DR.N.RajalakshmiTeam Leader

CFCT-ARCI, IITM RP, TaramaniChennai

rajalakshmi@arci.res.in12/18/2018 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

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With Fan-3x3cm - Temp-33C

WoFan-Temp-42C

WoFan-Temp-38C

With Fan - Memore -Temp -30C

0.0

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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

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pe

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oC

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Coolant Tank Temperature (°C)

Stack Power (KW)

Time (Hrs)

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ture

(oC

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ck P

ow

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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

12/18/2018 HAI Jodhpur Dec 2018 5

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

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Gas Authority of India Ltd (GAIL) 2016-2017

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er

(Watts)

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Power

12/18/2018 HAI Jodhpur Dec 2018 6

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

12/18/2018 HAI Jodhpur Dec 2018 7

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

12/18/2018 HAI Jodhpur Dec 2018 8

PRESENT STATUS

12/18/2018 9HAI Jodhpur Dec 2018

Fuel cell power system 2020 targets versus 2015 status (blue) for light-duty vehicle applications

12/18/2018 10HAI Jodhpur Dec 2018

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

12/18/2018 HAI Jodhpur Dec 2018 13

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*

12/18/2018 HAI Jodhpur Dec 2018 14

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

12/18/2018 15HAI Jodhpur Dec 2018

✓ 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

12/18/2018 HAI Jodhpur Dec 2018 16

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.

1712/18/2018 HAI Jodhpur Dec 2018

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.

1812/18/2018 HAI Jodhpur Dec 2018

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.

12/18/2018 HAI Jodhpur Dec 2018 19

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

2012/18/2018 HAI Jodhpur Dec 2018

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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

12/18/2018 HAI Jodhpur Dec 2018 22

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

12/18/2018 23HAI Jodhpur Dec 2018

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