IPHE March 2004

Russian R&D in Hydrogen Energy: 

Russian R&D in Hydrogen Energy 2nd Implementation-Liaison Committee-Meeting of the IPHE Reisensburg Castle, Germany 01 March 2004 – 03 March 2004

Slide2: 

In present Russian R&D in Hydrogen Energy is carried out within the Programs supported by: Ministry of Industry, Sciences and Technology Ministry of Atomic Energy Russian Aviation and Space Agency Russian Academy of Sciences Lately private investors are facing to the Hydrogen Energy (Norilskii Nikel has announced a $40 million program in Hydrogen Energy)

Basic R&D directions: 

Basic R&D directions Novel hydrogen production technologies Hydrogen purification technologies Hydrogen storage Fuel Cells New catalytic systems New proton exchange membranes Hydrogen combustion systems Infrastructure Safety and standards

HYDROGEN PRODUCTION: 

On-board and on-site H2 and syn-gas production from hydrocarbon materials on the basis of plasma catalysis Plasmachemical large scale H2 production from methane and acid gas in non-equilibrium SHF-dischargers Natural gas thermal decomposition and wood processing New catalytic systems and small scale fossil fuel processors Advanced electrolysis (SPE and alkaline) Advanced technologies for LH2 production, storage and transportation HYDROGEN PRODUCTION

PEM-electrolyzers: 

PEM-electrolyzers Contact person: Prof. Vladimir N. Fateev Address: HEPTI RRC “Kurchatov Institute”, 123182, Moscow, Russia Tel: (7-095)1969429 Fax: (7-095)1966278 E-mail: fat@hepti.kiae.ru Small scale production of PEM-electrolysers of different productivity (up to 10 m3/h) was organized by RRC “Kurchatov institute” together with GUP Company MATYS. At present time electrolyzers are operating at current up to 1 A/cm2 with energy consumption 3,9-4,2 kWh/m3, platinum group metals loading is 1,6-3,5 mg/cm2. Proved lifetime is 20000 hours. The goals of proposed project – development of new generation of PEM-electrolysers for different pressures up to 30 atmospheres, with specific productivity up to 2 A/cm2 with reduced energy consumption (3,7-4,0 kW*h/m3) and price (to reach same price as for alkaline electrolyzers). New membrane materials, modified platinum and not-platinum electrocatalysts, other construction materials, optimization of heat and mass transfer, improved design of electrolysis stack and the installation will be the subject of the R&D in the frame of the project.

NATURAL GAS PROCESSING FOR PRODUCTION OF HYDROGEN AND PURE CARBON MATERIALS: 

NATURAL GAS PROCESSING FOR PRODUCTION OF HYDROGEN AND PURE CARBON MATERIALS On the basis of two-stage pyrolysis of natural gas the technology to produce hydrogen from natural gas simultaneously with pure carbon material for broad commercial applications has been developed. Thermal decomposition of natural gas is carried out in the heated porous matrix and according to the heterogeneous mechanism the pyrocarbon is formed in the pores of the matrix. As a result a solid carbon monolith is produced. As a porous carbon skeleton for pyrocarbon stuffing other carbon containing materials can be used (e.g. wood waste products, generally the vegetable origin waste). Moisture content,% Volatile, % Ash, % Sulphite, % C,% H, % Calorific value, MJ/kg Density, g/cm3 0.01 0.43 0.04 0.02 99.56 0.25 33.18 1.62 0.52 1.12 1.54 0.30 97.38 0.27 32.57 0.743 Contact person: Prof. V. Zaichenko Address: IVTAN, 125412, Izhorskaya 13/19, Moscow E-mail: zaitch@oivtran.iitp.ru

RRC “Kurchatov Institute’s” Test Facility “POVOD” for Development and Scaling of Plasma Assisted Processes of Hydrogen and Syn-Gas Production: 

RRC “Kurchatov Institute’s” Test Facility “POVOD” for Development and Scaling of Plasma Assisted Processes of Hydrogen and Syn-Gas Production “POVOD” demonstration unit at RRC “Kurchatov Institute” was designed to investigate and demonstrate the whole set of gas-phase plasma chemical processes under effect of stationary microwave discharge with power range from 10kW to 1,000 kW at microwave frequency 915 MHz. Air, nitrogen, water vapor, carbon dioxide, methane, propane-butane, oxygen, argon with a flow rate up to 2,000 m3/h at pressure between 0.005 atm – 1.0 atm can be used to burn MW discharge. Contact persons: acad. Vladimir D. Rusanov, dr. Sergei V. Korobtsev Address: HEPTI RRC “Kurchatov Institute”, 123182, Moscow, Russia Tel: (7-095)1969439; Fax: (7-095)1966278 E-mail: s.korobtsev@hepti.kiae.ru

Methane Conversion to CO+H2 in Non-equilibrium Microwave Discharge: 

Methane Conversion to CO+H2 in Non-equilibrium Microwave Discharge High power microwave set-up “POVOD” includes double side symmetric microwave energy input from one hand and a high speed (150-200 m/s) gas vortex chamber with vortex number 0.7-1.2 from the other hand. Stable discharge proved for energy input from 0.1 kWh/m3 to 1.2 kWh/m3. Experimental results have shown high efficiency methane conversion to synthesis gas (CO + H2) in microwave plasma both for steam and carbon dioxide reforming. Minimum energy cost for conversion degree 50% was about 1 kWh/m3 and 1.5 kWh/m3 per 1 m3 of syn-gas. Minimum energy cost for conversion degree ~100% was less than 0.8 kWh/m3 per 1 m3 of syn-gas, in case of oxygen presence in initial gas mixture. Contact persons: acad. Vladimir D. Rusanov, dr. Sergei V. Korobtsev Address: HEPTI RRC “Kurchatov Institute”, 123182, Moscow, Russia Tel: (7-095)1969439; Fax: (7-095)1966278 E-mail: s.korobtsev@hepti.kiae.ru

Acid Gas (H2S – CO2) Conversion in MW Discharge : 

Acid Gas (H2S – CO2) Conversion in MW Discharge Direct plasma chemical dissociation of hydrogen sulfide into hydrogen and sulfur H2S = H2 + S and syn-gas production from H2S/CO2 mixture H2S + CO2 >H2 + CO + S + H2O. have been experimentally tested under effect of different types of discharges: microwave, radio frequency, arc, gliding arc, etc. The experimental value of energy consumption can be about 1 kWh per 1m3 of H2 or syn-gas, which is very close to an appropriate theoretical limit - 0.6 kWh/nm3. The demonstration plant with discharge power up to 1 MW and productivity up to 1000 m3/h is in operation at the Natural Gas Treatment Plant in Orenburg (Russia). Contact persons: acad. Vladimir D. Rusanov, dr. Sergei V. Korobtsev Address: HEPTI RRC “Kurchatov Institute”, 123182, Moscow, Russia Tel: (7-095)1969439; Fax: (7-095)1966278 E-mail: s.korobtsev@hepti.kiae.ru

Microwave reformers of hydrogen raw material conversion into synthesis gas: 

Microwave reformers of hydrogen raw material conversion into synthesis gas Two converter types have been developed: based on the impulse periodical microwave discharge, and on the stationary discharge. Reactor: mass – 2 kg; size 80 x 400 mm Internal heat exchanger: mass – 1.5 kg; size 150 x 350 mm Microwave generator: exit peak capacity – up to 6 kW, average capacity - 3 kW, mass – 18 kg, size – 203 x 304 x 368 mm. Stationary converter Synthesis gas production: 20 nm3/hour; Converter size: below 350 x 500 x 500 mm, Mass: 31.5 kg, converter volume: 0.1 m3. Typical gas composition at reactor exit: N2 < 54.2%; Syngas > 40.0%; CO2 < 2.5%; CH4 + C2H4+ C2H2 <3.3% Electric power expenses for syngas production 0.15 kWh/m3 Conversion efficiency (with heat recuperation) is 94%. Contact persons: Acad. Vladimir D. Rusanov, Dr. Sergei V. Korobtsev Address: HEPTI RRC “Kurchatov Institute”, 123182, Moscow, Russia Tel: (7-095)1969439; Fax: (7-095)1966278 E-mail: s.korobtsev@hepti.kiae.ru

HYDROGEN SEPARATION, PURIFICATION AND STORAGE: 

HYDROGEN SEPARATION, PURIFICATION AND STORAGE Systems with polymer membranes High-Performance Membrane Diffusion Hydrogen Purifiers MeHy-systems for hydrogen storage and purification Nano-structures for hydrogen accumulation Cryogenic tanks

Surface modification of polymer membranes for gas separation : 

Surface modification of polymer membranes for gas separation MAIN FEATURES: - Method improves the selectivity of any membrane containing polydimethylsiloxane (PDMS) in the surface layers. - Productivity of the available apparatus (5 kW) is 0.3 m per minute. - Higher efficiency ADVANTAGES: prescribed membrane selectivity is available; 100 times improvement of selectivity; low treatment cost. Contact persons: acad. Vladimir D. Rusanov, dr. Sergei V. Korobtsev Address: HEPTI RRC “Kurchatov Institute”, 123182, Moscow, Russia Tel: (7-095)1969439; Fax: (7-095)1966278 E-mail: s.korobtsev@hepti.kiae.ru

High-Performance Membrane Diffusion Hydrogen Purifiers: 

High-Performance Membrane Diffusion Hydrogen Purifiers The Prototype modules have undergone extensive trials in real industrial environment for uninterrupted period of operation of more than 2 years without any deterioration in performance and other characteristics, without any noticeable changes in appearance, and without any loss of hermeticity. Technical Characteristics: Hydrogen content in feed gas 30 – 98% Output Hydrogen Purity 99.9999% Temperature range 300 – 800 oC Tolerance to fouling feed gas impurities up to 1.5 % H2S, 15 % CO, 30 % CO2 Input feedstock pressure 0.15 – 10 MPa Output pure H2 pressure 0.1 – 3 MPa Pure Hydrogen specific permeability 20 – 300 Nm3/m2 hr MPa1/2 Membrane element diameter 50 mm 150 mm Hydrogen production rate 1.0 – 3.0 Nm3/hr 70 – 120 Nm3/hr Module weight at max production 20 kg 200 kg Pure Hydrogen output per kg of module weight 0.1 – 1.5 m3 0.35 – 6.0 m3 Contact: A.V. Topchiev Institute of Petrochemical Synthesis, RAS, JSC “SYNPLAZ” 29 Leninskii prospekt, Moscow 119991 Russia E-mail: Slovetsk@ips.ac.ru

Metal-hydride Storage and Purification Systems : 

Metal-hydride Storage and Purification Systems Contact person: Dr. Stanislav P. Malyshenko, Laboratory for Intensification of Thermal Processes (LITP) Address: IVTAN, Krasnokazarmennaya, 17a, 111250, Moscow Tel: (7-095)362-53-11; Fax: (7-095)362-07-84; E-mail: litp@dataforce.net Institute for High Temperatures (IVTAN) in cooperation with Moscow Power Engineering Institute (MPEI) and Moscow State University (MSU) created experimental MeHy systems for hydrogen storage (1.5 kg H2) and purification (up to 20 nm3/h). To optimization of design and operation of devices the two-dimensional mathematical model of heat and mass transfer in MeHy reactors has been developed.

Hydrogen-absorbing alloys and Nanomaterials from low-cost raw materials: 

Hydrogen-absorbing alloys and Nanomaterials from low-cost raw materials New intermetallic alloys and composed nanostructures are investigated in Research Institutes of RAS and Moscow State University: MmNi5-based alloys with hydrogen content up to 1.45 mass.% and electrochemical capacity 300-330 mAh/g, and (Ti,Zr)(V,Mn,Fe,Ni)2 alloys with hydrogen content up to 2 mass.% and electrochemical capacity 330-350 mAh/g. Special concern is given to the interconnection of composition and alloy structure with hydride properties, influence of redistribution of metallic components in the alloy within the homogeneity region on AB2 crystal structure. The mathematical model for prediction of dependence of hydride dissociation pressure on the alloy composition was developed.

Cryogenic hydrogen tanks characteristics JSC “Cryogenmash”: 

Cryogenic hydrogen tanks characteristics JSC “Cryogenmash”   Contact person: Dr. Anatoly M. Domashenko Address: JSC “Cryogenmash”, 67 Lenin Ave. 143900, Balashikha, Russia E-mail: otd201@criogenmash.ru

FUEL CELLS: 

FUEL CELLS Power units on the base of Hydrogen-Air Alcaline FC Solid Oxide FC Solid Polymer FC New Proton Exchange Membranes

Electrochemical Generator “Cascade-IP”: 

Electrochemical Generator “Cascade-IP” The generator is based on advanced Alkaline Fuel Cell modules. One of the unique features of the generator is a patented zero-waste regenerative scrubber used for the removal of carbon dioxide from the incoming air. The scrubber reduces the operational cost and increases the overall serviceability of the generator. General Maximum power: 6.0 kW; Voltage: 30.0 – 42.5 V Maximum current: 200 A; Fuel: Hydrogen H2 consumption < 4.5 m3/h; Air consumption < 36 m3/h Pressure: Atmospheric Performance Operating conditions Ambient temperature: -20 to +40 °С Relative humidity (max): 98% at 25 °С The scrubber Dimensions: 1250 x 582 x 863 mm; Gross weight: 240 kg CO2 scrubber: built-in, regenerative Start-up: self-starting with built-in hydrogen burner < 15 min at 20 °С Electrolyte: 6.6 M KOH (aqueous solution) Contact person: Ziya Karichev, Independent Power Technologies Ltd, Director Address: 3-d Mytishchinskaya 16, bldg 60 129626, Moscow, Russia Tel: (7-095)2312109; Fax: (7-095)2312078; E-mail: karichev@ independentpower.biz

Planar Solid Oxide Fuel Cell: 

Planar Solid Oxide Fuel Cell I. Solid oxide electrolyte: YSZ - (ZrO2)0.92 (Y2O3)0.08 Diameter: 60 – 100 mm Thickness: 250 – 500 μm II. Electrolyte supported SOFC (operation temperature ~ 950С): Electrolyte: YSZ (thickness 250 – 500 μm) Anode: NiO + YSZ Cathode (two layers): (I) LSM (La0.85Sr0.15MnO3) + YSZ; (II) LSM III. Anode supported SOFC (operation temperature 800 - 850С) Thin-film electrolyte: YSZ (thickness 5 – 20 μm) Anode: NiO + YSZ (thickness 500 – 1000 μm) Cathode (two layers): (I) LSM + YSZ , (II) LSM Experimental Planar SOFC Stack Number of cells: 5 – 40; Cell configuration: round or rectangular Operation temperature: 900 - 950С Stack-average power density: 200 – 250 mW/cm2 Fuel: H2 or syn-gas Oxidant: air Contact persons: Dr. Nikolai Khramushin, Dr. Vladimir Ruzhnikov Address: SSC “Institute for Physics & Power Engineering”, 249033, Bondarenko sq. 1, Obninsk, Kaluga reg., Russia E-mail: khramushin@ippe.obninsk.ru ; ruzhnikov@ippe.obninsk.ru

Proton exchange membranes and membrane electrode assemblies for PEMFC and DMFC : 

Proton exchange membranes and membrane electrode assemblies for PEMFC and DMFC Russian research center “Kurchatov institute” together with OAO “Plastpolymer” developed perfluorinater membrane with functional sulfo-groups for PEMFC. Small scale production of such membrane was organized by extrusion technology. The parameters of this membrane are close to the Nafion ones. In recent years new methods of membrane material solution production, laboratory methods of membrane production by casting technology, new methods of the membrane electrode assemblies production were developed. Contact person: Prof. Vladimir N. Fateev Address: HEPTI RRC “Kurchatov Institute”, 123182, Moscow, Russia Tel: (7-095)1969429 Fax: (7-095)1966278 E-mail: fat@hepti.kiae.ru Expected membrane parameters: Specific resistance – about10 Ohmcm at 200C Thickness – 30 – 120 mm Density – 1.95 – 2.10 g/cm3 Exchange capacity – 0.85 – 1.10 mg * eq./g Relative elongation at rupture – 40 – 60% Water concentration 10-50%, Operating temperature – up to 105oC

HYDROGEN COMBUSTION SYSTEMS: 

HYDROGEN COMBUSTION SYSTEMS

Small-scale high-pressure H2/O2-steam generators : 

Small-scale high-pressure H2/O2-steam generators Small-scale high-pressure H2/O2-steam generators are designed for use in stationary and mobile autonomous hydrogen zero emission power units (ZEPU) based on 30-150 kW mini-turbine. The main features of experimental device: working pressure, MPa: 1-4 steam temperature, К: 600-1000 thermal capacity, kW: 40-156 length, mm: 300 max diameter, mm: 90. Fields of application: transport, autonomous energy supply systems, including systems based on renewable resources (solar and wind power plants with hydrogen energy storage). In combination with steam or gas-steam mini-turbine and electric generator such systems form compact and ecologically clean power plants for various vehicles: automobiles, locomotives, ships, with efficiency well comparing with fuel cells but much cheaper. Contact person: Dr. Stanislav P. Malyshenko, Laboratory for Intensification of Thermal Processes (LITP) Address: IVTAN, Krasnokazarmennaya, 17a, 111250, Moscow Tel: (7-095)362-53-11; Fax: (7-095)362-07-84; E-mail: litp@dataforce.net

High-pressure H2/O2-steam generators : 

High-pressure H2/O2-steam generators Experimental high-pressure H2/O2-steam generator parameters (IVTAN and Keldysh Center): Fuel/Oxidant Supply GH2/LO2 GH2/GO2 Flow rate O2, g/s 1300 1400 H2, g/s 160 170 Steam Temperature, oC 500-1200 500-1200 Pressure, MPa 5-7 7-10 Thermal power, MW 10-18 25 Contact person: Dr. Stanislav P. Malyshenko, Laboratory for Intensification of Thermal Processes (LITP) Address: IVTAN, Krasnokazarmennaya, 17a, 111250, Moscow Tel: (7-095)362-53-11; Fax: (7-095)362-07-84; E-mail: litp@dataforce.net

SAFETY AND STANDARDS: 

SAFETY AND STANDARDS Experimental investigations and mathematical modeling on Fire and Explosion Safety Sensors and reburners Safety Regulations and Standards

Catalytic Hydrogen Reburner : 

Catalytic Hydrogen Reburner Features: Minimal hydrogen concentration in air: 0.7% (Т < 70 C), not limited (Т > 70 C) Water influence: relaxation time increase (Т < 70 C) no influence (Т > 70 C) Relaxation time: less than 20 s (Т < 70 C) (4vol.% H2 ): less than 1 s (Т > 70 C) Allowed humidity: up to 100% Contact persons: acad. Vladimir D. Rusanov, dr. Sergei V. Korobtsev Address: HEPTI RRC “Kurchatov Institute”, 123182, Moscow, Russia Tel: (7-095)1969439; Fax: (7-095)1966278 E-mail: s.korobtsev@hepti.kiae.ru

INFRASTRUCTUREandSOCIAL ECONOMY STUDIES: 

INFRASTRUCTURE and SOCIAL ECONOMY STUDIES

Integrated system of co-production of energyand chemicals from excess resources ofEnergy System: 

Integrated system of co-production of energy and chemicals from excess resources of Energy System

Slide28: 

Firing tests of rocket engines at tilted test stand Liquid hydrogen Production facility. View of construction site. Contact: Chemical Automatics Design Bureau, Russian Aerospace Agency Address: Voroshilova st. 22, Voronezh, 394006 Russia Tel.: (7-0732) 333673 Fax: (7-0732) 334122 E-mail: cadb@comch.ru