Hydrogen Refueling Station - University of Waterloochemeng.uwaterloo.ca/mfowler/h2station.pdf · Hydrogen Refueling Station Green Energy Consulting April 2, ... Aspen Modeling - Process

Design and Development of a Hydrogen Refueling Station

Green Energy ConsultingApril 2, 2003

Prepared by:Serena Lee, Sarah Wai Sze Li, Patricia Wong

Supervisor: M. Fowler

Project Goals

l Design a hydrogen refueling station to service the “Hydrogen Economy” of the future

l Create a safe, reliable, timely and cost-efficient design that can be easily utilized in the near future to refuel hydrogen-powered fuel cell vehicles

Justification

l Today’s vehicles rely on gasoline and diesel to run internal combustible engines which are harmful to urban air quality and global warming

l Future vehicles will likely be powered by hydrogen-powered fuel cells, which require no foreign oil and emit no harmful emissions or greenhouse gases

l Therefore, demand to distribute hydrogen in the community will make the design of a hydrogen refueling station a necessity

Hydrogen Economy

Hydrogen Economy - Current Projects

l President Bush's February 2003 State of the Union Address:– proposed an overall $1.7 billion for fuel cell

vehicle and hydrogen fuel R&D over the next 5 years

– proposal includes $720 million in new spending, plus $1 billion already budgeted

l 2 hydrogen refueling stations in Canada (Vancouver)

Hydrogen Car & Refueling Station

Mazda Demio

Ford P2000

Honda Hydrogen Refueling

BMW 7-series - LH2

Benefits

l Hydrogen fuel cell-powered vehicles offer the possibility of clean and efficient operation

l World crude oil production is declining: focus will shift to usage of alternative fuel to power vehicles

l Infrastructure to distribute Hydrogen will be the KEY driver in the development of the Hydrogen Economy and related technologies.

l Large-scale design leads to future development opportunities

Design Methodology

l Requirements of the Station – Based on Today transportantion practices (i.e. 500 refueled serviced per day)

l Evaluation of design options– Determine components in station

l Modeling: Using AspenPlus Software– Determine station specifications

l Review of Safety and Code Issues: – Hydrogen safety

l Challenges

Schematic of Future Hydrogen Refueling Station

H2 StorageDispensing

Compressor

SOFC Power Generation

Steam ReformerNatural Gas

Hydrogen Clean-up

Sulphur Removal

H2 and CO rich stream

Heat

Courtesy of Revolve Inc.

PdMembrane

Pure H2

CH4 + H2O à CO + 3H2

H2O + CO à CO2 + H2

CH4 + H2O à CO + 3H2

H2O + CO à CO2 + H2

•Avoids catalyst poisoning in the reformer using zinc oxide

Local Vehicle Fleet

Energy from SOFC

Modeling Results - Station Specifications 1

Fuel: Natural Gas

Sulphur Removal

Hydrogen & CO gas

CompressorDelivery system

Heat

Pure H2

Reformer Hydrogen Clean-up

H2Storage

Power generation from waste

stream

Energy

Aspen Modeling - Process Flow Diagram

NG-IN1NG-IN2

SULPHUR

DESF-GAS

STEAM1

HOT-GAS REFM-GS1

STEAM2

REFM-GS2 REFM-OUT

Q5

Q 7

Q

PUREH2

OTHERH2

COMPH2DISPENSE

WATER1 WATER2

AIR1

OXYGEN1

AIR2

Q 3

FUEL1FUEL2

Q 4

AIRIN1

Q 2

FUELLEFT

AIROUT

EXHAUST1

Q6FUELOUT

RECYCLE

H2-IN

FUELIN FUELIN1 FUELIN2

EXHAUST2

AIRIN

EXHAUST

Q1

Q

FUEL3

OXYGEN2

DPRES-H2 HEAT-H2 WASTEGAS

ZINC-BEDDESULF

REFORM GAS-SHIFHEATER

H-CLEAN

COMP-H2STORAGE

STEAMER1STEAMER2

COOLER

CATHODE

ANODE2

HEATER1

AFTERBUR

SPLIT

EJECTOR COOLER1

RECUPER

HEAT1

REFORMER ANODE3

ANODE1

SEP

MIXER

TURBINE

HEAT2FCIN-CTR


Fuel: Natural Gas

Sulphur Removal

Hydrogen & CO gas


Heat

Pure H2


H2Storage


stream

Energy

••Inlet = 25 Inlet = 25 kmolkmol/hr /hr ≅≅ 609,788.4 L/hr 609,788.4 L/hr ••Pressure = 1atmPressure = 1atm••Temperature = 25°CTemperature = 25°C


Fuel: Natural Gas

Sulphur Removal

Hydrogen & CO gas


Heat

Pure H2


H2Storage


stream

Energy

••Zinc Oxide Bed:Zinc Oxide Bed:••Pressure = 1 Pressure = 1 atmatm••Temperature = 25°CTemperature = 25°C


Fuel: Natural Gas

Sulphur Removal

Hydrogen & CO gas


Heat

Pure H2

ReformerHydrogen Clean-up

H2Storage


stream

Energy

••Steam inlet = 490.62 L/hrSteam inlet = 490.62 L/hr••Pressure = 34 Pressure = 34 atmatm••Temperature = 882.22°CTemperature = 882.22°C


Fuel: Natural Gas

Sulphur Removal

Hydrogen & CO gas


Heat

Pure H2


H2Storage


stream

Energy

••Palladium (Pd) MembranePalladium (Pd) Membrane••Efficiency up to 99.9%Efficiency up to 99.9%••Separates 30% of HSeparates 30% of H22 for retailfor retail

•• HH22 Generating Generating Rate = 5279.4L/hrRate = 5279.4L/hr


Fuel: Natural Gas

Sulphur Removal

Hydrogen & CO gas


Heat

Pure H2


H2Storage


stream

Energy

••Solid Oxide Fuel Cell (SOFC)Solid Oxide Fuel Cell (SOFC)••Inlet Fuel = 13,035.98 L/hr @ 200°C & 3.3 Inlet Fuel = 13,035.98 L/hr @ 200°C & 3.3 atmatm••Operates between 900°C Operates between 900°C -- 1000°C1000°C••Efficiency up to 85% of fuel conversionEfficiency up to 85% of fuel conversion

••Generates 111 kW Generates 111 kW of powerof power


Fuel: Natural Gas

Sulphur Removal Hydrogen

& CO gas


Heat

Pure H2


H2Storage


stream

Energy

•• Commercial CompressorCommercial Compressor•• Outlet Pressure = 5000 Outlet Pressure = 5000 psipsi (340 (340 atmatm))•• Requires 100.15 kW of powerRequires 100.15 kW of power•• Efficiency = 72%Efficiency = 72%


Fuel: Natural Gas

Sulphur Removal Hydrogen

& CO gas


Heat

Pure H2


H2 Storage


stream

Energy

•• Compressed gas storage tanksCompressed gas storage tanks••Tank material Tank material -- steel, steel, figerglassfigerglass w/ w/ aluminum or plastic corealuminum or plastic core••Pressure = 5000 Pressure = 5000 psipsi (340 (340 atmatm))••Size = 11000 L (for 2 hrs buffering)Size = 11000 L (for 2 hrs buffering)


Fuel: Natural Gas

Sulphur Removal

Hydrogen & CO gas


Heat

Pure H2


H2 Storage


stream

Energy

••Commercial DispenserCommercial Dispenser••Pump maximum flow rate = 22.7 kg/minPump maximum flow rate = 22.7 kg/min••Model Dispensing Rate = 87.99 L/min @5000 Model Dispensing Rate = 87.99 L/min @5000 psipsi


l Retail Station Operating Hours:– Operating Hours = 20 hrs– Retail Service from 5 a.m. to 11 p.m.– Buffer hydrogen generation for storage from

11p.m. to 1a.m.

l Service– Approximately 950 fuel cell vehicles/day – Total production = 105,588 L H2/day– Refueling time = 1 - 2 min/vehicle

Hydrogen Safety 1

• Public education is required for hydrogen acceptance

• Safety codes are currently being developed in North America for hydrogen storage and delivery

• In Canada, the Canadian Standards Association (CSA) has set standards for the transportation of hydrogen and piping systems

Hydrogen Safety 2

• A hydrogen refuelling station in California follows guidelines set by the National Fire Protection Association (NFPA) and the American Society of Mechanical Engineers (ASME)

• Hydrogen can be safely handled

Challenges

l Due to the current lack of infrastructure, and information for large scale H2 production, cost of operation cannot be determined at this stage

• ASPEN result needs to be validated due to fuel cell and reformer technology is still new

• Future improvement in reforming technology may lead to design modification

More details here

Summary

l Our aim is to satisfy the inevitable demand for hydrogen fuel by designing a feasible hydrogen refueling station

l We anticipate a future automobile market with near-zero emissions, and our design will enable us to obtain that goal efficiently, reliably and at the lowest possible cost!

Conclusion

l Hydrogen Retail station are posible based on today’s societies transportation practices

l A conceptual design of a station indicates that a station can be built base on Natural Gas feed refueling 900 cars a day

l Safety and Environmental regulation are still under development, but issues are resolvable

Questions?

Hydrogen Refueling Station - University of Waterloochemeng.uwaterloo.ca/mfowler/h2station.pdf · Hydrogen Refueling Station Green Energy Consulting April 2, ... Aspen Modeling - Process

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