SINAVY PEM Fuel Cell - Siemens Global Website · PDF fileAnswers for industry. Marine & Shipbuilding SINAVY PEM Fuel Cell For submarines

Answers for industry.

Marine & Shipbuilding

SINAVY PEM Fuel CellFor submarines

Introduction page 3

PEM Fuel Cell:

function and design page 6

PEM Fuel Cell:

modules and power plant page 8

Outlook page 11

2

Fuel cells enable the direct genera-tion of electric power from hydro-gen and oxygen with significantly higher efficiency, with noiseless operation and without pollutant emissions compared with conven-tional combustion engines.

3

Reformer gas/air

Decentral power plants Freighter

Grid-independent operation (SOFC, PEM FC)

Emergency power supply (PEM FC)

Railroad Gas tanker

Electrical propulsion (SOFC, PEM FC)

Electrical propulsion (SOFC, PEM FC)

Reformer gas/air

H2/O2 H2/air BusSubmarine

Fuel Cell power plants Present and future

applications

Emission-free and noiseless operation (PEM FC)

Air-independent propulsion (PEM FC)

Delivery trucks

Emission-free and noiseless operation (PEM FC)

Space shuttle

Air-independent power supply (PEM FC)

Passenger car

Emission-free and energy- efficient operation (PEM FC)

Storage system for regenerative energies

Siemens Electrolyzer (PEM FC)

Application potential

Fig. 1: Possible applications for fuel cell power plants4

Energy

Water

Hydrogen Oxygen

In addition to these basic advantages, the fuel cell with a solid, ion-conducting, polymeric membrane (polymer electrolyte membrane – PEM) has more positive properties:

◾ Quick switch-on, switch-off behavior ◾ Low voltage degradation and long service life ◾ Favorable load and temperature-cycle behavior ◾ Capability of overload operation ◾ Low operating temperature (80° Celsius) ◾ Absence of a liquid-corrosive electrolyte.

All of these characteristics make the SINAVY PEM Fuel Cell an ideal power unit. Aboard submarines they show their outstanding advantages over other AIP (air-independent propulsion) systems for conventional submarines. Using oxygen and hydrogen stored in liquid or gaseous form on board as reactants, the only process result besides electricity and small amounts of residual gases which are given into the boats atmosphere is process water which could be used for different purposes – such as weight balancing to avoid process-related needs for trim adaptions of the submarine. Siemens has two types of SINAVY PEM Fuel Cell modules for you to choose from. The FCM 34, with a rated power of 34 kW, and the FCM 120, with a rated power of 120 kW. Submarines of Class U 212 A (six in the German Navy and four in the Italian Navy) are equipped with FCM 34 modules, which were developed from 1985 at the request of the German Ministry of Defense. Submarines of Class 214 and Class 209 PN – in the Hellenic Navy, Republic of Korea Navy, Portuguese Navy, and Turkish Navy – are equipped with FCM 120 modules, which were

developed in a later phase. Development work on the third-generation module (FCM NG) has recently started. The rated power of FCM NG is flexible in the range between 80 and 160 kW.Operational submarines of Class 209 can be upgraded with an additional fuel-cell power plant during refit, and so acquire the benefits of air-independent propulsion (AIP) at a much lower price than for acquiring a new submarine. The suitability of fuel-cell technology on board subma-rines has been demonstrated by earlier tests and more recently on submarines of classes U 212 A, 214, and Dolphin AIP.

Fig. 2

5

A simplified representation of the SINAVY PEM Fuel Cells' basic function and design is shown in (Fig. 3): the electrochemical element at which the chemical energy is converted into electrical energy is the membrane electrode unit. It consists of the polymer electrolyte, the gas diffusion electrodes with a platinum catalyst and carbon sheets on each side. After the abstraction of the electrons from hydrogen – they flow from the anode via the electrical load to the cathode – the resulting protons migrate from the anode to the cathode where they combine with oxy-gen (and the electrons) to form water. The theoretical voltage of an H2/O2 fuel cell is 1.48 V (referred to the upper heat value of hydrogen). At zero-load conditions, slightly more than one volt per cell is available. The cooling units or bipolar plates, in combination with carbon diffusion layers, distribute the reactants uniformly across the area of the cell, conduct the

electrons across the stack, remove the heat from the electrodes, and separate the media from each other. Figure 4 shows the two core components of a cell with outside dimensions of 400 x 400 mm, as used in FCM 34 modules. Figure 5 compares the bipolar plate of the FCM 34 mod-ules to the FCM 120 and the FCM NG. Two cells of the FCM 120 produce about twice the power of one cell of the FCM 34 type with nearly the same active area. The theoretically high development potential in regard to the membrane material is shown in Figure 6. With improved materials, the power density can be nearly doubled. The voltage of a SINAVY PEM Fuel Cell with respect to the operating time is stable, and degradation rates are less than 2 µV/h per cell for FCM 34 module. Signifi-cantly lower values were achieved during the operation of a FCM 120. This module went through different oper-ational conditions (Fig. 7).

PEM Fuel Cell: function and design

6

Cooling unit

400

mm

Cooling unit

Membrane electrode unit

Hydrogen H2 Oxygen O2

Electrical load 4e⁻

2H2+4e⁻=4H⁺ O2+4e⁻=20⁻

20⁻+4H⁺=2H2O

Anode Cathode

H⁺

H⁺

H⁺

Product water H2O + O2

Polymer electrolyte

Waste

Naf 115

Naf 115

Naf 117

Naf 117

Cell

Volta

ge [U

C/V]

Cell

Out

put P

C/W

Current I/A

1.1

1.0

0.9

0.8

0.7

0.6

0.5

1000

800

600

400

200

00 500 1000 1500

Mod

ule

Volta

ge [V

]

Operational Hours [h]

240

248

228

224

216

220

212

2080 20001000500 1500 2500 3500 450040003000 5000 5500

232

236

244 FAT'

s

Cons

tant

Loa

d at

560

A / 7

0 °C

Star

t–St

op O

pera

tion

/ 70

°C

Star

t–St

op O

pera

tion

/ 75

°C

Star

t–St

op O

pera

tion

/ 75

°C

Star

t–St

op O

pera

tion

/ 70

°C / 7

0 %

VKW

Load

Pro

file /

70

°C

Load

Pro

file /

75

°C

Cons

tant

Loa

d at

39

0 A

/ 70

°C

Fig. 4: Components of cell

Fig. 6: Potential output increases by using various electrolytes Fig. 7: FCM 120 / Module Voltage at 560 A and 390 A

Fig. 5: Comparison of cells: FCM NG Type (back), FCM 34 Type (center), FCM 120 Type (front)

Fig. 3: Functional principle

7

PEM Fuel Cell modulesSiemens has put every effort into integrating the PEM Fuel Cell stack, valves, piping, and sensors as well as the corresponding module electronics control and the ancillaries into a single container making the best use of the limited space on board. The ancillaries comprise the equipment for supplying H2, O2, and N2 for reactant humidification, for product water, and waste heat and residual gas removal. The container is filled with N2 inert gas at 3.0 bar abs. to prevent a release of H2 and/or O2 in case of leakages. Thus, the operator can use the PEM Fuel Cell as a working black box without having to care about the processes inside the container. The PEM Fuel Cell module can be operated at various static and dynamic load currents. Currents below 650 A for FCM 34 modules or below 560 A for FCM 120 mod-ules can be applied in continuous operation. The output power/current characteristics for FCM 34 modules are shown in Figure 8. For currents above the rated current, the loading time is limited due to insufficient heat removal at these values. Even loads up to double the rated current can be applied for a short time. At the rated operating point, the overall efficiency is approximately 59 percent with respect to the lower heat value of H2 (LHV). It increases in the part-load range,

reaching a maximum of approximately 69 percent at a load factor of some 20 percent of the rated current (approximately 100 A) (Fig. 9). The properties of the FCM 34 and FCM 120 modules are listed in the table on page 10.

PEM Fuel Cell power plantAppropriate operating conditions for fuel-cell modules are provided for submarine applications by a fuel-cell system in which fuel cell modules are connected

◾ to the hydrogen and oxygen supply ◾ to disposal units for functions like – cooling – residual gas – reaction water

◾ to auxiliary systems for functions like – inert gas drying – degasing for cooling fluid – nitrogen supply – evacuation system

◾ to the propulsion/ship’s system as to supply it with demanded electrical power

PEM Fuel Cell: modules and power plant

8

FCPP peripheral devices:

◾ oxygen ◾ hydrogen ◾ product water ◾ residual gases ◾ cooling system ◾ evacuation ◾ ...

FCPP peripheral devices:

◾ oxygen ◾ hydrogen ◾ product water ◾ residual gases ◾ cooling system ◾ evacuation ◾ ...

boats mains (main

switch-board)

boats mains (main

switch-board)

boats mains (main

switch-board)

FCPP Switchboard 1

FCPP Switchboard

FCPP Switchboard

FCM 34

a

b

c

Converter

Converter

FCM 120

FCM NG

FCPP Switchboard 2

EMCS

EMCS

EMCS

or FCM NG

140

80

70

120

60

50100

8040

6030

40 20

20 10

0 0

Mod

ule

outp

ut [k

W]

Effic

ienc

y [%

/h0]

0 0700 800 1000200 400 6001400 1200Current [A] Current [A]

160

180

1050350

Operator control and visualization of the fuel-cell system are facilitated by the integrated platform management system or directly via the control panel of the fuel-cell system. Figure 10 gives a simplified overview of the AIP system. The fuel-cell system in its entirety – the complete fuel-cell power plant, especially the supply and disposal systems described above for AIP operation, including spatial and functional integration on board – has been developed by HDW (Howaldtswerke Deutsche Werft AG). The submarine classes U 212 A, 214, and Dolphin are equipped with the new fuel-cell power plant by HDW based on SINAVY PEM Fuel Cell modules by Siemens. An AIP system with SINAVY PEM Fuel Cell modules can be added to existing submarines.

Fig. 9: Efficiency of FCM 34, 120, and NGFig. 8: Performance Data of FCMs – outlook on different CM NG configurations

Fig. 10: Two types of fuel-cell power plants (FCPP) a: fuel-cell battery with FCM 34; direct coupling of

FC voltage to boats mains at class U 212 A submarine b: fuel-cell battery with FCM 120; coupling via converter at

class U 214 submarinec: fuel-cell battery with n FCM NG, eg. n x 80 kW allows

higher system availability

FCM NG 160 kW FCM NG 135 kW FCM NG 80 kW FCM 34 FCM 120

FCM NG FCM 34 FCM 120

9

35

30

25

20

15

10

5

0

Num

ber o

f Sub

mar

ines

Siemens FCM Stirling Mesma other FCM

Type of AIP System

Fig. 12: PEM Fuel Cell modules assembled in a test rackFig. 11: Comparison of installed/contracted AIP Systems

Technical data FCM 34 FCM120 FCMNG80 FCM NG 135

Rated power 34 kW 120 kW 80 kW 135 kW*

Voltage range 50–55 V 208–243 V 65–80 V 110–130 V

Efficiency at rated load, approx. 59 % 54 % 54 % 54 %

Efficiency at 20 % load, approx. 69 % 68 % 68 % 68 %

Operating temperature 75 °C 75 °C 75 °C 75 °C

H2 pressure 2.3 bar abs. 2.3 bar abs. 2.3 bar abs. 2.3 bar abs.

O2 pressure 2.6 bar abs. 2.6 bar abs. 2.6 bar abs. 2.6 bar abs.

Dimensions

H = 48 cm H = 50 cm Similar to FCM 120

W = 48 cm W = 53 cm

L = 145 cm L = 176 cm

Weight (without module electronics) 650 kg 900 kg Similar to FCM 120

* The nominal load will be defined at the end of the development in range of 130–140 kW

10

SINAVY PEM Fuel Cell modules BZM 34 and BZM 120 are

well-established in the market. They have proven their

performance and reliability in extensive tests, including

long-term tests on board of the Federal German Navy’s

submarines, and have formed an integral part of an

FC-based AIP systems for modern submarines like those of

class U 212 A, 214, and Dolphin AIP for more than a decade.

There is also the possibility to repower and refit operational

submarines with an AIP system with SINAVY PEM Fuel Cell

modules. The SINAVY PEM Fuel Cell technology’s field of

application will be extended, when suitable reformers

are available to produce hydrogen from liquid fuels, for

example, methanol and diesel. Then, fuel cells may become

the sole power source for the submarines of the future.

With the ongoing R&D work on the 3rd generation

(or BZM NG) fuel cells, an improved and more flexible

module design will be prepared to fulfill future

customer's expectations.

Summary and Outlook

11

The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the prod- ucts. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.

All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

Subject to change without prior notice 06/13 Order No.: E20001-A460-T197-X-7600 Dispo 16600 TH 464-130518 | WS | 06131. GD.LD.VM.XXMS.52.3.03 Printed in Germany © Siemens AG 2013

Siemens AG Industry Sector Marine & Shipbuilding P.O. Box 105609 20099 HAMBURG GERMANY

E-mail: [email protected]

More information: www.siemens.com/marine

Photo source: HDW, Blohm & Voss