Efficiente energietoevoer voor duurzame generatie van waterstof
Waterstof, een hype of een technologie die ons warm zal houden in een energiesysteem zonder fossiele brandstoffen? Hoewel de meningen hierover verdeeld zijn, staat het vast dat de Europese Unie ambities heeft om deze energiedrager een grote rol te laten spelen in het verminderen van de broeikasgasuitstoot. Het zal dus essentieel zijn om deze grondstof op een duurzame en efficiënte manier te produceren. Deze thesis biedt hiervoor een oplossing op industrieel niveau door het ontwerp van een efficiënte energietoevoer, of power converter.
Het duurzaam produceren van waterstof uit water, een techniek genaamd elektrolyse gevoed door (hernieuwbare) elektriciteit, gaat gebukt onder een lage efficiëntie van dit chemische proces. Waterstof gebruiken zal dus onvermijdelijk gepaard gaan met een verlies van waardevolle hernieuwbare energie. Desondanks zal de vraag naar duurzame waterstof in de toekomst zeker stijgen. Waterstof is in verschillende toepassingen de ideale vervanger van aardgas, bijvoorbeeld verwarmen op hoge temperaturen. Zodus kan met dit duurzaam alternatief de broeikasgasuitstoot verminderd worden, zowel voor bedrijven als gezinnen. Er wordt zelfs voorspeld dat in 2050 tot 24% van alle energieconsumptie in de vorm van waterstof zal zijn. Elke verbetering in de efficiëntie van het productieproces, zal dus een grote besparing van hernieuwbare elektriciteit teweeg brengen. Daarom focust deze thesis op het ontwerpen van een optimale energietoevoer.
Overvloed aan omvormers
De elektriciteit die nodig is voor de productie van waterstof verschilt van de typische elektriciteit die uit een stopcontact komt. Voor elektrolyse is er namelijk een gelijkstroom (DC) nodig, in tegenstelling tot de gebruikelijke wisselstroom (AC) van het elektriciteitsnet. Hedendaagse industriële elektrolyseapparaten gebruiken dus een power converter om de beschikbare AC stroom om te zetten naar DC. Deze conversie gebeurt in omgekeerde richting voor bepaalde hernieuwbare bronnen en opslagtechnieken, zoals zonnepanelen en batterijen, wiens DC stroom via een omzetting naar AC in het net geïnjecteerd wordt.
Elk van deze omvormingen gaat gepaard met een verlies van energie. Bovendien zijn de omvormers die gebruikt worden bij elektrolyse niet specifiek ontworpen voor deze toepassing. We kunnen dus de efficiëntie van het gehele proces verhogen door een specifieke omvormer te ontwerpen om de DC stroom te voorzien op het gepaste spanningsniveau voor de elektrolyse, gevoed door DC hernieuwbare bronnen: een geoptimaliseerde DC/DC converter.
Figuren 1 en 2 tonen respectievelijk de klassieke systeemopstelling en de voorgestelde opstelling met een geoptimaliseerde omvormer. Elke omvormer gaat gepaard met een beperkte efficiëntie en dus met energieverliezen. Bovendien zijn DC/DC omvormers efficiënter dan AC/DC of DC/AC convertoren, waardoor de voorgestelde systeemopstelling tot minder verliezen leidt bij de waterstofproductie met hernieuwbare energie.
Commerciële beschikbaarheid en schaal
In voorafgaand wetenschappelijk onderzoek over omvormers voor elektrolyse werd er steeds gewerkt met kleinschalige prototypes. Industriële installaties zijn echter vele malen groter, waardoor ook andere vereisten van toepassing zijn op de energietoevoer. Hoge vermogens op industriële schaal elimineren verscheidene klassieke converterontwerpen. Een gespecialiseerde converter voor hoge vermogens moet dus ontworpen worden om de elektrolyse optimaal aan te drijven.
Door samenwerking met producenten van commerciële elektrolysepparaten is er in dit onderzoek een realistisch model geconstrueerd, gebaseerd op wetenschappelijke voorkennis, om de optimale condities te berekenen voor de toegediende energie. Bovendien kan er via deze industriële partners een referentie vastgesteld worden voor de efficiëntie van de huidige omvormer die maximaal 97% bedraagt. Het doel van het voorgestelde converterontwerp zal dus zijn om deze efficiëntie te overtreffen.
Om industriële spelers een efficiënter alternatief te bieden dan de huidige omvormers, is het voorgestelde ontwerp gebaseerd op commercieel beschikbare componenten die online aangekocht kunnen worden. Zo kan dit onderzoek direct door bedrijven toegepast worden om de kost en energieconsumptie van waterstofproductie te verlagen.
Converter ontwerp en resultaten
Figuur 3 toont het finale converterontwerp waarmee de elektrolyse optimaal aangedreven kan worden. Door het aansturen van de schakelaars (S1-S6 op de figuur) kan het spanningsniveau aan de uitgangsklemmen van de converter bepaald worden. Doordat de inkomende stroom over zes parallelle paden verdeeld kan worden, heeft deze converter een hoge vermogenscapaciteit en is deze dus uitermate geschikt om commerciële elektrolyse aan te drijven.
Op het maximale vermogen heeft deze converter een efficiëntie van 99.1%. Er kan dus 2.1% van de toegevoerde energie bespaard worden. Op de industriële schaal (1.7MW) van de onderzochte apparaten komt dit overeen met een constante besparing van 37 kW, vergelijkbaar met het laadvermogen van 10 elektrische wagens.
Tot slot worden twee realistische situaties in rekening gebracht om de voorgestelde converter en het aangepaste systeemontwerp te vergelijken met de commerciële referentie. In deze gevallen wordt er gefocust op het maximaal benutten van hernieuwbare energie als bron.
In het eerste geval wordt het systeem getest op het maximale werkingsvermogen. In deze situatie wordt er aangenomen dat een bepaalde hoeveelheid generatie voorzien wordt door zonnepanelen en batterijen in DC. Aangezien men er niet zeker kan zijn dat er genoeg zonne-energie beschikbaar is om het maximale vermogen te voorzien, wordt een connectie met het klassieke AC net toegevoegd. Deze opstelling is weergegeven in figuur 4. De totale systeemefficiëntie is dus afhankelijk van de hoeveelheid energie die rechtstreeks door de hernieuwbare bronnen geproduceerd wordt. Vanaf een hernieuwbaar aandeel van 28.38% zal deze systeemopstelling het beter doen dan de commerciële referentie.
In de andere opstelling wordt een opstelling met enkel zonne-energie overwogen. De variabiliteit hiervan wordt dus in rekening gebracht voor een opstelling in België en in Marokko, waar de condities voor zonnepanelen significant beter zijn. Door gebruik te maken van een directe connectie met de ontworpen converter, kan er op beide locaties respectievelijk 17 370m3 en 27 220m3 aan waterstof extra geproduceerd worden per jaar.
Conclusie
De testresultaten tonen duidelijk aan dat het optimaliseren van de energietoevoer een positieve impact heeft op de opbrengst en energieconsumptie van waterstofproductie. Door deze commercieel beschikbare verbetering toe te passen, kunnen bedrijven besparen op hun energiekost. Dankzij dit duurzaam alternatief voor aardgas verlagen ze bovendien hun uitstoot. Optimalisaties zoals deze, die gefocust zijn op het maximaal benutten van beschikbare hernieuwbare energie, zullen in de toekomst essentieel worden om broeikasgasuitstoot te verminderen en de klimaatopwarming te beperken.
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