Massey University POST-GRAD Energy Conference

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Alkaline Fuel Cell System Research

• Massey University POST-GRAD Energy Conference
• Steve Broome
• Industrial Research Ltd
• 26 July 2006

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Contents of Presentation

• Ground Rules
• About IRL and Me
• Distributed Hydrogen Energy
• Alkaline Fuel Cells
• Electrolysers
• Combined Power Systems
• IRLs Set-up

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Ground Rules
Any questions? Just ask!
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About IRL and Me

• IRL Christchurch
• Industrial Research Ltd Formerly the DSIR.
• Chch site is full of research engineers.
• Wellington site is full of research scientists.
• Me
• Chemical Process Engineer from University of
  Canterbury.
• Masters with Fonterra and FRST played with big
  toys.
• Spent two years in Timaru the Ultimate O.E.!

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Distributed Hydrogen Energy
Reformer
H2
Methanol
Ethanol or methanol
Alkaline Fuel Cell
Electricity
Gasifier
H2
Syngas
Heat
Wood, coal or biomass
Electrolyser
Electricity
H2
Wind or wave power
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How Alkaline Fuel Cells Work
Electricity
Inlet H2
Inlet air
N2 O2
K OH-
H2O
Exhaust air
Exhaust H2
Cathode
Anode
0.5 O2 2e- H2O ? 2OH-
H2 2OH- ? 2 H2O 2e-
30 KOH Electrolyte
Heat
H2 0.5 O2 ? H2O electricity heat
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Hercules and MinotaurIRLs Experimental
Alkaline Fuel Cells
Air in
H2 in
Air in
H2 in
Air preheater exhaust cooler
Air preheater exhaust cooler
CO2 scrubber
Fuel Cell Stack
CO2 scrubber
Fuel Cell Stack
Vapour separators before outlet
Vapour separator for exhaust
KOH Sump
Vapour separators before outlet
Baby cyclone for exhaust
KOH Sump

• Minotaur
• DCI-1200 003

• Hercules
• DCI-1200 004

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Applications of AFCs

• Space Travel
• AFCs used on space shuttles since 1981.
• Developed by UTC Power.
• Carry 3x 12kW units.
• Use bottled H2 and O2.
• Over 90,000 hours of operation.
• Over 70 efficient
• Goal Domestic Combined Heat Power
• Introduce whisper-quiet electricity and heat
  generator to NZ homes.
• Supply electricity to home or the grid.
• Heating for domestic hot water,
• Especially useful for remote areas rural
  communities.
• Operating off conventional fuels air the
  challenge!

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IRL Progress on AFCs

• PEM fuel cell (Proton Exchange Membrane)
• Testing of a ReliOn PEM fuel cell at US Antarctic
  Centre during 2005-2006.
• Successful.
• Methanol ? Reformed to H2 ? Fed to fuel cell.
• Bottled H2 ? fed to fuel cell.
• Alkaline fuel cell
• About to begin field trial of Zetek alkaline fuel
  cell at US Antarctic Centre.
• Methanol ? Reformed to H2 ? Fed to fuel cell.
• Will build low-cost AFCs.

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Electrolysers
IRL Christchurch has one of these.
IRL Wellington is developing one of these.
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Combined Cycle System Totara Valley Hylink
Use wind energy to produce hydrogen in an
electrolyser. Hydrogen can be stored in a pipe
and used on demand. Its potentially cheaper to
run a polymer pipe for hydrogen than an
electrical cable. Experimental system has been
set up in Christchurch. A wind turbine has been
installed at Totara Valley.
Fuel Cell
Electrolyser
H2
Electricity
Electricity
O2
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Totara Valley Pipe System Christchurch style

• We have installed a medium density polymer pipe
• Like the one planned for Totara Valley.
• 160 m long and 1 inch diameter.
• Box is filled with sand.
• Holds hydrogen well at 4 bar gauge pressure.
• Electrolysed hydrogen stored in here.
• Run alkaline fuel cell off this hydrogen.
• Peter Sudol working on this next week.
• Brainwave
• Run H2 and O2 pipes to power an alkaline fuel
  cell.

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IRLs Set-up
Bottled hydrogen
Windmills
H2 Storage
Electrolyser
H2
H2
H2
Methanol
Reformer
Alkaline Fuel Cell
H2
Electricity Heat
Coal or biomass Syngas
Hydrogen purifier
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Summary

• IRL is working on distributed hydrogen energy
  research and development.
• Experiments and trials
• Alkaline fuel cells being tested.
• PEM electrolyser being powered off wind energy.
• Alkaline electrolysers being developed by IRL.
• Electrolysed hydrogen being stored in a polymer
  pipe.
• This is used to fuel an alkaline fuel cell.
• Hylink will be installed at Totara Valley in
  2006-2007.