Fuel Cell Technology &
Hybrid Renewable Energy Systems
Introduction
Heliocentris Facts
• Based in Berlin (Germany) / office in Vancouver (Canada)
• 15 years of expertise in New Energy education and Fuel Cell Technology
• Educational partners of the leading fuel cell manufacturers
• Supplied more than 50,000 fuel cell systems to 65 countries
CEV_FCH_K/2
Top Tier University Clients On All Continents
Activities
Education
Systems
Projects
Offer
Offer
Offer
Education solutions for:
Standard fuel cell systems and
application solutions for:
» Laboratories
» Prototyping
» Industrial development
Customized and turnkey
solutions for:
» Laboratories
» Prototyping
» Industrial development
Customer
Customer
Customer
» Schools & High Schools
» Vocational Schools
» Colleges & Universities
» Colleges & Universities
» R&D institutes
» Industry
» Colleges & Universities
» R&D institutes
» Industry
» Science Education
» Technical Training
4
Complete Laboratories for Fuel Cells and Renwabel Energy
5
Need for Energy
6
Annual World Energy Consumption In Terrawatts
TW
6
Oil
5
Coal
4
Gas
3
2
1
Nuclear
Hydro
0
`65
`70
`75
`80
`85
`90
`95
`00
`05
Year
GROWING DEMAND CAN ONLY BE COVERED BY RENEWABLE ENERGIES
7
Problem: CO2 = Global Warming
How can the increasing world energy
demand be met?
»
Energy from fossil fuels
»
Nuclear energy
»
Conservation and energy efficiency
→
Renewable energy
8
Germany: 25% Electricity from Renewable Energies
Population: 82 Million
25% = 20 Million People
450,000 New Jobs created
9
The Challenge with Renewable Energy
» They are available intermittently
» They vary in intensity
Electrical Power from Wind und PV partly > 30% (Daytime)
10
Use of Photovoltaic in Germany:
Quelle:: SMA solar technology
11
The Challenge with Renewable Energy
The Requirement: To create a fuel
» That can be stored and transported
» That can be converted to useful forms of
energy (electricity, mechanical)
» That does not pollute the environment
The Solution
There is such a fuel.
It is called: Hydrogen
12
Sustainable Fuel Generation
Oxygen
Solar energy
Hydrogen
Storage
Electrolyzer
Oxygen
Stationary
Fuel Cell
Wind energy
Water energy
Source: Honda
Water
Mobile
13
...for future energy supply!
Quelle: obs/TOTAL Deutschland GmbH
14
I. General Information
Hydrogen  Energy Storage
Production
Storage
Utilization
Hydrogen
Renewable Energy
Hydrogen Storage
Quelle: DWV
Stationary
Mobile
IN THE NEAR FUTURE, HYDROGEN WILL BE USED IN DIFFERENT APPLICATIONS
JUST LIKE TODAY’S CONVENTIONAL FUELS
15
What Is A Fuel Cell?
_
BATTERY
Fuel Cell
+
16
A Device That Converts Hydrogen To Electricity
Heat
_
Hydrogen
Oxygen
BATTERY
Fuel Cell
DC electricity
+
Water
17
A Simple PEM Fuel Cell
The PEM fuel cell combines hydrogen
and oxygen in a chemical reaction,
producing water and releasing
energy.
18
Polymer Electrolyte Membrane (PEM)
Polytetrafluoroethylene (PTFE) chains
Water collects
around the
clusters of
hydrophylic
sulphonate side
chains
Sulphonic
Acid
HSO3
50-175 microns
(2-7 sheets of paper)
Diagram courtesy of Heliocentris
After Larminie and Dicks, 2000
19
PEM Fuel Cells
How Does a PEM Fuel Cell Work?
Catalysis
Oxidation
4e-
Transpo rt
H
Platinumcatalyst
2H
2
4H+
2
Resistance
Nafion
O
2
H O
Anode
2
PlatinumKcatalyst
H+
Cathode
Polymer
electrolyte
(i.e. Nafion)
Reduction
4e-
O
2
Nafion
Carbon cloth
Carbon cloth
4H+
2H O
Nafion
2
2
F_K/20
PEM Fuel Cell – Electrochemical Reaction
Anode:
2H2
Cathode:
O2 + 4e- → 2O22O2- + 4H+ → 2H2O
O2 + 4e- + 4H+ → 2H2O (l) (reduction)
Overall reaction:
→ 4H+ + 4e- (oxidation)
2H2 + O2 →
2H2O (l)
1. Oxidation of hydrogen
2. Reduction of oxygen
Theoretical Voltage per single fuel cell: 1.23 V
Usable Voltage per fuel cell: (0.6 … 0.9 Volt DC)
21
Reactions in Fuel Cells
But Kinetics – Another important factor
ideal voltage U=U0
Usable Voltage: 0.9 – 0.6 V DC
F_K/22
How Does It Work?
» Fuel Cells are stacked in series
» Stacking allows to reach the required performance
Fuel Cell Stack
ALSO ON INDUSTRIAL LEVEL MANY APPLICATIONS REQUIRE MORE VOLTAGE THAN ONE
SINGLE FUEL CELL DELIVERS
23
Flow Field in Bipolar Plates
H2 IN
(from
previous cell)
H2 OUT
(to next cell)
Picture: Oak Ridge National
Laboratory (ORNL)
Fuel Cell Stacks Are Integrated Into Power Modules
Control Signals #1-7
Evaporator
Fuel Cell
Controller
Temperature, Pressure, [H2] , [O2]
FC Current, Air Mass Flow, Cell Voltage
Check, FC Voltage, Purge Cell Voltage
H2
H2
Main Gas Valve
On/Off Signal
P
CS 1
M
CS 5
CS
7
CS
7
Serial Port Communication
H2 Regulator
Pressure Relief Valve
H2
T
CS
4
Purge Valve
Air
Stack
V
Fuel Cell
Air Compressor
CVC
Purge
V
Humidity Exchanger
CS 3
Cooling Fan(s)
O2
CS 6
I
- Output
+ Output
Diode
Relay
25
Nexa® Integration System
26
Advantages of Fuel Cells
I. Cold combustion (Fuel cell)
» Controlled reaction (no flame)
» Direct conversion of chemical energy to electrical energy
O
Fuel
Fuel
Heat
H
H
Efficiency: 50%
Electricity
Movement
Electricity
Efficiency: 25%
II. Warm combustion (heat engine /motor/ via turbine)
» Uncontrolled reaction
» Released energy is transferred to a working medium (water, water vapor)
27
Fuel Cells: Advantages Over Batteries
Batteries
Fuel Cells
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Doubling capacity leads to
doubling volume and weight
Fuel
Fuel
Cell
Fuel
Fuel
Cell
Fuel
Fuel
Cell
Doubling capacity does not lead to
doubling volume and weight
28
Fuel Cells: Advantages Over Batteries
Weight comparison to generate 1
kWh of energy
Volume comparison to generate 1
kWh of energy
20
20
Volume (litres)
Weight (kilograms)
25
15
10
5
0
Compressed
H2
Lithium ion
battery
Lead-acid
battery
15
10
5
0
Compressed H2
at 200 bar
Lithium ion
battery
Lead-acid
battery
» Smaller size
» Lighter weight
» Longer supply of power
» No self-discharge over time
» Easy to replace fuel cartriges
29
Fuel Cells: Universal power supply
Mobile
Stationary
Portable
30
Fuel Cells - A Universal Power Supply
5 MW
Communities
Power Plants
Industrial
300 kW
5 kW
25 W
Office Buildings
Commuter Trains
Hospitals
Schools
Buses
Trucks
Cars
Mining Trains
Homes
Boats
Snowmobiles
Golf Carts
Wheel Chairs
Power Tools
Camping Equipment
Laptop Computer
Street Lamps
Cell Phone
Digital Camera
Toys
Watches
Hearing Aids
Calculator
31
Fuel Cells: First Technical Applications
Photo source: Smithsonian Institution
NASA Apollo fuel cell, 1964.
32
Fuel Cells: Military Applications
Submarine Drive , Battery Chargering
33
Fuel Cells: Commercialization Has Already Begun
Honda FCX
»
Propulsion: Motor 60 kW; 272 Nm
»
Fuel Cell: 78 kW
»
Fuel storage: Compressed H2, 350 bar
»
Range: 355 km
»
Top speed: 150 km/h
»
Commercial launch in 2009
Daimler Chrysler Citaro Bus
»
Propulsion: Ballard PEM-Stack 250 kW
»
Fuel storage: Compressed H2, 350 bar
»
Range: 200 km
»
Top speed: 80 km/h
»
Commercial launch in 2008
34
Hydrogen fuel cell vehicles do
not pollute!
35
Mobile
Fuel Cell Fork Lift
»
Manufacturer: Toyota Motors
»
Max. Lifting Capacity: 2,500 kg
»
Fuel Cell: 30 kW
Utility Vehicles & Cargo Lifters
36
CHP (Combined Heat & Power)
or Co-Generation Systems
Illustration by
Ballard Power
Systems Inc.
Viessmann
Illustration by Sulzer
European Fuel Cells
Illustration by Vaillant
Illustration by Ballard Power
Systems Inc.
CEV_FCH_K/37
Source: GEOS
Off-Grid And Backup Power Supply
250 W – 1,2 kW
Portable PEM Fuel Cell System
Source: IdaTech
Telecom Transmitter
5 kW Fuel Cell Backup
1,2 kW Fuel Cell Backup
38
Who Are The Main Customers for Fuel Cell Technology?
» Those who need 100 % energy security:
Telecom Repeater Stations
Illustration by BedfordHospitals
Hospitals
Server Stations
39
Fuel Cell Market
40
Fuel Cell Training Systems
Dr FuelCell® Professional
Measurement Box
Motor / Fan
Fuel Cell
Solar Module
Load Box
Electrolyzer
BASICS on Single PEM Fuel Cell / Hydrogen Generation / Solar Cells
42
Dr FuelCell® Professional
Introduction to Fuel Cells & Renewable Energy
Lessons Covered
Electrical characteristics of:
» A Solar Module
» A Hydrogen Generator
» A Single PEM Fuel Cell
» Characteristic curves & the power curve
» Optimal power points of various loads
» Faraday´s Law, Ohm´s Law, etc…
Incl. Course material with pre-prepared lessons for
professors and students for Chemistry, Physics and
Science
43
Clean Energy Trainer
» Experiment set for renewable energies and their
combination with hydrogen fuel cell technology
» Covers the complete energy chain including
generation, conversion, storage and supply
44
Software
Features:
» Manual and automatic graph generation for each component (wind generator, solar panel,
electrolyzer, fuel cell stack)
» Selectable source profiles for the simulation of wind generators and solar modules
» Selectable load profiles for the simulation of different home consumers (air conditioner,
computer, light, stove)
» Measurement of operating parameters
» Visualization of data in tables and graphs
» Exportable data acquisition (CSV file)
Scenario Simulation – Home Consumers
45
Instructor Training System
Analyze the Characteristics of a 50 W fuel cell stack (10 cells)
Hydrogen Storage
Fuel cell stack
with fan
LCD Displays
DC converter
Consumer load
Electronic load
Software
46
Instructor Training System
With the Instructor the interaction bewteen the stack and the supporting auxilliary components
can be analyzed….
Efficiency of the fuel cell stack
»
Determining the stack efficiency by power balance
»
Parasitic load
»
Effect of stack efficiency in practical applications
»
Determining the stack efficiency by current and voltage efficiency
»
Thermodynamic view of the different reference voltages
Parameters influencing the characteristic curve
»
Investigating the effects of air supply on V-I curve
»
Effects of increased internal resistance on V-I curve
»
Effects of temperature / air supply on V-I curve
47
Instructor Training System
Automated Experiments
e.g. Fuel Consumption
e.g. Stack Efficency vs. System Efficiency
e.g. Factors Effecting the Charactristic Curve (temperature, air supply, etc..)
45°C
25°C
Effect of Temperature
48
Solar Hydrogen Extension System
Photovoltaik
0.5 kWP
PV ~ 0,5m2
Load
Controler
Back-up Battery
In
v
30 ert
e
0
W r
=
~
O2
Electrolyzer
30 sl/h H2
hy-ExpertTM Instructor
Fuel Cell System
50 W
49
Hybridisation
Technical Application: Fuel Cell + DC/DC Converter + Battery
Example: 1 kWh required as 1 kW for 1 hour can be realized:
a)
By a 1 kW fuel cell which is operated for 1 hour per day
b)
By a small 50 W fuel cell in combination with a battery which provides the 1 kW for 1 hour, in
the following 20 load free hours, the 50 W fuel cell will slowly re-charge the battery for the next
power peak.
50
Nexa® Training System
Hybridization
Engineering of fuel cell powered application requires knowledge of the load profile (load distribution
over time).
In all relevant technical applications, fuel cells are combined with a buffer battery for:
»
Range extension to cover for temporary power peaks
»
Equalizing load distribution to save cost of the overall system
»
Protection the fuel cell from overloading by too high currents
Therefore the load profile and its impact on the system response should be carefully analyzed!
51
Nexa® Training System
Hybridization
For engineering of fuel cell applications the following parameters
have to be dimensioned / balanced:
a)
The fuel cell size (rated power in Watt)
b)
The battery size (capacity in Ah)
c)
The amount of fuel (stored hydrogen in liters)
A perfect tool for engineering and dimensioning is the
Nexa® Training System
52
Nexa® Training System
Based on an industrial 1.2 kW fuel cell power module
Incl. training and course material
Energy Management Module
I IN
A
26...48 Vdc
I LOAD
I OUT
A
+
A
Power IN
21...30 Vdc
A
+
IBAT
DC OUT
Battery
-
Relay
22...30 Vdc
DC/DC Converter
»
DC/DC converter (24 V)
»
Battery charger with Start- and Back-up Batteries
»
DC/AC Inverter (230 V)
-
~
~
230 Vac OUT
N
230 Vac
DC/AC Inverter
53
Nexa® Training System
A powerful 1.2 kW System to learn step by step:
1.2 kW
Power
»
The stable conditions for operation
»
Which fuel cell size is required
»
How to optimize the battery capacity versus hydrogen capacity
»
Hybrid system response on load change
»
How an Uninterruptable Power System (UPS) works
Mechanical Engineering
Electrical Engineering
Environmental Engineering
Automotive Engineering
Vocational Training
COMPLEX TRAINING SYSTEM FOR PRE-APPLICATION TRAINING / R&D
54
Nexa® Training System
Flow-Chart
Power-Chart
Efficiency & Losses
» Lab experiments with : fuel cell, hydrogen, battery, power electronics, electrical
system design and hybridization
» All application modes represents typical commercial applications
55
Fuel Cell Components
Instructor Integration System
Create your own projects…
Constructor / FC-50 Module
Incl. Fan & controller for Integration
57
Instructor Integration System
Fuel Cell Applications
Pheripheral components of the Fuel Cell
Hydrogen supply
Fuel Cell
CAR
Motor/ Motor controller
58
Nexa® Integration System
Fuel Cell Power Module
»
Rated Power: 1.2 kW, Air cooled
»
Most reliable and durable in operation incl. safety monitoring
»
Optional DC/DC Converter (24 V) with optional battery extension
»
Optional DC/AC inverter (230 V) to generate AC grid voltage
No.1 for Universities
59
Nexa® Integration System
Benefits and Conclusion
»
Students can create thier own car
»
Compete in international fuel cell races
»
Heliocentris offers all fuel cell and electrical
components for a safe operation
60
Nexa® Integration System
1.2 kW fuel cell integrated in cabin and oben car
61
FC-42 Evaluation Kit
Incl. Evaluation / Integration Kit
»
Liquid cooler and air compressor
»
Purge & security valves
»
Controller and monitoring unit
»
For safe ramp-up and operation
of the FC-42 stacks
Based on the liquid cooled
FC-42 fuel cell stacks
Single Stack
Double Stack
360 W
720 W
62
HyPM System Platform
HyPM Fuel Cell Series for High Power Applications
Incl. Evaluation / Integration Kit
»
Liquid cooled fuel cells for integration (vehicles, boats, off-grid power supplies….)
»
Rated power: 4 kW, 8 kW, 12 kW and 16 kW
»
Available with Integration / Evaluation Kit (cooling system, controller, …)
63
The Next Step: Management of Complex Hybrid Systems
64
65
New Energy Lab: Educational Laboratory for Renewable Energy
»
Gain knowledge and practical experience in
New Energy Management
»
Combines renewable energy generation
from solar, wind and fuel cell power with
modern energy storage technology
»
Create an autonomous hybrid system
Energy Components
Solar
1,200 Wp
Wind
400 Wp
Fuel Cell
1,200 Wp
Hydrogen Generator
60 sl/h
Battery
55 Ah
66
System Setup Follows Learning Objective
» Sources can be freely
connected to the energy
management unit
Renewable Energies
» The topic Energy
Management is covered
from every perspective
» Excess engergy can be
stored in battery bank or
converted into hyrogen
Power Supply
Hydrogen
Additional Energy
Energy
Management
Unit
Excess Energy
Additional Energy
Additional Energy
67
New Energy Lab
Input
Solar Modules
Energy Management & Storage
Output
Electronic Load
Small Wind Generator
Backup
Consumer Loads
Public Grid
68
New Energy Lab
» Different system setups with
a few clicks
» Individual investigation of
electrical energy paths
» Connection of multiple
loads to the energy
management unit (12, 24,
230 V)
» Multitude of measurements and sensors for data
logging
69
Data Acquisition (Sensors)
»
Wind speed
»
Load voltage
»
Solar radiation
»
Hydrogen flow
»
Ambient temperature
»
Hydrogen pressure
»
Module temperature
»
Hydrogen storage temperature
»
Turbine-current
»
FC-current
»
Turbine-voltage
»
FC-voltage
»
PV-current
»
DC/DC-current
»
PV-voltage
»
DC/DC-voltage
»
Backup battery current
»
Grid-current
»
Backup battery voltage
»
Grid-voltage
»
Backup battery temperature
»
Load current
70
Central Monitoring and Control Software
»
Data logging and analyzing
»
Online visualization of data and system status
»
Displaying energy flows between the components
»
Data visualization in real time
System overview
Measuring data
71
Select Realistic Operational Modes
» Component Test:
Investigate PV, Wind or Fuel Cell separately
and fully independently
» Island Grid Mode:
Disconnected from the public grid
May collapse in case of mismanagement
» UPS System Mode
Public grid = Main power source;
New Energy Lab provides power in case of grid failure
» Grid Backup Mode:
New Energy Lab = Main power source;
Grid power only used if New Energy is insufficient
72
New Energy Power Supply (5 kW)
73
New Energy Power Supply (Bahrain Project)
Battery
bank
Computer
with indoor
display
Wind
turbine
Photovoltaics
DC/AC
Fuel cell power
module
DC/AC
DC/AC
Public
outdoor
display
Web
DC/ACisland
inverter
Customer
load
Overall
system
control
Electrolyzer
Public grid
Hydrogen
storage
Internet
connection
New Energy Power Supply
» Combining all relevant new energy
technologies with conventional
energy sources
» Operates a technical application
fully autonomously with renewable
energies
» Worldwide accessibility through
web interface
» The ideal application for
educational and research purposes
75
Interaction of System Components
Function
Load Request
Off Grid
PV, Wind >
Request?
Supply Load
Charge battery
Produce Hydrogen
YES
NO
PV, Wind <
Request +
Battery SOC OK?
Supply Load
YES
NO
Hydrogentank
OK?
FC on
Supply Load
YES
NO
Grid Backup
Supply Load
Grid connected
77
Photovoltaic Modules / Wind turbine
Rated wind power/ voltage 1700W / 0…600V
Rated wind speed
12m/sec
Cut in wind speed
3m/sec
Output voltage
25Vdc
Rotor diameter / Mast
3m / 8m
PV Solar power (STC)
4 kW (20 x 200Wp)
Open circuit voltage
33,2V
Short circuit current
8,7A
Voltage / Current at MPP
25Vdc / 7.9 A
78
Fuel Cell, Hydrogen Generator & Storage
Hydrogen Generation & Storage
H2 flow rate
120 Nl/h
Capacity
3,000 NL @10bar
Max. refilling pressure
10…17bar
Fuel Cell
Rated power
1200W
DC voltage range
22…50V
Rated current
46A
Emission water
870ml/h @ rated power
79
Photo: King Saud University / Sustainable Energy Technology SET (E.E. Dpt.)
PLC-type Siemens S7
Sensors
Environmental data, hydrogen flow & pressure,
temperatures, current, voltage, mass flows etc….
80
Date
Total Energy
CO2 Saving
Feb 13, 2010
130 kWh
117.6 kg
Sep 4, 2010
2630.6 kg
Web-based User Interface & Visualization Software
»
System overview
»
Data logging & export
»
Data monitoring
»
Special mode for starting/ stopping hydrogen
generator and fuel cell manually
82
Example: Data capturing (taken during commissioning)
Commisioning Diagramm
5000
100
Controlled decreasing by
Island grid cused by SOC
and due to small costumer
load
4000
90
80
60
Power [W]
3000
50
Test air conditioning with
maximum heating and
cooling
2000
40
Battery State of Charge [%]
70
30
1000
20
10
0
8.2.10 12:00 AM
0
8.2.10 12:00 PM
SUN_Power
9.2.10 12:00 AM
WIND_Power
LOAD_POWER
9.2.10 12:00 PM
SOC_Battery
83
New Energy Power Supply, Bahrain
» Customer:
Bahrain Petroleum Company (BAPCO)
» Installation
Ground mounted
» Location:
Awali, Bahrain
Power electronics
Fuel cell module and
Hydrogen generators
PV array and Wind turbine
Visitor Center
84
85
Thank you for your attention