Applications of Fuel Cells in Stationary Power Generation

1. Applications of Fuel Cells in Stationary Power Generation

2. Applications of Fuel Cells in Stationary Power GenerationTerminology in Presentation Availability Remote/Point of Use Generation Co-generation Combined Heat/Power Peak vs. continuous Economic Efficiency Energy Efficiency

3. Traditional Fixed-Location Energy Production and Delivery Model Electricity Production Fuel Source (mine, well, etc.) Processing/Storage (ex: refinery, tank farm) Electricity Production (primarily coal, nuclear and fossil fuel) Heat Production Heating Fuel Distribution Electricity Distribution (“The Grid”) Point of Use (House, school, store, factory, farm, etc.)

4. Fuel Cell Fixed-Location Energy Production and Delivery Model (off-grid) Fuel Source (mine, well, etc.) Processing/Storage (ex: refinery, tank farm) Electricity Production (primarily coal, nuclear and fossil fuel) Heat Production Electricity Production Heating Fuel Distribution Electricity Distribution (“The Grid”) Point of Use (House, school, store, factory, farm, etc.)

5. Really multiple applications, each with unique considerations……no “one-size-fits-all” solution

6. Stationary vs. Mobile Applications 1 Derived from annual consumption rates as published by the US Energy Information Administration, Department of Energy http://www.eia.doe.gov/emeu/cbecs/cbecs2003/detailed_tables_2003/2003set10/2003pdf/c21.pdf 2 US Department of Energy Performance Statistics, http://www1.eere.energy.gov/vehiclesandfuels/avta/pdfs/fsev/eva_results/ev1_eva.pdf 3 Physics Factbook, http://hypertextbook.com/facts/2001/RadmilaIlyayeva.shtml

7. Potential Benefits • Reduced COx emissions • Reduces electric transmission power losses (~8% of electricity consumed) • Can reduce grid dependency • Can increase power availability • Can be used in co-generation mode (heat + electricity) to reduce point-of-use energy system complexity • Can be installed in convenient location • Very low noise • Can incorporate energy storage to reduce system size while accommodating usage peaks

8. Significant Problems • Currently one of the most expensive point-of-use alternative energy sources in terms of acquisition cost • Practical FC systems still use hydrocarbon based fuels • Tend to have a short useful life, making pay-back difficult to achieve • High efficiency requires careful monitoring and maintenance • Hydrogen storage and point-of-use production can be a safety risk • The biggest problem is the cost to acquire!!!

9. Solar Buzz, the NPD Group, http://www.solarbuzz.com/DistributedGeneration.htm

10. Why is it so expensive? Exotic materials are often required (ex: Nafion costs $566/m2, platinum cost ~$1000/m2 of PEM fuel cell)Efficiency and reliability difficult to maintain Temperature, fuel flow, hydration rates, and current draw must be carefully maintained to insure efficient output and good service life of componentsNo economies of scale Commercially viable systems suffer low volume production effects

11. Why is it so expensive? Economic and physical efficiency suffers under discontinuous operation Hard to effectively balance production and demand without co-generationSupply fuel must be very clean Often pre-processing at point of use is required to maintain fuel standards Example: Commercial-size UTC Power 400kW cogeneration-scale stationary system (installed cost) = $1,000,000 ($2,500/kW)

12. The Economics of Stationary Fuel Cells

13. Take the Cost to Acquire Solar Buzz, the NPD Group, http://www.solarbuzz.com/DistributedGeneration.htm

14. $$$ $$$ $$ $$ $ $ $ $ Consider the Cost to Operate (cost per kWh) Solar Buzz, the NPD Group, http://www.solarbuzz.com/DistributedGeneration.htm

15. $$$ $$$ $$$ $$$ $$$ $$ $$ $$ $$ $$ $ $ $ $ $ $ And Depreciation (Life span cost) Solar Buzz, the NPD Group, http://www.solarbuzz.com/DistributedGeneration.htm

16. Good Bad $$$ $$$ $$$ $$$ $$$ $$ $$ $$ $$ $$ $ $ $ $ $ $ Payback and Economic Efficiency depends on all three factors Solar Buzz, the NPD Group, http://www.solarbuzz.com/DistributedGeneration.htm

17. The Future of Stationary Fuel Cells

18. Promising Solutions to the Cost ProblemAlternatives to Nafion are being produced (ex: Solupor polyethylene by DSM)Alternatives to expensive catalysts are being researched (ex: carbon silk technology can reduce catalyst cost by 30% or $300/m2 per cell)Commercial Multi-fuel stationary fuel cell production is increasing (ex: Bloom Energy offering)

19. Promising Solutions to the Cost ProblemBetter heat recovery of heat produced by electric fuel cell allows viable residential/commercial heating/electricity combined systemsGovernment (and even power company) subsidies for use of fuel cells is increasingCogeneration and net-metering opportunities are improving at the residential/commercial levelFuel flexibility allows fuel cell investment to be retooled easily for least expensive fuel type, as market conditions change.

20. Possible Early Adopters:Niche MarketsElectricity generation at remote locations (ex: rural farms, military applications, 3rd world, shipping)Long-term and/or secure back-up power generation for high availability applications (ex: hospitals, military, data/com)High-cost/low-availability markets (ex: California)Emission and/or noise sensitive environments (ex: nurseries, research institutions, high-density metropolitan areas, forward based military units)

21. Case Study Industrial ScaleUS Army PAFC Pilot Program* 30 site installation (domestic)* Electricity + Heat Recapture* 168kW installed capacity* Average lifespan: 28,000 hours* Availability: 56.7% Generation 1 76.3% Generation 2* Reported Energy Savings: $1,761,000* Project Cost: $36,750,000US Army Engineering Research and Development Center, http://dodfuelcell.cecer.army.mil/fc/index.php

22. Case Study – Residential-Commercial ScaleUS Army PEM Pilot Program* 60 site installation, both electrical production and co-gen* 4.5kW average installed capacity* Fuel types: Natural Gas, H2, Propane* Applications: housing, remote communication stations, air traffic control power backup, pools, small armories, offices, museum* Reported electrical+thermal efficiency: 27%* Reported availability: 85%* Project Cost: $13,700,000US Army Engineering Research and Development Center, http://dodfuelcell.cecer.army.mil/fc/index.php

23. Case Study --PEM Pilot Program (cont)US Army Engineering Research and Development Center, http://dodfuelcell.cecer.army.mil/fc/index.php

24. Other Public Military FC ProgramsOngoing EffortsEnergy Savings for Silent Camp™ Hybrid TechnologiesModeling the hybrid configuration of a diesel genset, fuel cell, electrolyzer, and hydrogen storage.Distributed Hydrogen Production Utilizing Molten Carbonate Fuel CellsThe main objective of this 12-month research and development project is to design, develop, and test a high efficiency Electrochemical Hydrogen Separation (EHS) system.Logistics Fuel Reformer/Processor for Mobile Electric Power (MEP) Fuel Cells Power GenerationThe Air Force Research Laboratory is developing a microchannel-based logistic fuel processor suitable for mobility operations.Advanced Power & Energy Program (APEP)APEP seeks to promote fuel cell and advanced power and energy technology education as well as to develop advanced power generation requirements for the military and the broader interests of the nation.Development of a SOFC Power System for Military Diesel and JP-8 FuelsThe core program objective is to develop a viable diesel or JP-8 powered fuel processing system for SOFC systems for military use.Development of a Ramgen Fuel Cell Hybrid SystemRamgen plans to build and test a fuel cell turbine hybrid system using the best available fuel cell technology in combination with Ramgen’s supersonic compressor and expander technologies.Direct Carbon Fuel Cell ProjectThe objective of this project is to assess whether DCFCs have the potential to be used at large Army installations as part of a strategy to increase energy efficiency.Los Alamitos Joint Forces Training Base Fuel Cell DemonstrationA 200 kW Phosphoric Acid Fuel Cell (PAFC) will be designed and installed for the Joint Forces Training Base (JTFB), Los Alamitos, CA to demonstrate the capability of a fuel cell product in boosting the readiness of a Defense Satellite Communications facility by providing secure and reliable energy. US Army Engineering Research and Development Center, http://dodfuelcell.cecer.army.mil/fc/index.php

25. Other Public Military FC ProgramsCompleted EffortsInstallation Waste to Energy WorkshopMay 2008 workshop held at the Army Research Office in Research Triangle Park, NC used to discuss waste to energy systems at DoD installations.Waste to Energy Hydrogen Infrastructure Project at Fort Stewart, GAThe U.S. Army is interested in using energy from a wastewater treatment plant to develop a hydrogen infrastructure for both stationary and mobile fuel cell applications.Canola Oil Fuel Cell ProjectThis project evaluated the possibility of utilizing canola oil as an adequate and sustainable fuel source for fuel cell applications. Thermoelectric Power GenerationThe objective of this project was to evaluate the use of thermoelectric devices for supplemental electric power generation from waste heat sources that can lead to increased electrical generation efficiency and reduced environmental impact.Molten Carbonate Fuel Cell Operation with Dual Fuel FlexibilityThe goal of this project was to demonstrate propane in a MCFC as a back-up fuel to natural gas, with the added benefit of instantaneous fuel swapping from natural gas to propane.US Army Engineering Research and Development Center, http://dodfuelcell.cecer.army.mil/fc/index.php