A Vision of a Hydrogen Economy
Design of a Hydrogen Power Park2005 H2U Design Contest National Hydrogen Association, U.S Department of Energy, and ChevronTexacoTeam Members: Allison Mendes, Shirley Leung, Hani Fadali, Gordon Graff, Bryan Icyk, Bartosz Lomanowski, Abhay PatelAdvisor: Michael Fowler
Group 16: Design of a Hydrogen Power Park
Project Goal
To design a feasible, innovative & safe Hydrogen Power Park that will refuel fuel cell vehicles and produce electricity
Team VisionTo generate greater demand for aHydrogen Fuel Economy
Group 16: Design of a Hydrogen Power Park
Today’s Topics
The TeamPark requirements Park Design Safety EconomicsEnvironmental AnalysisMarketing Plan
Group 16: Design of a Hydrogen Power Park
Human Resources
The Team!
Allison Mendes
Chemical Eng.Shirley Leung
Chemical Eng.
Gordon Graff
Architect
Bartosz Lomanowski
Mechanical Eng.
Hani Fasali
Electrical Eng.
Bryan Icyk
Business/Marketing
Abhay Patel
Chemical Eng.
Dr. Michael Fowler, P.Eng.
Faculty Advisor
Chemical Eng
Group 16: Design of a Hydrogen Power Park
Your Energy Source
Group 16: Design of a Hydrogen Power Park
Park Requirements
The park will commence service in 2010 for a ten year service life
Generated and stored hydrogen on-site Increase capacity from 50 kg/day to 250 kg/day at 5 kg/carMaximum footprint: 21000 sq ftProvide a minimum of 100 kW of electrical power using green energyUse commercially available equipment
Group 16: Design of a Hydrogen Power Park
Park Design – Waterloo is A Perfect Location !
Become one of the pit stops along the Hydrogen Corridor between Windsor-MontrealAffiliation with the University of Waterloo
Education tool for university researchEncourage evolution of hydrogen technology
Location:
Waterloo Research and Technology Park
Group 16: Design of a Hydrogen Power Park
Park Design – 2D Site PlanFootprint: 21000 sq ft
Group 16: Design of a Hydrogen Power Park
Hydrogen Development Incubator
Aims:To develop and promote hydrogen production and distribution
Enhance the developmental and research efforts by serving as a ‘think tank’
Group 16: Design of a Hydrogen Power Park
Public Education CentreLocated in the Power Park for students and public to learn about hydrogen production and its advantages
Features of Educational FacilityCut-away models of hydrogen vehicles and equipments Posters
Group 16: Design of a Hydrogen Power Park
Park Design- Renewable Feed Source
Renewable and relatively cheap feed sourceThe process feed will be composed from a landfill gas from the Waterloo Landfill site in Southwest OntarioLandfill gas cost $0.045/m3 compared to $0.315/m3 for Natural Gas!
COHOHCH +↔+ 224 3Waterloo
Power Park
H2
Waste Disposal Site
Methane
Group 16: Design of a Hydrogen Power Park
Park Design – 3D Rendering [Side View]
Group 16: Design of a Hydrogen Power Park
Park Design – 3D Rendering (Top View]
Group 16: Design of a Hydrogen Power ParkEquipment 3D
Park Design – Process Equipment (3D)
Group 16: Design of a Hydrogen Power Park
Park Design – Expansion in 2016
Group 16: Design of a Hydrogen Power Park
Process Flow DiagramFeed Gas
Zinc-OxideTank
Pre-Reformer
Primary Reformer
Hydrogenation Reactor
Compressor
ZnS
Municipal WaterAir
SOFC
H2 Product
Electricity Produced
Dispenser
Bank #25014.7 psi
Bank #16264.7 psi
LegendGate Valve
Screw Down ValveMulti-Way Ball Valve
Control ValveSpring Loaded Pressure Release Valve
Buffer Bank #35014.7 psi
Ball Valve
H2 to Vehicles
Splitter / Mixer
Heat Exchanger
Air
Priority Sequencing System
PSA
Offgas
Check Valve
Generator Set
Pressure VesselsPressure Vessels
Pressure Vessels
•Conditioned landfill gas (≈ natural gas) is supplied by pipeline to power park
•The gas is reformed, compressed and stored onsite at high pressures and finally dispensed to FCVs.
•Electricity is generated by a 125 kW SOFC using a mix of partially reformed gas and PSA waste gas.
Group 16: Design of a Hydrogen Power Park
Park Design- Rational for Equipment Selection
Pre-reformer - Hydrogenics Corp.Increases % conversion of methane to hydrogen in SMR due to increased steam to carbon ratio (S:C).Act as a sulphur guard (extends life of expensive SMR & SOFC)
SMR (Steam methane reformer) - Hydrogenics Corp.Significantly less expensive than an electrolyserBased only on energy and capital costs:• electrolyser $555 US/kg• reformer $1.6 US/kg
PSA (Pressure Swing Adsorption) - Hydrogenics Corp.Purity of product stream yields 99.95% H2
Group 16: Design of a Hydrogen Power Park
Park Design- Rational for Equipment Selection125 kW Solid Oxide Fuel Cell (SOFC) – Siemens Westinghouse Power Corp
Lowest emissions of any power plant using natural gasIncorporates a power conditioning system to convert DC to ACHigh electrical efficiency even at part load
2-Stage Diaphragm Compressor - Products Industries Inc.Completely isolates process gas (pure H2) from contamination Relatively low maintenance
Group 16: Design of a Hydrogen Power Park
Park Design- Rational for Equipment SelectionCompressed Gas Storage System - CP Industries
3 storage banks under 2 different pressures Cascade filling system to minimize hydrogen storage capacity1-day buffer storage capacity (load flexibility)
H2 Dispenser - Fueling Technologies Inc.One dispenser with a single, side oriented, nozzleProvides temperature compensated fills (safety feature)
Bank1: 4x764.6 L (6264.7 psi)
Bank2: 6 x 968.4L (5014.7 psi)
Bank3: 14x 968.4L (buffer)
Group 16: Design of a Hydrogen Power Park
Park Design-Electrical System
A safe, realistic and practical design that adheres to all applicable codes and standards SOFC operates in parallel with the grid• Reduce the need to purchase electricity• Supplies critical site power in case of power
outage• Selling power to grid is unprofitable
100 kW generator set for stand-by operation in case of an outage on the supply utility system
Group 16: Design of a Hydrogen Power Park
U tility g rid
U tility d is c o n n e c tin g m e a n s
U tility b re a k e r U tility
S ys te m
D is c o n n e c tin g m e a n s - u tility
M a in e n tra n c e b re a k e r
T yp ic a l B u ild in g L o a d s
B re a k e r
T ra n s fo rm e r – 3 0 0 k V A P rim a ry : Y -, 8 k V , 3 p , 4W S e c o n d a ry : Y -, 4 8 0 V , 3 p , 4W
B re a k e r (s yn c h ro n iz e d )
F u e l C e ll
D is c o n n e c tin g m e a n s - g e n e ra to r
F C
M R e v e n u e M e te r
L o c a l B u s
D is tr ib u tio n P a n e l
T ra n s fo rm e r – 3 0 k V A P rim a ry : Y -, 4 8 0 V , 3 p , 4W
S e c o n d a ry : Y -, 2 0 8 V , 3 p , 4WB re a k e r
P ro c e s s a n d S p e c ia l L o a d s
G G e n e ra to r S e t
B re a k e r (s yn c h ro n iz e d )
B re a k e r (s yn c h ro n ize d ) P a ra lle lin g S w itc h b o a rd
Interconnection Diagram of Power Production Sources with Loads
Group 16: Design of a Hydrogen Power Park
Electrical RequirementsElectricity Consumption
0
50
100
150
200
20 0920 1020 1120 1220 1320 1420 1520 1620 1720 1820 19
Year
kW/d
ay
050100150200250300350
kg/d
ay
Daily Typical Loads (kW)
Daily Process Loads (kW) -ModerateTotal Daily Electricity Consumptionfrom the Grid (kW) - ModerateHydrogen Sales (kg/day)
SOFC: Able to produce 3000kWh/day and will only produce energy as required.
As the energy consumption increases beyond 3000kWh/day, the difference is drawn off the local power grid.
The SOFC produces less CO2 emissions than grid power.
SOFC: 440g of CO2per kWh
Grid: 453g of CO2 per kWh
Group 16: Design of a Hydrogen Power Park
Safety Considerations in the Park Design
4 major failure modes and their preventive measures:
1. Human Erroradequate employee trainingvisible warning signs and instructions
2. Gas Leakagesbuilt according to standards, regular inspections
3. Equipment Failurescheduled maintenance as suggested by manufacturers
4. Terrorism security cameras, card-accessed entrances
Group 16: Design of a Hydrogen Power Park
Safety Considerations in the Park Design
When there is hydrogen Fire /Leakage:
Infrared/UV sensors, smoke detectors, flow sensors audible alarms + red flashing light + emergency fail-safe shutdown emergency dispatcher fire department
Group 16: Design of a Hydrogen Power Park
Hydrogen Properties 1FlammableNon-toxicOdourlessColorless gas Small molecular size • prone to leakage
Compare to natural gasDiffuses in air 3.8x fasterRise 6x faster
Invisible flame (unless coloured by impurities)• significantly less radiant
heat than hydrocarbon fire
• reduce the risk of secondary fires
• but less warning as one approaches the invisible flame
Group 16: Design of a Hydrogen Power Park
Hydrogen Properties 2Combustion
Hydrogen → water vapourNatural gas (incomplete combustion) → toxic CO & CO2, water
Flammable mixtureAs long as ventilation is adequate, the probability of hydrogen forming a flammable mixture with air is very low
LeakLarge leak → flammable cloud + ignition source →fire/explosion• strict prohibition of open flames (e.g. smoking) and
cell phone usage
Group 16: Design of a Hydrogen Power Park
Hydrogen vs Natural Gas vs Gasoline
Flammability limits and ignition energy of H2, CH4 and gasoline with air
Flammability range of hydrogen is 7 times wider than methane
Group 16: Design of a Hydrogen Power Park
Safety Analysis
Safety analysis at conceptual stage: • opportunity for inherently safer design solutions• more cost-effective to operate the power park
Reduce chance of:• process safety related incidents • downtime and financial losses• losing public confidence
Advantages
Group 16: Design of a Hydrogen Power Park
HAZOP (Hazard and Operability)
HAZOP MethodologyLogical & systematic approach for identifying potential hazards Creates deviations from the process design intentOnly warrants qualitative analysis; not quantitativeConventional group approach discarded• Lack of experienced human
resources
Safeguards/MitigationsConsequencesCausesDeviationParameterProcessSection
GUIDE WORDS: more, higher, longer, less, lower, shorter, as well as, also, part of, reverse, other than, sooner, lower. ….
Group 16: Design of a Hydrogen Power Park
HAZOP Results SummaryEquipment of the highest risk:
Dispenser
Human error preventions:Trained operator to refuel vehicles Clear labels / instructions: • Manual emergency shutoff valves labelled with direction of
turning• Pipelines labelled with direction of flow
Group 16: Design of a Hydrogen Power Park
HAZOP Results Summary
Sparks generation preventions:Permanent bonding and grounding of equipmentsGrounding of person doing maintenance workUse tools that do not generate sparks
Sabotage/terrorism preventions:Surveillance/security systemRemote manual emergency shutdown system
Group 16: Design of a Hydrogen Power Park
High Risk Situations1. Maintenance, start-up and shut-down of equipment
• Venting or bleeding device to depressurize gas before dismantling• Start-up procedures (e.g. purging with an inert gas)
2. Control system fault • Cause: grid power outage
• SOFC & generator set can supply power to control system. • Cause: virus/hacking
• Anti-virus and firewall softwares• Watchdog timer to monitor
status of the control computer
Group 16: Design of a Hydrogen Power Park
Essential Safety ComponentsInstruments
Flammable gas detectorsSmoke detectorsUV/infrared hydrogen flame detectors Manual + automatic safety shutoff valvesPressure relief valvesGrounding/bonding
Systems:Redundant fail-safe shutdown (automatic and manual) Emergency ventilation Emergency powerSecurity
Group 16: Design of a Hydrogen Power Park
Economics – Purchase CostsTotal Purchase Cost$6,458,648 US
Dispenser $62,988Compressor $97,660Storage System $198,000100 kW SOFC $200,000Primary Reformer (2) $1,600,000Pre-Reformer (2) $1,400,000Control System $200,000Hydro-desulf. unit (2) $200,000Zinc-Oxide Bed (2) $200,000PSA $50,000piping, etc. $50,000Land $1,000,000Building $1,000,000Construction Costs $200,000
Group 16: Design of a Hydrogen Power Park
econ
Economics - ProfitabilityBreak-Even Point (Moderate Scenario)
-$8,000
-$6,000
-$4,000
-$2,000
$0
$2,000
$4,00020
09
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
Year
Thou
sand
s of
US
D
Annual Net Income Aggregate Annual Net Income
Revenue vs. Cost (Moderate Scenario)
$0$1,000
$2,000$3,000
$4,000$5,000
$6,000$7,000
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019Year
Thou
sand
s of
US
D
Total Annual Revenue Total Annual Cost
Break-even point: 2018
Payback period: 9 years.
Total revenue: $26.9 M•Mostly from hydrogen sales ($22.6 M, $53.38/kg)
•Other sources: convenience store, carbon emissions credits
Average production cost of H2: $33.95/kg
Group 16: Design of a Hydrogen Power Park
Economics – Cost breakdownTo t al C o st B reakd own
Tot al operat ing expenses
46%
Tot al COGS (Mid Level Scen.) 8%
Tot al Capit al Cost s46%
Operat ing C o st s B reakd o wn
Depreciat ion35%
Miscellaneous 10%
Maint enance 19%
Legal 4%
Insurance 10%
Labour12%
Market ing10%
Total capital costs: $9.1MPurchase costApplicable taxes (15%)Installation and transportation (2% of purchase cost)
Operating costs: start at $846Kin 2010 and rise with the projected rate of inflation
Average cost of goods sold: $138K• Electricity consumption• Feed gas• Convenience store
Group 16: Design of a Hydrogen Power Park
Environmental Analysis
SMR PSA
SOFC
Pre-Reformer
Landfill Site
FCV
Break in SystemCO2 emissionsElectricity
YES Power Park
Comparison of CO2 Emissions
0
100
200
300
400
500
600
Gas60
kg H
2/day
70 kg
H2/d
ay80
kg H
2/day
100 k
g H2/d
ay12
0 kg H
2/day
145 k
g H2/d
ay18
0 kg H
2/day
225 k
g H2/d
ay27
0 kg H
2/day
300 k
g H2/d
ay
Process
Avg
. CO
2 Em
issi
on (g
CO
2 /m
ile)
Vehicle operation
Production
Feedstockretrieval
As more hydrogen is produced per year, the average grams of CO2per mile decrease.
The major CO2emissions are localized at the power plant which makes CO2capture achievable.
Adopting hydrogen process reduces automobile-related emissions by at least 40%
Group 16: Design of a Hydrogen Power Park
Marketing PlanTargets1. Fuel cell vehicle owners:
i. Businesses operating FCV fleetsii. Early adopters.
2. Waterloo community
Marketing StrategiesPromote and support early adopters (e.g. ChallengeX Vehicle)Position hydrogen as an attractive fuel source (e.g. use of education center)Accelerate commercialization of the hydrogen economy
Looks and behaves like a gasoline stationAlign the park with the Toronto Hydrogen VillageLocated next to a Hydrogen Development Incubator
Group 16: Design of a Hydrogen Power Park
Marketing Plan - Implementation
The launch of the marketing campaign will corresponds with the 2010 Winter Olympic Games in Vancouver, British Columbia
Anticipated that hydrogen and related technologies will receive a significant amount of national and international exposure
Group 16: Design of a Hydrogen Power Park
Summary More than just a hydrogen refuelling stationDevelopment Incubator + education center to promotes the adoption of hydrogen technologyFeasible, innovative & safe Reduce and localize emissionsMarketing plans to achieve hydrogen acceptance
Group 16: Design of a Hydrogen Power Park
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Group 16: Design of a Hydrogen Power Park
Questions?