High Differential Pressure PEMBased Hydrogen Generation for Backup

High Differential Pressure PEM-Based Hydrogen Generation for Backup Power and Home Fueling By: E. Anderson, S. Szymanski, and L. Dalton NHA Hydrogen Conference & Expo Long Beach, CA 4 May 2010

Presentation Outline • • • Introduction to Proton Military Focus Areas in Contract Research Backup Power – “Silent Camp” Home Fueling Future Work NHA Hydrogen Conference & Expo 2010 2

Proton Energy Systems • Manufacturer of Proton Exchange Membrane (PEM) hydrogen generation products using electrolysis • • Founded in 1996 Headquarters in Wallingford, Connecticut. ISO 9001: 2008 registered Over 1, 200 systems operating in 60 different countries. NHA Hydrogen Conference & Expo 2010 3

Proton Capabilities PEM Cell Stacks • • • Complete Systems Storage Solutions Complete product manufacturing & testing Containerization and hydrogen storage solutions Integration of electrolysis into RFC systems Turnkey product installation World-wide sales and service Power Plants Heat Treating Semiconductors NHA Hydrogen Conference & Expo 2010 4 Laboratories Government

Hydrogen Products Commercial Products Future Products TM HOGEN Hydrogen Generators S Series Lab Gas Generators Fueling H Series Hydrogen Control Systems GC Backup Power TM Stable. Flow NHA Hydrogen Conference & Expo 2010 5 Renewable Energy Storage

R&D Focus and Agency Partners Military Markets • Submarine life support • Unmanned vehicles Commercial Markets • Industrial • Vehicle fueling • Telecomm backup • Renewable energy storage – UAV – UUV • Silent Camp – Back up power • Military fueling needs – Fork lifts – Light duty vehicles NHA Hydrogen Conference & Expo 2010 6

Forward Operating Bases: Problem Definition • Logistics of moving fuel can limit combat OPS • Operational issues with gensets operating at low capacity • Renewable power: How to make it dispatchable and reliable? • Low audible and thermal signatures needed at times • Expeditionary forces have additional mobile requirements NHA Hydrogen Conference & Expo 2010 7

Backup Power System Concept Using High Pressure Electrolyzer NHA Hydrogen Conference & Expo 2010 8

CERL Silent Camp® Phase I Program • Based on low pressure S -series design • 10 cell stack, 0. 1 ft 2 active area • 10 SCFH (0. 5 kg/day) hydrogen production rate • 2, 200 psig hydrogen pressure generation “Regenerative Fuel Cell” integrated into CERL’s Silent Camp system concept NHA Hydrogen Conference & Expo 2010 9

CERL Silent Camp® Phase I Program • Army/CERL installation for Silent Camp energy storage demo • >1 year field data achieved NHA Hydrogen Conference & Expo 2010 10

CERL Silent Camp® Phase 2 Program • Demonstrate 40 SCFH (2+ kg/day) • H 2 Generation pressure of 2400 psig • Conduct cost reduction activities for system design – Phase separation / drying – Power conversion • Develop, build & test outdoor system for electrolyzer with cost reductions • Integrate diesel gen-set, hydrogen storage, and fuel cell for system demo • Follow-on phase: Integrate with renewables and ruggedize system NHA Hydrogen Conference & Expo 2010 11

“Home Fueling” Product Requirements • • Small-scale generation Safe system, easy to operate ≥ 5, 000 psi (350 bar) dispensing pressure Potential integration with renewables Simple, low cost Small footprint Applicable Codes & Standards – ISO 22734 -2, “Hydrogen Generators Using Water Electrolysis Process – Part 2: Residential Applications” NHA Hydrogen Conference & Expo 2010 12

Proton’s System Approach to Small Distributed Fueling Applications • • High differential pressure, PEM electrolysis Ambient pressure O 2 1 to 2 kilograms per day production Some storage needed for “reasonable” fill time (e. g. not “fast fill”) • Leverage commercial platform and demonstrated high pressure capability – 2, 400 psi capability enabled by Silent Camp program • Integrate with commercial boost compressor and modest storage for complete 5, 000/10, 000 psi fills. • Further develop electrolysis capability to displace some/all mechanical compression NHA Hydrogen Conference & Expo 2010 13

Proton’s Home Fueling Pathways • H 2 generation/compression Current HOGEN® HP Electrolyzer Future Next Gen HP 2, 400 psi 2 kg/day Indoor HP Electrolyzer 2, 400 psi 2 kg/day Outdoor rated UAV Fueling 5, 000 psi 1 -2 kg/day No Mechanical Compression 5, 000 psi <1 kg/day Near Term HP Electrolyzer + Compressor 10, 000 psi 2 kg/day Timeline 2009 NHA Hydrogen Conference & Expo 2010 14 2011

Small Distributed Fueling System Concept Single stage boost compressor High pressure electrolyzer Outdoor rated Medium Pressure Storage (2, 400 psi) Packaged system boundary Simple dispensing interface Vehicle Fill 5 kg at up to 10, 000 psi NHA Hydrogen Conference & Expo 2010 15

UAV Fueling Concept • • • H 2 Production Rate: ≤ 94 g/hr Generation pressure: 10, 000 psi H 2 storage: 1. 3 kg Service Rating: 14 KVA Voltage: 240 VAC Conceptual Layout of High Pressure Electrolysis (Side View and Top View) (Chiller and Dispenser not shown) NHA Hydrogen Conference & Expo 2010 16

Home Fueling Trade Study Objectives • Define critical requirements for PEM Electrolysis Home Fueling System – Technical • Define hydrogen production capacity for a recharge time relevant to end-user • Estimate electrical service and physical size – – Capital and operating cost Codes and standards Product safety Operation and maintenance NHA Hydrogen Conference & Expo 2010 Page 17

5, 000 psi High Pressure PEM System • Based on 2, 400 psi platform • Simple Balance-of-Plant • Higher differential pressure stack development initiated • Timeline to be driven by market need NHA Hydrogen Conference & Expo 2010 18

Fueling Capacity - Scenarios NHA Hydrogen Conference & Expo 2010 19

Fueling Capacity - Estimates NHA Hydrogen Conference & Expo 2010 20

Conceptual Design NHA Hydrogen Conference & Expo 2010 Page 21

Summary & Future Work • Commercial markets driving business success and sustainability • Government support a key product area as well as a critical component to technology development • Silent Camp pushing RFC Backup Power Concept • Next steps will renewables and ruggedness • High differential pressure enabling small fueling opportunities for government and commercial markets • Continuing to push generation pressure to offset mechanical compression NHA Hydrogen Conference & Expo 2010 22

Thank you! Contact Info: Everett Anderson eanderson@protonenergy. com www. protonenergy. com Tel 203/678 -2105 Acknowledgements: Co-authors Sponsors NHA Hydrogen Conference & Expo 2010 23