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Nature Of Hydrogen Demand for Fuel Cells And NMRLs Experience on Onsite Hydrogen Generation

S Roy Choudhury, J. Rangarajan Naval Materials Research Laboratory, Ambernath-421506

Hydrogen Provision
Distributed hydrogen retail outlets for mobile / stationary applications
Compressed H2 transport by pipelines like CNG network Onsite H2 generation from other feed stocks
Coal Hydrocarbons Alcohols Ammonia

Hydrogen Provision
Online/onboard hydrogen generation for mobile systems
Reforming /cracking of hydrocarbon feed stocks Reforming/cracking of alcohols Other inorganic/organic feed stocks
Ammonia cracking Hydride hydrolysis/cracking

H2 quality
Impurity tolerance increases with increase in operating temperature of fuel cells

Low temperature acid FCs


Phosphoric acid fuel cell Operates at 1302000C CO tolerance < 2% S and Cl in ppm level Polymer electrolyte fuel cells Operates at 60-800C CO tolerance in ppm level S & Cl in ppm level

Limits the primary source of fuel

Low temperature alkaline FCs


Operates around 120-1700C High CO tolerance CO2 tolerance in ppm level Cl and S in ppm level

Difficult for terrestrial application

High temperature FCs


Solid Oxide FCs Can take CO as fuel S & Cl in ppm level Molten Carbonate FCs Can take high CO S & Cl in ppm level

The Key issues


The Fuel Quality

Fuel cells are advanced power generation devices requires quality feedstock, free from sulfur The oil refineries have to provide uniform low sulfur fuels.

The Key issues


The conversion Devices

High cost for CO removal PEMFC


Low reformer cost PAFC, SOFC, MCFC Compact thermal systems to realize mini converters

Fuel cell program in NMRL

Fuel cell Our mission


To develop totally indigenous fuel
cell for Indian armed forces & commercial use All necessary subsystems like fuel processor, startup systems etc. Spin off benefits

Achievements so far
Catalyst Electrode Acid holder
matrix Graphite gas distributor plate

Acid management
systems Humidifiers Thermal systems Power conditioners

Online hydrogen generation devices Hydrogen filter systems


Prototypes :- Fuel cell based power packs with all accessories

NMRLs View
Onsite hydrogen generation is the way to introduce Fuel Cells successfully
For mobile application supply purified H2 from onsite local generation center PEMFCs, PAFCs For stationary application build onsite H2 generation plant PAFCs, SOFC

NMRLs experience in onsite hydrogen generation for fuel cells

Generation of H2 for possible fuel cell applications From organic feed stocks From inorganic feed stocks NH3 Alcohols methanol ethanol CNG LPG Naptha, diesel etc. Bio H2 using algae Hydrocarbons Hydrazine

NMRLs interest

storage of H2 for possible fuel cell applications


Compressed gas Metal hydride NaAlH4 etc. Occluded H2 C SWNT, Organometallic framework etc. Chemical hydrides

Low temperature storage

NaBH4 , CaH2

High pressure light weight storage

NMRLs interest

H2 Content & requirement


Material CH3OH CNG CaH2 NaBH4
@200atm
** considering powder density=1

H2 wt % 18.75 50.00 9.52 21.05

H2 lit/lit @NTP 5250 8 2133** 4715** 200

1 kWatt power At 100 % efficiency At ~65% efficiency (~0.6V cell pot) At ~65% efficiency (~0.6V cell pot) With 70% utilization

H2 consumption (lpm @ NTP) 5.88

9.04

13

Comp H2 100.00

Hydrogen generation devices


Reformers Online generation of hydrogen by methanol reforming Various configurations, for 2lpm (100W), 80 lpm (5kW),900 lpm (60kW) power packs Output CO level <0.5% Hydrogen crackers One shot use Suitable for subwatt to 100 watt systems Different options: super-corroding alloy /Calcium hydride hydrolysis NaBH4 in caustic base solution catalyst induced hydrolysis

Pilot methanol reformer 8-10 lpm hydrogen output for process design and scale up studies (1997)

Compact reformer 1999 (80 lpm hydrogen)

Bukhari reformer 2003

2-5 lpm of hydrogen


Instrument free, very compact, zero powered / rotating device

High capacity methanol reformer , 50nM3/hr 2003 hydrogen, suitable to ~60kW PAFC power pack

Process design of reformer NMRL Detail engineering, control systems and installation Xytel India

Commissioning - NMRL

Hydrogen generator for small fuel cells


Liquid phase refillable cracker-NaBH4 in caustic Catalytic (Pt on IRA-100 resin) hydrolysis Capacity 0-2watt Protable, orientation free usage, Floating type Super corroding alloy, one shot cartridge Capacity 5-25 watt Controlled water hydrolysis CaH2 based, one shot cartridge Capacity 50-150 watt Controlled water hydrolysis

Thermal systems
Snadwich type steam heater/cooler for quick pre-heating and heat removing of PAFC stacks Bayonet type forced methanol based catalytic heater for compact reformer Capillary action based natural methanol catlytic burner Bayonet type natural & fan based hydrogen heater Cartridge type humidifier with hydrogen heater

NMRLs Fuel Cells Products available for commercial usage


700-1000 watt PAFC based UPS / generator with built in compact methanol reformer

Delivers 220V AC, 700-1000VA PAFC battery (35 Kg) Nova-1 / 2 Nominal power of 1000 watt

100 watt self contained power pack

Output :- 12+0.05 V DC upto 100 watt (max) Size 52x27x25 cm (12Kg) Hydrogen source by hydride cracking Hydrogen source by compact catalytic burner based reformer

Conclusion Hydrogen source, generation methodology & fuel cell type critical for successful application Available supply infrastructure can be catered for hydrogen application
This is possible through onsite hydrogen generation

Generally Hydrogen is produced in industry at the expense of utility

For fuel cell application utility is generated at the expense of hydrogen

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