Senior Design I Preliminary Design Review Project 05305

Senior Design I: Preliminary Design Review Project 05305: Conversion of Wind Power to Hydrogen Team Leader: Team Members: Quoc Khanh Ngo Sarah Braymiller Stephen Raymond Paul Williams Patrick Griffin Justin Szratter Michael Miller Project Sponsor: Project Mentors: Harbec Plastics, Environmental Protection Agency Professor Brian Thorn Professor Andres Carrano Project Coordinator: Professor Jacqueline Mozrall

PDR: Agenda • Company Background • Environmental Deliverable • Concept Evaluation • Financial Deliverable • Feasibility Assessment • Project Schedule • Team breakdown • Overall System Diagram/ Block Diagram • Detailed Design/ Process Design Schematics

PDR: Company Background Company Description • Founded in 1977 as a Tool and Die Company • Located in Ontario, NY • Currently a full service thermal injection mold and manufacturing facility Environmental Highlights • Developed current facilities for Energy Star compliance • Ability to Produce 100% of energy requirements off the grid • Developed initiatives to reduce plastic waste through recycling

PDR: Project Definition Project Mission Statement: To explore and develop a sustainable design that will capture, convert, and store excess energy created by an existing wind turbine Problem Description • 250 KW Fuhrländer Wind Turbine installed in 2001 • Manufacturing facility currently utilizes the turbine for five of the seven days a week • Energy produced during the weekend returns to the grid free of charge • Monitoring/Control Site

PDR: Project Specifications Project Work Statement: • Detail of technical challenges and solutions associated with energy conversion • Technical roadmap and program schedule for system implementation • Facilities analysis for potential implementation • Environmental impact analysis for all potential systems

PDR: Scope Limitations System Design Specifications • Design considerations: • Will be given primarily to commercially available products • Must provide the conversion to hydrogen • A consideration must include a fuel cell system • Will produce a payback period of eight to ten years • Should not increase emission generation produced by the facility

PDR: Team Breakdown Detail Component Research and Implementation Electrolyzer • Patrick Griffin - ME Storage Alternatives • Michael Miller - ME Wind Turbine, Power Production, Concept Development and Feasibility • Justin Szratter – ME Overall Systems Integration and Design Stephen Raymond - ME Financial Analysis and Facilities Planning • Quoc Khanh Ngo – ISE, Manager Environmental Planning, Sustainability, Feasibility, and Facilites Planning • Sarah Braymiller - ISE

PDR: Concept Development Primary Concepts Considered • Hydrogen Fuel Cells • Hythane – Micro-turbines Secondary Consideration • Hydrogen Engines Other Concepts • • • Water Reservoir Pump Flywheel Super Capacitors Fuel Cell/Reformer Mass-Energy Lift

Weight Relative System Kinetic Energy System Engine Energy baseline 5= much better than baseline Hydrogen baseline 3 = same as baseline 4 = better than Hythane worse than baseline concept 2 = worse than System baseline, score each attribute as: 1 = much Fuel Cell Evaluate each additional concept against the Energy System PDR: Feasibility Considerations Sufficient Student Skills? 3. 0 3 5 3 0% Research Material Availability 3. 0 1 3 5 9% Overall Cost Justification 3. 0 3 2 2 18% Available Human Resources 3. 0 3 2 2 7% Customer Expectation (Fuel Cell Concept) 3. 0 1 18% Multiple Concepts Complete by April 3. 0 3 3 3 9% New Technology 3. 0 3 5 4 2% Innovation 3. 0 2 5 2 7% Available for Implementation 3. 0 5 2 2 18% Scalability 3. 0 3 1 1 13% Weighted Score 3. 0 2. 8 2. 1 100. 0% 91. 9% 71. 1% 69. 6% Normalized Score

PDR: Concept Schematics

PDR: Concept Schematics

PDR: Concept Schematics

PDR: Fuel Cell Overall System Tree Diagram Key System Outputs Component Properties Key Goal Outputs System Components

Analysis: Overall Integration Select Electrolyzer -Water Distiller -Hydrogen Compressor -Oxygen Compressor Check Total Power Consumption -Water Storage -Hydrogen Storage -Oxygen Storage -Select Fuel Cell • Duration of Fuel Cell Operation • Floor Space Required by Components • Financial Analysis for 8 -10 Year Payback

Analysis: Electrolyzers Integration Issues – – – Electric Load Hydrogen Production Output Pressure Efficiency Feed Water

Analysis: Electrolyzer Loading Turbine Limitations – Wind turbine generates 300 MWh/year – Average output ~ 34 k. W Electrolyzer Limitations – – Requirements under 34 KW Utilize low-power units Potential to sustain multiple units Optimize hydrogen production

Analysis: Hydrogen Production/Pressure Run Time Constraints – System must operate for a continuous 96 hours – Pressure vessel shall accommodate 4 days of H 2 production Mechanical Constraints – Electrolyzer’s pressure all <370 psi • Too low • Will need a compressor for storage

Analysis: Electrolyzer Efficiency – Existing cogeneration facility Feed Water – Needs Purified Water (e. g. distillation, reverse osmosis) – On-site distiller Final Choice – HM-50 based on low electric load and high efficiency

Analysis: Storage Options Methods for Hydrogen Storage: • Hydrides • Liquid • Gaseous

Analysis: Hydride Storage • H 2 chemically adheres to metal powder • Recovered later with addition of heat • Volumetrically inefficient • High Maintenance

Analysis: Liquid Storage • Temperatures below 10 K (-263 o. C) • High Maintenance • Potential losses to boiling • Very inefficient

Analysis: Gaseous Storage • Requires Pressures above 2000 psi • Potential for hydrogen embrittlement • Hydrogen molecules are spread apart allowing for easy escape • Low maintenance • Highly efficient

Analysis: Storage Selection Criteria Decision Factors • • System integration Cost effectiveness Low maintenance Availability Choice • Gas Storage Pressure Vessels

Analysis: Fuel Cells Integration Issues – Hydrogen Consumption – Cogeneration – Electricity Production

Analysis: Hydrogen Consumption • Most fuel cells require input pressures of no more than 100 psi – Pressure regulator will be required between storage and fuel cell • Power output determines hydrogen consumption rate

Analysis: Cogeneration • Electrical efficiency ~35 – 45% – heat produced • By capturing waste heat overall efficiency can be increased to ~70 – 90% • Harbec’s HVAC system can be easily modified to capture waste heat – Waste heat can then be used for facility heating/cooling

Power Needs: Electricity Production • Power Output – Ideal fuel cell is the smallest (cheapest) that can run all week and consume the hydrogen produced in one weekend – 480 v 3 -phase or 120 v single phase AC power can be used by the plant – All fuel cell outputs explored are DC – The fuel cell does not come with an integrated DC to AC power inverter, an external one must be purchased

PDR: Benefits of Wind Power Environmental Impacts • Renewable Energy Resource • Pollutant Free – Creates energy with no combustion, no smoke and no waste. – Reduced emissions from not using fossil fuels.

PDR: Environmental Impacts • Using a fuel cell system would reduce emissions of nitrogen dioxide, sulfur dioxide and carbon dioxide. • Emission of these gases can lead to: – Global warming – Acid rain – Smog – Plant and water damage – Aesthetic damage to statues and sculptures.

PDR: Social Impacts Public Health Benefits: • Traditional Energy systems can lead to acute health defects and or toxic long term diseases. • Conventional energy produces toxic particles that can be linked to premature deaths from heart and lung disease, including cancer.

PDR: Economic Impacts • Wind power provides a constant source of energy • Wind power provides more jobs per unit of energy than other forms of energy • Wind energy brings jobs and revenue to rural communities. • The more wind that is purchased, the more wind farms will be developed.

PDR: Financial Analysis Estimated Energy System Cost: Fuel Cell • $309, 000. 00 Estimated Building and Systems Integration Costs • $75, 000. 00 Total Cost • $411, 000 with 10% slack costs Payback • Average $40, 320. 00/Year Required to payback the Fuel Cell System

PDR: Financial Analysis Key Financial Factors These factors include: Overall system cost Electrical output Hydrogen output Oxygen output Maintenance costs Gas Displacement (Hythane Concept) Oxygen, Hydrogen, and Natural Gas purchasing costs and trends Electric purchasing costs and trends Interest rates Inflation Depreciation (MACRS) Tax Codes and Laws Government Grants and Other Tax Breaks Smallest Payback given performance

PDR: Financial Analysis Strategies to Reducing Average Payback • Modular System Implementation • Develop the system on a smaller scale • Seek out government grants and tax breaks for green power • Implement N years from the current date • Assumptions • Cost of technology will decrease over time

PDR: Current State • Technical Feasibility and Design – Fuel cell concept Completed • Environmental Feasibility – Fuel cell concept Completed • Financial Analysis and Feasibility – Fuel cell concept In Progress • Hythane Micro-turbine Concept Technical Details – In Progress • Hythane Micro-turbine Concept Financial Details – In Progress

PDR: Future State Development of Implementation roadmap to be completed - Fuel Cell Concept • Facilities plan to be completed – Fuel Cell Concept • Financial Analysis to be completed – Hythane Micro-turbine • Development of EPA deliverable (Due April 12 th) • Technical Paper (People, Prosperity, Planet) • Financial Analysis for all concepts • Facilities Plan • Presentation Booth for Competition • Presentation Poster

PDR: GANNT-Activity Schedule

PDR: Questions

PDR: Financial Analysis MACRS – Modified Accelerated Capital Recovery System Fuel Cell Model falls under energy equipment • 5 Year Capital Recovery Schedule • 20% Year Zero • 32% Year One • 19. 2% Year Two • 19. 2% Year Three • 11. 1% Year Four • 5. 5% Year Five

PDR: Concept Feasibility Attributes • Sufficient Student Skills This attribute is based on the students technical knowledge and ability to complete the project • Research Material Availability This attribute is based on the availability of research material for the project. It also accounts for the feasibility of developing quotes for the project components. • Overall Cost Justification Feasibility This attribute is based on whether or not the concept will fall within the eight to ten year payback period • Available Financial Resources This attribute is based on the amount of financial resources that will be allocated towards the concepts for development • Customer Expectation for Concepts This attribute is based on the customer expectations from the concepts. What the concepts are, and their performance • Multiple Concepts Complete by April This attribute accounts for the nature of the project and the ability/time to produce more than one in depth concept. • Existing Technology • This attribute accounts for whether or not design work applies in concept • New Technology (Innovation) • This attribute accounts for the design aspect of the project, and how much design work goes into the concept • Available for Implementation This attribute accounts for whether or not the concept can be developed due given the availability of the project • Scalability This attribute accounts the modularity of the system and its ability to grow in size.

Analysis: Power Inverters Grid-parallel application – The inverter must be able to match the waveform from the grid Power input – Most commercial grid-parallel inverters are set up for sun power applications, with high voltage and low current – Inverter with lower voltage and higher current inputs is required

PDR: Microturbines Hydrogen Issues • Constant amount of Hydrogen • Less than 5% • Can burn out the combustors and injectors.

PDR: Microturbines Integration Issues • More piping installed • Cutting into natural gas lines (safety) • Regulate hydrogen and natural gas flow

PDR: Microturbines Positive outcomes • No fuel cell needed (save initial cost) • Offset amount of natural gas used • Possible quicker payback • Some parts already exist

PDR: OHSA Regulations and Standards for the Storage of Hydrogen

PDR: OHSA Regulations and Standards for the Storage of Hydrogen Design Specifications for Systems of 3, 000 CF or Less (Inside buildings not in a special room and exposed to other occupancies): • Adequate ventilation to the outdoors shall be provided. • Protected against damage or injury due to falling objects or working activity in the area. • More than one system of 3, 000 CF or less may be installed in the same room, provided the systems are separated by at least 50 feet. Each such system shall meet of the defined requirements.

PDR: RG&E’s Energy Production Mix • Nuclear (55%) • Coal (28%) • Hydroelectric energy (7%) • Natural Gas (7%) • Other resources (3%) "Product Content Label. " Catch the Wind. RG&E. 25 Jan. 2005

PDR: Environmental Impacts - Wildlife There were 183 bird deaths there over a two year period and wind turbines are not responsible for all of these deaths. • Automobiles are the cause of 57 million bird deaths a year • More than 97 million birds die by flying into plate glass each year • Approximately 1. 5 million birds die from collisions with structures (towers, stacks, bridges, and buildings) every year - according to the Audubon Society. 1 Frequently Asked Questions. " New Wind Energy. Niagara Mohawk.

PDR: Comparison of Energy Systems