Periodic Reporting for period 1 - EMPOWER (European methanol powered fuel cell CHP)
Période du rapport: 2020-01-01 au 2021-06-30
The EMPOWER project will develop, manufacture and validate a methanol fueled 5 kW combined heat and power (CHP) system based on high-temperature PEM fuel cell technology. The project will enhance the system efficiency to target the mini-CHP market and provide a cost competitive and low carbon solution. The developed CHP unit will be capable of fast start-up and fast dynamic response to help integration of intermittent power production from renewable energy sources. The developed system will be validated and demonstrated for six months at the site of an end user. The project will also plan a scale-up of the system to 50-100 kW and develop a business plan including all relevant elements of the methanol fuel cell value chain.
The developed methanol fuelled CHP system is targeted to replace current fossil fuelled (e.g. diesel) generators in various application areas of the society as one mean for climate change mitigation. Its advantages compared to conventional diesel generators are substantially lower CO2 emissions, lower noise and decreased particulate emissions. Further, the CHP system also produces usable amounts of heat in addition to electricity.
Methanol is a liquid fuel, which can be stored in a cost-effective way by using existing non-pressurized tank systems and is easily distributed through the existing infrastructure of road tanker trucks and refueling stations. Manufacturing renewable methanol from locally sourced feedstock supports sector coupling and reduces EU dependence on imported fossil fuels.
During the project, the following targets will be achieved:
• 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 developed methanol fuelled CHP system is targeted to replace current fossil fuelled (e.g. diesel) generators in various application areas of the society as one mean for climate change mitigation. Its advantages compared to conventional diesel generators are substantially lower CO2 emissions, lower noise and decreased particulate emissions. Further, the CHP system also produces usable amounts of heat in addition to electricity.
Methanol is a liquid fuel, which can be stored in a cost-effective way by using existing non-pressurized tank systems and is easily distributed through the existing infrastructure of road tanker trucks and refueling stations. Manufacturing renewable methanol from locally sourced feedstock supports sector coupling and reduces EU dependence on imported fossil fuels.
During the project, the following targets will be achieved:
• 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
Fuel cells stack development has included a new FC stack compression system that has already been developed, tested, and validated. The new compression reduces costs, increases manufacturability, and minimizes leaks. Further, new gasket materials and designs have been designed and tested. Other focus areas have been the materials and design of bipolar plate and gasket, which have been optimized for FC pressurization, reduction of leakages and overall costs, and a new electrode formulas for reducing Pt consumption on the MEA. Tests with a 5 kW FC under normal conditions show an electric efficiency at 52% and power output above 0.2 W/cm2. Pressurized operation at 0.6 bar in single cells indicates significant improvements in performance and the targets seem achievable.
The interfaces between the reformer and other subsystem have been defined. The complete reformer system (GPR) including heat exchangers, catalytic burner, MSR unit, WGS unit, mixers, evaporators, and electrical pre-heater has been designed, constructed, commissioned, and evaluated by Catator. Start-up with initial electric pre-heating and methanol combustion as well as combustion of various off-gas qualities work very well. Full functionality has been demonstrated and complete methanol conversion can be achieved at 100% capacity. The GPR is currently being sent to BWT for integration into the fuel cell system.
The work with FC system by BWT has progressed in close cooperation with system integrator THT Control. The objective is to develop the system layout, manufacture the complete HT-PEMFC system including FC stack, reformer, and BoP components. The main activities carried out during the first period are:
• Different use case scenarios and product specifications of the CHP system has been defined accordingly
• Functionality of the complete CHP system and sub-systems for different operation modes has been evaluated and described
• A model for high-level system control and interface between major sub-systems and end user has been developed
• A preliminary FMEA (Failure Mode and Effects Analysis) has been completed on major sub-systems, to investigate critical-to-operate failures;
• A detailed P&ID (Piping and Instrumentation Diagram) displaying major components, balance of plant components, valves, sensors, and energy flows has been developed. Major components have been sized and specified.
The system integration started with the identification of end users and customer segments. The 5kW CHP system will be integrated into a trailer-mounted container constituting a mobile workspace as wished by the customers. The product specifications have been defined to address multiple customer segments representing different needs for sequential and simultaneous cogeneration of heat and power. The mobile workspace has been designed and constructed. The control and automation system and the safety systems are under construction. Safety analysis are ongoing together with VTT. Electrical systems and cooling and heat management systems are in design and testing phase.
The topic of communication activities has been the potential fuel cell CHPs as well as the potential of renewable methanol in different fuel cell applications. The project has produced a press release, a newsletter, one webinar/industry workshop, project website, and social media pages for marketing events and sharing public results, and a video of the benefits of methanol power fuel cell CHPs on an easy-to-understand level. One peer-reviewed scientific article has been published as well as two MSc thesis. An initial study on market potential and business analysis on methanol fuelled HT-PEMFC CHP units was performed to help understanding how to optimize the project’s offering. The project has already identified a set of exploitable results and the partners are working on exploiting these.
In general, the project is progressing according to the work plan although the Covid19 pandemic caused a few months of delay in some work tasks.
The interfaces between the reformer and other subsystem have been defined. The complete reformer system (GPR) including heat exchangers, catalytic burner, MSR unit, WGS unit, mixers, evaporators, and electrical pre-heater has been designed, constructed, commissioned, and evaluated by Catator. Start-up with initial electric pre-heating and methanol combustion as well as combustion of various off-gas qualities work very well. Full functionality has been demonstrated and complete methanol conversion can be achieved at 100% capacity. The GPR is currently being sent to BWT for integration into the fuel cell system.
The work with FC system by BWT has progressed in close cooperation with system integrator THT Control. The objective is to develop the system layout, manufacture the complete HT-PEMFC system including FC stack, reformer, and BoP components. The main activities carried out during the first period are:
• Different use case scenarios and product specifications of the CHP system has been defined accordingly
• Functionality of the complete CHP system and sub-systems for different operation modes has been evaluated and described
• A model for high-level system control and interface between major sub-systems and end user has been developed
• A preliminary FMEA (Failure Mode and Effects Analysis) has been completed on major sub-systems, to investigate critical-to-operate failures;
• A detailed P&ID (Piping and Instrumentation Diagram) displaying major components, balance of plant components, valves, sensors, and energy flows has been developed. Major components have been sized and specified.
The system integration started with the identification of end users and customer segments. The 5kW CHP system will be integrated into a trailer-mounted container constituting a mobile workspace as wished by the customers. The product specifications have been defined to address multiple customer segments representing different needs for sequential and simultaneous cogeneration of heat and power. The mobile workspace has been designed and constructed. The control and automation system and the safety systems are under construction. Safety analysis are ongoing together with VTT. Electrical systems and cooling and heat management systems are in design and testing phase.
The topic of communication activities has been the potential fuel cell CHPs as well as the potential of renewable methanol in different fuel cell applications. The project has produced a press release, a newsletter, one webinar/industry workshop, project website, and social media pages for marketing events and sharing public results, and a video of the benefits of methanol power fuel cell CHPs on an easy-to-understand level. One peer-reviewed scientific article has been published as well as two MSc thesis. An initial study on market potential and business analysis on methanol fuelled HT-PEMFC CHP units was performed to help understanding how to optimize the project’s offering. The project has already identified a set of exploitable results and the partners are working on exploiting these.
In general, the project is progressing according to the work plan although the Covid19 pandemic caused a few months of delay in some work tasks.
The project has worked on improving performance of high-temperature PEM fuel cell stacks, novel reforming concepts for fuel cell applications, and novel thermal integration of system components to increase the efficiency. The project progress according to schedule and it is expected that the objectives will be reached. The project aims to produce a 5 kW fuel cell CHP system with a price below 3000 €/kW, with a volume density of 30 W/L and high electrical efficiency above 50%. The developed system will be demonstrated for six months at an end user site. First customer segments have been identified and their needs are taken into account in system development.
The impacts as listed in the project plan are still valid and are expected to be reached. In particular, the central impacts are to
• Decrease system cost for small-scale CHP unit
• Increase system life time
• Increase fuel cell stack efficiency
• Increased system efficiency
• Support the RES system with an always available, highly efficient and flexible power source
• Strengthen European fuel cell value chain
• Endorse the use of renewable methanol
The impacts as listed in the project plan are still valid and are expected to be reached. In particular, the central impacts are to
• Decrease system cost for small-scale CHP unit
• Increase system life time
• Increase fuel cell stack efficiency
• Increased system efficiency
• Support the RES system with an always available, highly efficient and flexible power source
• Strengthen European fuel cell value chain
• Endorse the use of renewable methanol