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ABSTRACT INTRODUCTION
This work discusses the development and the Reduction of primary energy consumption is
design of a Laboratory of Micro-Cogeneration at generally considered as one of the key options
Politecnico di Milano, devoted to small-scale to meet the ambitious EU Energy Roadmap
power generation with the main goals of testing target for the year 2050: a decarbonized energy
and improving the performance of systems that system which reduces its energy-related CO2
produce or utilize electric and thermal (hot emissions by over 80 percent compared to the
and/or cold) power in a very general sense, 1990 level [1,2]. A recent study shows how only
spanning from Combined Heat and Power the shift towards a highly-efficient electricity
(CHP) units to heaters, absorption chillers and supply system together with the maximum use
heat pumps, but also able to perform tests on of advanced technologies would allow to hit the
fuel processors and electrolyzers. The target; a substantial portion of the overall energy
laboratory features a supply of natural gas as savings may come from cogeneration and
well as H2 and O2 from a high pressure efficient heat generation [3].
electrolyzer and of CO, CO2 and N2 from bottles, Micro Combined Heat and Power (micro-CHP)
permitting to carry out experiments with is a well-known extension of the concept of
simulated synthesis fuels. The maximum cogeneration to small-scale applications.
allowable electrical power produced (exported to Several organizations (ranging from energy
the grid or to an electronic loadbank) or companies, gas distributors, independent power
consumed by the system under test is 100 kW; producers, and end users) are increasingly
maximum allowable thermal power is roughly looking for environmentally-friendly systems to
200 kW with variable temperature water circuits supply energy on a decentralized basis. Micro-
(from chilled water up to a 150°C at 8 bar CHP systems may fit well the energy demand of
superheated water loop). This work outlines also diverse types of buildings, such as single as well
the instruments used for on-line recording of as multi-family dwellings or small offices [4,5].
thermodynamic properties, emissions and
One of the central issues in the diffusion of
power, aiming at monitoring and reconstructing
micro-CHP systems is the possibility to rely on
mass and energy balances.
efficient, clean and reliable units, appropriately
One of the first experimental campaign has designed with respect to a defined load and able
been carried out on a CHP system based on to offer a reasonably fast payback time while
Polymer Electrolyte Membrane fuel cells (PEM), keeping best energy and environmental
a promising candidate for distributed CHP benefits. This requires, on one hand, the
thanks to low pollutant emissions and good development of innovative technologies to yield
efficiency, rapid startup and flexibility, although maximum efficiency and lowest emissions; on
affected by a rather complex fuel processing the other, it requires an accurate analysis and
section to provide the appropriate fuel to the verification of the CHP unit performances to
PEM. This work presents the experimental evaluate their potential. This is especially true
analysis of this 20 kW prototype PEM CHP considering that adequate CHP units should
system complete of fuel processor, fed with offer sound energy and emissions savings with
natural gas. The prototype is operated at LMC to respect to alternative power supplies, winning
characterize the processing section and the the continuous improvement of conventional
thermodynamic performances of the overall centralized power plants.
system. Despite its non-optimized layout, the
The small size precludes to the majority of
unit has shown encouraging total efficiency
micro-CHP prime movers on the market today
(76%) and primary energy saving index (6%).
the possibility to compete in terms of electrical
Keywords: MICROCOGENERATION, CHP, efficiency with large power plants; nevertheless,
TESTING, LABORATORY, FUEL CELL the landscape may change in the future with the
introduction of latest high efficiency fuel cell of these two fuels as well as any mixture
technologies [6,7]. However, it is already that simulates a synthesis gas.
realistic that micro-CHP systems can achieve trigeneration (CCHP) systems, which
significant primary energy savings, thanks to the produce electricity in addition to heating
possibility of operating in full cogeneration [4]. and / or cooling;
In the last years, the Group of Energy electrically or thermally-driven heat pumps,
Conversion Systems at Politecnico di Milano absorption refrigerators and boilers;
has dedicated an effort to set up a new hydrogen production appliances, including
Laboratory of Micro-cogeneration (LMC) [8]. The electrolyzers and fuel processing systems
laboratory is developed for testing CHP units for fuel cells.
fueled by natural gas, hydrogen, synthetic gas
or any mixtures of the previous. The laboratory
can test also trigeneration or Combined Cooling
Heating and Power (CCHP) systems using heat
pumps or thermal absorption chillers and
boilers, separated or integrated into complex
configurations [9]. The laboratory is designed to
simulate any plausible operating condition,
changing independently the water flow rates and
temperatures of hydraulic circuits, flow rate and
chemical composition of the fuel gas supply,
temperature of the ambient air and the electric
load. It aims, on one side, at characterizing a
micro-CHP in terms of realistic energy and Figure 1: The building hosting the LMC lab at
environmental performance, improving where Milano Bovisa campus of Politecnico di Milano.
necessary the control logic; secondly, it aims at
developing innovative systems and components LMC shares with the other adjacent laboratories
in the context of specific research projects. located in the same building (shown in Fig. 1) a
number of common infrastructures. They include
This work details the plant equipment and a gas distribution network and three water
laboratory instrument, the types of tests circuits (hot, cooled and chilled water, linked to a
specified, the pattern of the test circuit realized, dedicated centralized boiler, an evaporative
and finally an example of recent experiments tower and an electric chiller) which are the main
carried out on a PEM fuel cell CHP system. sources of heating/cooling used in the
PEM CHP systems are a promising candidate laboratory. Details are provided in Tab. 1.
for distributed cogeneration thanks to low The gas distribution network includes low
pollutant emissions and good efficiency, rapid pressure natural gas from local distributor
startup and flexibility, although they rely on a pipelines, as well as compressed natural gas
complex fuel processor to achieve a very low from a dedicated screw compressor (up to 30
carbon monoxide content to ensure long-term 3
Nm /h at 10 bar); other gases are stored in
performance of the PEM. Tests at LMC have bottles (CO, CO2, N2, H2, O2), with the additional
been developed to characterize the processing possibility of producing hydrogen and oxygen
section and the thermodynamic performances of through a dedicated electrolyzer. The latter
the overall system. features a hydrogen flow rate capacity of
3
THE LABORATORY 6 Nm /h at 30 bar, and a connection to a
3
storage system with 1 m pressurized vessels.
The laboratory basically consists of a set of
sensors and units adapt to reconstruct with high The laboratory is divided into three areas:
precision the mass and energy balances of the the test room, which will be described
unit under test, the operating parameters of the below (Fig. 2);
the control room (about 40 m , hosting the
2
relevant components and the corresponding
emissions. Therefore, it allows to measure flow control panel and data acquisition, as well
rates, chemical composition and thermodynamic as auxiliary instrumentations);
quantities of the flows featured by the process the plant area, placed above the ceiling of
developed in the system under test. the test room, hosting all the hydraulic
Experiments can be related to: circuits (Fig. 3), the test room air treatment
prime movers for CHP (based on internal unit and the electrical panels.
combustion reciprocating engines,
microturbines, fuel cells, Stirling engines),
fueled by natural gas, hydrogen, mixtures
Table 1: Common infrastructures at LMC c) Cooling generation tests. For compression
laboratory building. and absorption/adsorption chillers, with
electrical (up to 100 kW) or thermal (up to
Natural gas pipeline Condensation boiler
100 kW with pressurized water at 150°C)
connection and compressor (rated at 600 kW) and
3
(30 Nm /h at 10 bar); pump station for hot
feeding;
external deposit of gas water primary circuit d) Heat pump tests. For the compression and
bottles absorption heat pumps, with electrical or
thermal feeding (same as above), within a
Electrolyzer for H2 Cooling tower (503 kW max thermal power output of 200 kW;
3 3
production (6 Nm /h) and and 79 m /h) and pump e) Boiler tests. Up to 150°C at 8 bar and
3
O2 production (3 Nm /h) at station for cooled water 200 kW of useful thermal power output;
30 bar. primary circuit f) Trigeneration tests. For combined cooling,
Gas distribution network Chiller for chilled water heating and power systems (e.g. CHP +
(CH4, N2, CO2, CO, H2, O2, production (618 kW absorption chillers and/or heat pumps, with
compressed air); safety screw compressor) and mechanical or electrical drive, with
system for gas leakages pump station for cold separated or integrated units), according to
water primary circuit the CHP and cooling generation
specifications given above.
Starting from this requirement, the laboratory
has been developed according to a functional
diagram able to handle all the heating and
cooling flows involved by the above-mentioned
experiments. The simplified functional diagram,
with the main components of the hydraulic and
the air treatment plant is shown in Fig. 4. The
plant is developed starting from three primary
circuits for cooled, chilled and hot water, shown
on top of Fig. 4 (circuits 01, 02 and 03), that are
connected to the hydraulic loops of the
laboratory building (specified in Tab. 1, second
column). Three secondary circuits (circuit 11, 12
Figure 2. Test room with a prototype CHP plant and 13) interface the hydraulic plant with eight
(PEM FC system by ICI Caldaie SpA). flanges of possible connection with the system
under test. The latter are shown at the bottom of
Fig. 4 and are placed within the test room.
The secondary circuits, placed between the
primary loops and the system under test, allow
simulating the connection to a cogeneration or
trigeneration network. Depending on the type of
test listed above (cases a-f), they will be
controlled in different ways.
Heat recovery for cases a, b, d, e and f is
handled (i) at low temperature by circuit 12 (up
to 95°C) or (ii) at high temperature by circuit 11
(up to 150°C at 8 bar). In the first option, heat is
Figure 3. Hydraulic plants above the test room. dissipated by circuit 12 through the cooled water
primary loop (circuit 01 driven by the cooling
tower) and, if the cooled water temperature is
Experiments and functional layout too high, with the chilled water primary loop
LMC is designed to carry out the following type (circuit 02). In the second option all heat is
of experiments: dissipated by the cooled water loop (circuit 01).
a) Low temperature CHP tests. For units with For tests on absorption chillers or heat pumps
electrical power generation up to 100 kW (cases c and d), heating is produced by a
(grid connected or island mode) and hot 100 kW-electrical boiler that operates in circuit
water production up to 200 kW and 95°C. 11. The cooling power produced by the unit is
b) High temperature CHP tests. For units with recovered by circuit 13 to partially cool the
electrical power generation up to 100 kW condenser and absorber of the refrigerator; the
(grid connected or island mode) and remaining cooling duty being dissipated by
superheated hot water production up to circuit 12 with the same possibilities discussed
200 kW and 150°C at 8 bar. for the low temperature heat recovery case.
Finally, trigeneration tests (case f) require the provided that the AC unit is driven directly by the
simultaneous use of all circuits. An example prime mover heat production. On the other
could be an integrated system with a prime hand, it is also possible to run a test on a prime
mover (e.g. ICE, microturbine or fuel cell) and mover releasing heat both to high temperature
an Absorption Chiller (AC) that would be and low temperature heat recovery circuits,
connected to circuit 12 for low temperature heat where the first (circuit 11) would feed the
recovery and circuit 13 for cooling recovery, generator of the AC unit (bottom left of Fig. 4).
Circuit 02 Circuit 03
Circuit 11
Circuit 12
Boiler
Q Q
Circuit 13 Q - +
T T T T Air treatment unit PLANT AREA
Absorpt. Chiller High temp. heat Low temp. heat Cooling loop TEST ROOM
(AC) generator recovery recovery / AC cond. (evaporators)
Figure 4: Functional diagram of the hydraulic and air treatment circuits of the LMC laboratory.
The primary circuits are also used to feed an air The test room and control system
treatment unit (right side in Fig. 4) designed to 2
The test room is a 25 m cell where the
control between 10°C and 40°C an air flow rate hydraulic, electrical and gas circuits can be
3
of 2700 m /h. The unit can be expanded to connected to the unit under test.
include a humidity control section as well as a
A redundant leakage monitoring system on
refrigeration section to decrease the lower
flammable and toxic gases (CO, H2, O2, CH4),
bound of the temperature range. Air can be sent
together with a large capacity ventilation system
to the test room and/or directly to the inlet flange 3
(1200 Nm /h) and permanent external openings
of the unit under test. Air mass flow rate may be
ensures the possibility to comply with ATEX
measured by a Wilson grid.
standard requirements and carry out tests on
On the electrical side, electricity can be directly unclassified units and components. Exhaust
sent to the grid with a standard parallel gases can be sent to two external stacks (one of
connection or indirectly through an electronic which is designed for higher temperature or
loadbank that simulates island operations as potentially dangerous and corrosive gases).
well as grid distortions and failures. The bank
Within the cell the gas lines are organized with a
comprises two inverters, the first of which
measurement and control section (for pressure
emulates the electric load seen by the unit under
and flow rate) yielding the possibility of being
test, while the second reconverts the electrical
mixed for syngas simulation. In that case,
output of the previous in order to send the
dosing is controlled through a closed loop
electricity to the grid within requirements. Both
control based on periodical chemical analysis
inverters are rated at 100 kW in three-phase
through a micro-gaschromatographer.
configuration. The electric load is also capable
of being plugged to direct current storage This unit (Pollution VEGA-GC) includes two
systems to simulate hybrid setups. heated sampling systems able to handle up to
18 inlet lines, and is based on three columns In all tests the measured variables are mass
and a pre-concentrator for ppm-scale sulphur flow rate and temperature of the CHP water
analysis. The three columns are: entering and returning from the machine, where
CP-Sil5CB (length 8 m operating at 40°C the mass flow rate is controlled through the
and 90 kPa gauge) for CO2, ethane and pump speed and the inlet temperature is kept at
higher hydrocarbons; 30 to 45°C by the PID controller that manages
Molsieve5APLOT (length 20 m operating the cooling circuit. Below it is given a description
at 90°C and 180 kPa gauge) for H2, O2, of the main flow and energy measurements
N2, CH4 and CO. carried out during the test.
PoraPlotQ (length 10 m operating at 60°C Natural gas mass flow measurement is
and 110 kPa gauge) for H2S, H2O carried out with a low pressure drop
(steam), CO2 and natural gas odorizers. Bronkhorst IN-FLOW F106BZ hot wire
Data acquisition and process control is massic sensor with accuracy 1% of full
managed through a National Instruments scale upon calibration with pure methane.
Programmable Automation Controller (with more The reading is corrected for the actual
than 600 signals acquired for process composition of natural gas. When using the
management, supervision and measurements). high pressure natural gas pipeline, NG
A graphical user interface on a dedicated PC pressure can be reduced with a mechanical
allows plant management and control (Fig. 5). two stage regulator (Fiorentini Minireg FE6)
and measured through Bronkhorst IN-
PRESS P-502CI sensors. Temperature is
measured with TC type thermocouples.
Air is taken by the laboratory itself, which
can be controlled in temperature through a
dedicated air conditioning system.
Temperature and humidity at the inlet of the
unit under test are measured with Pt100
thermoresistances and a hygrometer Testo
H1.
Exhaust gas temperature is monitored with
a Pt100 thermoresistance. Exhaust gas
composition and emissions are monitored
Figure 5. A screenshot of the control system. after dehydratation (ABB Sample gas
cooler Advance SCC-C) via the micro-
TESTING A PEM FC CHP UNIT gaschromatograph and Testo 360 emission
control unit (with infrared and
In the first period of the laboratory activity some
electrochemical sensors) for CO, NO, NO2,
preliminary test campaigns were carried out on
SO2 and O2 content in the flue gas.
a CHP unit based on PEM fuel cells. The unit,
called Sidera 30 and manufactured by ICI Electrical power (active and reactive power,
Caldaie (partner of Politecnico di Milano in a exported or imported by the unit under test)
European Community FP7 project on the is measured by a power analyzer (Fluke
development of an advanced PEM CHP unit Norma 4000 with amperometer
[9]), is a prototype for distributed generation. It is transformers type Signaltec MCTS based
fuelled with natural gas that is transformed into a on Hall effect), with accuracy ±0.1% in all
hydrogen-rich syngas, which feeds the fuel cell, the relevant power range.
by a fuel processor (see the simplified system Water mass flow rate is measured by
diagram in Fig. 6) based on a steam reformer Coriolis sensors (Emerson Micromotion
with shift reactors and a section for CO Elite CMF100) with accuracy of ±0.1% of
abatement through preferential oxidation [10]. reading; pressure drop is measured by a
differential sensor (Emerson Rosemount
Heat recovery allows producing 60°C hot water 2051CF). Water temperature at inlet/outlet
by cooling the FC and the fuel processor. After of the unit under test is controlled by a PID
installation at the laboratory (Fig. 2), the unit has loop and measured with Pt100
been tested to verify the general energy thermoresistances. Water condensation
balances and emissions according to a research from the flue gases may be measured by a
project [11], and to support the development of weight scale (Bel Mark 1700) connected to
internal components (in particular the reactors the data acquisition system.
that make up the fuel processors, the PEM cell
stacks and the related heat exchangers circuit
for heat recovery) for next prototype evolutions.
Table 2. Main averaged measurements.