DOE Hydrogen, Fuel Cells and Infrastructure Technologies Program Integrated Hydrogen Production, Purification and Compression System

The project was started in April 2005 with the objective to meet the DOE target of delivered hydrogen of <$1.50/gge, which was later revised by DOE to $2-$3/gge range for hydrogen to be competitive with gasoline as a fuel for vehicles. For small, on-site hydrogen plants being evaluated at the time for refueling stations (the 'forecourt'), it was determined that capital cost is the main contributor to the high cost of delivered hydrogen. The concept of this project was to reduce the cost by combining unit operations for the entire generation, purification, and compression system (refer to Figure 1). To accomplish this, the Fluid Bed Membrane Reactor (FBMR) developed by MRT was used. The FBMR has hydrogen selective, palladium-alloy membrane modules immersed in the reformer vessel, thereby directly producing high purity hydrogen in a single step. The continuous removal of pure hydrogen from the reformer pushes the equilibrium 'forward', thereby maximizing the productivity with an associated reduction in the cost of product hydrogen. Additional gains were envisaged by the integration of the novel Metal Hydride Hydrogen Compressor (MHC) developed by Ergenics, which compresses hydrogen from 0.5 bar (7 psia) to 350 bar (5,076 psia) or higher in a single unit using thermal energy. Excess energy from the reformer provides up to 25% of the power used for driving the hydride compressor so that system integration improved efficiency. Hydrogen from the membrane reformer is of very high, fuel cell vehicle (FCV) quality (purity over 99.99%), eliminating the need for a separate purification step. The hydride compressor maintains hydrogen purity because it does not have dynamic seals or lubricating oil. The project team set out to integrate the membrane reformer developed by MRT and the hydride compression system developed by Ergenics in a single package. This was expected to result in lower cost and higher efficiency compared to conventional hydrogen production technologies. The overall objective was to develop an integrated system to directly produce high pressure, high-purity hydrogen from a single unit, which can meet the DOE cost H2 cost target of $2 - $3/gge when mass produced. The project was divided into two phases with the following tasks and corresponding milestones, targets and decision points. Phase 1 - Task 1 - Verify feasibility of the concept, perform a detailed techno-economic analysis, and develop a test plan; and Task 2: Build and experimentally test a Proof of Concept (POC) integrated membrane reformer/metal hydride compressor system. Phase 2 - Task 3: Build an Advanced Prototype (AP) system with modifications based on POC learning and demonstrate at a commercial site; and Task 4: Complete final product design for mass manufacturing units capable of achieving DOE 2010 H2 cost and performance targets.