Solar Hydrogen ProjectSolar Hydrogen ProjectIPRO 397 – 301IPRO 397 – 301

Advisor: Dr. Said Al-HallajAdvisor: Dr. Said Al-HallajSponsors: BP, BP Solar, Proton Energy Sponsors: BP, BP Solar, Proton Energy

Systems, ComEd & IL-DCEO Systems, ComEd & IL-DCEO

Team MembersTeam Members

Ariel Simons, Ronak Shah, Harsha Ariel Simons, Ronak Shah, Harsha Pannala, Vesna Dodevski, Umar Rabbani, Pannala, Vesna Dodevski, Umar Rabbani, Nishant Shah, Steven Peters, Ryad Nishant Shah, Steven Peters, Ryad Djerrouf, Elvir Kahrimanovic, Leonardo Djerrouf, Elvir Kahrimanovic, Leonardo Melo, Lyes Boundaoui, Adekunmi Keleko Melo, Lyes Boundaoui, Adekunmi Keleko (Team Leader).(Team Leader).

Brian  Kustwin (Consultant).Brian  Kustwin (Consultant).

OverviewOverview

Project ObjectiveProject Objective

Project SchematicsProject Schematics

Individual Group ApproachesIndividual Group Approaches

Q&A.Q&A.

ObjectiveObjective

The objective of this project is to design, The objective of this project is to design, assemble and analyze a stand-alone assemble and analyze a stand-alone distributed power generation system that distributed power generation system that utilizes solar energy through PV panels utilizes solar energy through PV panels and hydrogen storage and conversion to and hydrogen storage and conversion to power an LED sign. power an LED sign.

SchematicSchematic

Solar Hydrogen System Block Diagram

PHASE - IPV

PHASE - IIPV

ChargeController

Battery Bank

DC/AC Inverter

Load

DC/DC Converters

HydrogenStorage

HydrogenStorage

Fuel Cell

Fuel Cell -BatteryControlSystem

Electrolyzer

Auxillaries Cell Stack

H2

H2

ApproachApproach

Teams Teams 1&21&2

Inspect project site, test DC/DC converter, Inspect project site, test DC/DC converter, back engineer electrolyzer. Price back engineer electrolyzer. Price 120AC/240AC converters, wire AC/AC 120AC/240AC converters, wire AC/AC converter, price relays and switchesconverter, price relays and switches

Team 3Team 3 Inspect electrolyzer and storage tank, price Inspect electrolyzer and storage tank, price fuel cell equipment.fuel cell equipment.

Team 4Team 4 Summarize past data papers, look for data Summarize past data papers, look for data acquisition hardware. Perform acquisition hardware. Perform experiments.experiments.

Team 5Team 5 Purchase cameras, de-bug website, Purchase cameras, de-bug website, upload all documents onto website.upload all documents onto website.

The DC/DC ConverterThe DC/DC Converter

Converts PV output to a voltage usable by the Converts PV output to a voltage usable by the electrolyzerelectrolyzer

Needs protection from dust and heatNeeds protection from dust and heat

Housing should be made of aluminum, Housing should be made of aluminum, Plexiglas, or plasticPlexiglas, or plastic

Commercial units not acceptableCommercial units not acceptable Too expensive, provided outdoor protectionToo expensive, provided outdoor protection Too unprofessional, cheap Too unprofessional, cheap

Teams 1&2Teams 1&2

The DC/DC ConverterThe DC/DC Converter

DC/DC ConverterDC/DC Converter Experimental SetupExperimental Setup

Teams 1&2Teams 1&2

PV PHASE II SYSTEM I AREA I - V

Analog Port, DB 15-P

+

-

Input terminals Output terminals

+

-

HP6060B Digital Electronic Load

HP6632A System DC Power Supply

The TransformerThe Transformer

Previous IPROs underestimated input voltage Previous IPROs underestimated input voltage to electrolyzer auxiliaries (240 Vac instead of to electrolyzer auxiliaries (240 Vac instead of 120 Vac)120 Vac)

Need 120V/240V step-up transformer to fix Need 120V/240V step-up transformer to fix this problemthis problem

Decided on 1kVA rating to be safeDecided on 1kVA rating to be safe

http://phaseconverter.com/sptransformer.htmlhttp://phaseconverter.com/sptransformer.html

$150 before shipping$150 before shipping

Teams 1&2Teams 1&2

Project GoalsProject Goals

Go to site and inspect electrolyzer and storage Go to site and inspect electrolyzer and storage tank. tank. Find out how to connect the fuel cell to the four-Find out how to connect the fuel cell to the four-way valve for the hydrogen flow. way valve for the hydrogen flow. Find equipment and price that can be purchased Find equipment and price that can be purchased and used to connect the fuel cell to the four-way and used to connect the fuel cell to the four-way valve valve Find equipment and price for a back pressure Find equipment and price for a back pressure regulator (BPR) and steel tubing to connect the regulator (BPR) and steel tubing to connect the fuel cell intake with the hydrogen tanks fuel cell intake with the hydrogen tanks

Team 3Team 3

Electrolyzer and Storage TankElectrolyzer and Storage Tank

The water storage tank and electrolyzer The water storage tank and electrolyzer are already installed .are already installed .

The electrolyzer is currently inactive, the The electrolyzer is currently inactive, the water tank would needs to be periodically water tank would needs to be periodically refilled when the electrolyzer is active .refilled when the electrolyzer is active .

The pump needed to bring the water from The pump needed to bring the water from the tank to the electrolyzer was installed in the tank to the electrolyzer was installed in the storage tank standthe storage tank stand..

Team 3Team 3

Steel Tubing / Back Pressure Steel Tubing / Back Pressure Regulator (BPR)Regulator (BPR)

To transfer hydrogen to the fuel cell the four way To transfer hydrogen to the fuel cell the four way valve needs to be connected to the fuel cell valve needs to be connected to the fuel cell intake.intake.

Connected to the stainless steel tubing needs to Connected to the stainless steel tubing needs to be a BPR.be a BPR.

BPR takes 250psi inlet hydrogen down to BPR takes 250psi inlet hydrogen down to approximately 30psi outlet hydrogen.approximately 30psi outlet hydrogen.

Stainless steel tubing, at least 0.25in thick, is Stainless steel tubing, at least 0.25in thick, is needed to prevent significant hydrogen diffusion.needed to prevent significant hydrogen diffusion.

Team 3Team 3

Further ActionsFurther Actions

A BPR needs to be purchased before all of A BPR needs to be purchased before all of the gas systems can be put up.the gas systems can be put up.

The primary problem in searching for a The primary problem in searching for a suitable BPR involves finding an inline suitable BPR involves finding an inline BPR instead of the more prevalent panel-BPR instead of the more prevalent panel-mounted BPR.mounted BPR.

Team 3Team 3

Data Acquisition (DAQ)Data Acquisition (DAQ)

The data acquisition was done using The data acquisition was done using LabView which is designed to monitor the LabView which is designed to monitor the Solar Hydrogen System. It measured Solar Hydrogen System. It measured voltage, pressure, temperature, solar voltage, pressure, temperature, solar insulation and mass flow of the system insulation and mass flow of the system elements we studied in this project. elements we studied in this project.

Team 4Team 4

EquipmentEquipment

HP6060B Digital Electronic LoadHP6060B Digital Electronic Load

HP6632A System DC Power SupplyHP6632A System DC Power Supply

Battery BankBattery Bank

DC / DC Converter.DC / DC Converter.

Team 4Team 4

DataData

DC Converter Test DataDC Converter Test Data

Team 4Team 4

RESISTANCE VOLTAGE RANGE (V)

VOLTAGE STABILIZATION

CURRENT (A)

30 46 - 60 59.5 2

20 55 - 61 55 3

10 38 - 48 48 4

8 42 42 5

6 34 34 6

4 29 29 7

2 18 18 10

1 14 14 14

Data Data

Constant Resistance Mode DataConstant Resistance Mode Data

Team 4Team 4

RESISTANCE RESISTANCE VOLTAGE VOLTAGE RANGE (V) RANGE (V)

VOLTAGE VOLTAGE STABILIZATION STABILIZATION

CURRENT (A) CURRENT (A) PANELS PANELS

10 10 27 – 31 27 – 31 28 28 2.8 2.8 AREA I AREA I

10 10 34 – 36 34 – 36 35 35 3.5 3.5 AREA I, II AREA I, II

10 10 34 – 36 34 – 36 35 35 3.5 3.5 AREA I, II, III AREA I, II, III

10 10 32 – 33 32 – 33 32 32 3.2 3.2 AREA I, II, III, AREA I, II, III, IV IV

DataData

Constant Current Mode DataConstant Current Mode Data

Team 4Team 4

RESISTANCE RESISTANCE VOLTAGE VOLTAGE RANGE (V) RANGE (V)

VOLTAGE VOLTAGE STABILIZATION STABILIZATION

CURRENT (A) CURRENT (A) PANELS PANELS

10 10 32 – 33 32 – 33 32 32 3.2 3.2 AREA I - V AREA I - V

10 10 48 – 55 48 – 55 50 50 2.8 2.8 AREA I - IV AREA I - IV

10 10 34 – 36 34 – 36 35 35 3.5 3.5 AREA I - III AREA I - III

10 10 34 – 36 34 – 36 35 35 3.5 3.5 AREA I - II AREA I - II

AnalysisAnalysis

Resistance vs. Current Resistance vs. Current

Team 4Team 4

Current vs. Resistance

0

2

4

6

8

10

12

14

16

30 20 10 8 6 4 2 1

Resistance

Cu

rre

nt

AnalysisAnalysis

Voltage vs. Voltage vs. Resistance Resistance

Voltage vs. Resistance

59.555

4842

3429

1814

0

10

20

30

40

50

60

70

30 20 10 8 6 4 2 1

Resistance

Vo

lta

ge

Team 4Team 4

Signal CalculationSignal Calculation

Voltage (Volt): System voltageVoltage (Volt): System voltage

Current (Amp): System voltage/ Shunt Current (Amp): System voltage/ Shunt resistance.resistance.

PV Power (Watt): PV Power (Watt): PPinin = V = Vprpr*Area (PV)/ Cal*Area (PV)/ Cal PV Power Out (Watt): V*CurrentPV Power Out (Watt): V*Current

Team 4Team 4

Signal CalculationSignal Calculation

Solar Radiation Power (Watt/mSolar Radiation Power (Watt/m22): P): Psrsr = =

VVprpr/Cal/Cal

Total Power, PTotal Power, Ptotaltotal: Voltage*Current (of : Voltage*Current (of

PPv1v1+P+Pv2v2))

Efficiency (%) = PEfficiency (%) = Ptotaltotal/P/Pinin*100 *100

Battery Power (Watt): VBattery Power (Watt): Vbatbat*Current.*Current.

Team 4Team 4

Hydrogen SystemHydrogen System

The power available at given time of year.The power available at given time of year.

Team 4Team 4

(2.7kW Array)

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

1 2 3 4 5 6 7 8 9 10 11 12

Month

Po

we

r (k

W-h

/da

y)

Avg Power Min Power Max Power

Hydrogen SystemHydrogen System

The time needed to fill tanks at time of The time needed to fill tanks at time of year.year.

Team 4Team 4

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

1 2 3 4 5 6 7 8 9 10 11 12

Month

Tim

e (

da

ys

)

Avg Power Min Power Max Power

CalculationsCalculationsTeam 4Team 4

Tank and Electrolyzer CalculationsTank and Electrolyzer Calculations Power for MSX Power for MSX 5.99Kw-h/day5.99Kw-h/day

Power for Millennia Power for Millennia 21.16Kw-h/day21.16Kw-h/day

Power for BP Power for BP 13.67Kw-h/day13.67Kw-h/day

Total Power to stack Total Power to stack 8.98Kw-h/day8.98Kw-h/day

HH22 Production Rate Production Rate 38ft38ft33/h @200psi/h @200psi

Energy Consumption Energy Consumption 7.00Kw-Hour7.00Kw-Hour

Daily insulation data Daily insulation data 4.1Kw-h/m4.1Kw-h/m22/day/day

Number of Days Needed to fill Number of Days Needed to fill the tanks the tanks

0.780Days0.780Days

CalculationsCalculations

Fuel Cell CalculationsFuel Cell Calculations

Load Load 250Watts250Watts

Running Time Running Time 24hrs24hrs

Mass of HMass of H22 Required Required 288.00grams288.00grams

Mass of HMass of H22 in Tanks in Tanks 1307.51grams1307.51grams

Time Fuel Cell Can Time Fuel Cell Can Run on Full Tanks Run on Full Tanks

69.73hrs69.73hrs

Team 4Team 4

Upgraded CameraUpgraded CameraDVMR 80/CDN 12DVMR 80/CDN 12

Hardware Features:Hardware Features:It comes with four high It comes with four high quality digital camera inputquality digital camera inputAll weather Indoor/Outdoor All weather Indoor/Outdoor Rated CDD CamerasRated CDD CamerasProvides Sony True CCD Provides Sony True CCD Color QualityColor QualityAutomatic switch to infrared Automatic switch to infrared in Total Darkness up to 30 in Total Darkness up to 30 feetfeet Has a reusable (record over) Has a reusable (record over) 80 gig hard drive80 gig hard drive

Team 5Team 5

New Upgraded CameraNew Upgraded Camera

Software Software Features:Features:Allows viewing of all cameras Allows viewing of all cameras live and recorded video via live and recorded video via internetinternetHas user name and Has user name and password option for securitypassword option for securityHas split screen option Has split screen option Has ability to ZOOM Has ability to ZOOM 120 fps (frame per second) 120 fps (frame per second) capacitycapacity

Team 5Team 5

Order in progress

System InstalledSystem Installed

Ability to run LabView at all times to Ability to run LabView at all times to record and store datarecord and store dataShare folders, directories with existing Share folders, directories with existing system.system.To be networked wirelessly to the World To be networked wirelessly to the World Wide Web.Wide Web.Performed complete diagnostics to Performed complete diagnostics to improve its efficiency and latest drivers improve its efficiency and latest drivers installed.installed.

Team 5Team 5

WebsiteWebsite

Newer accurate documents/pictures Newer accurate documents/pictures uploaded and linked.uploaded and linked.

New design/layout applied to the website New design/layout applied to the website to reflect modern design.to reflect modern design.

Team 5Team 5

The EndThe End

Any Questions?Any Questions?