Embed Size (px)
Citation preview
Dr. SSV Ramakumar
Director (R&D), IndianOil Corporation Ltd.
Agenda
Challenges for Hydrogen Economy
Applications – HCNG / Fuel Cells
Hydrogen Production / Supply chain Options
INDCs Commitments and Role of Hydrogen
Global Energy Scenario
Summary
Global Energy Paradigm:
India take Lead
Change in energy demand, 2016-40 (Mtoe)
India
1005420
Asia
China
790
UnitedStates
-30Japan
-50
Southeast
Europe
-200
270Central and
SouthAmerica
485
Africa
135 Eurasia
480Middle
East
Old ways of understanding the world of energy are losing value as countries change roles
Middle East is fast becoming a major energy consumer & US a major exporter
Source : World Energy Outlook, 2017
INDC of India
❖Mobilize Investment to thetune of $2.5 trillion
❖Technology Transfer
❖Capability Building
To reduce Carbon Emission Intensity per GDP unit by 33-
35% from 2005 level over next 15 years
40% power from non fossil fuel by 2030
Additional carbon sink of 2.5 to 3 billion tonnes of carbon dioxide through additional
forest and tree cover by 2030
Imperative Journey Towards
Carbonless fuels
1700 1850 1950 2020
>
0.1
1
2
4
COAL
WOOD
OIL
NAT. GAS
H2
H/C
rat
io l
og.
sca
le
Year
2000
Hydrogen is the answer for meeting stringent environmental norms and mitigating climatic change without impacting the growth pace
Expected role of
hydrogen? •Medium for energy sector de-
carbonisation
• Electrification of Mobility sector -
Fuel cells
•Electrification of heat –
Decentralized power generation
•Optimizing energy systems –
energy carrier & storage medium
Hydrogen in Mobility Sector
Hydrogen In Mobility Sector
Hydrogen Blended CNG
(Interim technology, low quantum of benefits)
Hydrogen IC Engine
(Small Quenching Gap, Backfiring, Embrittlement)
RON= 130 / MON=30
Very low sensitivity
Fuel Cells
(best technology for using hydrogen,
Issues pertaining to cost, durability, fuel quality etc. )
Technology Desired Delivered Cost of Hydrogen
Hydrogen IC Engine
$1.5-2 /Kg Great Challenge
Fuel Cell $4-5 /kg Challengingbut can be met
Hydrogen Production
Water
Petroleum
Natural Gas
Coal
Bio-Mass
Hydrogen
Solar Power
Wind Power
Others
Electrolysis
Hydrogen Production Pathways
•Hydrogen can be produced from variety of sources•SMR and Coal gasification - preferred technologies for hydrogen production upto 2050•Refineries are the potential production centres for hydrogen supply for different applications
Hydrogen from Biomass
Biomass
•Multifeed stocks available in India
Pyrolysis or Gasification
•Process for converting biomass to hydrogen
Hydrogen Purification
•To be inline with Fuel quality requirements
Fuel Cells / Engines
• For captive utilization & distributed generation
Indian case:
• Annual Biomass production : 500 million tonnes
• Surplus biomass availability : 120-150 million
tonnes/year
• Viable option for Centralized hydrogen generation
• Optimal Model for rural India and captive power
production with scalable technology with lower
carbon footprints
Source: Study by IOC R&D & UC-Davis
H2 cost = $2-$2.5/kg
▪ Tri-reforming of NG
✓Reforming of NG in presence of Steam & CO2
✓Operating temperature 650-8000C
✓25 % CO2 in feed, Steam/ Carbon ratio ~ 0.5-2.5
✓35-40 % CO2 conversion
Decentralized Hydrogen Production
Reformer pilot plant
▪ Aqueous phase reforming
✓ No need to vaporize water
✓ Feedstock: Methanol / bio oil
✓ Low severity operation (Temp: 210-3000C Vs. 800-8250Cfor SMR)
✓ Hydrotalcite based catalysts developed with ICT, Mumbai
✓ Scale up studies done
✓ 75-80 % per pass carbon conversion and > 80 % H2
Selectivity
✓ Design of compact 5 Nm3/h reformer under progress
Compact methanol reformer
Temperature210-3000C
Pressure 20-50 bar
G-Lseparator
H2 rich gas
Water for recycle
Methanol
+
Water
Hydrogen Production through
Solar Energy
24x7 Solar
Thermal
Energy Storage
Power
Generation
(reverse mode
SOFC)
Hydrogen
Production
HeliostatsReceiver
Sloping Ground
Concentrated
Sunlight
Secondary
Reflector
Co-Electrolysis
CO2
Purification
H2
H2O
Exhaust from Refinery / Boiler
CO2-Separation
, CO
SOEC
PEC Water Splitting for Hydrogen Production
Major Goals
➢ Geometrical scale up of system and components thereof.
➢ Integration of PEC water splitting cells with other technologies such as Photovoltaics.
➢ Integration of tracker and concentrator in large scale PEC water splitting reactor.
Research Dimensions being Explored
• Development of Efficient & Reliable Photoactive materials
• Development of Scalable Synthesis Techniques
Basic Material Research
• Large electrodes Fabrication
• Innovative design strategies for current collection
Technology Scale up
• Use of Tracker & Concentrator
• Integration with Photovoltaics
Reactor Design &
Fabrication
✓Scale up of working electrodes done by a factor of 100x with respect to lab sample size of 1cm2
Technology Scale up
Hematite 100cm2 working electrode with multiple current collectors
Integration with Photovoltaics
✓ Verification of concept has been done under laboratory conditions.
✓ 100cm2 reactor design has been finalized for demonstration.
Photoelectrochemical Water Splitting
Hydrogen Demand & Supply –
Indian Context
Challenges:
•Market uncertainty
•Chicken & Egg situation
•Initial investments
•Statutory approvals for extending supply & transportation at high pressures
•SMR and Coal gasification are going to be the economical technologies for hydrogenproduction upto 2050•Refineries are the potential production centres for hydrogen supply for differentapplications
Source: KPMG
0
20
40
60
80
100
120
140
160
180
Ref 1 Ref 2 Ref 3 Ref 4 Ref 5 Ref 6 Ref 7 Ref 8
H2
Ca
pa
cit
ies
To
nn
es
pe
r a
nn
um
Th
ou
san
ds
Hydrogen Production in Refineries
Hydrogen Storage
Hydrogen Storage
Storage of 9.5 kg of H2 requires a 55 kg tank while 25 kg of petrol can be stored in17 kg tank.
H2 fuel typically takes 4 times space than petrol for same energy content.
Key R&D Areas
▪ Development of high pressure storage system
- Composite materials – Huge market potential in India
- Manufacturing & Testing infrastructure to be created for high pressure storage system
▪ Development of metal hydride storage systems
- To increase the hydrogen density requiring materials research
- To improve hydrogen absorption and release characteristics
- Durability of metal hydride systems
▪ Nano-technology based hydrogen storage interventions
Physical Storage
Material based Storage
Hydrogen Storage Options
In TANKS..…. In MATERIALS…..….
Benefits of MOFs→Lower mass density (e.g. 0.17 g/cm3)→High thermal stability (upto 600°C)→Specific surface area greater than zeolites
Mode of
Storage
Mass Pressure Temp.
Compositecylinder
13 mass % 700 bar 298 K
LiquidHydrogen
100 mass % 1 bar 21 K
Metal hydrides
2 mass % 1 bar 298 K
Physisorptionin MOF
4 mass % 70 bar 65 K
Hydrogen Storage Research at IOCL
▪Research on Synthesizing novel MOF – High surface area of thesynthesized MOF achieved
✓ IOCL synthesized MOF: ZIT: Zinc-Imidazole-BTC- Hydrogenstorage capability 12 wt% and surface area 1248 m2/g
✓ Challenge to achieve the desired storage capacity at Roomtemperature
▪Research under progress for synthesizing High Hydrogen holding
MOFs and its scale-up
▪Design of storage vessel with MOF for vehicle
▪Demonstration in vehicle
Material based Hydrogen storage
Physical Hydrogen storage
▪ High Pressure Hydrogen Cylinder Type-3Development for on board application
Source: IOC R&D Studies
Hydrogen Transportation & Dispensing
Hydrogen Transportation – Indian
Perspective
▪ Mostly hydrogen is produced in
decentralized locations and
transported to place of use
▪ Pipeline infrastructure not present
▪ Current transportation pressure
restricted to 200 bar
▪ No. of pressure bottles (50 lts. WC)
limited to 24 per site without
regulatory approvals
▪ Onsite re-filling under approval
▪ High pressure cylinders and tube
trailers under regulatory approvals
▪ Issues being taken up with
regulatory bodies to increase
hydrogen pressure upto 700 bar
Dispensing Infrastructure in India
IndianOil set up India’s first Hydrogen & HCNG Dispensing Station at its R&D Centre, Faridabad in Oct, 20054 hydrogen dispensing stations being used for demonstration trials under various capacities
Hydrogen Production and Storage
Infrastructure : IndianOil
Electrolyser Type: PEM Electrolyser,
❑ H2 Generation Capacity = 30 Nm3/hr
❑ H2 Delivery Pressure = 10 barH2 Purity = 99.999%
Compressor
Type: Diaphragm type / 2 stage
❑ Suction Pressure = 5-30 bar
❑ Max. operating pressure= 550 bar
❑ Flow rate = 30 Nm3/hr
High Pressure Storage Tubes• Capacity = 2400 Liters (4 tubes each tube
with 600 liters) water capacity• Max allowable working Pressure = 550 bar
1st high pressure storage infrastructure in the Country
IOC R&D is in process of setting up 90 Nm3/he with partial funding from CHT
Hydrogen Applications
Pilot trials to convert and run 50buses on 18%HCNG producedthrough IOC’s compact reformertechnology
HCNG for Demo in Delhi: APEX Court
HCNG Production Process
Pure Hydrogen
Natural Gas
Compression
Compression
Mixer HCNG
Reforming /Electrolysis
Conventional Process
ZnO
Bed
ReformerPiped
NG
Heat exchange
250 bar Compressor HCNG
IOC’s Compact Reforming Process
Salient Features
Cost can be reduced by innovative hydrogen / HCNG production technologiesConventional process needs high pressure hydrogen blendingMultiple steps involved in the process adds to costSingle step compact reforming of natural gas holds meritPrice differential w.r.t. CNG can be Rs.3-4/kg with significant emission reduction
Indian Patent Granted (03/18)– 294969
HCNG for Heavy Duty Applications
-20
0
20
40
60
80
100
CO Nox CH4 NMHC
% R
ed
uct
ion
% Reduction in Emissions with 18% HCNG*
*Based on tests conducted at ARAI,Pune on Heavy duty bus engine
241 233 236 245
277
222 224 232
0
50
100
150
200
250
300
1000 1500 2000 2500
BSF
C (
g/kW
-hr)
Engine RPM
BSFC vs Engine RPM*CNG 18% HCNG
Source: IOC R&D-ARAI Studies
• 18% HCNG can meet CO & HC emissionlimits set for BS VI
• Nox emissions can be reduced bysuitable calibration / exhaust aftertreatment interventions
• 4% - 5% benefits in fuel consumptionachieved at full load.
Fuel Cell bus – 1st Fuel Cell Vehicle in
India• Inaugurated on 10th March 2018
• 120 KW PEM Module
• On board High Pressure Type 3 composite
cylinders 40 Kg H2 @350 bar
• Fuel Cell bus range per fill ~300 Km
• Hydrogen refueling from IndianOil’s
dispensing stations
• Long duration Trials under progress
Fuel Cell Bus
38.6
26.528.1
26.8 26.828.1
26.4 26.1
20
22
24
26
28
30
32
34
36
38
40
Diesel Bus Trolley bus with
batteries
Battery Buses
Battery Buses-fast Charging
Battery Buses-Pulse
Charging
Diesel Hybrid Bus
CNG Hybrid Bus
Fuel Cell Bus
CO2 Emissions pre km per passenger (g/km/pass.)
CO2 Emissions per km
(WTW)
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
Diesel Bus Trolley bus with
batteries
Battery Buses
Battery Buses-fast Charging
Battery Buses-Pulse
Charging
Diesel Hybrid Bus
CNG Hybrid Bus
Fuel Cell Bus
Total Lifecycle Costs for Electric Bus-Based Mobility System (₹Cr./15 years)
Energy Costs over
lifecycle
Fuel Costs over lifecycle
Replacement Costs over
Lifecycle
Maintenance Costs over
Lifecycle
Project Capital Costs
Source: Tata Motors
350
320
140
180
240
0
50
100
150
200
250
300
350
400
Diesel Engine CNG Engine SOFC (NG) SOFC (LPG) PEM (NG)
Fuel Cons (gms/ KW-hr)
1100
864
380
541
648
0
200
400
600
800
1000
1200
DieselEngine
CNGEngine
SOFC (NG) SOFC(LPG)
PEM (NG)
CO2 Emissions (gms/KW-hr)
•65% CO2 reduction with SOFC (Natural gas)•50% CO2 reduction with LPG SOFC•25% CO2 reduction with PEM (H2 from Natural gas reforming)
• With India setting 10% import reduction target, can this be the USP for fuel cell companies• Economies of scale and available infrastructure favour low cost hydrogen generation withconventional fuels• Lower solar energy generation cost, better economics for renewable hydrogen
Potential CO2 / Energy Consumption
Reduction
Source: IOC R&D studies based on Indian data
Hydrogen Economy - Challenges
• Marketing challenges• Market penetration restricted by the cost of fuel cell
• Performance of the integrated system under Indian conditions
• Government plans on supporting the Green initiatives
• Technological challenges• Hydrogen storage technology, Fuel Cell system, Hydrogen and battery energy storage
improvements and advanced control systems
• Fuel Producer• Major investment required in Hydrogen production
• Infrastructure expansion: purification, compression and bottling
• Safety management• Co-existence of hydrogen & CNG/Diesel/Petrol dispensing stations
• Fuel safety (new standards for H2)
• New local safety and zoning requirements for fueling locations
• Regulatory and statutory approvals• To transport hydrogen at pressures > 200 bar
• To permit more storage capacity per site
• Mobile refueller or hydrogen pipeline
SUMMARY
Global energy appetite is on the rise
Hydrogen holds promise as an energy carrier
Apart from various emerging hydrogen pathways, SMR offers immediate solution
Hydrogen storage is an issue to reckon with
Statutory and regulatory interventions needed for hydrogen transportation at high pressures
HCNG based on IOC’s Compact Reforming technology is an interim measure to control the AQI
Indigenization of the Fuel cell technology is the need of the hour
Seamless integration of supply chain model in collaboration with energy companies may be explored in the coming future
Hydrogen Landscape
Hydrogen Production in Fertilizer &
Chlor-Alkali Plants
• Total hydrogen produced in Fertilizer plants is 2.38 MMTPA (2015-16)• No excess hydrogen available due to captive consumption
Fertilizer Plant
• Total hydrogen produced in Chlor-alkali plants is 0.0159 MMTPA• Hydrogen Purity available – 97-98%• Major Impurity = Cl2
• Rate of hydrogen (Source: MVS) from the chlor alkali plants:
• 2010-11: Rs 10/Nm3 (USD 2/kg)• 2012-13: Rs 20/Nm3 ( USD 4/kg)• 2014-15 : Rs 25-28/Nm3 (USD 5/kg)
• The price of Hydrogen used in industry for some metal processing applications is approx USD 0.8 per Nm3. (Source: http://www.rsrinnovations.com/ap/hydrogen.htm)
• The future Chlor Alkali plants coming in coastal belt of India, which would increase the cost of hydrogen many-folds depending upon the distance.
Chlor-alkali Plant
Current Capacities would not be able to support future hydrogen requirement
Source: IIT-Delhi
Techno-economic of Bio-hydrogen
through Gasification
•Scientists from IOC R&D and UC Davis established the techno-economics for
production of hydrogen from the non-fodder based feed-stocks in Haryana through
Gasification and its dispensing as 18% HCNG in Delhi
•On-site compression and storage facilities near the Gasification plant
•Feasibility of transportation and delivery of hydrogen in cascades at different pressures
considered for calculating the final end-mile delivery cost
Total Cost of Bio-hydrogen - India
• Production of hydrogen through Gasification of excess biomass is techno-economically viable process. Cost of hydrogen through gasification is ~USD 2-2.5/KG
• The cost of compression and distribution is ~1/3rd of the total hydrogen cost
Source: Hydrogen transportation in Delhi? Investigating the hydrogen-compressed natural gas (H-CNG) option, Paper no: 37(2012), International Journal of Hydrogen Energy
Comparison with DG set
Hydrogen supply from Refineries may be a preferred choice
8.1
9.4
7.5
11.7
7.0
Technology vs Cost (Rs./MJ)
Diesel Methanol Refinery Hydrogen fuel cell Electrolyzer (Solar) Biomass
• PEM Fuel Cell has better performance characteristics
•Low starting time•Better transient response
Tale of renewable hydrogen may not attract initially in few geographies to begin with.• In India even Electricity for Electric mobility may come from coal or NG (not renewable)•Refinery hydrogen for Centralized production and LPG/NG based hydrogen for decentralized / localized production options for India•Integrated packaged solutions (with fuel) is the need of an hour
Paradigm Shift
India - 1980
India - 2018
IndianOil’s Approach towards Clean Energy
Hydrogen as a Fuel
Fuel Cells
Hydrogen IC Engine
Retrofiited options
Hydrogen blended CNG
On-board hydrogen Dual fuel options (diesel/H2
blends)
Neat Hydrogen IC Engine
Fuel Cell Vehicles REEV or DFCEV
Hydrogen Production Technologies
Hydrogen Storage Hydrogen Supply
Future Green Mobility Options
ElectricityCoal / Natural Gas / Solar etc…. Refinery Independent
Fuel Cells
Natural Gas / LPG / Bio-CNG / Diesel / Naphtha / Biodiesel / Ethanol - Strong
co-relation with Bottom line & Refinery Product
Challenges for Energy & Transport Sector:
• Stringent environmental and fuel quality norms needs huge investments
• How to cushion ourselves against the crude oil price fluctuations ?
•What shall be the targets for capacity building in alternative energy technologies ?
•From plethora of available technologies, on which technologies we need to bet and when ?
•Benchmarking of cost of energy is difficult - depends upon volumes
Hydrogen Production Pathways:
Recent Research Trends
Hydrogen Source
Current H2-Prod Process New H2-Prod Process Options
Research Focus
Natural Gas Steam Reforming & Water Gas Shift
Advanced reforming & Membrane Processes
Catalysis & Materials Microchannel reformers
Petroleum Napththa reforming On-board/On-site Reforming & Adsorption Desulfurization
Reactor Configuration Processing Scheme
Coal Gasification, Cleanup & water Gas Shift
Advanced integrated Process & O2/H2 Membranes
Product Separation Membrane Separation
Biomass Gasification/Reforming & Water Gas Shift
Catalytic Production/Separation Biological H2 Production
System Optimization Integrated Systems
Water Electrolysis Using Electrical Energy
Thermochem Cycle & Membrane Photo-catalytic/Photo-electrochemical
Innovative Concepts / use of solar, wind or any other form of renewable energy
Collaborative work with Mahindra & Mahindra Ltd. On
development and demonstration of hydrogen fuelled internal
combustion engines for vehicles.
• Hydrogen Minibuses - 66 kW, 4 cylinder turbo charged H2
Engine.
• Type III cylinders - 74 Liters, 6 cylinders, total storage
capacity is 444 Lit.
• Nox optimized
• Higher efficiencies derived as compared to diesel.
• Dispensing / refueling hydrogen buses @ 350 bar.
• Successfully completed 30k km of field trial on neat H2 with
oil sampling & analysis undertaken at 0 km, 5k km, 10k km,
15k km, 20k km and 25k km - Engine oil results are favorable
upto 15k km.
Hydrogen fuelled Internal Combustion Engines
H2 ICE Buses
• Collaborative project undertaken with consortium of Automotive OEMs• HCNG blends evaluated on 7 light duty vehicles• 18% HCNG shortlisted based on Power and Emission characteristics• Long duration trials conducted on HCNG optimized vehicles• HCNG reduces CO emissions by 26%, HC by 20% and Fuel Economy increases by 3%-
4% as compared to CNG
Hydrogen blended CNG (HCNG)
Initiatives in Fuel Cells
PEM Fuel Cell Development for Refinery Hydrogen Evaluation & Demonstrations
Material Development & Optimization
Flow Field Design & Stack Sizing
System design & Integration of BoPs
Control design
Catalyst Development
Flow Field design
Modeling & Simulation and Operational Optimizations
Advance Control design & Optimization
Fuel Cells for Range Extension
Fuel cell forklift (Joint development)
In house stack development for stationary applications
Fuel Cell e-Rickshaw
• Country’s biggest fuel cell research
infrastructure
• Capabilities of development &
evaluation of PEM FC upto 10 kW
• Suitable for LT/HT PEM and Methanol
FC with contaminant doping facilities
Hydrogen Production Cost
▪ DoE Mandate: ▪ Develop technologies to produce hydrogen from clean domestic resources at a delivered and
dispensed cost of $2-$4 /gge H2 by 2020
▪ Indian Scenario▪ H2 production cost (SMR big size)* : Rs 200-250 /kg ($4-$5/kg)
▪ Electrolysis* : Rs 350-450 /kg ($7-$9/kg)
▪ Chlor-Alkali Industry : Rs 200-250/kg ($4-$5/kg)*Only production cost
Production Purification CompressionBottling &
TransportationDelivery at site
H2 End-mile Cost in India ($/kg)
99.9% $ 11-12
99.99% $ 17-18
99.999% $ 21-22
1 gallon of gasoline in India: $4.37
Note: 1 kg H2 = 1 gge
Other National Initiatives
•A National Steering Committee under Dr. K.Kasturirangan constituted to advise Govt. of
India on Hydrogen Energy & Fuel Cells in the country
•Five Sub-Committees formed by National Steering Committee to look into different
aspects of hydrogen energy and fuel cell development in India
•The Committees made recommendations to provide measures for:
✓hydrogen production, storage, transportation, applications and IPR for promotion ofhydrogen as clean fuel
• Major recommendations of the Committee
• 8 Mission Mode projects identified
• 50 vehicles on fuel cells proposed for development and demonstration
• Hydrogen Highway - 10 hydrogen dispensing stations
• Indigenous development of Hydrogen storage / PEM fuel cells / Renewable hydrogen
production
• Neat hydrogen based IC engines for transport applications
• Dual fuel (Diesel / H2) based retro-fitment solutions.
Total Fund allocation for Mission Mode projects: USD 45 million
DELHY-3W (DELHI HYDROGEN –3 WHEELERS)
Partners •UNIDO✓International Centre for Hydrogen Energy Technologies
(ICHET) of the United Nations Industrial DevelopmentOrganization (UNIDO) promoted the project
•Indian Institute of Technology Delhi •Mahindra & Mahindra (M&M)•Air Products •Indian Trade Promotion Organisation
Hydrogen fuelled IC Engine for
3-wheelers in India
Hydrogen powered 3-wheeler of M&M
•Indian Railways has set a target of 5% reduction in fossil fuels by 2020
•To install Auxiliary Power Units (APUs) on its diesel Locomotives
•In process of developing 300 kW (with transient power well in excess of 1 MW) fuel cell based hybrid locomotive
•Maximum speed of 130 km/h
•Two stacks with each stack module rated at 150 kWgross power at 624 VDC
•combined storage of 70 kg compressed hydrogen at350 bar (5100 psi).
•System to provide fuel for a rigorous 8-10 hourshunting duty cycle
Initiatives by Indian Railways
Source: RDSO
