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Fuel Cell Power Pack for 24V Scrubber - Deep Blue

1. 34 4 ird 35 APPENDIX D FUEL CELL SYSTEM SPECIFICATIONS 36 APPENDIX E HYDROGEN STORAGES 38 APPENDIX F POWER DATA FOR THE SCRUBBER 39 APPENDIX G PERFORMANCE DATA FOR THE FUEL CELL SYSTEM 40 APPENDIX FAILURE MODES AND EFFECTS ANALYSIS 42 APPENDIX l DC DC CONVERTER 43 APPENDIX J ENGINEERING DRAWINGS 45 APPENDIX K DC DC CONVERTER INSTRUCTIONS 48 APPENDIX L CHARTI 56 APPENDIX M BIOGRAPHIES A u un a aq sn en G Qaqa en en S a aG awas 57 NOMENCLATURE AFC Alkaline Fuel Cell Ah Ampere Hour cm Centimeter DMFC Direct Methanol Fuel Cell FCV Fuel Cell Vehicle HHV Hig
2. 21 LOWER WATER TANK MODIFICATION 22 FUEL CELL MOUNTING BRACKETS 4 eene eene eene tasas tta esas 23 5 u 23 HYDROGEN GAS COMPONENT ASSEMBLY 24 ELECTRICAL COMPONENT ASSEMNBLY 25 UPPER WATER TANK RISER Agence canada ecards 25 5 22625 26 FINAL 6 24 aQ 26 5 W S IIIa 28 TRO BLESHOOTING qa RE 28 FUTURE WORK S W S S an SGS aa Sus 29 CONCLUSION 30 je 4 Ie dB zwieid S uec 30 REFERENCES E 31 APPENDIGESL ys 4 33 APPENDIX A SUMMARY OF FUEL CELL CHARACTERISTICS 33 APPENDIX B MEETING WITH SPONSQOR
3. APPENDIX BIOGRAPHIES AMANDA CHRISTIANA Amanda grew up in southeastern Michigan She has worked various jobs to support her education at the University of Michigan most recently for a small research and development company in Ann Atbor A strong interest alternative energy attracted her to the Michigan Solar House in 2004 A design project related to hydrogen fuel cells stemmed from this activity but never left the conceptual stage Eventually she hopes to work in sustainable design or renewable energy JONATHAN DONADEE Jonathan was born and raised im Canfield Oh a small suburb near Youngstown In addition to studying Mechanical Engineering Jon is pursuing an Economics minor His activities at the University of Michigan include Dance Marathon and diving for the varsity swimming and diving team His favorite experience as an undergraduate was studying abroad in China during the summer of 2006 This experience helped him to understand the global economy and the challenges faced by industrializing countries He has a strong interest in studying renewable energy technologies and their adoption After graduation he plans to apply to graduate school for a master s degree engineering Eventually he hopes to have a career working with wind energy or alternative power sources in vehicles MATTHEW GARRITY Matthew was born on a Naval Base in Groton Connecticut as the last addition to a Coast Guard family Being part of a military f
4. 11 FUEL STORAGE SYSTEM a 11 ELECTRICAL SYSTEM RERO m 11 CONCEPT EVALUATION rien eu sees 11 FUEL CELL COMPARISON ssseseovscuscssesvessecsscdsvvosssscecesasssnsevacandocsbcausessevodecneevosesssosnddeaboutosedsdvavendsssscesesesense 11 FUEL STORAGE COMPARISON 4 2 etienne no nn 12 AUXILIARY BATTERY COMPARISON 14 SELECTED CONCEPTS 15 5 5 8 542 000 ala Qua aula 16 COMPRESSED FUEL STORAGE L l L w uet Uv E VON ERE NER RN 16 TENTATIVE BILL OF MATERIALS AND PRICE LLIST 17 ENGINEERING ANALYSIS 17 nz idR BERT TP Em 17 LIFE CYGLE ANALYSIS 5 52 bae RR RENS VR coe uen een ea Neun 19 PLANT BALANCE ANALYSIS RTT 21 RISK ASSESSMENT ANALYSIS ccscccsossccsssassccesvesscssasesstevscsosesvaconssasecescssaccbosssceotesesasensssasovasesconboossssenesvasoos 21 FINAL DESIGN AND ASSEMBLY
5. 5 25 9 00 CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF lt INSERT COMPANY NAME HERE gt REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF lt INSERT COMPANY HERE gt IS PROHIBITED DIMENSIONS ARE IN INCHES NAME PAE TOLERANCES DRAWN FRACTIONAL ANGULAR MACH BEND CHECKED TWO PLACE DECIMAL ENG APPR THREE PLACE DECIMAL MATEPIAL 5 FINISH NEXT ASSY USED ON SIZE DWG NO REV Cylinder Cage APPLICATION DO NOT SCALE DRAWING 47 APPENDIX K DC DC CONVERTER INSTRUCTIONS Installation Guide 24 V DCIDC Converter Item no 750 24 V DC DC Converter Installation Guide Installation Guide for the 24 V DC DC Converter Heliocentris item 750 34 Edition July 2005 Copyright 2005 Heliocentris Energiesysteme GmbH All rights reserved This Installation Guide and individual parts thereof are protected by copyright All exploitation duplication or photocopying is prohibited except in cases permitted by law Head office North American customers contact Heliocentris Energiesysteme GmbH Heliocentris Energy Systems Inc Rudower Chaussee 29 3250 East Mall 12489 Berlin Vancouver BC Germany Canada V6T 1W5 Tel
6. Eliminate diminishing capacity Less and or safer maintenance o Eliminate need for accessory charger Deliverables Research on current technology what it takes to get a fuel cell system going who is out there whats working when it will be available Feasibility of a system that will physically work ideally within or close to existing space constraints Component suppliers and cost Proof of concept working design What we don t need Manufacting installation assembly those are secondary concerns 34 APPENDIX QFD CHART Relationships Strong Positive Quality Function Development QFD Medium Positive Medium Negative Strong Negative Benchmarks gt more is better gt less is better a 5 o 3 5 28 s 9 5 B 8 3 5 5 5 5 DI 5 S Weight a 9 3 LTL 8 OT T Jt pens E 1 1 1 3 3 9 3 1 1 AAJ ERO RD Jof A EE BERE pep sp N C T EE Bt En lt 120 900 24 30 oo 76 gt 2 L 239 99 71 81 128 149 88 76 58 63 Normalized 0 23 0 09 0 07 0 08 0 12 0 14 0 08 0
7. 49 30 63 92 63 26 Tel 604 827 5066 Fax 49 30 63 92 63 29 Fax 604 827 5069 berlin heliocentris com vancouver heliocentris com www heliocentris com www heliocentris com 01 2005 Heliocentris Energiesysteme GmbH 49 24 DC DC Converter Installation Guide 1 General notes This Installation Guide is provided to assist in the integration of the DC DC converter with the Nexa Power Module It is not a standalone user manual but a supplement to the manuals of the individual components The DC DC converter and associated components are provided exclusively for operation with the Nexa Power Module Any other use is not intended and therefore prohibited 2 Use The DC DC converter BSZ PG 1200 transforms the variable load dependent fuel cell voltage to a constant load independent voltage 24 Vdc Rechargeable batteries at the converter s output guarantee a stable and dynamic operation The integrated battery management main tains the charge state of the batteries The system will deliver power to a load either from the Nexa and batteries or from the batteries alone If the battery voltage decreases the con verter starts the Nexa which charges the batteries as it delivers power to the load Output power and operating time depends on battery capacity Using the DC DC converter control unit you can manually switch the Nexa Power Module on and off as weli as read fuel cell and converter process parameters 3 Parts list All
8. Improper ventilation or insulation breach structure melts 9 obstruction of air flow 2 Odoll visual inspection 3 54 burning High stack temperature due to operating above rated power high Nexa has internal system of controls and sensors scrubber doesnt ambient temperature cooling fan or It will automatically shut down when operating out fuel cell system fails Y caiveipower 5 cooling exhaust obstruction cooling 5 of desired range If the system experiences a self 2 50 P fan motor failure air exhaust leaking test of software fault it will enter a non restartable into fan intake High or low pressure mode due to low fuel or low fuel delivery pres 1 potential for Scrubber falls over melts improper splashgusrd failure electrical shock use while refilling water inspection i 84 auxilliary battery HET cell wont 4 Battery not charged or defective 1 Confirm battery voltage 4 16 failure start component freezing Tuelcelbwont 2 Ambient temperature too low 1 Measure ambient temperature 1 2 start while frozen 42 APPENDIX I DC DC CONVERTER Converter isle Fuel Cell Power Supply Brief Description The d c d c converter BSZ PG 1200 was developed especially for the operation on the fuel cell made by the company Ballard The whole system consists of fuel cell the d c d c converter BSZ PG 1200 an accumulator and the load The BSZ PG 1200 has to handle the battery management an
9. 0 Ease of use 0 e Total Points 0 4 5 2 Table 5 Pugh chart evaluation of auxiliary power sources SELECTED CONCEPTS We have combined the results of each subsystem evaluation and generated selected system concepts The retail PEMFC systems are competitive options for this project in terms of cost space and complexity of integration Ballard s Nexa is the less expensive more established option plus it is easily monitored with standard diagnostic software ReliOn s T 1000 has longer warranty period and a modular cartridge design that could better match power requirements and potentially eliminate the need for an expensive power conditioner while improving usability Compressed hydrogen storage was selected mainly for its availability and relative cost Suppliers such as Lincoln Composites and Quantum Technology offer refillable high pressure fuel tanks while companies like Airgas deliver compressed cylinders filled with hydrogen industrial to research grade A Li ion battery pack will be used for start up and shut down power requirements because it has the greatest volumetric power density and smallest environmental impact 3 Composite models of possible system concepts and basic structural modification have been generated as shown in Figure 2 15 Figure 2 Three dimension model of Figure 2b Three dimension model of Concept A shows relative sizes of Concept B shows relative sizes of T3 T3 Scrubber to the T 10
10. System Mining Hydrogen Nexa Fuel Transport and Storage System g Efficiency 9096 60 90 48 96 Table 10 Energy efficiency of processes components the proposed system 20 PLANT BALANCE ANALYSIS We were able to obtain a copy of the manual for the Nexa fuel cell system The manual contained performance data that allows us to estimate performance characteristics for our proposed system using the Nexa Tennant Company provided us with voltage and current data from a conventional T3 scrubber operating at maximum load Appendix F This machine ran for 143 minutes before the batteries safe lower voltage limit was reached and the T3 was automatically shut off The power requirements and run time of the conventional T3 will serve as the basis for comparison with our proposed system Tennant s data shows the T3 consuming 828 W at 24 V If the ISLE DC to DC converter rated at 96 efficiency is providing this power then the fuel cell must provide 862 5 W to the converter The Nexa will output 862 5 W with a potential near 32 to 33 V anda current of 27 A In order to provide this power 10 to 11 slpm of H gt gas must be supplied The compressed hydrogen tank we will be using will last between 226 5 and 206 minutes Risk ASSESSMENT ANALYSIS In order to ensure the safety of the construction and operation of the prototype we completed an analysis of all possible risks associated with the fuel cell setup The bulk of this assessment came i
11. V Then use the black battery connection cable to connect the negative battery terminal to the converter negative output terminal SSC6 Do not connect the positive battery terminal yet Because there is a voltage smoothing capacitor at the converter output if you were to con nect the positive battery terminal to the converter an arc would occur on contact Although harmless it may shorten the capacitor s life Instead use the enclosed charge resistor to momentarily connect 2 seconds the positive battery terminal to the converter positive out put terminal SSC5 This will charge the capacitor Remove the charge resistor Then use the red battery connection cable to connect the positive battery terminal to the converter positive output terminal SSC5 After you have connected the batteries to the converter be careful of the voltage present while you install additional components LL zii 07 2005 Heliocentris Energiesysteme GmbH 4 53 24 V DC DC Converter Installation Guide 43 Interface converter RS232 RS485 Parts list RS232 RS485 converter incl wall mount power adaptor Connection cable to DC DC converter 5 pin screw clamp Adaptor cable to PC 25 pin D Sub to 9 pin D Sub Detailed connection diagram To wall mount power adaptor Nexa data for RS232 RS485 software connection cable 22 COM2 to DC DC adaptor cable S Mo
12. W Smart Fuel Cell EFOY 1200 DMFC 65 W Adaptive Technologies e50 SOFC 50 W Table 1 Retail fuel cell systems with power outputs of 1 2 kW or less SYSTEMS NEAR PRODUCTION A number of successful PEMFC demonstrations have been completed ranging from forklifts to radio controlled airplanes Some of the most advanced PEM systems are being developed for transportation Honda has announced plans to begin leasing fuel cell vehicles as early as 2008 The cells Honda will use pack 98 kW into a 67 kg and 0 0521 m stack and are connected to a Lithium ion Li ion battery to handle load peaks This FCV stores 4kg of hydrogen at 34 47 MPa giving it a range of 569 7 km This compares to Honda s first fuel cell system in 1999 which produced 58 kW out of a 202 kg and 0 1339 m stack 10 Another noteworthy product is the ENV motorcycle which is powered by an Intelligent Energy brand 1kW modular and removable fuel cell CORE system The CORE is supplemented by four 12 V 15 Ah lead acid batteries to handle load peaks The ENV cruises at 80 47 kmph lasts 4 hours between refueling and then fuels in minutes Hydrogen is stored in a high pressure carbon wrapped cylinder Most impressively the ENV motorcycle is set to go on sale in the second half of 2007 for around 6 000 11 HYDROGEN STORAGE Currently mobile PEM systems using pure hydrogen rely on one of two storage methods Either high pressure cylinders or metal hydride storage cylinders Metal hydride
13. fabricated to secure the upper water tank to the T3 in its new position atop the riser The brackets also allow the water tank to be hinged to our new design Plates of 1 8 inch aluminum were cut with a band saw drilled and bent on a brake into the design in Figure 12 m P 90 25 u 4 0 8125 5 Figure 12 Dimensional design upper water tank brackets FINAL BILL OF MATERIALS The components and materials discussed in this section are listed in Table 26 Supplier Description Price Heliocentris 1 2kW fuel cell w startup kit 6 500 00 Heliocentris 1200W DC DC converter w startup battery 3 100 00 Heliocentris Hydrogen leak and detection kit 860 00 Heliocentris Blocking diode 120 00 Cryogenic Gases Pre Purified Hydrogen 99 99 80 cubic feet 7 50 Two stage pressure reducing regulator CGA350 to Cryogenic Gases 1 4 160 00 Fuel Cell Store Brass in line flame arrester Max 50 psi 175 00 90 Degree 316 Stainless Steel Ball Valve McMaster Carr Lockable 24 51 Threaded Stem Polyurethane Caster Wheel 4 25 McMaster Carr Mount Height 10 71 6063 Aluminum 1 Square tube 1 8 thick ASAP 12 44 54 ASAP 6061 Aluminum Plate 12 square 1 4 thick 35 39 ASAP 6063 Aluminum 2 x 2 L 6 11 82 Ace Hardware Qty 2 3 Polypropelene Straps with snap buckles 5 72 Ace Hardware 2 Steel Link Chain 1 38 Ace Hardware Carabeener 1 29 Ace H
14. g P is still connected hydrogen leak in fuel ossible A hydrogen leak could come from a storage plumbing p leak in the hydrogen tank bad or External hydrogen detection before reaching R flammability 9 hd 2 3 54 system while system asphixiation broken seals loose fittings or a leak in flammable level is attended to regulator leak could come from nyaregen eae fugl possible operator FOR ci ite wrieless external hydrogen dectector could be Glee ae is 9 flammability 10 IG In tn hvdroden bador 3 usedto detect hydrogen leaks and send alerts to 3 90 y asphixiation a receiver up to 75 feet away unattended broken seals loose fittings or a leak in the hose or regulator motor damage control board electrical Power regulation failure fuel cell damage 9 1 Fuses break Burning odor 2 18 scrubber parts overheat loss of malfunction control ower insufficient to scrubber shuts Scrubber has minimum voltage detection Visual down poor 7 Fuelcell malfunction out of fuel 6 voltage detection on scrubber Gauge on fuel 2 84 run scrubber performance tank injury hydrogen leak cylinder Improperly secured fastener i tank mounting failure damage 8 malfunction mounting breaks shock 3 yr Inspection for loose parts Listen for 1 24 regulator load 9 A r polyethelene m insulation failure
15. storage tanks store hydrogen molecules within the molecular matrix of a metal alloy allowing for low pressure and high storage density per liter However cost and weight are greater than high pressure cylinders and thermal regulation is required for optimal charge and discharge In automotive applications hydrogen gas is stored at up to 69 MPa but this requires significant amounts of energy for compression 12 A Solid H brand CL 840 metal hydride tank is 11 18 cm in diameter and 25 15 cm long capable of storing 840 sl at 0 2 MPa and has total mass of 5 72 kg This tank is quoted to cost 1 320 but price varies significantly with specified operating conditions 13 Hydrogen gas itself can either be bought in compressed gas tanks from an industrial gas supplier or it can be produced on site by a variety of processes Water electrolysis and hydrocarbon reforming systems are available from most fuel cell manufacturers H2Gen Innovations Inc reports that hydrogen can be produced at fueling stations from natural gas at a price per energy equivalent to gasoline for 1 50 14 FUEL CELL COMPARISON Background research conducted on this project shows that the field of fuel cell technology is constantly growing While the Ballard Nexa fuel cell system was selected as the best fit fuel cell to meet the needs of the T3 scrubber it is important to understand that there are other fuel cell options This section will compare the costs of involved with va
16. the system making it easier to operate and more efficient The system could be designed to extend the current run time of 2 5 hours or at least offer a re fuel time on the order of a couple of minutes rather than several hours of recharging The low noise operation of fuel cells is comparable to battery power and system maintenance would never put the user in contact with corrosive fluids As an emerging technology fuel cell systems present several challenges In the current stage of development cost is a major obstacle Manufacturing processes are both expensive and energy intensive Existing systems have relatively low volumetric power densities with respect to batteries and combustion engines This creates a problem for non stationary applications Fuel storage and availability are also significant barriers Gaseous hydrogen storage units are large and heavy Liquid hydrogen systems are smaller and lighter but require much more energy to maintain cryogenic temperatures The extent to which these issues will limit integration with the T3 scrubber is to be examined The purpose of this project is to conduct research and specify a fuel cell suitable for powering Tennant Company s T3 floor scrubber We will assemble debug and characterize the working prototype We have researched fuel cell technology contacted our sponsor from Tennant to understand the company s requirements and organized a plan to ensure that we meet our goals We have gener
17. we have decided to proceed with the DC DC converter as is Later these lead acid batteries can be replaced with Li ion batteries as previously discussed The Nexa fuel cell module includes a 3 ft 5000psi hose to connect the fuel cell to the hydrogen supply It also includes a load relay and blocking diode to protect the fuel cell from back current surges We purchased a two stage Smith regulator from local gas 21 supplier Cryogenic Gases to manage pressure to the fuel cell system A flash arrester from the FuelCellStore com was installed in line prevent flame propagation A manual 90 degree lockable ball valve was placed inline to stop gas flow from the cylinder Additionally we made mounting blocks to support and secure the fuel cell module Detailed drawings of these parts are in Appendix J Figure 6 Three dimensional model of the final design LOWER WATER TANK MODIFICATION Some modifications were made to the scrubber The front column of the clean water tank was removed to make space for the fuel cell module as shown in Figure 7 A two dimensional sketch was made using the CAD model and used to laser cut a sheet of acrylic to fit the tank This was placed over the cut section of the tank sealed with silicon and bolted into the tank A hole was drilled and tapped to fit a 1 8 NPT adapter tube was connected to the barbed end of the adapter to allow air to vent as the tank fills with water Figure 7 Three dimensiona
18. 00 1 2 kW Scrubber to the Nexa 1 2 kW fuel cell fuel cell and the Tuffshell 3300 sl and the AirGas 2265 sl compressed compressed hydrogen fuel tank hydrogen fuel tank FUEL CELL SYSTEMS We need to modify the T3 floor scrubber to accommodate a fuel cell system A section will be removed from of the body of the scrubber and holes will be made through the opposite side to allow coolant airflow The Nexa fuel cell stack operates at 65 C and will be exposed to the air inside of the scrubber Air will exit the stack at approximately 50 C We will create a duct to direct this air out of the scrubber A layer of thermal insulation will line the structure of the T3 around the Nexa fuel cell This heat shield will ensure that the structure stays at or below the working temperature of polyethylene 40 C We do not anticipate the T 1000 will require any additional insulation An auxiliary power source will be required to power each fuel cell system Based on power requirements listed in the Nexa User Manual we selected a 24V 5600 mAh Li ion battery to be used for either system The unregulated output voltage from the Nexa fuel cell system will require a 1 2 kW DC DC switching converter for power conditioning to protect the scrubber s electronics Many of the operating conditions for the fuel cell systems are the same Some notable differences are summarized in Table 6 and complete specifications for each system can be found in Appendix D Nexa T 1000 Fuel
19. 006 SUBAT An assessment of sustainable battery technology Journal of Power Sources 162 2 913 919 4 U S Department of Energy Energy Efficiency and Renewable Energy http www eere energy gov hydrogenandfuelcells fuelcells pdfs fc comparison ch art pdf gt Retrieved 1 17 2006 5 Larminie J and A Dicks 2003 Fuel Cell Systems Explained 2nd Edition New York John Wiley amp Sons 6 Mandil C Ed 2005 Prospects for Hydrogen and Fuel Cells Energy Technology Analysis Paris France International Energy Agency 7 Ballard Power Systems Inc 2003 lt http www ballard com be_a_customer power_generation fuel_cell_powergen nexa_power_module gt Retrieved 1 19 2007 8 Hydrogenics Corporation 2006 lt http hydrogenics com power pdf 5CHyPM_HD XR Brochure pdf Retrieved 1 19 2007 9 Intelligent Energy Ltd 2006 http www intelligentenergy com images uploads 1 3kw 20system_a4_format pdf gt Retrieved 1 19 2007 10 English Andrew HERE COMES THE FUTURE The Daily Telegraph 25 Nov 2006 sec Motoring 1 LexisNexis University of Michigan Ann Arbor 20 Jan 2006 11 Env Bike 2005 http www envbike com gt Retrieved 1 17 2007 12 U S Department of Energy Energy Efficiency and Renewable Energy 11 06 2006 http wwwh1 eere energy gov hydrogenandfuelcells storage hydrogen storage html gt Retrieved 1 17 1007 13 FuelCellStore com 2003 http
20. 07 0 06 0 06 oo j 80 690 gopow j j joozw j x x 5 L L L L L Key 9 gt Strong Relationship 3 gt Medium Relationship 1 gt Small Relationship blank gt Not Related Weights are figured on a scale of 1 to 10 ten being most important 35 APPENDIX D FUEL CELL SYSTEM SPECIFICATIONS Ballard s Nexa Ballard fuel cell power module Nexa Specifications Performance Fuel Operating Environment Physical Certification Emissions Integration Beginning of life sea level rated temperature range 2 At rated net power 2 Non condensing Rated net power Rated current DC voltage range Operating lifetime Composition Supply pressure Consumption Ambient temperature Relative humidity Location Length x width x height Weight Liquid water Noise Fuel interface Electrical interface Control interface 1200 watts 46 Amps 22 to 50 Volts 1500 hours 99 99 dry gaseous hydrogen 10 to 250 PSIG lt 18 5 SLPM 3 C to 30 C 37 F to 86 F 0 to 9596 Indoors and outdoors 56x25x33 cm 22 x 10 x 13 in 13 kg 29 Ibs CSA UL 0 87 liters 30 fluid oz maximum per hour lt 72 dBA 1 meter 45 flared tube fitting for 1 4 OD tubing metallic 8 AWG electrical wire Full duplex RS 485 Unit must be protected from inclement weath
21. 2 to pin X6 2 and connect the control line to pins X1 3 and X6 1 Don t care about polarity and you must not remove the already connected cables Use the red power connection cable to connect the relay to the converter positive output terminal SSC5 Ensure the correct polarity at the relay see case markings After installing the relay you can connect consumer loads between Terminal Battery Minus 5506 of the converter and the load relay At least before starting up the system you have to install the battery set as described below The load relay closes when the DC DC converter is switched on It opens immediately upon switching off the converter or in case of an operation error 07 2005 Heliocentris Energiesysteme GmbH 3 24 V DC DC Converter Installation Guide 42 Battery Set Parts list 2rechargeable batteries 12 V 18 Ah 1 Battery connection cable red 16 mm 40 2 x cable shoe 6 1 Battery connection cable black 16 mm 40 2 x cable shoe 6 1 Battery link cable black 16 15 cm 2 x cable shoe M6 incl fuse BF1 150 A 1 Spare fuse 1 Charge resistor with alligator clip Detailed connection diagram DC DC Power Unit Battery Minus Battery Plus Battery Fuse Battery iV 10 12V M Power Output Power Output Minus Plus LI Connect the batteries in series using the battery link cable with integral fuse to produce total battery voltage of 24
22. 409 3048 232 1053 19222 3150 3295 934 26 6 100 7 237 89 8 184 x49 467 1245 157 712 9128 1496 1566 443 12 6 478 11 3 426 184 78 _ 467 x 1981 235 1066 15230 2496 2613 740 211 798 18 8 712 184x100 467x2540 303 1374 19695 3227 3379 960 272 103 2 184 120 467 x 3048 350 1588 23944 3924 4108 1163 33 1 125 4 211x60 536 x 1530 195 883 15304 _ 250 8 2624 743 212 803 19 0 719 211x80 536x2032 258 1170 21153 3466 3629 1028 29 3 110 8 26 1 98 8 211x120 536 3048 380 1724 32937 5397 5651 1600 45 6 172 5 407 1539 Pressure rating at 70 F 21 C Standard Cubic Feet Natural gas capacity is based on a tank at service pressure filled with gas at a specific gravity of 0 60 and a temperature of 70 F Port sizes 1 1 16 12 UNF 1 1 8 12 UNF 2 12 UNF Tanks are available in boss mount configurations Contact us for other sizes and service pressures Valves end plugs pressure relief devices bracket kits and tank packs are available Lincoln Composites Inc LINCOLN 6801 Cornhusker Highway Lincoln NE 68507 USA Tel 1 800 279 TANK or 402 464 6611 Fax 402 464 6777 OMPOSITES E mail tuffshell lincolncomposites com Member of Hexagon Composites Group www lincolncomposites com APPENDIX F POWER DATA FOR THE T3 SCRUBBER ETR 20049078 Beta 6 Trojan 155Ah and 20 amp charger 143 minutes 2 23 total run time 50cm dual down pressure 70 Ibs propelled machine Test D
23. 69 179 7 1649 467 13 3 50 3 11 9 449 16 0 82 406 x 2083 144 65 3 12977 2127 1951 552 15 7 596 14 0 53 1 181x69 457 1755 165 746 13236 216 9 1988 563 16 1 60 9 14 4 545 3600 PSI 248 BAR Size 0 D x Length Weight Water Volume Gas Capacity Gasoline Equivalent Diesel Equivalent Inches Millimeters Lbs Kg Liters SCF SCM Gallons Liters Gallons Liters 92x24 234 610 27 124 905 148 153 43 12 47 92x35 234x880 37 168 1425 234 244 69 20 75 92x40 234x 1016 42 19 1 1655 271 284 80 23 87 20 77 92x64 234 1626 68 30 8 2810 450 482 137 3 9 147 3 5 13 1 129x34 328 886 47 213 3061 50 2 531 151 44 16 5 3 9 147 139x35 353 889 65 295 3345 548 574 16 3 46 17 5 13 9 40 _ 353 x 1016 74 336 3932 644 675 191 54 20 6 13 9 45 353 1143 84 38 1 4515 740 775 219 6 2 23 6 139x55 353 1397 102 463 5695 93 3 977 277 79 29 8 139x82 353 x 2083 153 _ 694 8920 1462 1530 433 123 157 35 399 x 889 88 313 4390 719 5 157x40 399 1016 78 _ 354 5175 848 157x49 399 1245 95 _ 431 6685 1095 157 52 399 x 1321 118 535 7108 1165 157 55 399 1397 106 481 7525 1233 1291 366 10 4 394 157x62 _ 399 x 1575 119 540 8620 1413 1479 419 119 451 157x71 399 1803 147 667 10030 1644 1721 487 13 9 525 12 4 46 9 157x120 399x3048 235 1066 17620 2900 3023 860 244 923 217 823 161x71 409 1803 139 630 10883 1783 1867 529 151 570 134 508 161 120
24. 8 bar Nexa Run Time 975 W 5 4 2 hours 3 4 2 9 hours T 1000 Run Time 1 2 kW 3 3 hours 2 2 hours Table 7 Summary of dissimilar characteristics between two compressed hydrogen storage options TENTATIVE BILL OF MATERIALS AND PRICE LIST Vendors have been contacted for more detailed information Lead time for components has generally stated to be about two weeks A summary of the components needed to implement a system and available prices are shown in Table 8 Component Supplier Price Fuel Cell System Heliocentris Nexa 6 500 00 ReliOn T 1000 7 734 00 Air Gas 50 00 Lincoln Composite DC DC 1200W Converter Heliocentris 3 100 00 24 V Lithium lon Battery Pack Battery Space 145 95 Smart Charger Battery Space 34 95 Hydrogen Leak and Detection Kit Fuel Cell Store 860 00 Pressure Reducing Regulator Swagelock tbd Stainless Steel Braided Hose Assembly Swagelock tbd Sealed Quick Connect with Shut off Swagelock tbd Manual Purge System Swagelock tbd Heat Sheild tbd tbd Fuel Cell Mounting Block tbd tbd Fuel Storage Mounting Brackets tbd tbd Table 8 Bill of materials and price estimate for initial selected concept components ENGINEERING ANALYSIS The following section outlines our engineering analysis of heat transfer plant balance life cycle analysis and risk assessment HEAT TRANSFER ANALYSIS In order to determine the appropriate insulation required to protect our scrubber from the heat generated by the fuel cell s
25. Consumption at 1 2 kW lt 18 5 lt 16 9 slpm Fuel Supply Pressure 0 69 to 17 2 bar 0 24 to 0 41 bar Weight 13 kg 26 to 54 kg Dimensions w x x h 25 cm x 56 cm x 33 cm 33 cm x 48 cm x 60 cm Warranted Lifetime 1500 hours or 1 year 3000 hours or 2 years Table 6 Summary of dissimilar characteristics between two competitive 1 2 kW fuel cell systems COMPRESSED FUEL STORAGE Both compressed hydrogen storage tanks can be mounted to the structure of the scrubber All protruding components will be kept on one side in the final design This will ensure that the scrubber will still be able to clean floors near walls Although a cylinder from Quantum Technology is not shown here custom designs are available on 16 request These systems will need additional components that are not shown in the conceptual models The additional components could include a hydrogen leak detection kit pressure reducing regulator braided stainless steel hose assembly sealed quick connect with shut off and manual purge Most of these are available from Swagelock but we are still waiting for quoted prices Mounting systems will be required to secure either system to the body of the scrubber Some characteristics of each system are shown in Table 7 Specifications for Lincoln Composite s Tuffshell fuel tanks are in Appendix E Lincoln Composites AirGas Size OD x L 24 cm x 46 cm 18 cm x 91 cm Weight 7 1 kg tbd Gas Capacity 3300 sl 2265 sl Pressure 207 bar 13
26. Fuel Cell Power for 24V Scrubber Amanda Christiana Jon Donadee Matt Garrity Tim Korhumel Sponsor Tennant Company Section Instructor Suman Das ME450 Winter 2007 Team 1 Department of Mechanical Engineering University of Michigan Ann Arbor MI 48109 2125 Final Report April 13 2007 ABSTRACT Tennant Company would like to explore the possibility of replacing the deep cycle lead acid batteries that currently power the commercial T3 scrubber with a fuel cell power pack Fuel cell technology is being considered in anticipation of reducing environmental impact improving customer satisfaction by increasing operation time between charging and simplifying maintenance by eliminating use of lead acid batteries and the required accessory charger The deliverables of this project include an assessment of current and future fuel cell technology a feasibility analysis of a fuel cell system given the current space constraints quantified price to performance ratios and a working proof of concept This report contains the results of our market research concept generation and evaluation and selected concepts and final design with engineering manufacturing and testing analysis TABLE CONTENTS NOMENCLATURE occ 3 INTRODUCTION ome 3 BACKGROUND INFORMATIOLNN 4 TYPES OF FUEL GELES R AY A e Qa S qu Ts s
27. N CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF lt INSERT COMPANY NAME HERE ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF lt INSERT COMPANY NAME HERE IS PROHIBITED DIMENSIONS ARE IN INCHES TOLERANCES FRACTIONAL ANGULAR MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL NAME DATE DRAWN CHECKED ENG APPR MFG APPR MATERIAL 55 USED FINISH APPLICATION DO NOT SCALE DRAWING COMMENTS SEE A DWG Back Mount Feet SCALE 1 5 WEIGHT SHEET 1 OF 1 45 4 19 1 00 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF lt INSERT COMPANY NAME HERE gt ANY REPRODUCTION IN PART OR AS WHOLE WITHOUT THE WRITTEN PERMISSION lt INSERT COMPANY NAME HERE gt IS PROHIBITED Q N DIMENSIONS ARE IN INCHES DAE TOLERANCES DRAWN FRACTIONAL ANGULAR MACH BEND CHECKED TWO PLACE DECIMAL ENG APPR THREE PLACE DECIMAL MEGAPPE MATERIAL COMMENTS FINISH NEXTASSY USEDON E aN Middle of Back Mount APPLICATION DO SCALE DRAWING SCALE 1 2 WEIGHT SHEET 1 OF 1 46 40 25 26 25 12 25
28. al 4 ADDITIONAL SYSTEM CONSIDERATIONS 5 RESEARCH c5cscscssccossscdoss amp scosesonsedscsssccvesceosedscotcoussendonctendbcosseesveusaseoocosesesuesedsecbancevedesbesdegosbeusesSensses 6 RETAIL PRODUCTS 5552 6 SYSTEMS NEAR PRODUCTION ssssccsccossicsscesteconcossasesssasicsssevssescsetecdaconsesscsvestosecnasedccebacsscosvaceddecvesueseesaseasoss 7 HYDROGEN STORAGE 7 FUEL CELL COMPARISON cu 7 BALLARD NEXA EE Cu ETE 7 EFOY SMART F EE tectis ess cob teen eund ico oai uen wau appe Lie 8 ADAPTIVE MATERIALS E20 T has Pas be epos uae Qa ceca droee birsi 8 DESIGN Ro denne 8 CUSTOMER REQUIREMENTS eene tno Yee Une th rond aoa 8 ENGINEERING SPECIFICATIONS U enean senses sense ta seen essa sense ense ease ense tassa aeo 9 QUALITY FUNCTION DEPLOYMENT 9 CONCEPT GENERATIOLN 10 FUEL CELL SYSTEM awa aW walau
29. amily meant that Matt wouldn t stay in one place for long during his younger years His family moved away from Connecticut before his third birthday and hasn t remained in one place for more than four years since His homes have included Massachusetts West Virginia Michigan and Louisiana Matt became more and more interested in engineering throughout his life from watching trains in Massachusetts to learning about cars while living in Michigan After graduating from Thibodaux High School in 2003 Matthew came to the University of Michigan as an undecided engineer By the end of his first year it became clear that Mechanical Engineering was the field most appealing to him because of his interest in such areas as mechanical design and dynamic systems Upon graduation Matt hopes to leave the Midwest and find a job in the industry that will allow him to return to New England where most of his family resides Eventually he hopes to again be in a position where he is able to travel the country further broadening his horizons as an engineer TIMOTHY KORHUMEL Graduating from Saint Francis de Sales Highschool Tim has been a native of Toledo Ohio for the majority of his life In 2003 he decided to attend the University of Michigan School of Engineering Tim chose to declare into Mechanical Engineering because of his interest in math and physics and the versatility of the degree The majority of his work has been in the automotive industry but has in
30. ardware Trunbuckle 1 49 Ace Hardware 1 8 Thread to 1 4 Barb Adapter 0 99 Ace Hardware 1 4 ID Tubing 4 0 95 UM Machine Shop 2 Square 2 0 00 UM Machine Shop PVC 1 x 2 2 0 00 UM Machine Shop Acrylic 1 8 Thick 0 00 UM Machine Shop Various machine screws 0 00 UM X50 Lab 12 28 gauge copper wire 0 00 UM X50 Lab 0 25 W 10 kOhm resistors x2 0 00 Carpenter Bros Hardware Aluminum Hinges 2 89 Carpenter Bros Hardware Qty 3 1 4 NPT Elbow 8 97 Carpenter Bros Hardware Qty 2 1 4 NPT Nipple 6 98 Carpenter Bros Hardware Teflon Tape 1 29 Carpenter Bros Hardware 5 8 ID Vinyl Hose 3 2 25 Home Depot Aluminum flashing for heat sheild 10 48 Murray s Auto Parts Bondo 17 99 Murray s Auto Parts Bondo Hardener 3 99 Murray s Auto Parts Bondo Mixing board 2 99 Murray s Auto Parts Putty knife 2 99 Home Depot Rigid Insulation Foam 24 62 Home Depot Liquid Nails Industrial Adhesive 2 27 Home Depot 80 grit Sand Paper 7 34 Home Depot sanding block 4 97 Home Depot Grey Spray Paint 1 96 Home Depot Mounting Tape 3 97 Ace Hardware 220 grit sand paper 1 18 Ace Hardware Rivets 4 99 Ace Hardware steel wool 2 29 Ace Hardware igc tool 0 99 Ace Hardware Silicone for sealing x2 9 58 11 186 27 Table 11 Final bill of materials suppliers and price list 27 TESTING PLAN TROUBLESHOOTING In order to determine any problems with the system it is necessary to narrow down which components might be malfunctio
31. ate July 28 04 Run Time Battery Trans Trans Vacuum Brush Machine Number of Voltage Current Volts Current Current Current LED s 5 24 5 2 8 12 5 12 8 18 8 35 0 10 10 24 5 3 0 12 5 12 7 19 0 35 5 10 15 24 4 2 9 12 6 12 7 18 9 35 2 10 20 24 4 3 0 12 5 12 7 18 0 35 2 10 25 24 3 2 9 12 6 12 7 17 8 35 0 10 30 24 3 3 0 12 6 12 7 18 0 35 0 10 35 24 2 3 0 12 6 12 5 17 2 34 6 10 40 24 2 3 0 12 6 12 5 17 0 34 5 10 45 24 1 3 1 12 6 12 6 17 0 34 7 10 50 24 0 2 8 12 6 12 4 17 4 34 5 9 55 24 0 3 0 12 5 12 4 16 4 34 5 9 60 23 9 2 9 12 5 12 4 16 7 34 5 9 65 23 8 3 1 12 5 12 4 18 0 36 2 8 70 23 8 3 0 12 4 12 2 16 0 34 2 9 75 23 6 3 2 12 4 12 2 17 0 36 0 9 80 23 5 3 2 12 6 12 1 17 9 36 0 8 85 23 4 3 1 12 6 12 0 18 3 36 3 8 90 23 3 3 0 12 5 12 0 18 1 36 4 8 95 23 2 3 4 12 6 12 0 17 1 35 4 7 100 23 1 3 4 12 7 11 9 17 8 35 2 7 105 22 9 3 6 12 6 11 7 17 7 36 2 6 110 22 7 3 4 12 6 11 8 18 0 36 5 5 115 22 6 3 5 12 6 11 4 19 0 36 4 5 120 22 4 3 6 12 5 11 4 19 9 38 0 4 125 22 2 3 4 12 5 11 3 18 7 36 4 2 130 21 9 3 0 12 5 11 0 19 0 36 8 1 135 21 6 3 8 12 5 11 9 18 8 36 5 1 140 21 2 3 5 12 5 10 7 18 9 36 3 1 35 6 39 APPENDIX G DATA FOR THE FUEL CELL SYSTEM Net System Efficiency LHV 0 5 10 15 20 25 30 35 40 45 Net Current Amps Net Efficiency NetPower 50 Output Voltage Volts 0 5 10 15 20 25 30 35 40 45 Net Curr
32. ated and evaluated conceptual systems that meet the design specifications This paper details the results of our research and the system design concepts BACKGROUND INFORMATION A fuel cell like a battery is a galvanic cell that converts chemical energy directly to electrical energy Galvanic cells generally consist of two electrodes the anode and cathode and an electrolyte The anode is the negative electrode It is made of a substance that is easily oxidized releasing electrons The cathode is the positive electrode It is made of a substance that is easily reduced absorbing electrons Together the electrodes create a spontaneous oxidation reduction reaction An electrolyte is placed between the anode and cathode so the electrons can flow through an external load while allowing the reaction to proceed In contrast to batteries a fuel cell converts supplied fuel to electricity as long as reactant gases are supplied In fuel cells the fuel and oxidant gas comprise the anode and cathode respectively Neither the electrodes nor electrolyte are consumed during the course of operation TYPES OF FUEL CELLS There are six major classes of fuel cells classified primarily by the kind of electrolyte used electrolyte determines the chemical reaction the catalysts required the operating temperature the fuel required and the suitable applications summary of the basic information for each type of fuel cell is listed in Appendix A The ope
33. cluded experience in civil engineering facility planning and prototype testing After graduation he plans on going back to school for a masters in business or law Outside of work and school Tim is a member of the Alpha Phi Omega national service fraternity 57
34. components needed to operate the DC DC converter with the Nexa Power Module are provided DC DC converter BSZ PG 1200 incl control unit connecting cable to Nexa Power Module user manual and software CD Battery set incl 2 rechargeable batteries 12 V 18 Ah battery connection set e Interface converter RS232 RS485 incl adaptor cable to DC DC converter adaptor cable to PC Relay connection set Connection cable 9 pin D Sub Please check the completeness of your delivery before starting the installation In case of deficiencies please contact Heliocentris 07 2005 Heliocentris Energiesysteme GmbH 1 50 24 V DC DC Converter Installation Guide 4 Installation Before installing the DC DC converter BSZ PG 1200 you should read the user manuals of ali components especially the DC DC converter and the Nexa Power Module Pay special attention to the safety instructions Installation notes and a detailed connecting diagram can be found in the enclosed user man ual Technical Description BSZ PG 1200 on pages 13 and 19 Please follow the procedure described there for connecting the components To install the additional components see the following notes and connection diagrams Overall connection diagram Nexa control line DC DC control line 3 Power supply for start up shut down Interface Converter 4 Resistively grounded I Control Unit See Nexa User Man
35. d to control the fuel cell The d c d c converter BSZ PG 1200 complies following requirements 6 9 99 99 9 9 9 6 High efficiency also at light load Protection of battery and fuel cell Automatic load reduction if NEXA in non specified conditions Microprocessor controlled operation for optimum use of battery and fuel cell Fully automatic operation Manual controlling possibilities by supervisory control system Easy installation Compact design lightweight construction LCD Display shows Nexa and BSZ PG 1200 parameters Integrated galvanic isolated RS232 adapter Free programmable U profiles via Visualisation and P Relay contact to engage disengage external loads protection for hybrid battery The d c d c converter BSZ PG 1200 is available in two variants for use in 12V and 24V Systems Werner von Siemens Str 16 98693 Ilmenau 1 info isle ilmenau de Leistungselektronik GmbH www isle ilmenau de Tel 03677 4613 0 Fax 03677 4613 is Steuerungstechnik und Xii DITIAN a 43 DC DC Converter BSZ PG 1200 Specifications Nominal output voltage 12V 24V Output voltage range 11V 15V 22V 30V Accuracy of output voltage 2 Nominal output current 100A 50A Maximum output current 110A 55A Maximum output power 1200W Maximum output current ripple 2 Operating input voltage range 26VDC 48VDC Maximum input voltage 50V Minimum voltage drop input to output 1 5V Power consumpti
36. de switches Computer data for proj vis software 9 pin D Sub cable DC DC Control Unit RS232 1 I For standard operation set switches to and operating parameters of the DC DC converter read by the provided visualization software Projvis exe via RS232 interface 9 D Sub connector This software also shows the basic Nexa parameters To read all Nexa operating parameters use the provided NexaMon Software The required data are sent via the RS485 bus The interface is 5 pin screw clamp connector at the con trol unit of the DC DC converter adaptor cable is enclosed By using the interface converter the data can be converted to RS232 standard and connected to a PC by the D Sub adaptor cable 25 pin to 9 pin Note that the interface converter needs external power for operation A wall mount power adaptor is enclosed Hu 07 2005 Heliocentris Energiesysteme GmbH 5 24 V DC DC Converter Installation Guide 5 Start up and operation For start up and the operation of the DC DC converter and the peripheral components see the Technical Description BSZ PG 1200 pages 4 12 6 Shut down When you switch off the DC DC converter via the control unit only the consumer load will be disconnected the converter s output will remain connected to the batte
37. degree elbow connects to the 5000psi line which uses a 45 degree flare compression fitting to connect to the Nexa We successfully assembled a leak free gas system as shown in Figure 10 Our gas system was assembled and tested in a laboratory equipped with a ventilation hood The lab space was approved by the University of Michigan OSEH office Assemblers followed safety guidelines given by Dr Chang Kim These guidelines include 1 Never work alone with hydrogen gas 2 Always wear safety glasses 3 Secure compressed hydrogen gas tanks at all times with straps and chain 4 No open flames or electrical sparks in the lab 5 Keep vent hood on at all times 6 Turn on hydrogen sensor at all times 24 Figure10 Photograph of actual gas component assembly ELECTRICAL COMPONENT ASSEMBLY Electrical components were assembled following the directions provided by the manufacturers The ISLE BSG 1200 24VDC voltage regulating system was designed specifically for the Nexa fuel cell system The components other than the control console are secured to the scrubber using mounting tape A steel cable was attached to the back of the control console and it is hung on the left side of the scrubber by a 3M removable hook We followed all directions for integration that were provided by Ballard and Heliocentris Appendix K but we have not been able to switch the Nexa into startup mode We are currently troubleshooting the system and to date we have not bee
38. e of providing full extended run backup or intermittent electrical power for as long as fuel is supplied to the unit Brought to you by Ballard the world leader in fuel cell technology The power module is backed by over 15 years of experi ence in the development of premium fuel cell products for transportation stationary and portable applications t 604 454 0900 f 604 412 4700 www ballard com Ballard Power Systems Inc 4343 North Fraser Way Burnaby British Columbia Canada V5J 5J9 36 ReliOn s 1000 T 1 000 Hydrogen Fuel Cell Functional Diagram Hydrogen Fuel Product Specifications T 1000 T 1000 in Enclosure Physical Dimensions wx d x hl 12 75 x 19 x 23 5 18 x 26 x 35 32 5cm x 48 25cm x 59 69 45 75cm x 66cm x 89cm 5510 12010872510 54 9 12010 185 156 5610 4 Mountin 19 rack mount Pad Pole Wall Performance Rated net power 0 to 1 200 Watts Ratedicurrent Wes 2 DC voltage 24 or 48 VDC nominal Supply pressure to unit 3 5 to 6 psig 24 to 41 KPag 0 24 bar to 0 41 bar Consumption 600 Watts 16 9 stpm 1200 Watts Hydrogen Storage Capacity n a Modular solutions scalable from 8 to 96 kWh Relative humidity 0 95 non condensing Altitude 19760 13 800 4 60m to 4206m Location 22222 Outdoors Emissions Water TT Meax30OmL KWh Nose 53dBAQ328ft lmeter Monitoring Control Remote configuration 8 status H
39. ee of CO2 which can add to the cost of the system Alkaline fuel cells are historically used in military and space applications although as price in PEM fuel cells goes down they are becoming less practical The phosphoric acid fuel cell PAFC was the first to be commercially produced in quantities in the US Europe and Japan The reaction rate is relatively high due to the porous electrodes platinum catalysts and high operating temperature Natural gas can be reformed however carbon dioxide will be a by product and the equipment adds cost and complexity to the system Overall the PAFC system tends to be reliable and low maintenance Large numbers of 200 kW combined heat and power systems CHP are currently in use The solid oxide fuel cell SOFC operates at very high temperatures which eliminates the need for expensive catalysts Additionally natural gas can be used directly without the need for a separate reformer The ceramic material used in the cells is expensive and difficult to handle This system usually requires fuel and air pre heaters and the cooling process is complex Furthermore the SOFC system can takes 20 minutes or more to start up Notable exceptions include the e20 and e50 portable SOFC from Adaptive Materials Inc ADDITIONAL SYSTEM CONSIDERATIONS There are other important considerations that affect the overall efficiency of the system may vary greatly between applications designs including oxygen ai
40. egulator from impact Steel chain and a small turnbuckle with a carabineer end were fixed to the upper cage using U bolts This chain and two polypropylene belts which are riveted to the body of the scrubber are used to secure the cylinder A dimensioned drawing of the cage is in Appendix J 23 Figure 9 Three dimensional model protective tank cage HYDROGEN GAS COMPONENT ASSEMBLY The hydrogen gas Delivery system was fairly simple to construct and install The components were selected to safely deliver compressed hydrogen gas stored at 2000psi to our fuel cell at 40psi A Smith CGA 350 two stage pressure regulator is used to bring the pressure down to 40psi A CGA 350 Regulator is used for flammable gasses A flame arrestor rated for 50psi was installed in case a hydrogen leak ignites This arrestor will stop flames from reaching the hydrogen tank through the hydrogen gas lines The arrestor has 4 npt fittings to fasten to the regulator and ball valve We added a ball valve to the fuel line to enable a quick manual hydrogen shut off in the case of a hydrogen leak or solenoid valve failure All threads were wrapped in Teflon tape and we checked for gas leaks using Snoop and a handheld hydrogen sensor A 90 degree elbow was placed between the regulator and flame arrestor A close nipple connects the flame arrestor to another 90 degree elbow The elbow connects to our ball valve which has a 3 inch nipple on the other end A third 90
41. ent Amps Net Voltage Max Min Gross Power Net Power Max Min Parasitic Power 1400 1200 1000 800 600 400 200 2000 1800 1600 1400 1000 800 600 400 Power Watts Power Watts 40 Hydrogen Consumption 5 10 15 20 25 30 35 Net Current Amps gt gt H2 Consumption Net Power 45 50 1500 1350 1200 1050 Power Watts 41 APPENDIX H FAILURE MODES 5 ANALYSIS Preliminary FMEA for the Fuel Cell Scrubber System Eval Team Amanda Christiana 5 Severity 1 effect 10 inopperable Jon Donadee O Occurrence 1 very rare 10 inevitable Matt Garrity D Detection 1 easily detected 10 undetectable Tim Korhumel Failure Mode S Possible Causes O Detection Testing D RPN A hydrogen leak could come from a leak in the fuel cell bad or broken seals loose fittings or non functioning solenoid valves A hydrogen leak could come from non functioning hydrogen solenoid and hydrogen leak in the possible fuel cell while flammability 9 operating asphixiation Internal hydrogen sensors integrated in the Nexa 1 fuel cell system The system enters a non 1 9 restartable mode if this failure occurs hydrogen leak in possible External hydrogen detection before reaching not pri ere purge valve while the hydrogen supply i flammable level 3 ef P
42. er sand and dust Specifications and descriptions in this document were in effect at the time of publication Ballard Power Systems Inc reserves the right to change specifications or to discontinue products at any time 10 03 Ballard BALLARD Nexa and Power to Change the World are registered trademarks of Ballard Power Systems Inc 2003 Ballard Power Systems Inc SPC5000039 0E PRINTED IN CANADA BALLARD power to change the world Ballard Power Systems introduces the Nexa power module the world s first volume produced proton exchange membrane PEM fuel cell module designed for integration into a wide variety of stationary and portable power generation applications Using Ballard s PEM technology the Nexa power module converts hydrogen fuel and oxygen from air non combustive electro chemical reaction to generate up to 1200 watts of unregulated DC electrical power Emitting heat and water as by products of power generation the Nexa power module allows original equipment manufacturer products to be used in indoor environments and other locations not possible with conventional internal combustion engines The Nexa power module s quiet operation and compact size make it ideal for integration into uninterruptible power supply systems emergency power generators and recreational and portable products And unlike battery technology with limited run times the Nexa power module is capabl
43. erformance beyond that of the current battery based system and create a more environmentally friendly image for Tennant Notes on the first meeting with our sponsor can be found in Appendix A For environmental considerations the system needs to be recyclable and free from harmful emissions From a feasibility standpoint a fuel cell based system must have an external or working temperature below the melting temperature of the T3 s base materials it must fit into the current battery s space and it should run on a commercially available fuel new system needs to run longer between charges last longer on a single charge and weigh less than the current batteries The new system also needs to be safe easily operated and refueled and require little maintenance ENGINEERING SPECIFICATIONS From the customer requirements we quantified measurable engineering specifications shown below in Table 2 By achieving these specifications we can determine the success of the project as it progresses Specification Required Value Operating temperature lt 40 Power Output 1 kw Voltage 24 V Current 30 A Size 0 034 m Additional Components Fuel Consumption Rate L s Time Between Refuel 3 hrs Weight 76 kg Overall Lifetime gt 2 yr Table 2 Engineering Specifications QUALITY FUNCTION DEPLOYMENT Once we had determined the requirements and specifications of our design project we began organizing it into the QFD Appendix B The custo
44. ermal regulation to control charge and discharge flow rates Refilling procedures are quite time consuming so there would not be much of an advantage over using batteries that require recharging In order to reuse a metal hydride tank a supply of hydrogen would be needed for refilling This most likely means that compressed hydrogen will still be used eliminating the gains that metal hydrides provided in safety Another problem is that many of the metal hydride tanks available would not meet the flow rates needed to power a fuel cell for our power demands Liquefied hydrogen was the final option we considered for storing fuel for our fuel cell system The advantages of liquefied hydrogen are that it contains some of the highest energy per volume and energy per weight compared to other options this would make ita small and light way to contain the fuel for our system Unfortunately the liquefaction process requires a large amount of energy and in order to keep hydrogen in its liquid form it needs to be stored cryogenically at temperatures below 250 C in specially designed storage containers These problems cause liquefied hydrogen not to be commonly available and systems that are available come at very high costs For these reasons it is clearly not practical for our application While it may seem that methanol would be the obvious choice for our fuel storage based on the results of the Pugh Chart there are disadvantages in DMFCs that prevent the
45. es Electrical Path Denotes Fluid Path Safety u Ventilation Hood lt Plumbing Leak Detector Fuel Storage Pressure Regulator 4 Fuel Fuel Cell System System Controller 3 Pressure Regulator Flow Regulator Lo lectrical System d Air Compressor Ambient Air Temperature Pressure Auxillary Battery Flow Rata 17774 Humidifier Humidity Sensors 24V DC DC Converter lt MEA Stack Electrodes lt I Exhaust Gasses 4 Power to Figure 1 Functional schematic of main subsystems 10 FUEL CELL SYSTEM From our initial research we already determined a few possible solutions for the type of fuel cell needed to complete this project After talking with several manufacturers including Ballard ReliOn Hydrogenics and Intelligent Energy we came up with two potential systems available for purchase that would satisfy the engineering specifications of the project The Ballard Nexa and ReliOn T 1000 both had comparable electrical outputs to the lead acid batteries currently being used We also met with Dr Chang Kim and discussed the possibility of using a fuel cell stack that the University already owned This stack was given to Professor Levi Thompson and Dr Ki
46. f coal gasification technologies we will study a scenario where hydrogen is produced by coal gasification Figure 5 shows the chain of processes and components that transfer energy to the T3 scrubber for two scenarios The figure also shows what percent of the original HHV of coal is passed between the components and ultimately to the scrubber The top path shows the current path that energy travels by to power the scrubber The bottom path shows how energy would travel if coal gasification was used to produce the hydrogen and the T3 was powered by our design Mining and Coal Electric Electric AC to DC SLA Transport Power Plant Transmission Inverter Battery n T3 chc 54 gt 19 n 2 4 224 gt Mining and Coal to Hydrogen Compression Fuel DC Voltage Transport Hydrogen and Storage Cell Regulator Gasification System Figure 5 Chain of energy transfer processes and components to power T3 scrubber Under the proposed scenarios our design increases the total system s energy efficiency by 25 8 resulting in 22 less coal used and associated pollutants produced Tables 9 and 10 page 21 show the efficiency values used for each process or component in the two proposed scenarios 17 4 Current System p Coal Power Electric AC to DC SLA Transport Plant Transmission Inverter Battery Efficiency 9096 3296 9796 8596 7596 Table 9 Energy efficiency of processes or components in the current system Proposed
47. fuel cell power pack could be used to power the T3 scrubber We have selected Ballard s Nexa fuel cell as the system to power the scrubber and we have modified the scrubber so that it accommodates the fuel cell and all of its components While our tests have yet to see the Nexa system activate our solution still achieves our goals The fuel cell system we have selected is feasible it fits current size constraints and the scrubber can essentially fit the entire unit by simply redesigning the water tanks With continued troubleshooting the scrubber should be fully operational while being powered by the fuel cell system ACKNOWLEDGEMENTS We would like to thank Professor Shorya Awtar for guiding us in the right direction as our team first formed For assistance during our research we would like to thank Professor Suman Das We also thank Professor Levi Thompson and Dr Chang Kim for their assistance in finding a lab space Thank you to Stephen Frank from Heliocentris for providing technical support and the Nexa Fuel Cell Manual Finally we would like to thank Mr Fred Hekman P E and Tennant Company for all of the help throughout this project 30 REFERENCES 1 Tennant Company Inc http www tennantco com na en resources clean and green aspx Retrieved 1 17 2007 2 Battery Life Saver http www battery rechargeable charger com environmental protection batteries html Retrieved 1 14 2006 3 Van den Bossche P F Vergels et al 2
48. her Heating Value Kilogram kPA Kilopascal kmh Kilometers Per Hour kWw Kilowatt 1 Liter LFL Lower Flammahbility Level m Meter MCFC Molten Carbonate Fuel Cell MEA Membrane Electrolyte Assembly PAFC Phosphoric Acid Fuel Cell PEM Polymer Electrolyte Membrane sl Standard Liter SOFC Solid Oxide Fuel Cell INTRODUCTION Tennant Company is a leading manufacturer of commercial and industrial floor care machines worldwide They currently control around 10 of the market with annual revenues in excess of 500 million In addition to meeting performance standards Tennant strives to meet green cleaning standards They have developed environmentally friendly products from detergents and coatings to cleaning machines and systems 1 Deep cycle lead acid batteries power their portable scrubbers including the T3 Battery recycling is well established but there is a risk to the environment if they are not disposed of properly 3 Lead acid batteries are inexpensive but recharge time diminishing capacity limited life and environmental stigma have motivated Tennant to examine alternative energy storage Fuel cell systems offer unique advantages as portable energy storage units compared to lead acid batteries The major appeal of a fuel cell system stems from its potential to deliver pollution free energy when run on pure hydrogen complete fuel cell system could be lighter than the 76 kg pair of batteries that currently power
49. her stalling point for compressed hydrogen is that because hydrogen is a combustible gas a number of safety precautions must be taken at all times Not only when the hydrogen is in use but also while it is being stored For our application completely leak free piping would have to be tested and used to ensure that there is no hydrogen escaping from our system and a hydrogen detector will always be necessary Methanol seems like it may be the most practical way of storing fuel for a fuel cell Like compressed hydrogen it is readily available Methanol can store energy at a lower weight and volume than compressed hydrogen Methanol is also less of a hassle than compressed hydrogen since it is a liquid it does not need to be under high compression Although handling liquid methanol is safer than dealing with hydrogen CO emissions can be dangerous indoors Metal hydrides are an option that initially seemed very promising as a method of fuel containment for our system Metal hydrides store hydrogen by breaking H down into H atoms which can be absorbed into the metal crystal structure This means that hydrogen is stored with a very high amount of energy per volume While precautions would still be taken once the hydrogen is released from the tank the actual storage of 13 hydrogen would be much safer than storing the gas in its pure form However there some major drawbacks to using metal hydrides They are heavy and require complicated th
50. individual comparisons were then averaged to give the overall relationships found in the central importance matrix We then benchmarked several solutions to evaluate how they meet customer requirements on the right and listed their current values for each specification on the bottom From our evaluation of each benchmark we were able to immediately rule out three of the six different types of fuel cells due to their extremely high operating temperature Phosphoric Acid Fuel Cells Solid Oxide Fuel Cells and Molten Carbonate Fuel Cells Each of these had operating temperatures well over the 120 C melting temperature of the polyethylene body of the T3 Scrubber We then determined that a Direct Methanol Fuel Cell would not be able to generate the necessary power to run the scrubber Finally due to their high expense Alkaline Fuel Cells were ruled out 4 5 15 CONCEPT GENERATION After conducting our market research and meeting with Dr Chang Kim we began establishing the necessary components of a fuel cell system that would be required to complete our goal We came up with a schematic that organized the functionality of the system Figure 1 Our functional schematic categorizes the required components into three main groups fuel cell system fuel storage and electrical system We were then able to better organize some of the information we found from our initial research and better focus our concept generation Denot
51. istorical and operational data Communications RJ45 089 Dry Contact C Contact Us 15913 E Euclid Ave 2006 ReliOn Inc All rights reserved Spokane WA 99216 MODULAR Protected by U S Patent Nos 6 020 716 6 096 449 Tel 1 509 228 6500 CARTRIDGE 6 218 035 6 387 556 6 428 918 6 468 682 6 773 839 Toll Free 0 5 1 877 474 1993 Reli 0 n TECHNOLOGY and other patents pending Product specifications Fax 1 509 228 6510 are subject to change at any time www relion inc com 37 APPENDIX E HYDROGEN STORAGE Lincoln Composite s Tuffshell Fuel Tanks TUFFSHELL Fuel Tanks Type 4 All Composite All sizes meet the requirements of ANSI CSA NGV2 US DOT FMVSS 304 CAN CSA B51 TC 301 2 METI KHK ISO 11439 and ECE R110 Dimensions weights and capacities are nominal 3000 PSI 207 Size 0 D x Length Weight Water Volume Gas Capacity Gasoline Equivalent Diesel Equivalent Inches Millimeters Lbs Kg Cu In Liters SCF SCM Gallons Liters Gallons Liters 9 5 x 19 241 x 500 19 7 1 769 12 6 116 3 3 0 9 3 6 08 3 2 95x57 241 x 1448 46 20 9 2913 477 438 124 3 5 13 3 31 11 6 15 6 55 396 x 1397 105 476 7540 1236 1133 321 91 346 82 30 9 156x71 396 x 1803 137 621 10112 1657 1520 430 12 3 464 10 9 41 4 156x84 _ 396 x 2134 160 726 12200 1999 1834 519 14 8 56 0 13 2 49 9 16 0 60 _ 406 1524 106 481 9097 149 1 1368 387 11 0 417 98 37 2 16 0 71 406 1803 124 56 2 109
52. it was understood that there would be four main fuel storage options These options include compressed hydrogen gas methanol metal hydrides and liquefied hydrogen Compressed hydrogen gas was selected as the datum in the Pugh chart below because it is well documented and relatively easy to obtain 12 Option 1 Option 2 Option 3 Compressed Methanol Metal Hydride Liquefied Evaluation Criteria Gas H Energy Volume Energy Weight Commercial Availability Ease of Use Safety Cost Flow Rate 0 0 Total Points 2 2 Table 4 Pugh chart evaluation of fuel storage methods Compressed hydrogen gas is a readily available method of hydrogen storage Several vendors including Lincoln Composites Quantum Technology and Airgas all distribute compressed hydrogen in cylindrical tanks of varying sizes Compressed gas storage is very common so the cost of storing hydrogen this way is very reasonable Using a compressed gas would work well in our system the gas will easily reach the required flow rate because of the pressure difference caused by compression Unfortunately there are several drawbacks to storing hydrogen as a compressed gas The first of which is that compressed hydrogen stores the smallest amount of energy per volume among our possible options making it the bulkiest possibility For a mobile device such as a floor scrubber this is certainly not ideal Anot
53. l model of clean water tank showing modification of the front column left and sketch used to laser cut acrylic cap right 22 FUEL CELL MOUNTING BRACKETS Mounting brackets were fabricated to fit the fuel cell onto the remaining surface of the lower water tank as shown in Figure 8 Two inch square blocks were used to make the back mounting blocks Holes were cut to fit the diameter of the vibration mounts and mounting feet then notches were cut to fit around the compressor The front mounting block and the back spacer were made from 1 2 blocks of PVC Holes were drilled to fit the mounting feet Detailed drawings are in Appendix J Figure 8 Mounting blocks have been fabricated to hold the fuel cell module in place within the scrubber GAS CYLINDER CAGE We made a protective cage for the hydrogen cylinder as shown in Figure 9 The base plate was machined out of 12 x12 6061 Aluminum Plate 1 4 thick 6 long 6063 Aluminum 2 x2 right angle was welded to the back of the plate and three 1 4 holes were drilled to attach the assembly to steel frame of the scrubber The upper and lower cage structure was made out of 6063 Aluminum 1 square tube 1 8 thick The links of each section were welded together A pair of hinges was bolted to the upper and lower cage as shown The actual cylinder was larger than expected so we added an additional section on the top of the upper cage as shown This is to protect the cylinder and r
54. lyte management problems Suitable for CHP Comparison basic information for five classes of fuel cells Note that Direct Methanol Fuel Cells DMFC are a developing type of PEMFC with low power output lt 100W that operate at 60 100 C 4 33 APPENDIX WITH SPONSOR Meeting with Mr Fred Hekman Pricipal Engineer of Advanced Product Development 1 16 2007 Company Tennant Company Inc Commercial and industrial floor care machines Currently have 10 of the market 550 million Major competitors include Nilfisk Advance Karcher Electrolux etc Product T3 Commercial Scrubber Generally has about a 5 year life List price 5997 Runtime between charges 2 3hours Structure is made out of rotationally molded polyethylene melting temp The user may need to refill H20 every 1 2 hour or so Current Power Source Two 12V 155Ah deep cycle lead acid batteries Trojan 1030120 List price 215 Cycle life translates into only about 2 years 500 cycles Experiences diminishing capacity over time Requires accessory charger and takes as long to charge as discharge Maintenance is complicated and puts user in direct contact with corrosive acid Motivation Environmental concerns o Lead is toxic o Consumer appeal of clean energy of the future connotation associated with fuel cells Performance o Longerrun time and or shorter refueling time 2hr min Cycle life Possibly indefinite and reusable
55. m from becoming our fuel cell of choice for this application Instead we will be using compressed hydrogen option because at this time it is the most feasible way to store hydrogen for a small mobile application AUXILIARY BATTERY COMPARISON The Pugh chatt for auxiliary battery options is shown in Table 5 A sealed lead acid battery SLA is used as the datum because this type is currently used as the power source for the T3 scrubber Sealed acid batteries are a cheap and mature technology but their weight safety concerns and the environmental impact are Rechargeable Li ion and NiMH batteries can both match the performance of SLA batteries with reduced size weight and environmental impact 3 Plugging in the system during startup and shutdown is also an option for providing auxiliary power An AC DC converting system would be more complicated to use than a rechargeable battery but it removes the environmental impact of battery chemicals and their manufacture A Li ion battery pack was selected for use as an auxiliary power source because it can meet system requirements in a small and easy to use package with a lower environmental impact 14 Sealed Lead Evaluation Criteria Acid Li ion SLA Size 0 Discharge rate 0 0 0 0 Weight 0 0 Commercial Availability 0 0 0 0 Ease of integration 0 0 0 Safety 0 Cost 0 Energy Capacity 0 0 0 Environmental impact
56. m after Visteon shut down its fuel cell program in Michigan While conducting our research we found two other fuel cell technologies available for purchase being used on a smaller scale Smart Fuel Cell s EFOY DMFC and Adaptive Material s e20 SOFC system FUEL STORAGE SYSTEM After determining the possible fuel cells that could be implemented for this project we began brainstorming the actual fuel and storage options that would be required For the PEM fuel cells that we were considering hydrogen would be necessary We looked at three main types of hydrogen storage that would be usable compressed gas metal hydride and cryogenic liquid H2 For the DMFC or SOFC we would need a methanol or propane fuel respectively ELECTRICAL SYSTEM Other than the Adaptive Materials SOFC the fuel cells we were considering would require some form of an external start up voltage We held a brainstorming session and came up with various auxiliary power solutions Along with wall power the majority of the brainstorming revolved around types of batteries We decided to look at and compare Nickel metal hydride Ni MH Li ion and lead acid batteries along with wall power CONCEPT EVALUATION After researching and generating ideas for a fuel cell powered T3 scrubber we compared the realistic options for each critical subsystem A Pugh chart was used to compare the advantages and disadvantages of possible components in a simplified and easy to under
57. mer requirements were listed in the leftmost column We then did a direct comparison between each requirement to find their relative importance While the majority of the requirements focus on improving the performance and usability of the T3 Scrubber an importance was placed on the safety of the fuel cell powered scrubber from a user and environmental standpoint Considering that this will be a prototype some of the requirements that would be more important for a production model were downplayed For example as technologies progress and fuel cells become more widely used lifetime will very likely improve size and weight will decrease and more recyclable materials will be put into use Along with the safety issues the more important requirements focused on the feasibility of implementing a fuel cell based system i e commercial availability of fuel and meeting current size constraints The engineering specifications and their units and target values were listed in the middle columns Each specification was then compared to each other for correlation in the upper roof matrix Values of or blank were filled into this portion to determine the correlation between each specification We each then compared the specifications to the customer requirements by filling in the central importance matrix with 0 1 3 or 9 These values give a rating of how strong each customer requirement relates to each engineering specification The
58. n able to communicate with the fuel cell control board via the ISLE console or directly using the supplied software We plan on contacting Heliocentris for troubleshooting advice See Figure 13 page 26 for a connection schematic of the electrical system UPPER WATER TANK RISER In order to fit the Nexa into the T3 we needed to raise the top water tank 10 inches This was accomplished by fabricating a riser to permanently support the upper tank Using the CAD models provided by Tennant we sketched the surface that the upper water normally lies on This drawing was printed out in true dimensions and pasted with a glue stick to a sheet of 2 inch thick Foamular R250 insulation board We then cut along the outline with a band saw producing our first layer This first piece was traced 4 times to produce the 5 layers The layers were glued together in a stack and then coated with bondo A section was cut out of the ring to allow cooling air to leave the T3 s interior This cut was 15 and 25 1 2 inches long beginning 14 inches from the rear foam piece s exterior was then coated with Bondo sanded primered sanded and painted 4 small brackets were made out of aluminum angle scrap for holding the riser in place on the T3 Mounting tape is also used on the bottom of the riser A three dimensional model of the riser is shown in Figure 11 Figure 11 Three dimensional model of upper tank riser UPPER WATER TANK BRACKETS Brackets were
59. n the form of a failure modes effect analysis Appendix H From the FMEA we found that the greatest safety risks came from the possibility of hydrogen leaks in the system especially while the system is off and unattended To counter each risk we looked at safety measures that can be taken In order to prepare for leaking our most significant safety risk we will have the system equipped with hydrogen detecting hardware and make sure the scrubber is always stored in a ventilated area Along with our FMEA we had to complete a student team risk assessment model to submit for approval by Lisa Stowe OSEH In this assessment we described the purpose of our project and gave an outline of all safety features in our desired lab space We also gave details on the safety rules and guidelines we will follow while working in the lab ref student team risk assessment In addition to working with safe equipment each of our team members have been trained by Dr Chang Kim to work with compressed gases in the lab FINAL DESIGN AND ASSEMBLY The main components of the final design include Ballard s Nexa fuel cell module a Q sized compressed hydrogen cylinder supplied by Cryogenic Gases cylinder cage and the ISLE brand 1200 W DC DC converter The DC DC converter is designed specifically for the Nexa module It comes with two small lead acid batteries to provide power to the fuel cell for start up and shut down Due to time constraints and ease of integration
60. nics and back up home generation DMFCs are particularly well suited for small electronics and soldier power units due to space and weight restrictions with a power requirement on the order of tens of watts Fuel cell powered battery chargers and home generators generally use PEMs on the scale of hundreds of watts up to a few kilowatts RETAIL PRODUCTS Fuel cells can be purchased as stack components stacks and complete systems Our search was focused on systems near to the T3 s power requirement around 1 kW There are several low kW range turn key systems available from companies such as Ballard ReliOn Intelligent Energy Hydrogenics ECD Ovonics and Arcotronics to name a few Most manufacturers websites will only provide quotes upon request Currently there are only a few retail websites such as www fuelcellstore com selling complete fuel cell systems These systems come with components for heat and water management fuel and airflow and internal control Five examples of retail systems currently on the market are listed in Table 1 PEM stacks produced in low quantities currently cost approximately 2000 kW but mass produced systems can achieve a price closer to 100 kW 6 Manufacturers claim that their systems have lifetimes ranging from 1500 hours for the Ballard Nexa 7 to unlimited for the Hydrogenics HyPM 8 Manufacturer System Type of Fuel Cell Power Ballard Nexa PEM 1200 W ReliOn T 1000 PEM 1200 W ReliOn 1000 1000
61. ning There are two main systems that need to be considered in detail the electrical system and the fuel line Electrical System Connections Schematic Status Readout System Load Relay Batteries Figure 13 Electrical system connections schematic In the electrical system the DC DC converter is the central hub through which all the power and signals flow It connects the startup power to the Nexa circuit board The converter also takes the fuel cell output and connects it to the batteries and scrubber This way the fuel cell charges the batteries or powers the scrubber The batteries are also connected in series to the scrubber which allows for a backup power source in the absence of hydrogen The controller takes data from the Nexa and the DC DC converter and gives a status readout on a laptop computer If any one of the connections is broken including the internal circuitry on the Nexa and the converter various controller errors will occur If for example the fuel cell fails to start up the controller will output DC DC Converter Error 080 It is up to the user to determine the cause of the error but technical support is available through Ballard Determining if certain power connections output a voltage can aid in narrowing down problematic components Once the electrical system is deemed to be running appropriately the fuel line system needs to be checked The follo
62. nsive removal AFC of potassium 194 212 F Space faster in alkaline of CO from fuel and hydroxide soaked electrolyte so high air streams required in a matrix performance Phosphoric Liquid 150 200 C SOkW 1MW 80 to 85 overall Distributed High efficiency Requires platinum Acid phosphoric acid 302 392 F 250kW module with combined heat generation Increased tolerance to catalysts PAFC soaked typical and power CHP impurities in hydrogen Low current and matrix 36 42 electric e Suitable for CHP power Large size weight Molten Liquid solution of 600 700 C SIEW 1MW 85 overall with Electric utility e High efficiency High temperature Carbonate lithium sodium 1112 1292 F 250kW module CHP e Large distributed e Fuel flexibility speeds corrosion and MCFC and or potassium typical 60 electric generation a variety of breakdown of cell carbonates catalysts components soaked in a e Suitable for CHP Complex electrolyte matrix management Slow start up Solid Oxide Solid zirconium 650 1000 C S5kW 3MW 85 overall with Auxiliary power High efficiency High temperature SOFC oxide to which a 1202 1832 F CHP Electric utility e Fuc flexibility enhances corrosion small amount of 60 electric e Large distributed e Can use a variety of and breakdown of yttira is added generation catalysts cell components e Solid electrolyte Slow start up reduces electro
63. om its more basic elements such as PEM stack pumps humidifier sensors and control unit Dr Chang Kim of the University of Michigan Chemical Engineering department offered to work with us to build a system The ease of integration and time constraints for this option are restrictive but a custom made system would allow us to better match power and performance requirements Based on our research and Pugh chart we have selected the Ballard Nexa and Relion T 1000 as our final options for a fuel cell power plant The available information scale of power and ease of integration for these systems makes them preferable to other commercially available fuel cell systems We would like to get more information on the T 1000 before making our final decision Datum Option 1 Option 2 Option 3 Option 4 Ballard Nexa Relion DMFC Build Our Adaptive Evaluation PEMFC T 1000 Own PEMFC Materials Criteria PEMFC System Micro SOFC Size 0 Power Output 0 0 Weight 0 a Temperature 0 0 Commercial Availability 0 d 9 3 i Ease of Use 0 Safety 0 Cost 0 Ease of Integration 0 Ease of Fueling 0 0 0 Total Points 0 2 5 4 3 Table 3 Pugh chart evaluation of fuel cell systems FUEL STORAGE COMPARISON The Pugh chart for fuel storage options is shown in Table 4 After conducting extensive research into the fuel requirements for fuel cells
64. on standby 2W Ambient temperature 0 C 40 C Efficiency 94 12V 96 24V Short circuit proof Yes Thermal protection Internal 80 C Interface RS232 BSZ PG 1200 RS485 Mechanical dimensions 320 x 14 x 80 mm Weight Approx 1 5 kg Scope of supply themes Phase 0 0 min vini Lisey bn O v gt 29 Ws hs v a n 8 DT Tes E ae CEI O lam Power unit with 6 screw connector to and battery Display control unit with cable connection to Nexa and power unit Cable for Nexa power supply External 12V 24V 4 5A d c d c converter only for 12V systems Visualisation software with first order the customer obtains the licence of visualisation software Visualisation of d c d c parameters Visualisation of Nexa parameters For more informations please contact ISLE GmbH 16 Steuerungstechnik und Leistungselektronik GmbH Status 06 2004 Werner von Siemens Str 16 98693 Ilmenau Tel 03677 4613 0 Fax 03677 46 13 90 info cisle ilmenau de www isle ilmenau de 44 APPENDIX J ENGINEERING DRAWINGS 1 88 8 00 4 00 2 00 50 24 3 00 L Q1 00Y 1 00 QTY 2 Back Mount Feet PROPRIETARY AND CONFIDENTIAL THE INFORMATIO
65. r supply hydrogen supply water management heat management operating pressure hydrogen storage and power conditioning To address these issues additional system components are needed Air and fuel may need to be circulated through the stack using pumps or blowers Water content the electrolyte must be carefully balanced as to maximize the proton conductivity without flooding the pores of the membrane often requiring external humidification of the oxidant gas before entry to the cell A separate source of air or water may be needed to remove excess heat produced by the cells A compressor or regulator and a feedback control system are generally needed to control the pressure within the stack Hydrogen storage is also an important factor low pressure metal hydride tanks can be heavy and expensive while highly compressed hydrogen storage can be energy intensive Some power conditioning such as a voltage regulator will be needed for connection to the electric load Fuel cell systems are typically installed in parallel with batteries or capacitors to manage load peaks MARKET RESEARCH Current estimates predict that the portable power market for fuel cells will be worth 2 billion by 2011 and many companies are already competing for their share of this emerging market Fuel cell stacks currently available on the market or in the near term are targeting applications such as battery chargers electrical power sources for soldiers small electro
66. rating conditions of the polymer electrolyte membrane fuel cell PEMFC make it the most suitable for mobile applications such as Tennant s T3 Scrubber The has a relatively low operating temperature using highly developed catalysts and electrodes to compensate for the otherwise slow reaction rate Additionally there are no corrosive fluids needed for operation and the cell can operate in any orientation The power output of the PEMFC can be scaled from a couple of watts to tens of kilowatts The electrolyte is a solid polymer membrane with a catalyst coated porous electrode bonded and sealed to each side The most widely used polymer is Dupont s Nafion Noble metals such as platinum are often used as the catalyst but today less expensive alternatives exist Because the membranes are sensitive to fuel impurities it is important to use pure hydrogen as a fuel for PEM fuel cells The direct methanol fuel cell DMFC is a type of PEMFC that is able to use methanol directly in liquid form as opposed to extracting the hydrogen externally These fuel cells are low power usually less than 100 W making them most appropriate for applications requiring slow and steady power for long periods of time such as portable electronics Alkaline fuel cells overcome slow reaction rates by using very porous electrodes and platinum catalysts while operating at high pressure The operation temperature is usually around 1009 The fuel and air supply must be fr
67. rious fuel cell systems BALLARD NEXA The Ballard Nexa fuel cell system more than meets the power requirements of the scrubber producing 1 2 kW Unfortunately this power needs to be regulated using a DC DC converter The price of the fuel cell comes to 6 500 but in order to provide the proper amount of power to the scrubber the additional cost of the DC DC converter must be added taking the price of 1 kW of power 9 600 The Nexa system runs using compressed hydrogen which is available at a price of 7 50 for an 80 f cylinder The expected run time for one cylinder is 243 minutes making the price per kWh of fuel for the Nexa system 1 83 EFOY SMART FUEL CELL The Smart Fuel Cell SFC system from Energy For You EFOY is a direct methanol fuel cell system that operates by recharging lead acid batteries Since the key to this project is the removal of lead acid batteries from the scrubber we will consider the power output of the fuel cell bypassing the batteries A single SFC unit only supplies 65 W which is not sufficient to power the scrubber In order to reach the needed output two units could be connected in parallel The cost of two units necessary for reaching 1 kW of power would come to 8 900 The SFC system runs on pure methanol which comes in a 10 liter fuel cartridge The system uses 1 1 liters of methanol per kWh with two fuel cells each time the system is refilled with two cartridges it should be able to run for 14 hours Ata cos
68. ry Therefore you should disconnect the batteries from the converter if not using it for a long time Note that the capacitors are still charged after disconnecting the batteries and could cause arcing Use the charge resistor AFTER disconnecting the batteries to discharge the capacitors at the converter s output Because the batteries lose their charge over time even when idle it may be necessary after a long time to recharge the batteries using an external battery charger 7 Grounding Ground every component your fuel cell system to the same potential to avoid ground rents from developing For detailed information for Nexa grounding please see grounding advices in the Nexa User s Manual chapter 6 6 Use only isolated data acquisition devices especially for measuring within the power line gt 9 s Nn o 07 2005 Heliocentris Energiesysteme GmbH 6 GANNT CHART 4020 uon lu s iq odx3 i 7 Ou shea s 20 2 712 8 eoueuuojog ezuojoeleuo E 10608 70 62 6 manoy 10v L0 jgz shea 6 1 mI skea z lquu ssv 10 96 sfeq OL Bununoyy 12145000 Lose fea mamay ufis q LO ZL E feq sped 19pJO 10 9 skea zi sajes YIM 20 012 O LG Z fea
69. s ric AT 0 0776 1 005 k 17K 1325W 2 kg Where c is the specific heat and AT is the temperature difference between the out flowing coolant air and the ambient With this we can determine the remaining power left for heat transfer through the sides and bottom of the stack to the scrubber body Por 1650W 1325W 325W 8 18 With each of the three remaining sides of the stack having approximately the same area 0 0393m we can consider one side with a heat transfer of 108W From the Heat Diffusion Equation 16 kA qona 77 4 Where k is the thermal conductivity of the insulation Lis the thickness of the insulation and dT is the temperature difference between the sides of the insulation For this model we assume that the insulation will be in direct contact with the stack and the body of the scrubber This will over estimate the necessary insulation thickness because there will be some space between the two From our engineering specifications page 7 we have a safe scrubber body temperature of 40 C Assuming it operates at a uniform temperature throughout the surface temperature of the stack is approximately 65 C Price per m 3 1004 r I rag Polystyrene Foam Closed Cell 0 020 y Polyethylene Foam HD30 Polypropylene foam Closed Cell 0 03 Polypropylene foam Closed Cell 0 02
70. s on the Nexa are that it cannot be mounted at an angle greater than 45 from level In terms of potential for other project teams there are few components that could be redesigned First the external cage could be improved by decreasing the weight and form factor The safety cage could be made with lighter materials and a form fitting design Through the use of plastic welding the scrubber body could be cut so that the tank doesn t stick out so much 29 components for the fuel system could also be improved upon electronically controlled valve system could be implemented to allow for the connections to be completely covered This would eliminate the danger of breaking off a regulator and creating a hydrogen propelled rocket tank This improvement could also allow for the tank to be mounted at a more horizontal position to move the center of gravity back over the wheels and increase traction Finally the auxiliary batteries could be replaced with a comparable set of Lithium Ion Lithium ion batteries would be lighter and could be created into a geometry to specifically fit space requirements CONCLUSION The goals of this project have been to explore the current and future states of technology to analyze the feasibility of a fuel cell system given space constraints and to deliver a working proof of concept for a fuel cell powered T3 scrubber After analyzing the current state of fuel cell technology we determined that a
71. stand manner Our previous research allows us to eliminate some of our unrealistic or unavailable concepts before comparing available options FUEL CELL COMPARISON The Pugh chart for fuel cell system options is shown in Table 3 Ballard s Nexa System was Selected as our datum because it is the most mature and documented option The Nexa is a fully functional power plant with fully developed electrical thermal and fluid control systems Although it does not match our space and power requirements exactly Ballard provides good support for product integration The ReliOn T 1000 fuel cell APU is a complete commercial system with capabilities and performance similar to the Nexa It also offers modular power capabilities that could remove the need for a DC DC converter The T 1000 is designed to be stationary and is therefore larger and heavier 11 than the Nexa making integration more difficult DMFC systems use methanol as a hydrogen carrier offering easy hydrogen storage and refueling However the power output of these systems is limited We considered using multiple DMFC units wired together but cost and system size would still be prohibitive A similar concept of wiring multiple Micro SOFC units together was considered These units use propane as a fuel and were not ready for cost effective production DMFCs and SOFCs both emit carbon dioxide creating risks for indoor use We also considered custom building a fuel cell power system fr
72. t T 2e4 5 4 163 e 001 Insulation Thickness Figure 4 Screenshot of CES EduPack showing potential insulation solutions Using Equation 4 and the CES Edupack we were able to determine possible materials for insulation and their necessary thicknesses Graphing this against price per area we were able to select the most cost effective solution LIFE CYCLE ANALYSIS Tennant Company is interested in comparing the environmental impact of using SLA batteries against that of our hydrogen powered design The electrochemical reaction within Hydrogen fuel cells is much more efficient for creating electricity than combustion The average efficiency of the total U S electrical grid power is near 32 19 while our commercially available fuel cell operates at up to 50 efficiency based on the higher heating value HHV of their fuels Of course there is a long chain of processes necessary to provide electric power to the T3 s scrub brush by means of hydrogen or the current battery system Each link in the power supply chain has alternatives and each has an efficiency associated with it There are many options being considered for future hydrogen production in mass quantities including coal gasification steam reforming natural gas or electrolyzing water The world s first commercial coal gasification power plant is currently being sited and should be completed by 2011 18 Due to the currently advanced and near commercial state o
73. t of 40 per fuel cartridge each refill of methanol will cost 80 making the cost of fuel 5 71 per kWh ADAPTIVE MATERIALS E20 Adaptive Materials e20 is a solid oxide fuel cell system The e20 is a 20 Watt system this would mean that at least 5 units will be necessary for power the T3 scrubber With an estimated unit cost of 5 149 this would become the most expensive system at 25 745 per kW The advantage would come in the cost of fuel for the system Even running five units simultaneously the cost of propane fuel for one kWh would only be about 0 50 DESIGN OBJECTIVES In order to better understand the core requirements of our project we met with Mr Fred Hekman from Tennant to establish customer requirements and their relative importance We then derived quantified engineering specifications and prepared a Quality Function Deployment QFD chart This method helped us identify the major requirements as they relate to our design objectives and determine which fuel cell technologies best fulfill the customer s need CUSTOMER REQUIREMENTS When determining our customer requirements the sponsor Tennant Company and the end user were considered We met with our contact at Tennant Mr Fred Hekman and discussed the overall motivation of the project From our discussion we determined that the focus of the project was to alleviate the environmental concerns of lead acid batteries determine the feasibility of a fuel cell based system show p
74. tack we performed a thermal analysis of the system The cell stack could be considered with the following model 17 Coolant Airflow 1325 W 0 131m Conductive Heat XS 939 Dissipation 0 131m 108 W x 3 Sides Figure 3 Heat Transfer Model of Nexa Fuel Cell Stack We assumed the front and rear ends of the system to be adiabatic or insulated due to the components that cover these portions The top of the stack includes convective heat transfer from the coolant airflow through the stack The remaining heat is transferred from the sides and bottom of the stack by conduction through the air to the scrubber body Before calculating the heat transferred to the body we had to determine the amount that is lost through the coolant flow that will be ducted away from the scrubber From the manual we know the maximum heat power generated by the stack is P 1650W and the majority of this is lost in the cool air flow We also know that the coolant airflow is 3600 slpm when operating at peak power and that it leaves the stack at a temperature of 17 C higher than the inlet air approximately 40 C when assuming a room temperature of 22 C The mass flow rate m was then calculated pV 1 293 e 0 06 007764 1 Where is the volumetric flow rate and p is the density of air at 40 assuming an ideal gas with the determined mass flow rate we could then calculate the heat transfer q in Watt
75. ual and Technical Description BSZ PG 1200 for details DC DC Data 5 DC DC rv CMS Power Unit c S x 8 lt os 5 o DC DC Power Output Battery Set Relay Connection Set Regulated Connection details see below Power Output Be careful with polarity when making the electrical connections and attend to the grounding of every device to avoid ground currents from developing For detailed information about this topic see Nexa User s Manual chapter 6 07 2005 Heliocentris Energiesysteme GmbH 2 51 24 V DC DC Converter Installation Guide 41 Relay Connection Set Parts list Relay power connection cable red 16 mm 15 cm 2 x cable shoe M6 Relay control line to load relay incl connector Link cable 0 5 mm 15 cm Detailed connection diagram DC DC Power Unit 9 Battery Minus Battery Plus Connector Nexa Load Relay Q v V Power Output Power Output Minus Plus The relay connection set is provided for you to connect the load relay included in the Nexa Start up Kit to the DC DC converter The integrated series resistor reduces the 24 V con verter voltage to the needed 12 V relay control voltage Connect relay and the link cable as shown in the connecting diagram on page 19 of Technical Description BSZ PG 1200 connect pin X1
76. uosueduio 10002 20 00 6 ss oo1d 100024 40 00 6 10 602 LO BL Z sis jeuy jeuueu 206 2 feat uoneziundo 08 27 0 ubiseq 8 6 206 0 skea s jueuisessy C fea 1edeg fed z manay 105 2 1018 2 sheq 1 eoeds einoeg LOIGIZ 0 6 z sishjeuy LO EIZ LOEIZ fed ueyo Loree 0 fedt Duiuuojsureig 10 6 2 shea 6 20 212 0 skea z 199 2002 0 2 skea 4 Suedx3 10 0 LOIEZIL sheq 1 squawalinbay WwajsAs LO EZ L manay 10041 70 02 JOMOd MANSY 1 1 515 3 1 m 5 5 3 1 4 8 5 3 1 v 1 W 5 3 4 M1 4 8 5 wis 5 ysiuly ues uoneing 4079 194 40 8 idv 10 1 idv LO SZ JEW 8L 40 LL JEW L0 y JEW 10 494 40 8 994 LO 984 4077 993 10 ez uer 10 be uer APPENDIX L 56
77. wing schematic shows the major components without the in between connections of the fuel line system 28 Fuel System Pressure Flame Ball Tank Regulator Arrestor Valve Figure 14 Schematic of fuel system connections If the controller is reading zero inlet pressure or flow the fuel system must be inspected First a check to see if the valves are open should be conducted In the even that all the valves are open and there is still no inlet flow the pressure needs to be checked to determine if there is any hydrogen left in the tank If the problem is a hydrogen leak that is being picked up by the portable detector then a check of all the inline connections needs to be performed With the valves all opened some liquid Snoop is squirted around each connection If bubbles form then there is a small leak and the fixture should be tightened FUTURE WORK Because of the limited timeframe for the project there are many improvements that can be made to this design Firstly it is important to note that this was a retro fit to an already existing product In the current marketplace these scrubbers are built around their power sources It is likely that a scrubber making use of this fuel cell would be built with the new space requirements in mind The body could be modified to fit the hydrogen tank within eliminating the need for an external cage It could also allow for different mounting orientations The only limitation
78. www fuelcellstore com products hci product desc htm Retrieved 1 17 2007 14 H2Gen Innovations Inc http h2gen com pages hydrogen economy subpages sub6 html Retrieved 1 22 2007 15 University of Princeton Fuel Cells Performance Data http www princeton edu chm333 2002 spring FuelCells types data shtml Retrieved 1 19 2007 16 Incropera F DeWitt D 2002 Fundamentals of Heat and Mass Transfer 5th Edition 31 New York John Wiley amp Sons 17 R Cha 5 Colella W Prinz F 2005 Fuel Cell Fundamentals New York Wiley amp Sons 18 Future Generation Alliance 2006 lt http www futuregenalliance org gt Retrieved 3 13 2006 32 APPENDICES APPENDIX A SUMMARY OF FUEL CELL CHARACTERISTICS Fuel Common Operating System Output Efficiency Applications Advantages Disadvantages Type Electrolyte Temperature Polymer Solid organic 50 100 C lt 1kW 250kW 50 60 electric Back up power e Solid electrolyte Requires expensive Electrolyte polymer poly 122 212 F Portable power reduces corrosion amp catalysts Membrane perfluorosulfonic e Small distributed electrolyte High sensitivity to PEM acid generation management problems fuel impurities e Transportation Low temperature Low temperature e Quick start up waste heat Alkaline Aqueous solution 90 100 C 10kW 100kW 60 70 electric Military Cathode reaction Expe

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