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DON QUICHOTE Report Summary

Project ID: 303411
Funded under: FP7-JTI
Country: Belgium

Periodic Report Summary 3 - DON QUICHOTE (Demonstration Of New Qualitative Innovative Concept of Hydrogen Out of windTurbine Electricity)

Project Context and Objectives:
The project Don Quichote is the next logical step towards the integration of ‘renewable electricity’ and ‘hydrogen’. The idea of Don Quichote is to stepwise adding components to an existing hydrogen refueling system; innovative, more efficient components, and integrating them with a renewable energy source, thereby realizing a renewable energy storage capacity based on hydrogen.

The hydrogen can then be used to refuel mobile applications or to feed a fuel cell connected to the grid. The project aims to:
• demonstrate and validate the system level technology readiness by improving the existing bottlenecks for high reliability and availability.
• generate further facts based data for the exploitation of renewable electricity to hydrogen fuelled sustainable mobility.

This proposal did not start from scratch, based on regional funding in 2011, a hydrogen refuelling station was put in operation near Brussels. Starting from this system as an existing test platform, the following innovations and demonstrations are being carried out within this project:
• extensive testing of the existing system, focused on dynamic behavior, efficiencies, actual degradation figures, availability, total cost of operation
• doubling the hydrogen capacity by adding a very efficient and dynamic PEM-electrolyser (storage 130 kg/day)
• developing, testing, demonstration and validation of direct coupling between wind turbine (1,5 MW) and solar panels (800 kW) and the electrolyser technology
• Expanding the existing compression capacity of the diaphragm compressor with an additional compressor. The main driver for this is the limited availability of the existing system in view of the expected expansion of H2-fueld fleet by 2017.
• An increase of hydrogen applications (e.g. additional forklifts, not part of this project) in this refueling station will generate additional field experience.

Regarding “innovation” the focus in this project is:
• direct coupling of intermittent renewable electricity sources to electrolysers
• more efficient, fast-reacting PEM- electrolyser
• higher system reliability by adding extra compression capacity
• development of a complete containerized fuel cell system for outdoor installation to optimize the fuel cell system efficiency and footprint

Regarding “implementation” the focus of this project is:
• analysis of the RCS towards the existing regulation, codes and standards, related to the whole system with specific attention to new technologies and definition of lifetime, availability
• analysis of the LCA/LCI of a complete system going from renewable electricity to hydrogen in different user-modes
• analysis of total cost of ownership of a complete system
• dissemination of the results to key players in local grid management and renewable energy deployment at national and EU level, involving relevant EU and national energy associations as well as local authorities

Project Results:
The work that has been performed up to the end of the current reporting period (M1-M48) of the Don Quichote concerns:
• development and implementation of a control system for the electrolyser to be responsive to a power set point. As such the electrolyser can help stabilizing the grid.
• identification of relevant regulations, codes and standards, preparation of permitting dossier and safety report for on-site installation
• Design, engineering, construction, testing and on-site installation of a 150kW PEM electrolyser
• Development, engineering and construction of a 120 kW PEM fuel cell rack integrated for electricity delivery to a grid
• optimalisation of a 1 Nm³/hr electrochemical compressor, testing and troubleshooting new stack hardware design; testing MEA with new materials, modified construction; System development 2-5 kg/day system
• testing of existing hydrogen refuelling infrastructure
• scoping documentation of life cycle assessment approach, data acquisition system installation, operational monitoring of the installation on site
o Preparations regarding installation phase III system. Since the electrochemical compressor could not be upscaled within the budget, an alternative compressor has been selected for installation in 2017. New amendment submitted and accepted by FCH JU
o Extensive discussions with partners regarding the report about upscaling scenario’s, contract negotiations on the post project life and use of the installation with performance and service guarantees for the end user are on-going.
o Operational and performance characteristics are continuously being monitored. During the first 48 months, approx. 3.795 re-fuellings took place and 2.790 kg of hydrogen has been dispensed to 12 different application types (mainly material handling equipment). In October, project month 49, 10 extra forklift trucks will be added to the total fleet of Colruyt Group.
o Various communication and dissemination activities

Potential Impact:
Don Quichote combines a 1,5 MW wind turbine and a 1050 kW solar-system with an effective coupling to hydrogen delivery structure for a large logistic center. At the start of the project 2 fork lifts on hydrogen were deployerd, in the mean time partner Colruyt, owner of the logistic center en owner of the wind turbine and the solar-system, is able to invest in additional equipment for transport on hydrogen (75 fork lifts by 2017, 200 fork lifts by 2018. The ‘test and demonstration platform’ Don Quichote is thus being upgraded to a large plant of renewable electricity towards sustainable transport on hydrogen.

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