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UNESCO UNESCO DesireDesire – Net project – Net project
Molten Carbonate Fuel Cells:Molten Carbonate Fuel Cells:
an opportunity for decentralized generationan opportunity for decentralized generation
Angelo Moreno, Viviana Cigolotti Angelo Moreno, Viviana Cigolotti ENEA – ENEA – HydrogenHydrogen and Fuel Cell Project and Fuel Cell Project
[email protected]@casaccia.enea.itviviana.cigolotti@[email protected]
UNESCOUNESCORome, 16Rome, 16thth April 2007 April 2007
PART A
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FC lessons programme
6 June 2006Hydrogen as energy carrier
ENEA Moreno
8 June 2006 Fuel Cells ENEA Moreno
13 March 2007 MCFC ENEAMoreno
McPhail
14 March 2007 MCFCAnsaldo Fuel Cell
Parodi
29 March 2007 MCFCAnsaldo Fuel Cell
Capobianco
16 April 2007MCFC System configurations
ENEAMoreno
Cigolotti
PEM/SOFC lessons in planning
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SummaryPART APART A
• MCFC: synthesis of main characteristicsMCFC: synthesis of main characteristics
• Distributed GenerationDistributed Generation
• MCFC: innovative solution for distributed MCFC: innovative solution for distributed
generation and for generation and for energy independence in energy independence in
rural economyrural economy
PART BPART B
• Sustainable Strategies based on Best Sustainable Strategies based on Best
Practices and Best Available TechnologiesPractices and Best Available Technologies
• Case StudiesCase Studies
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Hydrogen and Fuel Cells
Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA
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No thermal cycles
Fuel Cells – principle
No thermodynamic limitations (Carnot)
Electric power
Hydrogen(Fuel)
Oxygen(air - oxidant)+
heat
water
Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA
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MCFC – stack
Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA
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MCFC – system
Fuel
Treatment
Heat
Recovery
MCFC
Stack
System
Control
Fuel
Heat
Heat
Heat
H2O
H2, CO
DC
AC
Air
Power
Cond.
Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA
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˙Temperature: 600-650 °C˙Efficiency: 45-55%˙State of the art technology: 100 kW - 3 MW ˙Applications: CHP, distributed generation
(plants up to 20 MW)
MCFC System Characteristics
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Main characteristics of fuel cells plants
• High conversion efficiency
• Efficiency almost independent from load and plant size
• Rapid load following capability
• Low environmental impact, low noise and negligible emissions
• Modular installation to match load and increase reliability
• Site and Fuel flexibility
Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA
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Emissions from different plants
CO2 (g/kWh)
NOx (mg/kWh)
SO2 (mg/kWh)
Powders (mg/kWh)
Hydrocarbons (mg/kWh)
1400
1200
1000
800
600
400
200
0 Coal Plant Oil Plant Gas Plant Fuel Cell Plant
2400
Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA
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Key Technological Targets Current and Expected
CCuurrrreenntt SSttaattuuss
OObbjjeeccttiivvee ooff DDeemmoo PPhhaassee
LLoonngg--tteerrmm CCoommmmeerrcciiaall TTaarrggeett
Stack Life (hours)
> 12,000* > 30,000 > 40,000
Electrical Efficiency (%)
> 47.0% > 49.0% > 55.0%
Efficiency Using Cogen (%)
> 80.0% > 80.0% > 80.0%
Decay Rate (% mV/1000h)
1.0% < 0.5% < 0.2%
Production Cost (€/kW)
> 5,800 < 2,300 1,200
* Demonstrated at cell level
Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA
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Current and future cost of Stationary Fuel Cell
CurrentCurrent
$5.000 to $8.000/kW installed
$0,085 to $0,065/kWh
40% to 50% efficiency
Source: DOE Oak Ridge Nat’l lab, Federal CHP Market and Fuel Cells
Future GoalFuture Goal
$1.500/kW installed
$0,015/kWh
>50% efficiency
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1500
1000
500
€/kW
MW
0,3 10,1 3 10 30 100 300 1000
Gas Piston Engine
42 %
30 %
Gas Turbine
25 %
40 %
50 %
58 %Gas and Steam
Fuel Cell50 % 54 %
Performance, efficiencies and Costs
Source: MTU
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New Energy Vision
Desire-Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic
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How CHP Saves Energy
Desire-Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic
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It is an Integrated System that: – Supplies electrical or mechanical power
– Uses thermal output for space or water heating,
dehumidification, or process heat
– Is located at/or near user
– Can serve a single facility or district energy system
– Can range in size from a few kW to 100+MW
Combined Heat and Power
Desire-Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic
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USEFUL HEATCOOLELECTRICAL POWER
Combined Cool Heat & Power: CCHP
Desire-Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic
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Realize Decentralized Stationary Consumable Energy Supply
To demonstrate Stationary Energy Supply based on Fuel Cells
Production on demand of consumable energies
• Electrical power• Heat Trigeneration• Cold
using decentralized energy sources
• natural gas• other gasified energy carriers• regenerative and secondary fuels from biomass and waste
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It is a Prime Mover
which transfers
chemical energy of a fuel
to electrical energy (LHV efficiency ~ 50%)
and high useful heat (LHV efficiency ~ 45%)
FUEL CELL
It is characterized by
Fuel Flexibility
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Fuel Flexibility• Primary fuels:
• natural gas, gasified primary energy carriers, e. g. gasoline, diesel, etc.
• coal gas (synthesis gas)
• Secondary gaseous or gasified Hydrocarbons:
• biogas from anaerobic digestion (CH4, CO2)
• sewage gas, landfill gas, coal mine gas (CH4, CO2)
• gasified liquid and solid hydrocarbons, methanol, ethanol, plastic material, etc.
• biodiesel
• Synthesis gases (H2, CO, CH4, CO2):
• gases from thermal gasification processes (pyrolysis) using biomass and even waste material
• purge gases e. g. from refineries, chemical industry
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Secondary FuelsCharacteristics
• Mostly renewable
• High Contents of inert components: N2, CO2, H2O
• Low heating value
• Decentrally available, but not everywhere
• Fluctuating properties
• Variety of different contaminants
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High efficiency of fuel cells could optimise the use of secondary fuels
High quality utilization of secondary fuels: • Trigeneration – electrical energy, thermal energy, cooling
energy
Saving primary energy sources:• Reduction of dependence on primary energy sources• Reduction of pollution by greenhouse gases and
contaminants• Reduction of transport losses by utilization of energy sources
in situ and production of consumable energy forms in situ
Energy supply for Remote Areas
Why Combine Fuel Cell withSecondary Energy Sources
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MCFC – Fuelling
Fuel:
• H2
• CO (< 20%)
Possible sources:
• Natural gas• Light hydrocarbons (butane, methanol, …)
Yield: • H2 75%• CO 10%• CO2 15% Traces of NH3, CH4, SOx…
Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA
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MCFC – Fuelling
Fuel:
• H2
• CO (< 20%)
Possible sources:
• Biomass (gasification)• Heavy hydrocarbons (distillate, oil)
Yield: • H2 20%• CO 25%• CO2 10%• N2 40% CH4, NH3, SOx, H2S, HCl, …
Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA
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MCFC – FuellingFuel:
• CHCH44
Possible sources:
• Animal manure, sewage sludge• Organic fraction of municipal solid waste• Residue, By- product• Organic industrial waste
Yield: • CH4 55-75%• CO2 25-45%• H2S 0-1,5%• N2 0-10%
Traces of H2 ,CO, Halogens, Siloxane
Reforming
Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA
H2 + CO
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MCFC – Fuelling
Fuel:
• H2
Possible sources:
• Animal manure, sewage sludge• Organic fraction of municipal solid waste• Residue, By- product
Yield: • H2 70-90%• CO2 10-30%
Traces of sulphidesTechnology under development
Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA
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MCFC – Fuelling
• High efficiency conversion• CO is a fuel: it will be shifted into H2 in reforming step• MCFC operates efficiently with CO2 – containing fuels
Source: MTU
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Biomass gasification, Waste pyrolisis, anaerobic digestion,…
MCFC ideal for green electricity generation
Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA
MCFC – Fuelling
• High efficiency conversion• CO is a fuel: it will be shifted into H2 in reforming step• MCFC operates efficiently with CO2 – containing fuels
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BUT
Fuel gas clean-up is still restrictive: low tolerance and high cost
MCFC ideal for green electricity generation
Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA
MCFC – Fuelling
• High efficiency conversion• CO is a fuel: it will be shifted into H2 in reforming step• MCFC operates efficiently with CO2 – containing fuels
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MCFC – FuellingContaminations
Sulphur Containing Compounds H2S, THT, Mercaptanes, Thioester,
Thioether, COS, (SO2)
Nitrogen Containing Compounds NH3, NOx, Amines, N2 (Gasification)
Olefinic Hydrocarbons, Tar R2C=CR2, aromatic HC, undefined products from cracking reactions
Halogens F, Cl, Br, I, aliphatic, aromatic
Volatile metal organic Compounds R3-Si-O-Si-R3 (Siloxanes)
If present most of them can limit the lifetime of the fuel cell system
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Cell type Tolerance limits
AFC 0% CO2, 0% H2S
PEFC CO < 10 ppm
PAFCCO < 1%v
H2S + COS < 50 ppm
MCFCH2S < 10 ppm, COS < 1 ppm
HCl < 1 ppm, NH3* < 4%v
SOFC H2S < 1 ppm, HCl < 1 ppm
NH3 < 1000 ppm *Under this % NH3 is a fuel Desire-Net Lesson: Fuel Cell, 8 June 200 – Angelo Moreno ENEA
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Available Clean-up Systems
Conventional Systems:
• derived from methods used in chemical industry; technical mature, but expensive in small scales adapted to decentralized CHP systems:
Cooling down - drying – condensing – washing – adsorption on activated carbon.
H2S removal:
• Adsorption• Chemical scrubbers• Catalytic oxidation• Membrane separation• Bio-filters• Bio-scrubbers
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Cost estimations clean-up
Gas Clean-up Costs:
0.4 to 8.0! €cts/kWhel
regenerative/non-regenerative systems
Source: MTU
WARNING: Clean-up is a tricky system
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Methanol MCFCLandfill Gas
Coal Mine Gas
Coal Gas
Synthesis Gas
Biogas
Natural Gas
Sewage Gas
MCFC suitable forRegenerative andRegenerative andsecondary fuels secondary fuels
Gaseous Gaseous hydrocarbons hydrocarbons
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BIOMASSWASTE MCFC
DECENTRALIZED HEAT & POWER
GENERATION
• reducing transmission losses• reducing dependence from availability of fuel and/or
electricity grid • reducing emissions of GHG and pollutant• reducing dependence on primary energy carriers imports
From the production to the end use
Rural economy
Energy independence
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CHP System Sizes
MCFC
MCFC
Desire- Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic
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Institutional Hospitals Universities
Commercial Hotels Data Centers Office/Shopping
Industrial Waste Water Telecom Food & Beverage Chemical Manufacturing Utility Grid-support
MCFC: Target Customers
Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA
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* - Allied Business Intelligence’s 2001 Study, “Stationary Fuel Cells: U.S. and Global Early Market Opportunities.”
Uses anaerobic digester gas from industrial and municipal waste water treatment facilities
Use of “biogas makes this a “renewable” application.
Favorable economics – fuel generated by application
King County, Kirin Brewery, Terminal Island, City of Fukuoka
Over 500 MW Waste Water Fuel Cell Installations by 2011*Over 500 MW Waste Water Fuel Cell Installations by 2011*
MCFC: Waste Water Treatment FacilitiesA Unique Opportunity for market entry
Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA
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Wabash River Energy Ltd., Terre Haute, Indiana
DFC® 3000
Headquarters Building (LADWP)Los Angeles, California
DFC® 300
Multi-megawatt systems
FCE main realizations
King County Wastewater Treatment FacilityRenton, Washington
DFC® 1500
Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA
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FCE experience: King Country 1 MW power plant
First Fuel Switching ApplicationOperated on Natural Gas and Digester Gas Source: FCE
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King Country 1 MW power plant
Overall process flow Source: FCE
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Types of Gases used by the King Country Fuel Cell
Digester Gas Natural Gas
• 90 -100% CH4
• 9,3 - 10,3 kWh/Nm3
• Odorised for safety, typically 3 ppm Sulphur, max 20 ppm
• 50 -80% CH4 (60% typically)
• 5,2 - 8,3 kWh/Nm3
• Sulphur present naturally at tens to hundred of ppm
• It contains Siloxanes
Source: FCE
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Types of Gases used by the King Country Fuel Cell
Source: FCE
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MTU experience: Leonberg Germany
Source: MTU
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AFCO
MCFC – Plant
Source: AFCO
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AFCo Demonstration Program
Source: AFCO
Size (Class) Fuel Market segmentFirst of a kind Series 2TW Natural gas Stationary DGTecnodemo Series 100 Natural gas Stationary DGHybrid Cycle Series 100 Natural gas DGNaval Application Series 2TW Diesel Naval
Biomass Appication Series 100Biomass
Gassification Waste to Energy
H2 /CO2 Series 2TW Hydrogen
MC-WAP NAVAL APU
Series 2TW Diesel Naval
BICEPS 1 MW-class Digester gasBICEPS 1 MW-class Landfill GasPRIOLO Series 100 SyngasH2 FILSTAT Series 2TW Natural gas DGFURTHER DEMOS MW-class various various
Waste to EnergyWaste to Energy
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AFCOOngoing Field Tests: MCFC-NAV
• Installed at Marmara Research Center, Istanbul (Turkey)
• Fuelled with NATO F76 Diesel Oil
• Conceived for future boarding on military ships and for “stand alone” use in remote areas and military bases
• Fuel Processing System successfully tested
• Installed at Marmara Research Center, Istanbul (Turkey)
• Fuelled with NATO F76 Diesel Oil
• Conceived for future boarding on military ships and for “stand alone” use in remote areas and military bases
• Fuel Processing System successfully tested
Source: AFCO
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• BICEPS – 2 “MW-Class” plants running on biogas:
• 1 MW in Terni (Italy) on ADG (beg. 2008)• 1MW in Murcia (Spain) on landfill gas (2008)
– Project cost shared by the European Commission
• PULP&PAPER– An integrated waste AND energy solution for the P&P industry:
• Reforming/Gasification of “pulper” waste and conversion to power and heat with MCFC.
– Framework agreement in place with Italian P&P industrial ass.n and Italian Government:
• 1 MW prototype in 2007• 2 x 4MW plants from 2008/9
AFCOField Tests: Ongoing projects
Source: AFCO
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• REFINERY WASTE
– Agreement with a major Italian Oil&Gas Company for a demo plant running on tar gasification plant to be installed in 2007
• OTHER WASTE TO ENERGY PROJECTS
– Conversion of Chicken Manure through gasification and MCFC
• REFINERY WASTE
– Agreement with a major Italian Oil&Gas Company for a demo plant running on tar gasification plant to be installed in 2007
• OTHER WASTE TO ENERGY PROJECTS
– Conversion of Chicken Manure through gasification and MCFC
AFCOField Tests: Ongoing projects
Source: AFCO
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CONCLUSIONSPART A
• MCFC is a viable, clean, sustainable power generation alternative
• Very HIGH EFFICIENT TECHNOLOGY
suitable for DISTRIBUTED GENERATION AND RURAL ECONOMY
and characterized by FUEL FLEXIBILITY
PART B
• Sustainable Strategies based on Best Practices and
Best Available Technologies
• WASTE TO ENERGY Case Studies