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

2. 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
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H2 Generation Systems --

3. Presentation Overview
Client description
Problem description
H2 Generation’s Deliverables
System Component Layout
Individual System Design
Conclusion
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4. The Client Dr. Thomas Acker Professor of Mechanical Engineering
Northern Arizona University
Coordinator of the Renewable Energies Resource Center
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5. 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
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6. 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.
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7. Additional Design Criteria
Hydrogen use in internal combustion
Purity of 99%
Hydrogen use in fuel cell technology
Purity of %
USCAR (United States Council for Automotive Research)
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8. H2 Generation Deliverables:
System design incorporating:
Specified Design
Thermodynamic analysis
Maintenance cycles
Simulation
Website
Proof of concept model:
Design and construct
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9. 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
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10. Design Budget Approximately $1000
Acquiring resource materials for use in design (books, software, etc.)
Document construction (paper, copies, etc.)
Model construction (electrolyzer, tubes, etc.)
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11. 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.
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12. 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.
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13. Water Collection And Treatment
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14. 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
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15. 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)
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16. Water Collection and Treatment
System Design
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17. 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
9/17/2018

18. 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
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19. 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: gal./day (winter)
1.58 gal./day (summer)
SolAqua
P.O. Box 4976
El Paso, Texas
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20. Water Collection and Treatment
“55 gallon Water Barrel”
Specifications
Capacity: 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
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21. 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
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22. 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
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23. Electrolyzer System Design
H2 Leak Detection
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24. 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 %
2 Internal combustion 99.9%
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25. System Design I Fuel Cell Implementation
Packard Hydrogen Generator B9800
Hydrogen purity at %
Solid polymer electrolyte
Inline valve for continuous water fill
Output pressure 58 psig, with 72 L/h of H2 production
Cost: $19,802.00
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26. 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 )
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27. System I Total Cost
Packard H2 Generator
$19,802.00
Total=
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28. System Design II Hydrogen for internal combustion system
3 PEM electrolyzers
(Polymer-electrolyte membrane)
2 Purification trains
Hydrogen leak detection
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29. 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
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30. 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: $ per unit
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31. 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
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32. Detection Specifications
Power: 9-15 V, 30mA max
Hydrogen detection: 0-10% in air
Explosion limits of H2 in are 4% to 74%
Automatic shutoff at selectable limits
Explosion proof cast aluminum
Cost: $1,408.00
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33. 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
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34. Hydrogen Storage
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35. 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.
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36. Hydrogen Storage
Necessary Components to compress hydrogen into a compressed gas cylinder:
Propane Tank
Gas Booster
Air Compressor
Compressed Gas Cylinder
Cyl-Tec, Inc.
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37. Hydrogen Storage
System Design
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38. 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
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39. 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
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40. 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
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41. 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.
9/17/2018

42. 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
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43. 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
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44. Renewable Energy and Rainwater Availability
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45. 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
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46. 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
National Renewable Energy Laboratory
NREL’s data collection system accounted for location and angle of array
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47. PV Cells What about shading? Shading factor of 15%
Total power from PV Cells:
13,740 kWh/year
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48. 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
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49. Bergey Wind Turbine Total power from wind: 215 kWh/year
Compare to Bergey information (based on annual average wind speed)
200 – 250 kWh/year
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50. Renewable Power Monthly Break-Down
Solar accounts for 98.5%
Wind accounts for 1.5%
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51. Battery / Power Demand Battery Bank – 6 Volts @ 460 Amp-hr
Invert to and supply 120 VAC
Electrical demand – Electrolyzer, compressor and sensor/control devices
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52. 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
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53. Working Hours Total Team Hours: 346 hours
Average teammate hours: hours
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54. 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

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

56. Questions or Comments?
9/17/2018