1. Hawaii Hydrogen Power Park Kahua Ranch Severine Busquet, Mitch Ewan, Rick Rocheleau Hawaii Natural Energy Institute University of Hawaii NHA conference, April 1 st 2008

2. Hawaii Hydrogen Power Park Overview 2002Power Park was established, USDOE’s Technology Validation Program - Engineering and economic validation of pre- commercial hydrogen technologies Phase 1 (2002 - 2005) testing of major system components including a 12 kg/day Stuart TTR225 electrolyzer, and a 5 kW GenCore Plug Power fuel cell power system at its Hawaii Fuel Cell Test Facility in Honolulu. Phase 2 (2005 - 2007) development of wind-photovoltaic-electrolysis- hydrogen-fuel cell system at Kahua Ranch on the Big Island. Phase 3 (2008) Renewable hydrogen fueling infrastructure to provide hydrogen fuel for vehicles at Volcanoes National Park. $2.4 million project. Objectives: Integration and operation of renewable energy and commercial hydrogen technologies

3. OUTLINE 1.Kahua Ranch – Initial Village Power Plant 2.Renewable Energy – Hydrogen (RE-H 2 ) Power Park 1.Main components 2.Interface/Control System 3.First Experimental Results 3.Conclusions

4. Hydrogen Power Park – Phase 2 History - Kahua Ranch - Monty Richards 1985First Big Island Wind Farm 2.3 MW, connected to HELCO 1996PICHTR – Renewable-Hybrid-Village-Power demonstration plant – WT/PV/Battery/Diesel 360 kWh/d – Supply of Kahua Ranch (greenhouse, 11 homes, shops) 2006 Kahua Ranch switches to HELCO services (WT defect) 2007RE-Hydrogen Power Park – HNEI Establish a wind-photovoltaic-electrolysis & fuel cell test bed at Kahua Ranch on the Big Island HELCO: Hawaii ELectric Company PICHTR: Pacific International Center for High Technology Research

5. Village Power Plant 9 years of operation – 360 kWh/d Essential information on technology operation and maintenance* * Publications from J. B. Clarkson, P. R. Shackelford, L. A. Vega

6. RE-H 2 Power Park Remove fossil fuel consumption Test Facility for Stationary Hydrogen Storage System Separate Power & Energy Long term storage H2 supply Heat generation Grid

7. HNEI Tasks Design 48VDC bus bar power distribution system Common voltage for RE systems Hydrogen Power Park Phase 1 Test of Plug Power GenCore® 5kW Fuel Cell 1: Reliability, 2: Adequate power, 3: Low Bus Operation Initial system modifications (RE generators, batteries) Component selection (EL) Development of interface to control the overall installation Expandable Easily movable Visible/controllable via internet

8. Kahua Ranch Layout PV WT for pumping (out of order) Electric Room Office Battery Room Hydrogen Room Hydrogen Storage WT

9. Renewable Energy Primary Energy Sources 5.9kWp PV array: 20 ASE GP8 -295W Outback MPPT MX60 charge controllers Wind turbine Bergey Excel 7.5kW, 300Vac, 25A, 3 phases Outback VCS-10 RE generators -Rewire or reinstall -Transformer and/or regulator to produce 48VDC -Control based on battery voltage

10. Battery Room Trojan batteries Flooded lead acid 96 cells: 2 V – 1785 Ah 10 years old 343 kWh (max) Reconnected into 48 VDC 4 parallels strings of 24 cells Primary Storage System

11. Hydrogen Storage System Electrolyzer Eh! 2 kW, 48 VDC, 0.2 Nm 3 /h, 12 bar Excess RE energy Secondary Storage System Deficit of RE energy Deionized Water Tank Hydrogen Storage 9 bottles, 50 liters, 12 bar (175psi) 452 g of hydrogen or 5.4 Nm3 or 17.8 kWh (HHV) 2H 2 O  2H 2 + O 2 2H 2 + O 2  2H 2 O Fuel Cell Plug Power 5 kW, 48 VDC, 4 Nm 3 /h, 2 bar Air Water e¯e¯ O2O2 e¯ H2H2 H2H2 (FC: Low Bus Voltage Mode) PEM

12. Interface/Control System Functions: Connects all components electrically and mechanically Controls overall system Optimizes the energy management in the system. Visible and controllable from everywhere over internet. Design: Includes sensors, valves and relays connected to the Data Acquisition and Control System (DACS) for system control and data recording Safety analysis  Safety equipment  Fail-safe system

13. Interface/Control System – PID Four (4) assemblies Easily movable for shipping Main components

14. Transition from HFCTF to Kahua Freight to Kahua Ranch May 2007 6 m 3 (218cf) container Gas Panel # 2 Water Tank Hydrogen Bottle Electrolyzer Load Bank DACS FC Gas Panel # 1 & Electrical Panel #1 Nitrogen Bottle Electrical Panel #2 Global view of the test bench at HFCTF in Honolulu

15. Installation at Kahua Ranch – Hydrogen Room Breaker Box FC Spare FC HNEI Interface DACS EL LB Water Tank N2 Supply Gas Panel #2 H2 line

16. Storage Area - Safety Equipment Fire Sensor Gas Storage anchored and grounded Signs and Labels Firewall Battery Room Door Emergency Buttons (3) + Earthquake sensor + Hydrogen sensor (hydrogen room) + O 2 content in H 2 line Fence

17. Control System – DACS Microprocessor (FP-2000 National Instruments, Labview) Controller program One cycle per 250 ms – Safe Stand-alone controller – Still secures installation without Host computer Modifications allowed without stopping test bench - Configuration files (analog, digital, control) - Remote control Automatic Mode for Stand-alone system operation

18. Data Visualization and Remote Control Operation Mode Component Control Information Data History List of alarms Remote Control Information Control Buttons Safety Component Status Real Time Data Data visualization and control screen snapshot (Labview) Visible on the project web site

19. Kahua Ranch First Experimental Results Automatic mode First conclusions Eh! electrolyzer adapted design short warm up period (5 min) delivers hydrogen in only 3 min 36%* efficient (50.2% with new stack) Plug Power FC unit adequate design: low bus mode might be oversized / battery capacity. 34.3%* efficient Two MPPT controllers for PV parallel operation conflict Only one MPPT unit *Higher Heating Value basis

20. Kahua Ranch Results – Installation Load consumption PV prod WT Production (Added to PV prod) Battery Discharge Battery Charge Electrolyzer consumption FC Production FC Battery Charge 2-month Stand Alone Operation - hourly average kW

21. Kahua Ranch Conclusions Test Stand in place Integration and operation of renewable energy and commercial hydrogen technologies Interface/control system Safe stand-alone system operation Reliable and easy to use Expand the size of the system components Test stand expandable/modifiable Gas storage (2,000 gallons LP tank or 200 bar) Electrolyzer/FC units (200A, 3/8”) Variable battery size (4 parallel strings of 48VDC) Add any other components Change control strategy Different load configurations DC load Bank AC consumption (stand alone – Office with small house appliances) Grid connected capable Internet capable Remote control Education

22. Kahua Ranch Potential Use Test Facility for Stationary Hydrogen Storage System Test H 2 technology components Other FC units or electrolyzers ICE (heat + electricity) H 2 compressors H 2 supply to ranch ATVs – Eco-tourism Help in design of H 2 technology components Help in design of complete system (PV-EL, WT-EL, …) Simulation tool

23. Acknowledgments USDOE State of Hawaii: Department of Business Economic Development & Tourism (DBEDT) PICHTR: Luis Vega RES: Peter & Rolland Shakelford HNEI: Rick Rocheleau, Mitch Ewan HFCTF: Gunter, Jack, Keith, Mebs, Suzane, Mike, Chuck Administrative: Sandy, Michele, Grace, David… Kahua Ranch: Monty, John & Tim Richards, Don, paniolos…

24. Mahalo!