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Technological assessment of PEFC power


generation system using by-product hydrogen
produced from a caustic soda plant

Takahide Haneda a,b,*, Atsushi Akisawa b


a
Tokyo Gas Co., Ltd, Energy System Research Institute, 1-7-7, Suehiro-cho, Tsurumi-ku, Yokohama, Kanagawa,
Japan
b
Tokyo University of Agriculture and Technology, 2-24-16 Nakacho, Koganei, Tokyo, Japan

article info abstract

Article history: The potential of an energy system that comprises a hydrogen-fueled PEFC (H2-PEFC), a
Received 1 August 2016 boiler, and a gas turbine combined heat and power system (GT), using by-product hydrogen
Received in revised form produced from a caustic soda plant was evaluated using a mathematical model based on
4 October 2016 linear programming. Based on the optimization results to minimize the system cost by
Accepted 25 October 2016 optimizing the equipment capacity and energy balance of the energy system, the system
Available online xxx cost reduction effect and CO2 reduction effect were calculated in relation to the power
generation efficiency and the installation cost of the H2-PEFC. As a result, the conditions
Keywords: for the H2-PEFC where a system cost reduction could be achieved in the PEFC, boiler, and
PEFC GT system, compared with the boiler system, were clearly shown to be an initial cost lower
Energy system than 3500 $/kW or a power generation efficiency greater than 50%.
Gas turbine combined heat and © 2016 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.
power system
By-product hydrogen
Caustic soda plant
Linear programming

(salt solution) consuming huge amounts of electricity [3,4]; in


Introduction Japan the average electricity for each ton of NaOH produced is
2.5 MWh [5]. Considering the rising cost of electricity, the
Sodium hydroxide (NaOH) is one of the most widely used in- caustic soda industry needs a technological breakthrough to
dustrial chemicals, such as in the pulp, paper, alumina, decrease energy consumption [6].
textile, electroplating, detergent, and waste water industries Hydrogen is also produced as by-product along with NaOH
[1]. The global consumption of NaOH is approximately 80 in caustic soda plants and is often discarded as waste or used
million tons per year and set to expand at nearly 3% com- for heat production, except when a neighboring chemical
pound annual grows rate during 2016e2020 with Asia-Pacific plant can use the hydrogen as a chemical feedstock [7].
leading all regions with a 50% market share [2]. In caustic Generating electricity from the by-product hydrogen could
soda plants, NaOH is manufactured by the electrolysis of brine substantially reduce electricity costs of a caustic soda plant.

* Corresponding author. Tokyo Gas Co., Ltd, Energy System Research Institute, 1-7-7, Suehiro-cho, Tsurumi-ku, Yokohama, Kanagawa,
230-0045, Japan. Fax: þ81 45 500 8790.
E-mail address: haneda@tokyo-gas.co.jp (T. Haneda).
http://dx.doi.org/10.1016/j.ijhydene.2016.10.142
0360-3199/© 2016 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.

Please cite this article in press as: Haneda T, Akisawa A, Technological assessment of PEFC power generation system using by-product
hydrogen produced from a caustic soda plant, International Journal of Hydrogen Energy (2016), http://dx.doi.org/10.1016/
j.ijhydene.2016.10.142
2 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 6 ) 1 e1 0

Polymer electrolyte fuel cells (PEFC) is considered a


promising alternative energy conversion device and the Methods
best match to the hydrogen flow produced by caustic soda
plants because it has the highest power generation effi- To minimize the system cost of the energy system in a caustic
ciency and the best load following capability in the power soda plant, the optimum equipment capacity and energy
generator for the hydrogen fuel. These devices generate balance of the boiler, H2-PEFC, and GT was calculated based
water, heat, and electricity without emission of pollutants on linear programming.
via an electrochemical reaction of hydrogen as a fuel with
oxygen or air as an oxidant [8e10]. Residential PEFC Mathematical model
cogeneration systems were launched in 2009 [11e13], and
more than 150,000 units have been installed in the Japanese The following three energy system cases were constructed for
market as of 2015 [14]. Additionally, recent interest has the model for the technological assessment. Figs. 1e3 show
increased in the development of large-scale hydrogen- the configurations of these energy system cases, which are (a)
fueled PEFC, with increasing focus on the research and boiler system, (b) PEFC and boiler system, and (c) PEFC, boiler,
development of hydrogen energy as a renewable resource to and GT system. Table 1 shows the definitions of the symbols
eliminate dependence on fossil fuels [10,15,16]. To our used in Figs. 1e3.
Knowledge, Ballard and Nedstack currently have been
focusing on hydrogen that is vented into the atmosphere (a) Boiler system
and generating electricity from wasted hydrogen could
substantially reduce electricity costs of a caustic soda plant. The boiler system represents the conventional system and
Ballard Power Systems has announced the installation at is composed of a boiler. The boiler generates all its steam for
the First Energy Generation Corp's Eastlake Plant in Ohio the plant from natural gas and by-product hydrogen produced
[17] and a 1 MW PEFC unit for wasted hydrogen at a bleach from the plant.
plant in California [17]. NedStack Fuel Cell Technology has
put a 1 MW PEFC Power Plant for wasted hydrogen that is (b) PEFC and boiler system
vented into the atmosphere into operation at Solvay, in
2011 [17]. However, the amount of wasted hydrogen has The PEFC and boiler system is composed of a H2-PEFC and a
been decreasing annually [7] and is much smaller than boiler. The H2-PEFC generates power and hot water from
hydrogen used for heat production that is essential to heat by-product hydrogen produced from the plant. The boiler
fluids, particularly to achieve NaOH concentrations of 50% generates all its steam for the plant from natural gas and the
[7]; in Japan, the fraction of the wasted hydrogen is 5% remaining by-product hydrogen produced from the plant that
while 47% is used for heat production [18]. Therefore, we is not consumed by the H2-PEFC.
have focused on hydrogen used for heat production and
have proposed the energy system with high efficiency (c) PEFC, boiler, and GT system
conversion for the hydrogen. The concept of the energy
system is that by supplying natural gas to the plant instead The PEFC, boiler, and GT system is composed of a H2-PEFC,
of hydrogen for heat production and using the hydrogen a boiler, and a GT. The H2-PEFC generates power and hot
that has the high quality with about 1 ppm of NaOH as the water from by-product hydrogen produced from the plant.
only contaminant, for hydrogen-fueled PEFC the exergy of The GT generates power and steam for the plant from natural
the plant can be vastly improved and the plant's energy gas and the remaining by-product hydrogen produced from
consumption and CO2 emissions can be dramatically the plant that is not consumed by the H2-PEFC. The boiler
reduced. The inferred global production of hydrogen as a generates all remaining steam for the plant from natural gas
by-product from caustic soda plants in 2010 is 16 billion and any remaining by-product hydrogen from the plant that is
Nm3 [7]. High efficiency conversion (50% (LHV)) of this not consumed by the H2-PEFC or the GT.
quantity of hydrogen could yield around 240 TWh of elec-
tricity. At present, the fraction of hydrogen used for heat
Constraints
production could provide 110 TWh of electricity, which is
8% of the plant's electricity consumption.
The output and energy balance of the boiler, H2-PEFC, and GT
The objective of this study was to use a mathematical model
were set to satisfy Eqs. (1)e(10), which means all steam was
to evaluate the potential of an energy system that comprises a
generated in the energy system from natural gas and by-
hydrogen-fueled PEFC (H2-PEFC), a boiler, and a gas turbine
product hydrogen produced from the plant. Hot water gener-
combined heat and power system (GT), using by-product
ated by the PEFC supplied the boiler with its water supply for
hydrogen produced from a caustic soda plant to save energy
preheating, and any remaining hot water was set as waste
and CO2 emissions. The scope of this work was to optimize the
heat. The mixing rates of by-product hydrogen and natural
equipment capacity and energy balance to minimize the sys-
gas for the boiler and GT were set under 50%.
tem cost, including the energy cost, maintenance cost and the
 
amortization cost of the energy system. Based on the optimi- f3 ðtÞ ¼ e1  f1 ðtÞ þ f4 ðtÞ þ h3 ðtÞ (1)
zation results, the system cost reduction effect and CO2
reduction effect were calculated in relation to the power gen- f5 ðtÞ þ f6 ðtÞ ¼ e2  h4 ðtÞ (2)
eration efficiency and the installation cost of the H2-PEFC.

Please cite this article in press as: Haneda T, Akisawa A, Technological assessment of PEFC power generation system using by-product
hydrogen produced from a caustic soda plant, International Journal of Hydrogen Energy (2016), http://dx.doi.org/10.1016/
j.ijhydene.2016.10.142
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 6 ) 1 e1 0 3

Fig. 1 e Configuration of the boiler system.

Fig. 2 e Configuration of the PEFC and boiler system.

f7 ðtÞ ¼ e3  h4 ðtÞ (3) d2 ðtÞS f7 ðtÞ þ f9 ðtÞ (7)

 
f8 ðtÞ ¼ e4  f2 ðtÞ þ h5 ðtÞ (4) h1 ðtÞ ¼ h2 ðtÞ þ h3 ðtÞ þ h4 ðtÞ þ h5 ðtÞ (8)

 
f9 ðtÞ ¼ e5  f2 ðtÞ þ h5 ðtÞ (5) f1 ðtÞSh3 ðtÞ (9)

d1 ðtÞ&f3 ðtÞ þ f8 ðtÞ (6) f2 ðtÞSh5 ðtÞ (10)

Please cite this article in press as: Haneda T, Akisawa A, Technological assessment of PEFC power generation system using by-product
hydrogen produced from a caustic soda plant, International Journal of Hydrogen Energy (2016), http://dx.doi.org/10.1016/
j.ijhydene.2016.10.142
4 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 6 ) 1 e1 0

Fig. 3 e Configuration of the PEFC, boiler, and GT system.

Objective function generated by the H2-PEFC and GT, and is defined as a negative
amount when consumed in the plant.
The objective function was designed to minimize the system CO2 emission coefficient for electric power (o1) was set to
cost (CT) of the energy system, including the energy cost and 0.36 ton-CO2/MWh that is total average CO2 emission coeffi-
amortization cost, which is defined in Eqs. (11)e(14). The en- cient in Japan in 2010 and CO2 emission coefficient for natural
ergy cost derives from the power generated by the H2-PEFC gas (o2) was set to 0.183 ton-CO2/MWh.
and GT, and is defined as a negative amount when
consumed in the plant. CD ¼ CD1 þ CD2  CD3  CD4 (15)

CT ¼ CT1 þ CT2 þ CT3 (11) X 


CD1 ¼ o2  f1 ðtÞ 1000 (16)
X      
CT1 ¼ c2  f1 ðtÞ þ f2 ðtÞ  c1  f7 ðtÞ þ f9 ðtÞ (12) X 
CD2 ¼ o2  f2 ðtÞ 1000 (17)
 
CT2 ¼ c3  p2 þ c4  p3 n (13) X 
CD3 ¼ o1  f7 ðtÞ 1000 (18)
X 
CT3 ¼ c5  f9 ðtÞ (14) X 
CD4 ¼ o1  f9 ðtÞ 1000 (19)
Calculation conditions
Tables 2e4 show the specifications for the boiler, H2-PEFC,
The installation target of the energy system was a middle- and GT. It was assumed that a boiler with an output of
sized caustic soda plant with a production of 100,000 ton/ 14.0 MW, which is able to generate all the steam (300,000 GJ/
year, a steam consumption of 3000 MJ/ton-NaOH, an electricity year) at 180  C [18] required for the plant, had been already
consumption of 2.5 MWh and 1500 MJ/ton-NaOH of by-product installed in the plant. The heat generation efficiency (e2) of the
hydrogen supplied to the boiler [14]. Additionally, the plant H2-PEFC which generates hot water at 60  C [19] was set as
operation time (t) was assumed to be 6000 h/year (20 h/day, 95%  e3, the power generation efficiency (e3) was set as a
300 days/year), and the steam and by-product hydrogen pro- parameter under 65%, the initial cost (c3) was set as parameter
duction were assumed to remain constant during plant oper- under 5000 $/kW, and the maintenance cost was included in
ation. The installation of the energy system at the plant was set the initial cost (c3).
to follow the steam and by-product hydrogen production of the The GT parameters were set to allow comparisons of
plant. Investment payback time (n) was set to 10 years to match models with different specifications. The initial cost (c4) of
the expected life of the Residential PEFC cogeneration systems the GT was set to 2000 $/kW [20], the same cost as that of
[19]. Exchange rate was set to 100 JPY to the dollar ($). the gas engine combined heat and power system, because it
CO2 emissions (CD) were defined with Eqs. (15)e(19) and was assumed that a hydrogen and natural gas fueled GT
CO2 reduction effect was analyzed in the calculated optimum would be more expensive than a standard GT, which costs
energy system. CO2 emissions derive from the power 1500 $/kW [20], while IHI has a good track record in

Please cite this article in press as: Haneda T, Akisawa A, Technological assessment of PEFC power generation system using by-product
hydrogen produced from a caustic soda plant, International Journal of Hydrogen Energy (2016), http://dx.doi.org/10.1016/
j.ijhydene.2016.10.142
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 6 ) 1 e1 0 5

Table 1 e Definition of symbols.


Symbol Unit Definition
c1 $/kWh Specific and base cost of power grid
c2 $/kWh Specific and base cost of natural gas
c3 $/kWh Investment cost per capacity by PEFC
c4 $/kWh Investment cost per capacity by GT
c5 $/kWh Maintenance cost per power generated by GT
CD ton-CO2/year Total CO2 emissions
CD1 ton-CO2/year CO2 emissions for boiler
CD2 ton-CO2/year CO2 emissions for GT
CD3 ton-CO2/year CO2 emissions derived from power generated by PEFC
CD4 ton-CO2/year CO2 emissions derived from power generated by GT
CT $/year Total cost
CT1 $/year Operation cost
CT2 $/year Investment cost
CT3 $/year Maintenance cost
d1(t) kWh Heat demand
d2(t) kWh Power demand
e1 % Heat generation efficiency of boiler
e2 % Heat generation efficiency of PEFC
e3 % Power generation efficiency of PEFC
e4 % Heat generation efficiency of GT
e5 % Power generation efficiency of GT
f1(t) kWh Natural gas for boiler
f2(t) kWh Natural gas for GT
f3(t) kWh Heat generated by boiler
f4(t) kWh Heat generated by PEFC
f5(t) kWh Heat for boiler
f6(t) kWh Waste heat
f7(t) kWh Power generated by PEFC
f8(t) kWh Heat generated by GT
f9(t) kWh Power generated by GT
h1(t) kWh Hydrogen generated by electrolyzer
h2(t) kWh Waste hydrogen
h3(t) kWh Hydrogen for boiler
h4(t) kWh Hydrogen for PEFC
h5(t) kWh Hydrogen for GT
n Year Payout time
o1 ton-CO2/MWh CO2 emissions coefficient of power grid
o2 ton-CO2/MWh CO2 emissions coefficient of natural gas
p1 kW Capacity of boiler
p2 kW Capacity of PEFC
p3 kW Capacity of GT
t Hour Operation time

Table 4 e Specifications for the GT [20, 23].


Table 2 e Specifications for the boiler [22].
Model Output e4 e5 c4 c6
Output [kW/unit] e1 [%]
name [kW/unit] [%] [%] [$/kW] [$/kWh]
14,000 95.0
PUC30D 2910 58.1 23.7 2000 0.02
PUC60D 5360 55.6 29.2 2000 0.02
PUC80D 7610 52.1 33.1 2000 0.02
producing hydrogen and natural gas fueled GTs [21]. Table 5
shows the electric power price plan of the Tokyo Electric
gas price plan of Tokyo Gas, which was used as a calculation
Company, which was used as a calculation condition and
condition and adapted and estimated for industrial cus-
adapted for industrial customers based on the electric
tomers based on the natural gas consumption of the energy
power consumption of the plant. Table 6 shows the natural
system.

Table 3 e Specifications for the H2-PEFC. Table 5 e Electric power prices [24].
Output [kW/unit] e2 [%] e3 [%] c3 [$/kW] Specific cost [$/kWh] Base cost [$/kWh] c1 [$/kWh]
100 95  e3 c.40e65 c.1500e5000 0.1371 0.0226 0.1597

Please cite this article in press as: Haneda T, Akisawa A, Technological assessment of PEFC power generation system using by-product
hydrogen produced from a caustic soda plant, International Journal of Hydrogen Energy (2016), http://dx.doi.org/10.1016/
j.ijhydene.2016.10.142
6 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 6 ) 1 e1 0

Table 6 e Natural gas prices [25].


Natural gas consumption c2 [$/kWh]
[MWh/year]
5625e11,249 0.0820
11,250e22,499 0.0796
22,500e44,999 0.0764
45,000e67,499 0.0729
67,500e89,999 0.0711*Estimated price
90,000e 0.0693*Estimated price

Results

PEFC and boiler system


Fig. 5 e Correlations between the system cost and the
initial cost (c3) for different power generation efficiencies
The optimal solution for the equipment capacity and energy
(e3) of the H2-PEFC, under the optimal conditions for the
balance in the PEFC and boiler system was calculated using
PEFC and boiler system.
the power generation efficiency (e3) of the H2-PEFC based on
linear programming, using the objective function to minimize
the system cost. The resulting optimal solution showed that
the steam required for the plant could be completely provided system cost reduction could be achieved in the PEFC and
by the boiler (13.89 MW) using natural gas and by-product boiler system, compared with the boiler system, are clearly
hydrogen, and the optimal by-product hydrogen supply for shown to be an initial cost (c3) lower than 3000 $/kW or a
the boiler and H2-PEFC was calculated based on the power power generation efficiency (e3) greater than 55%.
generation efficiency (e3) of the H2-PEFC. The capacity (p2) of The CO2 reduction rate and amount, as compared with the
the H2-PEFC under the optimal conditions for the PEFC and boiler system and using the optimal conditions for the PEFC
boiler system is shown in Fig. 4. We define the solution with a and boiler system, are shown in Fig. 6. The CO2 reduction rate
large capacity for the H2-PEFC (p2) as the “low cost case,” and and amount in the PEFC and boiler system, compared with the
the solution with a small capacity (p2) for the H2-PEFC as the boiler system, increases depending on the power generation
“high cost case” in Fig. 4. efficiency (e3) of the H2-PEFC, while there is no CO2 reduction
The system cost reduction rate, as compared with the effect in the PEFC and boiler system for the “high cost case”
boiler system and using the optimal conditions for the PEFC when the power generation efficiency (e3) of the H2-PEFC is
and boiler system, is shown in Fig. 5. In the case where the less than 55%.
system cost reduction was 0%, the capacity (p2) of the H2-PEFC
was 0 kW because its installation provided no advantage to PEFC, boiler, and GT system
the system. Generally, the system cost reduction for the PEFC
and boiler system, when compared with the boiler system, The optimal solution for the equipment capacity and energy
increases depending on the power generation efficiency (e3) of balance in the PEFC, boiler, and GT system was calculated
the H2-PEFC. The conditions of the H2-PEFC for which a using the power generation efficiency (e3) of the H2-PEFC

Fig. 4 e Correlations between the capacity (p2) and the Fig. 6 e Correlation between CO2 reduction rate or CO2
initial cost (c3) for different power generation efficiencies reduction amount and the power generation efficiency (e3)
(e3) of the H2-PEFC, under the optimal conditions for the of the H2-PEFC, under the optimal conditions for the PEFC
PEFC and boiler system. and boiler system.

Please cite this article in press as: Haneda T, Akisawa A, Technological assessment of PEFC power generation system using by-product
hydrogen produced from a caustic soda plant, International Journal of Hydrogen Energy (2016), http://dx.doi.org/10.1016/
j.ijhydene.2016.10.142
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 6 ) 1 e1 0 7

based on linear programming, using the objective function to


minimize the system cost. The resulting optimal solution for
the PEFC, boiler, and GT system showed that the steam
required for the plant could be completely provided by a
PUC80D unit (7.61 MW) using natural gas and by-product
hydrogen; this configuration produces the highest power
generation efficiency among all the GT and boiler (1.91 MW)
combinations using natural gas and by-product hydrogen,
regardless of the power generation efficiency of H2-PEFC. The
by-product hydrogen supply for the H2-PEFC and GT was
calculated based on the power generation efficiency (e3) of the
H2-PEFC and the capacity (p2) of the H2-PEFC under the
optimal conditions for the PEFC, boiler, and GT system, as
shown in Fig. 7. The H2-PEFC was installed at the plant
regardless of the initial cost (c3) and the power generation Fig. 8 e Correlations between the system cost and the
efficiency (e3) of the H2-PEFC. The capacity (p2) of the H2-PEFC initial cost (c3) for different power generation efficiencies
is very small, and the installation provides little advantage to (e3) of the H2-PEFC, under the optimal conditions for the
the system when the power generation efficiency (e3) of the PEFC, boiler, and GT system.
H2-PEFC was less than 50%. When the power generation effi-
ciency (e3) of the H2-PEFC is greater than 50%, there are two
cases for the capacity (p2) of the H2-PEFC, depending on the shown in Fig. 9. The CO2 reduction rate and amount in the
power generation efficiency (e3) and initial cost (c3) of the H2- PEFC, GT, and boiler system, compared with the boiler system,
PEFC: we define the solution with a large capacity for the H2- drastically increases for the “low cost case” when the power
generation efficiency (e3) of the H2-PEFC is greater than 50%,
PEFC (p2) as the “low cost case,” and the solution with a small
while the CO2 reduction in the PEFC, GT, and boiler system,
capacity (p2) for the H2-PEFC as the “high cost case” in Fig. 7.
compared with the boiler system, slightly increases depend-
The system cost reduction rate, as compared with the
ing on the power generation efficiency (e3) of the H2-PEFC for
boiler system and under the optimal conditions for the PEFC,
boiler, and GT system, is shown in Fig. 8. The results show that the “high cost case”, or when the power generation efficiency
the system cost reduction of the PEFC, boiler, and GT system (e3) of the H2-PEFC is less than 50% for the “low cost case.”
compared with the boiler system, almost depends on the ef-
fect of GT because the capacity and advantage of the H2-PEFC
are small when the power generation efficiency (e3) of the H2- Discussions
PEFC is less than 50% and initial cost (c3) is higher than 3500 $/
kW. On the other hand, additional system cost reductions can PEFC and boiler system
be achieved using the H2-PEFC in addition to the GT when the
power generation efficiency (e3) of the H2-PEFC is greater than The correlations between the energy balances and the power
50% and the initial cost is lower than 3500 $/kW. generation efficiency (e3) of the H2-PEFC in the PEFC and boiler
The CO2 reduction rate and amount in the PEFC, GT, and system, is shown in Fig. 10. The results show that the by-
boiler system, as compared with the boiler system and under product hydrogen and natural gas supplies remain almost
the optimal conditions for the PEFC, boiler, and GT system, are constant, while there is no by-product hydrogen supply to the

Fig. 7 e Correlations between the capacity (p2) and the Fig. 9 e Correlation between CO2 reduction rate or CO2
initial cost (c3) for different power generation efficiencies reduction amount and the power generation efficiency (e3)
(e3) of the H2-PEFC, under the optimal conditions for the of the H2-PEFC, under the optimal conditions for the PEFC,
PEFC, boiler, and GT system. boiler, and GT system.

Please cite this article in press as: Haneda T, Akisawa A, Technological assessment of PEFC power generation system using by-product
hydrogen produced from a caustic soda plant, International Journal of Hydrogen Energy (2016), http://dx.doi.org/10.1016/
j.ijhydene.2016.10.142
8 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 6 ) 1 e1 0

H2-PEFC in the “high cost case” when the power generation


efficiency (e3) of the H2-PEFC is less than 55%. This is because
the by-product hydrogen supply for the H2-PEFC is deter-
mined by minimizing the waste heat (f6(t)), balancing the hot
water generated by the H2-PEFC with the preheating water for
the boiler, and to exceed a natural gas supply of 67,500 MWh,
which is the threshold between 0.0729 $/kWh and 0.0711 $/
kWh based on the natural gas price plan used in this study.
Additionally, the by-product hydrogen supply to the H2-PEFC
increases rapidly when the power generation efficiency (e3)
is greater than 55%, compared with the case when the power
generation efficiency is less than 55%. This is considered to be
due to the fact that almost all the by-product hydrogen is
supplied to the H2-PEFC, because the total energy efficiency of
the H2-PEFC is much larger than that of the boiler, regardless
of the balance between the hot water generated by the H2-
PEFC and the preheating water for the boiler. Fig. 11 e Correlations between the energy balances and the
power generation efficiency (e3) of the H2-PEFC of the PEFC,
PEFC, boiler, and GT system boiler, and GT system.

The correlations between the energy balances and the power


generation efficiency (e3) of the H2-PEFC in the PEFC, boiler,
shown in Fig. 12 for a power generation efficiency (e3) for the
and GT system, are shown in Fig. 11. The results show that the
H2-PEFC of 55%; this efficiency level has already been
by-product hydrogen and natural gas supplies are almost
accomplished by Toshiba Fuel cell Power System [26], and an
constant when the power generation efficiency (e3) of H2-PEFC
efficiency of 60% is considered a significant possibility in the
is less than 50%, for the same reasons as those given for the
future. The results show that the system cost reduction of the
PEFC and boiler system. The by-product hydrogen supply to
PEFC, boiler, and GT system is larger than that of the PEFC
the H2-PEFC increases rapidly when the power generation
and boiler system when the initial cost (c3) of the H2-PEFC is
efficiency is greater than 50% compared with when the power
high and the power generation efficiency (e3) of the H2-PEFC
generation efficiency is less than 50%. This is considered to be
is low. However, the system cost reduction of the PEFC,
due to the fact that almost all the by-product hydrogen is
boiler, and GT system is almost equal to that of the PEFC and
supplied to the H2-PEFC because the total energy efficiency of
boiler system when the initial cost (c3) of the H2-PEFC is low
the H2-PEFC is much larger than that of the GT, regardless of
and the power generation efficiency (e3) of the H2-PEFC is
the balance between the hot water generated by the H2-PEFC
high. Therefore, the PEFC, boiler, and GT system would be
and the preheating water for the boiler.
most suitable for a caustic soda plant until a low initial cost
and high efficiency can be realized for the H2-PEFC. On the
Comparison of the PEFC and boiler system with the PEFC,
other hand, a PEFC and boiler system would be most suitable
boiler, and GT system

A comparison of the system cost reduction rates for the PEFC


and boiler system and the PEFC, boiler, and GT system is

Fig. 10 e Correlations between the energy balances and the Fig. 12 e Comparison of the system cost reduction rates for
power generation efficiency (e3) of the H2-PEFC of the PEFC the PEFC and boiler system and the PEFC, boiler, and GT
and boiler system. system.

Please cite this article in press as: Haneda T, Akisawa A, Technological assessment of PEFC power generation system using by-product
hydrogen produced from a caustic soda plant, International Journal of Hydrogen Energy (2016), http://dx.doi.org/10.1016/
j.ijhydene.2016.10.142
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 6 ) 1 e1 0 9

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Please cite this article in press as: Haneda T, Akisawa A, Technological assessment of PEFC power generation system using by-product
hydrogen produced from a caustic soda plant, International Journal of Hydrogen Energy (2016), http://dx.doi.org/10.1016/
j.ijhydene.2016.10.142
10 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 6 ) 1 e1 0

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Please cite this article in press as: Haneda T, Akisawa A, Technological assessment of PEFC power generation system using by-product
hydrogen produced from a caustic soda plant, International Journal of Hydrogen Energy (2016), http://dx.doi.org/10.1016/
j.ijhydene.2016.10.142

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