Polttokennot

10.6.2014Jari IhonenVTT Technical Research Centre of Finland

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Esityksen sisältö

Johdanto polttokennoihin

PEMFC-polttokennojen teknologinen kehitys ja markkinatilanne

VTT:n polttokennotutkimus

VTT:n PEMFC-järjestelmien kehityskaari

DuraDemo ja DuraDemo2 -projektit

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Johdanto polttokennoihin

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Polttokennon toimintaperiaate

Polttokenno on sähkökemiallinen laite, joka muuntaa polttoaineen sisältämän kemiallisen energian suoraan sähkö- ja lämpöenergiaksi.

Polttokenno koostuu kahdesta elektrodista, anodista ja katodista, jotka on erotettu toisistaan elektrolyytillä = MEA (membrane electrode assembly)

Anodilla polttoaine hapettuu, elektroni vapautuu Elektroni kulkee ulkoisen virtapiirin kautta katodille Katodilla elektroni ja hapetin reagoivat Elektrolyytin tehtävänä on kuljettaa reaktioissa syntyneet ionit elektrodilta toiselle.

Elektrolyytin tyypistä riippuu (negatiivinen/positiivinen ionijohtavuus) syntyvätkö reaktiotuotteet anodilla vai katodilla

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Polttokennoston rakenne

Yhdellä kennolla pieni jännite, mutta suuri virta Yhden kennon jännite ~1 V Jännitettä nostetaan pinoamalla kennot sarjaan

Kennosto koostuu Polttokennosta (elektrodit ja elektrolyytti) Bipolaari/interconnect –levyistä Tiivisteistä

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Polttokennotehonlähteen rakenne ja toimintaperiaate Polttoaineen prosessointi Polttokennosto/kennostot Virranmuokkaus ja verkkoonliityntä/latausjärjestelmä Pakokaasun käsittely (jos tarpeen) Ohjausjärjestelmä Muut komponentit

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Esimerkki - SOFC CHP järjestelmä

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Polttokennotyypit elektrolyytin ja toimintalämpötilan mukaan

TypePolymer

electrolyte fuel cell

Alkaline fuel cellPhosphoric acid

fuel cell

Molten carbonate fuel

cell

Solid oxide fuel cell

Acronym PEFC/DMFC AFC PAFC/PBI-FC MCFC SOFC

Electrolyte

Hydrated polymeric ion

exhange membranes

Potassium hydroxide in

asbestos matrix

Immobilized liquid

phosphoric acid in SiC /in PBI

Immobilized liquid molted carbonate in

LiAlO2

Perovskites (ceramics),

typically 8-mol% yttria stabilized

zirconia

Electrodes CarbonTransition

metalsCarbon

Nickel and Nickel oxide

Perovskite and perovskite-

metal cermet

Catalyst Platinum Platinum PlatinumElectrode material

Electrode material

Interconnect Carbon or Metal Metal GraphiteStainless or

NickelNickel, ceramic

or steel

Operating temperature

40 - 90 °C 100 - 250 °C 150-200 °C 600-700 °C 600-1000 °C

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Ensimmäiset polttokennosovellukset

Apollo lennot1959

Gemini lennot60 -luku

Gemini 7 PEFC 1965

UTCApollo

Avaruussukkulanpolttokennoyksikkö

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Polymeeripolttokenno (PEFC, Polymer Electrolyte Fuel Cell)

Eniten tutkittu tyyppi tällä hetkellä, suuri virrantiheys

Kiinteä polymeerielektrolyytti, H+ johde Anodi: H2 2H+ + 2e-

Katodi: ½ O2 + 2H+ + 2e- H2O

Katalyyttinä platina Nopea käynnistys alhaisen

toimintalämpötilan johdosta Elektrolyytin ionijohtavuus vaatii riittävästi

nestemäistä vettä Ohut elektrolyytti aiheuttaa vedyn tihkumista

katodille Toimintalämpötila <100°C, paineita

kasvattaa lämpötilaa Katalyytti myrkyttyy helposti (50 ppm CO)Ballardin PEFC -kennosto

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Fosforihappopolttokenno (PAFC, Phosphoric Acid Fuel Cell )

Nestemäinen fosforihappoelektrolyytti, H+ johde

Platina katalyyttinä Reaktiot kuten PEFC:ssa

Korkeamman lämpötilan johdosta sietää huomattavasti paremmin CO:ta (2%)

Kaupallinen tuote, mutta korkea hinta rajoittanut laajamittaisen käyttöönoton

UTC Fuel Cells PC25s in Anchorage, Alaska, supplying electrical power to the main postal sorting facility. Source: UTC Fuel

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Sovelluskohteita eri kennotyypeille

PEFC, DMFC (+ ja osin PBI-FC) - Nopeus Ajoneuvosovellukset Nopeasti käynnistyvä varavoima (UPS) Hajautettu energian tuotanto Kannettava elektroniikka

ACF - Luotettavuus, korkea hyötysuhde Avaruussovellukset

SOFC, MCFC (+ ja osin PBI-FC) – Hyötysuhde ja lämpöenergia

Voimalaitokset Hajautettu energiantuotanto Yhdistetty sähkön- ja lämmön tuotanto APU –yksiköt

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PEMFC-polttokennojen teknologinen kehitys ja markkinatilanne

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PEMFC market and technology development

PEMFC is rapidly becoming a mature technology

Market growth exceeds 50% in both competitive and subsidized segments

The introduction of FCEV in 2014-2017 will increase the total market and help also niche markets (MHE)

Topics of R&D&D are changing rapidly as less basic R&D needed

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PEMFC market segments and megawatts(excluding toys and educational sets)

Average size = 1 kW

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Fuel cell application areas

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The size of the existing main markets

Micro-CHP > 90 % of the market is in the Japan 1 kW size units mostly, several 10000 units per year

Telecom back-up The market is truly global, Mostly 1-5 kW units 10000-20000 units (?) per year

Material handling The market is mainly in USA, Plug Power by far the largest supplier 2-10 kW units mostly, 1000-2000 units per year

Transportation The market is in USA/Japan/Germany/UK/Korea, 50-100 kW units, hundreds of units per year in 2014, thousands in 2015

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In micro-CHP the market taken over by FC

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MicroCHP market is and will be Japan

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Telecom back-up – a truly global market

PEMFC in telecom is competitive without subsidies

Market for telecom applications is truly global Market penetration depend on the grid reliability and other conditions There are growing opportunities in Finland, too

Hybrid systems (with PV solar) have high potential Cost of PV panels is 5 times lower than 10 years ago

Market environment is extremely competitive Cost of stack significant part of the total cost Strategic partnerships with stack, MEA supplier needed

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Material handling equipment (MHE) market

Sales of Plug Power GenDrive units about 1000 per year New orders indicate 2000-3000 per year 1-10 kW (24-48 V) units, few 80V systems available

Economics of forklift applications depend on the user profile Size of the fleet and utilization rate are very important!

The market growth needs help from automotive market and more intelligent system design

Stack, H2 storage cost reduction with help of larger market size Battery, DC/DC cost reduction with intelligent system design

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PEMFC R&D&D opportunities in FCH JU

In FCH2 JU is still the main instrument for PEMFC research Funding rates are much better in H2020

Preliminary estimate 55-60%, but even > 60% possible Much less projects for PEMFC R&D – much harder competition

In FCH JU there are more demo projects, especially for H2 production, purification and distribution

Finland should focus on the demos, in which there are Finnish companies Even very large (MW-scale) projects possible

In smaller projects subcontracting is an opportunity

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Conclusions for PEMFC market and technology development PEMFC is becoming mature technology – less R&D needed

The market for all PEMFC applications is growing fast – focus of the work should be on demos and refueling

The focus of VTT PEMFC research (system level, H2 quality) has been well chosen, but the future is more on demos

R&D opportunities still remain – but the focus has already changed from component/system development to commercialization issues

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VTT:n polttokennotutkimus

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VTT:n PEMFC-järjestelmien kehityskaari

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PowerPEM

2004

WorkingPEM

2007

TopDrive

2010

DuraDemo

2012

Demonstration of a stationary PEMFC system in chlor-alkali application (back to building an in-house system).Hydrogen quality gaining momentum.

Focus shifting from system building to control-oriented modeling and operation of commercial system modules.

PEMFC systems R&D projects at VTT

PEMFC hybrid drivetrains research begins. Fuel cell hybrid working machine demonstration with a forklift (2009).

PEMFC systems research starts. First in-house system built at VTT together with TKK (2006).

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PEMFC systems built and operated

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WorkingPEM (2007 – 2010)(Application of PEMFC technology in non-road mobile machinery)

User need● Applying PEMFC technology in working machines is a potential

early market for fuel cells● Demonstration of the technology is is necessary to convince

stakeholders

Solution● Building of FC BoP and stack characterization infrastructure to

evaluate the technology● Construction of a hybrid FC power source to an electric

counterweight forklift

Benefits● Technology successfully demonstrated and existing issues in

technology identified● Increase in competence and number of PEMFC experts in

Finland

Users● PEMFC system integrators● Non-road mobile machinery manufacturers● Companies in the value chain

11,3 11,8 12,3 12,8707580859095

100

Bu

s v

olt

ag

e (

V)

Time (min)

Bus voltage

11,3 11,8 12,3 12,8-400-300-200-100

0100200300400500600700 Total current

Ultracap current Battery current PEMFC current

Cu

rre

nt

(A)

Time (min)

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TopDrive (2010 – 2012)(Topology optimization fuel cell hybrid drivetrains)

User need● Design and optimization electric drivetrain involving fuel cells

involves many uncertainties from system integrator point of view

Solution● Methods to ensure system lifetime and reduce costs

● Experimental work related to system control and fuel quality● Development of modeling tools for energy storage and fuel cell

capacity optimization and control design

Benefits● Guidelines and state-of-the-art review of technology for project

participants and domestic industry● Increase in competence and number of PEMFC experts in

Finland

Users● PEMFC system integrators● Non-road mobile machinery manufacturers● Companies in the value chain

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DuraDemo (2012 – 2014)(Durability demonstration of PEMFC in process industry by-product hydrogen application)User need

● Chlor-alkali industry produces large amounts of hydrogen that could be utilized in more sensible way than is possible with current technology

Solution● PEMFC is a suitable option to harness the produced hydrogen,

offering high efficiency and low emissions● Once the durability has been proven and hydrogen quality

requirements revised, PEMFC becomes a very attractive alternative

Benefits● Reduced electricity consumption from the grid for plant operator● Successful demonstration prepares the way for launching

commercial business in stationary PEMFC market in Finland

Users● PEMFC system integrators● Non-road mobile machinery manufacturers● Hydrogen producers● Companies in the value chain

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DuraDemo ja DuraDemo2 -projektit

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DuraDemo 2012-2014

Motivation Durability demonstration of PEMFC technology is important to

confirm technology readiness (to Finnish industry) Chlor-alkali industry by-product is a near term market Peak power / reserve power (with low capital cost) increasingly

interesting as share of solar/wind electricity increases -> PEMFC (fast start-up and shutdown, high efficiency, zero local emissions)

Project goals A PEMFC power plant in pilot scale operated on by-product

hydrogen with varying quality Utilization and further development of system level simulation tools

and capabilities at VTT BoP and power electronics components characterization and

development of control strategies Effects of hydrogen quality on PEMFC performance (from single cell

to full systems)

Duration: 2 years (project ending 31.5.2014) Budget: 1,5 M€ (70% Tekes , 20% VTT, 10% industry)

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DuraDemo – pilot scale PEMFC system

System design and FAT testing reported in:

Keränen, T. M., Karimäki, H., Nikiforow, K., Kukkonen, S., Uusalo, H., Viitakangas, J. and Ihonen, J.

(2014), A 50 kW PEMFC Pilot Plant Operated with Industry Grade Hydrogen – System Design and Site

Integration. Fuel Cells. doi: 10.1002/fuce.201300241

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DuraDemo – pilot scale system results

System has been operating at designed operating point since mid-March 2014

1500 hours of operation has been gained so far

Key characteristics 3-6/2014

Electric efficiency: ~44-45 % (”supply-to-grid”) ~54-56 % (fuel cell stack)

Power to grid 11.3. - 3.6. : ~ 51 MWh Availability 11.3. - 3.6. : ~ 66,3 %

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10

20

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40

50

60

Time

Fue

l Cel

l Pow

er (

kWe)

12/03/14 00:00 22/03/14 00:00 01/04/14 00:00 11/04/14 00:00 21/04/14 00:00 01/05/14 00:00 11/05/14 00:000

20

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Time

Fue

l Cel

l Eff

icie

ncy

(%)

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DuraDemo – pilot scale system results

More operating hours needed to determine long term irreversible degradation

Difficulties related to operating in real industrial environment

Unexpected shutdowns Maintaining constant operating

conditions

12/03 17/03 22/03 27/03 01/04 06/04 11/04 16/04 21/04 26/04 01/05 06/05 11/05 16/05500

600

700

800

Time (dd/mm)

Vo

lta

ge

(m

V)

12/03 17/03 22/03 27/03 01/04 06/04 11/04 16/04 21/04 26/04 01/05 06/05 11/05 16/0580

100

120

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160

Time (dd/mm)

Cu

rre

nt

(A)

80 100 120 140 160600

620

640

660

680

700

720

Current (A)

Vol

tage

(m

V)

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DuraDemo 2 – motivation

Preparing for MW-scale demonstration in FCH JU project

The pilot scale PEMFC power plant is fully operational and accumulating operating hours at Kemira site in Äetsä

Maintaining and demonstrating the system for one more year is possible with relatively minor commitment from VTT and project partners

Operating the system offers Data on stack degradation rate of PEMFC

with industrial hydrogen quality System availability data (BoP & other failures,

also external to system itself) PEMFC system applicability for peak and

reserve power production Projections on operating costs and value

added of end-user

Key characteristics 3-4/2014

Electric efficiency: ~44 % (”supply-to-grid”) Power to grid 11.3. - 15.5. : ~ 39 MWh Availability 11.3. - 15.5. : ~ 64,4 %

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DuraDemo 2 – project goals

Source: http://en.wikipedia.org/wiki/Operating_reserve

A PEMFC power plant maintained and operated on by-product hydrogen until end-of-life reached (expected ~10000 -15000 h)

Implementation of minor modifications on system design and control strategy to improve reliability, robustness, ramp rate and efficiency

Analysis of PEMFC technology for base, regulation, peak and reserve power production.

Long term monitoring of hydrogen quality at Kemira site in Äetsä to track possible sources of fuel cell degradation

End-of-life analysis of the system including consideration of operating expenses and possible cost estimates for commercial scale system

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Acknowledgements

Most part of the research presented here has been conducted under the “Fuel Cell 2007- 2013” technology program of Tekes, the Finnish Funding Agency for Technology and Innovation.

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