Electrolysis Production

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Electrolysis Production of Hydrogen from Wind
and Hydropower DOE-NREL, 9-10 Sept 03,
Washington, DC Bill Leighty The Leighty
Foundation
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The Great Plains Wind Resource
How shall we bring the large, stranded, Great
Plains wind to market ?
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Obvious GW - scale Transmission Alternatives

• HVAC or HVDC overhead elec trans lines
• HVDC underground elec trans lines
• Gaseous hydrogen (GH2) pipelines
• Liquid hydrogen (LH2) rail
• EPRI Energy Pipeline superconducting
• Liquid HC fuels DME, MEOH, Cyclohexane ltgt
  Benzene

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From W. Amos, Costs of Transporting and Storing
Hydrogen, NREL/TP-570-25106, Nov
98 10,000 kg/hr 240 tpd 400 MW, 12
pipeline _at_ 1,000 psi 100,000 kg/hr 2,400 tpd
4,000 MW, 36 pipeline _at_ 1,000 psi
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• Focus Large-scale windpower, biomass
• Lowest cost renewables
• Very large resources worldwide
• Most is stranded new transmission
• GH2 challenges, costs
• GH2 must reduce cost, add value
• Synergy with
• NG pipeline transmission geologic storage ?
• Biomass gasification
• Coal gasification
• near zero emissions plants

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ALL Denmarks energy from windpower

• WHEC, Montreal, June 02
• Prof Bent Sorensen, Roskilde Univ, DK
• ALL Denmarks energy from wind
• Elec, oil, gas
• Transport, space heat-cool, industry
• IF convert fraction to H2, store in extant salt
  caverns
• Can USA do same?
• Start with transport fuel ?

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Denmark natural gas system pipelines and
geologic storage
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Total USA Wind Resource Estimate PNL-7789
(1991)USA electric energy consumed in year 2000
3,500 TWh (billion kWh)

• TWh / year MW (nameplate, at 40 CF)
• 1,210 345,320
• 1,190 339,612
• 1,070 305,365
• 1,030 293,950
• 1,020 291,096
• 868 247,717
• 747 213,185
• 725 206,906
• 657 187,500
• 551 157,249
• 481 137,272
• 435 124,144
• 9,900 2,840,000
• 73 20,833
• 65 18,550
• 62 17,694
• 61 17,409
• 59 16,838

• North Dakota
• Texas
• Kansas
• South Dakota
• Montana
• Nebraska
• Wyoming
• Oklahoma
• Minnesota
• Iowa
• Colorado
• New Mexico
• Idaho
• Michigan
• New York
• Illinois
• California
• Wisconsin

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Example Flowgate InterfacesMAPP Mid-continent
Area Power Pool
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Exporting From 12 Windiest Great Plains
States Number of GH2 pipelines or HVDC electric
lines necessary to export total wind resource
Wind energy source PNL-7789, 1991
at 500 miles average length
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Proposed North East Asia Pipeline Network Loop
Wind Power Hydrogen Hybrid Systems and
Natural Gas Pipeline Systems in Northeast Asia
K. OHashi, Nippon Steel M. Hirata, Shibaura
Institute K. Ono, Kyoto University
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Large Renewable Resources ?
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Shall these pipelines be built of
hydrogen-capable line pipe ?

• Pass through, near renewables - rich areas
• Future NG depleted
• hythane transition CH4 ? CH4 H2 ?
  H2
• 100 hydrogen, fuel cell grade (99.999 )
• Incremental investment ?
• Enhance pipeline NPV ?
• ESFE Eastern Siberia to Far East pipeline
  project
• IHPF International Hydrogen Pipeline Forum
• Japan Integrated Hydrogen Energy Industrial
  Forum
• Design ? Materials ? None exists

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Proposed Alaska Highway ANS Gas Pipeline
Project ALCAN Route
Foothills Pipe Lines Ltd. Canada
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ANS gas value-added strategy

• Convert CH4 ? H2 CO2 at ANS,
• via SMR
• Pipeline H2 south to markets vehicles
• Sequester CO2 at ANS, OG fields
• Solve CO2 problem at source
• Maintain reservoir pressure
• enhance OG recovery-- billions
• Future renewables transmission on ROW
• ANS Alaksa North Slope

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Renewable Energy Sources

• Distant
• Dispersed
• Diffuse
• Stranded
• Diverse
• Time-varying
• Hourly
• Daily
• Seasonally
• Randomly, unpredictably
• Gathering Transmission Challenge

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RHS Renewables-Hydrogen Service for GH2
pipelines

• New specification
• Corridor, not transmission line
• Gathering and transmission
• Many input, output nodes, wide size range
• 100 GH2 low energy density (volume)
• Long-distance, high-capacity diam, pressure
• High purity five nines, for PEMFC
• Time-varying output
• Hourly, daily
• Seasonally
• Severe pressure cycling frequency, magnitude
• H2 attack on steel fatigue, HIC, HCC, HE
• Frequent inspections pigging other
• Storage valuable
• Low cost needed capital, OM, on-ramps
• Public apprehension permitting, siting

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Harvesting Stranded Great Plains Wind

• Extant grid insignificant
• New electric lines
• HVAC
• HVDC
• Double six phase (Osborne, MISO)
• New hydrogen gas pipelines
• E-Pipe, EPRI continental supergrid
• superconducting LVDC
• 100 GW electric
• 100 GW liquid hydrogen
• Rock tunnel 100 m subsurface
• Access for wind? Elec or H2? On-ramp? Storage?

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Superconducting Energy Pipeline Paul Grant,
EPRI 100 GW electrical 100 GW LH2
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Natural Gas Pipelines in Shield Tunnel Energy
Engineering, Nippon Steel, 2001
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May 03, Palm Springs, CA Stuart electrolyzer
will produce H2 fuel from windpower for city
FCEV buses FCEV fuel cell electric vehicle
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Bald Eagle Power Company Inc. Offshore Long
Island, NY

• Applied for ACOE permits
• Offshore, shallow continental shelf
• 402 sq miles, 9 sites, S shore
• Public Notice expected mid 03
• SeahorseTM wind farms, 7,000 MW
• All wind energy converted to hydrogen offshore
• 1 billion kg hydrogen per year fuel all LA cars
• Demo Phase I 20 MW
• Phase II Max 1,925 turbines, 3.6 MW each

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THINK Multi-GW scale, beyond Cherry Picking

• Best wind sites
• Close to transmission
• No-cost transmission access, wheeling
• Limited game over soon
• Wind must pay ALL transmission costs
• stranded
• Capacity Factor (CF) problem
• Wind cost doubled ?

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The Great Plains Wind Resource

• 4,000 MW nameplate windplant
• 1,600 km ND Chicago
• / - 500 kv HVDC
• 36 GH2 pipeline, 1,000 - 500 psi

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350 Sq Mi
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4,000 MW of Nameplate Wind Generation 53 x 53
grid 500 m spacing
2,809 wind generators at 1,400 kW each 675 sq
km 325 sq miles
850 sq km 350 sq mi
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Distributed Collection 4,000 MW of Nameplate
Wind Generation 150 x 19 grid 500 m spacing
2,850 wind generators at 1,400 kW each 750 sq
km
750 sq km 300 sq mi
10 km
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Electrical Transmission Scenario
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System B Multi- terminal source HVDC
transmission 60 Hz AC collection LCC
Line-commutated converters
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• Electrical Transmission Scenario
• VSCs at North Dakota source
• Multiple VSC entry points

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Stuart Energy Hydrogen Energy Station
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North Dakota wind needs 115 new lines at 3,000
MW each
Twelve Plains states wind needs 890 new
lines at 3,000 MW each
SIEMENS HVDC line /- 500 kv
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How much can we upgrade capacity of extant ROW
and structures, with no net loss of perceived
or real safety or tranquility ?
Zion nuclear plant 2 of 3 tower systems HVDC
potential 6 bipoles _at_ 3,000 MW 18,000 MW
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Distribution Problem !
Stuart Energy Hydrogen Energy Station
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Hydrogen Transmission Scenario

• Low-pressure electrolyzers
• Pack pipeline 1-2 days storage 120 GWh

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Hydrogen Transmission Scenario Collection
Topology Options Electrolyzer and Rectifier
Location
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• Pipeline
• Delivery Nodes
• Simple
• Low cost
• Large or small
• Closely spaced

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• Hydrogen Transmission Scenario
• Electricity delivery
• Two conversions
• Not profitable

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Annual Profit / Loss Wind Energy Generation,
Transmission Wholesale Delivery of
Electricity With PTC Wind Capital Cost 700
/ kW
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Twelve Great Plains states wind needs 400 H2
gas Pipelines 6,000 MW each 36 diameter, 65 bar
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We know how to pipeline hydrogen Air
Products 10,000 miles of GH2 pipeline, worldwide
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Air Products CompanyREFINERY ACTIVITY LOS
ANGELES BASIN, CALIFORNIA
DOMINGUEZ CHANNEL
ARTESIA BEACH FRWY.
91
19
190th St.
SHELL (SHUT DOWN)
MOBIL TORRANCE
110
CARSON H2
LONG BEACH ARPT.
VAN NESS AVE.
SEPULVEDA BLVD
ARCO CARSON
TEXACO WILMINGTON
FLETCHER (SHUT DOWN)
TOSCO CARSON
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AIR PRODUCTS FACILITY EXISTING H2
PIPELINE PROPOSED H2 PIPELINE
ANAHEIM STREET
ULTRAMAR WILMINGTON
TOSCO WILMINGTON
WILMINGTON H2
110
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Composite Reinforced Line Pipe (CRLP) 42
diameter 3,400 psi .75 X70 steel .75
composite NCF Industries and TransCanada
Pipelines ASME International Pipeline
Conference and Exposition, Calgary, AB, Canada,
October 02.
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Composite exterior
Low-alloy steel liner
Composite Reinforced Line Pipe (CRLP) 3,400
psi, .75 X70 steel plus .75 composite NCF
Industries and TransCanada Pipelines ASME
International Pipeline Conference and Exposition,
Calgary, AB, Canada, October 02.
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Intelligent Pig for Pipeline Inspection
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Norsk Hydro Electrolyzers 2,000 kW each
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Norsk Hydro Complete Electrolyzer Plant,
KOH (proposed) 265 MWe capacity 570 / kWe ,
70 efficiency
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Reciprocating Compressor Natural gas 3,000
hp Electric Motor Drive
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Hydrogen Transmission Scenario Hydrogen Fuel
Delivery High-pressure electrolyzers
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Hydrogen Transmission Scenario Hydrogen
Storage
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Hydrogen Distributed Transmission for
Distributed Generation
Numerous Delivery Nodes
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Hydrogen Distributed Transmission for
Distributed Generation
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Zero Emissions Coal Synergy

• ND, MT, WY are wind and coal states
• Oxygen byproduct of electrolysis to
• zero emissions coal gasification plants
• 4,000 MW windplant produces
• 3.1 million tons O2 per year
• value 19.17 / ton at coal plant
• 59 million per year delivered O2
• Share transmission CF improve ?
• Is zero emissions coal clean ?
• Will CO2 sequestration work ?

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Proposed Transmission Routing and Generation
Sites Black Veatch TAGG
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Raw gas H2 CO2 CO CH4 H2O
Dakotas Gasification Company Beulah, ND
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Hydrogen Fuel Cost in MinneapolisFrom Dakotas
Gasification Company (DGC) Lignite

• Lignite source GH2 at DGC plant, Beulah, ND _at_
  1 atm 4.44 / Mscf
• GGEE 1.58 / gal
• Volume 55 billion scf / year 56 million
  gallons gasoline
• (Assume C-sequestration, included in cost)
• Annual and 400 miles transmission pipeline and
  compression costs
• 350 M pipeline _at_ 12 CRF 42 M
• Pipeline OM 5 M
• Compression energy 10 M
• Total annual cost 57 M / 56 M gallons
  1.02 / gal
• Wholesale price of GH2 fuel in Minneapolis,
  end-of-pipe 2.60 / gal
• Distribution and fuel station cost 0.79
  1.45 / gal
• Retail price of GH2 fuel in Minneapolis
  3.39 4.05 / gal
• Drive train efficiency ratio FCEV / ICEV
  (gasoline) 2
• Equivalent retail price GH2 fuel per vehicle-mile
  1.70 2.03 / gal

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Wind-Hydrogen Fuel Price in ChicagoNo PTC
subsidy

• Wind-generated electricity in ND 0.045 / kWh
• Hydrogen conversion and 1,000 miles transmission
  0.052 / kWh
• _________
• Wholesale price of GH2 fuel in Chicago,
  end-of-pipe 0.097 / kWh
• Equivalent per-gallon-gasoline-energy price
  3.49 / gal
• Distribution and fuel station cost 0.79
  1.45 / gal
• ________________
• Retail price of GH2 fuel in Chicago 4.28
  4.94 / gal
• Drive train efficiency ratio FCEV / ICEV 2
• Equivalent retail price GH2 fuel per vehicle-mile
  2.14 2.47 / gal
• 1 GJ 278 kWh 1 gallon gasoline 0.13 GJ
  (HHV) 36 kWh _at_ 0.08 / kWh 2.89 / gallon
  
• HHV means higher heating value of hydrogen.
• GH2 means compressed gaseous hydrogen

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Study Primary Questions

• How bring stranded Great Plains wind energy to
  market ? At what cost ?
• Shall we deliver electricity or H2 in Chicago?
• Might hydrogen transmission yield higher
• benefit / cost than electricity ?
• What wind generation transmission systems are
  bankable ?

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• Study Method
• Deliver wholesale electricity? Chicago
• Two transmission systems HVDC, H2
• 9 scenarios
• Cost Model
• Profit Model
• Cost of wholesale H2 ? Chicago
• Year 2010 technology, US 2001
• Further Study Catalog

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Cost Model ResultsDrives Profit ModelSimple
CRF (capital recovery factor), not DCF
(discounted cash flows)
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Profit Model ResultsProfit Revenues gt Costs
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Report Conclusions

• Only profitable cases
• Electricity with PTC, 700 / kW
• Hydrogen NG price gt 15-20 / mmbtu
• No GH2 pipeline gtgt electricity
• Cant afford double-conversion
• Wholesale COE delivered in Chicago
• .06 - .07 / kWh as electricity
• .06 - .09 / kWh as hydrogen

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Report Conclusions

• Hydrogen storage valuable
• gt 100 million / year
• Pipeline packing
• Generate on-peak
• H2 embrittlement
• Hydro interface, exchange
• Geologic ?
• Capacity Factor problem
• Wind generator CF 40 in North Dakota
• Size transmission for WG peak ? Curtail ?
• Far more study required

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IRHTDF

• International Renewable Hydrogen Transmission
  Demonstration Facility
• Pilot-scale pipeline system
• Can we deliver renewable-source H2 fuel to
  major urban markets for
• 3.00 / gallon-gasoline-energy- equivalent?
• Necessary critical path to GH2 - RHS

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Ft. Dodge
NHTDF
Ames, ISU
Iowa Energy Center, 2521 Elwood Dr., Suite 124,
Ames, IA 50010-8263 515-294-8819 FAX -9912
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IRHTDF generation, conversion, collection,
storage, transmission corridor
Biomass and Wind Catchment Areas, with Delivery
Points to GH2 pipeline
GH2 geologic storage ?

O2 pipeline

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I R H T D F

• Pilot scale renewables-hydrogen system
• Generation
• Conversion
• Collection
• Transmission
• Storage
• Distribution, end users
• Intelligence, control
• Synergy O2, seasonal
• 10 100 MW
• 50 - 100 km pipeline
• Defining it reveals RD to precede it
• Next steps Propose RFP

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I R H T D F

• Multiple renewables sources
• Demonstration, through back yards
• Allay public fears of H2
• Building it proves feasibility, acceptance
• Operating it proves
• technology maturity
• economics
• safety
• 40 50 million investment
• Upper Midwest location ?

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I R H T D F

• Included in World Gas Conference paper, Tokyo,
  1-5 June 03
• Requested Japan fed METI funding
• 7 Oct 03 Brussels NaturalHY project, GERG
  (European Gas Research Group)
• DOE-GO93007 preliminary app

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How shall we bring the large, stranded, Great
Plains renewables to market ?

• Delivered COE can renewables compete ?
• Whole-system design, optimization
• Generation
• Collection
• Transmission
• Storage
• Distribution
• End-use
• Intelligence control, integrate

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Conclusions

• All USA energy from Great Plains stranded
  renewables wind, biomass
• ND wind-GH2 fuel, Chicago, retail, untaxed
• 4.00 per gal gasoline energy equivalent
• Whats incremental cost of making new NG
  pipelines RHS-capable?
• Improve NPV of a new NG pipeline?
• No regrets all new NG pipelines H2-capable?
• Start with IRHTDF pilot pipeline
• soon
• Canada, Japan, USA, Germany, EU
• Electricity very competitive
• Continent-scale grid study, a la ISET

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Why hydrogen pipeline transmissionfor Great
Plains renewables ?

• Higher benefit / cost per kWh than electric
• Synergies renewables, coal gasification
• Systems engineering, economics, grid
• Storage pipeline, geologic - seasonal
• Nascent markets vehicle fuel, DG
• Cant build 900 new 3 GW electric lines
• Underground more secure, acceptable,
  permittable than elec lines
• Established pipeline industry, technology

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Electrolysis Production of Hydrogen from Wind
and Hydropower DOE-NREL, 9-10 Sept 03,
Washington, DC Bill Leighty The Leighty
Foundation Presentation on CD your card, please
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Major GH2 pipeline questions

• Under what conditions attractive ?
• Electricity tough competition
• Whats incremental cost of making new NG
  pipelines RHS-capable ?
• Improve NPV of a new NG pipeline?
• No regrets
• Geologic storage available ?
• Low cost
• Seasonal scale
• Market for clean GH2 fuel ?

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The Conversion Project

• Gasoline costs too much, as vehicle fuel
• GAO study full cost
• Wind is lowest-cost renewable
• Wind-source hydrogen costs less than gasoline ?
• Yes ? Major PR, education campaign
• Renewable Energy Hydrogen Production Act
• Initiate in Congress
• Build transmission
• Subsidize renew - hydrogen fuel production
• Accelerate conversion from oil to wind-hydrogen
  transportation fuel

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• Great Plains Wind Huge, Stranded
• Big Market Hydrogen Fuel, not Grid
• Accelerate Conversion