NREL Wind to Hydrogen Project:

Renewable Hydrogen Production

for Energy Storage & Transportation

NREL
Hydrogen Technologies
and Systems Center

Todd Ramsden,
Kevin Harrison,
Darlene Steward

November 16, 2009

NREL/PR-560-47432

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
NREL Wind2H2 RD&D Project

• The National Renewable Energy

Laboratory in partnership with
Xcel Energy and DOE has
designed, operates, and
continues to perform testing on
the wind-to-hydrogen (Wind2H2)
project at the National Wind
Technology Center in Boulder

• The Wind2H2 project integrates

wind turbines, PV arrays and
electrolyzers to produce from
renewable energy

National Renewable Energy Laboratory 2 Innovation for Our Energy Future

 Sustainable Paths to Hydrogen

Solar Energy

Biomass
Heat

Mechanical Energy

Thermo-
Electricity Chemical &
Biological
Conversion
Thermolysis Electrolysis Photolysis

Hydrogen

National Renewable Energy Laboratory 3 Innovation for Our Energy Future

Hydrogen Potential from Sustainable Resources

Wind Biomass

Solar

National Renewable Energy Laboratory 4 Innovation for Our Energy Future

20% Wind Energy by 2030 Scenario

300
Offshore
Cumulative Installed Capacity (GW)

Land-based
250

200

150

100

50
2008
0
2000 2006 2012 2018 2024 2030

National Renewable Energy Laboratory 5 Innovation for Our Energy Future

How Much Wind is Available in the U.S.?

160
Onshore
Class 7
Offshore
Class 7
10% of Existing
140 Class 6 Class 6 Transmission Capacity
Levelized Cost of Energy, $/MWh

Class 5 Class 5 Available to Wind

120 Class 4 Class 4

Class 3 Class 3

100
20% Goal
80

60

40

20

0
- 200 400 600 800 1,000
Quantity Available, GW
2010 Costs w/o PTC, $1,600/MW-mile, w/o Integration costs Source: Black & Veatch/NREL

National Renewable Energy Laboratory 6 Innovation for Our Energy Future

Technology Challenges to Meet 20% Goal
• Massive growth in installations
– 8 GW installed in 2008
– ~29 GW total as of 2009
– Over 300GW by 2030
• Widely distributed across the
nation
– Many high wind sites
– Substantial installation in
moderate resource areas
– Some offshore is needed
• Performance is critical
– Capital cost
– Capacity Factor
– O&M
• Every 1 ¢/kWh of cost reduction
saves the nation over $10 billion
per year at 20% penetration
National Renewable Energy Laboratory 7 Innovation for Our Energy Future
Wind2H2 Project – Overall Goal

• Provide RD&D to help DOE Challenges

• Reduce capital costs of electrolysis
achieve it cost target for hydrogen system through improved designs and
production from wind-based water lower cost materials
• Develop low-cost hydrogen
electrolysis of $4.80/gge by 2012 production from electrolysis through
and to <$3.00/gge by 2017 integration with renewable electricity
sources
• Develop strategies for low cost
hydrogen production from electrolysis
through utility coordination

National Renewable Energy Laboratory 8 Innovation for Our Energy Future

Wind2H2 Project – Main Objectives
• Research the cost and capability of “time
shifting” wind and PV energy through utility-
scale hydrogen-based energy storage
• Research optimal wind/hydrogen through
systems engineering
• Characterize and control wind turbine/PV
and H2-producing stack
• Evaluate synergies from co-production of
electricity and hydrogen
• Compare response and performance of
alkaline and PEM electrolyzer technologies
• Realize efficiency gains though simplified
and integrated power controllers
• Working towards ‘ideal’ wind to hydrogen
– Simplifying PE, common controls, closely
coupling wind input to stack, electricity
regulation
National Renewable Energy Laboratory 9 Innovation for Our Energy Future
 Wind2H2 System Operating Modes

National Renewable Energy Laboratory 10 Innovation for Our Energy Future

 PV Configuration Testing

100%

Direct connect versus various input voltages (Ein) through power controller

65% -
90%

National Renewable Energy Laboratory 11 Innovation for Our Energy Future

 PV Powered Electrolysis
• Onboard power electronics account for 15 to 30% of
the overall electrolyzer system cost
• Minimize redundant components
• Test data illustrates improvement in energy capture
to stack when using MPPT power electronics
• Testing showed a 10% – 20% increase in energy
capture

4000 MPPT power

electronics
E-130 connected
through MPPT
3500 power electronics

3000

2500
Stack Power [W]

2000
Direct connect
E-120 direct
connect to PV
1500

1000

500

0
9:18 9:38 9:59 10:19 10:39 10:59 11:19 11:39 11:59
Time of Day

National Renewable Energy Laboratory 12 Innovation for Our Energy Future

 10kW Wind Turbine Powered Electrolysis
• Initial tests with third generation power electronics, wind speed
measurement and control algorithm indicate further improved energy
capture of wind electricity into hydrogen production

14000

12000 Available
= Preliminary results wind power

showing increased energy

10000
capture with new TSR
algorithm. Algorithm is Planned increased
currently being tuned for energy capture from
Power (Watts)

8000
stability. Gen 2 to Gen 3

6000

Increased energy
capture from Gen 1
4000
to Gen 2

2000

Gen 2 – DC Power Gen 1 – DC Power

0
0 5 10 15 20 25 30 35 40
Wind Speed (MPH)

National Renewable Energy Laboratory 13 Innovation for Our Energy Future

 100kW Wind Turbine Powered Electrolysis

• Instrumented power signal from

Grid AC
100 kW wind turbine to drive 33
kW alkaline stack current to follow 100 kW
Powe
r Data
power available from turbine Wind
Varying Stack
Turbine
Current

260 5.5
Stack Current [A]
240 5
H2 Flow [Nm^3/hr]
220
4.5
200

Hydrogen Flow [Nm^3

4
180
Stack Current [

160 3.5
140 3
120 2.5
100 2
80
1.5
60
1
40
20 0.5
0 0
10:43

10:43

10:43

10:43

10:43

10:43

10:44

10:44

10:44

10:44

10:44

10:44

10:45
Time

National Renewable Energy Laboratory 14 Innovation for Our Energy Future

 Electrolyzer System Efficiency
• Wind2H2 system used to assess electrolyzer performance
• Stack and system efficiency of alkaline (33 kW stack, 40 kW system)
and PEM-based (6 kW stack, 7 kW system) measured

Efficiency PEM Electrolyzer Alkaline Electrolyzer

LHV HHV LHV HHV

Stack Efficiency

Low Current 80% (5A) 95% (5A) 78% (30A) 92% (30A)
Rated Current 63% (135A) 75% (135A) 59% (220A) 70% (220A)

System Efficiency

Low Current 0% (15A) 0% (15A) 0% (35A) 0% (35A)

Rated Current 49% (135A) 57% (135A) 35% (220A) 41% (220A)

National Renewable Energy Laboratory 15 Innovation for Our Energy Future

 Cost Analysis

Capital Component (uninstalled)

Baseline Optimized • Cost analysis performed based
System System
1.5 MW Wind Turbine
on NREL’s power electronics
Rotor $248,000 $248,000
optimization and testing and
Drive Train $1,280,000 $1,180,000 on our electrolyzer cost
including power
$100,000 $0
analysis study
electronics
Control System $10,000 $10,000
• Large centralized system
Tower $184,000 $184,000
capable of 50,000 kg per day
Balance of Station $262,000 $262,000 production
2.33 MW Electrolyzer $1,570,000 $1,350,000 • Optimized power conversion
including power
electronics
$220,000 $0 system due to a closer
New Power Electronics Interface $0 $70,000
coupling of the wind turbine to
Resulting Hydrogen Cost ($/kg) $6.25 $5.83 the electrolyzer stack can
reduce the total cost of
hydrogen by 7%.

National Renewable Energy Laboratory 16 Innovation for Our Energy Future

 350 bar Vehicle Fueling System

• Outdoor rated compressor

• 400 bar tank (18 kg)
• 350 bar non-communication fill
dispenser
• 1.8 kg (110 mile range) Mercedes-
Benz FC vehicle

National Renewable Energy Laboratory 17 Innovation for Our Energy Future

 Key Findings from Wind2H2 RD&D

System Efficiency (HHV): At rated stack current…

– The PEM electrolyzer system efficiency of 57%
– The alkaline system had a system efficiency of 41%
• H2 production about 20% lower than the manufacturer’s rated flow rate
• 50% system efficiency would be realized if rated flow were achieved

Cost Reductions from Power Electronics Optimization:

– Analysis showed a potential 7% reduction in cost per kg of
hydrogen based on capital cost improvement
• Projected cost of hydrogen falling to $5.83/kg from a baseline of
$6.25/kg

Energy Transfer Improvements: PV configuration testing compared

direct-connection to the electrolyzer stack with a connection through
power electronics
– The MPPT power electronics system captured between 10% and
20% more energy than the direct-connect configuration

National Renewable Energy Laboratory 18 Innovation for Our Energy Future

 Hydrogen-Based Energy Storage Cost Analysis

Project Objective:
• Evaluate the economic viability of the use of hydrogen for
medium- to large-scale energy storage applications in
comparison with other electricity storage technologies
Project Background:
• FY2009 study builds upon and expands on an initial scoping
study of hydrogen-based energy storage conducted in FY2008
• Benchmarking against competing technologies (batteries,
pumped hydro, CAES)
• Expanded analysis of PEM fuel cells and hydrogen combustion
turbine
• Analysis of production of excess hydrogen for vehicles
• Preliminary analysis of environmental impacts
National Renewable Energy Laboratory 19 Innovation for Our Energy Future
 Energy Storage Scenario

Nominal storage volume is 300 MWh (50 MW, 6 hours)

– Electricity is produced from the storage system during 6 peak hours
(1 to 7 pm) on weekdays
– Electricity is purchased during off peak hours to charge the system
Electricity source: excess wind / off peak grid electricity
– Assumed steady and unlimited supply during off peak hours (18 hours
on weekdays and 24 hours on weekends)
– Assumed fixed purchase price of 3.8¢/kWh with sensitivities run at
2.5¢/kWh and 6¢/kWh
National Renewable Energy Laboratory 20 Innovation for Our Energy Future
 Analysis Framework

Major Assumptions
• No taxes or transmission charges are included in the analysis
• The supply of off peak and/or renewable electricity is unlimited
• Costs are presented in $2008
Timeframes
• High cost or “current” technology
• Mid range cost
– Some installations exist
– Some cost reductions for bulk manufacturing and system integration have
been realized
– Installations are assumed in the near future; 3 to 5 years.
• Low range cost
– Estimates for fully mature technologies and facility experience
Cost analysis performed using the HOMER model
– Results are presented as levelized cost of energy; $/kWh or $/kg for hydrogen

National Renewable Energy Laboratory 21 Innovation for Our Energy Future

 Energy Storage Study Findings
Levelized cost of output electricity (¢/KWh)

120.0

100.0

83
80.0

60.0

40.0
28 25 28
24
20.0 19
13 10
0.0

ry
nd

ro
e

ry

ry

S
ic

in

AE
og

tte
tte

tte

d
ou

rb

hy
l

ba
ba

ba

C
eo
r

tu
eg

d
/g

pe
n

aS

x
d
v

do
io

iC
bo

FC

m
N
st

re
/a

Pu
bu

um
FC

m
co

di
na
/
on

Va
si
n
pa
ex
en
ogr
yd
H

Comparison of hydrogen and competing technologies

National Renewable Energy Laboratory 22 Innovation for Our Energy Future
 Analysis Results - Hydrogen
Hydrogen fuel cell with geologic storage
LOW-COST CASE
$0.18
Electricity price
Fuel cell capital cost
Electrolyzer efficiency
Fixed O&M
Geologic storage capital cost
Electrolyzer capital cost

MID-RANGE CASE $0.24

Electricity price
Fuel cell capital cost
Electrolyzer efficiency
Fixed O&M
Geologic storage capital cost
Electrolyzer capital cost

HIGH-COST CASE
$0.50
Electricity price
Fuel cell capital cost
Electrolyzer efficiency
Fixed O&M
Geologic storage capital cost
Electrolyzer capital cost

0.14 0.18 0.22 0.26 0.3 0.34 0.38 0.42 0.46 0.5 0.54 0.58
Cost of Energy ($/kWh)

National Renewable Energy Laboratory 23 Innovation for Our Energy Future

 Analysis Results - Hydrogen
Hydrogen gas turbine with geologic storage
LOW-COST CASE
$0.17
Electricity price
Electrolyzer efficiency
Combustion Turbine capital cost
Electrolyzer capital cost
Fixed O&M
Geologic Storage capital cost

MID-RANGE CASE $0.19

Electricity price
Electrolyzer efficiency
Combustion Turbine capital cost
Electrolyzer capital cost
Fixed O&M
Geologic Storage capital cost

HIGH-COST CASE $0.26

Electricity price
Electrolyzer efficiency
Combustion Turbine capital cost
Electrolyzer capital cost
Fixed O&M
Steel Tank capital cost

0.14 0.16 0.18 0.2 0.22 0.24 0.26 0.28 0.3 0.32 0.34

Cost of Energy ($/kWh)

National Renewable Energy Laboratory 24 Innovation for Our Energy Future

Recent Publications

http://www.nrel.gov/hydrogen/proj_wind_hydrogen.html

Technical Report
NREL/TP-TP-550-44103
December 2008 Technical Report
NREL/TP-581-44082
April 2009

National Renewable Energy Laboratory 25 Innovation for Our Energy Future

 Acknowledgments

Xcel Energy
– Frank Novachek
– Vicki McCarl
– Brad Hollenbaugh
DOE
– Roxanne Garland
– Richard Farmer
– Monterey Gardiner
Contractors
– John Cornish (EPC)
– Marc Mann (Spectrum)
NREL
– Kevin Harrison
– Greg Martin
– Keith Wipke
– George Sverdrup
– Robert Remick
– Genevieve Saur
– Bill Kramer
– Ben Kroposki
– Mike Stewart

National Renewable Energy Laboratory 26 Innovation for Our Energy Future