#1ONREL Transforming ENERGY ARIES/ Flatirons Facility - Hydrogen System Capability Buildout DOE Hydrogen Program Presenter: Jeffrey Mohr Pl: Daniel Leighton Riley Abel Tavis Hanna Josh Martin Jake Thorson Vivek Singh National Renewable Energy Laboratory AOP WBS #: 7.2.9.9 June 7th, 2023 2023 Annual Merit Review and Peer Evaluation Meeting Project ID: TA048 Photo from iStock-627281636 This presentation does not contain any proprietary, confidential, or otherwise restricted information#2Project Goal • Under the "Advanced Research on Integrated Energy Systems" (ARIES) initiative, hydrogen system capabilities including a MW-scale electrolyzer, storage system, and MW-scale fuel cell generator will be designed and commissioned at NREL's Flatirons Campus • This hydrogen infrastructure will support H2@Scale goals by enabling integrated systems R&D to study the science of scaling for hydrogen energy systems . The system is designed with flexibility to provide a testbed to demonstrate systems integration, grid services, energy storage, direct renewable hydrogen production, and innovative end use applications (e.g. HD transportation, natural gas blending, etc.) NREL 2#3Overview Timeline and Budget • Project start date: 05/06/2020 • • • FY22 DOE funding: $350,000 FY23 planned DOE funding: $0 Total DOE funds received to date*: $4,430,145 * Since the project started · Barriers Demonstration of electrolyzer and stationary fuel cell technology under real-world conditions Production of hydrogen using directly coupled zero-carbon energy sources Hydrogen energy storage and grid stabilization for high-penetration renewable electric grid Partners Project lead: NREL • Pl: Daniel Leighton NREL 3#4Relevance/Potential Impact • This project establishes a research capability for future projects to conduct MW-scale research in the areas of hydrogen generation, energy storage, end-use distribution, and power production - Proving technologies and addressing integration challenges at scale is a critical precursor to deployment and investment nation-wide to reduce green house gas emissions through the construction of clean U.S. energy infrastructure Key to this is integration of hydrogen as an energy carrying molecule coupled to other technology areas such as wind, solar, energy systems (grid), etc. This capability will also support additional technology areas relevant to H2@Scale as they mature and need to be evaluated with an integrated MW-scale platform - - Molecule building, blending with natural gas, heavy-duty vehicle fueling, etc. Supports efforts within the hydrogen industry and other integrated EERE areas NREL | 4#5Wind Solar Storage Hydro Approach: ARIES Vision Distribution System Geothermal Electrolyzet EV Charges Individual Technologies at MW Scale 13.2KM 115kV Bulk-Power System Behind-the-Meter Storage Microgrid Renewable Hybrid System Co-Located Multi-Technology Energy Systems Highly integrated and configurable Integrated energy research with analysis, modeling, and hardware experiments Varies in scale (devices, types, sizes up to 20 MW, and beyond virtually) Provide a collaborative hands-on experience NREL 5#6Approach: Hydrogen System H 27 hours of 1.25 MW Electrolysis H 600 KG Ground Storage MW H PEM Fuel Cell 1.25MW PEM Electrolysis H 3k PSI 20 MWh Chemical H₂ Compression H AC or DC Input [integrated grid] H H 10 hours of 1 MW FC AC or DC Output [integrated grid] NREL | 6#7Approach: ARIES Grid Equipment ESIF HPC, Visualization and HIL Capabilities Control Center *Under Development Grid Research Pads XXXX Switchgear Building Dynamometer Flatirons Campus 20-MW Substation 5-MW 20 MW CGI "Under Development 7MW CGI Research Grids 1MW/1MWh Li-Ion Battery 3MW Load Bank Utility Grid Large PV Arrays Dynamometer 2.5-MW Megawatt Scale Hydrogen System *Under Development NREL 7#8DC/AC Fuel Cell Inverter Approach: Flatirons Site 1 MW PEM Toyota Fuel Cell H₂ Capabilities 600 kg H₂ Storage Hydropac Compressor 1.25 MW Nel Hydrogen Electrolyzer West 119th Avenue 20 MW CGI DI Water Tank DI Water Polishing Cooling System AC/DC Electrolyzer Rectifier H₂ Systems Integration Flatirons Hydrogen Infrastructure Solar Panels NREL 8#9Simplex HMI Approach: Hybrid Controller Hybrid Controls Map ☐ 1000 PLC1 PLC2 Load Bank 3MVA RLC 430 kW PV 45 kW D Communication Interface 45 kW AC 口 45 kW 45 kW 125 kW 中 -◉+ 125 kW AC +RTAC 3555 SEL DOE1.5 Turbine Hybrid Plant Controller Hybrid Plant 3555 +RTAC Internal Control Algorithms R() G(s) Control Mode H(5) ☐ ☐ ☐ ☐ ☐ HMI Controls RTDS Labview External Interfaces Protyping/PHIL Matlab C(s) Maintenance Interface Site Ops 35 30 RTAC Opto 22 PLC Data Acquisition Plant 250kW/400kWh PV+BESS 卡卡节 NREL PEM 10MWh 1MW Fuel Cell Tumm DC AC DC AC 1.25 MW Electrolyzer NREL 1MW/1MWh Li-ion BESS 卡卡 DC AC ロー anna ☐ CGI PMUS NREL 9#10Accomplishments and Progress: All Equipment Delivered TOYOTA TOYOTA nel Future site infrastructure NREL 10#11Accomplishments and Progress: Build Complete YOTA NREL | 11#12Accomplishments and Progress: Build Complete TOYOTA POWERED BY HYDROGEN H2 TOYOTA TOYOTA POWERED BY HYDROGEN H2 NREL 12#13Accomplishments and Progress: Build Complete NREL 13#14Accomplishments and Progress: Build Complete ERED BY ROGEN H2 TOYOTA HOME NREL 14#15Accomplishments and Progress: Build Complete NREL 15#16Accomplishments and Progress: Summary of FY23 • All design work and safety evaluations completed • All equipment delivered • • All infrastructure built and commissioned - - - Electrical (13.2kVAC, 480VAC, 220/120VAC, 24VDC controls) Compressed air Integrated thermal management system - Deionized water storage, polishing, and delivery system All sub-systems integrated - - - Electrolyzer (including chiller and HVAC sub-systems) Hydrogen compressor Gas management panel Ground storage tanks - Fuel cell generator (excepting electrical which is partially complete) Site electrical power commissioned, including auxiliary sub-systems NREL 16#17Response to 2021 Reviewers' Comments . • • • • Numerous comments on a weakness being a lack of onsite water and the drawbacks of trucking in deionized water. Agreements have been secured for water rights in a reservoir several miles away, and design of the pipeline upgrades and campus water treatment facility is nearing completion. The electrolyzer already has a deionization system installed to make use of this future water source. Operability of this water supply is several years out, but the hydrogen system demands are being factored into the future campus needs. The external collaboration is weak. Only Nel Hydrogen is listed as a collaborator. The future plans need to include more details for such a big project. - This project is an infrastructure installation project and doesn't include research itself, but rather supports future research. There are numerous funded projects that will use this infrastructure once it is commissioned, and many more projects with additional partners are currently under negotiation. There are limitations for longer-term hydrogen production (projects) due to hydrogen storage system size. - There are projects and plans in the works, both funded and not funded yet, to expand to >1,500 kg storage capacity onsite. Additional space is available to expand further as needed for research. It would be great if solar or wind could be integrated in the system so the intermittency of renewable energy could be studied. Both solar and wind are being directly integrated and several future research projects currently planned will study the intermittency of renewable energy for hydrogen production. The end use of the hydrogen was a bit unclear. It is unclear whether it can be sold or used for other downstream applications. The current end use for the hydrogen is the 1 MW fuel cell for research and power export. NREL cannot sell hydrogen on the market. There are several additional end uses being planned for the hydrogen. NREL 17#18Collaboration and Coordination For the electrolyzer we have been working closely with the industry supplier, Nel Hydrogen, with our MC250 which is the second constructed • We have a CRADA to evaluate Toyota's first-of-its-kind 1 MW stationary fuel cell generator prototype Multiple funded projects will leverage this new capability, including the following CRADAS: - - - EPRI: Hydrogen production, grid integration, and scaling for the future GE and Nel Hydrogen: Optimization of wind turbines for hydrogen electrolysis GKN and SoCal Gas: Metal hydride tank R&D coupled with electrolysis and fuel cell systems EPRI/GTI (et al.): Next Generation Hydrogen Leak Detection--Smart Distributed Monitoring for Unintended Hydrogen Releases NREL 18#19Remaining Challenges and Barriers The project scope is nearing a close as the infrastructure is being brought online, the next stage is to execute the research scope of other projects using this infrastructure NREL 19#20Proposed Future Work • Produce and store >50kg of hydrogen using on-site wind power as a milestone to prove functionality • Complete integration and commissioning of 1 MW fuel cell generator • Store renewably generated hydrogen for longer than a week and demonstrate resiliency by using fuel cell generator to then grid-form the Flatirons medium voltage research grid, producing 1 MWh of electrical energy • Transition hydrogen capabilities into multiple research projects within the ARIES platform Note: Any proposed future work is subject to change based on funding levels NREL 20#21. • Summary Construction and integration of the infrastructure and equipment is complete (less fuel cell electrical) Commissioning is underway and nearing completion Remaining tasks include demonstration of capability through renewable energy storage and grid formation operation • This infrastructure will support future research projects under the ARIES umbrella, specifically in the areas of energy storage, direct hydrogen production coupling with renewables, grid stabilization, electrons to molecules, heavy duty transportation, and other innovative end uses NREL 21#22Thank You www.nrel.gov NREL/PR-5700-85914 This work was authored by the National Renewable Energy Laboratory, operated by Alliance for Sustainable Energy, LLC, for the U.S. Department of Energy (DOE) under Contract No. DE-AC36-08G028308. Funding provided by U.S. Department of Energy Office of Energy Efficiency and Renewable Energy Hydrogen and Fuel Cell Technologies Office. The views expressed in the article do not necessarily represent the views of the DOE or the U.S. Government. The U.S. Government retains and the publisher, by accepting the article for publication, acknowledges that the U.S. Government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for U.S. Government purposes. NREL Transforming ENERGY#23Technical Backup and Additional Information#24. Technology Transfer Activities • No patent, licensing, or technology transfer is planned as a part of this funded work . The work funded is creating a capability that supports multiple future collaborative research projects with industry, academia, and other national laboratories NREL 24#25DOAL Fuel Cell Inverter 1 MW PEM Toyota Fuel Cell DI Water Tank Technical Backup Slide: Systems Integration 1 MW PEM Toyota Fuel Cell 600 kg, Storage OCIAC Hydropac Hell Cell Compressor Inverter 1.25 MW Nel Hydrogen Electrolyzer DI Water Polishing Cooling System AC/DC Electrolyzer Rectifier Hydrogen Connections 600 kg Storage Hydropac Compressor 1.25 MW Nell Hydrogen Electrolyzer DOAC 1 MW PEM Toyota Fuel Cell Fuel Cell Inverter DI Water Tank Dl Water Polishing Cooling System AC/DC Electrolyzer Rectifier 13.2 kW Grid Connections 600 kg H, Storage Hydropac Compressor 1.25 MW Nel Hydrogen Electrolyzer 1MW PEM Toyota Fuel Cell DUAL Fuel Cell Inverter O Water Tank DIWater Polishing Cealing Systern AC/DC Electrolyzer Rectifier DC Connections 600 kg, Storage Нуфторис Compressor 1.25MW Nel Hydragen Electrolyzer DIWater Tank DI Water Polishing Cooling System AC/DC Electrolyter Rectifier DI Water Connections 1 MW PEM Toyota Fuel Cell 600 kg, Storage DUAL Fuel Cell Inverter DI Water Tank DI Water Polishing Hydropac Compressor 1.25MW Nel Hydrogen Electrolyzer Cooling System MC/DC Electrolyzer Rectifier System Map NREL 25