Field Application of Fuel Cells Increasing Energy Security. Jon Rice, Ultra Electronics

Transcription

1 Field Application of Fuel Cells Increasing Energy Security Jon Rice, Ultra Electronics

2 Agenda Define typical loads, systems in our market Define challenges in power delivery and deployment Existing power sources for remote applications Introduction to fuel cell Fuel cell functionality Design of hybrid systems Case studies Q&A SLIDE 2

3 Typical remote loads in O&G SLIDE 3 Radios PLC, RTU VSAT Valve Actuators Impressed Current CP Gas chromatographs

4 Typical remote load power requirements SLIDE 4 PLC / RTU, 10-50W depending on configuration and application VSAT stations, add 30-50W depending on data load WiFi access points, 30W, PoE Radio relay points, ~15W Flow meters, valve actuators, gas chromatographs vary greatly, still within range

5 Challenging conditions SLIDE 5 Extreme cold No way to reach the systems in the dead of Winter Wind turbine seizures No sunshine for prolonged periods

6 Challenging conditions SLIDE 6 Extreme cold No way to reach the systems in the dead of Winter Wind turbine seizures No sunshine for prolonged periods

7 Challenging conditions SLIDE 7

8 Challenging conditions SLIDE 8 Permanent shade Expensive site visits Dangerous working environment Shaded right-ofway

9 Challenging conditions SLIDE 9 No space Extremely expensive refueling trips Costly retrofits with long lead times

10 Common power sources: Solar power supplies Very reliable when correctly sized Inexpensive in temperate climates Easy to service and maintain Bulky to transport, large footprint required Not a good solution where sunlight or space is limited SLIDE 10

11 Common power sources: Wind turbines Reliability issues in extreme environments Moving parts, high maintenance Wind resource not as predictable as solar Mostly lacks temperature compensation when charging batteries SLIDE 11

12 Common power sources: Turbo-electric generators SLIDE 12 Uses gas flow in pipelines over differential pressure 40W 12V or 24V from psi C1D2 Powered by upstream gas compressors Efficiency not a concern

13 Common power sources: Thermoelectric Generators Single units typically 30W - 500W, can be paralleled Good for pipeline applications where abundant fuel is present Inefficient (typically 3%), see above Reliable with clean gas Good source of prime power, wide temperature range Not too good with motor loads without battery banks present SLIDE 13

14 Common power sources: SLIDE 14 Generators Plenty power, any form you need Relatively inexpensive, widely available Easy to control remotely High maintenance, needs people around Struggles with cold Diesel, gasoline, propane, natural gas Modifications needed to power small loads

15 What s missing? A power supply that: Can charge batteries Consumes common fuel Can endure low temp Is small and light Is highly efficient Needs little or no maintenance Can be communicated with NEED PICTURE OF P250I P02 SLIDE 15

16 Layering Energy Security SLIDE 16

17 Layering Energy Security SLIDE 17

18 Fuel cell technology SOLID OXIDE FUEL CELLS SOFC The Differentiator Fuel Cells SLIDE 18 Rugged with High Performance Oxygen through electrolyte Enables use of hydrocarbon fuels Ceramic fuel cells Inexpensive raw materials Tubular SOFC architecture Thermal shock rapid start Mechanical shock - rugged High Temperature, ºC Direct hydrocarbon fuels

19 Fuel cell advantage SLIDE 19

20 Designing and Sizing a Hybrid System SLIDE 20 Solar Wind Fuel Hybrid Battery Fuel Cell Total Stored Energy Remote Power Generation Short Term Energy Storage Fuel = Total Run Time Fuel Cell = Remote automated battery recharging / backup Hybrid Battery = Electrical energy storage 2013 Ultra Electronics

21 Energy System Modeling - Inputs SLIDE 21 Location Date of install 18-Dec-12 System Configuration Primary Power Const Load TRUE Precip Based Load Temp Based Load FALSE Precip (%) 0 Constant Load (W) Latitude (deg) 15-Feb-00 Max Charger Input 250 W Precip Based Load FALSE 75 Longitude (deg) 9-Apr-00 (For use in backup only) Day Light Based Load FALSE Rain Load (W) 0 Time Based Load FALSE Snow Load (W) 0 Random Backup Power Outage Use Solar TRUE Single Battery 265 Ah Train Activity Load FALSE Outages/ Yr 3 Use Wind Turbine FALSE Number of Batt 4 Heat Enclosure FALSE Time Based Max Duration 75 Hours Solar Panel Details Temp Derate Curve Lead Acid Hour Power Min Duration 5 Hours Max 10 outages Daylight Based 1 0 SOC ON 50 % Night Load (W) Catastrophic Outage Event PTC Rating for 1 panel 236 SOC OFF 93 % Day Load (W) Outage/ Yr Duration 21 days Number of Panels 2 Single Batt Mass 165 lbs 5 0 Max 4 outages Charge Control Derating (%) 92% Ambient Temp Based 6 0 Shading Percent 10% Number of Fuel Cells 1 Temp ( C) Power (W) 7 0 Temp Derate (%/C) -0.45% Train Activity Load System Fuel on 900 sccm Lights 72 W Wind Turbine Details Input Factors Fuel Cell Cabinet Data Load Factors Sensor 0 W Turbine Cut in (Mph) 7.5 Start Up time 30 min Gate 0 W Rated Power (W) Rated Power Speed (Mph) 28 Power Per Fuel Cell 250 W Gate Duration 0 sec Cut Out Speed (Mph) Trains per Day 35 Self Heating 10 %load Train Duration 10 min Insulation 0.2 in Enclosure Heater Enclosure Volume 500 ft^3 foam k 0.02 W/mk Enclosure Temp 32 F R Value 30 US Units Battery box 0.61 L (m) Battery box 0.61 H (m) Battery box 0.91 W (m) Site Fuel Capacity 80 lbs Ultra Electronics: Proprietary Data

22 SLIDE 22 Energy System Modeling -Output Results - System Performance Temperature Fuel Consumed (lbs) System Cycles Average Cycle Duration (hrs) Max On Duration (hrs) Average Off Duration (hrs) Total On Time (hrs) Average Load (w) Cycles per Week Fuel Per Week (lbs) Annual Site Visits Required 1 12 Month Temperature Profile Oct 7-Dec 26-Jan 17-Mar 6-May 25-Jun 14-Aug 3-Oct Nov 0 11-Jan Battery Temp Ambient Temp Heater Power 0 100% 80% 400 Power 60% 40% % 12 Month Power Profile 1-Jan 26-Jan 20-Feb 17-Mar 11-Apr 6-May 31-May 25-Jun Solar Power Wind Power 20-Jul 14-Aug 8-Sep Fuel Cell Power 3-Oct Battery State of Charge Nov 7-Dec Heater Power W Fuel Cell Usage Per Year 0% 28-Oct 22-Nov 17-Dec 11-Jan Battery State of Charge

23 SLIDE 23 Energy System Modeling Output (Solar Only) Results - System Performance Nov 7-Dec Temperature #DIV/0! #DIV/0! Oct 7-Dec 26-Jan 17-Mar 6-May 25-Jun 14-Aug 3-Oct Nov 0 11-Jan Battery Temp Ambient Temp Heater Power 0 100% 80% 60% 40% 20% 12 Month Power Profile 1-Jan 26-Jan 20-Feb 17-Mar 11-Apr 6-May 31-May 25-Jun Solar Power Wind Power 20-Jul 14-Aug 8-Sep Fuel Cell Power 3-Oct Battery State of Charge Power Fuel Consumed (lbs) System Cycles Average Cycle Duration (hrs) Max On Duration (hrs) Average Off Duration (hrs) Total On Time (hrs) Average Load (w) Cycles per Week Fuel Per Week (lbs) Annual Site Visits Required 1 12 Month Temperature Profile Heater Power W Fuel Cell Usage Per Year 0% 28-Oct 22-Nov 17-Dec 11-Jan Battery State of Charge 4X increase in size of array to meet energy requirement

24 SLIDE 24 RIGHT SIZING POWER SOLUTIONS

25 Right Sizing Power Solutions Sample Scenario - Generator SLIDE 25 Fuel Cell Eliminates Generator (published spec) Every hr oil changes Wet stacking due to under utilization DC to AC to DC conversion inefficiencies Typically 15-20% 2 kw 1kg fuel/hr Net Efficiency 16.6% at full load x7 Fuel Cell 300 watts 0.12kg fuel/hr Net Efficiency 22% at full load 20% reduction in fuel resupply to maintain operations 77.5% reduction in fuel resupply to maintain operations

26 Sample Scenario SLIDE watt average sensor power draw Limited solar availability Duration, Days

27 Real World Examples Right sizing power solutions SLIDE 27 Military Exercise, Thailand 3000 watt Tactical Quiet Generator 0.35 gallon fuel/hr $5-50 dollar/gallon in theater 560 MTBF Charging a single ipod 1 watt load Matching the demand to the supply is critical in maximizing efficiency and lowering operating cost

28 Real World Examples Right sizing power solutions SLIDE 28 Medical Readiness Training Exercise Unexpected power outage 5 gallons of JP-8 to run a 3kW generator each day Powering a single laptop Flown in on a CH-53E $20,000 / flight hour Rock Slide Warning System, Colorado Matching the demand to the supply is critical in maximizing efficiency and lowering operating cost Ultra Electronics 2012

29 Examples of field installations SLIDE 29 Harris County traffic light back-up 500W power for a 380W load Can power an intersection indefinitely from city gas supply Hurricane contingency measure

30 Traffic Signal Backup SLIDE 30 Within 4 days of installation fuel cell was triggered by AC power surge that tripped breaker Another power surge 11 months later triggered breaker again Fuel cell supplied 3 months of continuous intersection power before AC power was restored.

31 Examples of field installations SLIDE 31 Iliamna AK Met. Tower prime power supply Powers the onboard heaters of anemometers on the tower Directive was 8 months without site visit Delivered by air

32 Examples of field installations SLIDE 32

33 Examples of field installations SLIDE 33 Northern Washington State, prime power supply Low flyer radar and acoustic sensors Directive was 12 months without site visit Solar / fuel cell hybrid

34 Examples of field installations SLIDE 34 Northern Washington State, prime power supply Geological and mammalian challenges

35 Examples of field installations SLIDE 35 CSX Grade Crossing North Baltimore Ohio crossings per day Major intermodal junction Backup for gates, signals, and train predictor

36 Examples of field installations CSX Grade Crossing North Baltimore Ohio SLIDE 36 Constant Power Charge Constant Voltage Charge Individual Trains Fuel Cell Start Up Fuel Cell Shut down

37 Examples of field installations CSX Grade Crossing North Baltimore Ohio SLIDE 37 Real Time Performance Data Streaming Charge Cycle 25% reduction in battery capacity 2013 Ultra Electronics

38 The So What? SLIDE 38 50% reduction in battery bank size 30-70% reduction in solar array size 80% reduction in fuel burn compared to TEG Multi-year maintenance free monitoring capability

39 Parting Thought SLIDE 39 A good neighbor is a fellow who smiles at you over the back fence, but doesn't climb over it. Arthur Baer