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Integrated Wind-Hydrogen Systems for Wind Parks. E. Varkaraki, N. Lymberopoulos, E. Zoulias, E. Kalyvas , C. Christodoulou, P. Vionis, P. Chaviaropoulos. INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS. _____________________________________________________. OUTLINE OF THE PRESENTATION.

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integrated wind hydrogen systems for wind parks

Integrated Wind-Hydrogen Systems for Wind Parks

E. Varkaraki, N. Lymberopoulos, E. Zoulias, E. Kalyvas , C. Christodoulou, P. Vionis, P. Chaviaropoulos

integrated wind hydrogen systems for wind parks1
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

OUTLINE OF THE PRESENTATION

  • System description
  • Hydrogen generation section
  • Hydrogen compressor & Filling station
  • Metal hydride tanks
  • Auxiliaries
  • Power and Control
  • Results and Discussion
  • Conclusions
integrated wind hydrogen systems for wind parks2
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

SYSTEM DESCRIPTION

  • 500 kW gearless, synchronous, multipole Enercon E-40
  • 25 kW alkaline electrolyser, 5 Nm3/h H2 at 20 bar
  • One-stage hydrogen compressor up to 220 bar
  • Filling station for high pressure cylinders, 120 Nm3 H2
  • Metal hydride tanks, 42 Nm3 H2
  • Water chiller and closed cooling circuit
  • Instrument air compressor
  • Power board
  • Control and monitoring section based on PLC
  • Developed in the frame of the EU project RES2H2 (FP5)
integrated wind hydrogen systems for wind parks3
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

SYSTEM DESCRIPTION

integrated wind hydrogen systems for wind parks4
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

HYDROGEN GENERATION SECTION

Casale Chemicals SA, Switzerland

Alkaline electrolyser 25 kW

Power operating range: 20-100%

DC operation: 0 - 300 A, 0 - 120 V

H2 production: 0.45 kg/h (5 Nm3/h)

H2 purity: 99.98%v. (after purification)

Demineralised water consumption 4.1 l/h

Electrolyte: KOH solution 30%w.

integrated wind hydrogen systems for wind parks5
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

HYDROGEN COMPRESSOR & FILLING STATION

PDC Machines Inc., USA

Single-stage hydrogen compressor

Triple metal diaphragm

Inlet pressure: 10 – 18 bar

Inlet temperature: 30 - 40C

Outlet pressure: 220 bar

5 Nm3/h at 14bar/40C inlet

Buffer: 360 L volume

Filling station: 10.7 kg H2 (120 Nm3)

integrated wind hydrogen systems for wind parks6
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

METAL HYDRIDE TANKS

FIT, Cyprus

& Labtech SA, Bulgaria

6 Metal Hydride tanks

Metal alloy: La0.75Ce0.25Ni5

Total hydrogen capacity:

3.78 kg H2 (42 Nm3)

Total weight: 564 kg

Mass specific H2 capacity:

1.28 %w (alloy)

0.66 %w (MHT)

Hot water boiler 4 kW

integrated wind hydrogen systems for wind parks7
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

AUXILIARIES

WATER CHILLER

Cooling water in closed circuit

Mean electrical power requirement: 1.5 kW

INSTRUMENT AIR COMPRESSOR

Pneumatic valve actuation

Mean electrical power requirement: 0.2 kW

NITROGEN

Inertisation of electrolyser and hydrogen circuit

integrated wind hydrogen systems for wind parks8
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

POWER and CONTROL

integrated wind hydrogen systems for wind parks9
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

RESULTS and DISCUSSION

Electrolyser operation

29.12.05

integrated wind hydrogen systems for wind parks10
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

RESULTS and DISCUSSION

Electrolyser operation

DC current measurement, 1 kHz

DC current applied: 120 A

AC/DC conversion efficiency

85-90% at full power

70-75% at 20% of full capacity

integrated wind hydrogen systems for wind parks11
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

RESULTS and DISCUSSION

Electrolyser operation

Variable power input

integrated wind hydrogen systems for wind parks12
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

RESULTS and DISCUSSION

Electrolyser operation

Protective polarisation

Mean values:

DC current: 2.5 A

DC voltage: 61 V

DC power: 0.15 kW

AC power: 0.35 kW

  • Protective polarisation applied for 27 weeks consumes 1.6 MWh
  • NO protective polarisation thanks to activated electrodes!
integrated wind hydrogen systems for wind parks13
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

RESULTS and DISCUSSION

Electrolyser operation

Stack efficiency:

70-80% (HHV)

AC power efficiency:

55-65% (HHV)

integrated wind hydrogen systems for wind parks14
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

RESULTS and DISCUSSION

Electrolyser operation

filling the buffer

At 1:30 start compressor

filling one HP cylinder

Overall electrical efficiency from AC power to compressed H2:

50% (HHV)

integrated wind hydrogen systems for wind parks15
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

RESULTS and DISCUSSION

Metal Hydride Tanks operation

Preheating phase

Winter conditions

4 kW boiler operating 2 hours

P mht: 18 bar

integrated wind hydrogen systems for wind parks16
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

RESULTS and DISCUSSION

  • Several lessons learned from the realisation of the plant until now:
  • Interfacing of the various units is key, in relation to hydrogen flow, electricity
    • and information flow
  • - Minimisation of buffer tank volume
  • - Transportation and installation issues in remote areas with poor access
  • - PLC based control system is safer but less flexible than PC based
  • Protection of hardware from nature’s elements, theft and even wild animals
  • Special care for the integration of auxiliaries, vital for safe operation
integrated wind hydrogen systems for wind parks17
INTEGRATED WIND-HYDROGEN SYSTEMS FOR WIND PARKS

_____________________________________________________

CONCLUSIONS

  • The wind-hydrogen system installed at the wind park of CRES operates well
  • System efficiency from AC power to compressed hydrogen fuel: 50% (HHV)
  • Important margins for efficiency increase
    • power electronics of the electrolyser
    • wind turbine – electrolyser interface
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