Periodic Reporting for period 2 - EMPOWER (European methanol powered fuel cell CHP)
Reporting period: 2021-07-01 to 2023-11-30
European methanol powered fuel cell CHP. EMPOWER, was a project dedicated to developing a highly efficient and versatile mini combined heat and power (CHP) system based on high-temperature proton exchange membrane fuel cells (HT-PEMFC). The primary objective of the project was to design and demonstrate a methanol-fuelled mobile CHP system utilizing HT-PEMFC technology for simultaneous heat and electricity generation.
Designed to function as a backup or off-grid solution in both industrial and residential settings, the EMPOWER system aimed to provide utility-grade electricity, with waste heat repurposed for space heating and domestic hot water applications. The overarching goal was to enhance system efficiency, specifically targeting the mini-CHP market, while ensuring cost competitiveness and a low-carbon footprint.
The methanol-fueled CHP system was developed to replace diesel generators, providing lower CO2 emissions, reduced noise, and heat generation. Methanol's liquid form enables cost-effective storage and seamless distribution through existing infrastructure, fostering renewable production and reducing dependence on imported fossil fuels.
The development work carried out during the project was guided by the following objectives:
• Prove the scalability of the components, systems and processes cost reduction for systems up to 50 kW
• Strengthen the EU knowledge on the CHP technology and result in strong synergies or joint ventures including beyond the consortium for the manufacturing of viable and competitive products
• Show that can produce cheap and secure electricity with low carbon footprint
• Improving system efficiency above 50% with novel ideas of thermal integration
• Increase stack efficiency above 55% and fuel utilization above 95%
• Demonstrate a flexible power source with fast start up in less than 10 min and dynamic adaptation during variable power demand within few seconds)
The outcomes of the actions during project can be summarized as follows:
• Improving materials for fuel cell stacks and refining their quality control methods.
• Novel concept of aqueous-phase reforming studied as pre-reforming technology of methanol.
• Highly efficient gas-phase reformer developed.
• Custom-made fuel cell system for demonstration purposes developed.
• Mobile CHP container, acting as platform for fuel cell system developed. Integration and short-term test of CHP system executed.
• Final demonstration activities focusing on stand-alone performance demonstration of fuel cell system in relevant conditions.
• Scalability, cost reduction, low carbon footprint, and business potential for project concept proven.
Designed to function as a backup or off-grid solution in both industrial and residential settings, the EMPOWER system aimed to provide utility-grade electricity, with waste heat repurposed for space heating and domestic hot water applications. The overarching goal was to enhance system efficiency, specifically targeting the mini-CHP market, while ensuring cost competitiveness and a low-carbon footprint.
The methanol-fueled CHP system was developed to replace diesel generators, providing lower CO2 emissions, reduced noise, and heat generation. Methanol's liquid form enables cost-effective storage and seamless distribution through existing infrastructure, fostering renewable production and reducing dependence on imported fossil fuels.
The development work carried out during the project was guided by the following objectives:
• Prove the scalability of the components, systems and processes cost reduction for systems up to 50 kW
• Strengthen the EU knowledge on the CHP technology and result in strong synergies or joint ventures including beyond the consortium for the manufacturing of viable and competitive products
• Show that can produce cheap and secure electricity with low carbon footprint
• Improving system efficiency above 50% with novel ideas of thermal integration
• Increase stack efficiency above 55% and fuel utilization above 95%
• Demonstrate a flexible power source with fast start up in less than 10 min and dynamic adaptation during variable power demand within few seconds)
The outcomes of the actions during project can be summarized as follows:
• Improving materials for fuel cell stacks and refining their quality control methods.
• Novel concept of aqueous-phase reforming studied as pre-reforming technology of methanol.
• Highly efficient gas-phase reformer developed.
• Custom-made fuel cell system for demonstration purposes developed.
• Mobile CHP container, acting as platform for fuel cell system developed. Integration and short-term test of CHP system executed.
• Final demonstration activities focusing on stand-alone performance demonstration of fuel cell system in relevant conditions.
• Scalability, cost reduction, low carbon footprint, and business potential for project concept proven.
Fuel cells stack development included a new compression reducing costs, increases manufacturability, and minimizes leaks. Further, new gasket materials and designs were designed and tested. Other focus areas were the materials and design of bipolar plate and gasket, which were optimized for fuel cell pressurization, reduction of leakages and overall costs, and a new electrode formulas for reducing Pt consumption on the MEA.
Investigation of an innovative aqueous-phase reforming concept as a pre-reforming technology for methanol was as one of focus areas in reformer development. Promising Pt-based catalysts suitable for elevated process conditions were identified, but further research is needed for integration of this method as a pre-reforming unit. The complete gas-phase reformer system was designed, constructed, commissioned, and evaluated. Full functionality was demonstrated and complete methanol conversion could be achieved at 100% capacity.
The fuel cell system development successfully concluded with the completion of an HT-PEMFC system, which includes the fuel cell stack, reformer, and balance of plant components. A detailed P&I diagram was created, and major components were sized and specified. The developed system underwent a successful factory acceptance test, during which it demonstrated the proper functioning of control and safety systems while producing 5 kW of power. Additionally, manufacturing costs were analysed, suggesting that simplifying the reforming setup could reduce the manufacturing cost to 2,587 € per kilowatt for an annual production of 20,000 units.
The integration process commenced by identifying end users and customer segments. Based on gathered inputs, a mobile CHP container was designed and constructed. To enhance the system, a comprehensive safety analysis was conducted, and recommended improvements were incorporated. The fuel cell system was integrated into the finalized container workspace, and a short-term test of the CHP system was carried out. The final demonstration activities were focusing on a stand-alone performance demonstration of the fuel cell system in relevant conditions. The demonstration contained long-term operation period alongside 70 start-stop cycles. Throughout the demonstration period, it achieved a peak stack electrical efficiency of 53.7%, generated a maximum power output of 6.5 kW, and accumulated a total energy production of 1.8 MWh. Results were thoroughly analyzed, and development points were identified, with changes to components.
Communication activities focused on promoting the potential of fuel cell CHP systems and exploring the applications of renewable methanol in fuel cells. Four major dissemination events were organized, targeting the general public, academic audience, and industrial shareholders. The project yielded two peer-reviewed scientific articles, and the involvement of a PhD student and the completion of two MSc theses contributed to its academic dimension. Market potential and business analyses were conducted on methanol-fueled HT-PEMFC CHP units to identify potential market segments for the developed product. Comparative studies indicated a lower carbon footprint for the system when using any of the renewable methanol feedstocks compared to diesel generators.
The project has identified a range of exploitable results and partners are actively working on leveraging them. Below, a selection of these outcomes are listed.
• Integration of a 5-kW fuel cell system with a heat pump for 20-30 kW heat production
• Bipolar plate design for gasket stability
• Mechanical endplate design and compression system
• BoP component selection for the fuel cell system
• Integration of a thermoelectric generator in the fuel cell system
• GPR unit for methanol reforming
Investigation of an innovative aqueous-phase reforming concept as a pre-reforming technology for methanol was as one of focus areas in reformer development. Promising Pt-based catalysts suitable for elevated process conditions were identified, but further research is needed for integration of this method as a pre-reforming unit. The complete gas-phase reformer system was designed, constructed, commissioned, and evaluated. Full functionality was demonstrated and complete methanol conversion could be achieved at 100% capacity.
The fuel cell system development successfully concluded with the completion of an HT-PEMFC system, which includes the fuel cell stack, reformer, and balance of plant components. A detailed P&I diagram was created, and major components were sized and specified. The developed system underwent a successful factory acceptance test, during which it demonstrated the proper functioning of control and safety systems while producing 5 kW of power. Additionally, manufacturing costs were analysed, suggesting that simplifying the reforming setup could reduce the manufacturing cost to 2,587 € per kilowatt for an annual production of 20,000 units.
The integration process commenced by identifying end users and customer segments. Based on gathered inputs, a mobile CHP container was designed and constructed. To enhance the system, a comprehensive safety analysis was conducted, and recommended improvements were incorporated. The fuel cell system was integrated into the finalized container workspace, and a short-term test of the CHP system was carried out. The final demonstration activities were focusing on a stand-alone performance demonstration of the fuel cell system in relevant conditions. The demonstration contained long-term operation period alongside 70 start-stop cycles. Throughout the demonstration period, it achieved a peak stack electrical efficiency of 53.7%, generated a maximum power output of 6.5 kW, and accumulated a total energy production of 1.8 MWh. Results were thoroughly analyzed, and development points were identified, with changes to components.
Communication activities focused on promoting the potential of fuel cell CHP systems and exploring the applications of renewable methanol in fuel cells. Four major dissemination events were organized, targeting the general public, academic audience, and industrial shareholders. The project yielded two peer-reviewed scientific articles, and the involvement of a PhD student and the completion of two MSc theses contributed to its academic dimension. Market potential and business analyses were conducted on methanol-fueled HT-PEMFC CHP units to identify potential market segments for the developed product. Comparative studies indicated a lower carbon footprint for the system when using any of the renewable methanol feedstocks compared to diesel generators.
The project has identified a range of exploitable results and partners are actively working on leveraging them. Below, a selection of these outcomes are listed.
• Integration of a 5-kW fuel cell system with a heat pump for 20-30 kW heat production
• Bipolar plate design for gasket stability
• Mechanical endplate design and compression system
• BoP component selection for the fuel cell system
• Integration of a thermoelectric generator in the fuel cell system
• GPR unit for methanol reforming
The project focused on enhancing the performance of HT-PEMFC stacks, exploring novel reforming concepts for fuel cell applications, and implementing innovative thermal integration of system components to improve overall efficiency. A 5 kW fuel cell CHP system concept was successfully developed, aiming for a cost below €3,000/kW and showcasing high electrical efficiency potential. The validated CHP system and demonstrated fuel cell system were tested under relevant conditions. User and customer segment identification informed the system development, considering their specific needs.
The work carried out during the project contributed to the realization of the following central impacts outlined in the project plan:
• Decrease system cost for small-scale CHP unit
• Increase system life time
• Increase fuel cell stack efficiency
• Increased system efficiency
• Prove the scalability of the components, systems and processes cost reduction for systems up to 50 kW
The work carried out during the project contributed to the realization of the following central impacts outlined in the project plan:
• Decrease system cost for small-scale CHP unit
• Increase system life time
• Increase fuel cell stack efficiency
• Increased system efficiency
• Prove the scalability of the components, systems and processes cost reduction for systems up to 50 kW