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Abstract
Many inventions are not commercially successful because they do not meet market requirements.
Engineers who are experts in their field design them, but they do not know the market requirements of
the customers.
The following article demonstrates how a hydrogen energy cycle device can be successfully designed
to meet market requirements. These requirements can be obtained by analysing the bulk of customer
data and known facts. Masses of data will be evaluated. Statistical methods will be used to find a design
that potentially can be successful in the market.
With clearly explained decision trees, substantiated and backed up by statistical data a potentially
successful configuration was found.
This article demonstrates that alternative energy design needs are different from the classic grid
supported power solutions.
It should be demonstrated how slim and flexible design can be, to avoid individual customization and
permanent reengineering.
Key Words:
Decision tree, customer benefit, statistical, method, solution findings, Monte Carlo,
standard design, optimization.
Content list
Introduction ................................................................................................................................ 2
Hydrogen Energy cycle system .................................................................................................. 3
Problem solving procedure......................................................................................................... 5
Customer needs .......................................................................................................................... 6
Custom behaviour model ........................................................................................................... 9
Monte Carlo Simulation ........................................................................................................... 16
Battery Sizing ........................................................................................................................... 21
Fuel Cell ................................................................................................................................... 22
Power to gas ............................................................................................................................. 24
Tank sizing ............................................................................................................................... 25
Final Arrangement .................................................................................................................... 26
Decision Process ...................................................................................................................... 27
Summary .................................................................................................................................. 28
Conclusion ................................................................................................................................ 29
Bibliography/ References: ........................................................................................................ 30
Introduction
Since almost 60 years numerous mathematical models of fuel cells and batteries
have been reported, showing powerful capabilities for in silico studies for a large
diversity of mechanisms and processes.[8] But why are no commercially available
products available or still in the prototype stage?
The following article will introduce a hydrogen energy cycle device that is capable to
produce hydrogen from distilled water and utilizes the produced hydrogen to produce
electrical energy on demand.
The device to be investigated is called Blue Hamster, which is a German English
combination. In the following study, it is called ‘the system’ or ‘the device’. Blue is the
colour of hydrogen bottles and hamster is for the capability of harvesting food
(energy) in the winter.
It was developed by the Mossau Company at the beginning of the year 2000 and it
was well ahead of time. Unfortunately, the system was not successfully marketed and
due to the age of the owner and the lack of interest of the successor of the company,
the core development team was diverted into other industries. With the lack of vision,
competence and funding the system felt into oblivion.
The complete system was designed for home use and small industrial applications.
However, it was built only as a proof of concept model without back up of market
demands and strategies.
The initial source of energy is not considered in this article. Hydrogen is an energy
carrier, which is only useful for long-term energy storage. The production of hydrogen
is quite energy intensive and by each conversion of hydrogen to energy there is a
loss.
As commonly known the public grid system becomes more and more unstable due to
the exponentially increasing numbers of energy producers. [11] Therefore, the
alternative energy production can hardly expand because suitable long-time energy
storage systems are not available in the market, yet. Especially in Germany, you can
see clearly that there are limits to the generation of wind and solar energy. E.g.,
Windmills are running only for few hours a day and the other time the windmills are
standing idle.
As long as there are no consumers available for the abandon energy the windmills
can never run continuously, which is a total waste of resources and government
subsidies and funding.
What is needed is a system that can utilize the abandon energy in low power demand
time when it is cheap and give the energy back at peak power time or at customers
demand. If it is widely installed, it is capable to even out the countrywide power
demand and it would make the grid system more reliable with more and more
alternative energy generation.
The system should be mass-produced, and it should fit into the budget of a family or
small business unit.
December 19 Decision Tree for alternative energy hydrogen devices Page 2
Comenius University Faculty of Management Bratislava
The main intention was to make houses or companies completely independent from
grid use, which means fully autonomous and ideally at affordable costs. However, the
system can be more profitable if it is still connected to the grid and can take part in
energy trading.
The following study should find out what would be a suitable size and arrangement,
which could cover private habitats from 2 up to 18 persons.
The study is based on market research, statistic models and basic calculations
related to off the shelf equipment. Therefore, the readers should not be overwhelmed
by the amount of numbers and charts. The study takes only results developed by an
engineering company into consideration and builds up the decision on the result.
The main purpose is to find a model, using management methods and decision trees,
which can be verified and are understandable to non-technical persons. In the end,
we need a robust configuration, which would fit the market requirement.
The study always shows ways how to define systems, which could be used for other
alternative energy devices, too. Consequently, the study is not limited to the Blue
Hamster.
The number of charts is necessary for the decision-making process and the logic
behind is always driven by common sense or physical requirements. Further studies
need to be conducted to develop a business model and a holistic concept, which will
be a commercial success.
Master Module
Frequency Converter
Fuel Cell
Electrolyser
The shown device is a fully operational device called Blue Hamster based on the idea
to harvest hydrogen in the summer with surplus energy from solar systems and wind
generators.
The prototype is fully operational and will suit most of the client’s needs for three major
client groups, which have cheap energy sources that are not fully utilized (e.g. solar
panels, wind or water generators nearby.)
It is understood that the device is not cheap, and it will not be more cost-efficient than
a large power station.
The costs for the prototype are around 160,000 Euros installed at the customer, which
would not fit in most owner’s budget for a power supply system.
The system has several dependencies, which influence the design. These
dependencies also influence each other and are segregated into seven individual
components. It is important to solve the dependencies to find a solution that is
acceptable to the customer.
Batteries
Persons
Power Demand
Peak Power
DC Voltage
Power Demand
Size Quantity
Cost Habits
Inverter
Peak Power
DC Voltage
Quantity
Cost
Surplus Energy
Master module
First, one must find the key driver, which is the prime element that determines the size
of the design. From the direction of arrows, it is apparent that the persons module is
the prime element that influences all other components in deciding the design.
Now data need to be found to determine the needs of the persons, which can be
substantiated by intensive market research and consumer data. Once it is found the
the equation can be solved and the design can be fixed. It would be an ideal case for
the sales department if there were only one remaining question: how many persons
are in one household?
The system should be flexible enough to cover from a single household with 2-4
persons up to six Apartment blocks with 6-18 people. For small communities with more
than six Apartments, the system can be duplicated or repeated multiple times.
Customer needs
To understand customer needs we should find out the power consumption behaviour
of customers. Meanwhile, there is a large fleet of private houses, which have installed
solar systems on the top of roofs. These owners will be the prime target as customers.
Each house has a solar converter, which is feeding the house with electricity and feed
abandon energy back into the grid.
The house can earn a substantial amount of money from feeding the grid with power.
However, the total cost of the solar system is not covered by the amount earned by
feeding the grid plus the government subsidy. In the best case, the breakeven can be
reached after 20-25 years in operation. However, after these 20-25 years of operation,
[13] the power output of the solar cells is so much degraded and guaranteed high
compensation for power generation is gone.
The owner of these systems has the dilemma that he cannot use the energy he
produces at the time he needs and for the power he is feeding the grid he is getting
<10% of the original compensation.[13] Additionally, he has to buy expensive power
from the grid when he needs power but does not have it himself. Therefore, these solar
systems installed on the tops of the roofs of many houses become more of a burden
than a benefit after the sponsored time of 20-25 years. Solar energy is still not
competitive without government subsidies.
A similar situation is with the windmill owners. The grid owner can switch the windmills
remotely off when there is low power demand. Therefore, most windmills are running
only 6-8 hours a day on average, which does not match with the business model. With
a longer running time of the windmill, the ROI would come much faster.
What is needed is to decouple the power production time with the power demand time
with a long term energy storage system. Hydrogen as a long term storable energy
carries will be a solution for decoupling the production and consumption of energy over
time.
Fig.2. Solar energy production and home energy consumption during a day
As long as the energy cannot be stored or used when it is produced, it is totally wasted.
[14] The data from Fig.2 has been derived from photovoltaic solar systems that are
installed worldwide and connected over the internet to the OEM supplier. As part of the
PV solar system a frequency converter is installed which is tracking the demand of the
habitants precisely. Due to the huge fleet of solar systems installed the consumption
data are recorded, published and can be considered as a reliable source. Every
economist can understand if you cannot sell a product at the time you have it and
when you have it there is no customer, then there is no way to make money
successfully. Most grid systems are “regulated” by government or agencies and
therefore free trade is not possible.
For understanding the customer needs, we must go more in detail and obtain data
precisely reflecting the customer’s behaviour. Fortunately, these data are available in
detail from the databases of the solar power converter companies. They track each of
their products at customer sites and make the data available to the owners to justify
their investment as well as to show what amount of energy their fleet of equipment
have produced. Additionally the system tracks as well the climate conditions (sunshine
and temperature) at multiple distributed locations, which is beneficial for the weather
forecast agencies.
We can see clearly that the consumption of energy is varying over the day of the week.
It is understandable because we normally have a job and we are not at home during
working days, therefore the power consumption during working days is the lowest. On
Saturday, we are at home, washing clothes, vacuuming the house and cooking food
for the whole family. Therefore, the power consumption is the highest on Saturdays.
On Sunday, the focus is on cooking lunch and dinner. It is for the whole family and
therefore the cooking time is longer and more intense than on other days. Generally,
the peak power is in the evening when people are normally at home, cooking food and
watching TV.
An electric system would be ideal if the consumption would be constant. Then the
production cost would be the lowest and the grid could be stabilized best. [12]
Unfortunately, constant demand is not the reality and therefore storage devices are
needed to even out the demand.
Consequently, we cannot ignore it, if we want to build a realistic model that is applicable
for one year. The model needs to be considered over one year because alternative
energy resources and demand varies from summer to winter. In particular, the longer
days and sunlight / solar energy are ideal to harvest in summer and the harvested
energy can be used in the winter. As storage media, we are considering hydrogen
because it can be stored indefinitely in a tank for a certain time. Hydrogen does not
have the problem of a battery whose charge depletes over time within a month.
Therefore, batteries can be only considered as a short-term storage device. [15]
For building a model covering one week, we need three equations, for working days,
Saturdays and Sundays. We are using Excel to develop these formulas. The formulas
are used to calculate the energy demand for sizing the equipment and the possible
amount of energy that can be harvested in summertime.
Time Load workday INTEGRAL Time2 Sunday INTEGRAL3 Time3 Saturday INTEGRAL5
0 40 34.0 0 35 37.5 0 45 36.5
1 28 24.5 1 40 32.5 1 28 24.5
2 21 19.5 2 25 23.5 2 21 20.5
3 18 17.5 3 22 21.5 3 20 20.0
4 17 17.0 4 21 20.5 4 20 20.0
5 17 21.0 5 20 20.0 5 20 20.5
6 25 40.5 6 20 21.0 6 21 23.0
7 56 60.5 7 22 23.5 7 25 35.0
8 65 62.5 8 25 37.5 8 45 52.5
9 60 58.0 9 50 60.0 9 60 65.0
10 56 55.5 10 70 74.0 10 70 71.0
11 55 57.5 11 78 89.0 11 72 72.5
12 60 62.5 12 100 95.0 12 73 74.5
13 65 63.5 13 90 82.5 13 76 75.5
14 62 57.5 14 75 66.5 14 75 73.5
15 53 51.0 15 58 55.0 15 72 71.5
16 49 49.5 16 52 51.0 16 71 70.5
17 50 55.0 17 50 55.0 17 70 74.0
18 60 72.5 18 60 67.5 18 78 88.0
19 85 85.0 19 75 77.5 19 98 99.0
20 85 77.5 20 80 75.0 20 100 86.0
21 70 62.5 21 70 62.5 21 72 66.0
22 55 47.5 22 55 47.5 22 60 57.0
23 40 40.0 23 40 37.5 23 54 49.5
Load workday ∫f(x)*dx 1192 Sunday 1233 Saturday 1346
Conversion Factor in KWH rounded up 1.2 1.3 1.4
Mean 49.66666667 Mean 51.375 Mean 56.041667
Standard Error 4.08809985 Standard Error 5.0118745 Standard Error 5.1942273
Median 55 Median 51 Median 65
Mode 60 Mode 40 Mode 20
Standard Deviation 20.0275173 Standard Deviation 24.55307 Standard Deviation 25.446413
Sample Variance 401.1014493 Sample Variance 602.85326 Sample Variance 647.51993
Kurtosis -0.617668864 Kurtosis -1.071463 Kurtosis -1.134424
Skewness -0.248823979 Skewness 0.2264561 Skewness -0.220784
Range 68 Range 80 Range 79
Minimum 17 Minimum 20 Minimum 20
Maximum 85 Maximum 100 Maximum 100
Sum 1192 Sum 1233 Sum 1345
Count 24 Count 24 Count 24
Largest(1) 85 Largest(1) 100 Largest(1) 99
Smallest(1) 17 Smallest(1) 20 Smallest(1) 20
Confidence Level(95.0%) 8.456878868 Confidence Level(95.0%) 10.367852 Confidence Level(95.0%) 10.745078
Relatively load/workday 100% 103% 113%
Fig. 4: Data for power demand model
The chart (Fig 3) is standardized to 100%, which is ideal because we can enter the
total peak consumption equal to 100%. If we know the household, how many people
are inside, we can multiply it with the peak demand (equal to 100%) but our model can
only be applied if we know the number of persons in the household. The peak power
depends on the customer. (Fig 5) The prime customers are listed in the chart below in
green. Single households are normally living in apartments and therefore it will be
difficult for these households to have the facility to host a hydrogen energy device.
Additionally, we will consider more than just the standard case. We will consider that
the power consumption will rise by +10 and +20% due to additional demand and more
consumption at home that makes our life more convenient (e.g. Electric car). On the
other hand, we will also consider a reduction of demand based on energy saving
devices (Edison light bulb and new LED) and environmentally friendly behaviour.
Load Workday
100
90
80
70
60
50
40
30
20
10
y = -6E-05x6 + 0.0031x5 - 0.0471x4 + 0.0206x3 + 4.3112x2 - 21.173x + 42.628
0
R² = 0.8595
0 5 10 15 20 25
Load Saturday
120
100
80
60
40
20
Load Sunday
120
100
80
60
40
20
As a calculation basis reviewing cost, the price of electric power in Germany from
2011 until 2018 is considered. As a basis for the cost model, 0.295 € per KWH is
considered as a solid cost model. If the price per KWH goes higher, the return of
investment will become shorter for hydrogen energy devices.
All the values and curves are standardized in percentage in relation to the peak
power, which depends on the persons per household, only. Therefore, we can use
the persons as a key input for the model because it is precisely known what the
average consumption of a person is. The daily consumption varies during the entire
year and varies from country to country a little bit, which we consider as D in our
model. D is as well the date of the year, which switches from workdays to Saturdays
and Sundays.
The selector needs some input to vary the peak power (depending on number of
persons) per day over the year.
From this chart, [Fig 12] we can see the customer behaviour. Power demand is
inverse to temperature. As for peak consumption, we will note that January is the
peak month, and May the lowest month of the year.
The model is built with enough accuracy to calculate the power consumption
distribute over entire year.
The accuracy of the formula is quite precise, (R 2 = 0.98, 0.87, 092, 0.85) therefore,
we can assume that the customer behaviour is within the predicted trends.
However, in order to be sure that we have found the mean customer behaviour, a
sensitivity study is needed to investigate possible scenarios. The energy
consumption per household is not coordinated and completely random. A Monte
Carlo simulation can find out what would be a possible boundary and what can the
customer expect from the system.
Electrical device Watt/h Ontime/d kW/h Per € cost per day kwh/d kwh/a Cost per a
Computer 400 8 0.26 € 0.83 € 3.20 1168 304 €
Water heater 4000 1.2 0.26 € 1.25 € 4.80 1752 456 €
Light 200 4 0.26 € 0.21 € 0.80 292 76 €
TV 120 4 0.26 € 0.12 € 45.55 175 46 €
Dish washer 850 3 0.26 € 0.66 € 2.55 931 242 €
Cooker&Oven 4000 3 0.26 € 3.12 € 12.00 4380 1,139 €
coffee machine 1000 2 0.26 € 0.52 € 2.00 730 189 €
Air conditioning 2500 3 0.26 € 1.95 € 7.50 2738 712 €
Refrigde 35 8 0.26 € 0.07 € 0.28 102 27 €
Microwave 700 1.5 0.26 € 0.55 € 2.10 767 199 €
Vacuum cleaner 1500 1 0.26 € 0.39 € 1.50 548 142 €
HIFI 1000 2 0.26 € 0.52 € 2.00 730 190 €
Dryer 1000 2 0.26 € 0.52 € 2.00 730 190 €
Waching machine 1200 2 0.26 € 0.62 € 2.40 876 228 €
Iron 1000 1 0.26 € 0.26 € 1.00 365 95 €
Sauna 7500 0.15 0.26 € 0.29 € 1.13 411 107 €
Hair dryer 800 0.5 0.26 € 0.10 € 0.40 146 38 €
Water cattle 2000 1 0.26 € 0.52 € 2.00 730 190 €
Freezer 500 3 0.26 € 0.39 € 1.50 548 142 €
Heat pump 10000 3 0.26 € 7.80 € 30.00 10950 2,847 €
Electric Heater 500 12 0.26 € 1.56 € 6.00 2190 569 €
Toaster 1000 0.5 0.26 € 0.13 € 0.50 183 47 €
Electric Grass Cutter 1400 0.2 0.26 € 0.07 € 0.28 102 27 €
Electric Grill 1400 0.2 0.26 € 0.10 € 0.40 146 38 €
Fig. 14: Power consumption of different household devices
The heat pump will not be taken into consideration because the power consumption
is too high and it would overshoot the peak power inappropriately. The usage of
primary power such as gas should be preferred for environmentally friendly houses
for heating and cooking.
The Fig 15 is taken from the homepage of the German federal grid agency, therefore
it is written in German. For better understanding, the following translation can be
used.
With the known devices per household, the utilization per day and the distribution in
average over a day, we use our Monte Carlo Model as follows:
The total sum of power is limited based on the nature of the maximum power
available in an autonomous system. To determine the max. necessary peak power
over a year, the simulation should provide data based on the distribution per category
under the consideration that the operation hours of the devices could be modified.
Under Miscellaneous are considered following loads:
It gives the simulation more flexibility and the result will be more realistic to human
behaviour.
The simulation was run for 100000 days and with an increment of a minute over a
day. The theoretical persons could switch on and off power at a random choice with
following the average distribution of Fig.15.
The collected data was averaged from minutes to one hour. The reduced data were
subject of statistical evaluation.
Electrical device Watt/h Category Prio % h Minutes Max power Value Days
Light 200 Light 1 9 2 120 5000 100000
Microwave 700 Cooking 2 11 1.5 90
Cooker&Oven 2000 Cooking 2 11 2 120 Results Mean W
Oven 2000 Cooking 2 11 2 120 Mean 4808
refrigde 35 Cooling Freezing 3 17 8 480 Standard Error 11
Freezer 500 Cooling Freezing 3 17 3 180 Median 4814
Dryer 1000 Washing/Drying 4 13 2 120 Mode 4668
Washing machine 1200 Washing/Drying 4 13 2 120 Standard Deviation 356
Hair dryer 800 cleaning 5 7 0.5 30 Sample Variance 126482
Dish waher 850 cleaning 5 7 3 180 Kurtosis 1
Vacuum cleaner 1500 cleaning 5 7 1 60 Skewness 0
TV 120 TV/Audio/PC 6 27 4 240 Range 2884
Computer 400 TV/Audio/PC 6 27 8 480 Minimum 3050
HIFI 1000 TV/Audio/PC 6 25 2 120 Maximum 5934
Coffee machine 1000 Misc 7 16 2 120 Sum 4692449
Iron 1000 Misc 7 16 1 60 Count 976
Toaster 1000 Misc 7 16 0.5 30 Largest(1) 5934
Electric Grass Cutter 1400 MIsc 7 16 0.2 12 Smallest(1) 3050
Electric Grill 1400 MIsc 7 16 0.2 12 Confidence Level(95.0%) 22
water cattle 2000 Misc 7 16 1 60
With the obtained data, a suitable power inverter can be selected that can feed the
load. Off the shelf, standard power inverter should be selected because of cost and
reliability. According to the simulation, the mean value is 4808W, with a Maximum at
5934W.
A 5000W rate frequency converter would have the capability to provide enough
power to cover this demand. (Fig.19) The next smaller converter with 3000W would
not be suitable because it cannot cover the required range (3050 to 5934 Watt). It
would give too many restrictions to daily life, which would decrease the acceptance
level.
The following charts show two converters from different companies. (Fig.20, 21)
Both companies have a suitable type available. (5000W). It can be seen for the
available power range and higher, both companies are using 48V as Battery power.
Consequently, the buffer battery size is chosen too. (48V is equal to 4 car batteries in
series)
With the availability off the shelf inverters, it is possible to combine them in parallel.
The parallel configuration gives the flexibility to match the power demand
Conclusion:
With two inverters, we can cover from a single couple house up to a household with
16 people or 8 living units (of two persons). The inverter split has as well a positive
side effect. Two inverters can work as redundancy and enable an energy source
sizing.
Battery Sizing
The batteries in the system are required to cover the instant demand of the inverter.
The response time of the fuel cell is not as fast as a battery. As a backup for the fuel
cell, one day full back up is considered for the battery. The battery sizing considers
that the battery will not discharge below 40% most of the time (working days), which
will help for a longer lifetime of the batteries. On Saturdays and Sundays, we allow
the batteries to be discharged lower, otherwise the battery size and the cost will
significantly increase. (See influential diagram Fig.0)
As we have seen from the Monte Carlo simulation, the full demand happens
infrequently. With energy awareness from the customer and behaviour change, the
discharge can be kept under control during the week.
Fig 23. Battery Sizing and total power consumption per day, month and year
The energy demand per year will be used for sizing the fuel cell and the hydrogen
tank. Meanwhile, Lithium batteries are commonly available and in an affordable
range. Based on the power requirements in Fig 23. Green column following battery
configurations will be considered.
The selected batteries packs are fit into a 19” rack and therefore ideal for the blue
hamster design. (see fig.31)
Fuel Cell
The fuel cell converts the energy back from hydrogen to electricity. Therefore, we can
consider the fuel cell as an electrical generator that produces the energy to charge
the batteries. The fuel cell can work discontinuously which will be triggered to start if
the batteries charge is at 40% level and no cheap energy source is available from the
grid or PV system.
To define the size or the fuel cell we can solve the integral of Fig. 6, 7 and 8 and
obtain a number, which is the area under the curve. We need to know the workload
(kWh) that we need to provide.
We can now try to match the power requirement with a combination of fuel cells with
different power outputs.
Yellow: More hydrogen can be produced than needed and configuration can
potentially reduce the size of channel B.
Red: The spare capacity can be used to reduce the size of the battery. Additional
engineering is required to suit customer requirements if cost is a concern.
Alternatively, we can consider the price of a fuel cell and check if a single fuel cell is a
better option.
Light green: one fuel cell configuration with 5000W or 10000W size
Red: the fuel cell cannot provide the peak demand in the wintertime. Additional
engineers or larger battery sizes will be required.
As we can see clearly, the option 2 with one fuel cell beats the option 1 with a parallel
configuration in all size cases except in the 20000 W case. In this case, additional
engineering is required to close the gap of the undersupply of 17%. The possible
solution is to back up the batteries by a larger battery pack or a large PV solar array
or windmill generator of more power from the grid.
Alternatively, the customer power consumption can be interlocked, e.g. if the storage
is lower the estimated power demand for essential electrical devices then
unnecessary wastage of energy can be blocked by a control system. (Smart homes)
If people want to live a green life, the awareness of depleting resources and the
careful utilization of power should be accepted.
Power to gas
We have found a method to estimate a power demand for a home. Now we
investigate what will be the proper size of a hydrogen generator suitable for the
power demand.
demand Electrolyser
Household Fuelcell Configuration 1.2
Inverter Size in Watt Persons 56% 40% A B C D Surples W Surplus Wh
3000 2 1680 4200 5000 800 960
5000 4 2800 7000 5000 3000 1000 1200
7000 5000 5000 3000 3600
6000 5 3360 8400 5000 5000 1600 1920
8000 6 4480 11200 5000 5000 3000 1800 2160
11200 5000 5000 5000 3800 4560
10000 8 5600 14000 5000 5000 5000 1000 1200
11000 9 6160 15400 5000 5000 5000 1000 600 720
15400 5000 5000 5000 5000 4600 5520
13000 11 7280 18200 5000 5000 5000 5000 1800 2160
15000 12 8400 21000 5000 5000 5000 5000 -1000 -1200
20000 18 11200 28000 5000 5000 5000 5000 -8000 -9600
Fig.28 Quad configuration of an electrolyser
Orange: Electrolyser sizes for 3000W and 1000W should be avoided, if commercially
beneficial. It would simplify the production process, spare part handling,
maintenance, and service cost if only one type of electrolyser is produced.
Red: For households up to 12 persons we have the same issue as we have with fuel
cell. We will have an undersupply of hydrogen, which will affect the power availability
during the wintertime.
The electrolyser is quite costly. The size has a direct impact on the cost. In contrast
to a fuel cell, an electrolyser does not have a significant reduction in cost for a larger
size. Additionally, there are only three sizes available, which would fit into a 19” rack
design.
To cover all possible design scenarios we need to take the largest electrolyser and
stack it into multiple channels A, B, C, and D with 5000W. Depending on the supplier
agreement, it might be possible to get a better price if bigger quantities of one type is
ordered, only.
Tank sizing
The sizing of the hydrogen tank depends on the amount of hydrogen, which can be
accumulated for 6 months. In the storage cycle, it is considered that in summertime,
the hydrogen will be stored and in wintertime, it will be used.
Tank Sizing For 6H A day
Electrolyseur configuration Efficiency 75%
nominal
H2 yearly Running Running
Electrilys Produktio productio Energy time per time per Tank size Tank Size
Persons KWH/a er Watt n m3/h Surplus n Qm content day year /h Tank size 30bar 300bar 700 bar
2 1360.8 5000 1.1 960 462.528 1387.584 6 2190 8 1 0.40
4 2268 10000 2.2 1200 578.16 1734.48 6 2190 10 1 0.50
5 2722 10000 2.2 1920 925.056 2775.168 6 2190 15 2 0.70
6 3629 15000 3.3 2160 1040.688 3122.064 6 2190 17 2 0.80
8 4536 15000 3.3 1200 578.16 1734.48 6 2190 10 1 0.50
9 4990 20000 4.4 5520 2659.536 7978.608 6 2190 44 4 1.90
The maximum tank storage pressure makes a big difference in the size of the
hydrogen tank. Three pressure ratings have been considered 30 bar, 300 bar and
700 bar, which are common in the industry. The tank size is calculated based on the
running hours of the electrolyser and the production rate. (Running time *hour rate
(QM)* 6 months / pressure= tank size (QM))
A general recommendation cannot be given for the selection of the tank size because
it totally depends on the location and preference of the customer. If there is space, a
lower pressure tank (max. 30 bar) is recommended because the electrolyser can
produce directly the max. Storage pressure of 30 bar. Therefore, no extra hydrogen
compressor is needed, which saves energy that can be used for producing more
hydrogen.
In the case of space being a concern, higher pressure is the only option of choice.
Higher compressed hydrogen reduces the required space/volume significantly
because the pressure is in the denominator of the equation. However, the higher
pressure comes with a price that a compressor is needed, which is very costly and
consumes energy that cannot be recovered from the process. If possible, a
compressor should be avoided.
Final Arrangement
The final arrangement will be suitable for households from 2 to 18 people. Based on
standard components and technical requirement determined by customer’s demand
the final arrangement of the system can be demonstrated as follows:
Final Configuration Inverter Fuel Cell Elektrolyzer Batterie Water Tank Hydrogentank
Size Channel A B C D LIPO 30bar 300bar 700bar
Persons Watt A B Watts Watts Watts Watts Watts KW/h Liters qm qm qm
2 3000 3000 3000 5000 4800 internal 20L 30 3 1
4 5000 5000 3000 5000 5000 7000 internal 20L 40 4 2
5 6000 3000 3000 5000 5000 5000 9600 external 100L 60 6 3
6 8000 5000 5000 5000 5000 5000 10500 external 100L 80 8 4
8 10000 5000 5000 10000 5000 5000 5000 14000 external 100L 80 10 5
9 11000 6500 6500 10000 5000 5000 5000 17500 external 100L 100 11 5
11 13000 6500 6500 10000 5000 5000 5000 5000 19200 external 200l 120 12 7
12 16000 8000 8000 10000 5000 5000 5000 5000 21000 external 200l 140 14 7
18 20000 10000 10000 10000 5000 5000 5000 5000 28000 external 200l 160 16 10
Orange: For 12 to 18 people households, the design should be verified again to fit
the customer demands. E.g. with the current set up the hydrogen generation will not
be enough, and external hydrogen generators must be added to suit the demand. In
the design of the master module, it has to be considered to control external hydrogen
producers. It can be realized by a bus connection or a hardwired signal for requesting
more hydrogen.
Yellow: The design is at the limit and additional engineering will be required. E.g., the
battery pack should be redundant and combinations of larger battery sizes could
compensate for the lack of hydrogen production.
Decision Process
With Fig 30, we have found a design configuration, which is matching the customer
demands. Now for the sales team, it is very easy to select a design that should meet
customer needs.
How
many
persons?
Space Standard
<12 yes constrains no
Design
no
Split the
project in yes <18
two parts
no
yes
Additional
Engineering
no
Implement
Do able? yes additional measures
For existing buildings, it might not be possible. Then an external source of hydrogen
which can supplement the electrolyser constrains has to be found.
The decision process is clear and does not leave any ambiguity.
Summary
For the final design of the Blue Hamster, a configuration was found which suits
customer’s condition for a 2 to 11 person building with off the shelf products. The
design can be utilized with additional engineering and additional components up to 18
persons per building. However, from 12 to 18 persons per building more refined design
will be needed to suit customer requirements, mainly to find a cost-optimized solution.
The cost of additional engineering can be absorbed by larger projects.
However, this is not a showstopper for the selected design because buildings with 12
to 18 persons are rare and exist mainly in big cities. It can be expected that big cities
have additional requirements for size and regulations. E.g., the selection of storage
tank will be a challenge because it depends mainly on space available and local
regulatory requirements, which is unique at every location.
The following figure should depict what is the outcome of the decision tree based on
available data.
The shown energy cycle has substantial losses, which are generating heat. If the
system is installed within the house, it can contribute to the heating system as well.
December 19 Decision Tree for alternative energy hydrogen devices Page 28
Comenius University Faculty of Management Bratislava
Conclusion
The design proposal is suitable to cover most of the customer's needs in Germany and
potentially in Europe. (2-18 persons). It is capable to even out the unstable grid power
demand and therefore it is a big plus if countries with unstable grid situations could
introduce this device more and more.
The concept is already proofed therefore we limited the study only on the arrangement
of components and their sizing. It was demonstrated that with off the shelf products
most of the customer needs could be met. A cost reduction can be expected in mass
production. Now the Master Module needs to be redesigned to manage the
configurations found. [Fig30]
In general, it is stated that this system is the solution to enable further expansion of the
alternative energy industry. The dilemma of alternative energy not having a storage
capacity is solved, too. Because if this system is installed in mass quantities and
decentralized at the final user, it creates so much storage that windmills, solar farms,
and bio plants have always enough storage capacity to enable them to run in steady
state. It makes the entire alternative energy industry more profitable and competitive.
The system might be expensive, but it avoids the need for a complete upgrade of the
German power grid system to suit electromobility and expansion for alternative energy
production. It provides hydrogen for cars as well if communities group together and
select a higher pressure of hydrogen tank (300-700bar).
The system has the potential to make an entire society completely free from toxic
pollutants, create more independence from grid power and free from the domination of
conglomerates. On the other hand, it will help grid owners to stabilize the grid of
communities. Small companies can have a better price for the power supply because
stable, predictive power is cheaper than unexpected power demand. [14, 15]
The study will give clear guidance for the designers to develop this system further.
It is now time for the engineers to make it market competitive and ready for the market.
Bibliography/ References:
Figures:
Fig.0: Influencing diagram of hydrogen energy cycle systems.
Fig.4: Data for power demand model Source: JFE LTD Germany
Fig.6: Power diagram for working days, Courtesy of JFE LTD Germany 2019
Fig.7: Power diagram for Saturdays, Courtesy of JFE LTD Germany 2019
Fig.8: Power diagram for Sundays, Courtesy of JFE LTD Germany 2019
Fig.11: basic calculation model scheme, Courtesy of JFE LTD Germany 2019
Fig.13: Power consumption per month, Courtesy of JFE LTD Germany 2019
Fig.16: Monte Carlo Simulation Model, Courtesy of JFE LTD Germany 2019
Fig.17: Typical Main Power consumer per household, Courtesy of JFE LTD Germany
2019
Fig.18: Monte Carlo Simulation result over 100000 days, Courtesy of JFE LTD
Germany 2019
Fig.22: Peak Power consumption per person, Courtesy of JFE LTD Germany 2019
Fig.23: Battery Sizing and total power consumption, per day, month, year
Fig.25: Determination of the fuel cell size in relation to the peak power, the price per
fuel cell per Watt, Shandon Cantian 2019
Fig.26: Dual channel configuration or fuel cell and cost estimate, Courtesy of JFE
LTD Germany 2019
Fig.27: Mono channel configuration or fuel cell and cost estimate, Courtesy of JFE
LTD Germany 2019
Fig.28: Quad configuration of the electrolyser, Courtesy of JFE LTD Germany 2019
Fig.29: Sizing of hydrogen pressure tanks, Courtesy of JFE LTD Germany 2019
Fig.30: Final Configuration of master model and Blue Hamster, Courtesy of JFE LTD
Germany 2019
Fig.31: Overall arrangement JFE LTD, Free Internet, and Mossau Company, Struder
E-mail: FJ1808@web.de
First Peer-Reviewed by
prof. RNDr. Michal Greguš, PhD.,
Dean
Faculty of Management,
Comenius University in Bratislava,
Odbojárov 10,
820 05 Bratislava 25,
Slovak Republic
Second Peer-Reviewed by
Prof. Dr. Vera Bennarova
Faculty of Management,
Comenius University in Bratislava,
Odbojárov 10,
820 05 Bratislava 25,
Slovak Republic