US DOE Fuel Cell Technologies Office and ARPA-E Investments in Hydrogen Technology Advancements September 19, 2017

Transcription

1 US DOE Fuel Cell Technologies Office and ARPA-E Investments in Hydrogen Technology Advancements September 19, 2017 NEESC is funded through a contract with the U.S. Small Business Administration

2 House Keeping All participants are in Listen-Only mode. Select Use Mic & Speakers to avoid toll charges and use your computer s VOIP capabilities. Or select Use Telephone and enter your PIN onto your phone key pad. Submit your questions at any time by typing in the Question Box and hitting Send. This webinar is being recorded You will find a recording of this webinar, as well as previous NEESC webinars online at: NEESC is funded through a contract with the U.S. Small Business Administration

3 About NEESC The Northeast Electrochemical Energy Storage Cluster (NEESC) is a network of industry, academic, government and non-governmental leaders working together to help businesses provide energy storage solutions. The cluster is focused on businesses that provide the innovative development, production, promotion and deployment of hydrogen fuels and fuel cells to meet the pressing demand for energy storage solutions. The cluster spans an area in the northeastern United States from New Jersey to Maine. Its formal organization is funded by the US Small Business Administration s Regional Cluster Initiative. NEESC is administered by the Connecticut Center for Advanced Technology, Inc. (CCAT) and its local state partners: NEESC is funded through a contract with the U.S. Small Business Administration

4 Today s Guest Speakers Dr. Katherine Ayers, Vice President, Research and Development, Proton OnSite Dr. Madhav Acharya, Technology-to-Market Advisor, Advanced Research Projects Agency-Energy (ARPA-E) NEESC is funded through a contract with the U.S. Small Business Administration

5 US DOE FCTO and ARPA E Investments in Hydrogen Technology Advancements Dr. Katherine Ayers Vice President, Research and Development September 19, Proton Energy Systems, Inc.

6 Outline Company and Technology Overview Importance of hydrogen Materials and applied research Realities of scale and product development Portfolio approach and federal funding Conclusions 2

7 Proton-Nel Overview Now the largest electrolysis company worldwide Manufacturer, packaged products, systems Well established applications and markets >3500 fielded units in 80 countries Growing to address energy markets ISO 9001:2008 certified; ~150 employees PEM Electrolysis Cell 3

8 PEM application history: Why we are where we are Designed for life support in closed environments Qualified for O 2 generation in space and underwater Safer handling in confined spaces Optimized for high reliability; less for cost and efficiency Shock and vibration mil specs; 50,000 hour life Internal $ focused on scale up HOGEN GC HOGEN S Series HOGEN H Series HOGEN C Series M Series 4

9 Environmental Impact Only 4% of H 2 globally is from non-fossil sources Renewable hydrogen needed for decarbonization Example: Ammonia is largest energy consumer and GHG emitter, largely due to reforming step 5

10 How do we enable more renewable hydrogen penetration? Electrolysis reaching relevant scale Multiple companies concepting multi-mw systems/plants 1-2 MW stacks for PEM and KOH New technology development has a 20 year time frame 10 years: end of research to developed product 10 years: market penetration Need to leverage/improve what we have today Hydrogenics 45 MW plant 13HydrogenicsRobertHarvey.pdf (CO 2 emissions) Stolten, October 2014: The Potential Role of Hydrogen Technology for Future Mobility. How Can this Improve Our Life? 6

11 Nascent Technology Platform Iterations: Electrolysis 4 major platform changes over ~5 orders of magnitude New technology has to go through similar progression Existing PEM Electrolysis Designs (4 active area platforms) Future Platforms: SMR Scale 7

12 Reliability and manufacturing Scale up is capital intensive; need reliability and market Underutilization of equipment, high scrap, warranty exposure Test component fabrication manufacturing 25 cm 2 test cell vs. >1 million cm 2 (4 MW, ~1500 kg/day) Transition from lab to assembly floor requires different mind-set Need error-proof instructions Criteria for acceptability 10 years of fielded cells: 95% still operational 8

13 Collaboration and Roadmap Strategy Clearly define long and short term directed research pathways Match with agency strategy and mission NSF, DOE-BES ARPA- E, USDA DOE-EERE, NASA DoD (Navy, Air Force, Army) High Risk Development Stage/Risk Level High Fidelity Adv. Materials Proof of Concept Applied R&D Deployable Prototypes Leverage key competencies of partners to extend technology National Labs, universities, and companies as collaborators Internal funding to take materials and manufacturing science to product Page 9 9

14 % of baseline (quantity/thickness/cost) Active area scale (m2) Opportunities for improvement: Implemented vs. possible Stack Progression Internal $ s focused on scale up Where we are bipolar assembly bipolar assembly - actual 0.4 membrane catalyst loading membrane - actual catalyst loading - actual 10 scale (active area) Where we 0 could be Year 10

15 R&D program portfolio: 2 case studies MEA Bipolar plate Many interacting pieces Small parts funded under different programs All pieces funded together Able to complete full development cycle 11

16 Hydrogen Uptake vs. Baseline Bipolar plate case study - FCTO Evaluated and selected manufacturing techniques Prototyped parts and alternate coating: improved resistance to environment and lower cost Stack design and analysis for strength and fluid flow 100% 80% 60% Accelerated embrittlement study Baseline Post Annealed Nitrided Coated ORNL 40% 20% Finite element analysis & Computational fluid dynamics 0% Time (h) Commercial stack, 40% cost reduction 12

17 Implementation Timeline Bipolar plate project initiated 2009 Subscale components and materials development: Analysis and scale up, larger active area: Proton internal funding: full scale stack and system prototyping and validation: First commercial systems 2016, sited in

18 Catalyst Loading Reduction FCTO, AMO Several methods show promise for 10x reductions 500 hours operation at <0.1 mg/cm 2 loading Brookhaven 3M NSTF Spray deposition - UConn Core shell catalysts Page 14 14

19 Electrode integration Need to consider impact of other cell components Many materials optimized for fuel cell vs. electrolyzer Wetproofing, gas vs. liquid flow Manufacturing maturity needs to catch up for electrolysis Fuel cell has demonstrated continuous processes vs. batch Anode GDL concept, DLR 3M NSTF Cathode GDL w/w/out MPL Core shell catalysts 15

20 ARPA-E Experience Seeds new technology and provides pathway for reduction of high risk elements Rigorous program management and milestones Proton has successfully obtained non-arpa-e follow on funding (including EERE-FCTO) Transitioning learnings to existing products along the way Currently involved in several programs, leading one 16

21 % Baseline Electrolysis Example: AEM: A Long Term Option? Need new pathways to achieve ultimate capital cost reductions Anion exchange membrane provides potential lower cost Flow fields have as much or greater impact than catalyst Less mature but gaining in understanding and stability Capex vs. Opex scenario trade: H2@Scale 100% 90% PEM Alkaline 80% 70% 60% 50% 40% 30% 20% 10% Projected PEM progression Materials only Materials and labor 0% Baseline Cathode FF Anode FF + MEA Labor Alkaline Baseline Alkaline FF + MEA Alkaline Labor Potential to move to new cost curve 17

22 AEM technology status DOE, ARPA-E Performance/reliability has continued to improve Higher currents and more stable voltages Lower platinum group metal content Still require low differential pressure and carbonate for stability LANL, Sandia, Northeastern IIT, Georgia Tech, Pajarito, U. New Mexico, Penn State, Northeastern 18

23 Synergistic Technologies Flow Batteries Carbon Dioxide Pumping/Compression/Conversion High Pressure Oxygen and Hydrogen Generation Grid or Renewable Power Input Concept Stack & System Scale-up Electrochemical Conversion of N 2 to Ammonia 19

24 Hydrogen-Iron Flow Battery Flow batteries: very similar to electrolyzers Hydrogen-based systems: common parts Hydrogen provides flexibility (electrical or chemical feedsource) Energy storage H 2 use Flow battery Common hydrogen electrode Electrolyzer 20

25 Other ARPA-E Program Roles Reversible hydrogen catalyst no precious metals Electrode development and benchmarking Anion exchange membranes (IONICS program) Characterization of device relevant parameters Carbon dioxide conversion to fuels (REFUEL program) Cell stack and system integration Distributed ammonia production (REFUEL program) Gap analysis for renewable hydrogen component Provide early material access to us and perspective to partners on critical considerations 21

26 Benefits of Advanced Technologies Pathway to technology after next concepts Solve fundamental problems Develop capabilities Ability to leverage learnings in existing products Electrode Development Cell Design Device Configuration Operating Conditions Systems, Codes and Standards Fundamental Research DFT and Synthesis Catalyst Structure Porous Layers Polymer Design Coatings Multi-scale Modeling End Goal Building Blocks Related Technologies Mechanistic Understanding Characterization Tools Tailored Materials Integration 22

27 Conclusions The road to product and scale is long Scientific and engineering challenges in complex mixtures Understanding both fundamental and applied perspectives accelerates technical progress Long term research guides short term improvements while existing technology provides stepping stones and infrastructure for new technology Collaborations and synergies need to be cultivated 23

28 ARPA-E Funding to Advance Hydrogen Technology NEESC Webinar September 19, 2017 Madhav Acharya Technology to Market Advisor

29 A Brief History of ARPA-E In 2007, The National Academies recommended Congress establish an Advanced Research Projects Agency within the U.S. Department of Energy The new agency proposed herein [ARPA-E] is patterned after that model [of DARPA] and would sponsor creative, out-of-the-box, transformational, generic energy research in those areas where industry by itself cannot or will not undertake such sponsorship, where risks and potential payoffs are high, and where success could provide dramatic benefits for the nation Coming soon Awards Announced Programs To Date America COMPETES Act Signed $400M (Recovery Act) $180M (FY11) $275M (FY12) $251M (FY13) $280M (FY14) 2015 $280M (FY15) 2016 $291M (FY16) 2017 $306M (FY17) $275 Million (FY2012) $280 Million (FY2015) 1

30 ARPA-E Mission Mission: To overcome long-term and high-risk technological barriers in the development of energy technologies Means: Identify and promote revolutionary advances in fundamental and applied sciences Translate scientific discoveries and cutting-edge inventions into technological innovations Accelerate transformational technological advances in areas that industry by itself is not likely to undertake because of technical and financial uncertainty 2

31 Where Do ARPA-E Programs Come From? ARPA-E Program Directors If it works will it matter? 3

32 Alumni Active Breadth of Program Portfolio ELECTRICITY GENERATION EFFICIENCY & EMISSIONS TRANSPORTATION & STORAGE GRID & GRID STORAGE MOSAIC GENSETS CIRCUITS PNDIODES NEXTCAR REFUEL IONICS GRID DATA ALPHA ENLITENED SHIELD ROOTS TRANSNET TERRA CHARGES NODES REBELS FOCUS MONITOR ARID DELTA RANGE REMOTE SOLAR ADEPT SWITCHES METALS MOVE PETRO HEATS GENI IMPACCT REACT BEETIT ADEPT ELECTROFUELS AMPED BEEST OPEN 2009, 2012, & 2015 Solicitations Complement Focused Programs GRIDS 4

33 REFUEL Program: Genesis Reduce GHG Emissions Integrate Renewable Energy Can we store renewable energy in a form that can also help reduce transportation emissions? 5

34 Chemical Storage Has Several Advantages Very high energy density (vs batteries) Long duration storage (months years) Utilizes existing infrastructure Flexibility in end use Source: IEC Electrical Storage Whitepaper 6

35 Potential Carbon Neutral Liquid Fuels Fuel B.p., deg C Wt. % H Energy density, kwh/l E 0, V, % Synthetic gasoline Biodiesel Methanol Dimethyl ether (DME) Ethanol Formic acid (88%) Ammonia Hydrazine hydrate Liquid hydrogen Compressed hydrogen (700 bar) gas G.Soloveichik, Beilstein J. Nanotechnol. 2014, 5,

36 How do we make these fuels? Air: N 2, O 2, CO 2 Water: H 2, O 2 N N O C O O O H H H N H H H H H C H O H H C O C H AMMONIA H x (M)ETHANOL H DIMETHYL ETHER H 8

37 REFUEL: Renewable energy storage and delivery via carbon neutral liquid fuels Synthesis of liquid fuels Fuels transportation Application space Air Direct use (blending) in ICE vehicles (drop-in fuel) Direct use in stationary gensets Medium to long term energy storage Water Energy delivery from remote locations Energy delivery from stranded sources Energy storage and delivery combined Hydrogen generation for fueling stations Seasonal energy storage

38 Energy storage comparison 6 x = 1,000kg H 2 Linde storage in Germany or 30,000 gallon underground tank contains 200 MWh (plus 600 MMBTU CHP heat Capital cost ~$100K 40 x 5 MWh A123 battery in Chile Capital cost $50, ,000K Liquid fuels provide smallest footprint and CAPEX 10

39 Energy transportation capacity and losses Energy transmission losses (% per 1000 km) Energy transmission capacity (at the same capital cost) Power line Compr H 2 (350 bar) Liquid NH Capacity 1.2 GW 6.5GW 41GW Protective zone m 10 m 10 m OHVAC HVDC Truck Train Pipeline D. Stolten (Institute of Electrochemical Process Engineering), BASF Science Symposium, 2015 Electricity Liquid ammonia Liquid pipelines have highest capacity and efficiency 11

40 Overall energy efficiency (2,000 km) Electricity Ammonia % 55.4% % Electricity transportation is more efficient if we can use it directly 12

41 Delivery cost, $/day Cost of energy storage and transportation Case study Solar PV array 500 MW 8 hrs active, storage capacity 50% 4 GWh electricity or 120,000 kg H 2 or 860 ton NH 3 Delivery from Utah to East Coast (2000 miles) Power line capital cost $16.2M/mile Storage volume, m Storage volume and energy delivery cost (including storage) Electricity 1 Compr 2 H 2 Ammonia 3 0 Storage volume Daily delivery cost DuraTrack PV array 13

42 Liquid fuels can enable H 2 refueling stations Hydrogen fueling station cost breakdown Liquid fuels for H 2 refueling Smaller storage CAPEX and footprint Compressor downsizing Modular design for increased reliability Possibilities for cost reduction Hydrogen Station Compression, Storage, and Dispensing Technical Status and Costs. NREL report BK-6A , 2014

43 REFUEL Awardees Chemtronergy Total Funds Allocated: $ 33M 15

44 Summary Liquid fuels are ideal candidates for long term energy storage and long distance energy delivery from renewable intermittent sources - high energy density - infrastructure for storage and delivery technologies in place - can be used in fuel cells and thermal engines Hydrogen rich liquid fuels may enable hydrogen fueling infrastructure - inexpensive, compact and safe storage - dehydrogenation methods known Technical (reaction rate, conversion efficiency, production down scaling), economical (electricity and capital costs) and societal (policies and public acceptance) challenges ahead 16

45 Contact: 17

46 Questions Dr. Katherine Ayers Vice President, R&D Proton Onsite Dr. Madhav Acharya Technology-to-Market Advisor ARPA-E Alexander Barton Energy Specialist NEESC NEESC is funded through a contract with the U.S. Small Business Administration