From DuraDemo to MARANDA project - use of industrial site for hydrogen fuel cell durability testing

Transcription

1 From DuraDemo to MARANDA project - use of industrial site for hydrogen fuel cell durability testing October 9 th 2017, Kivimiehentie 3 Espoo, Finland Jari Ihonen, VTT

2 Contents PEMFC durability testing results from Durademo project The possible use of by-product hydrogen from sodium chlorate production as vehicle fuel PEMFC durability testing in MARANDA project and how it will help for accepting by-product hydrogen as vehicle fuel in fuel cell electric vehicles (FCEV) 2

3 DURADEMO PROJECT

4 Motivation for the DuraDemo project In TEKES FC programme supported industry project Demo 2013 Durability demonstration of PEMFC technology was and still is important for working machine industry In Finnish sodium chlorate and chlor-alkali industry need for large PEMFC systems for the use of by-product hydrogen near term market NaCl + 3 H 2 O > 2 NaClO H 2 (and O 2 + Cl 2 ) 2 H 2 O + 2 NaCl > 2 NaOH + H 2 + Cl 2 VTT had sufficient knowledge to demonstrate PEMFC systems using by-product hydrogen from e.g. sodium chlorate industry 4

5 DuraDemo project phases and industry participation Initially 2-year ( ) TEKES funded project supporting Demo2013 Initial total budget 1,5 M 10% industry 70% Tekes 20% VTT Extension of the project duration and budget (up to 1.66 M ) in September 2014 Only WP1 work (demo) was continued Extension of the project duration until the end of 2015 (accepted in May 2015) 5

6 The durability testing site at Kemira sodium chlorate factory Sastamala, Finland 6

7 Results from Durademo project - overview 5 stages of operation during 21 months Initial start-up was difficult due to water condensation when stack were cold Remote start-up required a lot of extra work The main reliability issue was hydrogen supply side components leading long down-time System control and system safety feature worked without any problems 7 Jari Ihonen; Pauli Koski; Valtteri Pulkkinen; Timo Keränen; Henri Karimäki; Sonja Auvinen; Kaj Nikiforow; Mikko Kotisaari; Heidi Tuiskula; Jaana Viitakangas. Operational experiences of PEMFC pilot plant using low grade hydrogen from sodium chlorate production process International Journal of Hydrogen energy. in press (Available online 8 October 2017)

8 Results from Durademo project performance fluctuation Hydrogen supply pressure triggered most of the shutdowns (>100) Slow fluctuation of performance could be linked to H2 quality Operation T <60 C Longest continuous operation was over 700 hours 8

9 Durability testing results from Durademo project Degradation rate was 2-3 mvolts / h for A range At higher current densities the rate was higher Degradation rate was similar to the literature results with higher quality hydrogen Extrapolated lifetime > h, when 20% voltage degradation as end-of-life criteria 9

10 By-product hydrogen production in Finland and globally Largest by-products sites now in Finland: Kemira Chemicals, Äetsä, Kuusankoski, Joutseno Total > ton/a (> 0,6 TWh) Significant increase of H2 from Joutseno in 2018 Eka Chemicals (Akzo Nobel), Oulu about 2000 ton/a ton/a would fuel city buses Globally By product H2 from chlorine production is about ton/a By product H2 from sodium chlorate production is about ton/a Enough for 5-10 million fuel cell electric vehicles! 10

11 The quality of by-product hydrogen from sodium chlorate production According to thesis of Braxenholm by-product hydrogen from sodium chlorate production can not be used as FCEV fuel as it does not fulfil ISO :2012 requirements Is this true? What can be done to make this hydrogen suitable as FCEV fuel? 11

12 A typical sodium chlorate hydrogen purification system* Reaction: NaCl + 3 H 2 O > 2 NaClO H 2 (and O 2 + Cl 2 ) * Braxenholm, D. By-Product Hydrogen to Fuel Cell Vehicles 12

13 In DuraDemo and HyCoRA projects the quality of hydrogen in Sastamala has been measured ISO :2012 Requirements > vol-% < 100 vol-ppm < vol-ppm < 0.05 vol-ppm < 5 vol-ppm < 0.2 vol-ppm < 2 vol-ppm < 5 vol-ppm < 100 vol-ppm [27] Braxenholm, D. By-Product Hydrogen to Fuel Cell Vehicles 13

14 CO measurements in HyCoRA project (5 weeks) ISO limit 200 ppb Exceeded frequently, even if average CO level was <100 ppb HyCoRA Deliverable 6.7 final report 14

15 CO2 measurements in HyCoRA project (5 weeks) ISO limit 2 ppm exceeded all the time HyCoRA Deliverable 6.7 final report 15

16 Some conclusions According to measurements hydrogen sodium chlorate production from does not fulfil ISO :2012 or ISO :2014 CO2 level is the main issue (as for H2 from chlor-alkali*) CO level is within limits most of the time N2, O2 and HCl level have not been measured According to DuraDemo results hydrogen is pure enough that it does not cause additional degradation Indirect evidence for low HCl level Options for getting this H2 available for FCEV fuel Additional purification can be expensive Change CO2 limit in ISO :2012 will take 2-4 years Use H2 only in bus fleets no issues if H2 quality measured * 16

17 MARANDA durability testing timeline 17

18 Some goals of durability testing in MARANDA project Validate the system performance on a powertrain test bench and in a target marine vessel for a period of minimum 6 months (4380 hours) Fuel cell stack life should exceed 15,000 hours Same power 10% lower stack voltage Monitor quality of by-product hydrogen, including all relevant impurities in ISO :2012 standard 18

19 WP7 FC System integration to containers with fuel storage T7.1 Designing and building a durability test bench T7.2 Designing and integration of fuel cell systems into containers for the target vessel T7.3 Safety assessments of the fuel cell systems and hydrogen T7.4 Initial testing of the fuel cell systems and hydrogen storage solution 19

20 Task 7.1 Designing and building a durability test bench D7.1 (M8) Oct 2017 D7.4 (M12) Feb 2018 Design Phase System Integration Initial Testing at VTT Durability test in Äetsä MS2 (M9) Nov 2017 MS3 (M13) Mar

21 Task 7.1 Designing and building a durability test bench Integration and containerization Fuel Cell Power Module (SH) Power Electronics (ABB) Higher-level control system (VTT) 21

22 Hydrogen gas purity control in MARANDA project during durability testing Continuously: CO, CO2, CH4, N2, O2 and H2O Methods: GC-FID with methaniser (CO, CO2, CH4) and TCD for N2 and O2 Valve flushing in GC with Ar/He to enable ppm level O2 measurements H2O measurement with humidity sensor (?) A measurement campaign (few weeks to few months): HCl Instrument to be selected Filtering and collection of particles 22

23 Acknowledgements DuraDemo project work was carried out under the Fuel Cells research program of TEKES, the Finnish Funding Agency for Technology, within a jointly funded project involving VTT Technical Research Centre of Finland Ltd and Finnish industry partners Kemira Chemicals Oy, Cargotec Finland Oy, Konecranes Plc, Leppäkosken sähkö Oy, ABB Oy, Woikoski Oy, MSc Electronics Oy, Wärtsilä Finland Oy and Fuel Cell Finland industry grouping, a part of Teknologiateollisuus Ry. MARANDA project has received funding from the Fuel Cells and Hydrogen 2 Joint Undertaking under grant agreement No This Joint Undertaking receives support from the European Union s Horizon 2020 research and innovation programme and Hydrogen Europe and N.ERGHY HyCoRA project: The research leading to these results has received funding from the European Union's Seventh Framework Programme(FP7/ )for the Fuel Cells and Hydrogen Joint Technology Initiative under grant agreement n