Co-production of Electricity and Hydrogen Using NH3-Fueled ...Co-production of Electricity and...

Co-production of Electricity andHydrogen Using NH3-Fueled SOFC

Systems

Presented at

Ammonia Fuel Conference 2006

Golden, CO

October 9-10, 2006

Pinakin PatelFuelCell Energy, Inc.

Danbury, CT

Randy PetriVersa Power Systems

Denver, CO

Versa Power Proprietary 2

Overview

! VPS Team Intro

! VPS SOFC Technology Status

! Ammonia fuel cell systems

! SOFCs & the Hydrogen Infrastructure

! Path forward


Company Overview: Versa Power Systems

! A U.S. for-profit company withoperations in Colorado and Calgary– Founded in 2001: a joint venture between

the members of the Solid Oxide Fuel CellConsortium

! Strategic Alliances– Cummins: mobile and small scale

applications– FuelCell Energy: commercial and industrial

DG/combined heat and power (CHP)

! Our product: planar solid oxide fuelcell system– Demonstrated ability to achieve high

electrical power densities and long lifeusing low cost materials

– Validated manufacturing processes;scalable to high volume production rates


U.S. DOE SECA: ~$1.5 billion Program! Program goal: accelerate commercialization of low-cost SOFCs through

attainment of technical and cost metrics

! VPS is part of two out of six industrial teams– VPS/FuelCell Energy– VPS/Cummins– General Electric– Siemens Westinghouse– Delphi/Battelle– Acumentrics

! $600MM of basic technology research is available to the industrial teams.Research conducted by—– MIT, University of Utah, UC Berkeley, Northwestern University, University of

Wisconsin,– Los Alamos National Laboratories, National Energy Technology Laboratory, Pacific

Northwest National Laboratory, Argonne National Laboratory, and ChevronTechnology Ventures


Introduction to Fuel Cell Technology! A fuel cell is an electrochemical energy conversion device that generates

electricity directly from electrochemical reactions between a fuel and anoxidant

! A solid oxide fuel cell is a high temperature electrochemical device with asolid oxide electrolyte that produces electric power from a variety of fuels(such as hydrogen, natural gas, propane or diesel)

! Higher efficiency than competing technologies

! The core SOFC cell is ceramic and has three principallayers

– Anode, electrolyte and cathode

– Inexpensive materials

Fuel

Air


SOFC Principle of Operation

2H2 + 2O= —! 2H2O + 4e-

2CO + 2O= —! 2CO2 + 4e-

Air

Fuel

ElectrolyteO= O=

Anode _

Cathode O2 + 4e- —! 2O= +

E = —— ln ———————RT PO2 (oxidant)

4F PO2 (fuel)

e-

e-

e-

e-

Anode

Cathode

Electrolyte

• Anode – nickel-zirconia cermet, ~ 1 mm thick

• Electrolyte – yttria-stabilized zirconia (YSZ), ~ 5 µm thick

• Cathode – conducting ceramic, ~ 50 µm thick


Benefits of Solid Oxide Fuel Cell Technology

! Customer & environmentally friendly– Quiet operation

– Compact package for more flexible installations

– Negligible emissions of air pollutants

– Ideal for residential and commercial CHP

! Higher efficiency than competing technologies– SOFCs are expected to be around 50% efficient at converting fuel to electricity

– In applications that capture the system's waste heat (CHP), overall fuel useefficiencies could top 80%

– Higher efficiencies lead to lower emissions levels than competing technologies

! Adaptability to many practical fuels– Solid oxide fuel cells operate at high temperatures (around 650-1,000°C)

– Removes the need for precious-metal catalyst, thereby reducing cost

– Allows SOFCs to reform fuels internally, enabling the use of a variety of fuels andreduces the cost associated with adding a reformer to the system

8

VPS Planar SOFC Design

9

Single Cell Test

Long term benchmark testing achieves 26,000 hrs

Trend Data

Test #10545; (Long Term Test: TSC1, 10 x 10 cm2)

Test Stand #6, January 9, 2002 - January 10, 2005

0.000

0.200

0.400

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0.800

1.000

0 5000 10000 15000 20000 25000

Elapsed Time, h

Vo

ltag

e, V

Test Conditions:

750°C, 556 mA/cm2 389 mA/cm

2

54% fuel utilization:

630 439 mlpm H2, 630 439 mlpm N2, 3% H2O

27% air utilization:

3000 2092 mlpm air

Degradation rate:1.3% per 1000 h

(11 mV per 1000 h)


VPS Cell ReliabilityTest 101406: Steady-State Cell Voltage Degradation Over 250 Thermal Cycles

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0 500 1000 1500 2000 2500 3000 3500 4000 4500

Time at Current (h)

Ce

ll V

olt

ag

e (

V)

TC

5

TC

10

0

TC

75

TC

50

TC

17

TC

7

TC

6

TC

15

0

TC

12

5

Cell Dimensions 10 x 10 cm?

T = 750°C

I = 0.500 A/cm?

Ua = 25%

Uf = 50%

Fuel = 50:50 H2:N2 Mix / 3% Water

TC

20

0

TC

17

5

TC

22

5

TC

25

0

VPS single cell demonstrated durability-- steady-state voltages after250 thermal cycles and 4700 hours operation


Cell

Seal

Interconnect

Contacts

Current Collection

ComponentDevelopment

TechnologyDevelopment

Flow Management

Thermal Management

Manufacturability

Repeatability

Tolerance

Stack Development Path

Stack EngineeringIntegration

Stack ManufacturingProcess Development


Stack Performance- Characterization & Qualification -


Development of Low Cost SOFCManufacturing at Versa Power Systems

The VPS “TSC” process for SOFC manufactureis proven:

! One firing step! Cost effective! High yields: a result of process control

Tape Casting “T”

Screen Printing“S”

Co-Sintering“C”


Stack Repeatability28 Cell Stacks

60A, TC1 and 3 hour holdMin/Max/Average

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Vo

ltag

e

28 Cell Stacks @ 121 cm2 active area

23.5% Uf, 28% Ua, 0.496 A/cm2

42 slpm H2, 37.8 slpm N2, 84 slpm Air

725°C Furnace Temperature

Stack Number


Manufacturing Process Development

Co

st

Co

st

Co

stPro

cess

Yie

ld

Pro

cess

Yie

ld

Th

rou

gh

pu

t Th

rou

gh

pu

t

Pro

cess

Yie

ld

Th

rou

gh

pu

t

0%

20%

40%

60%

80%

100%

1999: 16 steps/5 firings 2001: 14 steps/3 firings 2002: 10 steps/1 firing


SOFC Power System Build-Up-Up

Stack

Thermal

Management

Fuel

Reformer

Air

BlowerFuelSupply

ControlsPower

Electronics

Ceramic cell+interconnects &

seals

form unit cell

Multi unitcells are

combined intostack

The stack is integrated withthe balance of plant

components into a powersystem


System Testing


• Thermally integratedpower system

• Pipeline natural gas fuel

• Autonomous control

• Grid connected (parallel)

• Designed towardsapplicable codes andstandards compliance

• Builds on the experiencegained from >40,000 h ofaccumulated operation ofprevious prototypes

3 kW Prototype System (3-1)


The VPS SOFC Technology

25040

Stack Cell

3

1,400950

Stack Cell

500

System

System

26,0008,800

Stack Cell

3,400

SystemDemonstratedTest Duration

(hrs.)

DemonstratedDeep Thermal Cycles (TCs)

DemonstratedPower Density

(mW/cm2)


SECA Targets

40,000 hrs.

>1,000 hrs.

NG

<1% / 10 cycles

80%<2% / 500 hrs.

Mobile - 25%Stationary - 35%

$US 800 / kW@50,000 / yr.

3 – 10 kW

SECAPhase 1

40,000 hrs.

>1,000 hrs.

NG, Propane,Diesel

<0.5% / 10 cycles

85%<1% / 500 hrs.


$US 600 / kW@50,000 / yr.

3 – 10 kW

SECAPhase 2

3 – 10 kWPower

SECAPhase 3

Minimum Requirements

Design Lifetime

Maintenance Interval

Fuel Type

Transient Operation

Steady State Operation- Availability- Delta Power

Efficiency

Cost

40,000 hrs.

>1,000 hrs.

NG, Propane,Diesel

<0.1% / 10 cycles

95%<0.1% / 500 hrs.


$US 400 / kW@50,000 / yr.


System Efficiency & Power vs. Time

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

0 168 336 504 672 840 1008 1176 1344 1512 1680 1848 2016 2184

Time Since Start [Hours]

Eff

icie

ncy [

%]

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1.0

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2.0

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3.0

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4.0

4.5

5.0

.

Po

we

r [k

W]

Net AC Efficiency (PM) [%]

Calc. Net DC Efficiency [%]

Net AC (PwrMtr) [kW]

Calc. Net DC (C) [kW]

Efficiency and Power Output3-1 System

Net AC Efficiency (%)

Net DC Efficiency (%)

Net AC Power (kW)

Net DC Power (kW)

Temperature: 730°C

42 A (0.347 A/cm2)

58% U f, 43% U a,

Nominal Operating Condition


98.6%! 80%Availability

Pipeline NGNatural GasFuel Type

36.4%! 35%EOT Net DC Electrical Efficiency

$773/kW" 800/kWCost

0.87%" 1%Transient degradation over 10 cycles

1.28% / 500 h" 2% / 500 hSteady state degradation

! 35%

3-10 kW

DOE Target

5.26 kWPeak Net DC Electrical Power

39.6%

Result

Peak Net DC Electrical Efficiency

Prototype 3-1 kW System Test Summary

Notes: Hourly averaged data Efficiencies based on LHV Calgary pipeline natural gas


VPS SOFC System Status & Markets

Completed: $70MM

>100kW

Industrial

CHP

3-10kWMobile

APU

Early Adopter& Small/Med DG

1-50kWin Technology

Development


The Co-production Concept Using Ammonia

Ammonia Fuel CellElectricity

Hydrogen

heat2NH3 N2 + 3 H2

(34 lbs) (28 lbs) (6 lbs)


Ammonia and Different Types of FuelCells

Thermal integrationSimplest; highestsystem efficiency

700-900Solid Oxide (SOFC)

Source of CO2High efficiency;moderate simplesystem

600-700Carbonate (MCFC)

! Filter for traceammonia

! Ammonia cracker

! Reduced fuelprocessing steps

! Moderate efficiency

60-120

180-200

Polymer ElectrolyteMembrane (PEM)

Phosphoric Acid(PAFC)

ConsiderationsPotential BenefitsOperatingTemp., °C

Type of Fuel Cell

SOFC is the Most Suitable Technology


C

A

T

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AGO -1

HEAT

RECOVERY

UNIT

ANODE

GAS OXID.

HEAT

RECOVERY

UNIT

PRECONVERTER

PRECONVERTER

AFTER FILTER

DESULFURIZER

HUMIDIFYING

EXCHANGER

GAS

ELECTRIC

HEATER

NG/PROPANE

DEOXIDIZER

C

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T

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AGO -1

HEAT

RECOVERY

UNIT

GAS OXID.

HEAT

RECOVERY

UNIT

PRECONVERTER

PRECONVERTER

AFTER FILTER

DESULFURIZER

HUMIDIFYING

EXCHANGER

GAS

ELECTRIC

HEATER

NG/PROPANE

DEOXIDIZER

VENT

RO/DI

WATER

AIR

Conventional Hydrocarbon-Based SOFC System:

Highlighted fuel pre-treatment equipment increases system complexity and cost.

Ammonia Vs. Conventional Fuel Systems


Ammonia Vs. Conventional Fuel Systems

AMMONIA

C

A

T

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C

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D

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AGO-1

HEAT

RECOVERY

UNIT

ANODE

GAS OXID.

HEAT

RECOVERY

UNIT

AMMONIA

VAPORIZER

FRESH

AIR

AMMONIA

VENT/EXHUST

AMMONIA

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T

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E

A

N

O

D

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AGO-1

HEAT

RECOVERY

UNIT

ANODE

GAS OXID.

HEAT

RECOVERY

UNIT

AMMONIA

VAPORIZER

FRESH

AIR

AMMONIA

Candidate Ammonia SOFC System:

Simple system with practically no fuel pre-treatment equipment.


Ammonia and Propane System Costs and Cost ofElectricity

$/kW PSOFC ASOFC

Fuel Processing 788 67

Fuel Cell Stack 1,079 636

Inverter 841 745

Auxiliary Equipment 231 127

Total Cost 2,739 1,575

Estimated Levelized Cost of Electricity, cents/kWh

$5/MMBTU $10/MMBTU $15/MMBTU

PSOFC 17.8 22.2 26.6

ASOFC 11.6 16.0 20.5

Ammonia can cost more than $6/MMBTU higher than propane and deliver thesame COE.


Old Generation Performance on Ammonia and Hydrogen(100 cm2, 2-cell Stack)

0.0

0.5

1.0

1.5

2.0

2.5

0 5 10 15 20 25 30 35 40 45

Current, A

Vo

lta

ge,

V

0

5

10

15

20

25

30

35

40

45

50

Po

wer,

W

Voltage, V(H2)

Voltage, V(NH3)

Power, W(H2)

Power, W(NH3)

Preliminary Data Indicates Performance Comparable toOperation on Hydrogen


Ammonia Required for Co-production

Co-production

250

1000

300

1200

250

1000

2.5

10.0

Sub-MW

Megawatt

Fuel CellCars ServedHydrogen

lbs/dayElectricity

kW

AmmoniaRequiredtons/day

Size of FuelCell


Ammonia & the Hydrogen Infrastructure

! Ammonia as a carrier of hydrogen has ~18 wt% capacity(DOE target: >6 wt%)

! Safety and handling systems are established

! Distribution system is reasonably developed in the US(pipeline, train, large, trucks)

! On-site extraction of hydrogen via catalytic cracking iscommercially available & relatively simple

! Can be made from coal, the abundant feed stock

! Can contribute to the much needed “bridge” to HydrogenEconomy


Ammonia Pipeline Infrastructure

MAPCO and GULFPipelines


Rural Electric Coop Operating Territories


Co-op Electric Demand; AmmoniaProduction and Consumption

Coop Electric Consumptionmillion kWh, 2000

30,000

Ammonia Productionthousand mT, 2001

5,500

Ammonia Consumptionthousand T, 2001

20 to 5050 to 110

110 to 230230 to 480480 to 560


Ammonia SOFC in Co-Op Applications-Perspective

! Rough Ammonia SOFC Consumption:– ~ 9 slpm/kW

– ~0.9 lb/kWh

! Basis: Per 1% of Co-Op Annual Electric Consumption Converted toASOFC: ~2BBkW-h

! At ~11,500 kW-h per household per year:– ~175,000 households

– ~ 0.8 MM mtons ammonia consumed

! REF: Total US Ammonia Consumption 2005, ~14.7MM mtons

Per 1% of Co-Op Electric Consumption Converted to ASOFC– Thisrepresents ~175,000 households, and ~ 6% of the annual

ammonia consumption.


Improved energy security, reduced imports

New use: creates additional demand and jobs

Utilization of indigenous, domestic feedstock

Potential BenefitsFeatures of ASOFC

Ammonia-SOFC Opportunities & National Economic Benefits


Attractive for remote generation in agriculturalcommunities

Simple system, virtually maintenance-free, doesnot require water







Easier introduction to market, no newinvestment in infrastructure, enhanced naturalsecurity

Utilization of fuel with an establishedinfrastructure for distributed generation

(from rail and pipeline, to end user delivery system,servicing small-volume, widely dispersed agriculturalcustomers)


Simple system, virtually maintenance-free, does notrequire water







Rural users of the ASOFC require no additionaltraining or added familiarity

User acceptance already established

Easier introduction to market, no new investment ininfrastructure, enhanced natural security

Utilization of fuel with an established infrastructurefor distributed generation

(from rail and pipeline, to end user delivery system, servicingsmall-volume, widely dispersed agricultural customers)











Improved economics, facilitates new businessopportunities

High eff & quality power at competitive prices:

!Significant reduction in costs of SOFC power plantsystems

!Direct use of NH3 eliminates costly fuel processingequipment














Creates new jobs, supports U.S. economicgrowth

Domestic manufacturability



!Significant reduction in costs of SOFC power plant systems















Can Accelerate SOFC commercialization andexport markets in general

Significant reduction in system cost

Creates new jobs, supports U.S. economic growthDomestic manufacturability



!Significant reduction in costs of SOFC power plant systems












Co-production of Electricity and Hydrogen Using NH3-Fueled ...Co-production of Electricity and...

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Transcript of Co-production of Electricity and Hydrogen Using NH3-Fueled ...Co-production of Electricity and...