Renewable Energy Based Hydrogen Production Presented By: H2 Generation Client: Dr. Tom Acker 9/17/2018

Joshua Spear – Team Leader Robert Burke – Team Mediator Team Members: Joshua Spear – Team Leader Robert Burke – Team Mediator Ryan Hirschi – Financial Officer Andrew Boone – Secretary/Webpage 9/17/2018 H2 Generation Systems --

Presentation Overview Client description Problem description H2 Generation’s Deliverables System Component Layout Individual System Design Conclusion 9/17/2018

The Client Dr. Thomas Acker Professor of Mechanical Engineering Northern Arizona University Coordinator of the Renewable Energies Resource Center http://www.cet.nau.edu/Projects/RERC/ 9/17/2018

Is there an Alternative ? “With a new national commitment, our scientists and engineers will overcome obstacles to taking these cars from laboratory to showroom, so that the first car driven by a child born today could be powered by hydrogen, and pollution-free.” President George W. Bush 2003 State of the Union Address 9/17/2018

Problem Statement Create a renewable energy based hydrogen generation station. Client Requirements: Use existing renewable energy sources to produce hydrogen gas. Hydrogen must be produced using water collected on site. Hydrogen must be stored in a manner available to fuel a vehicle. 9/17/2018

Additional Design Criteria Hydrogen use in internal combustion Purity of 99% http://www.homepower.com/files/Hp67p42.pdf Hydrogen use in fuel cell technology Purity of 99.999% USCAR (United States Council for Automotive Research) http://www.uscar.org/Media/2002issue2/hydrogen.htm 9/17/2018

H2 Generation Deliverables: System design incorporating: Specified Design Thermodynamic analysis Maintenance cycles Simulation Website Proof of concept model: Design and construct 9/17/2018

Project Milestones 3 - Model Delivered 4/21/03 4 - Finalized Design 4/21/03 5 - Capstone Presentation 4/25/03 6 - Final Report Due 5/5/03 9/17/2018

Design Budget Approximately $1000 Acquiring resource materials for use in design (books, software, etc.) Document construction (paper, copies, etc.) Model construction (electrolyzer, tubes, etc.) 9/17/2018

Design Philosophy Success Through Division & Simplification. H2 Generation has… Broken down the large scale design of a hydrogen generation station into manageable components. Components will then be individually analyzed for safety, environmental issues maintainability,and cost. 9/17/2018

Proposed Project Components Layout of Major System Components WATER H20 Collection and Treatment Oxygen Gas Electrolysis of H20 ENERGY REACTION: H20 + ENERGY H2 + O2 ENERGY Storage of Compressed Hydrogen Power Generation and Storage This diagram displays the major design components of the system. 9/17/2018

Water Collection And Treatment 9/17/2018

Water Collection and Treatment Design Constraints Amount of water required for electrolysis Flowrate required to keep up with electrolyzer Level of purity required by electrolyzer Conservative electric energy use Able to be automated through control system 9/17/2018

Water Collection and Treatment Calculations Q: How much H2 for 1 gal. of H20? A: 1 gal of H20 => 1300 gal. of H2 gas Q: Water flowrate of Electrolyzer? A: .116 gal/Day Q: Amount of water needed per year? A: ~= 40 gallons per year Using mass ratio of hydrogen to water Working backwards from flowrate of hydrogen Figuring out how much fuel is required for an assumed vehicle. (35 mpg traveling 600 miles per year) 9/17/2018

Water Collection and Treatment System Design 9/17/2018

Water Collection and Treatment “The RainCatcher” Specifications Size Dimensions: 32" H x 24" W Capacity: 55 gallons Weight: 18 lbs when empty Composition: made from recycled materials The Green Culture 23192 Verdugo Dr., Suite D Laguna Hills, CA 92653 http://www.watersavers.com 9/17/2018

Water Collection and Storage “Gilmour 9100” Lawn Timer Specifications Removable electronics for easy programming Swivel nut for easy connection to faucet Low battery indicator - requires 4 AA Alkaline Digital display indicates program http://www.amazon.com http://www.gilmour.com/ 9/17/2018

Water Collection and Treatment “The Rainmaker” Specifications Size: 76 cm (30") x 122 cm (48") Area: 0.93 m2 (10 ft2) Weight: 18.2 kg (40 lbs) Produces: 0.528 gal./day (winter) 1.58 gal./day (summer) SolAqua P.O. Box 4976 El Paso, Texas 79914-4976 http://www.solaqua.com/index.html 9/17/2018

Water Collection and Treatment “55 gallon Water Barrel” Specifications Capacity: 57 .5 Gallons Actual Weight: 24.5 lbs. Height: 35 1/2" Top Diameter: 23 3/4“ 2 - 3/4 inch openings for water pumps Material: High molecular weight polyethylene Frontier Survival 75 South Main Street Manti, UT 84642 http://www.frontiersurvival.com 9/17/2018

Water Collection and Treatment Summary of Design Benefits Two Stages of Water Storage-~1 year Supply Lawn Timer- Automates distiller Distiller provides excellent purity at acceptable rate No electrical draw (except lawn timer batteries) Solar Distiller wastes water, but water is in excess 9/17/2018

Water Collection and Treatment Cost Projection The RainCatcher $119.50 Gilmore 9100 $26.99 The Rainmaker $398 55 gallon Drum $29.95 Misc.* $50.00 Total= $624.44 *Miscellaneous Parts: Garden Hose Fittings 9/17/2018

Electrolyzer System Design H2 Leak Detection 9/17/2018

Hydrogen Production Design Constraints: Two system design layouts: Hydrogen must be produced by electrolysis Volume of hydrogen generation is specified by distance traveled by car Two system design layouts: 1 Fuel cell technology @ 99.999% 2 Internal combustion engine @ 99.9% 9/17/2018

System Design I Fuel Cell Implementation Packard Hydrogen Generator B9800 Hydrogen purity at 99.9999% Solid polymer electrolyte Inline valve for continuous water fill Output pressure 58 psig, with 72 L/h of H2 production Cost: $19,802.00 http://www.alltechweb.com/productinfo/technical/datasheets/90741d.pdf 9/17/2018

Packard Hydrogen Generator B9800 Hours to produce hydrogen: 7.4 h/day Automatic shutoff Hydrogen leak detection Certified Safety: National Fire Protection Agency, and (OSHA-1910.103 ) http://www.alltechweb.com/productinfo/technical/datasheets/90741d.pdf 9/17/2018

System I Total Cost Packard H2 Generator $19,802.00 Total= 9/17/2018

System Design II Hydrogen for internal combustion system 3 PEM electrolyzers (Polymer-electrolyte membrane) 2 Purification trains Hydrogen leak detection 9/17/2018

Electrolyzer Selection Thermodine Systems Model HM4200 Power: 6 Volt, 30 A/cm² H2 production rate: 22.7 L/h Delivery Pressure: 50 psig Gas purity: 99% Cost: $490.00 http://www.pege.org/greenwinds/electrolyzer.htm 9/17/2018

Purification Train H-ion Products: Delivery of H2 purity: 99.9% Delivery pressure: 58 psig Flowrate of H2: 47 L/h * 2= 93L/h Cost: $1750.00 per unit http://www.hionsolar.com/n-pt-3.htm 9/17/2018

Hydrogen Detection System LED display Analog output Two alarm set points Front panel reset switch Self testing Remote reset panel Plugable terminal blocks AFC International Inc. Gas Detection System 9/17/2018

Detection Specifications Power: 9-15 V, 30mA max Hydrogen detection: 0-10% in air Explosion limits of H2 in are 4% to 74% http://www.homepower.com/files/Hp67p42.pdf Automatic shutoff at selectable limits Explosion proof cast aluminum Cost: $1,408.00 9/17/2018

System II Total Cost $1,470.00 $3,500.00 $1,408.00 $6,378.00 HM4800 H2 Generator $1,470.00 Purification Train $3,500.00 H2 sensor $1,408.00 Total= $6,378.00 9/17/2018

Hydrogen Storage 9/17/2018

Hydrogen Storage Design Constraint Design Decision A vehicle requires about 4300 gallons of hydrogen gas to be collected to travel 50 miles per month. Design Decision The simplest and most economical method to store this much hydrogen is in a compressed gas cylinder. 9/17/2018

Hydrogen Storage Necessary Components to compress hydrogen into a compressed gas cylinder: Propane Tank Gas Booster Air Compressor Compressed Gas Cylinder Cyl-Tec, Inc. http://www.cyl-tec.com 9/17/2018

Hydrogen Storage System Design 9/17/2018

Hydrogen Storage Propane Tank Specifications Dimensions: 9’11” L x 37” OD Capacity: 4000 gallons H2 gas Pressure: 90 psi Weight: 950 lbs American Welding & Tank http://www.awtank.com 9/17/2018

Hydrogen Storage Gas Booster Specifications Dimensions: 24” L x 12” W x 12” H Powered by: Air at 80psi, 45 SCFM (minimum) Weight: 50 lbs MaxPro Technologies http://www.maxprotech.com 9/17/2018

Hydrogen Storage Air Compressor Specifications Dimensions: 72” L x 28” W x 57” H Power Usage: 15 hp (11.2 kW) Weight: 1000 lbs Ingersoll-Rand http://www.air.irco.com 9/17/2018

Hydrogen Storage Compressed Gas Cylinder Specifications Dimensions: 51” H x 9” OD Capacity: 2300 gallons H2 gas Pressure: 2200 psi Weight: 115 lbs Cyl-Tec, Inc. http://www.cyl-tec.com 9/17/2018

Hydrogen Storage Summary of Design Benefits Large propane tank allows for long-term hydrogen gas storage at low pressure Gas Booster can compress high-purity hydrogen gas System compresses hydrogen gas automatically 9/17/2018

Hydrogen Storage *Other Parts: $716 Cost Projection $3,500 $4,461 $148 Propane Tank $716 Gas Booster $3,500 Air Compressor $4,461 Gas Cylinder $148 Other Parts* $100 Total = $8,925 *Other Parts: Pipes to connect components Fittings/Adapters Flashback Arrestors Valves 9/17/2018

Renewable Energy and Rainwater Availability 9/17/2018

Renewable Energies – Specifications and Analysis Sun – PV Cells Roof of the “Solar Shack” 45 Degree South array Wind – Wind Turbines 1.5kW Bergey wind turbine Precipitation – water collection Roof of solar shack is used to collect water 9/17/2018

PV Cells PV Cells have approx. 10% efficiency collecting the suns power Example: The sun produces 10kWh/m², we will collect 1kWh/m² NREL data collected from 1961-1990 National Renewable Energy Laboratory NREL’s data collection system accounted for location and angle of array 9/17/2018

PV Cells What about shading? Shading factor of 15% Total power from PV Cells: 13,740 kWh/year 9/17/2018

Bergey Wind Turbine Betz’s Equation for approximate monthly power: Power = Cp [(½)(air density)(wind speed)³(swept area)] Variables: Air density for Flagstaff, AZ Average wind speeds from wrcc.dri.edu Swept area of Bergey 1.5kW – 7m² 9/17/2018

Bergey Wind Turbine Total power from wind: 215 kWh/year Compare to Bergey information (based on annual average wind speed) 200 – 250 kWh/year 9/17/2018

Renewable Power Monthly Break-Down Solar accounts for 98.5% Wind accounts for 1.5% 9/17/2018

Battery / Power Demand Battery Bank – 6 Volts @ 460 Amp-hr Invert to and supply 120 VAC Electrical demand – Electrolyzer, compressor and sensor/control devices 9/17/2018

Precipitation Analysis Area of collection: Roof of “Solar Shack” Precipitation averages include over 30 years of data Evaporation/Snow Adjustment factor: 25% of precipitation lost Total water collection (for one year): 8,175 gallons of water 9/17/2018

Working Hours Total Team Hours: 346 hours Average teammate hours: 86.5 hours 9/17/2018

Bill of Materials System #1 System #2 $625 $19,802 $8,925 $29,352 $625 Water Collection and Treatment $625 Electrolyzer $19,802 Hydrogen Storage $8,925 Total: $29,352 Water Collection and Treatment $625 Electrolyzer $6,325 Hydrogen Storage $8,925 Total: $15,875 9/17/2018

Future Work… Detailed thermodynamic analysis Computer simulation Small demonstration model System maintenance manual Additional control system components 9/17/2018

Questions or Comments? 9/17/2018