Development of compact FC- and fuel processor based auxiliary power units using micro-channel reactor technique

Transcription

1 Development of compact FC- and fuel processor based auxiliary power units using micro-channel reactor technique Institut für Mikrotechnik Mainz GmbH Dr. Gunther Kolb Head of Energy Technology and Catalysis Department Institut für Mikrotechnik Mainz GmbH Adress: Dr. Gunther Kolb, Institut für Mikrotechnik Mainz GmbH, Carl-Zeiss-Strasse 18-20, Mainz, Germany Tel: IMM,

2 IMM - Centre of Excellence in Microtechnology We are an application oriented R&D institute founded to bridge the gap between academic research and industry Facts: founded in December 1990 owned by the federal state of Rheinland-Pfalz 145 employees around 230 projects per IMM,

3 Distributed Energy and Fuel Production by Micro-technology Electrical Power Supply by Fuel Cells Plants for Syngas Conversion and Hydrogen Production Fuel Supply and Production Energy Storage by Liquid Hydrogen Sorce: Source: Velocys Biodiesel IMM,

4 Fuel Processor - Definitions Reformer + CO-Clean-up + Heat-exchangers = Fuel Processor Fuel Processor + Fuel Cell + Balance-of-Plant (BoP) = Auxiliary Power Unit (APU) Purified Reformate Fuel Cell IMM,

5 Feed2 323 C kg/h FuelEt11 0 Air21 25 C 60 C 0.0 kg/h Feed3 Prod1 Prod2 2.0 kg/h 685 C 708 C 366 C 31.0 kg/h 31.0 kg/h 31.0 kg/h Flue1 Mixcomb2 Air C 470 C C 32.2 kg/h 39.6 kg/h 2.0 kg/h Mix 2 RB PC Flue2 Air2 109 C C Flue kg/h 30.0 kg/h 726 C Prod3 Offgas1 AP kg/h 357 C 290 C Air kg/h 14.6 kg/h 60 C 30.0 kg/h Mixcomb1 Air C 725 C Feed2b 32.2 kg/h 20.0 kg/h Mix C AP2 WGS Cool kg/h C FuelEt kg/h 362 C Prod4 2.2 kg/h 293 C FuelEt1 Cool kg/h 25 C C 2.2 kg/h 26.0 kg/h FEV Prod5 232 C 1193 EV Flue kg/h Flue C OP 79 C 39.6 kg/h kg/h EVB Feed2a 65 C 31.0 kg/h H2O Offgas Feed1 Cool3 Air13 Air12 Cond 45 C 25 C C 60 C 60 C 14.6 kg/h 31.0 kg/h 26.0 kg/h 5.0 kg/h 20.0 kg/h FP Prod7 Prod_H2 Cool C 45 C 59 C 17.2 kg/h 2.6 kg/h Split 1 VSSL 100 PSA 26.0 kg/h Air11 Drain 60 C 45 C 25.0 kg/h 13.8 kg/h PC1 All Main Development Issues for Microreactors covered by one Institute SYSTEM INTEGRATION AND TESTING REACTOR FABRICATION & TESTING DEVELOPMENT OF CHEAP FABRICATION TECHNIQUES CATALYST DEVELOPMENT AND DURABILITY TESTING PROCESS SIMULATION, SYSTEM DESIGN & IMM,

6 Core Technology: Plate Heat-exchanger with Catalyst Coating and Microchannels J.M. Redenius, L.D. Schmidt, O. Deutschmann, Millisecond catalytic wall reactors: I Radiant burner, AIChE J. 47 (5) (2001) IMM,

7 Application Example 1: Power Supply for Recreational Vehicles - IMM,

8 Power Supply for Recreational Vehicles - Introduction Power supply of recreational vehicles is a critical issue as soon as the power grid is not available. Fuel cell technology bears advantages concerning efficiency and noise emissions compared to small scale Auxiliary Power Units (APU) working with internal combustion engines. LPG is an attractive fuel, because it is readily available at the vehicle and, more recently, also owing to its IMM,

9 Power Supply for Recreational Vehicles Introduction (2) TRUMA Gerätetechnik is a leading European supplier of comfort equipment for recreational vehicles: - heating and air conditioning systems - hot water generation - shunting equipment. Truma is Europe s largest manufacturer for LPG based heating systems for recreational vehicles Therefore the company decided to develop a LPG-based PEM fuel cell system. Plate heat-exchanger technology of IMM allows compact and efficient system design for the fuel processor. Therefore a cooperation between Truma and IMM was IMM,

10 Business Conditions Recreational vehicles are an ideal market for fuel cell systems because: Increasing customer demand for comfort and thus increasing power consumption Higher customer demand for autarky High price achievable, customers technology-driven Moderate life cycle duration ( 5,000 h) Application as hybrid system in combination with the vehicle battery (battery charger) End user benefits concerning: - autarky - noise - IMM,

11 Technical Framework The power demand in recreational vehicles: 300 1,000 Wh/d on the average (without air conditioning) An 11 kg LPG cylinder contains 142 kwh of thermal energy This is converted to 28 kwh electrical energy by the VeGA system Electrical efficiency of 20% This is two to four times higher compared to small scale internal combustion IMM,

12 Basic Flow Scheme of the VeGA System Heating System Desulphurisation Microstructured Fuel Processor HT-PEM-Fuel Cell Cooking Air Refrigerator LPG Supply Recreational Vehicle Power Supply TV DC/DC-Converter Light Heater Fan White Goods (Coffee Machine) Air IMM,

13 History of the Fuel Processor / System Development 2003: Catalyst development and system studies 2004: Catalyst stability tests and single component (reactors, heat-exchangers) development and testing 2005: Set-up of a first laboratory prototype and testing Re-design and set-up of a second generation prototype (including tests) 2006: Re-design and fabrication of third generation prototypes 2007: Re-design and fabrication of a-series systems 2008: Re-design and fabrication of 60 b-series systems; 2009: Field trials 2010/2011: Advanced tests with additional 50 units; pilot production (100 IMM,

14 First, Second and Third Generation Fuel Processor IMM,

15 2008: Systems Ready for Field Trials Until end of 2011 fabrication and test of about 200 units in-house and in Recreational Vehicles of customers and OEMs MARKET INTRODUCTION IMM,

16 Laboratory Tests of the Complete System at IMM,

17 Practical Tests in Recreational Vehicles A fuel processor which had been operated for 1,350 h in a complete system with fuel cell was cut out and tested separately, full conversion of the LPG feed observed and only 50% higher concentration of CO in the purified reformate at full load Systems were operated up to 3,500 hours VeGA systems were tested at a test course for vehicle vibration and proved durable for a simulated 170,000 kilometres Field trials units were tested between 9 and 18 months in RVs across Europe, one system even in IMM,

18 Acknowledgement The authors gratefully acknowledge the funding of part of the development work presented here by the Bavarian Ministry of Economic Affairs, Infrastructure, Traffic and Technology German Federal Ministry of Economics and Technology German Federal Ministry of Transport, Building and Urban Development German National Organisation for Hydrogen and Fuel Cell Technology IMM,

19 System Specifications Power output W Charging current up to 20 A Voltage V Weight 40 kg Dimensions 71.7 x 46.2 x 29 cm Gas consumption g/h Start-up time min Operation mode fully automatic Control panel 4.3 colour touch screen *technical data subject to IMM,

20 Application Example 2: Application of Micro-technology: Fuel Cell APU for IMM,

21 Application of Micro-technology: Fuel Cell APU for Aircrafts Electrical Power Supply by Main Engines during ground operation has very low efficiency Current Solution: Gas Turbine with low efficiency (< 20%) Possible Future Solution: Fuel Cell Technology; Targeted Fuel: Methanol Electrical Power Demand of Passenger Aircrafts: 50 kw 500 IMM,

22 Complete 20 kw th Methanol Fuel Processor without and with Housing and with IMM,

23 Current Status of 5 kw el Methanol Fuel Processor Development Functionality of Reformer proven Functionality of Fuel Processor proven Operation together with 1 kw High Temperature PEM successful Future Tasks: Development of fully integrated System Next Scale up Size: 50 kw el 100 kw el IMM,

24 Catalyst Development and Durability IMM,

25 c [Vol.%] H2O, CO2 vol% / % CO [ppm] c (H2, H2O, CH4) / vol% c (CO2, CO) / vol% [%] C3H8, CO, H2 vol% / % IMM Catalyst development for fuel processing - Durability Long term HT-WGS test H2 CO H2O CH4 CO CO conversion H2 content CO2 content CO content H2O content Time [h] Time [hr] ,000 hours durability test self developed coating for propane steam reforming CO2 H2O C3H ,000 hours durability test self developed coating for water-gas shift hr Prox Time [h] 1,000 hours durability test self developed coating for propane total oxidation (375 C) H2O CO2 CO H2 C3H Time on stream / h 1,000 hours durability test self developed coating for propane total oxidation (750 C) Time [hr] 1,000 hours durability test self developed coating for CO IMM,

26 Catalyst coated Heat-exchanger Reactor for Laboratory Exhaust Cleaning Purposes Reactor in Operation at CRI Catalyst Leuna GmbH for 35,000 hours Heat Generation of Oxidation Reaction 2.5 kw, which is removed by cooling IMM,

27 Fabrication of the Fuel IMM,

28 Production Steps Introduction of Microchannels into metal foils (Catalyst Coating) Bonding (= Sealing) Attachment of Connections/ IMM,

29 Fabrication Issues Mass Production of Microreactors How to make 1,000 10,000 reactors / year? Screen Printing of Catalyst Coatings Laser Welding of Reactors; Speed: 360 m/h Laser welded Plate Stack IMM,

30 Embossing Embossed and laser welded microstructured heat exchanger First Design of a follow-on Composite tool for Reactor IMM,

31 Conclusions Microstructured reactors offer significant potential for size reduction of dezentralized energy systems Other applications in fields of biodiesel production and liquified hydrogen technology and syngas conversion (e.g. Fischer-Tropschsynthesis) are on their way Microstructured plate heat-exchanger reactors are going to be a mass-product (1,000 units/y +) in the nearest IMM,

32 Thank you for your attention IMM,