In late 2024, a first-of-a-kind, absolutely practical undertaking spearheaded by Duke Power, GE Vernova, and Sargent and Lundy may start demonstrating industrial peaking capabilities of an built-in hydrogen power-to-power system at Duke Power’s DeBary energy plant in Florida. In an unique interview, undertaking companions revealed particulars of the doubtless trailblazing set up, slated to turn out to be the primary within the nation and among the many world’s first energy vegetation to provide and use renewable hydrogen to energy a gasoline turbine for peaking energy functions.
Whereas formally unveiled on Oct. 27, planning and growth for the DeBary Hydrogen Undertaking have been underway for a number of years, and its one-year development is poised to start later this yr. The “end-to-end” power system will probably be co-located on the DeBary plant in Volusia County. The Duke Power Florida plant at the moment includes a 74.5-MW photo voltaic PV plant, opened in 2020, and a 692-MW gasoline energy plant pushed by six GE 7B and 4 GE 7E gasoline generators, which have been commissioned in 1975.
The businesses instructed POWER that the hydrogen demonstration will leverage extra photo voltaic technology throughout peak technology and low demand occasions from DeBary’s 300,000-panel photo voltaic PV array to separate water, using two 1-MW proton change membrane (PEM) electrolyzers Duke Power will procure from Plug Energy. That includes an effectivity of about 65%, the electrolyzers are slated to provide about 36 kilograms (kg) of hydrogen per hour.
That hydrogen will then be saved onsite in tanks able to holding 2,500 kg of compressed hydrogen. As a part of the undertaking, GE Vernova will, through the third quarter of 2024, improve one in every of DeBary’s 4 83-MW GE 7E gasoline generators, enabling it to combust as much as 100% hydrogen (by quantity) to cater to durations of peak demand—making it GE’s first industrial demonstration of an E-class machine operating at 100%. At ambient Florida web site situations, the turbine may have an output of 75 MW, Jay Bryant, GE Vernova senior product supervisor—7E Fuel Generators, instructed POWER.
“We’re fairly proud of the two,500 kg as a result of we’re a runtime of between about half-hour to 3 hours, relying on the % hydrogen mix,” stated Clift Pompee, Duke Power’s managing director of Era Expertise. “The three hours is vital as a result of [the gas] models usually dispatch for about three hours—they’re peaking models, so after they do dispatch, they solely run about three hours throughout peak occasions within the evenings,” he famous.
Nevertheless, the undertaking’s extra appreciable prowess will probably be to point out an “present gasoline turbine could be retrofitted cost-effectively to go as much as 100% hydrogen and a system that may be built-in end-to-end,” Pompee added. Duke Power has pointedly developed DeBary as a smaller-scale undertaking. The profit, he instructed, is that it’s well-suited to function a sensible case research for future utility-scale built-in hydrogen energy deployments, which should think about economics, scale, and utility.
“I believe that’s going to present folks much more confidence to make funding choices on both smaller or bigger tasks,” he stated. “That’s what we wish—we wish the {industry} to proceed shifting ahead. We’ll be a part of that, and this our first [effort].”
A Small However Probably Influential Undertaking
When it comes on-line in 2024, the DeBary Hydrogen Undertaking could also be quickly adopted by the 300-GWh Superior Clear Power Storage Hub (ACES Delta), whose development is underway in Delta, Utah, and is slated to start working in 2025. Nevertheless, ACES Delta will begin operating its Mitsubishi Energy M501JAC gasoline generators with a hydrogen gas mix of 30% earlier than ultimately ramping as much as obtain a 100% hydrogen combustion quantity. One other much-watched undertaking, HYFLEXPOWER, is underway at a transformed ENGIE 12-MWe mixed warmth and energy (CHP) plant in France. The commercial-scale built-in hydrogen power-to-power demonstration that includes a Siemens Power SGT-400 gasoline turbine not too long ago powered its gasoline turbine with 100% renewable hydrogen.
Whereas on a smaller scale, DeBary is an industry-led effort and will probably be commercially relevant, Pompee underscored. Whereas Duke Power’s staff “needed to do extra,” it thought of present market demand and dangers—together with inflation and wild card prices, he famous. “The limitation on the runtime has nothing to do with the {hardware}. It has nothing to do with the expertise,” he stated. “It has to do with simply how a lot storage we’ve on-site,” he confused.
Groundbreaking, marking the undertaking’s first important milestone, will observe practically three years of meticulous planning and growth, throughout which the undertaking was rigorously formed and refined to align with Duke Power’s stringent requirements for air permits and security rules, making certain its compliance and adherence to environmental and security norms.
In response to Pompee, the undertaking’s origins hint again to even earlier than Duke Power shaped its Era and Transmission Technique phase, a enterprise division now instrumental in steering the nation’s largest utility towards its formidable net-zero aim introduced in 2019. Its early phases have been modestly supported by Duke Power’s Imaginative and prescient Florida initiative—a program dedicated to exploring groundbreaking tasks like microgrids, battery storage, and floating photo voltaic.
“As we began working increasingly on the undertaking, we actually discovered some wonderful undertaking companions, together with GE and Sergeant Lundy,” Pompee stated. And because the undertaking’s growth progressed, its position in Duke Power’s bigger decarbonization roadmap grew to become clearer.
The advantage of launching an illustration—not only a pilot—additionally grew to become clear, Pompee stated. “We have now some learnings that we’re attempting to get out of the undertaking,” he added. Nevertheless, and “extra importantly, the property that we put into service will keep in service and can proceed so as to add worth to our fleet,” he famous.
Courtesy: Duke Power
Getting an E-Class Prepared for Decarbonized Peaking
As a result of the DeBary undertaking will function commercially—demonstrating market viability from its outset—its most important enterprise will probably be efficiently integrating modifications to the 7E gasoline turbine.
Whereas GE Vernova has lately marked a sequence of notable hydrogen “firsts” as a part of buyer tasks to check hydrogen combustion on H-class, F-class, and aeroderivative gasoline generators, its industrial fleet—6B, 7E, and 9E gasoline turbine fashions—function combustion methods that make them already technically able to combusting 100% (by quantity) hydrogen when blended with pure gasoline, Byrant defined. For instance, the 7E in focus at DeBary makes use of a multi-nozzle quiet combustor (MNQC), a diffusion-based combustion system, which has been used because the Eighties for generators operating on syngas and different low-BTU fuels.
“And so, they’re beginning out with a gasoline turbine that has an incredible quantity of innate hydrogen functionality,” he famous. “We simply want so as to add some options to it.” The improve will combine the fuel-blending pores and skin, valves, and piping that may deal with 100% hydrogen by quantity and supply the operational flexibility wanted to keep up plant reliability, he stated.
As pivotally, the improve will remodel the 7E “from a twin gas unit with pure gasoline and distillate” capabilities to a “tri-unit” gas unit, “the place it may go pure gasoline, distillate, or hydrogen, or a mix of hydrogen and pure gasoline,” Byrant stated. “We have now this functionality right this moment, however there’s a couple of modifications wanted to take it to 100% hydrogen, [such as] leak prevention gasket sealing, and a little bit bit higher grade of steel to protect in opposition to embrittlement that happens at these ranges of hydrogen,” he stated.
The set up “will probably be in industrial operation,” Byrant underscored. “It isn’t the place we’re placing some momentary {hardware} on there and operating it for a couple of hours. “That is going to be the configuration of the unit going ahead, in order that they’ll have full gas functionality to play with nonetheless they should go ahead,” he stated.
To make sure clean undertaking execution of the improve, GE says it has leveraged expertise from “a number of engineering and consulting groups” worldwide. It notes it started working with Duke Power as a part of a hydrogen plant readiness evaluation in 2021. GE has to date carried out testing at its combustion lab in Greenville.
“We’ve carried out a few rounds of testing, and we work collectively to show issues—like nitrogen oxide (NOx) ranges and water injection ranges—to point out that we are able to keep every part that Duke has right this moment from a allow compliance standpoint whereas operating on the excessive manufacturing,” Byrant stated. Nevertheless, the demonstration will nonetheless provide helpful classes each from a “management standpoint and a turbine operation standpoint,” he stated.
A Key Goal: Optimum, Value-Efficient Operation
Among the many undertaking’s most outstanding aims is pinpointing a “candy spot” for optimum operation.
“After we discuss in regards to the power loss to electrolyze water to hydrogen, everyone understands it’s not a sustainable technique to simply pump power in and electrolyze hydrogen as a result of the power loss doesn’t make sense,” Pompee stated. Nevertheless, he underscored that DeBary will make the most of curtailed solar energy sourced onsite, an element that would contribute to the undertaking’s pricing and comfort. “We’re not utilizing energy that may usually be going out into the grid,” he stated.
And, when Duke Power commissions the unit, it should take a look at totally different gas blends with particular testing standards to find out tips on how to run the undertaking finest, Pompee stated. Which will entail bringing in extra hydrogen to have longer runs. “And as we run it extra, we’ll discover the proper mix that is sensible economically for the unit by way of how shortly we’re capable of generate hydrogen, by way of how a lot curtailed energy we’ve, and the way typically the unit will get dispatched,” he stated.
“Tips on how to finest dispatch the electrolyzers” can even be a vital a part of the “studying,” Pompee stated. All these elements, nonetheless, underscore why operating a full-scale built-in hydrogen system demonstration will probably be helpful, he famous.
Defining a New Function for Fuel Energy: Decarbonized Peaking
The DeBary Hydrogen Undertaking’s launch arrives as energy markets ramp up their quest to hunt decarbonized but dispatchable property that would bolster renewable power integration cost-effectively. Because the world’s energy profile transforms, the ability {industry} is more and more involved about reliability vulnerabilities throughout night peaks. Whereas influenced by a fancy array of things, some grids are already struggling to cowl diminishing photo voltaic assets at sundown—significantly in durations of excessive demand.
Fuel technology has usually offered the required short-term fast ramp-up of dispatchable energy to fulfill demand spikes. Many of the 1,000-plus peaker vegetation within the U.S., a mixed 260 GW utilized to fulfill rare peaks in demand within the U.S., are fueled by pure gasoline, owing to their low capital prices. Nevertheless, some estimates counsel 20 GW of peaking capability could also be wanted over the subsequent decade as energy methods take in extra renewables.
Power storage installations present promise as a decarbonized peaking different however endure lifespan and effectivity limitations and prohibitive prices. Because the Nationwide Renewable Power Laboratory (NREL) explains in a current technical report, storage plant peaking capability provides two major worth sources: offering bodily capability to fulfill peak demand and time-shifting (or arbitrage), the place power is saved as low-cost off-peak power after which utilized in periods of highest demand. By the top of 2022, about 90% of the 9 GW of power storage added to the grid since 2010 had a period of 4 hours or much less, and 99% have been lithium-ion batteries. In the meantime, “The mix of the 4-hour capability rule and the form of the arbitrage worth curve end in little financial incentive for deploying durations past 4 hours in lots of areas,” NREL famous.
That’s why hydrogen power-to-power seems so profitable, Jeff Goldmeer, GE Vernova’s world Hydrogen Chief, instructed. “The worth of hydrogen storage is it offers you the power to time-shift renewables,” he stated. “And when you have extra renewables, you’ll be able to retailer the electrical energy as electrical energy,” he instructed POWER.
Duke Power may accomplish this “with a lithium-ion battery to some extent,” he acknowledged, “however you actually don’t wish to have lithium-ion batteries substitute each single gasoline turbine due to the dimensions of battery you want. When you’ve got the power now to time-shift renewables—not for 2 or 4 hours, however days or even weeks or months—and achieve this at grid scale utilizing present property, that’s an actual win,” he stated. “So it actually does create this nice alternative for Duke and their charge base.”
A Broader Significance for the Way forward for Hydrogen Energy
Decarbonizing gasoline energy, nonetheless, has been elusive. Within the U.S., the ability {industry} has fiercely pushed again in opposition to a proposed Environmental Safety Company (EPA) rule that units limits on particular gas-fired combustion generators that would apply inside a decade, citing sensible misgivings, together with expertise gaps, technical limitations, and, prominently, that clear hydrogen’s manufacturing and availability are at the moment severely restricted.
The Electrical Energy Analysis Institute, for instance, means that assuming a 75% capability issue, the nation’s mixed cycle gasoline fleet of round 160 GW presumably affected by the rule (which might be required to fireside a 30% volumetric-based hydrogen mix), would want a mixed 7 million metric tons. (Home hydrogen manufacturing in 2021 hovered at 10 million metric tons, and 95% was not clear hydrogen.) And even when water electrolysis turns into a longtime manufacturing methodology, greater than 200 GW of recent renewable energy could also be wanted by 2030 to assist demand, {industry} has identified, citing the Division of Power’s (DOE’s) personal estimations.
To handle the essential hydrogen provide hole, the DOE not too long ago unveiled seven hydrogen hubs that may obtain $7 billion in Bipartisan Infrastructure Legislation funding. Notably, it handed over the Southeast Hydrogen Hub, a proposal submitted by Duke Power and 5 different utilities. Whereas disillusioned the hub was not chosen, Duke Power stated it will “proceed to hunt alternatives to associate with DOE, peer utilities, and different stakeholders to advance clear hydrogen in methods that may profit our clients and our communities.”
In the meantime, the ability {industry} stays skeptical in regards to the widespread adoption of hydrogen combustion, primarily as a result of the handful of hydrogen take a look at burns have been restricted to decrease volumes and span a brief period. In feedback to the EPA this August, main gasoline turbines throughout the nation bluntly stated hydrogen combustion nonetheless fell far in need of “adequately demonstrated.”
Some, together with Duke Power, lambasted the EPA for failing to differentiate between “functionality” and “feasibility.” “EPA’s expectation that the provision and infrastructure to assist the brand new requirements will probably be in place in lower than a decade is an illogical interpretation of the time period ‘adequately demonstrated,’ because it ignores prices, allowing and interconnection challenges, and siting points whereas jeopardizing the reliability and affordability of the nation’s producing fleet,” the utility instructed the company.
Prices, particularly, stay a big concern. Utilities—which usually function conservatively with reliability and buyer affordability as paramount priorities—have instructed that models outfitted to burn hydrogen will not be dispatched for energy till a hydrogen expertise and market have been developed, prices for electrolysis and storage have fallen, and sufficient carbon-free power surpluses turn out to be out there to permit sufficient hydrogen manufacturing.
A Flagship Demonstration for Duke Power
However for Duke Power, ready for an {industry} breakthrough shouldn’t be an possibility. The utility holds 21 present mixed cycle models—together with a number of affected by the EPA’s proposed rule—that depend on gas oil as a backup gas supply, particularly throughout winter peaks. This August, it confused to the EPA that “to accommodate hydrogen, producers must present a burner for combustion generators that may burn three fuels”—hydrogen, oil, and pure gasoline. It famous to this point that “Solely one in every of three main gasoline turbine producers has a confirmed burner design to accommodate three fuels.”
In the meantime, as a part of its net-zero ambitions, Duke Power is already navigating the most important coal retirement within the {industry}, aiming to realize a complete coal phaseout (at the moment 17% of its technology combine) by 2035. To satisfy its 2050 aim whereas persevering with to serve electrical energy demand—which may surge as electrification expands—the corporate is pursuing increasing its renewable fleet, looking for to personal, function, or contract 30 GW of regulated wind and photo voltaic by 2035. On the similar time, it estimates it wants 40 GW of recent dispatchable, zero-emitting load-following assets.
That’s another excuse DeBary is poised to turn out to be a flagship demonstration for the corporate, Pompee instructed.
Whereas DeBary’s exact replicability is proscribed—given the 7E’s area of interest combustion system—the undertaking may mannequin new approaches that present optionality, he stated. He famous that Duke Power holds a big 7E fleet and is energetic in 7E and 7F consumer teams. “So any of these models with the proper combustion system may very well be upgradeable, in the identical manner we’ve carried out with [DeBary],” he stated.
Nevertheless, for now, “Our plans right this moment are that we don’t have any plans to develop this specific facility now. However our plans are to study as a lot as we are able to for the peaking unit,” he stated.
Together with DeBary, Duke Power is evaluating different hydrogen choices. It’s, for instance, at the moment testing a GKN steel hydride hydrogen technology, storage, and electrical energy manufacturing unit, which consists of an electrolyzer, hydrogen storage, and gas cell in a single containerized resolution.
“After which we’ve different tasks that we’re evaluating for a baseload unit, Pompee stated. “We are going to begin to study—as a result of they’re totally different in the way you dispatch them, how you use them, and the way you combine the methods and every part else. After which we intend to remain leaders, engaged within the hydrogen area, and when the price of hydrogen and electrolyzers actually begin to come down, then we begin to dispatch extra hydrogen, we begin to put in additional hydrogen tasks,” he stated.
Nonetheless, “these plans are sooner or later, and regardless that we’ve decarbonization plans right this moment, they’re actually fluid,” he stated.
Final Worth: Flexibility, Seasonal Storage, Prevented Stranded Belongings
Each GE and Duke Power instructed POWER that DeBary’s most important contribution to {industry} efforts lies within the alternative to evaluate an built-in system as an entire—and in a real-world setting. “It’s the power to have all these methods onweb site to look at their operation collectively, all the best way as much as 100%,” Goldmeer emphasised. “It offers Duke Power not simply the flexibleness, but it surely offers them the power to do the carbon discount all the best way all the way down to near-zero carbon discount when operating on 100% hydrogen,” he stated.
“It’s not clear to me what different energy plant facility on the planet may have that capability to provide energy on demand with zero-carbon emissions, primarily based on operating 100% hydrogen,” he added. “That makes us extremely distinctive.”
Goldmeer additionally famous DeBary is a bigger energy plant with room to develop.”There’s a couple of unit on the web site. As photo voltaic turns into extra out there, as extra storage turns into out there, Duke can scale up.” That functionality arms Duke Power with “extra competencies,” he famous.
Pompee agreed. “We consider hydrogen primarily as storage versus gas,” he stated. However the DeBary undertaking is sort of “sort of splitting the distinction between, like your conventional battery and this chemical storage, which we perceive,” he stated.
An inherent profit is having the potential to retailer extra photo voltaic technology through the shoulder months [in spring and fall] after which deploy it as dispatchable technology within the winter. “You’ll be able to’t do seasonal storage with batteries,” he stated.
It’s true that in “right this moment’s world, for a couple of hours of technology, you’re higher off to deploy lithium-ion,” Pompee acknowledged. “However this undertaking isn’t meant to compete with lithium-ion,” he stated. “It’s meant for us to start out our journey towards decarbonization,” with the view that “there are gasoline property that we’ve in our fleet that may proceed to function past 2050 after we are at net-zero, and our net-zero technique requires these dispatchable assets to be fired on hydrogen.”
“That’s the place we see the worth: it’s prevented stranded property in addition to seasonal storage,” he stated.
—Sonal Patel is a POWER senior affiliate editor (@sonalcpatel, @POWERmagazine).
