November 2007 HYDROGEN & FUEL CELL TECHNOLOGIES Prepared for The Asian Development Bank www. t er i i n. or g The Energy and Resources Institute TIe Energy und Resources nsLILuLe zoo; Suggested format for citation T E R . zoo; RepIuce LIIs IIne wILI LIe LILIe oI LIe reporL New DeIII: TIe Energy und Resources nsLILuLe. For more information ProjecL MonILorIng CeII T E R Tel zq68 z1oo or zq68 z111 DurburI SeLI BIock I-muil pmcLerI.res.In HC CompIex, odII Roud Iux zq68 z1qq or zq68 z1q New DeIII - 11o oo Web www.LerI I n.org ndIu ndIu +q1 DeIII (o) 11 TABLE OF CONTENT nLroducLIon.........................................................................................................................1 AIkuIIne eIecLroIyLe IueI ceII (uIc)........................................................................................ q dIrecL meLIunoI IueI ceII (dmIc) ......................................................................................... q pIospIorIc ucId IueI ceII (puIc)........................................................................................... moILen curbonuLe IueI ceII (mcIc) ....................................................................................... soIId oxIde IueI ceII (soIc).................................................................................................... 6 Hydrogen Energy And ueI CeII TecInoIogy n ndIu........................................................ 6 PrIorILIes And TurgeLs..........................................................................................................; Hydrogen ProducLIon & Coz CupLure And SLoruge..............................................................; Hydrogen SLoruge, TrunsporLuLIon And DIsLrIbuLIon ........................................................ 8 AppIIcuLIons n C EngInes And ueI CeIIs......................................................................... q Hydrogen SuIeLy And Codes And SLundurds ...................................................................... q OvervIew oI Iydrogen und IueI ceII IndusLry In IndIu........................................................1o LecInoIogIes- currenL sLuLus und deveIopmenL LurgeLs In IndIu ........................................1z InLernuLIonuI LurgeLs und r&d ucLIvILIes In Iydrogen und IueI ceII LecInoIogy..................1q SLuLIonury Power AppIIcuLIon............................................................................................1q VeIIcuIur AppIIcuLIons...................................................................................................... zo Hydrogen ProducLIon And SLoruge TecInoIogIes ............................................................ zq Key PIuyers WorkIng On Hydrogen And ueI CeII TecInoIogy n ndIu ......................... z8 Benurus HIndu UnIversILy (BHU)..................................................................................... zq BIuruL Heuvy EIecLrIcuIs ImILed (BHE) ....................................................................... zq ndIun nsLILuLe OI TecInoIogy (T)................................................................................ zq SouLIern PeLrocIemIcuI ndusLrIes CorporuLIon ScIence ounduLIon (SPC-S) ........... zq NuLIonuI CIemIcuI uboruLory (NC), Pune: ................................................................... zq ndIun OII CorporuLIon ImILed........................................................................................ o ndIun nsLILuLe OI ScIence (Isc), BunguIore And CenLruI GIuss & CerumIc ReseurcI nsLILuLe (CGCR), KoIkuLu ............................................................................................... o MuIIndru & MuIIndru Ld................................................................................................ o TuLu MoLors....................................................................................................................... o TeIecommunIcuLIons ConsuILunLs ndIu Ld (TC) ........................................................ o Key nLernuLIonuI PIuyers And TIeIr ProjecLs On Hydrogen And ueI CeII TecInoIogy:.1 RuIIwuys .............................................................................................................................1 Aerospuce And Spuce.........................................................................................................1 Two- And TIree- WIeeIed VeIIcIes ................................................................................. orkIIIL And ndusLrIuI VeIIcIes ....................................................................................... q UnIversILy And AcudemIc nsLILuLIons.............................................................................. ReIerences......................................................................................................................... 6 Introduction ueI ceIIs ure In LIe eurIy sLuges oI deveIopmenL us un eIIIcIenL power generuLIon sysLem. Use oI IueI ceIIs In power generuLIon promIses Lo greuLIy reduce greenIouse gus emIssIons LIrougI ILs reIuLIve eIIIcIenL operuLIon (wIen compured Lo convenLIonuI LecInoIogIes). n uddILIon, u IueI ceII sysLem wILI IewJno movIng purLs oIIers u IowJ noIse-Iree operuLIon und cun operuLe on u vurIeLy oI IueIs, LIereIore oIIerIng severuI beneIILs wIIIe used In severuI oI LIe IdenLIIIed uppIIcuLIons Loduy. n 1q;o`s, IueI ceIIs were used us power generuLIon sysLems In ApoIIo spuce mIssIons. Toduy, upurL Irom spuce uppIIcuLIons IueI ceIIs ure beIng used In sLuLIonury und veIIcuIur power uppIIcuLIons. uLure uppIIcuLIons beIng InvesLIguLed Loduy IncIude IupLops, mobIIe pIones und oLIer remoLe communIcuLIon uppIIcuLIons. Figure 1: Comparison of power overall efficiency vs. plant capacity (Source: Fuel Cells for Distributed Generation, A Technology and Marketing Summary, March 2000, Energy Centre of Wisconsin, U.S)2 Hydrogen & Fuel Cell Technologies 2 A IueI ceII consIsLs oI un eIecLroIyLe sundwIcIed beLween un unode und cuLIode. TIe unode und cuLIode Iorm LIe eIecLrodes oI LIe IueI ceII. n u LypIcuI IueI ceII, IueI Is Ied conLInuousIy Lo LIe unode (neguLIve eIecLrode) und un oxIdunL (oILen oxygen Irom uIr) Is Ied conLInuousIy Lo LIe cuLIode (posILIve eIecLrode). TIe eIecLrocIemIcuI reucLIons Luke pIuce uL LIe eIecLrodes Lo produce un eIecLrIc currenL LIrougI LIe eIecLroIyLe, wIIIe drIvIng u compIemenLury eIecLrIc currenL LIuL perIorms work on LIe Ioud. AILIougI u IueI ceII Is sImIIur Lo u LypIcuI buLLery In muny wuys, IL dIIIers In severuI respecLs. TIe buLLery Is un energy sLoruge devIce In wIIcI uII LIe energy uvuIIubIe Is sLored wILIIn LIe buLLery ILseII (uL IeusL LIe reducLunL). TIe buLLery wIII ceuse Lo produce eIecLrIcuI energy wIen LIe cIemIcuI reucLunLs ure consumed (I.e., dIscIurged). A IueI ceII, on LIe oLIer Iund, Is un energy conversIon devIce Lo wIIcI IueI und oxIdunL ure suppIIed conLInuousIy. n prIncIpIe, LIe IueI ceII produces power Ior us Iong us IueI Is suppIIed. TIe workIng oI u IueI ceII cun expIuIned wILI LIe beIow governIng equuLIons, AL unode, zHz qH+ + qe- AL cuLIode, Oz + qe- + qH+ zHzO TIereIore overuII reucLIon Is, Hz + Oz HzO AL LIe unode, LIe IueI (Iydrogen) Is oxIdIzed Lo produce eIecLrons und H+ Ions (or proLons) und LIe oxIdunL (oxygen) Is reduced Lo Iorm wuLer uL LIe cuLIode, I.e. LIe oxygen moIecuIes reucL wILI LIe eIecLrons Irom LIe unode und H+ Ions Irom LIe eIecLroIyLe Lo Iorm wuLer. TIe eIecLrons LruveI LIrougI un exLernuI cIrcuIL, wIIIe LIe proLons LruveI LIrougI LIe Ion-conducLIng eIecLroIyLe. TIe reucLIons occur sImuILuneousIy und proceed conLInuousIy uL LIe eIecLrode surIuces us Iong us LIe guses ure suppIIed und LIe movemenL or mIgruLIon oI e- und H+ Ions Is noL resLrIcLed. 3 Hydrogen & Fuel Cell Technologies 3 Figure 2: Components of a fuel cell (Source: Gokul Ramamurthy, Validation of a novel approach of evaluating PEM catalysts, KTH Applied Electrochemistry, 2006) ReseurcI und deveIopmenL ucLIvILIes on IueI ceII LecInoIogy Ior LIe IusL coupIe oI decudes IoIIowIng ILs use In LerresLrIuI uppIIcuLIons Ius prImurIIy Iocused on deveIopmenL und unuIysIs oI u key pIysIcuI componenL, LIe cuLuIysL. TIe cuLuIysL, usuuIIy, PIuLInum (PL) pIuys un ImporLunL In LIe eIecLrocIemIcuI reucLIons LIuL Lukes pIuce InsIde u IueI ceII. PL cuLuIysL ucLs us u promoLer oI LIe ORR wIIcI Is u sIuggIsI eIecLrocIemIcuI reucLIon In compurIson Lo LIe HOR occurrIng uL LIe unode. ReseurcI wILI regurd Lo IueI ceII cuLuIysL Ius concenLruLed on Lwo key ureus- deveIopmenL oI newer cuLuIysLs (uIIoys LIuL ure compuruLIveIy cIeuper) und PL cuLuIysL sIze reducLIon. OLIer ureus oI currenL reseurcI concenLruLIon IncIude deveIopmenL oI sLubIe eIecLroIyLe und curbon supporL muLerIuI, eIIIcIenL wuLer und gus LrunsporL InsIde LIe IueI ceIIs. BeIow u brIeI descrIpLIon oI LIe dIIIerenL Lypes oI IueI ceIIs Is provIded. 4 Hydrogen & Fuel Cell Technologies 4 Alkaline electrolyte fuel cell (AFC) TIe eIecLroIyLe oI un uIkuIIne IueI ceII cun be eILIer sodIum IydroxIde or poLussIum IydroxIde. PoLussIum IydroxIde Is used quILe oILen us LIe eIecLroIyLe due ILs sLubIe cIurucLerIsLIcs. TIe operuLIng LemperuLure Is ubouL zooC wILI un eIecLroIyLe concenLruLIon oI 8wL% (und q weIgIL percenL, reduce over uII sIze, Improve recycIe IIIe und ensure suIe LrunsporLuLIon und reIueIIIng. 9 Hydrogen & Fuel Cell Technologies 9 Applications in IC engines and fuel cells Across LIe worId, IueI ceII LecInoIogIes ure sLIII In LIe eurIy sLuges oI deveIopmenL. SeveruI LecInoIogIcuI Issues concernIng cIoIce oI muLerIuIs, ImprovemenLs In desIgn und perIormunce oI IueI ceII sLucks und sysLems ure yeL Lo be IuIIy resoIved. Advunced reseurcI, LecInoIogy deveIopmenL und demonsLruLIon oI IueI ceII LecInoIogy Is requIred ndIu. TIe Roud Mup recommends LIuL pubIIc-prIvuLe purLnersIIps be esLubIIsIed Lo move Irom LIe reseurcI Iubs Lo IndusLrIes Ior evenLuuI commercIuIIzuLIon oI dIIIerenL LecInoIogIes In ndIu. n uddILIon, IL uIso recommends LIuL demonsLruLIon projecLs ure quIckIy Luken up wIIcI wouId noL onIy provIde operuLIng experIence In key Iydrogen uppIIcuLIons sucI us decenLruIIzed power generuLIon und use In uuLomobIIes, buL uIso IucIIILuLe creuLIon oI supporL InIrusLrucLure LIrougI pubIIc-prIvuLe purLnersIIp. SucI demonsLruLIon projecLs wouId uIso IucIIILuLe deveIopmenL oI Iow cosL, suIe und reIIubIe LecInoIogIes Ior producLIon oI Iydrogen, ILs sLoruge und suIe LrunsporL und deIIvery. Hydrogen safety and codes and standards TIe use oI Iydrogen us un energy currIer Is yeL Lo be expIoILed In LIe counLry. However, LIe IndusLrIuI use oI Iydrogen Ius been LukIng pIuce Ior u Iong LIme. As u resuIL severuI suIeLy codes und sLundurds Iuve been deveIoped. TIese sLundurds ure concerned wILI LIe IndusLrIuI uppIIcuLIons oI Iydrogen. And LIe presenL reguIuLIons ure Iocused on LrunsporLuLIon oI Iydrogen Lo und Irom LIe sILes. TIe Bureuu oI ndIun SLundurds (BS) Ius Issued specIIIcuLIon Ior compressed guseous Iydrogen sLoruge (S - 1oqo). TIe DepurLmenL oI ExpIosIves Is enLrusLed wILI LIe udmInIsLruLIon oI ExpIosIves AcL, 188q, PeLroIeum AcL, 1qq, nIIummubIe AcL, 1qz und oLIer ruIes Irumed under LIese ucLs wIIcI uIso IncIudes sLuLIc und mobIIe pressure vesseI (unIIred) ruIes, 1q81 und LIe gus cyIInder ruIes, 1q81. TIe OII ndusLry SuIeLy DIrecLoruLe (OSD) Ius IormuIuLed und coordInuLed ImpIemenLuLIon oI u serIes oI seII-reguIuLory meusures uImed uL enIuncIng LIe suIeLy In oII und gus IndusLry In ndIu However, wILI LIe ubsence oI reIevunL codes und sLundurds, IL Is IeIL LIuL LIe uccepLunce und commercIuIIzuLIon oI new LecInoIogIes sucI us IueI ceIIs deveIopmenL oI codes und sLundurds ure ImperuLIve. TIe Roud mup recommends LIuL codes und sLundurds Ior LIe enLIre runge oI Iydrogen energy be deveIoped. n uddILIon, LIe Roud mup suggesLs LIuL reIevunL ucLs 10 Hydrogen & Fuel Cell Technologies 10 concernIng LrunsporL secLor, envIronmenL und uIr quuIILy wIII requIre umendmenLs Lo encouruge suIe use oI Iydrogen. Overview of Hydrogen and Fuel Cell industry in India A mujorILy oI R&D ucLIvILIes on Hydrogen und ueI CeII LecInoIogIes Is beIng underLuken by pubIIc reseurcI InsLILuLIons IIke CSR, BHE Ld und some reIuLIveIy Iew prIvuLe IndusLrIuI Iouses sucI us SPC (SouLIern PeLrocIemIcuI ndusLrIuI CorporuLIon). Figure 3: Organization those involved in Hydrogen and Fuel Cell technologies (by type) (Source: Fuel Cells in India: A survey of current developments, 2007, Fuel Cells Today) n LIe ndIu conLexL, u Iurge umounL oI reseurcI Is Iocused on deveIopIng smuII sLuLIonury uppIIcuLIons usIng IueI ceIIs, wIIcI oIIers LIe greuLesL poLenLIuI uL presenL. ndusLrIuI users Iuve Iong used convenLIonuI sources Lo suppIy LIeIr own dIsLrIbuLed power und ure now IookIng Lowurds IueI ceIIs Lo provIde eILIer sLuLIonury buckup power or LIe muIn source oI power In IuLure. WILI LIe prevuIenL sILuuLIon oI IrreguIur suppIy oI power, power ouLuges even In mujor cILIes, sLuLIonury IueI ceII sysLems couId IeIp meeL LIe necessury demund eIIecLIveIy. TIe uuLomoLIve secLor Is LIe nexL mosL common uppIIcuLIon Iocus oI IueI ceII munuIucLurers In ndIu. 11 Hydrogen & Fuel Cell Technologies 11 Figure 4: Application focus of Indian industries and research institutions. (Source: Fuel Cells in India: A survey of current developments, 2007, Fuel Cells Today) Over LIe IusL Iew yeurs ucLIvILIes In LIIs Ius reusonubIy Increused. TIIs yeur, LIree sepuruLe worksIops on IueI ceIIs Look pIuce In ndIun nsLILuLes oI TecInoIogy (Ts). ueI ceII LecInoIogy Is LuugIL us u subjecL uL severuI ndIun unIversILIes, uILIougI LIere Is perceIved Lo be u skIIIs sIorLuge, purLIcuIurIy Ior IueI ceII munuIucLure und muInLenunce. However, despILe LIe sLrong R&D buse In ndIun unIversILIes, LIere Is currenLIy IILLIe IueI ceII munuIucLurIng experLIse. SeveruI compunIes In LIe sLuLIonury power und uuLomoLIve secLors ure suId Lo be IookIng Ior InLernuLIonuI coIIuboruLIons on IueI ceIIs Ior dIsLrIbuLed generuLIon und LrunsporL uppIIcuLIons. TIe DepurLmenL oI ScIence und TecInoIogy (DST) Ius esLubIIsIed u CenLre Ior ueI CeII TecInoIogy (CCT) In CIennuI, TumII Nudu wILI LIe specIIIc objecLIve oI demonsLruLIng und vuIIduLIng commercIuI uppIIcuLIons oI PEM IueI ceIIs In coIIuboruLIon wILI nuLIonuI und InLernuLIonuI IndusLry. CCT Ius creuLed 1-1o kW sLucks Ior remoLe power generuLIon wIIcI ure expecLed Lo be uvuIIubIe Ior commercIuIIzuLIon beIore LIe projecL`s end In eurIy zooq. TIe CouncII Ior ScIenLIIIc und ndusLrIuI ReseurcI (CSR), un IndusLrIuI R&D urm oI DST comprIsIng oI dIIIerenL InsLILuLes IncIudIng LIe NuLIonuI CIemIcuI uboruLory (NC) und LIe CenLruI GIuss & CerumIc ReseurcI nsLILuLe (CGCR), ure ucLIveIy InvoIved In reseurcIIng PEM und oLIer C LecInoIogy. 12 Hydrogen & Fuel Cell Technologies 12 TIe WorkIng Group on R&D Ior LIe 11LI Ive Yeur PIun recenLIy recommended LIuL reseurcI sIouId be currIed ouL on sysLem us weII us muLerIuIs deveIopmenL Ior Iow LemperuLure IueI ceIIs (uIkuIIne und PEMC); IIgI LemperuLure IueI ceIIs (MCC und SOC); IIgI LemperuLure reversIbIe IueI ceIIs; und DMCs. n purLIcuIur membrunes, bIpoIur pIuLes, cuLuIysLs und eIecLrodes need Lo be reseurcIed. OLIer muLerIuIs LIuL ure beIng proposed Ior deveIopmenL ure Iow cosL Iydrogen sensors und IeuL excIungers. TIere ure pIuns uL LIe ndIun nsLILuLe oI TecInoIogy (T) Mudrus und VeIIore nsLILuLe oI TecInoIogy (VT) Lo deveIop PEMC bused LecInoIogy Ior decenLruIIzed power generuLIon. AL LIe CenLruI GIuss und CerumIcs ReseurcI nsLILuLe (CGCR), u new generuLIon oI IIgI LemperuLure SOCs Is under deveIopmenL. TIe nsLILuLe Is workIng on SOCs und Is pIunnIng ucLIvILIes In coIIuboruLIon wILI BIuruL Heuvy EIecLrIcuI Ld., one oI ndIu`s IeudIng compunIes. ndIun nsLILuLe oI ScIence, BunguIore Is workIng on LIe deveIopmenL oI uIkuIIne und DMCs. TIe CouncII Ior ScIenLIIIc und ndusLrIuI ReseurcI Ius u mIssIon projecL InvoIvIng u number oI IuboruLorIes IncIudIng LIe NuLIonuI CIemIcuI uboruLory (NC), Pune, CenLruI EIecLrocIemIcuI ReseurcI nsLILuLe (CECR), KuruIkudI und oLIers. NC und CECR Iuve deveIoped u PEMC sLuck wIIcI LIey reporL Is seL Ior commercIuIIzuLIon. Technologies- current status and development targets in India TIe LubIe beIow provIdes u deLuIIed descrIpLIon oI LIe LurgeLs und proposed LIme-Irume Lo ucIIeve LIe LurgeLs seL by MNRE. Table 1: Technologies- current status and development targets (Source: National Hydrogen Energy Road Map, Ministry of New and Renewable Energy, Government f India, 2007) Technology International Status National Technology Gaps Proposed Time Frame for bridging the gaps By-product hydrogen By-product is hydrogen is available from chemical industry By-product hydrogen is available from chemical industry Purification, pressurization and storage of by-product hydrogen 2005-10 Steam Reformation (natural gas naptha etc.)/ Technology is proven and commercially available Used in oil refineries and fertilizer industry - Indigenisation of technology - Efficiency improvement - Hydrogenpurity (>99.9%) - Carbon sequestration 2005-15 13 Hydrogen & Fuel Cell Technologies 13 Technology International Status National Technology Gaps Proposed Time Frame for bridging the gaps Electrolysis of water Technology is proven and commercially available Technology is proven and commercially available Improvement in efficiency and reduction in energy consumption through development of new materials, components, sub-systems etc. for conventional alkaline and PEM electrolysers including high temperature electrolysis, using renewable energy sources like small hydro and wind energy etc. 2005-15 Gasification of coal and heavy residues Technology is commercially available Efforts under-way for development of technology - R & D for pilot scale FBG for producing hydrogen through coal gasification for Indian coal - Gas clean-up technology - CO2 separation (PSA & membrane) - Conversion to methanol (Fischer Tropsh process) - Integrated Gasification Combined Cycle - Carbon sequestration 2005-15 Biomass Gasification /Pyrolysis In pre-commercial stage In R & D stage R & D for pilot scale gasifiers for producing hydrogen through biomass 2005-15 Biological Routes In pre-commercial In pre-commercial - Scale up - Purification recovery 2005-15 Stage Stage - Compression - Screening of microbes - Bio-reactor design Specific energy consumption 2005-20 Photo-electrochemical, Photocatalytic In R & D stage In R & D stage - Thermo-chemical splitting of water using nuclear/ solar heat In R & D stage In R & D stage Thermo-chemical process: - Technology development for reactions & separations etc. - Materials, Catalyst, Membranes development - Development of Special processing methods & equipment - Measurement and control instruments & methods development - Close loop operations and stability - Solar thermal assisted thermo chemical splitting of water - Integration with Nuclear reactor High temperature nuclear reactors: - Special materials development - Corrosion and oxidation resistant coatings development 14 Hydrogen & Fuel Cell Technologies 14 Technology International Status National Technology Gaps Proposed Time Frame for bridging the gaps - High temperature & High performance fuel related development - Technology development for passive reactor safety system - Technology development for passive reactor safety system - Technology development for passive high flux heat removal system - Liquid metal related technologies - High temperature instrumentation High Pressure Gaseous Storage Several companies involved in development of high pressure gaseous storage (350-700 bar) No high pressure gaseous storage technology exists in the country. Indigenous development of high pressure gaseous storage 2005-10 Liquid hydrogen Technology is commercially available Liquid hydrogen plant is installed near Trivandrum by ISRO, used in space programme No experience of using liquid hydrogen for vehicular transport power generation - Hydrides R & D efforts are in progress in Japan, USA and other countries. Hydrogen storage capacity 1.5-2.o wt% for ambient conditions and 5-6 wt% for high temperature hydrides achieved. Research groups at BHU, IIT, Madras and ARCI, Hyderabad engaged in development. Hydrides with 2.42wt% storage capacity developed. Hydrides with (a) storage capacity up to 3 through 6 to 9wt%, and (b) cycle life of greater than 1500 are required to be developed for transport application. 2005-15 Other new Hydrogen Storage Materials and complex hydrides (carbon nanotubes, sodium alanates, etc.) In R & D stage In R & D stage. BHU, IITM and other upcoming institutions R & D efforts need to supported and strengthened 2005-2020 Unusual Routes Efforts being made on several unusual routes such as storage in zeolites, glass microspheres, chemical hydrides. R & D efforts to be initiated. Geological Survey of India to map out depleted mined R & D exploration efforts to be initiated 2005-2020 Hydrogen use in IC Engine CNG-Hydrogen blends used in IC engines In R & D and initial demonstration stage - To gain experience in CNG- hydrogen blending for use in IC engines - To overcome problems of per-2005-10 15 Hydrogen & Fuel Cell Technologies 15 Technology International Status National Technology Gaps Proposed Time Frame for bridging the gaps ignition, backfire and reduced output - To develop an IC engine suitable for hydrogen Fuel Cells Phosphoric Acid Fuel Cell (PAFC) Commercially available. More than 200 units of 200 kW capacity each deployed world over. Technology for development of units up to 25 kW capacity developed and demonstrated by BHEL. The Expert Group on Power Generation has indicated that there is declining interest in this technology world over. However, the relevance of PAFC has to be assessed in the context of requirements in the country and our experience and achievements in it so far. Polymer Electrolyte Membrane Fuel Cell (PEMFC) Commercially available. Number of companies are engaged in manufacturing such fuel cells. Fuel Cell stacks up to 5 kW developed and demonstrated by SPIC Science Foundation (SSF). SSF and BHEL are presently involved in development - To develop indigenous low cost proton exchange membrane. - To develop low cost bipolar plates (graphite based, high conductivity, impervious) preferably with flow grooves incorporated during moulding itself. Assembled stacks with imported materials for performance data. - To develop higher CO-tolerant anode catalyst - To develop cheaper cathode catalyst. - To develop cheaper cathode catalyst. - To develop electrode support substrate (graphite paper) 2005-2012 Alkaline Fuel Cell (AFC) Mature technology for space application In R & D stage. CECRI worked in this area earlier. Currently BHEL is working on development and supply of a 500 W power pack. - To develop compact, low power electrolyte re-circulation system. - To develop low cost CO2 scrubber & alkali-water heat exchanger. - To develop low cost catalysts (Ni-Co spinel, MnO2 /C). - To develop suppliers for low cost resin based mono-plates/ cell enclosures. 2005-2020 Solid Oxide Fuel Cell (SOFC) In R & D and demonstration stage In initial stages of R & D CGCRI, BHEL and NAL are engaged in development - To generate long term performance data & operational experience. - To develop indigenous sources for raw materials required for SOFC 2005-17 Molten Carbonate Fuel Cell (MCFC) Technology developed in USA. Presently in demonstration and early commercialization phase In early R & D stage. CECRI was involved in development. NTPC is keen to pursue this technology Technology yet to be developed in India even in R & D stage. Technological gaps can be identified after some progress is achieved in R & D efforts 2005-20 16 Hydrogen & Fuel Cell Technologies 16 Table 2: Targets and activities (Source: Ministry of New and Renewable Energy, Government of India) Area Year Activities Hydrogen production & Co2 capture and storage FY 2005-2007 - Estimation of by-product hydrogen for meeting the immediate requirement for demonstration projects. - Pilot demonstration plant for hydrogen production from hydrocarbons (Natural gas etc.) dedicated for emerging applications as energy carrier - Pilot scale reactors for production of hydrogen through biological, biomass routes - R&D on electrolysers including high pressure electrolysers - R&D on small reformers suitable for onsite and on-board reformation - R&D on gasification of coal for hydrogen production - R&D on carbon dioxide sequestration - R&D on thermo chemical methods of hydrogen production (Nuclear, Solar) - R&D on emerging methods of hydrogen production - Improvements in electrolysis process - Demonstration of small reformers FY 2007-2012 - Centralized hydrogen production from hydrocarbons - Pilot plant production of hydrogen production from renewable methods for on-site hydrogen production with a cost of Rs. 160 per kg at the production plant from electrolysis and Rs. 125 per kg from biomass - Design and development of coal gasification plant for hydrogen production - Carbon dioxide sequestration demonstration projects suitable for Indian conditions FY 2012-2017 - Large centralized hydrogen production facilities from hydrocarbons, cost of hydrogen to be progressively reduced to Rs. 70 / kg at the fuelling station or actual point of use - Hydrogen production using locally available renewable sources including on-site hydrogen production - Hydrogen Production from Electrolysis - Production of hydrogen reformers suitable for different feed stocks - Development and demonstration of thermo chemical water splitting methods - Hydrogen production through coal gasification - Large scale carbon dioxide sequestration FY 2017-2020 - Large scale production of hydrogen from centralized plants, and decentralized /on-site generation through several cost effective methods - Large scale use of small reformers suitable for different feed stocks - Large scale carbon dioxide sequestration - Choice of technologies for commercial production of hydrogen Hydrogen storage, transportation and distribution FY 2005-07 - Pilot plant for production of Intermetallic hydrides - R&D for improving hydride storage efficiency to 3 weight %, cycle life- 1,000 - R&D in other novel solid-state storage materials like carbon nanostructures. - R & D on complex hydrides like Alanates, Amides, Clatherates etc. - R & D on liquid hydrides, glass microspheres, zeolites, etc. - Development of high pressure hydrogen storage tanks and their testing ( 300 Bar) FY 2007-2012 - Large scale production of intermetallic hydrides - R&D for improving solid state storage efficiency to 5 weight %, > 1,000 cycles - Development of Nano and other Storage Systems (Carbon and other nano-17 Hydrogen & Fuel Cell Technologies 17 Area Year Activities materials, Alanates, Amides, Clatherates etc - Development of liquid hydrides - Demonstration of other hydrogen storage systems - Enlarging network of hydrogen pipeline linked to hydrogen production plants to areas having concentrated users of hydrogen - Production of high pressure hydrogen storage tanks (> 300 bar) for transportation of hydrogen - Use of other solid state hydrogen storage systems for vehicular application FY 2012-2017 - Expanding production facilities for metal hydrides - R&D for improving storage efficiency to 7.5 weight %, cycle life - 1500 - Enlarging network of hydrogen pipeline linked to hydrogen production plants to areas having concentrated users of hydrogen - Production of high pressure hydrogen storage tanks (300 700 bar) for transportation of hydrogen - Use of other solid state hydrogen storage systems for vehicular application FY 2017-2020 - R&D for improving storage efficiency to 9 weight %, cycle life > 1500 - Enlarging network of hydrogen pipeline linked to hydrogen production plants to areas having concentrated users of hydrogen - Production of high pressure hydrogen storage tanks (up to 700 bar) for transportation of hydrogen - Production and large scale use of other solid state hydrogen storage systems (up to 9 wt%) for vehicular application Applications in IC engines and fuel cells FY 2005-2007 - Extensive testing of hydrogen based IC Engine for evaluating their performance and limited demonstration for (i) in automotive engines, (ii) decentralized power generation; in selected locations - Demonstration of CNG-Hydrogen blend in three/four wheelers and buses - Development and demonstration of PEMFC for automotive and decentralized power generation - Development and demonstration of PAFC for decentralized power generation - Demonstration of PEM fuel cell-battery hybrid vehicles (vans/mini-buses) - R&D in other types of fuel cells (both low and high temperature type) - Development of micro fuel cells for power supplies of air-borne systems FY 2007-2012 - Expanded demonstration of hydrogen based IC Engine in automobiles and for decentralized power generation in areas having hydrogen supply or on site hydrogen production facilities - Widening the user base of CNG-Hydrogen blend in four wheelers and buses - Improvements in performance and cost of PEMFC for automotive and decentralized power generation - Expanded demonstration programme on fuel cell systems for decentralized power generation - Demonstration of fuel cell-battery hybrid vans/mini-buses and large buses - Development and demonstration of fuel cell vehicles - Development and demonstration of other fuel cell technologies for combined heat and power application and also of DMFC and DEFC - Demonstration of fuel cell systems for mobile applications 18 Hydrogen & Fuel Cell Technologies 18 Area Year Activities FY 2012-2017 - Expanded demonstration of hydrogen based IC Engine in automobiles and for decentralized power generation in areas having hydrogen supply or on site hydrogen production facilities - Expanding the user base of CNG-Hydrogen blend in three/four wheelers and buses - Improvements in performance and reduction in cost of PEM fuel cells for automotive applications to Rs. 5,000 per kW - Improvements in performance and reduction in cost of fuel cells for decentralized power generation to Rs. 40,000 per kW with >50,000 operating hours - Expanded demonstration programme on high temperature fuel cell systems for decentralized power generation and heat management - Demonstration and large scale use of fuel cell vehicles - Improvements in performance and reduction in cost of other fuel cell technologies for combined heat and power application and also of DMFC and DEFC - Expanding the use of fuel cells for mobile applications - Commercial production of IC engines/turbines suitable for hydrogen fuel FY 2017-2020 - Large scale use of hydrogen based IC Engine and fuel cells in automobiles and for decentralized power generation - Production of fuel cell systems for automotive and decentralized power generation to increase their demand. - Large scale use of hydrogen based IC Engine and fuel cells for (i) decentralized power generation, and (ii) automobiles - One million vehicles on road by 2020 - 1,000 MW aggregate capacity for power generation Hydrogen safety and codes and standards FY 2005-2007 - Study the specific safety requirements for hydrogen production, transport, storage and applications - Develop safety devices, sensors and systems for various hydrogen applications - Study the present Indian standards and international standards and identify the areas where additional / new standards are required FY 2007-2012 - Study the specific safety requirements for hydrogen production, transport, storage and applications - Develop safety devices, sensors and systems for various hydrogen applications - Study and incorporation of international safety standards for Indian conditions to improve existing standards - Development of new standards and codes FY 2012-2017 - Develop and adopt new standards and codes in harmony with international standards and codes - Develop and adopt safety regulations for vehicles - Publish documentation for all stake holders on recommended practices on safety FY 2017-2020 - Develop and adopt standards and codes in harmony with international standards and codes 19 Hydrogen & Fuel Cell Technologies 19 International targets and R&D activities in Hydrogen and Fuel Cell technology Stationary Power Application Over LIe IusL yeur, LIe IueI ceII sysLems In Iurge sLuLIonury uppIIcuLIons secLor Iuve moved Iorwurd. nLernuLIonuIIy, LIe muIn deveIopmenLs Iuve Iocused uround LIe drIve Lo commercIuIIzuLIon. AImosL uII compunIes In LIIs secLor Is specIIIcuIIy deveIopIng Iurge (>1okW) IueI ceIIs Ior sLuLIonury use. TIIs Lrend Is seL Lo conLInue over LIe nexL Iew yeurs wILI deveIopers sucI us ueI CeII Energy, UTC ueI CeIIs und SIemens movIng InLo LIe muILI-MW murkeL. Figure 5: Annual and cummulative new units (Source: 2007 Large Stationary Survey, 2007, Fuel Cells Today) 20 Hydrogen & Fuel Cell Technologies 20 Figure 6: Purcell Mode 200 Power Solution (Source: http://www.utcpower.com/fs/com/bin/fs_com_Page/0, 11491, 0104, 00.html) NorLI AmerIcu Is sLIII domInunL, und wILIIn IL CuIIIornIu und ConnecLIcuL uccounL Ior ureus wILI u Iurge mujorILy oI InsLuIIed cupucILy In LIe counLry. WILIIn AsIu, IncIudIng Jupun, IL Is onIy Koreu LIuL Ius uny reuI Iocus on Iurge sLuLIonury unILs. CIInu und Jupun ure boLI more InLeresLed In LrunsporL und smuII sLuLIonury unILs. Figure 7: Region of operation (Source: 2007 Large Stationary Survey, 2007, Fuel Cells Today) Vehicular Applications TIe LrunsporL secLors Iuve Iud unoLIer very posILIve yeur. A IundIuI oI compunIes Iuve been mukIng commercIuI sLrIdes. 21 Hydrogen & Fuel Cell Technologies 21 TecInoIogIcuI udopLIon conLInues Lo be vurIed wILI LIe IuII suILe oI eIecLroIyLes beIng used In vurIous cupucILIes. n recenL yeurs, severuI more counLrIes ure udopLIng IueI ceIIs In nIcIe LrunsporL uppIIcuLIons. TIe reusons Ior LIIs InLeresL IncIude: Iower burrIers Lo enLry LIuL mosL oLIer uppIIcuLIons, LIe ubIIILy oI LIe IobbyIsL Lo muke u reuI conLrIbuLIon, IncreusIng IegIsIuLIon drIvIng muny ureus Iorwurd und economIcs oI udopLIon IILLIng sweeL spoLs. n Lerms oI numbers oI unILs produced LIere Ius been u decIInIng Lrend. TIere Ius been un Increuse In LIe deveIopmenL oI IorkIIILs und IIoor-sIop crunes by severuI compunIes In LIe U.S und EU. DeveIopmenL oI LruIns, uILIougI beIng un ureu oI IncreusIng Iocus, IIke uerospuce, IL Is noL un uppIIcuLIon wIere new projecLs wIII see new unILs quIckIy. TIIs yeur Ius been ubouL LIe Increuse In InLeresL und guInIng u beLLer undersLundIng oI LIe cosLs und beneIILs ruLIer LIun new Iurdwure. TIereIore uILIougI LIe ucLuuI numbers ure noL us IIgI us expecLed, IL Is sLIII very posILIve. Figure 8: New Units installed in 2007 (Source: 2007 Niche Transport Survey (!), Fuel Cell Today) 22 Hydrogen & Fuel Cell Technologies 22 Figure 9: Fuel cell Technologies in 2007 (Source: 2007 Niche Transport Survey (!), Fuel Cell Today) Figure 10: HyFish-Jet (Source: Horizon Fuel Cells) 23 Hydrogen & Fuel Cell Technologies 23 Figure 11: H2 Truck and refuelling Station from H2 Logic n Lerms oI udopLIon, NorLI AmerIcu (USA und Cunudu combIned) sLIII domInuLes LIIs secLor. TIIs Ius been expIuIned Lo be becuuse oI LIe deveIopmenL und LesLIng oI IorkIIIL, us ILs suIe Lo LIe IndusLrIuI Is expecLed Lo kIckIng oII by LIe end oI LIIs yeur. ConverseIy scooLers und oLIer Lwo- und LIree-wIeeIed veIIcIes uppeur Lo be oI very IImILed InLeresL In AmerIcun conLInenL, wIIIsL oI IIgI InLeresL Lo counLrIes IIke CIInu und Jupun. Some gouIs und proposed R&D ucLIvILIes oI LIe Europeun UnIon und U.S. Is provIded In LIe LubIe beIow. Figure 12: New units by country of manufacture (Source: 2007 Niche Transport Survey (!), Fuel Cell Today) ndusLry Iocus Ius IeuvIIy cenLered on LIe deveIopmenL oI IorkIIILs, LIe uppIIcuLIon LIuL Is beIIeved Lo be cIosesL Lo commercIuI. L Is expecL LIuL LIere wIII u sLeudy growLI In mosL ureus wILI IorkIIILs sIowIng IusLer upLuke und LruIns uLLrucLIng 24 Hydrogen & Fuel Cell Technologies 24 Increused poIILIcuI InLeresL. TIe mIIILury Is u key udopLer, und drIver, In LIIs ureu, especIuIIy In LIe UAV secLor. Hydrogen production and storage technologies L Is esLImuLed LIuL more LIun q% oI generuLed Iydrogen Is produced by reIormIng convenLIonuI Iydrocurbon IueIs or Irom couI. EIecLroIysIs - LIe spIILLIng oI wuLer usIng eIecLrIcILy, uccounLIng Ior LIe remuInIng %, Is LIe oIdesL oI LIe Iydrogen producLIon LecInoIogIes. TIIs LecInoIogy Ius IuII bIown commercIuI sysLems Ior IndusLrIuI use. TIe cIemIcuI eIecLroIyLe used In LIe eIecLroIysIs Is beIng repIuced by proLon excIunge membrune (PEM). PEM eIImInuLes LIe need Ior mecIunIcuI compressIon Lo ucIIeve desIrubIe pressure IeveIs. UnIIke LIe convenLIonuI IueIs, LIe InIerenL properLIes oI Iydrogen muke IL u dIIIIcuIL commodILy Lo produce, sLore und IundIe on u Iurge scuIe. However severuI compunIes und reseurcIers uL Lop UnIversILIes ure IncIIng uIeud by proposIng soIuLIons Lo LIe probIems In Hydrogen LecInoIogIes. Toduy LIe LecInoIogIes Ior Iydrogen producLIon und sLoruge ure uL vurIous sLuges oI commercIuI deveIopmenL. Some compunIes ure conLempIuLIng on usIng soIur power Lo breuk LIe wuLer moIecuIe Lo IIberuLe Iydrogen. PEM eIecLroIysIs und LIe soIur Iydrogen producLIon ure In LIe puLIwuy Lo commercIuIIzuLIon. TIese Iydrogen producLIon LecInoIogIes IInd uppIIcuLIons sucI us buck up power sources und Lo power uuLomobIIes wIen used In concerL wILI u IueI ceII. TIere ure LecInoIogIes wIIcI produce Iydrogen usIng eIecLroIysers In uuLomobIIes Lo Ieed InLernuI combusLIon engInes uIong wILI LIe convenLIonuI Iydrocurbon IueIs. TIIs LecInoIogy eIImInuLes LIe need Ior IueI ceIIs us Iydrogen Is generuLed us und wIen requIred by LIe uuLomobIIes. Compressed und guseous Iydrogen sLoruge LecInoIogIes ure unLIcIpuLed Lo seL Lrends In IueIIIng sLuLIons or Ior on bourd veIIcIe sLoruge. However, LIe success oI LIese LecInoIogIes depends on LIe deveIopmenL oI Iydrogen InIrusLrucLure und LIe deveIopmenL oI InLernuI combusLIon engInes Ior uuLomobIIes. MeLuI IydrIde und cIemIcuI IydrIde Iydrogen sLoruge LecInoIogIes ure proposed Ior porLubIe uppIIcuLIons IIke mobIIe pIones, IupLops personuI dIgILuI ussIsLunLs eLc. TIe meLuI IydrIde LecInoIogIes Iuve Lo compeLe on LIe compucLness und LIe cIemIcuI IydrIdes sLoruge LecInoIogIes 25 Hydrogen & Fuel Cell Technologies 25 Iuve Lo prove ILs envIronmenL IrIendIIness wIIIe recycIIng LIe reucLed cIemIcuIs buck us ruw muLerIuIs. TIe reseurcI communILy Is on ILs InnovuLIve puLI Lo propose soIuLIons In Iydrogen producLIon sucI us soIur reucLors Ior co-producIng Iydrogen und curbon bIuck, oxIduLIve reIormIng oI eLIunoI over pIuLInum cuLuIysLs, soIId sLuLe reucLIons, und soIur energy. Hydrogen sLoruge reseurcIers ure workIng on muLerIuIs sucI us boron nILrIde, curbon nunoLubes, dry sodIum boroIydrIde, nonporous orgunIc muLerIuIs, nunoscuIe muLerIuIs und nIckeI mugnesIum IydrIde buLLerIes By zoo8, we sIouId see u IoL oI uuLomobIIes usIng Iydrogen (produced by eIecLroIysIs) uIong wILI LIe convenLIonuI Iydrocurbon IueIs In LIe InLernuI combusLIon engInes oI veIIcIes. Buckup power sources usIng eIecLroIysIs und mIIILury porLubIe uppIIcuLIons wouId become cosL compeLILIve by zo1o. TIe IoIIowIng IIgure sIows LIe LIme IIne oI LIe evoIuLIon oI vurIous Iydrogen powered uppIIcuLIons. ApurL Irom Table 3: International targets and R&D activities Country Goal Proposed R&D activities United States of America A hydrogen fuel Cell Vehicle equal to or less than the competitive gasoline vehicle in 2015 Production: Reduce the cost of distributed production of hydrogen from natural gas to $2.50/gge (delivered, untaxed) at the pump (without carbon sequestration) by 2010; and reduce the cost of distributed hydrogen production from biomass-derived renewable liquids to $2.00 - $3.00/gge (delivered, untaxed) at the pump by 2015. Verify grid-connected distributed water electrolysis at a projected delivered hydrogen cost of $2.85/gge by 2010, and by 2015, verify central hydrogen production from renewable energy sources at a projected cost of $2.75/gge delivered. Reduce the cost of hydrogen produced from biomass to $1.60/gge at the plant gate ($2.60 delivered) by 2015. Develop advanced renewable photo-electrochemical and biological hydrogen generation technologies. By 2015, verify the feasibility of these technologies to be cost-competitive in the long term. Research and develop high-temperature thermo-chemical cycles driven by concentrated solar power processes to produce hydrogen with a projected cost of $3.00/gge at the plant gate ($4.00 delivered) by 2015 Hydrogen Delivery: By 2010, develop technologies to reduce the cost of hydrogen delivery from 26 Hydrogen & Fuel Cell Technologies 26 Country Goal Proposed R&D activities central and semi-central production facilities to the gate of refuelling stations and other end users to