Stationary Fuel Cell Evaluation

Project ID # TV016

This presentation does not contain any proprietary, confidential, or otherwise restricted information.

2014 DOE Annual Merit Review

Genevieve Saur (PI), Jennifer Kurtz, Chris Ainscough, Michael Peters

National Renewable Energy Laboratory

June 19, 2014

2

Overview

Timeline Project start date: Oct. 2011 Project end date: Sep. 2014* Percent complete: On-going

Barriers B. Lack of Data on Stationary Fuel Cells in Real-World Applications E. Codes & Standards

Budget FY13 DOE Funding:$200k Planned FY14 DOE Funding:$100k Total DOE Project value:$365k

Partners • California Stationary Fuel Cell

Collaborative, (review results) • National Fuel Cell Research

Center (UCI), (subcontractor) • Five OEM data providers,

developing others. *Project continuation and direction determined annually by DOE

3

Relevance - Objectives

Independently assess, validate, and report operation targets and stationary fuel cell system performance under real operating conditions.

B. Lack of Data on Stationary Fuel Cells in Real-World Applications

Addressing the gap in knowledge as stationary fuel cell installations have increased dramatically

E. Codes & Standards Providing data and context to C&S activities.

3

4 4

Approach - Milestones

• Quarterly data analysis (based on available data) • Publication of technical stationary fuel cell

composite data products

FY12 Q4 FY13 Q1 FY13 Q2 FY13 Q3 FY13 Q4

Completed

Scheduled

FY14 Q1 FY14 Q2 FY14 Q3 FY14 Q4

5

CDPs

DDPs

Public

Composite Data Products (CDPs) • Aggregated data across multiple systems,

sites, and teams • Publish analysis results every six months

without revealing proprietary data

Detailed Data Products (DDPs) • Individual data analyses

• Identify individual contribution to CDPs • Shared every six months only with the

partner who supplied the data

www.nrel.gov/hydrogen/proj_tech_validation.html

Approach: NFCTEC Analysis and Reporting of Real-World Operation Data

Results

Bundled data (operation & maintenance/safety) delivered

to NREL quarterly Internal analysis

completed quarterly in NFCTEC

National Fuel Cell Technology Evaluation Center

6 6

Approach - Stationary Fuel Cell Systems • Deployment and cost data

o Publically available data from California SGIP (2001-present) o Includes systems providing prime, continuous, or regular

power to a site (not backup power) o Includes multiple fuel cell types - proton exchange membrane

(high and low temperature), solid oxide, phosphoric acid, and molten carbonate

o Includes fuel types for fuel cells (natural gas, biomass, digester gas, landfill gas)

o Small, kilowatt-scale to large, megawatt-scale o Cost data for projects including incentives

• Operations data o All data voluntary

• 28 total cdps

7 7

Approach - Data Processing, Analysis, and Reporting Tools

• NREL Fleet Analysis Toolkit (NRELFAT) — Developed first under fuel cell vehicle

Learning Demonstration — Restructured architecture and interface to

effectively handle new applications and projects and for flexible analysis

— Leverage analyses already created

• Report results – Detailed and composite results – Target key stakeholders such as fuel cell and hydrogen developers,

and end users

8

Accomplishments and Progress

3%

4%

10%

11%64%

Deployment Count By Status*

Other Categories: ICF ReviewICF Technical ReviewICF Pending PaymentPPM Technical ReviewRRF ReviewRRF Technical Review

Definitions: RRF = Reservation Request Form, is the first step in the SGIP incentive claim process.PPM = Proof of Project Milestone; the applicant must prove progress and committment to the project.ICF = Incentive Claim Form is the step where the appliant, after meeting all SGIP requirements requests payment of the incentive.PBI = Performance Based Incentive is the way in which the incentive is paid out over time based on performance of the system.

OtherICF InspectionRRF ReservedPPM ConfirmedPayment PBI in ProcessPayment Completed

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 20130

100

200

300

400

Proj

ect C

ount

Cumulative Deployment Count by Year*

Total = 317 units

TotalFuel Cell CHPFuel Cell Electric

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 20130

50

100

150

Cap

acity

[MW

]

Cumulative Capacity by Year*

Total = 131 MW

TotalFuel Cell CHPFuel Cell Electric

1

California SGIP program has 317 fuel cell projects (CHP and electric) in various stages of development.

California SGIP has 317 fuel cell projects (CHP and electric) in various stages of development.

Fuel cell projects in the California SGIP account for 21% of projects with CHP potential technologies* (317 projects out of 1493) and 28% of the capacity (131 MW out of 460 MW). * Technologies included: fuel cell, gas turbine, internal combustion engine, microturbine, pressure reduction turbine

9

Accomplishments and Progress • Most of the recent projects since 2011

have been natural gas. There was a small resurgence of biomass projects in late 2013.

• Renewable fuels project have generally larger capacities by project.

• Digester gas has several large projects

Biomass Digester Gas Landfill Gas Natural Gas0

100

200

300

400

500

600

700

Inst

alle

d C

apac

ity (k

W)

Installation Capacity Statistics by Fuel Type*

75% Percentile

Median

25% Percentile

Mean

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 20130

10

20

30

40

50

60

Year

Tota

l Ann

ual I

nsta

lled

Cap

acity

(MW

)

Installed Fuel Type By Year*

BiomassDigester GasLandfill GasNatural Gas

74% of California SGIP fuel cell projects use natural gas and they

account for 66% of the capacity

10

Accomplishments and Progress

0

10

20

30

Average Prices No Incentive, Incentive0-50 kW = $10,808/kW, $8,299/kWAverage Prices No Incentive, Incentive

51-200 kW = $10,932/kW, $6,725/kW

Average Prices No Incentive, Incentive

201-400 kW = $9,950/kW, $6,046/kW

Average Prices No Incentive, Incentive

401+ kW = $9,524/kW, $5,587/kWData points with less than 2 projects filtered.

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Price [$2010/kW] No Incentive

Installed Eligible Cost Per kW By Capacity*Adjusted To 2010 Dollars

0-50kW

51-200 kW

201-400 kW

>400 kW

DOE 2020 Target

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Price [$2010/kW] With IncentiveNREL cdp_stat_26Created: Apr 16 14 9:36 AM | Data Range: 2001Q2 2013Q3

Eligible Costs May Include: Planning & Feasibility Study,Engineering & Design, Permitting, Self-GenerationEquipment, Waste Heat Recovery Costs, Construction &Installation Costs, Gas & Electric Interconnection, Warranty,Maintenance Contract, Metering, Monitoring & DataAcquisition System, Emission Control Equipment Capital,Gasline Installation, Fuel Gas Clean-up Equipment,Electricity Storage Devices, Bond to Certify RenewableFuel, Sales Tax, Fuel Supply (digesters, gas gathering, etc.),Thermal Load, & Other Eligible Costs

• Larger projects generally have lower unit prices($/kW) • Larger projects generally receive more incentives thereby lowering the average unit

prices($/kW) more than smaller projects • Few projects with incentives meet the DOE target of $1,500/kW

Average All Projects

$10,189/kW no

incentive

$6,722/kW with incentive

11

Accomplishments and Progress

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 20130

20

40

60

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100

120

140

Cap

acity

[MW

]

Year2000

2500

3000

3500

4000

4500

5000

5500

Ince

ntiv

e Sp

endi

ng ($

2010

) Per

kW

Inst

alle

d

Total Incentive ($2010) per kW by Year*

• The average unit prices for fuel cell

projects has fluctuated very little, but more variation is seen when separated by size

• Total incentive spending in fuel cell projects have decreased since 2010 while project counts continues to increase steadily

23 new fuel cell projects have been accepted into the California SGIP with a total capacity of 10 MW between Q2 2013 and Q4 2013

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 20130

5

10

15

Ave

rage

$20

10/W

of In

stal

led

Cap

acity

Average Eligible Cost $2010/W Trend for Overall Deployments*

Without IncentiveWith IncentiveDOE 2020 Target

0

5

10

15

200120

0220

0320

0420

0520

0620

0720

0820

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1020

1120

1220

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Capacity < 500 kW

Ave

rage

$20

10/W

of In

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Cap

acity

0

5

10

15

200120

0220

0320

0420

0520

0620

0720

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500 kW <= Capacity < 1000 kW

0

5

10

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200120

0220

0320

0420

0520

0620

0720

0820

0920

1020

1120

1220

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Capacity >= 1000 kW

12

Accomplishments and Progress

0 200 400 600 800 1000 >10000

5

10

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25

30

35

40

45

50

System Size (kW)

Tota

l Ins

talle

d C

apac

ity (M

W)

Installed Capacity And Fuel Type*

BiomassDigester GasLandfill GasNatural Gas

0

0 200 400 600 800 1000 >10000

3000

6000

9000

12000

15000

18000

System Size (kW)

$201

0/kW

of In

stal

led

Cap

acity

Range of Installed Eligible Cost Per kW Biogas Sources by Capacity

Biogas Sources with IncentiveBiogas Sources without IncentiveMean with IncentiveMedian with IncentiveMean without IncentiveMedian without Incentive

cdp_stat_28d: Apr-16-14 9:37 AM | Data Range: 2001Q2-2013Q3

Insufficientdata toprotect

anonymity

Insufficientdata toprotect

anonymity

*Data from the Cal

Eligible Costs May Include: Planning & Feasibility Study, Engineering & Design, Permitting, Self-Generation Equipment, Waste HeatRecovery Costs, Construction & Installation Costs, Gas & Electric Interconnection, Warranty, Maintenance Contract, Metering, Monitoring &Data Acquisition System, Emission Control Equipment Capital, Gasline Installation, Fuel Gas Clean-up Equipment, Electricity StorageDevices, Bond to Certify Renewable Fuel, Sales Tax, Fuel Supply (digesters, gas gathering, etc.), Thermal Load, & Other Eligible Costs

• 25% of fuel cell sites have biogas fuel sources and account for 33% of the capacity

• The average and range of the cost ($/kW) of biogas sourced fuel cell projects generally decreases with project size.

25% of 317 fuel cell sites have biogas fuel sources and account for 33% of 131 MW of the total fuel cell capacity

12% of 112 fuel cell CHP sites have biogas fuel sources for 45% of the 28 MW of total capacity

Biogas fuel cells

13

Accomplishments and Progress

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 20130

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1000

1500

Proj

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ount

Cumulative Deployment Count by Category and Year*

Total = 1493 units

TotalFuel Cell CHPFuel Cell ElectricGas TurbineInternal CombustionMicroturbinePressure Reduction Turbine

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 20130

100

200

300

400

500

Cap

acity

[MW

]

Cumulative Capacity by Category and Year*

Total = 460 MW

TotalFuel Cell CHPFuel Cell ElectricGas TurbineInternal CombustionMicroturbinePressure Reduction Turbine

0 200 400 600 800 1000 1200 1400 1600 1800 2000 >20000

50

100

150

200

250Distribution of Capacity by Equipment Type*

Capacity (kW)

Tota

l # o

f Sys

tem

s

Fuel Cell CHPFuel Cell ElectricGas TurbineInternal CombustionMicroturbinePressure Reduction Turbine

4

• Fuel cells mainly compete with internal

combustion engines and microturbines in terms of capacity ranges

• Since 2010 fuel cells are making significant progress compared to other technologies by numbers of installations and capacity

• Fuel cells are generally more expensive than the competing technologies even with incentives

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 20130

5

10

15

20

25

Ave

rage

$20

10/W

of In

stal

led

Cap

acity

Average Eligible Cost $2010/W Trend for Overall Deployments*Without Incentives

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 20130

5

10

15

20

25

Average Eligible Cost $2010/W Trend for Overall Deployments*With Incentives

Ave

rage

$20

10/W

of In

stal

led

Cap

acity

Fuel Cell CHPFuel Cell ElectricGas TurbineInternal CombustionMicroturbinePressure Reduction Turbine

14

Accomplishments and Progress

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 140000

5

10

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35

40

% o

f Uni

ts

Mean Time (hr) between Stoppages

Mean Time Between Stoppage (hours)*

Overall Mean = 2742 hours

10 15 20 25 30 35 40 450

5

10

15

20

25

30

35

% o

f Uni

ts

Mean Unit Electrical Efficiency (% HHV)

Unit Lifetime Mean Electrical Efficiency (HHV)*†

04 PM | Data Range: 2010Q10-2013Q2

Overall Mean = 27 %

†Includes startup, shutdown, transient and partial power operation *Data from outs

40 45 50 55 60 65 70 75 80 85 90 95 1000

5

10

15

20

25

30

35

40

% o

f Uni

ts

Mean Unit Availability (%)

Unit Mean Availability*

Overall Mean = 93 %

NREL has begun to collect operations data, additional data is

expected in the Q4 results

* Unit refers to a single fuel cell system

15

Accomplishments and Progress: Responses to Previous Year Reviewers’ Comments

• “The pre-commercial days are over, so stationary fuel cells will need to compete with heat engines and the grid on cost and value.” o Several new cdp’s have been developed to compare fuel cells to other

competing technologies from a size and cost standpoint.

• However, few data are given about the operations of the systems themselves. o 3 new cdp’s have been developed to begin to address operational

usage and key areas as efficiency and availability. o More data is expected and we are continuing to investigate additional

data partners.

• The data span a large set of power levels, combined heat and power (CHP)/non-CHP and other various technologies, so it is a bit hard to see trends, draw conclusions, etc. o We have begun to create cdp’s which separate sizes and CHP systems.

16

Collaborations • Partners for data delivered at the end of 2012

o National Fuel Cell Research Center

o Five fuel cell OEMs

o California Stationary Fuel Cell Collaborative

• Communicating with several organizations to establish agreements for sharing data with NREL o State and regional fuel cell organizations

o Fuel cell developers

17

Remaining Challenges and Barriers

• Develop additional state project partners for deployment numbers, cost trends, and operations data.

• Work with fuel cell companies to obtain data for assessing key DOE targets

• Analyze key deployment barriers and identify elements of successful deployment.

18

Proposed Future Work

• Q4 2014 milestone: Update all cdp’s with current data • Remainder of 2014:

o Continue to analyze current California SGIP deployment data o Collect additional operations data for updates to operations

cdps o Expand analysis to include new cdps which address further

segmentation of the data (CHP/non-CHP, competing technologies, fuel sources) and trends over time

o Look into other data partners (state and federal programs) o Work with fuel cell OEMs for possibility of additional data sets

19

Summary • NREL is leveraging a large pool of technology validation analyses

and knowledge • Stationary fuel cell deployment is increasing steadily, incentive

expenditure (in California SGIP) is decreasing, but project prices are still generally higher for fuel cells.

• Natural gas is the leading fuel source, but a significant number of larger installations are using biogas fuel sources (23 biogas FC projects are ≥ 600 kW)

• Fuel cells continue to be installed in the California SGIP (23 new FC projects between Q2 2013 and Q4 2013)

• Larger projects tend to have lower unit cost ($/kW) and often take advantage of more incentives.

• The mean availability of fuel cells systems is 93% with ~35% of systems over 95%.

• The mean electrical efficiency of fuel cells is 27% with <3% of the systems analysed over 35% electrical efficiency (based on HHV).

Technical Back-Up Slides

21

CDP-STAT-06 Fuel Cell Stationary Capacity and Average Prices

0 200 400 600 800 1000 >10000

5

10

15

20

25

30Distribution of Capacity and Average Eligible Cost $2010/kW*

Capacity (kW)

% o

f sys

tem

s

0 200 400 600 800 1000 >10000

2,000

4,000

6,000

8,000

10,000

12,000

Avg

. $/k

W

$/kW w/o Incentive$/kW w/ Incentive2020 DOE Target†

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Capacity (kW)

% o

f sys

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Detailed Capacity Distribution

0 10 20 30 40 500

20406080

Capacity (kW)

% o

f sys

tem

s

NREL cdp_stat_06Created: Apr-16-14 9:36 AM | Data Range: 2001Q2-2013Q3

†for the year 2020, operating on natural gas.*Data from the California SGIP.

Eligible Costs May Include: Planning & Feasibility Study, Engineering & Design, Permitting, Self-Generation Equipment, WasteHeat Recovery Costs, Construction & Installation Costs, Gas & Electric Interconnection, Warranty, Maintenance Contract,Metering, Monitoring & Data Acquisition System, Emission Control Equipment Capital, Gasline Installation, Fuel Gas Clean-upEquipment, Electricity Storage Devices, Bond to Certify Renewable Fuel, Sales Tax, Fuel Supply (digesters, gas gathering,etc.), Thermal Load, & Other Eligible Costs

22

CDP-STAT-22 Distribution of Capacity and Eligible Cost (CHP Fuel Cells)

0 200 400 600 800 1000 >10000

10

20

30

40

50

60

70Distribution of Capacity and Average Eligible Cost $2010/kW (CHP Fuel Cell)*

Capacity (kW)

% o

f sys

tem

s

0 200 400 600 800 1000 >10000

2,000

4,000

6,000

8,000

10,000

Avg

. $/k

W

$/kW w/o Incentive$/kW w/ Incentive2020 DOE Target†

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Capacity (kW)

% o

f sys

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Detailed Capacity Distribution

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Capacity (kW)

% o

f sys

tem

s

NREL cdp_stat_22Created: Apr-16-14 9:36 AM | Data Range: 2001Q2-2013Q3

†for the year 2020, operating on natural gas.*Data from the California SGIP.

Eligible Costs May Include: Planning & Feasibility Study, Engineering & Design, Permitting, Self-Generation Equipment, WasteHeat Recovery Costs, Construction & Installation Costs, Gas & Electric Interconnection, Warranty, Maintenance Contract,Metering, Monitoring & Data Acquisition System, Emission Control Equipment Capital, Gasline Installation, Fuel Gas Clean-upEquipment, Electricity Storage Devices, Bond to Certify Renewable Fuel, Sales Tax, Fuel Supply (digesters, gas gathering,etc.), Thermal Load, & Other Eligible Costs

23

CDP-STAT-04 Stationary Fuel Cell System Count and Capacity by Fuel Type

4%10%

11%

74%

Site Count by Fuel Type*

Biomass

Digester Gas

Landfill Gas

Natural Gas

4%

17%

13%

66%

Installed Capacity by Fuel Type

NREL cdp_stat_04Created: Apr-16-14 9:37 AM | Data Range: 2001Q2-2013Q3

Includes Status Categories:ICF InspectionICF Pending PaymentICF ReviewICF Technical ReviewPPM ConfirmedPPM Technical ReviewPayment CompletedPayment PBI in ProcessRRF ReservedRRF ReviewRRF Technical ReviewTotal Capacity: 131 MWTotal Sites: 316

Installations by Fuel Type(All Fuel Cell Systems)

Definitions: RRF = Reservation Request Form, is the first step in the SGIP incentive claim process.PPM = Proof of Project Milestone; the applicant must prove progress and committment to the project.ICF = Incentive Claim Form is the step where the appliant, after meeting all SGIP requirements requests payment of the incentive.PBI = Performance Based Incentive is the way in which the incentive is paid out over time based on performance of the system. *Data from the California SGIP.

24

CDP-STAT-20 Installations By Fuel Type (CHP Fuel Cells)

8%

4%

88%

Site Count by Fuel Type*

Digester Gas

Landfill Gas

Natural Gas

32%

13%

55%

Installed Capacity by Fuel Type

NREL cdp_stat_20Created: Apr-16-14 9:36 AM | Data Range: 2001Q2-2013Q3

Includes Status Categories:ICF Technical ReviewPPM ConfirmedPPM Technical ReviewPayment CompletedPayment PBI in ProcessRRF ReservedRRF Technical Review

Total Capacity: 28 MWTotal Sites: 112

Installations by Fuel Type(CHP Fuel Cell Systems)

Definitions: RRF = Reservation Request Form, is the first step in the SGIP incentive claim process.PPM = Proof of Project Milestone; the applicant must prove progress and committment to the project.ICF = Incentive Claim Form is the step where the appliant, after meeting all SGIP requirements requests payment of the incentive.PBI = Performance Based Incentive is the way in which the incentive is paid out over time based on performance of the system. *Data from the California SGIP.

25

CDP-STAT-07 Distribution of Stationary Fuel Cell Install Price with and without Incentives

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Price without incentives [$2010/kW]

Installed Eligible Cost Per kW*Adjusted To 2010 Dollars

Avg** = $10,189 $/kW

CurrentDOE 2020 Target

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Price with incentives [$2010/kW]

Avg** = $6,722 $/kW

CurrentDOE 2020 Target

NREL cdp_stat_07Created: Apr-16-14 9:37 AM | Data Range: 2001Q2-2013Q3 *Data from the California SGIP.

Eligible Costs May Include: Planning & Feasibility Study, Engineering & Design, Permitting, Self-Generation Equipment, WasteHeat Recovery Costs, Construction & Installation Costs, Gas & Electric Interconnection, Warranty, Maintenance Contract,Metering, Monitoring & Data Acquisition System, Emission Control Equipment Capital, Gasline Installation, Fuel Gas Clean-upEquipment, Electricity Storage Devices, Bond to Certify Renewable Fuel, Sales Tax, Fuel Supply (digesters, gas gathering,etc.), Thermal Load, & Other Eligible Costs

**Data points with less than 2projects filtered.

26

CDP-STAT-23 Distribution of Eligible Cost with and w/o Incentives (CHP Fuel Cells)

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Price without incentives [$2010/kW]

Installed Eligible Cost Per kW (CHP Fuel Cell)*Adjusted To 2010 Dollars

Avg** = $9,997 $/kW

CurrentDOE 2020 Target

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Price with incentives [$2010/kW]

Avg** = $7,107 $/kW

CurrentDOE 2020 Target

NREL cdp_stat_23Created: Apr-16-14 9:37 AM | Data Range: 2001Q2-2013Q3 *Data from the California SGIP.

Eligible Costs May Include: Planning & Feasibility Study, Engineering & Design, Permitting, Self-Generation Equipment, WasteHeat Recovery Costs, Construction & Installation Costs, Gas & Electric Interconnection, Warranty, Maintenance Contract,Metering, Monitoring & Data Acquisition System, Emission Control Equipment Capital, Gasline Installation, Fuel Gas Clean-upEquipment, Electricity Storage Devices, Bond to Certify Renewable Fuel, Sales Tax, Fuel Supply (digesters, gas gathering,etc.), Thermal Load, & Other Eligible Costs

**Data points with less than 2projects filtered.

27

CDP-STAT-27 Installed Eligible Cost per kW By Capacity (CHP Fuel Cell)

0

10

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Average Prices No Incentive, Incentive0-50 kW = $10,830/kW, $8,320/kWAverage Prices No Incentive, Incentive

51-200 kW = $NaN/kW, $NaN/kW

Average Prices No Incentive, Incentive

201-400 kW = $8,817/kW, $5,330/kW

Average Prices No Incentive, Incentive

401+ kW = $7,582/kW, $3,647/kWData points with less than 2 projects filtered.

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Price [$2010/kW] No Incentive

Installed Eligible Cost Per kW By Capacity (CHP Fuel Cell)*Adjusted To 2010 Dollars

0-50kW

51-200 kW

201-400 kW

>400 kW

DOE 2020 Target

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Price [$2010/kW] With IncentiveNREL cdp_stat_27Created: Apr-16-14 9:37 AM | Data Range: 2001Q2-2013Q3 *Data from the California SGIP.

Eligible Costs May Include: Planning & Feasibility Study,Engineering & Design, Permitting, Self-GenerationEquipment, Waste Heat Recovery Costs, Construction &Installation Costs, Gas & Electric Interconnection, Warranty,Maintenance Contract, Metering, Monitoring & DataAcquisition System, Emission Control Equipment Capital,Gasline Installation, Fuel Gas Clean-up Equipment,Electricity Storage Devices, Bond to Certify RenewableFuel, Sales Tax, Fuel Supply (digesters, gas gathering, etc.),Thermal Load, & Other Eligible Costs