© National Fuel Cell Research Center, 2013 1/24 High Temperature Fuel Cell Tri-Generation of Power,...

© National Fuel Cell Research Center, 2013

1/24

High Temperature Fuel Cell Tri-Generation of Power, Heat & H2 from Waste

Jack Brouwer, Ph.D.June 26, 2013

UPP Down Under Program


2/24

Outline

• Introduction and Background

• Tri-Generation/Poly-Generation Analyses

• OCSD Project Introduction


3/24

Introduction and Background

• Hydrogen fuel cell vehicle performance is outstanding

• Energy density of H2 is much greater than batteries• Rapid fueling, long range ZEV

• H2 must be produced• energy intensive, may have emissions, fossil fuels, economies of scale

• Low volumetric energy density of H2 compared to current infrastructure fuels (@ STP)• H2 handling (storage, transport and dispensing) can be energy and

emissions intensive

An emerging strategy is poly-generation

of hydrogen, heat and power from a

high-temperature fuel cell (HTFC)

There is a need for a distributed, high-efficiency, low emissions hydrogen

production method able to use a variety of feedstocks


4/24

Tri-Generation Energy Station Concept 1, 2, 3

Locally available

feedstock:

Natural Gas, ADG,

Landfill Gas, ….

Electricity

Heat

Hydrogen

Energy Station ConceptIntroduction and Background

1 Brouwer et al., 2001; 2 CHHN Blueprint Plan, 2005; 3 Leal and Brouwer, 2006


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Poly-generation of Power, Heat and H2

• Advantages: 4, 5, 6

• H2 production is at the point of use averting emissions and energy impacts of hydrogen and electricity transport

• Fuel cell produces sufficient heat and steam as the primary inputs for the endothermic reforming process

• Synergistic impacts of lower fuel utilization increase overall efficiency (i.e., higher Nernst Voltage, lower polarization losses, lower cooling requirement and associated air blower parasitic load)

• Potential Disadvantage:• Distributed production may not be compatible with carbon

sequestration

4 Leal and Brouwer, 2006; 5 O’Hayre, R., 2009; 6 Margalef et. al, 2008


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High Temperature Fuel Cell (HTFC) Stack• Solid Oxide Fuel Cell Example


CH4+H2O 3H2+CO

2H2+O2- 2H2O + 4e-

O2 + 4e- 2O2-

Electrolyte

Reformation rxn

Fuel cell rxn

A NC

AT

H

load

Stack Operating Temperature Range = 650oC to 950oC

HE

AT{CH4, H2O}

O2 Depleted

Air

O2(Air)

{H2, CO, CO2}

{H2}

HE

AT

• Fuel Utilization Factor (Uf) = ~

85%

• Air Utilization Factor = ~ 15 %

~ 60%

~ 30%

O2-


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Outline





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Recall: High Temperature Fuel Cell (HTFC) Stack• Molten Carbonate Fuel Cell Example

Analyses of Synergies

CH4+H2O 3H2+CO

2H2+2CO32- 2H2O + 2CO2 + 4e-

O2 + 2CO2 + 4e- 2CO3

2-

Electrolyte

Reformation

Electrochemistry

A NC

AT

H

load

Stack Operating Temperature Range = 550oC to 650oC

CH4, H2O

O2 Depleted

Air

O2, CO2

H2, CO, CO2

HE

AT

2CO32-

Air Flow and parasitic blower power can be reduced

Endothermic

Exothermic


9/24

~

C.C.

CH4Air

Exhaustgases

1

Water

SOFC

2

3

4

78

9

6

5CH4

H2H2O

Reformer

(1)

CH4

H2H2O

Reformer

(2)

CH4

H2H2O

Reformer

(3)

CH4

H2H2O

Reformer

(4)

~

C.C.

Exhaustgases

1

SOFC

2

3

4

78

9

6

5CH4

H2H2O

Reformer

(1)

CH4

H2H2O

Reformer

(2)

CH4

H2H2O

Reformer

(3)

CH4

H2H2O

Reformer

(4)

Placement of a reformer in different locations: Configuration 1 reformer after the air preheater, Configuration 2 reformer after the water preheater, Configuration 3 reformer after the natural gas preheater, Configuration 4 reformer after the combustion chamber.

Cycle ConfigurationsAirWaterNatural Gas


10/24

Configuration 5: External reforming with combustion chamber after the air preheater.

15

~

SOFC

H2H2O

C.C.

Water Air

7

10

CH4

CH4

8

3

2

9

4 6

REF

11 12Exhaust gases

13

14165

1

Configuration 6: Internal reforming

1

C.C.

~

SOFC

H2

8 7

13

9

H2O CH4Air

Exhaust gases11

12

26 4

5 3

10

Cycle Configurations


11/24

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

Configurations

Hyd

rog

en p

rod

uct

ion

[g

/s]

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

Fir

st L

aw E

ffic

ien

cy

Hydrogen production Electrical efficiency Thermal efficiency Overall efficiency

Thermodynamic Analyses

• Energy performance analysis


12/24

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 100000

0.10.20.30.40.50.60.70.80.9

11.11.21.3

0

1000

2000

3000

4000

5000

6000

7000

8000

Electrochemical heat at different utilization factors (P=5000 A/m2)

0.4 0.6 0.8 EMF 0.4 0.6 0.8

Current Density [A/m2]

Cel

l vo

ltag

e [V

olt

s]

Po

we

r D

en

sit

y [

W/m

2]

Poly-Generation Analyses

Electrochemical Heat

]kW[hΔnV

)VV(Heat fH

max

cellmax2

• Synergy #1: Electrochemical heat & voltage

Fuel Utilization Values


13/24

• Electrochemistry & Reformation Synergy #2 – Air Flow

0.4 0.5 0.6 0.7 0.830

40

50

60

70

80

90

100

Fuel Utilization Factor

Air

flo

w i

n [

kmo

l/h

r]

Factor #1electrochem.

heat


Factor#2reformation

cooling


14/24

• EXAMPLE: Efficiency of a Poly-Generating Hydrogen Energy Station (H2ES) without valuing heat


Electricity production with state-of-the-art

natural gas combined cycle

Centralized SMR Plant

(H2 production)

(Case: H2ES) Poly-generating

HTFC

Fuel

Fuel

Fuel

Electricity

Hydrogen

η el,1 = 61.2%η el,2 = 51.7%η el,3 = 58.4%

η H2,1 = 80.9%η H2,2 = 54.9%η H2,3 = 83.5%

η el,pp = 60%

η H2,SMR = 79%

ηtot = 69.5%


15/24

Poly-Generation Dynamic Analyses

0 0.2 0.4 0.6 0.8 10

250

500

750

1000

Po

wer

[kW

]

0 0.2 0.4 0.6 0.8 10

20

40

H2 in

Tan

k [k

g]

12:00 AM 6:00 AM 12:00 PM 6:00 PM 12:00 AM0.5

1

1.5

2

2.5

3

3.5

H

2

/C

O o

ut o

f co

llecto

r[g

/s]

H2

CO

• Diurnal dynamic operation of SOFC• Hydrogen tank fills forcing end of tri-generation• Control of system temperatures during transient is possible

12:00 AM 6:00 AM 12:00 PM 6:00 PM 12:00 AM950

1000

1050

1100

1150

1200

1250

1300

Tem

p [

K]

Tan,in

Tca,in

Tca,out

Tan,out


16/24

Outline





17/24

STORAGETANK

ADG

HOTWATER

HEAT EXCHANGER ANAEROBIC

DIGESTION GAS HOLDER

SLUDGE

DIGESTER

BOILER

HYDROGENHYDROGENSTORAGE

HYDROGENDISPENSER

FUEL TREATMENT

ACPOWER

HIGH-TFUEL CELL

World’s First Demonstration

• Orange County Sanitation District

• Euclid Exit, I405, Fountain Valley

• Support: DOE, ARB, AQMD

Renewable Tri-Generation of Power, Heat & H2

Sponsors/Participants:


18/24

OCSD Project – World’s First

• Installation complete, Operation on natural gas (6 months), ADG operation underway for ~1 year

Renewable H2

Filling Station

ADG fueledDFC-H2 ®Production Unit


19/24

FCE Equipment

Air Products Equipment

Anode Exhaust

Skid

DFC (Direct

Fuel Cell)

ADG Clean-up Skid

Syngas Compressor

SkidPSA Skid (pressure swing

absorption)

Compressor Skid

Hydrogen Storage Tubes

Inverter &

Electrical BoP

Mechanical BoP


20/24

OCSD Project – Status Update

Last Quarter Performance:

MONTHPROCESSED

ADGSCF

PROCESSED ADGLBS

April 111,652 7,695

May 249,535 17,199

June 410,123 28,268

Quarter Total 771,310 53,162


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Last Quarter Performance:

MONTH OPERATING HOURS

GROSS AC GENERATED

kWh

NET AC GENERATED

kWh

April 284 57,999 28,772

May 649 161,048 121,585

June 661 147,574 103,429

Quarter Total

1,594 366,621 253,786


22/24


Last Quarter Performance – steady state, natural gas, June 11, 2012:

METHOD EFFICIENCY

ηCH2P 51.9%

Margalef et al

Hydrogen Efficiency 45.7%

Margalef et al

Electrical Efficiency 54.7%

The UC Irvine Team

Credit: Steve Zylius/UC Irvine Communications

Thank YouFor Your Attention!

© National Fuel Cell Research Center, 2013 1/24 High Temperature Fuel Cell Tri-Generation of Power,...

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Transcript of © National Fuel Cell Research Center, 2013 1/24 High Temperature Fuel Cell Tri-Generation of Power,...