Grantee Research Project Results
Final Report: Standalone “Green” Community-Center Buildings: Hydrogen Generation/Storage/Delivery System for when Primary Energy Storage is at Capacity
EPA Grant Number: SU833529Title: Standalone “Green” Community-Center Buildings: Hydrogen Generation/Storage/Delivery System for when Primary Energy Storage is at Capacity
Investigators: McBride, Troy , Ayres, Bill , Lappin, Dan , Chong, Gabriel , Watson, Heather , Fullerton, Jean , Peropat, Jeremiah , Robinson, Phil , Pagut, Thomas , Iezzi, Timothy
Institution: Elizabethtown College
EPA Project Officer: Page, Angela
Phase: I
Project Period: September 30, 2007 through May 31, 2008
Project Amount: $10,000
RFA: P3 Awards: A National Student Design Competition for Sustainability Focusing on People, Prosperity and the Planet (2007) RFA Text | Recipients Lists
Research Category: Pollution Prevention/Sustainable Development , P3 Challenge Area - Air Quality , P3 Awards , Sustainable and Healthy Communities
Objective:
Elizabethtown College’s 2007-08 Phase I EPA P3 project is based on a supplementary hydrogen energy storage system for use in standalone solar-powered facilities. In particular, this EPA P3 funded system; is used to generate hydrogen when the primary energy storage system (e.g., batteries) is full and excess solar power is available. This hydrogen project is part of a long-term multi-disciplinary initiative called “Standalone ‘Green’-power for (International) Village Settings.” The long-term goal of this initiative is to design and provide highly-reliable, low-maintenance, long-lifetime (>30 years), low-environmental-impact community-center buildings powered entirely by a renewable energy source.
The primary technical challenge related to sustainability in standalone wind or solar-powered buildings, and research focus of the Elizabethtown College initiative, is the realization of a moderate-scale energy storage system with very long lifetime, high system efficiency, and reasonable cost. At Elizabethtown College, we have constructed a 200 sq.ft. 2.2 kWpeak Solar Cabin that serves in part as a test platform for alternative energy storage systems. In particular, additional to this 2007-08 EPA P3 Phase I project, we are studying a hydraulic-pneumatic energy storage system that shows promise for substantially longer lifetime than current battery based systems. In this EPA P3 project, we research, design, and implement a ‘smart’ electrolysis system which is used to generate hydrogen when the primary energy storage system is full. Through this supplementary storage system, we seek to maximize energy storage and minimize waste by capturing power generation potential that is typically wasted in standalone installations. Hydrogen generation as a supplementary energy storage medium and for usage in small engine and cooking equipment serves as an example of a “zero waste” strategy to maximize usage of solar resources, while providing a valuable clean-burning fuel product.
The “Standalone ‘Green’ Power for Village Settings Initiative” at Elizabethtown College strives to provide a centralized, affordable, empowering, environmentally and socially proactive solution to those villages that would benefit from a community-center building with reliable electrical power. The core worldwide issue addressed in this overall initiative, as related to people, prosperity, and the planet, is access to electricity. Today, roughly 25% of the world lacks electricity --on the order of 2 billion persons. To a lesser extent this project can provide some clean nighttime cooking via hydrogen. The burning of wood/charcoal/dung for cooking is widespread (nearly 1/3 of the world’s population or roughly 2.4 billion persons), a significant health hazard (the WHO estimates 1.5 million persons deaths each year can be attributed to indoor air pollution arising from open stoves in the household, and a substantial contributor to local deforestation, indoor/outdoor air pollution, and even global warming.
Hydrogen electrolysis energy storage systems have been successfully implemented by several individuals and researchers. Also, hydrogen electrolysis, storage, and dispensing as a fuel for mobile equipment has been accomplished and is commercially available in limited fashions. The innovative aspect of this project is the use of a hydrogen generation system as supplementary energy storage. This idea is particularly suited to moderate scale applications, such as the proposed community-center buildings, where a substantial amount of hydrogen fuel will be generated. In addition, the hydrogen fuel will be useful in regions without access to inexpensive petroleum fuels. Finally, by starting such communities down the road of using hydrogen-based power equipment, we can hope that their future path with economic growth will continue to involve usage of these sustainable technologies.
In this project, we proposed to design, construct, and monitor a hydrogen-fuel supplementary energy storage system at the Elizabethtown College Solar Cabin which automatically switches to hydrogen electrolysis whenever the primary energy storage system is full and excess solar power is available. A second team of students worked to adapt small engine equipment (a lawnmower and weed trimmer) and cooking equipment (a BBQ grill) to run on the stored hydrogen gas. The measurable results will include 1) a series of engineering student team’s competitive design proposals, 2) a working prototype secondary energy storage system, 3) publicly available design and coding for the power system controls, 4) cost, performance, and test data from the prototype installation, and 5,6) final reports/papers/presentations.
Summary/Accomplishments (Outputs/Outcomes):
Overall, the implementation of a computer-controlled hydrogen generation system and subsequent conversion of small engine equipment for hydrogen use has been surprisingly straightforward from an engineering and technology standpoint. More testing is required to get a better grasp on a longer-term installation of the hydrogen generation system especially in an infrequently monitored facility. This EPA P3 Phase I hydrogen project, which is a component of this larger initiative, has been surprisingly trouble-free in its implementation and thus we currently plan to implement as a part of the initial full-scale community center implementation in the Kwa-Zulu Natal region of South Africa. This actual field implementation will be a true test of the usefulness and durability of the hydrogen system. We are skeptical of the durability and long-term usage of the hydrogen system in a challenging infrequently-monitored environment, but have been pleasantly surprised by the ease of conversion of small engine equipment and cooking equipment.
Specific products from the 2007-08 EPA P3 Phase I project include 1) simulation software for the supplementary storage system, 2) a prototype hydrogen generation system, 3) two small engine conversions, and 4) a grill conversion.
1) A LabView simulation was developed to have inputs of hourly solar data, solar array size and efficiency, battery capacity, power usage, and hydrogen generator average power and flow rate. The simulation processes archived solar insolation data to determine current power levels and uses time of day, current battery level (kWhr remaining), and power levels to decide when the lights are on, when hydrogen is generated, and so forth. The simulation allows us to modify our designs based on solar array size, location of installation, battery sizing, hydrogen generator sizing and hydrogen storage capacity. For example, for the current parameters for the Elizabethtown College Solar Cabin, the simulation provides an estimate of 55 of our Ovonics metal hydride 900 standard liter containers would be filled per year. The simulation provides a plethora of information for analysis, including times when the battery level is dangerously low, when there is substantial excess power even with the hydrogen system running, and the effects of changing any number of design parameters.
2) The hydrogen generation and control system is the centerpiece of this EPA Phase I project. The workhorse is a Distributed Energy HoGEN 300 Hydrogen Generator ($9,900) with storage provided by three 900 Liter Ovonics metal hydride containers ($633 x 3). The generation of hydrogen is turned on/off by computer controlled relay based on inputs of battery voltage and solar irradiance. The setup is sufficient to operate lawn equipment or cooking equipment approximately two hours per week. Meaningful data from the hydrogen generation and control system are not yet available. The hydrogen generation system has not been operated outside of the laboratory, where only preliminary testing has taken place. While the portable hydrogen system will be demonstrated at the April 2008 EPA P3 Expo, data from operation at the Solar Cabin will not be available until late 2008.
3) Conversion of small 4-cycle engines to run on hydrogen is relatively straightforward. In both the lawnmower and weed trimmer conversion, the design goal was to bring the hydrogen as close as possible to the engine intake. For our primary test bed – a set of Tecumseh TVS-90 lawnmower engines – conversion was as simple as drilling the fuel intake line to admit a hydrogen line. For the lawnmower, engine starting remains an issue, but once running the lawnmower operates well. A Craftsman 4-cycle 29 cc convertible gas weed-trimmer was also “converted” for hydrogen use. The intake manifold is quite small and plastic, so modification of the weed trimmer was accomplished by removing the gas tank, plugging the fuel return line and attaching the hydrogen supply to the fuel intake line. Carrying the hydrogen cylinder remains a challenge and is currently designed to be carried on the back with a flexible plastic tubing in place of the stainless steel tubing of the lawnmower prototype. Data for the small engine equipment on fuel consumption and emissions data (from a standard automobile 5 gas analyzer) has yet to have been acquired, but will be available for the April 2008 EPA P3 Expo.
4) Grill conversion is also relatively straightforward, with the primary modifications related to connecting the hydrogen containers to the propane lines and replacement of the original propane burners. We use a Kenmore gas grill and replace the burners with shaped stainless steel pipes welded shut at one end and drilled with a series of small holes (#68 drill). The gas grill conversion is not complete at the time of this writing.
Conclusions:
No technical hurdles exist for implementing a supplementary hydrogen generation and storage system for standalone solar sites. From a technical standpoint, this EPA P3 Phase I project is proceeding well, in part because we are integrating and modifying primarily off-theshelf components. The implementation of the prototype hydrogen generation system and conversion of small engine equipment for hydrogen use has been straightforward. Student enthusiasm for the project has been excellent, including two students pursuing and locating material donations for equipment conversion. Overall, student initiative and the hands-on learning of technical knowledge, design, teamwork, and project management skills that develop from this challenging and relevant project are one of the leading outcomes of the project. We currently plan to implement this supplemental hydrogen storage as a part of the initial full-scale community center implementation in the Kwa-Zulu Natal region of South Africa. This actual field implementation will be a true test of the usefulness and durability of the hydrogen system.
Project Period for Phase II: 05/31/2008 – 05/31/2010
Proposed Phase II Objectives and Strategies:
Our EPA P3 2007-08 Phase I project was entitled “Standalone “green” community-center buildings: Hydrogen generation/storage/delivery system for when primary energy storage is at capacity”. The Phase I portion focuses on the design, testing, and implementation of a supplementary energy storage system based on hydrogen. The larger initiative – “Standalone Green-Power for Village Settings Initiative” – is focused on long lifetime low maintenance energy storage. In this Phase II portion of the project, we propose to use the EPA P3 funding to support the implementation of a full-scale standalone community center in the KwaZulu Natal region of SA. In particular, the EPA P3 Phase II funding will support two full-scale research energy storage systems for construction, installation, monitoring, and testing in a South African village in the Vokani region of the KwaZulu Natal Province. All other costs associated with this project (e.g., building materials, solar system, faculty/partner salary and benefits, faculty/student/partner travel, accommodation) are being funded through other means.
The Standalone Green-Power for Village Settings Initiative was started in late 2004. The testing, prototype systems, and research at the Elizabethtown College Solar Cabin has led to the design for a full-scale community-center building (to serve on the order of 200+ families) in KwaZulu-Natal Province in South Africa. This portion of the project has been titled “Project uGesi” which is Zulu for “Power to the People”. After an initial visit in March 2007 by Professors McBride and Ayres to the region, a site has been chosen and funding pursued by Bruce Alan Johnson Associates located in Pietermaritzburg, South Africa. Based on our current design for the first installation of Project uGesi, we have planned for four trips, each approximately 2 weeks in duration, to the region for construction and testing – 1) for initial foundation work and structural work, 2) for solar and electrical installations, 3) for energy storage system installation and testing, and 4) for follow-up testing, monitoring, and initial assessment of impact. The first construction trip is scheduled for May 2008, with project completion taking place over an 18-24 month period.
Our first colloboration focuses on a partnership with the Zulu people of South Africa of KwaZulu-Natal. In the Zulu region of South Africa, Elizabethtown College has hired Bruce Alan Johnson Associates (Pty) Ltd of KwaZulu-Natal to assure the cultural and social aspects of the project are properly implemented and that maintenance of the system is assured throughout the years. Overall, the implementation of this first project should have a mutual positive impact on the College community that is involved in the project and the Zulu community members that partner in the construction and use.
We expect to be able to bring approximately four students on each of the four first location trips, highlighting both the engineering (McBride) and sociological (Ayres) aspects of the project and the visit. For our students, we feel strongly that this is an outstanding opportunity for students to combine engineering of the community-center building, research into alternative energy storage systems and sociological aspects/impacts of the project, with the amazing history and culture of the Zulu region of South Africa, in an unforgettable series of experiences.
In this project, we will design, construct, and monitor a hydraulic pneumatic energy storage (HPES) primary energy storage system and a hydrogen-fuel supplementary energy storage system in the KwaZulu Natal region of South Africa as part of the design and construction of a standalone solar powered community center building. The measurable results will include 1) design proposals and final designs for a HPES system and supplementary hydrogen system, 2) a working electrical system including an HPES system, 3) a working supplementary hydrogen system and power system controls, 4) cost and performance data from the installation, including remote monitoring and posting of data on a daily basis 5,6) a final EPA P3 report (May 2010) and at minimum two additional technical papers (late 2009 & 2010) summarizing the project, the results, and the overall efficacy including cost/benefit analysis of the HPES and supplementary hydrogen energy storage system. Additional, less quantifiable outcomes include 7) the development of a strong positive relationship between Elizabethtown College faculty and students with community members and leaders in the Zulu region of South Africa, 8) a positive educational and lasting experiences for up to 16 Elizabethtown College students.
In the final community-center installation, the power generation / usage, HPES and hydrogen system parameters will be monitored at all times by computer and transmitted automatically once per day (and in case of alert levels) to a computer at Elizabethtown College. The recorded data will be used to analyze the system efficiency, reliability, and expected costs / benefits. Number of maintenance trips and other issues will be recorded. Additionally, caretaker interviews and regular visits by BAJ Associates will provide qualitative assessments. All data will be recorded and summarized in a final report, as well as be made available in raw format on our website. Evaluation of the project will include an early sociological assessment of the impact of the community center project; EPA P3 reporting will focus on cost, performance, and efficiency data.
This proposal provides another step towards the realization of an energy storage system that meets all the markers of sustainability – long life, zero waste, low maintenance, and low environmental impact – our primary technical objective. Affordable, reliable energy storage is a key component and key technical hurdle to any renewable energy future. At Elizabethtown College, we are strategically positioned at a small college with a mix of pre-professional and liberal arts programs, brought together under the umbrella of our Center for Global Citizenship, to take forth this multi-disciplinary project through completion – implementing truly sustainable standalone community-center installations in areas of poor or zero electrification and providing some electrical power and clean fuel for a few of the nearly 2 billion persons lacking electricity.
Supplemental Keywords:
innovative technology, renewable, engineering, monitoring, building systems, global power, sustainable environment, technology for sustainable environment, clean technologies, clean energy, ecological design, energy efficiency, photovoltaics, renewable resource,Relevant Websites:
http://www.etown.edu/physicsengineering.aspx?topic=P3 Exit
http://www.etown.edu/solarcabin Exit
http://users.etown.edu/m/mcbridet/uGesi/intro.html Exit
The perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.