DR.N.Rajalakshmi Team Leader CFCT-ARCI, IITM RP, Taramani Chennai [email protected] 12/18/2018 HAI Jodhpur Dec 2018 1
DR.N.RajalakshmiTeam Leader
CFCT-ARCI, IITM RP, TaramaniChennai
[email protected]/18/2018 HAI Jodhpur Dec 2018 1
CENTRE FOR FUEL CELL TECHNOLOGY (CFCT-ARCI)
• Forefront in Proton Exchange Membrane Fuel Cell development in the country
Development of Proton Exchange Membrane Fuel Cell systems
❖ Application in decentralized power generation systems and transport applications
❖ Material development, Stack & System design and Engineering
Hydrogen generation
Hydrogen storage materials
Off-spin activities
Next-gen batteries
Super capacitors
R & D activities
Major activities
Inclusion of Industries at various stages of technology development (Bipolar plates, power converters, assembly components)
Knowledge dissemination and manpower generation in the field of fuel cell12/18/2018 HAI Jodhpur Dec 2018 2
PEMFC– STATIONARY APPLICATION
Grid Integrated Power Supply (GIPS) MILESTONES
Air breathing Fuel cell - application Development of Micro Fuel Cell
Micro Fuel Cell Rated power
Dimensions Weight Photograph
ARCI-Home made 0.75 W 8 x 2.1 x 1.8 cm 100 g
MiniPak (Horizon) 1.5 W 10.4 x 6.8 x 2.5 cm 120 g
0.0 0.2 0.4 0.6 0.8 1.00.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
Vo
lta
ge
(V
)
Current (A)
With Fan-3x3cm - Temp-33C
WoFan-Temp-42C
WoFan-Temp-38C
With Fan - Memore -Temp -30C
0.0
0.2
0.4
0.6
0.8
1.0 With Fan-3x3cm - Temp-33C
WoFan-Temp-42C
WoFan-Temp-38C
With Fan - Memore -Temp -30C
To
tal P
ow
er
(W)
H2 - 200 SCCM
MEA Area - 5.2 cm2
2016-2018
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PEMFC - Stationary and for forklift applications
Achievement
Way Forward
1. Stacks of 5 KW module
2. Continuously tested for
24 hours
• Development of air
cooled systems
• Testing at Industrial site
• Testing of PEMFC
forforklift aplications
OBJECTIVES
1. Continuous operation
2. Efficient thermal Management system
3. Open loop to closed loop water
4. Turn key solution with all the controls and safety
0 5 10 15 20 25
30
35
40
45
50
55
Tem
pe
ratu
re (
oC
)
Stack Temperature (°C)
Coolant Tank Temperature (°C)
Stack Power (KW)
Time (Hrs)
25
30
35
40
45
50
Tank T
em
pera
ture
(oC
)
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
Sta
ck P
ow
er
(kW
)
Two prototypes 5/7 kW system
Development of Air cooled stack
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1kW PEMFC Vehicle
One of the mandates for the Centre for Fuel Cell Technology is to demonstrate fuel cells in transportation application.
Fuel cell Range Extender - Air cooled stack car operated for more than 100kms.
Hub motor based single wheel drive Go-Kart. A top speed of 30kms under 200 kg load
REVA Car
Fuel cell hybrid vehicle use fuel cell with battery and/or supercapacitor to power its motor as the traction drive demands high power in a short time (acceleration & deceleration), ~ 2 times of average power during drive cycle.
5kW capacity water cooled PEMFC stack. Range extension : 17-18kms in hybrid mode. Completed 100 kms of vehicle running in hybrid conditions
PEMFC – TRANSPORT APPLICATION
250 W
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FIELD TRIALS
Neyveli Lignite Corporation Ltd (NLC) 2015-2016
5 KW PEMFC system features : FC controller & Monitoring Equipment, Load following based gas flow control, Controls for current, Voltage, Wattage and reactants, Temp Monitoring, Cutoff for overload, voltage, current & temperature.
0 50 100 150 2000
10
20
30
40
50
60
Current, A
Vo
ltag
e, V
0
2
4
6
8
Po
wer
/ W
0 2000 4000 6000 8000
0
1
2
3
4
5
Maxim
um Po
wer
Cumulative time (Min)
Maximum Power
Gas Authority of India Ltd (GAIL) 2016-2017
0 20 40 60 80
0
1000
2000
Po
we
r (W
)
Current (A)
Power
0 10 20 300
500
1000
1500
2000
Pow
er
(Watts)
Time (hour)
Power
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HYDROGEN GENERATION
ECMR – combination of Electrolysis of water and reformation of alcohol
X-OH + H2O → CO2 + 3H2 E = 0.02 V vs. RHE Advantages➢ Energy consumption is 1/3rd of water electrolysis➢ Carbon based materials can be used➢ Hydrogen separation from CO, CO2 steps are not required➢ Easy and quick start-up and shut down
I. Electrochemical alcohol reformation
Progress➢ 1.0 Nm3/hr /2.5 Nm3Energy consumption : 1.4kWhr/Nm3
Operating hours - ~500 hrs
32 cells (GEN-1)
32 cells (GEN-2)1 Nm3 H2 generator system
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R&D activities
Development of Electrocatalysts and support materials for fuel cells and electrolyzers
Development of ion exchange membranes1. Proton exchange
ePTFE-Nafion-TNT composite
Sulfonated Polyvinyledene
fluoride/ Zirconium phosphate
2. Anion exchange
Polyphenylene oxide/Quaternized
graphene oxide composite
Pd/N doped Graphene
N doped Mesoporous C
Graphene
200 nm
Mesoporous Pt
Pt/G
TiN coated SS316L
by CAPVD technique
SS bipolar plate Fuel cell with metallic bipolar plates
Polarization curve of Pt deposited 316L SS compared
with bare substrate and coated with Polyaniline
Metallic bipolar plates
TNTs
Co Nano flowers Mn/C
SS bipolar plate
Additive manufacturing
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PRESENT STATUS
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Fuel cell power system 2020 targets versus 2015 status (blue) for light-duty vehicle applications
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Fuel cell systems – Technical and cost Requirements
CostDurabilityPerformanceH2 Infrastructure
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The analysis indicates that the fuel cell stack would account for 66% and 43% of the total system cost at 1,000 and 500,000 systems per year, respectively. Of the various components, two (catalyst and bipolar plates) are dominated by commodity materials costs (platinum and bipolar plates (ss)), which are relatively insensitive to manufacturing volume.
IIT-D,TERIIIP,NPL,ACME,IOCL,BPCL,IIT-R
UoR BHUIIT-K, DEITata/Plugpower
CGCRI, Arora Matthey IIT--Kgr, BESU, CMERI, NIT-Dgp,HIT
IIT-GAIISTTU
IMMT,CIPET
CSMCRI,MSUB,ERDC
NMRL, IIT-B,NCL,PU, SU,NEERI,SICESBARC,RIL, IndiaSoft,Thermax, Digitronics,Bloom Energy
IIScNAL , ISAC,REVA,NanoRamIE, Bloom EnergyDaimler,GE
BHEL, Assam Carbon
IIT-M, CECRI, SSF, MCRC,NCCR,, IGCAR, CFCT,ARCI , Anna Univ.,Satyabama Univ., VIT, NIT-T, PSGIAS,Alagappa Univ., TCE,MKU, K-Pas, Alacrity, HEB, TVS, AL, M&M, Anabond-Sai Energy, Ingsman , Nissan Renault,
VSSC,C-DACTATA,Sued chemie
TU,DCRU,UPES
Few Indian industries •Traders not included
MNRE to establish the National Centre for Hydrogen Energy and Fuel Cell
1980’s and early 90’s
Present
13
NEERI, MNNIT, Uni.Albd, LMDDD
CIMFR,NIT-Rkl
BITS, Goa
Major Hydrogen and Fuel Cell Activities in India
IICT, Andhra Uni. , JNTU, OU,UoH,ARCI,NFMTDC, Falcon Ind.,, IIT-H
Arrows are indicative of region , may not be precise
Increase from ~ 10 institutions in the early 90s to more than 100 research groups
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Organizations Nature of work
H2- ICE
BHU Transportation application – demo – 2,3,4 wheelers
Many Universities, IITs Transportation application – studies ( Direct combustion, mixing with other fuels etc., )
Bajaj, Birla ,M &M , AL,
Kinetic (?), TVS (?)
Transportation application – demo – 2 or 3 wheelers
Alkaline Fuel Cells Birla, Bajaj Transportation application
PEM FC
TATA & ISRO System integration using bought out stacks, simulation for applications – BUS
REVA System integration using bought out stacks, 4-wheeler ( van ?)
Birla , Bajaj , M&M ,TVS, REVA,
System integration using bought out stacks, simulation for applications
SSF, ARCI & REVA 4 wheeler demo, Range extender
M&M & ARCI 3 wheeler demo, Range extender
PAFC Defense Lab & REVA 4 wheeler demo
Hydrogen in Transportation Technology Development -Indian Scenario*
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Country Name of the project Funding Number of Installations Power Period Fuel cell supplier New
developments
Japan Ene Farm US$460 1.4 million by 2020 5.3
million by 2030
0.7-0.75 kW 2009-2015 Panasonic and
Toshiba
In 2015 Panasonic announced improvements to its PEM offering: Reconfiguring
the stack, Simplifying the system and 3.Reducing the number of components by
15%, 20% reductions in platinum usage ,weight reduction from 90 kg to 77 kg,
durability from 60,000 to 70,000 hours ,maintaining total efficiency at 95%.
,system with a ‘black out’ function able to generate 500 W for up to 96 hours.
50000 2015 SOFC (10%) from
Aisin Seiki’s
Netherlands FCH JU MW level 2015 Ballard cleargen
Nedstack
To use hydrogen at AkzoNobel’s sodium chlorate plant in Bordeaux
China FCH JU supported by the
FCH JU
2 MW Ballard 2MW of stack for a facility in Yingkou, China, alongside AkzoNobel, MTSA
Technopower and Ynnovate Sanzheng Fine Chemicals.,
This unit will also use waste hydrogen, from the chlor-alkali process,
china USTDA 2 15kW First Element
Energy
Feasibility study and pilot project, for Jiangsu Communications Services Company, Ltd. to evaluate fuel cell applications for busload and off-grid power within the telecommunications infrastructure in China.
India 50 in 2015
200 in
2016
Ballard
Electragen
Intelligent
energy(IE)
Telecom sector
Microqual Techno Limited Ascend Telecom Infrastructure Private Limited –Hydro Industries Reliance
Philipines AeCi 5 kw 20 units Ballard Electragen Methanol-fuelled ElectraGen™-ME backup power systems were installed on rooftop locations in Manila for Globe Telecom.
South Africa Eskom, Anglo American Platinum South Africa
5 kW 1 Ballard A 12-month field trial of a 5-kW ElectraGen™-ME fuel cell in an off-grid residential application in the rural community of Naledi Trust. The fuel cell will be integrated with a battery bank and inverter to operate within a micro-grid to power 34 rural homes, with monthly delivery of liquid methanol fuel to an external storage tank.
Caribean Precision Power & Air Caribbean
13/25 5 kW Ballard Methanol-fuelled ElectraGen™-ME backup power systems were deployed at critical sites in the Digicel Group Limited’s network in Jamaica.
International Demonstrations
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✓ In India Chloro-alkali industry turnover is about 25,000/-crores and provides employment to nearly 20 lakh people.
✓ 34 chloro alkali industry in India - 31 is functioning✓ 3262 lakhs MT Annualy corresponds to 8643Nm3/2016-17✓ Avg. Plant Operating ratio - 81%✓ H2- Utilisation
28% - Used in HCL Industry38% - As fuel in boiler
16% - As Bottled cylinder1.2 % - Hydrogen consuming products
About10% - FlairedConsumption percentage increasing from 90 to 98.5 % over last five years
✓ Raw materials - Salt and power
✓ Salt production - 81 % Gujarat, 9% -Rajashthan, 8%- Tamilnadu, 2%- Andhra Pradesh
✓ Power cost is about -<Rs.1/unit
H2 Production - Indian Chloro-Alkali industry –Overview
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PV Based Hydrogen Dispensing station at NISE- Features
❖Commissioned in Feb 2014
❖120 kW- PV module- Poly crystalline based
❖125 kW inverter is also under usage for grid power utilization
❖4250AH, 240V- Battery Bank is used
❖Volume of Buffer Tank - 1000L water capacity-ASME regulation
❖System - AWE-5.0 Nm3/hr
❖Two Stage Diaphragm Compressor - 5 bar to 350 to 550 bar
❖Storage Tube – 3 nos. Each -2100 L water capacity - 60 Kg Hydrogen at 550 bar
❖Hydrogen Dispensing rate - 1kg/min@350 bar
❖Deoxo Dryer
❖Nitrogen is purged at Hydrogen line in case of Emergency
❖Flow control manifold.
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Snapshots of Hydrogen production& Fuel Cell Activities in India
1. PV based water electrolysis and then corresponding dispensing two unitis available in India . One at (1) NISE (AWE based) (2) IOCL (PEM based)
2. Reformation of biomass –Glycerol based at IICT, Hyderabad- 2 Nm3/hrCMERI, Durgapur- Composite Cylinders.
IITD and IITK working on reducing Nox emission in Hydrogen fuelled EngineNot succeeded in some of the vehicle.
@Dwaraka, IOCL (hydrogen &CNG) dispensing system is available.
3. Fuel Induction time chart, Refer his paper published in IJHE ,1990 (LM DAS, IITD)
Does not require any changes in common man perspective to implement his Hydrogen engine based vehicle. Since they are handling already CNG Hydrogen mileage - 25 Km/Kg of Hydrogen.
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4. IOCL Hydrogen and CNG mixing ratio was varied ( 12,15,18,20.25% )18 % optimised30Nm3/hr- PEM based ArevaPressure – 550 barHydrogen Nozzle replacement 4-5 yearsHydrogen engine powered buses20,000 km trial completed, 60,000 km Target
60+ years of Hydrogen Experience5. Air Products 6 million kg/per day production
Largely from SMRElectrolyser – Through third party agreement
6. IICT, Hyderabad Biological Hydrogen Production350kg food wastage produce 11 kg of HydrogenRs.150/ kg Hydrogen
7. IISc, Bangalore 60 g Hydrogen/kg of BiomassAimed to produce 60 kg Hydrogen/day –to run the
Tata motor fuel cell bus.
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8. ONGC Cu-Cl cycle for Hydrogen ProductionRs.16/Kg Hydrogen (expected)Energy consumption for Hydrogen productionwill vary depends on operating temperature.
9. Tata Motors 20 km/ kg Hydrogen10,000 km ran so far.Mileage per fill – 300 km
10. Mahindra & Mahindra Spark Plug cap reduced to o.3 mm for H2 enginefrom CNG engineAl lined with carbon composite material used in the cylinders (25 km/Kg Hydrogen.)
11. 48V Dc required for Telecom tower applicationIntelligent Energy 7 unit installed in India
Hydrogen Fuel cell for (3 completely off grid, 24 hrs operationTelecom application 04 parallel with grid power, 10-12 hrs/day operation
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Manufactuerer Product name Type Output
Avalence Hydrofiller 15 Alkaline 750g/day
Hydrofiller 50 3 Kg/day
Hydrofiller 85 5kG/day
Hydrofiller 175 10kG/day
Element 1 H35 Reformer 4.5kg/day
H75 9.7kg/day
H110 14.3kg/day
Hydrogenics Hystat Alkaline 8.6 to 128kg/day
Hylyzer PEM electrolysis 1-2 Nm3/H( 2kg/day -4 kg/day)
ITM Hpac10 PEMelectrolysis 1.3- 5 Kg/day
Hpac 40 1.3- 5 Kg/day
HFuel H2 stn 5-100kg/day
Hgas 25-400Kg/day
Nuvera Power tap Reformer 50kG/day
Proton on site Hogen S series PEM electrolysis 0.56-2.27 kG/day
Hogen H series 4.31-12.94 kG/day
Hogen C series 21.6-65kG/day
H2 Infrastructure stations GoalsCalifornia’s Goal: 68 by 2016 --- 1.5 million ZEVs by 2025.Japan’s Goal: 100 by 2025Germany’s Goal: 50 by 2025Scandinavia’s Goal: 45 by 2025 --100% tax on imported vehicles is waived for a ZEV.UK’s Goal: First 65, then 1,150 by 2030Commercially available Hydrogen generation systems 2012
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Properties Battery EV
Tesla Chevy spark
FCV
Miles offered (1kWh) 2.63 3.30 3.57 miles – 100 kW EV
equivalent
1 KW of renewable energy (at
120 MJ = 54.65 KWh/Kg for
hydrogen) after 39% conversion
losses in electrolysis
100kW – 134hp 0.86 miles
(47mpKg) Hyundai Tucson)
1.25 miles (68.3 mpKg 90KW
Toyota 2015 FCV
1 KWh of natural gas heating
energy (1/13.1KWh/Kg LHV
energy/3.629 Kg Ch4 per Kg
Hydrogen) produces 0.021Kg of
Hydrogen
1.32 miles
(Tesla Model S
P85 at
380Wh/mile)
1.79 miles
(100KW Chevy
Spark EV at
280Wh/mile).
0.987 miles (Hyundai)
1.428 miles (Toyota).
Some calculations to illustrate the economic benefits of FCV vs EV energy costs via renewable vs fossil fuel pathways
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1. There are 21 companies world wide manufacturing PEMFC system for stationary applications with major players like Ballard, Hydrogenics, powercell. Plugpower, Intelligent energy etc., with manufacturing capability.
2. With respect to the Demonstrations, Japan leads the show with funding from Government using Panasonic/Toshiba fuel cell stacks.
3. Most of the back up power for telecom sector is handled by PEMFC systems of maximum 10 kW capacity . However there are only two demonstrations at the mega watt level, one at Netherlands and another one at China. Both use the byproduct hydrogen available at the chloralkali plant.
4. With respect to funding, 12 companies are supported by public and remaining are private venture capital.
5. R & D investment is about $14m by ballard, Plugpower $6M , while hydrogenics spends more than 50% of its funding to R &D.
6. The private investment in USA is about 50% , ($800M) of the total investment world wide.
Conclusions
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Technology Science