3.2. Detail of system components
In this study, hydrogen and oxygen are produced on-site at a WWTP in Thuriniga, Germany by electrolysis using grid electricity (Scenario 1) or PV electricity generated in-house and supplemented by grid electricity (Scenario 2). In this way, climate-neutral hydrogen for fuel cell electric vehicles (FCEV) can be produced directly at the HRS (here: publicly accessible, for public use). Oxygen can also be used directly in the biological purification stage of the WWTP after intermediate storage, see here
Figure 1. On-site electrolysers offer the great advantage that the refuelling station as well as the aeration basin is independent of hydrogen or oxygen supplies, transport costs are eliminated and the investment costs remain low. Before the hydrogen can be delivered to a vehicle, it must be compressed to the required pressure. The aerator for pure oxygen only works at an operating pressure of approx. 2.5 bar [
28]. Therefore, the gas can be depressurized from 90 bar before it is introduced into the aeration tank of the WWTP. The hydrogen and oxygen storage tanks are bundle battery plants in a modular system. This makes it possible to expand existing plants without any problems. The hydrogen refuelling station consists of a high-pressure compressor, a dispenser's pre-cooling unit, a remote monitoring system, a regulation and control system and H
2-dispensers. [
47]
Figure 1.
Model of the power-to-gas (PtG) plant with on-site HRS and oxygen utilization in the aeration tank of a wastewater treatment plant (WWTP) at Thuringia, Germany.
Figure 1.
Model of the power-to-gas (PtG) plant with on-site HRS and oxygen utilization in the aeration tank of a wastewater treatment plant (WWTP) at Thuringia, Germany.
The system components to design this model are illustrated below:
a. Electrolyser
The simulation was based on an alkaline high-pressure electrolyser (AEL), which provides the product gases hydrogen and oxygen at a pressure of 90 bar [
10,
11]. In alkaline electrolysis, the water is usually added at the cathode side (HER – Hydrogen Evolution Reaction), where the hydrogen and the OH
- ions, the charge carriers, are formed. The latter cross the microporous or anion-conducting membrane and are converted to oxygen and water on the anode side (OER – Oxygen Evolution Reaction). The half-cell reaction of alkaline electrolysis looks as follows [
48]:
The electrolyser can be scaled as required due to its modular design. The power of the electrolyser for the scenario is 1.125 MW with a hydrogen production of 148,457.43 kg and an oxygen production of 978,768.00 kg. The power-independent losses of hydrogen and oxygen due to, for example, gas measurement or backwashing for gas conditioning and the power-dependent losses of oxygen for water dosing are already deducted here and are taken into account from the outset in the simulation. These can be individually defined by the user of the software. Both gases are initially stored temporarily at 90 bar. In this case study, the hydrogen is then compressed to 875 bar.
b. Photovoltaic system
With the help of a dynamic simulation programme, PV*SOL premium [
49], a south-facing ground-mounted PV system was simulated in Sonneberg-Heubisch (Thuringia), the location of the LocalHy project [
10,
11]. The energy yield of the PV plant generated by the csv-file with hourly resolution is temporarily stored in a separate file by GHOST as an output value and can be linearly scaled in size as required during the system simulation.
According to the ordinance on tendering of Financial Support for ground-mounted systems, there is an upper limit for the size of the offer for a PV ground-mounted system: The offers must each have a size of an installed capacity of at least 100 kWp and at most 10 MWp [
50]. For this reason, the maximum size of 10 MWp was fixed as a simulation value. If the average, volume-weighted surcharge value (ct/kWh) is considered over the last few years, the result is an average value of 5,221 ct/kWh. [
51]. This was given as the revenue for feeding the remaining PV electricity into the grid in Scenario 2.
c. Oxygen utilization in WWTP
The electricity demand in WWTP could be saved by using pure oxygen from electrolysis. With an average share of 20 %, WWTP are usually the largest consumers of electricity in the municipal sector and consume more electricity than schools, hospitals, administrative buildings or other municipal facilities. The high electricity consumption is due to the aeration of the aeration tank of a WWTP, which usually requires by far the most energy of all the process steps of a municipal WWTP. This is around 50 to 80 % of the total electricity demand of the WWTP. [
52] In
Table 2 the average specific electricity consumption of WWTPs is listed according to the size class. The population equivalent (PE) is defined as the average load of biodegradable substances in the wastewater of a resident. The inhabitant-specific, annual electricity consumption kWh/(PE*a) is used to evaluate and compare the energy parameters. The investigated WWTP is assigned to size class 4. The share of the total electricity demand is 60 % in the study example. The main goal in system optimization of WWTPs is thus to reduce electricity consumption using the oxygen from water electrolysis.
Table 2.
Average specific electricity consumption of WWTP by size class according to the Federal Environment Agency. [
52].
Table 2.
Average specific electricity consumption of WWTP by size class according to the Federal Environment Agency. [
52].
WWTP size |
Number of inhabitants |
Specific power consumption [kWh/PE*a]
|
Size class 1 |
< 1,000 |
75 |
Size class 2 |
1,001 - 5,000 |
55 |
Size class 3 |
5,001 - 10,000 |
44 |
Size class 4 |
10,001 - 100,000 |
35 |
Size class 5 |
> 100,000 |
32 |
In drainage engineering, a difference is made between the combined system and the separate system. The construction of new sewer networks in the mixed system has largely been completed. All new systems will be separate systems in order not to mix rainwater with wastewater and to divert it separately. In Thuringia there are still predominantly combined sewer systems. [
53] Due to fluctuating amounts of precipitation, there is an irregular supply of electrolytically produced oxygen. The wastewater changes over time. Thus, higher precipitation amounts are associated with lower substance concentrations and thus also lower oxygen demand. In the course of time, there are always outliers that require a significantly higher amount of oxygen per hour. This is due to the fact that sudden heavy rainfall events are often accompanied by a so-called flushing surge, which is associated with a high volume of wastewater and high concentrations of substances. This also causes a disproportionately high oxygen demand [
54].
Economically, it would be unfavourable to design the entire PtG system according to these outliers, as otherwise the entire system would be oversized and thus could no longer be transferred to economic viability. For this reason, redundancies in the form of oxygen bundles are provided for these cases, which are also considered as additional expenditure for oxygen utilization. Here, the calculation is based on the energy requirement for oxygen from air separation plants, which is offset against the missing quantity of oxygen.
d. Hydrogen refuelling station
SAE J2601 is a refuelling protocol that specifies the requirements of HRS in terms of performance, refuelling process and other operating parameters. The compression process and the refuelling time are also determined here. The latter depends on several parameters, such as delivery pressure (700 or 350 bar), ambient temperature, initial pressure in the vehicle, size of the tank and the degree of refuelling to be achieved. SAE J2601 defines the following parameters as "reference" refuelling values to determine a target for the refuelling time:
- -
Delivery parameter: 70 MPa @ -40 °C (H70-T40)
- -
Ambient temperature: 20 °C
- -
Initial pressure in the vehicle tank: 10 MPa
- -
Refuelling level to be achieved: 95 %
Under these reference conditions, the maximum refuelling time is set at three minutes. [
55] In addition, there is a waiting time until the pump is ready for the next customer (see also
Table 3).
Different constellations are possible for both off-site (central hydrogen production) and on-site refuelling stations (on-site production). Fraunhofer ISE together with e-mobil BW GmbH (2013) have prepared an overview of various possible HRS concepts. Since off-site refuelling stations are not the focus of this publication, they are not discussed further. [
56]. For refuelling stations with decentralized hydrogen production, there are two options for storage and delivery: In cascade refuelling, the gaseous energy carrier flows from the storage tank into the vehicle due to the pressure difference. [
57]. In cascading, hydrogen is compressed from the low-pressure to the high-pressure storage tank, if necessary. As soon as a refuelling process starts, the vehicle is filled from the high-pressure storage tank until the pressure is equalized. Hydrogen is then filled from a pressure tank at the next higher pressure. As soon as pressure equalization occurs, a pressure tank with a higher pressure is used. Cascading with as many stages as possible can thus reduce energy losses and is the most sensible solution in terms of energy. However, higher investment and operating costs for the pressure tanks are detrimental to economic efficiency. For this reason, the general conditions are often analysed in cascading in order to determine the refuelling station configuration [
58].
In order to achieve a certain refuelling level in the cascade configuration, an overpressure is required. For this reason, hydrogen is usually stored at between 800 and 900 bar in the high-pressure tank. [
58,
59,
60]. In the case that the refuelling process starts with more than 875 bar (900 bar tank), there is usually a pressure reducer that prevents the pressure from exceeding 875 bar. Therefore, 875 bar was specified as the maximum pressure in the simulation.
In addition, refuelling with a so-called booster compressor is possible. Here, hydrogen is compressed from a low-pressure container directly into the vehicle tank. This publication focuses on cascading.
H2 MOBILITY divides HRS into four broad categories. In Table 3 the most important parameters that characterize the different sizes are listed. The simulated HRS is a refuelling station of size M - Medium with two dispensers.
Table 3.
Parameters of hydrogen refuelling station (HRS) sizes (excerpt) according to the H2 Mobility initiative. [
56,
61].
Table 3.
Parameters of hydrogen refuelling station (HRS) sizes (excerpt) according to the H2 Mobility initiative. [
56,
61].
|
Very small |
Small |
Medium |
Large |
Numbers of dispensers |
1 |
1 |
2 |
4 |
Allowed waiting time between two refuelling events in min |
20 |
5 |
5 |
0 |
Max. number of refuelling events per dispenser and hour |
2.5 |
6 |
6 |
10 |
Number of refuelling events per day (average/max) |
10/20 |
30/38 |
60/75 |
125/180 |
Max. dispensed H2 in kg/h |
18 |
33.6 |
67.5 |
224 |
Dispensed H2 in kg/d (average/max) |
56/80 |
168/212 |
336/420 |
700/1000 |
The hydrogen consumption at the HRS was determined for the simulation with 110,000 kg hydrogen, which is sold for 9.50 €/kg at the refuelling station
1. This corresponds to about 550 FCEV at an annual average mileage of 20,000 km per vehicle [
62]. The hydrogen storage (90 bar) is equipped with 60x50 litre cylinder bundles. This corresponds to a total volume of 3,000 litres (total H
2 stored @ 90 bar: 19.26 kg). The total volume of the hydrogen storage at 875 bar is 24,000 litres (total H
2 stored @ 875 bar: 1,048.30 kg). The present compressor is a hydraulically driven piston compressor that compresses the hydrogen from the 90 bar storage into the 875 bar storage. According to a study by Fasihi et al. [
33], hydrogen could be produced on all continents in 2050 at a price of 1.58 €/kg hydrogen. This assumes a reduction in the electricity production costs of renewable energies and an increase in the CO
2 emission licence prices. Furthermore, according to this study, cost degressions of PV plants, wind energy plants, hydrogen compressors and water electrolysers are to be expected up to 2050. Government subsidies, lower investment risks and a lower WACC can also improve local competitiveness [
33]. Cost reduction potentials arise primarily from the continuous increase in annual production quantities and the transition to series production.
An increase in utilization cannot be guaranteed by the constellation of electrolyser and storage. Outages may occur, which will not to be considered in this scenario. An increase in the size of the storage facility would also not have had the desired effect. It would have had to be significantly enlarged, which would not have been economical. The focus of this paper is on investigating the influence of the additional use of the by-product oxygen from electrolysis. For this reason, the simulation was set for a 100 % security of supply of around 550 FCEVs with an assumed driven distance of 20,000 km/year. The remaining approximately 38,500 kg of hydrogen in the storage at the end of the year was sold to the surrounding industry for 4.50 € in the present scenario, but could also serve as a buffer in the storage for the new year.
3.3. Levelized Cost of Hydrogen
The LCOH (inferred from the Levelized Cost of Electricity (LCOE)) is considered the most important indicator among the economic valuation indices. Therefore, special attention will be paid to the investigation of these. The LCOH is estimated on the basis of the NPV method. Kuckshinrichs et al. [
63] lists not only the LCOH for the cost assessment, but also the NPV for the attractiveness analysis and the variable costs for the analysis of market flexibility.
In the valuation of investments, the NPV method is the most common calculation method. It belongs to the asset value methods and in this sense aims to maximize the final assets. Its result is the
, which is calculated from the present value of all cash inflows (
) and cash outflows
) of the investment object at time
thus represents the net cash flow in the individual periods during the project term (
). The calculation interest rate (equated here with the
) is given as
and
is the number of periods. If the NPV assumes a positive value (
), the project is absolutely advantageous and thus preferable to investing money on the capital market. According to the maximization calculation, the project with the highest NPV is therefore relatively advantageous. If, on the other hand, the NPV is negative (
), investing money in the project proves to be disadvantageous. With a NPV of zero, no advantageous decision can be made using this method, since the return on the investment corresponds to the return on the capital market. In this case, the decision-maker is indifferent to both alternative courses of action. Blohm et al. [
64], on the other hand, also see this case as advantageous, since here the desired minimum interest rate is achieved at the calculation interest rate. The NPV formula also shows that the cost of capital increases as the interest rate rises. From this it can be concluded that a higher calculation interest rate causes a lower NPV and thus has a significant influence on it. [
64,
65] The basic form of the formula of the NPV is as follows [
5,
64,
65]:
In order to further specify this formula, additional parameters are first defined. The payments at the beginning of the project are called initial investment costs
( and do not need to be discounted due to their temporal occurrence in
t = 0. At the end of the project (
t = T) the liquidation proceeds (
) can be added to the payment surpluses of the last period [
66]. The sum of all cash inflows and the liquidation proceeds after deducting the cash outflows results in the net payments. Their cash value in turn leads to the capital value, which is therefore also referred to as the NPV. This can now be represented as [
64,
65]:
Inferred from the NPV method, the
with the unit [€/kg H
2] is defined as [30, 64]:
The total expenditure in each period, includes the annual maintenance and operating costs and the annualised replacement cost; is the yearly mass of hydrogen produced, refers to the annual income from the sale (feed-in) of surplus electricity from the PV system to the grid. is the rate of change during the period of time, not only the system degradation rate. can also be positive or negative. For the present calculations was assumed to be zero. If liquidation proceeds accrue towards the end of the project, these must also be considered in the calculation of the . In this project, it is assumed that the individual components reach the end of their service life after a term of 30 years and thus no liquidation proceeds arise in the 30th project year.
with the unit [€/kg H
2] stands for the specific hydrogen production costs, in which the additional revenue from the sale of oxygen was taken into account in each period. The expenses for the additional use of oxygen (e.g. oxygen storage, aeration system) are also included in
. The
decrease compared to the
only if the expenses for oxygen use are lower than the additional revenue from the sale of oxygen (
. There is a cross-financing of hydrogen production by the revenues of oxygen utilization.
In this example, the revenue from oxygen sales corresponds to the savings in electricity for the blower originally used to aerate the aeration basins. A major advantage of this project is that the electrolytically produced oxygen is already under pressure and therefore no longer needs to be compressed for storage. In addition, there is no need for high-purity oxygen for aeration of the aeration basin, as is the case for medical applications, and thus no purification is required, which does not result in unnecessary costs.