Senior Design I: Preliminary Design Review
Project 05305: Conversion of Wind Power to Hydrogen
Team Leader:
Team Members:
Quoc Khanh Ngo
Sarah Braymiller
Stephen Raymond
Paul Williams
Patrick Griffin
Justin Szratter
Michael Miller
Project Sponsor:
Project Mentors:
Harbec Plastics, Environmental Protection Agency
Professor Brian Thorn
Professor Andres Carrano
Project Coordinator: Professor Jacqueline Mozrall
PDR: Agenda
• Company Background
• Environmental Deliverable
• Concept Evaluation
• Financial Deliverable
• Feasibility Assessment
• Project Schedule
• Team breakdown
• Overall System Diagram/ Block
Diagram
• Detailed Design/ Process Design
Schematics
PDR: Company Background
Company Description
• Founded in 1977 as a Tool and Die Company
• Located in Ontario, NY
• Currently a full service thermal injection mold and manufacturing facility
Environmental Highlights
• Developed current facilities for Energy Star compliance
• Ability to Produce 100% of energy requirements off the grid
• Developed initiatives to reduce plastic waste through recycling
PDR: Project Definition
Project Mission Statement:
To explore and develop a sustainable design that will capture, convert, and store
excess energy created by an existing wind turbine
Problem Description
• 250 KW Fuhrländer Wind Turbine installed in 2001
• Manufacturing facility currently utilizes the turbine for five of the seven days a
week
• Energy produced during the weekend returns to the grid free of charge
• Monitoring/Control Site
PDR: Project Specifications
Project Work Statement:
• Detail of technical challenges and solutions associated with energy
conversion
• Technical roadmap and program schedule for system implementation
• Facilities analysis for potential implementation
• Environmental impact analysis for all potential systems
PDR: Scope Limitations
System Design Specifications
• Design considerations:
• Will be given primarily to commercially available products
• Must provide the conversion to hydrogen
• A consideration must include a fuel cell system
• Will produce a payback period of eight to ten years
• Should not increase emission generation produced by the facility
PDR: Team Breakdown
Detail Component Research and
Implementation
Electrolyzer
• Patrick Griffin - ME
Storage Alternatives
• Michael Miller - ME
Wind Turbine, Power Production,
Concept Development and Feasibility
• Justin Szratter – ME
Overall Systems Integration and
Design
Stephen Raymond - ME
Financial Analysis and Facilities
Planning
• Quoc Khanh Ngo – ISE, Manager
Environmental Planning,
Sustainability, Feasibility, and
Facilites Planning
• Sarah Braymiller - ISE
PDR: Concept Development
Primary Concepts Considered
• Hydrogen Fuel Cells
• Hythane – Micro-turbines
Secondary Consideration
• Hydrogen Engines
Other Concepts
•
•
•
•
•
Water Reservoir Pump
Flywheel
Super Capacitors
Fuel Cell/Reformer
Mass-Energy Lift
Weight
Relative
System
Kinetic Energy
System
Engine Energy
baseline 5= much better than baseline
Hydrogen
baseline 3 = same as baseline 4 = better than
Hythane
worse than baseline concept 2 = worse than
System
baseline, score each attribute as: 1 = much
Fuel Cell
Evaluate each additional concept against the
Energy System
PDR: Feasibility Considerations
Sufficient Student Skills?
3.0
3
5
3
0%
Research Material Availability
3.0
1
3
5
9%
Overall Cost Justification
3.0
3
2
2
18%
Available Human Resources
3.0
3
2
2
7%
Customer Expectation (Fuel Cell Concept)
3.0
1
1
1
18%
Multiple Concepts Complete by April
3.0
3
3
3
9%
New Technology
3.0
3
5
4
2%
Innovation
3.0
2
5
2
7%
Available for Implementation
3.0
5
2
2
18%
Scalability
3.0
3
1
1
13%
Weighted Score
3.0
2.8
2.1
2.1
100.0%
91.9%
71.1%
69.6%
Normalized Score
PDR: Concept Schematics
Fuel Cell Schematic
Oxygen Storage
Oxygen Compressor
Windmill
Electrolyzer
Hydrogen
Compressor
Hydrogen Storage
Water Distiller
Water Storage
Fuel Cells
Gas Turbines
Natural Gas
Power Inverter
Electrical Energy
Production
PDR: Concept Schematics
Hythane Schematic
Oxygen Storage
Oxygen Compressor
Windmill
Electrolyzer
Hydrogen
Compressor
Water Distiller
Water Storage
Hydrogen Storage
Gas Turbines
Natural Gas
Electrical Energy
Production
PDR: Concept Schematics
Hydrogen Engine
Oxygen Storage
Oxygen Compressor
Windmill
Electrolyzer
Hydrogen
Compressor
Hydrogen Storage
Water Distiller
Water Storage
Hydrogen Engine
Power Inverter
Gas Turbines
Electrical Energy
Production
Natural Gas
PDR: Fuel Cell Overall System Tree Diagram
Windmill Power
Generation
Green Power (No
Emissions)
Allowable Floor
Space
8-10 Year
Payback
Power Output
Fuel Cell
Electrolyzer
Distiller
Hydrogen
Consumption
Hydrogen
Production
Distilled Water
Process Rate
Water Storage
Oxygen
Production
Key
System Outputs
Component Properties
Key Goal Outputs
System Components
Cost
Hydrogen/Oxygen
Storage
Compressor
Volume and
Pressure
Pressurization
Analysis: Overall Integration
Select Electrolyzer
-Water Distiller
-Hydrogen Compressor
-Oxygen Compressor
Check Total Power Consumption
-Water Storage
-Hydrogen Storage
-Oxygen Storage
-Select Fuel Cell
•
Duration of Fuel Cell Operation
•
Floor Space Required by Components
•
Financial Analysis for 8-10 Year Payback
Analysis: Electrolyzers
Integration Issues
–
–
–
–
–
Electric Load
Hydrogen Production
Output Pressure
Efficiency
Feed Water
Analysis: Electrolyzer Loading
Turbine Limitations
– Wind turbine generates 300 MWh/year
– Average output ~ 34kW
Electrolyzer Limitations
–
–
–
–
Requirements under 34 KW
Utilize low-power units
Potential to sustain multiple units
Optimize hydrogen production
Analysis: Hydrogen Production/Pressure
Run Time Constraints
– System must operate for a continuous 96 hours
– Pressure vessel shall accommodate 4 days of H2
production
Mechanical Constraints
– Electrolyzer’s pressure are all <370psi
• Too low
• Will need a compressor for storage
Analysis: Electrolyzer
Efficiency
– Existing cogeneration facility
Feed Water
– Needs Purified Water (e.g. distillation,
reverse osmosis)
– On-site distiller
Final Choice
– HM-50 based on low electric load and
high efficiency
Analysis: Storage Options
Methods for Hydrogen
Storage:
• Hydrides
• Liquid
• Gaseous
Analysis: Hydride Storage
• H2 chemically adheres to
metal powder
• Recovered later with
addition of heat
• Volumetrically inefficient
• High Maintenance
Analysis: Liquid Storage
• Temperatures below 10K (-263oC)
• High Maintenance
• Potential losses to boiling
• Very inefficient
Analysis: Gaseous Storage
• Requires Pressures above
2000psi
• Potential for hydrogen
embrittlement
• Hydrogen molecules are spread
apart allowing for easy escape
• Low maintenance
• Highly efficient
Analysis: Storage Selection Criteria
Decision Factors
•
•
•
•
System integration
Cost effectiveness
Low maintenance
Availability
Choice
• Gas Storage Pressure Vessels
Analysis: Fuel Cells
Integration Issues
– Hydrogen Consumption
– Cogeneration
– Electricity Production
Analysis: Hydrogen Consumption
• Most fuel cells require input pressures of no
more than 100psi
– Pressure regulator will be required between storage
and fuel cell
• Power output determines hydrogen
consumption rate
Analysis: Cogeneration
• Electrical efficiency ~35 – 45%
– heat produced
• By capturing waste heat overall efficiency can be
increased to ~70 – 90%
• Harbec’s HVAC system can be easily modified
to capture waste heat
– Waste heat can then be used for facility
heating/cooling
Power Needs: Electricity Production
• Power Output
– Ideal fuel cell is the smallest (cheapest) that can run
all week and consume the hydrogen produced in one
weekend
– 480v 3-phase or 120v single phase AC power can be
used by the plant
– All fuel cell outputs explored are DC
– The fuel cell does not come with an integrated DC to
AC power inverter, an external one must be purchased
PDR: Benefits of Wind Power
Environmental Impacts
• Renewable Energy Resource
• Pollutant Free
– Creates energy with no combustion, no smoke and no
waste.
– Reduced emissions from not using fossil fuels.
PDR: Environmental Impacts
• Using a fuel cell system would reduce emissions
of nitrogen dioxide, sulfur dioxide and carbon
dioxide.
• Emission of these gases can lead to:
– Global warming
– Acid rain
– Smog
– Plant and water damage
– Aesthetic damage to statues and sculptures.
PDR: Social Impacts
Public Health Benefits:
• Traditional Energy systems can lead to acute health
defects and or toxic long term diseases.
• Conventional energy produces toxic particles that can be
linked to premature deaths from heart and lung disease,
including cancer.
PDR: Economic Impacts
• Wind power provides a
constant source of energy
• Wind power provides more jobs
per unit of energy than other
forms of energy
• Wind energy brings jobs and
revenue to rural communities.
• The more wind that is
purchased, the more wind
farms will be developed.
PDR: Financial Analysis
Estimated Energy System Cost: Fuel Cell
• $309,000.00
Estimated Building and Systems Integration Costs
• $75,000.00
Total Cost
• $411,000 with 10% slack costs
Payback
• Average $40,320.00/Year Required to payback the Fuel Cell System
PDR: Financial Analysis
Key Financial Factors
These factors include:
Overall system cost
Electrical output
Hydrogen output
Oxygen output
Maintenance costs
Gas Displacement (Hythane Concept)
Oxygen, Hydrogen, and Natural Gas purchasing costs and trends
Electric purchasing costs and trends
Interest rates
Inflation
Depreciation (MACRS)
Tax Codes and Laws
Government Grants and Other Tax Breaks
Smallest Payback given performance
PDR: Financial Analysis
Strategies to Reducing Average Payback
• Modular System Implementation
• Develop the system on a smaller scale
• Seek out government grants and tax breaks for green
power
• Implement N years from the current date
• Assumptions
• Cost of technology will decrease over time
PDR: Current State
Current State
• Technical Feasibility and Design – Fuel cell concept Completed
• Environmental Feasibility – Fuel cell concept Completed
• Financial Analysis and Feasibility – Fuel cell concept In Progress
• Hythane Micro-turbine Concept Technical Details – In Progress
• Hythane Micro-turbine Concept Financial Details – In Progress
PDR: Future State
Development of Implementation roadmap to be completed - Fuel Cell Concept
• Facilities plan to be completed – Fuel Cell Concept
• Financial Analysis to be completed – Hythane Micro-turbine
• Development of EPA deliverable (Due April 12th)
• Technical Paper (People, Prosperity, Planet)
• Financial Analysis for all concepts
• Facilities Plan
• Presentation Booth for Competition
• Presentation Poster
PDR: GANNT-Activity Schedule
PDR: Questions
PDR: Financial Analysis
MACRS – Modified Accelerated Capital Recovery System
Fuel Cell Model falls under energy equipment
•5 Year Capital Recovery Schedule
•20%
Year Zero
•32%
Year One
•19.2% Year Two
•19.2% Year Three
•11.1% Year Four
•5.5% Year Five
PDR: Concept Feasibility Attributes
•Sufficient Student Skills
This attribute is based on the students technical knowledge and ability to complete the project
•Research Material Availability
This attribute is based on the availability of research material for the project. It also accounts for the feasibility of
developing quotes for the project components.
•Overall Cost Justification Feasibility
This attribute is based on whether or not the concept will fall within the eight to ten year payback period
•Available Financial Resources
This attribute is based on the amount of financial resources that will be allocated towards the concepts for development
•Customer Expectation for Concepts
This attribute is based on the customer expectations from the concepts. What the concepts are, and their performance
•Multiple Concepts Complete by April
This attribute accounts for the nature of the project and the ability/time to produce more than one in depth concept.
•Existing Technology
•This attribute accounts for whether or not design work applies in concept
•New Technology (Innovation)
•This attribute accounts for the design aspect of the project, and how much design work goes into the concept
•Available for Implementation
This attribute accounts for whether or not the concept can be developed due given the availability of the project
•Scalability
This attribute accounts the modularity of the system and its ability to grow in size.
Analysis: Power Inverters
Grid-parallel application
– The inverter must be able to match the waveform from
the grid
Power input
– Most commercial grid-parallel inverters are set up for
sun power applications, with high voltage and low
current
– Inverter with lower voltage and higher current inputs is
required
PDR: Microturbines
Hydrogen Issues
•
Constant amount of Hydrogen
• Less than 5%
• Can burn out the combustors and injectors.
PDR: Microturbines
Integration Issues
• More piping installed
• Cutting into natural gas lines (safety)
• Regulate hydrogen and natural gas flow
PDR: Microturbines
Positive outcomes
• No fuel cell needed (save initial cost)
• Offset amount of natural gas used
• Possible quicker payback
• Some parts already exist
PDR: OHSA Regulations and Standards for the Storage of Hydrogen
PDR: OHSA Regulations and Standards for the Storage of Hydrogen
Design Specifications for Systems of 3,000 CF or Less (Inside
buildings not in a special room and exposed to other occupancies):
•Adequate ventilation to the outdoors shall be provided.
•Protected against damage or injury due to falling objects or working
activity in the area.
•More than one system of 3,000 CF or less may be installed in the
same room, provided the systems are separated by at least 50 feet.
Each such system shall meet of the defined requirements.
PDR: RG&E’s Energy Production Mix
Fuel Emissions from RG&E Produced Electricity
Other
Hydroelectric
Natural Gas
Nuclear
Coal
• Nuclear (55%)
• Coal (28%)
• Hydroelectric energy
(7%)
• Natural Gas (7%)
• Other resources (3%)
"Product Content Label." Catch the Wind. RG&E. 25 Jan. 2005
PDR: Environmental Impacts - Wildlife
There were 183 bird deaths there over a two year
period and wind turbines are not responsible for all
of these deaths.
• Automobiles are the cause of 57 million bird
deaths a year
• More than 97 million birds die by flying into plate
glass each year
• Approximately 1.5 million birds die from collisions
with structures (towers, stacks, bridges, and
buildings) every year - according to the Audubon
Society.
1Frequently
Asked Questions." New Wind Energy. Niagara Mohawk.
PDR: Comparison of Energy Systems
Saved Sulfur Dioxide Emissions
Saved Carbon Dioxide Emissions
400.00
30000.00
350.00
25000.00
20000.00
Emissions (lbs./ year)
250.00
200.00
150.00
15000.00
10000.00
100.00
5000.00
50.00
0.00
Coal Power Plant
Oil Power Plant
Gas Power Plant
0.00
C30 Capstone Microturbines
Coal Power Plant
Energy Systems
Oil Power Plant
Gas Power Plant
Energy Systems
Saved Nitrogen Dioxide Emissions
160.00
140.00
120.00
Emissions (lbs./year)
Emissions (lbs./year)
300.00
100.00
80.00
60.00
40.00
20.00
0.00
Coal Power Plant
Oil Power Plant
Gas Power Plant
Energy Systems
C30 Capstone Microturbines
C30 Capstone Microturbines