Dipl.-Ing. TU Andreas Brinner · Dipl.-Ing. Andreas Brinner 09.07.10 Institute of Vehicle Concepts Room air supervision Assurance of gas quality Operation safety Signalisation devices

Development of Operating Buildings, PV-Electrolysis Facilities & Safety Technology

German-Saudi Arabian Joint Project HYSOLAR (HYdrogen from SOLAR Energy) 1986 – 1995

Visit of a Delegation of the King Faisal University of Dammam, Kingdom of Saudi Arabia, on July 9th, 2010

Dipl.-Ing. TU Andreas Brinner German Aerospace Center (DLR)Institute of Vehicle Concepts (DLR-FK)Pfaffenwaldring 38-40, D-70569 Stuttgart, GermanyTel: ++ 49 (0)711 6862 574 / Fax: ++ 49 (0)711 6862 1574E-mail: [email protected] / Internet: www.dlr.de/fk

Dipl.-Ing. Andreas Brinner 09.07.10Institute of Vehicle Concepts

Contents of the Presentation

Short introduction to the HYSOLAR projectTest- and production demonstration facilitiesConceptual system and electrolysis block variantsExperimental and regular operationImportant resultsImprovement potentials


Project Hysolar: Mission & Partners

1986 - 1995


Project Financing & Working Packages


Functional Principle of an Alkaline Electrolysis Cell


Development and use of a test and data evaluation standardLong-term examination of coupling behaviour of a PV-electrolysis system

Coupling of energy converters

Experimental system setup in the HYSOLAR projectExamination and evaluation of different coupling principles between photovoltaics and electrolysis

Functional Principle

Technical Principle


PV-Electrolysis-Plants of the Project

350/500kW Solar-hydrogen

production demonstration plant

10kW Solar hydrogen

research and development facility

3kW Solar hydrogen

test facility

Demonstration operation

1993 - 2000

Experimental operation

1987 - 2004

Test operation

1989 - 1995

RIYADHJEDDAH

STUTTGART


Electrolysis Facilities of the ProjectP = 2 – 350/ 500kW, p = 1 -10barabs, T = 40 – 95°C(1) Research/ Test systems

Original Deliverer

HYDROTECHNIK

3 / 2kW

Original Deliverer

HYDROGEN SYSTEMS /

METKON ALYZER 10kW

Original Deliverer

FZ JÜLICH

10kW

HT/DLR

HTHT/DLR

HS

HS/DLR

MA

MA/DLR

FZJ

FZJ/DLR

FZJ/DLR


10 kWN Photovoltaic-Electrolysis Facilityin the HYSOLAR Building

HydrogenStorage System

ElectrolysisEquipment

OperationControl

Data Acquisitionand Evaluation

PV-field14,3 kWp / 10 kWN


10 kWN Photovoltaic-Electrolysis Facilityin the HYSOLAR Building, Main Requirements for Concept

ElectromagneticCompatibility

High CurrentHigh Power

H2 & O2Caustic Solution

PressureEx-Condition

H2-GasHigh PressureHot SurfaceEx-Condition


Electrolysis Plant of the ProjectP = 2 – 350/ 500kW, p = 1 -10barabs, T = 40 – 95°C(2) Produktion demonstration

350/500 kW pressure electrolysis plantapproved by TUEV,

in operating condition

5000cm2- block V.1

Not accepted

5000cm2- Block V.2

Not accepted

2500cm2- Block V.3

Accepted and approved


350 kWp PV-Field of KACST in Riyadh for H2-Production


ElektrolysisInstallation

HydrogenPurification & Compression

PV-Field Control &Power Adaptation

WaterTank

Hydrogen &Oxygen Outlets

HydrogenStorage System

Control Room &Cooling Systems

Facility Building of the 350 kWp Photovoltaic Elektrolysis Plant


HYDROGEN & OXYGEN

NITROGENSUPPLY

HARD-WIREDSAFETY SYSTEM

(HWSS)

BLOWER

H2 & O2 GAS

OPERATIONCOMPUTER (PLC)

ROOM AIRSUPERVISION

SYSTEM (RASS)

ANALYSIS SYSTEM(GAS)

LOOP

N2HYS350-P&I-06

HYS350-P&I-09 O2 H2

CWB: COOLING WATER CIRC. BLOW.CWC: COOLING WATER CIRC. CHILL.

PRESSURISEDAIR

DC PWR: DC ELECTRIC POWER

HYS350-P&I-07

O2: OXYGENN2: NITROGEN

H2: HYDROGEN

PA

WATERTREATMENT

HYS350-P&I-08CWC

CWC

HYS350-P&I-02

TRANSFORMER/RECTIFIER DC PWR

HYS350-P&I-02

SUPPLYSOLAR POWER DC PWR

ELECTROLYTELOOP

PAH2HYS350-P&I-03

CWB

O2

HYDROGENCOMPRESSOR

HYS350-P&I-10

CHILLER/COOLER

LOOP

CWC

HYS350-P&I-05

H2

HYS350-P&I-05

H2 BOTTLERACK 2

H2 STORAGE

H2

HYS350-P&I-04

CWC

GAS TREATMENT

PA

H2

O2N2

H2

H2

VESSELHYS350-P&I-05

H2 BOTTLERACK 1

HYS350-P&I-05

N2

Block Diagram of the 350 kW PV-Electrolysis Plant


System Installation of the 350 kWp PV-Electrolysis Facility

C&

D P

an

el

HS

CPIDR

SA

CS

BP

DA

PD

Invert.

RA

SS

UP

S3

N

GA

S

AC

HP

DH

PD

DC

AC

PD

HW

SS A

CC

P

ELECTRICALROOM

1UPS

BATTERYROOM

Au

x.

AC

PD

2

Ele

ctro

lysi

s

UndergroundElectrolyte Tank

CoolersBlowers

Blo

ck

UTILITIESROOM

US

PROCESSROOM

PS

HB

2

Com

pres

sor

H2

Ves

sel

GASHANDLING

ROOM

NB

S

HB

1

CONTROLROOM


Alkaline 0,5 MWN Pressure Electrolyser

N2-PurgeSystem

ElektrolysisBlock

H2-Water-Separation

WaterSeparator

WaterCircuit

KOHCircuit


Dynamically Operated H2-Purification and Storage System


H2-Purification and Storage System of the 350 kW Facility

HydrogenCompressor65 Nm3 from

9 to 151 barabs

IntermediateStorage

40 Nm3 Contentat 9 barabs

PurificationSystem

from Quality99.9 to 99.999


Hydrogen / Nitrogen Storage of the 350 kW Facility

HydrogenBundle 2

Nitrogen InertisationSystem

HydrogenBundle 1


Room airsupervision

Assuranceof gas quality

Operationsafety

Signalisationdevices

Emergencyshut down

Dynamic electrolysis operation is safe with actualtechological state of the art and can be approved regularely

HYS 10 & HYS 350Operating permission for production

and delivery of solar hydrogen

Safety technology can be standardisedfor all kinds and power levels of electrolysis plant


Improvement potentials

► EFFICIENCY Improved materials für membranes and cell frames

► COSTS Simplification of system peripherals

► OPERATING RANGE Increase of product gas quality in dynamic operation

► OPERATING RANGE Improvement of tolerance to user lower water qualities

► AUTONOMITY Grid autonomy of the entire system

► OPERATING COSTS Automation of dynamic operation

► AVAILABILITY Industrialisation of development results

What is left to be done? A LOT!!!

Thank you very much for your attention !

Documents

Dipl.-Ing. TU Andreas Brinner · Dipl.-Ing. Andreas Brinner 09.07.10 Institute of Vehicle Concepts Room air supervision Assurance of gas quality Operation safety Signalisation devices