1. 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

2. Presentation Outline
Introduction to Proton
Military Focus Areas in Contract Research
Backup Power – “Silent Camp”
Home Fueling
Future Work

3. 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.

4. Proton Capabilities Complete product manufacturing & testing
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
Laboratories
Government

5. Hydrogen Products Commercial Products Future Products S Series
HOGEN Hydrogen Generators TM
S Series
Fueling
H Series
Lab Gas Generators
Hydrogen Control
Systems
Renewable Energy
Storage
Backup Power GC
StableFlow TM

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

7. Forward Operating Bases: Problem Definition
Logistics of moving fuel can limit combat OPS
Operational issues with gen-sets 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

8. Backup Power System Concept Using High Pressure Electrolyzer

9. CERL Silent Camp® Phase I Program
Based on low pressure S-series design
10 cell stack, 0.1 ft2 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

10. CERL Silent Camp® Phase I Program
Army/CERL installation for Silent Camp energy storage demo
>1 year field data achieved

11. CERL Silent Camp® Phase 2 Program
Demonstrate 40 SCFH (2+ kg/day)
H2 Generation pressure of 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

12. “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 , “Hydrogen Generators Using Water Electrolysis Process – Part 2: Residential Applications”

13. Proton’s System Approach to Small Distributed Fueling Applications
High differential pressure, PEM electrolysis
Ambient pressure O2
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

14. Proton’s Home Fueling Pathways
H2 generation/compression
Current
HOGEN® HP
Electrolyzer
2,400 psi
2 kg/day
Indoor
Next Gen HP
Electrolyzer
2,400 psi
2 kg/day
Outdoor rated
Future
HP Electrolyzer
5,000 psi
1-2 kg/day
No Mechanical
Compression
UAV Fueling
5,000 psi
<1 kg/day
Near Term
HP Electrolyzer
+ Compressor
10,000 psi
2 kg/day
Timeline
2009
2010
2011

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

16. (Chiller and Dispenser not shown)
UAV Fueling Concept
H2 Production Rate: ≤ 94 g/hr
Generation pressure: 10,000 psi
H2 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)

17. 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

18. 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

19. Fueling Capacity - Scenarios

20. Fueling Capacity - Estimates

21. Conceptual Design

22. 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

23. Thank you!
Contact Info: Everett Anderson Tel 203/ Acknowledgements: Co-authors Sponsors