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CLEARGEN DEMO Report Summary

Project ID: 303458
Funded under: FP7-JTI
Country: Denmark

Periodic Report Summary 5 - CLEARGEN DEMO (The Integration and demonstration of Large Stationary Fuel Cell Systems for Distributed Generation)

Project Context and Objectives:
The CLEARgen Demo project addresses the topic “SP1-JTI-FCH.2011.3.6 aiming on Field demonstration of large stationary fuel cell systems for distributed generation and other relevant commercial or industrial applications”. Certain industries, such as chemical production or petroleum refining have been identified as producing large quantities of by-product hydrogen that can be used to produce clean, load-following power on a distributed basis, reducing reliance on fossil fuels. While the chemical production industry generally acknowledges the potential value of stationary fuel cell applications, the lack of multiple megawatt-scale European reference sites is a significant barrier to widespread adoption.
The CLEARgen Demo proposal aims to address this need.
The main objectives of the CLEARgen Demo Project are:
1)The development and construction of a large scale fuel cell system for conversion of by-product hydrogen, purpose-built for the European market,
2)The validation of the technical and economic readiness of the fuel cell system power generation at the megawatt scale,
3)The field demonstration and deployment of fuel cell megawatt scale power system at a European chemical production plant.

Project Results:
The project CLEARgen Demo has finalized its study phase. All specifications are determined and we have now a complete overview of the system, including the purification system for hydrogen and the fuel cell system. The ClearGen system is composed of 2 power banks of 500 kW net power. A cooling system of 4 air coolers is connected to each unit. Even if for automation, one unit operates as a master and one as a slave, each of the two power banks include all equipment to manage gas, electricity and safety.
The power banks are divided in 2 compartments:
•A process room including stacks, hydrogen, air and water management (drawings below).
•An electrical room including automation, inverters, transformer for utilities and all electrical components
The Factory acceptance test (FAT) was performed two times, one for each power bank. The first one on the 13th and the 14th of September 2017, the second one on the 22th and 23th of November 2017.
The main tests performed were:
•Start-up time measurement
•Minimum power operation: 2h at 300kW
•Maximum power operation: 8h at 500kW

The start-up time is 3.5 minutes but a part of this time is use to check security and safety of the unit. The efficiency over 4 hours of measurements is 46.8 % for bank 1 and 46.4 % for bank 2 at full power. We can notice a better efficiency at minimum power of 200 kW : no protocoled measurement but above 50 %.
All studies are completed except for pipelines inside the refinery facilities. The paths of pipelines are defined but the points to support pipelines are not yet determined. A specific study is ongoing and must take into consideration the current pipelines already attached in the calculation note for each point. This work will be achieved in early April 2018.
The studies realised concern :
• Implementation study
• Process
• Safety study
• Civil work
• Steel structure
• Pipeline
• Instrumentation
A construction review was realized from the 16th to the 18th of January 2018 with HDF, SARA/Aquipac and Technip. The aim of such review is to clarify each step of the construction, to identify interactions with current facilities and other projects and to prepare the management of the construction site.
Potential Impact:
It is expected that the ClearGen Demo field demonstration will show that the large stationary PEM fuel cell systems for distributed power generation are environmentally friendly and commercially relevant for Chemical process industrial applications, where alternatively excess of hydrogen today is vented. Certain Chemical production and petroleum refineries are today producing large quantities of by-product hydrogen that can be used to produce clean, load-following electrical power on a distributed basis, reducing reliance on fossil fuels. The aim of the project ClearGen Demo remains the implementation of a large fuel cell in respect to EU specifications in the site of SARA Martinique and the deminstration of the viability of such technology, the decrease of operation costs and the increase of stacks lifetime.
Demonstrating the ClearGen Demo shows that the technology now is ready for a broader deployment in the connection with the relevant industries and the setup will serve as a showcase for other relevant industries and will break the ground for further installations in Europe.
The conversion of vented hydrogen into useful electrical power and heat will lower the environmental load on the planet. The demonstration site was chosen for the ability to provide a strong reference and show showcase in order to convince other European industries with hydrogen as a by-product that large fuel cell power systems will be a greener solution to get value from vented hydrogen.
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