Periodic Reporting for period 2 - MultiPLHY (Multimegawatt high-temperature electrolyser to generate green hydrogen for production of high-quality biofuels)
Periodo di rendicontazione: 2021-01-01 al 2021-12-31
The shift to a low-carbon EU economy raises the challenge of integrating renewable energy (RES) and cutting the CO2 emissions of energy intensive industries (EII). In this context, hydrogen produced from RES will contribute to decarbonize those industries, as feedstock/fuel/energy storage. MULTIPLHY thus aims to install, integrate and operate the world's first high-temperature electrolyser (HTE) system in multi-megawatt-scale (~2.4 MW), at a renewable products refinery in Rotterdam (NL) to produce hydrogen (≥ 60 kg/h) for the refinery's processes.
MULTIPLHY will demonstrate the technological and industrial leadership of the EU in Solid Oxide Electrolyser Cell (SOEC) technology. With its rated electrical connection of ~3.5 MWel,AC,BOL, electrical rated nominal power of ~2.6 MWel,AC and a hydrogen production rate ≥ 670 Nm³/h. MULTIPLHY's electrical efficiency (85 %el,LHV) will be at least 20 % higher than efficiencies of low temperature electrolysers, enabling the cutting of operational costs and the reduction of the connected load at the refinery and hence the impact on the local power grid.
MULTIPLHY will demonstrate the technological and industrial leadership of the EU in Solid Oxide Electrolyser Cell (SOEC) technology. With its rated electrical connection of ~3.5 MWel,AC,BOL, electrical rated nominal power of ~2.6 MWel,AC and a hydrogen production rate ≥ 670 Nm³/h. MULTIPLHY's electrical efficiency (85 %el,LHV) will be at least 20 % higher than efficiencies of low temperature electrolysers, enabling the cutting of operational costs and the reduction of the connected load at the refinery and hence the impact on the local power grid.
During periods 1, and 2 seven of the eight Work Packages were active as planned. The overall progress of the project is as planned. Some tasks are delayed and the situation has been explained to the Project officer during the period, first in July 2021 and with a status e-mail sent on October 27th 2021. A contingency plan to minimise the impact of this delay has been jointly defined by the partners, and has also been presented to the Project officer. It allows to secure the demonstration phase of the project, as detailed below in the report. The revised dates for delayed milestones and deliverables take this contingency plan into account.
Achivements towards objectives:
Objective 1: Scale-up of technology to multi-MW
Works on HTE system engineering and optimization have been performed as planned. Following the start of a first HyLink Gen 2.0 ‘Proof of Concept’ module, an important return on experiment has been done. The HyLink module Gen 2.1.0 has been manufactured, commissioned and tested successfully in stable operation mode but also through testing the limits. The detailed engineering of the MULTIPLHY HTE System is upon finalisation. Long-lead items have been identified and ordered. Stack production is also ongoing as planned.
In order to secure the start of the demonstration it has been split up in agreement with PO. This leads to a new aim of 50 % FAT in M29 and 100 % FAT by M34.
The concept engineering and basic engineering of hydrogen processing unit (HPU) is completed and detail engineering is progressing well, together with manufacturing activities. The compressor is already manufactured, as well as the air cooler. Other components are under manufacturing.
Objective 2: Optimization of efficiencies
The design of the HTE and HPU units is focused to achieve the targeted levels of efficiencies, at both the overall design scale and the coupling between the two units, but also in the selection of improved BoP (balance of plant) components. The test results obtained on the HyLink module Gen 2.1.0 were useful to check the performance against the project targets. Hydrogen output was confirmed during testing of Gen 2.1.0 module.
Objective 3: Increase of availability and Improve operations
A service and maintenance concept has been prepared and communicated to the partners. As an ongoing task it will be continuously adapted and optimized during the project phases. Tests performed on HPU auxiliary components done also contribute to a better knowledge of the reliability of those components.
Objective 4: Improvement of stack durability
Sunfire stack and CEA stack have been successfully tested over 7900h and more than 6000h.
For both stacks, it has been possible to operate the stacks with no production loss over those durations, thanks to the operation strategy adopted consisting in compensating degradation by an increase of the temperature. The results obtained allowed to compare both stacks (based on electrolyte or electrode supported cell technology) in terms of performance and durability.
Objective 5: Reduction of capital cost and of O&M expenditures
A Design-to-Cost strategy has been developed, with the support of several tools to perform the strategic cost planning and support the persons in charge for the different system sub-units to find the optimal engineering decision.
The cost analysis has been based on the 1st prototype system that has been manufactured end of 2020 as basis and addresses 12 modules of Gen. 2.1 which are manufactured in 2021 and a series production of 120 modules end of 2022. It includes a new Gen. 3 that will be available in 2024, where the stack design is changed so that the stack costs are decreased significantly. In 2024, the new stack design will bring costs down considerably.
Objective 6: Showcasing business opportunities
techno-economic evaluations have been performed, providing methodology and reference values for several scenarios. Selected application cases of the steam electrolysis technology related to the production hydrogen in biofuels refinery have been proposed and the techno-economic specifications of the SOEC system designed for industrial application have been determined. The results obtained so far show that the bigger the plant, the higher the impact of Electricity Prices & Efficiency and CAPEX Total Integration Cost. Second, the bigger the plant, the lower the impact of CAPEX Stack. Lastly, in all scenarios beneficial are high full load hours and lower discount rates.
Based on the above-mentioned results recommendations for future projects can be formulated.
Objective 7: Defining a procurement strategy for renewable electricity
The review of the regulatory context performed highlighted the uncertainties around the system for GO.
Three options for sourcing of renewable power have been done, and for the specific case of NESTE refinery the best option has been defined.
Objective 8: Certifying renewable properties of the product
MULTIPLHY developed a methodology that addresses different steam supply configurations and which can therefore be applied to any SOEC project, i.e. not only MultiPLHY. The process approval within the WG’s that was planned to be completed in 2021 is now expected to be achieved within WG2 in March 2022 and further endorsement by WG1 in early Q2 2022.
Achivements towards objectives:
Objective 1: Scale-up of technology to multi-MW
Works on HTE system engineering and optimization have been performed as planned. Following the start of a first HyLink Gen 2.0 ‘Proof of Concept’ module, an important return on experiment has been done. The HyLink module Gen 2.1.0 has been manufactured, commissioned and tested successfully in stable operation mode but also through testing the limits. The detailed engineering of the MULTIPLHY HTE System is upon finalisation. Long-lead items have been identified and ordered. Stack production is also ongoing as planned.
In order to secure the start of the demonstration it has been split up in agreement with PO. This leads to a new aim of 50 % FAT in M29 and 100 % FAT by M34.
The concept engineering and basic engineering of hydrogen processing unit (HPU) is completed and detail engineering is progressing well, together with manufacturing activities. The compressor is already manufactured, as well as the air cooler. Other components are under manufacturing.
Objective 2: Optimization of efficiencies
The design of the HTE and HPU units is focused to achieve the targeted levels of efficiencies, at both the overall design scale and the coupling between the two units, but also in the selection of improved BoP (balance of plant) components. The test results obtained on the HyLink module Gen 2.1.0 were useful to check the performance against the project targets. Hydrogen output was confirmed during testing of Gen 2.1.0 module.
Objective 3: Increase of availability and Improve operations
A service and maintenance concept has been prepared and communicated to the partners. As an ongoing task it will be continuously adapted and optimized during the project phases. Tests performed on HPU auxiliary components done also contribute to a better knowledge of the reliability of those components.
Objective 4: Improvement of stack durability
Sunfire stack and CEA stack have been successfully tested over 7900h and more than 6000h.
For both stacks, it has been possible to operate the stacks with no production loss over those durations, thanks to the operation strategy adopted consisting in compensating degradation by an increase of the temperature. The results obtained allowed to compare both stacks (based on electrolyte or electrode supported cell technology) in terms of performance and durability.
Objective 5: Reduction of capital cost and of O&M expenditures
A Design-to-Cost strategy has been developed, with the support of several tools to perform the strategic cost planning and support the persons in charge for the different system sub-units to find the optimal engineering decision.
The cost analysis has been based on the 1st prototype system that has been manufactured end of 2020 as basis and addresses 12 modules of Gen. 2.1 which are manufactured in 2021 and a series production of 120 modules end of 2022. It includes a new Gen. 3 that will be available in 2024, where the stack design is changed so that the stack costs are decreased significantly. In 2024, the new stack design will bring costs down considerably.
Objective 6: Showcasing business opportunities
techno-economic evaluations have been performed, providing methodology and reference values for several scenarios. Selected application cases of the steam electrolysis technology related to the production hydrogen in biofuels refinery have been proposed and the techno-economic specifications of the SOEC system designed for industrial application have been determined. The results obtained so far show that the bigger the plant, the higher the impact of Electricity Prices & Efficiency and CAPEX Total Integration Cost. Second, the bigger the plant, the lower the impact of CAPEX Stack. Lastly, in all scenarios beneficial are high full load hours and lower discount rates.
Based on the above-mentioned results recommendations for future projects can be formulated.
Objective 7: Defining a procurement strategy for renewable electricity
The review of the regulatory context performed highlighted the uncertainties around the system for GO.
Three options for sourcing of renewable power have been done, and for the specific case of NESTE refinery the best option has been defined.
Objective 8: Certifying renewable properties of the product
MULTIPLHY developed a methodology that addresses different steam supply configurations and which can therefore be applied to any SOEC project, i.e. not only MultiPLHY. The process approval within the WG’s that was planned to be completed in 2021 is now expected to be achieved within WG2 in March 2022 and further endorsement by WG1 in early Q2 2022.
MULTIPLHY will be the largest SOE system installed worldwide.
MULTIPLHY will contribute
1. To increase the energy efficiency of production of hydrogen mainly from water electrolysis and re-newable sources while reducing operating and capital costs,
2. to demonstrate on a large scale the feasibility of using hydrogen to support the integration of re-newable energy sources into the energy systems.
Through a multitude of improvements (e.g. efficiency, durability, costs, and scale), MULTIPLHY will signif-icantly impact the competitiveness of green hydrogen production compared to fossil alternatives.
The produced information on the operational, technical and financial performance of the HTE itself and the illustration of the integration into the commercial and technical processes of NESTE will ensure that the re-sults have the maximum impact for further market deployment.
MULTIPLHY will contribute
1. To increase the energy efficiency of production of hydrogen mainly from water electrolysis and re-newable sources while reducing operating and capital costs,
2. to demonstrate on a large scale the feasibility of using hydrogen to support the integration of re-newable energy sources into the energy systems.
Through a multitude of improvements (e.g. efficiency, durability, costs, and scale), MULTIPLHY will signif-icantly impact the competitiveness of green hydrogen production compared to fossil alternatives.
The produced information on the operational, technical and financial performance of the HTE itself and the illustration of the integration into the commercial and technical processes of NESTE will ensure that the re-sults have the maximum impact for further market deployment.