HyLOG: CO2-freie Logistiklösung mit Solarwasserstoff und

HyLOG: CO2-freie Logistiklösung mit Solarwasserstoff und

HyLOG: CO2-freie Logistiklösung mit
Solarwasserstoff und Brennstoffzelle
Dr. Ewald Wahlmüller
Fronius International GmbH
Research and Development
Günter Fronius Straße
4600 Wels-Thalheim
Austria
Vortrag beim 26. Deutschen Logistik-Kongress, InterContinental / Schweizerhof Berlin, 21. – 23. Oktober 2010
© Fronius 2010/10
Content
z
z
z
z
z
z
z
The Fronius Company
Vision / Status Solar Powered Energy Cell
The HyLOG Project
CO2 Reduction Potential
Energy Infrastructure Perspective
HyLOG Fleet
Summary
© Fronius 2010/10
Fronius Company
Division Battery Charging Systems
Division Welding Technology
Division Solar Electronics
© Fronius 2010/10
A closer look at the Fronius Group
2009
2008
2677
2500
Employees R&D
358
309
Group turnover (million €)
329
370
14.9 %
8.6 %
93 %
90 %
649
585
Employees worldwide
Investment quota
Export quota
Active patents
© Fronius 2010/10
Vision “Solar Powered Energy Cell”
Power
Heat
PV Module
Hydrogen
Storage
Oxygen
Solar Power
Inverter
Electrolysis
Fuel Cell
Water
© Fronius 2010/10
Vision “Solar Powered Energy Cell”
Power
Heat
PV Module
Hydrogen
Storage
Oxygen
Solar Power
Inverter
Electrolysis
Fuel Cell
Water
© Fronius 2010/10
Fronius Energy Cell
785
Power
Voltage
IP Protection
Compliance
Certification
Fuel Supply
Available for
Projects
4 kW
Applications
2 kW
1 kW
48VDC
24VDC
IP20 (upgradable to IP54)
EN62282-5-1:2007
Standard Compressed Hydrogen 30 – 700 bar
Hydrogen Gas Grid
Electrolyser
DC/AC Power Generator
Mobile Applications
0
90
475
z
z
z
z
z
z
PEM fuel cell power generator
High overall efficiency
Silent operation
Perfect safety strategy
Easy to use and service, user-friendly
Complete remote system monitoring
790
0
79
310
© Fronius 2010/10
The HyLOG Project
© Fronius 2010/10
The HyLOG Project - Milestones
1
v
o
.N
6
.0
c.
e
D
06
Development
De
0
c.
7
Certification & Approval
31
8
.t 0
c
.O
Start
Authority Contact for Legal
Requirements
De
0
c.
8
Demonstration
Implementation of
H2 Fuelling Station &
Range-Extender Tow Truck
De
0
c.
9
ongoing
Safety Assessment,
TÜV Certification,
Authority Approval
© Fronius 2010/10
HyLOG Tow Truck
with Energy Cell
26 lt. H2 Cartridge 350bar
Total Weight Vehicle [kg]
1005
with Battery
500 Ah
1005
Total Weight Power Supply [kg] 150
380
Weight of Energy Storage [kg]
25
380
Amount of Energy [kWh]
11
9,6
Time to Refuel / Recharge [min] <5
>500
System Voltage [VDC]
24
24
Power Socket 230V/50Hz
yes
no
© Fronius 2010/10
HyLOG Power Train / Interfaces
Signal Light
H2 Cartridge
H2
Energy Cell
Drive Train
Tank Valve
P: 2 kW
Pressure Sensor
V: 24V
Temperature
H2 Relief Valve
On/Off, Emergency Stop
© Fronius 2010/10
Solar H2 Filling Station Sattledt
Solar Hydrogen Capacity:
Annual Capacity Electrolysis 823 kg / 27.200 kWh
12 kg / 396 kWh
Annual Cartridge Refillings
1.100
Refuelling Time
3 – 4 min
PV Generator
Nitrogen / Air for H2 Compression 8 – 10 bar
Hydrogen 5 – 13,8 bar
Bitter STS 26L
Air Products350
S100
bar, 0.7 kg H2
Fronius IG 500
Inverter
240 VAC, 50Hz
H2 Storage Capacity
Feedwater
Peak Load
Bundle
Buffer Bundle
Electrolyser HOGEN S40
Proton Energy Systems Inc.
© Fronius 2010/10
Solar H2 Filling Station Sattledt
© Fronius 2010/10
H2 Infrastructure Sattledt
Solar H2 Filling Station
Indoor Cartridge Allocation
Cartridge Exchange Place
© Fronius 2010/10
Authority Approval
z
Product certification requirements (CE)
z HyLOG Tow Truck (98/37/EC machinery directive)
z Fronius Energy Cell (EN62282-5-1:2007)
z 350bar Hydrogen Cartridge (99/36/EC transportable pressure
equipment directive (TPED) and 94/55/EC carriage of dangerous goods
(ADR))
z 350bar Hydrogen Refuelling Station (97/23/EC pressure equipment
directive (PED))
z Electrolyser HOGEN S40 (98/37/EC machinery directive and 94/9/EC
ATEX directive)
z
Risk and safety analysis requirements
z Indoor operation of 5 HyLOG tow trucks
z Installation and operation of 350bar H2 refuelling station (commissioning
inspection and in-service inspection by authorised body required)
z 350bar H2 cartridge filling and handling (in-service inspection by
authorised body required)
© Fronius 2010/10
Status Demonstration / Results
z
Since May 2009: 5 days/week 2-shift operation
z 4 – 5 shifts / cartridge exchange
z
Key advantages
z Fast refuelling increases system flexibility and availability
z Increased productivity through constant power, reduced
maintenance, reduced space demand
z Energy management capability
z No emissions
z
Improvement potentials / critical aspects
z Minimum vehicle fleet size for economic operation required
z Competitive price for hydrogen as an energy carrier
z Replacement of cartridge by indoor / onboard refuelling
z System cost reduction through volume manufacturing
© Fronius 2010/10
H2 Technology / CO2 Reduction Potential
Estimate
z
Annual traction power: 17.000 kWh/a
z (E-Forklift: 48V, 600Ah, 1 x battery recharging per shift (battery exchange
required), 3 shifts/day, 49 weeks/year, 5 days per week)
Quelle CO2 Daten:
1) Dem Leitfaden "Klima schützen - Kosten senken" des LfU
2) Der Datenbank GEMIS in der Version 4.2
© Fronius 2010/10
H2 Technology / CO2 Reduction Potential
Estimate
z
Annual traction power: 17.000 kWh/a
z (E-Forklift: 48V, 600Ah, 1 x battery recharging per shift (battery exchange
required), 3 shifts/day, 49 weeks/year, 5 days per week)
z
ICE Forklift: Diesel 11.565 l/a, CO2 30.646 kg/a
z
z
(Diesel ICE, 15% drive cycle efficiency, Diesel Fuel 9,8 kWh/l, 2650 g/l CO2)
E-Forklift: Grid Electricity 25.758 kWh/a, CO2 16.021 kg/a
z
(Wh efficiency of lead acid battery 66%, CO2 of EU grid electricity mix 0,622 kg/kWh)
Quelle CO2 Daten:
1) Dem Leitfaden "Klima schützen - Kosten senken" des LfU
2) Der Datenbank GEMIS in der Version 4.2
© Fronius 2010/10
H2 Technology / CO2 Reduction Potential
Estimate
z
Annual traction power: 17.000 kWh/a
z (E-Forklift: 48V, 600Ah, 1 x battery recharging per shift (battery exchange
required), 3 shifts/day, 49 weeks/year, 5 days per week)
z
ICE Forklift: Diesel 11.565 l/a, CO2 30.646 kg/a
z
z
E-Forklift: Grid Electricity 25.758 kWh/a, CO2 16.021 kg/a
z
z
(Wh efficiency of lead acid battery 66%, CO2 of EU grid electricity mix 0,622 kg/kWh)
- 40%
FC Forklift, fossile H2 refuelled: 12.614 m3/a, CO2 9.480 kg/a
z
z
(Diesel ICE, 15% drive cycle efficiency, Diesel Fuel 9,8 kWh/l, 2650 g/l CO2)
(efficiency reforming 85% -> 44.444 kWh/a natural gas , CO2 of H2 logistics neglected,
CO2 natural gas 2,15 kg/m³, 10,08 kWh/m³, electric system efficiency fuel cell 45%)
FC Forklift, solar H2 refuelled: 12.614 m3/a, CO2 0.0 kg/a
z
(efficiency electrolysis 60% -> 62.965 kWh/a solar electricity, CO2 solar electricity 0 kg/m³,
electric system efficiency fuel cell 45%)
Quelle CO2 Daten:
1) Dem Leitfaden "Klima schützen - Kosten senken" des LfU
2) Der Datenbank GEMIS in der Version 4.2
© Fronius 2010/10
H2 Technology / CO2 Reduction Potential
Estimate
z
Annual traction power: 17.000 kWh/a
z (E-Forklift: 48V, 600Ah, 1 x battery recharging per shift (battery exchange
required), 3 shifts/day, 49 weeks/year, 5 days per week)
z
ICE Forklift: Diesel 11.565 l/a, CO2 30.646 kg/a
z
z
E-Forklift: Grid Electricity 25.758 kWh/a, CO2 16.021 kg/a
z
z
(Wh efficiency of lead acid battery 66%, CO2 of EU grid electricity mix 0,622 kg/kWh)
- 40%
FC Forklift, fossile H2 refuelled: 12.614 m3/a, CO2 9.480 kg/a
z
z
(Diesel ICE, 15% drive cycle efficiency, Diesel Fuel 9,8 kWh/l, 2650 g/l CO2)
(efficiency reforming 85% -> 44.444 kWh/a natural gas , CO2 of H2 logistics neglected,
CO2 natural gas 2,15 kg/m³, 10,08 kWh/m³, electric system efficiency fuel cell 45%)
FC Forklift, solar H2 refuelled: 12.614 m3/a, CO2 0.0 kg/a
z
(efficiency electrolysis 60% -> 62.965 kWh/a solar electricity, CO2 solar electricity 0 kg/m³,
electric system efficiency fuel cell 45%)
Quelle CO2 Daten:
1) Dem Leitfaden "Klima schützen - Kosten senken" des LfU
2) Der Datenbank GEMIS in der Version 4.2
© Fronius 2010/10
Energy Infrastructure Perspective
Battery Charger
Battery Truck
State of Art
Customer Site
© Fronius 2010/10
Energy Infrastructure Perspective
High Pressure
Electrolyser
H2 Storage
Indoor Refuelling
Fuel Cell Truck
Future
H2
°C
Heat Storage
Battery Charger
Battery Truck
State of Art
Customer Site
© Fronius 2010/10
Energy Infrastructure Perspective
High Pressure
Electrolyser
Indoor Refuelling
H2 Storage
Fuel Cell Truck
Future
H2
°C
Heat Storage
Indoor Refuelling
Fuel Cell Truck
H2 Reformer
Natural Gas / Biogas
H2
H2 Delivery
Compression
H2
H2 Storage
°C
Heat Storage
Battery Charger
Battery Truck
State of Art
Customer Site
© Fronius 2010/10
HyLOG Fleet / E-LOG-Bio-Fleet
Objectives
z
z
z
C-H2 Delivery
(Tube Trailer)
z
z
L-H2 Delivery
Development, certification and demonstration of a warehouse
tow truck fleet (15 vehicles) with fuel cell range extender
Installation, authority approval and demonstration of indoors
and onboard bio-hydrogen refuelling of the warehouse truck
fleet
CO2 neutral generation of bio-hydrogen using reformed
biogas as source of energy
Environmental and socio-economic assessment of the
innovative and sustainable warehouse logistic application
Preparation for enhanced market entry
Compression and
Filling Station
Biogas
H2 350bar
H2 Reformer
Bio-H2
CH2
© Fronius 2010/10
Summary
z
z
z
z
z
The HyLOG project demonstrates a zero emission
solution for intralogistics
Hydrogen as a fuel can be used safely indoors without
any limitations
Key benefits of fuel cells for intralogistics are fast
refuelling, constant performance, reduced
maintenance and less space demand
Hydrogen used for energy storage can play a major
role within a smart and renewables based infrastructure
The HyLOG Fleet project will further enhance market
entry of the innovative technology
© Fronius 2010/10
© Fronius 2010/10