Alkaline Fuel Cell System Research

1. Alkaline Fuel Cell System Research Massey University POST-GRAD Energy Conference Steve Broome Industrial Research Ltd 26 July 2006

2. Contents of Presentation • Ground Rules • About IRL and Me • Distributed Hydrogen Energy • Alkaline Fuel Cells • Electrolysers • Combined Power Systems • IRL’s Set-up

3. Ground Rules Any questions? Just ask!

4. 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.!

5. 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

6. 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

7. Hercules and MinotaurIRL’s Experimental Alkaline Fuel Cells H2 in Air in H2 in Air in Air preheater & exhaust cooler Air preheater & exhaust cooler Fuel Cell Stack CO2 scrubber Fuel Cell Stack CO2 scrubber Vapour separator for exhaust KOH Sump Vapour separators before outlet Baby cyclone for exhaust KOH Sump Vapour separators before outlet • Minotaur • DCI-1200 #003 • Hercules • DCI-1200 #004

8. 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!

9. 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.

10. Electrolysers IRL Christchurch has one of these. IRL Wellington is developing one of these.

11. 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. – It’s 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. Electrolyser Fuel Cell H2 Electricity Electricity O2

12. 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.

13. IRL’s 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

14. 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.