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HELION
International Workshop on high temperature water electrolysis limiting factors
Specifications for Solid Oxide Electrolysis Stacks
to be coupled with Wind Turbines or
Nuclear Power
Karlsruhe/Germany, 9&10 June 2009
Thomas Nietsch / HelionJohn Boegild Hansen / Haldor Topsoe
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 239833 3HELION
Overview
1. Introduction Areva – Helion Haldor Topsoe
2. Introduction High temperature steam electrolysis
3. The wind case
4. The nuclear case
5. Summary
HELION
Introduction Areva – Helion Haldor Topsoe
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 239835 5HELION
An integrated offer serving energy professionals
5
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 239836 6HELION
Wind power
Offshore wind energy
Hydrogen power
Fuel cell & electrolyser based systems
Bioenergies
Biomass power plant design & integration
business
HELION – an AREVA R Subsidiary
HELIONMULTIBRID KOBLITZ
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 239837 7HELION
HELION Hydrogen Power – Key figures
Founded in 2001, HELION designs, manufactures and integrates PEM fuel cell and electrolysis solutions
A strong R&D backbone in electrochemistry and engineering
Headcount: more than 50 employees
75% engineers
Headquarter : Aix-en-Provence (France)
( Environment dedicated high-tech facilities complex )
A R&D oriented company specialized in hydrogen energy and fuel cellsmoving towards an industrial company, profitable on its early niche markets
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 239838 8HELION
HELION Hydrogen Power
HELION develops PEM Fuel Cell and Electrolyser for:Backup power applications
Niche transport applications
Air-independent applications
Hydrogen production
Energy storage
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 239839 9HELION
Briefly on Topsoe Fuel CellDevelopment, manufacturing, marketing and sales of SOFC technology
Founded in 2004
Subsidiary of Haldor Topsøe A/S (wholly owned)
SOFC research & development since 1989
Employees: 100+
Strategic research partnership with RisøDTU (National Laboratory for Sustainable Energy)
>50 empl. engaged in SOFC
HELION
Introduction High temperature steam electrolysis
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398311 11HELION
SOEC more efficient than present Electrolysers
0,0
0,5
1,0
1,5
2,0
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3,0
3,5
4,0
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5,0
0 100 200 300 400 500 600 700 800 900 1000Temperature T/°C
Ene
rgy
E/k
wh/
m3 H
2
theoretical stack total enery demand= heat demand + electrical energy demand: Δhr
theoretical stack electrical energy demand: Δgr
theoretical stack heat demand: TΔsr
liquid water
steam
p = 1 bar
theoretical and real energy imput to electrolyser
real PEM Esystem
"real" SOECsystem
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398312 12HELION
Results from Hi2H2 project, a pre assessor of RelHy
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398313 13HELION
RelHY Project – 2.9 M€ Support from EU 7th framework program
Participants
CEA, F
DTU Risø, DK
ECN, NL
Imperial College, UK
Topsoe Fuel Cell, DK
Eiffer (EDF), F
Helion (Arreva), F
Goals
1 A/cm2
Steam utilsation > 60 %
800 °C
System efficiency = 80 %
Degradation < 1 %/1000 h
Availability = 99 %
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398314 14HELION
RelHy Project Overview
RelHy25-cell stack prototype,operated at
800°C
Cells
SRUs
5-cell Stacks
Materials optimisationDurable electrodes/electrolyte, Sealing, Material compatibility and stability, Cost effective materials and processes
Design innovationsThermo mechanics, Tightness, Water management
State of the Art
• Good cells• No compromise
in stacks nor SRUsbetween durability and efficiency
Integration of optimised materials and innovative design in areliable and efficient
laboratory electrolyser prototype
Instru
mente
d
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398315 15HELION
Technical challenges: generic roadmap
»Cell efficiency + durability(electrolyte conductivity,
catalysts efficiency, stability vs corrosion)
From electrolysistechnology…
»Stack efficiency(fluids, heat, mass transfer management,
Mechanical assembly, Gas tight conception)
»Module architecture(stack association, process management )
Material knowledge
Thermomechanical, thermohydraulic, gasketing and assembly knowledge
Electrochemical and thermodynamical
processes knowledge
»Plant definition(module association, process management )
Plant process, regulation and safety knowledge
… to H2 production plant
HELION
The wind case
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398317 17HELION
Wind Power Production - West Denmark As percent of consumption and production
Averages 26 and 24 %
0%
20%
40%
60%
80%
100%
120%
140%
0 1000 2000 3000 4000 5000 6000 7000 8000 9000Hours of 2007
Win
d po
wer
%
% of Production% of Consumption
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398318 18HELION
Electricity spot price – West Denmark Diurnal Variations - 2007
0
20
40
60
80
100
120
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200
0 2 4 6 8 10 12 14 16 18 20 22 24Hours no 2007
€/M
Wh
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398319 19HELION
Average spot COE price as function of operating hours West Denmark 2007
0
5
10
15
20
25
30
35
0 1000 2000 3000 4000 5000 6000 7000 8000 9000Operating Hours
€/M
Wh
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398320 20HELION
Depreciation cost vs operating hours/yr 750 €/kW – 10 years depreciation
0
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30
40
50
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70
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90
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0 1000 2000 3000 4000 5000 6000 7000 8000 9000Hours no 2007
€/M
Wh
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398321 21HELION
Cost of Hydrogen Investment 750 €/kW + average spot COE price 35 €/MWh
0,00
0,05
0,10
0,15
0,20
0,25
0 1000 2000 3000 4000 5000 6000 7000 8000 9000Hours of operation per year
€/N
m3
H2
1.55 V1.9 V
2 US $/kg
70 €/kWh => 3.x US$/kg
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398322 22HELION
HTSE with wind power in Denmark
(Cheap CO2 free) electricity from wind
Heat from existing CHP plants / district heating
From biomass using oxygen for increasing the efficiency and easier CO2 sequestration
Complex system
Energy management is crucial
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398323 23HELION
Active Power Control valuable in Wind Scenario
Consumer's power demand
Electrolyser’s answer
Wind mils answer
Increases Decrease Load
Fast Response ?
Increase generation
Only possible in special cases with
prior reduction
Decreases Increase Load
Slow Response
Decrease Generation
Fast response
< 5 seconds
HELION
The nuclear case
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398325 25HELION
Current density
The figure gives an example for the number of cells vscurrent density with active area as parameter.
This figure illustrates nicely that a reasonable reduction of number of cells can be achieved for an active area around 600 cm² and around a current density of 2 A/cm². 0
200 000
400 000
600 000
800 000
1 000 000
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0current density j A/cm²
tota
l num
ber o
f cel
ls
S_A 100 cm²
200 cm²
400 cm²
600 cm²800 cm²1 000 cm²
200 t/day H23,8 kWh/m326 petrol stations
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398326 26HELION
Operating temperature
The steam temperature of a Evolutionary Pressurised Nuclear Reactor (EPR) is some what near 300 °C.
The sate of the art operating temperature for SOFCs is some what around 850 °C, therefore this temperature is considered as starting or reference temperature.
Operating temperature reduction in the future is proposed for:Better match the nuclear reactors outlet temperature so higher efficiency
Easier and more efficient heat transport
Using cheaper materials and
(Lower the degradation rate).
(The steam temperatures of a High Temperature Nuclear Reactor (HTR) or a Very High Temperature Reactor (VHTR) can be higher than 800 °C.)
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398327 27HELION
Degradation / life time
There is no definition for life time or for end of life neither for SOFC nor SOEC.
A commonly proposed criterion for end of life is a loss in performance of 20 %.
Assuming a life time of about 40 000 h for achieving cost targets in the SOFC case give a degradation rate of about 5 to 10 µV/h.
SOFC targets are chosen as a starting point
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398328 28HELION
Operating profile
Coupled with nuclear power.
Flat out production during a long period of time, possibly a year or longer.
Start up time can be one working shift.
A very few start ups, shut downs and redox cycles during life time are required.
Coupled with RES (wind).Stochastic energy production by RES but smoothened by thermal capacity of the stack.
Start up time about one hour.
Some more thermal / redoxcycles required.
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398329 29HELION
Cell voltage
Efficiency, energy consumption and cell voltage are closely related.
Modern PEM and alkaline electrolyser systems are aiming for efficiencies of about 75 % and 80 % respectively or about 1,6 V. (Ref: fuel cells and hydrogen joint undertaking (FCH JU), annual implementation plan 2008 )
A HTSE should aim for higher efficiency to compensate for possible higher capital cost.
Assuming an 85 % efficient HTSE gives a stack voltage around 1,47 V.
241 KJ/mol/2/(96500As/mol)/0,85 = 1,47 V
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398330 30HELION
Example: sketch of HTSE coupled with apressurized water reactor,
heat extraction at 280 °C from the boiler
Remark: the boiler could be fired by biomass
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398331 31HELION
Example: sketch of HTSE coupled with apressurized water reactor,
heat extraction at 180 °C from HP turbine outlet
Remark: the boiler could be fired by biomass
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398332 32HELION
Deployment for HTSE plant
EPRTM use in a cogeneration mode:
Production targeted: 500 t/dof H2
Electrical Input: 720 MW
Thermal Energy extracted: 140 MW at 240°C
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398333 33HELION
HELION
Summary
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398335 35HELION
Differences Nuclear/Wind Scenario RelHY milestone delivered in January
Nuclear Wind
Short Medium Short Medium
Degradation (µ/h) 10 5 15 5
Lifetime (h) 10000 20000 16000 40000
Thermal cycles/year 2 5 7 14
Voltage/cell (V) 1.5 1.45 1.7 1.55
Current (A/cm2) 1.5 2.0 1.0 1.5
Pressure max (bar) 50 50 20 30
Active Area (cm2) 400 800 300 600
Start up from 600 C < 4 h < 4h < 2 < 1h
Turn down to 20 % ? ? < 2 min. < 30 sec.
HELION
> Int Workshop on HTWE Specifications for SOE Stacks, Karlsruhe, June 09 T. Nietsch, J.B. Hansen Helion 2398337 37HELION
References
(1) JP Py and A. Capiyaine, Hydrogen production by high temperature electrolysis of water vapor and nuclear reactors, WHEC 2006, Lyon(2) Hering, INL, NEA, 3rd IEM, 5 Oct 05(3) Hotely 1982, US Department for Commerce, NTIS(4) M. Zahid, high efficient, high temperature hydrogen production by water electrolysis, Hi2H2, hydrogen and fuel cells review days 2007, Brussels, 10th & 11th October