integrated hybrid system for - european energy research ... · integration) fed by naturalgas 400...

Joint “EERA - ON-SITE Project” Workshop onHybrid Energy and Energy Storage Systems

21-22 September 2017Marco Ferraro (CNR-ITAE)

Operation of a Novel Sofc-battery

Integrated hybrid system for

Telecommunication Energy systems

CONTENTS

General project information - project data and consortium

ONSITE’s mission and targets

The core of the ONSITE system – the SOFC generator

The SOFC/SNC BATT integration

History of the ONSITE prototype development so far

Final system: shelter operated at Telecom Operator’s site in Palermo (Italy)

TCO assessment

Concluding remarks



GENERAL PROJECT INFORMATION - PROJECT DATA AND CONSORTIUM



TOPIC: SP1-JTI-FCH.2012.3.5 System level proof of concept for stationary power and

CHP fuel cell systems at a representative scale

Overall objective:

to prove the concept by construction and operation of a sheltered hybrid SOFC/SNC-

battery system

- that generates power at high efficiency (>40% electrical, >85% as CHP)

- at potential economically competitive cost (SOFC mass production)

Budget: 5.525.540 Euro (3.012.0338 Euro funding from FCH JU)Duration: 51 months (started on July 2013)Partners from Italy, Germany, Poland, Switzerland

ONSITE’S MISSION AND TARGETS



SNC batteries SOFC System

Characteristics Values Characteristics Values

Operating Voltage 42-56 V Operating Voltage 50 - 60 V

Operating temperature 250-270 °C Exhausts temperature 220-230 °C

Drawbacks … as solution

A SNC battery consumes about 14% of the storedenergy per day to keep it warm during stand by or low charge/discharge current

Heat recovered from SOFC exhaust at 220-230 °C used to keep the SNC battery warm

Thermal management system needed Thermal management system needed

… as solution Drawbacks

Load following Slow load following (2 Amps/minute)

Lower cost per kW (than SOFC) High cost per kW




Source: An Analysis of Power TAC 2013 Trial; Jurica Babic and Vedran Podobnikhttps://www.researchgate.net/publication/256438877_An_analysis_of_power_TAC_2013_trial

ICT and Smart Grids

To use the TLC station and Datacenter Power Supplies to generate power on site and to provide ancillary services to the DSO (grid balancing)

Telecom 2 Grid (T2G)Virtual Power Plant




INWIT Radio Base Stations in Rome

http://www.inwit.it/mappa-dei-siti




INWIT Radio base Stations in Sicily and Palermo

http://www.inwit.it/mappa-dei-siti




INWIT Radio base Stations in Palermo vs electricity consumption map

RBS sites in Palermo downtown: ≈ 100

White zones -> higher electricityconsumption




To develop a hybrid generator, SOFC/SNC battery, with high overall efficiency, to be installed in telecom sites

To take advantage of the large diffusion of Radio Base Stations and Fixed Telecom Stations in urban areas to supply energy services for TLC, buildings and Smart Resilient Micro Grids

To use natural gas for on site electricity generation decreasing CO2 emissions

Distributed generation and storage overlaps distributed loads in urban areas




Containerized system comprising a SOFC/SNC battery hybrid system that generates more than 10 kWe

High efficiency (+40%), low GhG emissions

Replace the DC power supply and back-up power with the ONSITE prototype

Managing DC and AC in bidirectional way and both in grid connected/islanding mode to increase the reliability and the flexibility of the system

- Thermal and Electrical integration

- Smart Storage management- SOFC works at fixed power

with low modulation depending on the average

load

THE CORE OF THE ONSITE SYSTEM – THE SOFC GENERATOR



the system will consist of a 2,5 kW SOFC generator with two 1,25 kW stacks

and two SNC batteries (200Ah @48V)

each stack has its own DC/DC converter taking the stack voltage to battery level

Heat Exchanger

Cathode blower

Desulph. Cartridge

Deio Water Cartridge

Water tank

Burner blower Cooling

water IN

Vent

Cooling water OUT

Air

Natural gas

Tap water Power IN

(start/stop)

Power OUT Grid

Heat recovery

loop

Thermal load

DC/DC

BoP (piping,

valves, …) Control Board

Grid

HOT BOX

Stack #2

Reformer

Heat exchanger

Stack #1

DC/DC

SNC BATT

DC/AC

Exhaust

THE CORE OF THE ONSITE SYSTEM – THE SOFC GENERATOR



the system will consist of a 2,5 kW SOFC generator with two 1,25 kW stacks

- each stack has its own DC/DC converter taking the stack voltage to battery level

“hot box” with 2 stacks, reformer and high-temp. heat exchanger

“cold box” with low temp. balance of plant components

THE SOFC/SNC BATT INTEGRATION



SOFC/SNC BATT ELECTRICAL INTEGRATION

SOFC/SNC BATT THERMAL INTEGRATION

Development of DC/DC and DC/ACDesign of the optimal layout

HISTORY OF THE ONSITE PROTOTYPE DEVELOPMENT SO FAR



First SOFC 2.5 kW system (no thermal integration)Fed by naturalgas230 Vac out – Grid connectedElectrical Efficiency 40%Total Efficiency 85%Hours of operation: 480 hrsStart-up time 20-22 hrsForming gas used




Second SOFC 2.5 kW system (modified for thermalintegration)Fed by naturalgas48 Vdc out

Electrical Efficiency 37%Hours of operation: 100 hrsStart-up time 20-22 hrsForming gas usedElectrical integration with SNC battery




Third SOFC 2.5 kW system (modified for thermalintegration)Fed by naturalgas400 Vdc out* Electrical Efficiency 40%Hours of operation: 600 hrsStart-up time 20-22 hrsForming gas usedElectrical integration with SNC battery and DC/DC + DC/AC (bidirectional)Integration with adsorption heat pump (63% efficiency –cold generation)

*48 V bas DC abandoned for the following reasons:- no inverter for the grid connection able to manage

the low voltage- 400 Vdc is becoming the standard for Datacenters




Fourth SOFC 2.5 kW system (modified for thermalintegration)Fed by naturalgas400 Vdc out Electrical Efficiency 40%Hours of operation: 10 hrs (failed during start-up)Forming gas usedElectrical integration with SNC battery and DC/DC 400-48Vdc + DC/AC (bidirectional) – 400 VacThermal integration with batteries

A fifth 2.5 kW system delivered for the DEMO at telecomoperator’s site

FINAL SYSTEM: SHELTER OPERATED AT TELECOM OPERATOR’S SITE IN

PALERMO (ITALY)




PALERMO (ITALY)



ONSITE footprint -> about 5 m2


PALERMO (ITALY)



48 V DC bus and 400V DC bus stability over time during power fluctuation

Power flowing through the inverter to/from the grid


PALERMO (ITALY)



The inverter switched from grid connected mode to a disconnection from the AC side in order to investigate how it reacts to a grid failure during the system/load operation. The voltage recorded at the inverter DC section showed the ability of the DC-DC converter to make surviving the DC-Link.


PALERMO (ITALY)



0

500

1000

1500

2000

2500

3000

0 2000 4000 6000 8000 10000 12000

Power(W

)

Time(min)

FCPowervsTime

y=5E-05x+0,2577R²=0,94098

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

1400 1600 1800 2000 2200 2400 2600 2800 3000Efficiency(%)

Power(W)

FCEfficiencyvsPower


PALERMO (ITALY)



1 week of SOFC operation1 stack broken

No possibility to restart

The consortium decided to continue to keep on using a new more and stronger SOFC generator in order to

carry on the work done

In particular the site arrangement in Palermo able to host further demo activities

TCO ASSESSMENT



TCO

CAPEX

10 yeardiscounted

annualOPEX

Equipment

Installation and commissioning

Power and naturalgas

Maintenance

Battery and SOFC

replacement



0,00

500,00

1.000,00

1.500,00

2.000,00

2.500,00

Dec-15

Jan-16

Mar-16

May-16

Jun-16

Aug-16

Oct-16

Nov-16

Jan-17

Energy(kW

h/year)

Time(year)

TLCsta onconsump on

AC+DC DC

DC load -> traffic almost constant over timeAC load -> Air conditioning varies according to external temperature

Totat load (DC+AC)

kWh

Average per

hour

Jan-16 1.363,00 1,83

Feb-16 1.358,00 2,02

Mar-16 1.346,00 1,81

Apr-16 1.526,00 2,12

May-16 1.477,00 1,99

Jun-16 1.606,00 2,23

Jul-16 2.022,00 2,72

Aug-16 1.966,00 2,64

Sep-16 1.809,00 2,51

Oct-16 1.928,00 2,59

Nov-16 1.651,00 2,29

Dec-16 1.401,00 1,88

19.453,00 2,22

Electricity cost: 0.16 c€/kWhNG cost: 0.25 c€/Nm3Including taxes, etc.

TCO ASSESSMENT

TCO ASSESSMENT



TCO Comparison: b.a.u. vs ONSITE

TCO ASSESSMENT



-60000

-40000

-20000

0

20000

40000

60000

80000

0 2 4 6 8 10 12

Cap

Ex+OpExCumula

veCosts

(€)

years

10YearsTotalCostofOwnership

ONSITEprototype(FCcostPACEproject)

ONSITEprototype(FCcostmassproduc on)

ONSITEprototype(FCcostmassproduc on+Eff.

5 5%)

ONSITEprototype(FCcostmassproduc on+Eff.55%+Incen ves)

b.a.u.

TCO ASSESSMENT



TCO Comparison: b.a.u. vs BLUGEN

TCO ASSESSMENT



-30000

-20000

-10000

0

10000

20000

30000

40000

50000

0 2 4 6 8 10 12

Cap

Ex+OpExCumula

veCosts

(€)

years

10YearsTotalCostofOwnership

FC(Power1.5kW;Efficiency60%;FCcostPACEproject)

FC(Power1.5kW;Efficiency60%;FCcost4,000€/kW)

FC(Power1.5kW;Efficiency60%;FCcostPACEproject+Incen ves)

b.a.u.

CONCLUDING REMARKS



- The design and realization of the SOFC/SNC hybrid was carried out

- Power converters, control system, cooling system, energy storage system, SOFC

operation were successfully tested to comply with the project requirements

- SOFC electrical efficiency 40%

- SOFC total efficiency (electrical + thermal) 85%

- Sheltered SOFC/SNC hybrid prototype realized, tested and demonstrated

- Unfortunately only 600 hrs of continuous operation reached instead of the 3,000

expected

- A new SOFC generator will be installed and switched on in October 2017 at the

Telecom Operator demo site (Palermo)

CONCLUDING REMARKS



- TCO assessment thanks to the demo site arrangement

- ONSITE prototype (including T2G) far ahead of current market

- TCO for the BLUGEN shows that the SOFC (alone, with no T2G) could be a viable option

- SOFC cost reduction is mandatory; Mass production cost estimation (4,000 €/kWh) will

open up the TLC market (grid connected TLC station)

integrated hybrid system for - european energy research ... · integration) fed by naturalgas 400...

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