Work Package 6 „Prototype“

Based on the simulation results in WP2 and the experimental results in WPs 3-5 a decision will be taken by all partners at the beginning of WP6 on the final system setup of the prototype unit. The existing natural gas test rig will be adapted according to the NEMESIS 2+ requirements. The modules and materials tested in work packages 3, 4 and 5, will be integrated into the proof-of-principle prototype and additional components such as a water purification system, pressure swing adsorption module, hydrogen storage vessel, off-gas vessel and balance of plant (BoP) components will be integrated. In order to increase fuel processing efficiency an elaborated thermal heat integration system will be established.

After debugging (adapt controls, adapt/change components if needed) start-up and shut-down tests will be performed and load variation tests will be carried out. An elaborated measuring system will be installed in order to be able to calculate mass- and energy balance of the overall system as well as thermal hydrogen efficiency and fuel processing efficiency.

Description of work
The work in WP6 is broken down into 3 tasks:

6.1 Adaptation of basic test rig (HYG, m19 – m27)

  • Upgrade of existing natural gas test rig
  • Update of measurement system (mass flow controllers, thermocouples etc.)

6.2 Integration of modules (HYG, APTL m28 – m30)

  • Connection of integrated reformer unit and desulphurisation unit (HYG, APTL)
  • Integration with BoP components (water purification, cooling circuit, heat exchangers, pumps etc.)
  • Integration with existing PSA (from NEMESIS project) or upgraded PSA from parallel project
  • Integration with balance of plant components for HCM (off-gas vessel, hydrogen storage vessel etc.)

6.3 Prototype testing (HYG, APTL m31 – m36)

  • Test and update of controls
  • Test of start-up and shut-down procedure, test of load modulation
  • Determination of functionality of desulphurisation unit, reformer and burner (HYG, APTL)
  • Determination of catalyst performance and – if necessary – dismantling and analysis in the lab followed by replacement with other catalysts to improve performance
  • Ex-situ determination of sulphur content via provision of suitable sampling points (feed fuel, desulphurised fuel, reformate gas, purified reformate gas, off-gas from PSA) with support from APTL and DLR (HYG, APTL, DLR)
  • Feedback on behaviour of sub-components
  • Extended test of 1000 hours
  • Determination of efficiency, hydrogen yield and purity