours)
Cell 1 Cell 2 Cell 3
6
Run Time (hours)
Hydrogen Cost Progression
$10
$6
$8
odel
$
$4
H2, H2A
m
$‐
$2
F lG 65 150 k /d 150 k /d
$/kg H
FuelGen65, current stack
150 kg/day system, next
generation stack
150 kg/day system,
advanced stack*
*Assumes volumes
, product
introduction
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*Assumes volumes of 500 units/year
Two Main Types of Low Temp ElectrolysisAlkaline Liquid Electrolyte
Low bubble point requires
Proton Exchange Membrane (PEM)
+ Membrane enables balanced pressure Controlled shutdown required High pressure oxygen
differential pressure+ Load following+ Ambient pressure oxygen
Corrosive solvent Complex balance of plant,
high pressure lines
+ Pure water+ Simple balance of plant,
plastic on O fluids loophigh pressure lines Low current densities+ Less expensive materials
plastic on O2 fluids loop+ High current densities High cost catalysts and flow
of construction fields
Alkaline membrane technology could provide best of both systems
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gy p y
PEM / AEM Cell Comparison
4H+
Hydrogen+ vapor
Air (O2)+ vapor
Oxygen electrode (cathode)Hydrogen electrode (anode)
Solid polymer electrolyte
4H+
Hydrogen OxygenOxygen electrode (anode)Hydrogen electrode (cathode)
Solid polymer electrolyte
ProtonicWater
ProcessWater, heat
4H +4e+
2H2O+
4H + 4e+O2
4e
(-) (+)
H2 O
ProductWater
+ Depleted Air+ Heat
22H
4H
4H +4e 2H2+
2H2O+
4H + 4e+O2
4
(-) (+)
H2O
ProcessWater
4e
DC Load
Heat 4e
DC Power
Solid Alkaline Membrane
PEMAEM
4OH-
Hydrogen OxygenOxygen electrode (cathode)Hydrogen electrode (anode)
4OH-
Hydrogen OxygenOxygen electrode (anode)Hydrogen electrode (cathode)
Solid Alkaline Membrane
Water
AEM
+ 4e-
4e
(-) (+)Water
H2O2H2 4OH- 2H2O +4e-+ 4OH-O24H2O + 4H2O + 4e-
4e
(-) (+)
DC P
Process Water
H2O2H2+4OH- 2H2O +4e-+4OH- O2
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DC LoadDC Power
Rationale• Alkaline advantage over PEM: lower cost materials
of construction• Disadvantages of alkaline liquid system:
– Corrosive electrolyte– High pressure oxygen– Complex balance of plant
L it h d– Lower purity hydrogen– Lower efficiency
• Alkaline membranes showing feasibility• Alkaline membranes showing feasibility– Enables PEM advantages at low cost– Enables lower current density for high efficiency
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Enables lower current density for high efficiency
Cost Justification 100%line
• 3-pronged approach40%
60%
80%
ercentage of base
$10 000
$100,000
b
0%
20%
40%
40 kW 220 kW 500 kW
$/kW
cost a
s pe
$10
$100
$1,000
$10,000
Raw M
aterial $/lb 40 kW 220 kW 500 kW
System Capacity
$1
$10
Platinum Iridium Nickel Titanium Stainless
Catalyst Flow fields
R
MaterialLabor minimization and hi h d f t ihigh speed manufacturing at high production volume
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Proposed Approach• Design Trade Study
– Select RFC configuration• Membrane and Ionomer Development
– Maximize durability and minimize ionic resistance and crossover• Catalyst Development y p
– Reduce activation overpotential• MEA Fabrication
Optimize catalyst membrane interaction– Optimize catalyst-membrane interaction• Cell Stack Design
– Leverage Proton experience and substitute materials• System Design
– Leverage Proton balance of plant designs• Cost Analysis
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Cost a ys s
DRFC – Discrete RFC– Separate fuel cell and
l t l t kTrade Study:C fi ti O ti
URFC – Unitized RFC
electrolyzer stacks
Fuel CellElectrolyzer
Regenerative Fuel Cell
Configuration Options
– A single cell stack that operates as both fuel cell and electrolyzer
hydrogen
DC electricity DC electricity oxygen
Unitized Regenerative Fuel Cell
water
Regenerative Fuel CellDC electricity oxygen
Unitized Regenerative Fuel Cell
h d
DC electricity DC electricity oxygen
Fuel CellElectrolyzerair
hydrogen
hydrogen
water
water
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Trade Study – Electrolysis Example
2 5
Polarization Comparison
Flow URFC Flow EC
2
2.5
} 1.5
Volts
}~300 mV loss for URFC
0.5
1V
00 500 1000 1500 2000 2500 3000 3500
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Current Density (mA/cm2)
Trade Study: O2 vs. air feedy 2
• High pressure oxygen adds balance of plant
• Membrane is sensitive to COadds balance of plant
complexity• Requires special
CO2
• Carbonate can replace OH- sites and reduceRequires special
cleaning >150 psi• O2 feed requires drying
OH sites and reduce conductivity
• Removal of carbon from of both gases air reduces efficiency
and increases cost
Need to look at trade of cost, efficiency, and simplicity in context of safety considerationsin context of safety considerations
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Trade Study: Anode vs. Cathode FeedPEM l t l iAlkaline electrolysis
• Water consumed on oxygen side of cell
PEM electrolysis• Water consumed on hydrogen
side of cell• Hydrogen is typically gas of
interest, oxygen vented• Hydrogen primary interest
4e‐4e‐
2H22H2 + 4OH‐ O2 + 4H+O2 + 2H2O
4e4e
H+OH‐
4H
2e‐Anode Cathode Anode Cathode
4H+
2H2O 2H2O4OH‐
Alkaline Acid
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Trade Study: PEM Comparison
oltage
Relative vo
Cathode feed
Anode feed
R
0 500 1000 1500 2000C t d it ( A/ 2)Current density (mA/cm2)
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Membrane and Ionomer Development• Penn State-led effort to develop an anion
exchange membrane (AEM) and ionomer binderReduced cost through use of commercially available– Reduced cost through use of commercially available monomers
– “Tune” ion exchange capacity and cross-linking to b l d ti it d h i l ti /balance conductivity and mechanical properties/gas cross-over.
• Proton to assist with characterization– Conduct diffusion and performance evaluation to
provide feedback on how to iterate on configurationHa e Tok ama membranes and ionomers to test as a– Have Tokuyama membranes and ionomers to test as a baseline for AEMs.
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Catalyst Development• Apply processes from
PEM experience to AEM catalystcatalyst
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MEA Fabrication• Vary temperature and dwell time
– Find combination most conducive to electrode attachment
• Sub-scale membrane samples to be used for pressing half MEAshalf-MEAs– Two fabrication approaches to be considered
• Trials rated on uniformity, adhesion to membrane, and degree of flow for ink samples. M b d f h i l d d ti• Membrane assessed for mechanical degradation resulting from process
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Electrolysis Stack DesignWill i f h d d• Will incorporate outputs from the trade study to dictate configuration
Bipolar plate design (high efficiency low pressure)– Bipolar plate design (high-efficiency, low-pressure)– Round design (lower-efficiency, high pressure)
• Primary effort will be material substitutiony– Alkaline allows replacement of titanium components with stainless
steel.
Solid Plate
Inserts
Bipolar plate design
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Round architecture Bipolar plate design
Electrolysis Cell Modeling
temperature distribution current density distribution
J
oxygen transport
JO2
yg p
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Fuel Cell Modeling
current density distribution Liquid water distributioncurrent density distribution Liquid water distribution
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Electrolysis and Fuel Cell Stack Test Plany• Design phase and concept review• Prototype flow field fabricated using production• Prototype flow field fabricated using production
tooling and techniques• Anode flow field verificationAnode flow field verification• Cathode flow field verification• Short stack testing and operation for prototype• Short stack testing and operation for prototype
review• Deliverable stack assembly and operationDeliverable stack assembly and operation
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Cell Stack Operational Verificationp
• Multi-cell operational testing• Allows for fine control over operating parameters
– Temperature– Generation Pressure– Current Control
W t Fl R t– Water Flow Rates
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Energy Storage System Design• PEM system should be largely transferrable to
proposed AEM-based systemCommon fluids of interest (H H O O )– Common fluids of interest (H2, H2O, O2)
• Trade study work will impact type of system• Leverage prior experience in closed loop REFCsLeverage prior experience in closed loop REFCs• Output:
– Design Intent Documentg– P&ID– Component selection (comprehensive BOM)
H d d i i– Haz-op and design review
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Alkaline REFC Approach• Well-suited to load-following• Easily scalabley
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Figure 1. Closed-loop, pure oxygen, discrete regenerative fuel cell system P&ID.
Examples of Demonstrated Energy Storage Systems
“Regenerative Fuel Cell” integratedinto CERL’s Silent Camp system concept
Missile Defense Agency: Cl d l RFC
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Closed loop RFC
Near-Term Milestones
• Kickoff meeting – October 6, 2010T d t d lt di t iti d t k• Trade study results on discrete vs. unitized stack
• Initial survey of commercial catalysts• MEA formulation studies with baseline membrane
and catalystS f t k t il bilit i lt t• Survey of stack part availability in alternate materials
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Major Project Milestonesj j
• System Configuration Trade StudyEl t l i d F l C ll M b M t i l• Electrolysis and Fuel Cell Membrane Material ImprovementsEl t l i d F l C ll M b El t d• Electrolysis and Fuel Cell Membrane-Electrode-Assembly Fabrication Optimization
• Fuel Cell Stack Design and Test• Fuel Cell Stack Design and Test• Electrolysis Stack Design and Test
I t t d E St S t D t ti• Integrated Energy Storage System Demonstration
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