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30SEPTEMBER08, International Pittsburgh Coal Conference, Pittsburgh, PA
Clean Economic Energy in a Carbon Challenged World
Wayne A. SurdovalTechnology Manager, Fuel CellsNational Energy Technology LaboratoryUnited States Department of Energy
2 2
Department of Energy
*Deputy Secretary also serves as Chief Operating Officer
Under Secretary for Nuclear Security/Administrator for National Nuclear Security
AdministrationThomas P. D’Agostino, Acting
Assistant Secretaryfor Congressional &Intergovernmental
Affairs
Economic Impact & Diversity
Management
Health, Safety & Security
Intelligence and Counterintelligence
Inspector General
Public Affairs
Hearings & Appeals
Bonneville Power Administration
Associate Administratorfor Emergency
Operations
Associate Administratorfor Defense Nuclear
Security
Associate Administratorfor Infrastructure& Environment
Associate Administratorfor Management& Administration
Assistant Secretaryfor Energy
Efficiency & Renewable Energy
Assistant Secretary for Nuclear Energy
Assistant Secretaryfor Fossil Energy
Advanced Scientific Computing Research
Biological & Environmental
Research
Basic Energy Sciences
Under Secretary
Clarence H. “Bud” Albright
Deputy Administratorfor Defense Programs
Deputy Under Secretaryfor Counter-terrorism
Deputy Administratorfor Defense Nuclear
Nonproliferation
Deputy Administrator for Naval Reactors
Chief FinancialOfficer
Human CapitalManagement
10/26/2005
Southeastern Power
Administration
Southwestern Power
Administration
Western Area Power
Administration
Under Secretary forScience
Dr. Raymond L. Orbach
Civilian Radioactive Waste Management
Electricity Delivery & Energy Reliability
Legacy Management
Fusion Energy Science
High Energy Physics
Nuclear Physics
Workforce Development for
Teachers & Scientists
Assistant Secretaryfor Policy &
International Affairs
General Counsel
Chief InformationOfficer
Energy InformationAdministration
Assistant Secretary for Environmental
Management
Office of Science
Federal EnergyRegulatory
Commission
SecretaryDr. Samuel Bodman
Acting Deputy Secretary*Jeff Kupfer
3 3
FY 09 Fossil Energy Fuel Cell Program Solid State Energy Conversion Alliance
(SECA)
$0
$10
$20
$30
$40
$50
$60
$70
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
Request Appropriation
SECA FY 09…...$60,000,000
Universities, Small Business
SECA Cost ReductionIndustry SECA Coal Based Systems
Industry
National Laboratories
$15,030,000$26,000,000
$18,970
4 4
SECA Program Structure
Industry Input Program Management
Industry Integration Teams
Core Technology Program
Project Management
SECA Cost Reduction
SECA Coal Based Systems
NATIONAL
LAB
NATIONAL
LAB
UNIVERSITY
UNIVERSITY
INDUSTRY
INDUSTRY
SMALL
BUSINESS
SMALL
BUSINESS
Research TopicsNeeds
TechnologyTransfer
FuelProcessing
FuelProcessing
ManufacturingManufacturing
Balance of Plant
Coal Contaminants
Coal Contaminants
Modeling &SimulationModeling &Simulation
MaterialsMaterials
5 5
Intellectual PropertyCornerstone of the Alliance
• Non-Exclusive License
- Ready market of potential licensees
- Best designs vs. highest bidder
• Promotes Collaboration - Limits Redundancy
CTP Industry Teams
6 6
SECA Industry Teams & Major Subcontractors
VersaPowerSystems
00076 10-22-08 WAS
Calgary
7 7
2008 SECA Core Technology & Other Partners
ANL
NEXTECH
MATERIALS
NEXTECH
MATERIALS
00076 7-25-08 WAS
8 8
DOE’s Office of Fossil EnergyAdvanced (Coal) Power Systems Goals
• 2010: – 45-50% Efficiency (HHV)– 99% SO2 removal– NOx< 0.01 lb/MM Btu– 90% Hg removal
• 2012:– 90% CO2 capture– <10% increase in COE with
carbon sequestration• 2015
– Multi-product capability (e.g, power + H2)– 60% efficiency (measured without carbon capture)
9 9
Solid State Energy Conversion Alliance Performance Assessment Rating Tool (OMB)
2010
Stack Cost ~ $100/kW stack
Capital Cost < $400/kW system
Maintain Economic Power Density with Increased Scale ~ 300mW/cm2
Mass customization – stacks used in multiple applications….large and small systems
Ref: 2002Goal: 2010
10 10
How Big are the U.S. Markets?Coal
EIA/AEO 2007 New Capacity Forecast
0.050.0
100.0150.0200.0250.0300.0350.0
2010 2015 2020 2025 2030
YEAR
Cum
ulat
ive
Addi
tions
(G
W)
New Coal Capacity All New Capacity
SECA Fuel Cells available for installation in 2018New Coal Capacity, 2018 – 2030…….110 GWAverage SECA Fuel Cell Production …. 9.2 GW/yr
EIA Annual Energy Outlook (AEO) for 2007 pp. 82-83
11 11
Atoms for Peace1953
Department of Energy
October 22, 1953:The Atomic Energy Commission announces that an AEC-owned demonstration power plant of 60 MW will be built at Shippingport, PA, jointly by Westinghouse Electric Corporation and Pittsburgh’s Duquesne Light Company under the direction of the U.S. Navy/AEC Naval Reactors Branch.
The more important responsibility of this atomic energy agency would be to devise methods whereby this fissionable material would be allocated to serve the peaceful pursuits of mankind. Experts would be mobilized to apply atomic energy to the needs of agriculture, medicine and other peaceful activities. A special purpose would be to provide abundant electrical energy in the power-starved areas of the world.
Dwight D. Eisenhower, President of the United States of America, to the 470th Plenary Meeting of the United Nations General AssemblyTuesday, 8 December 1953
Photograph of the Shippingport Atomic Power Station in Shippingport, Pennsylvania, the first full-scale nuclear power generating station in the United States which began operating in 1957.
12 12
How Big are the U.S. Markets?Overnight TrucksNew Retail Truck Sales Class 8
Transportation Energy Data Book - Edition 26-2007 Table 5.3
0
50
100
150
200
250
300
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005
Truc
k S
ales
(tho
usan
ds)
Average Size of a Truck APU – 5kWAverage Annual Production – 200,000 unitsAverage SECA Fuel Cell Production…. 1 GW/yr
13 13
Fuel Cells in a DOD Application’s
• DOD Requirements– Extend mission length– Quiet– Combined functions – power, heat and water – Volume and weight
• Operate with High Specific Energy Fuels – Liquids• DOE’s power density targets (based on cost) minimize stack
size and volume to diminishing returns. • Further size and weight improvements – Focus on the
Balance of Plant
14 14
Solid State Energy conversion Alliance Fuel Cells Technology Timeline
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2020
SECA R&D
SECA Cost Reduction
SECA Coal Based Systems
SECA Manufacturing
Validation test Validation test
Operate Single Module (1 MW) Scale
Operate Multiple Module (5 MW)
Scale with Turbines
$400/kWRef: 2002
250 – 500 MW IGFC
Coal-Based Fuel Cell Objective
Technology Solutions and Enabling Technology
15 15
Combustor
SECA Coal Based Systems Reduced Water Requirement
> 90% Carbon Capture
Gas CleaningCoal
H2O
Marketable Ash/Slag
By-product
Air
O2
SulfurRecovery
MarketableSulfur
By-product
Anode
Cathode
CO2
Gasification
AirSeparation
EnhancedOil Recovery
Deep SalineAquifer
UnmineableCoal Beds Depleted Oil & Gas
Reservoirs
Sequestration
Air
H2,
Heat Recoverye.g., HRSG
• Atmospheric SOFC with conventional coal gasification• Combined Fuel and Air Streams• Steam cycle – reduced external water requirement• Cycle Efficiency (HHV); 90% Capture
~40% with CO2 Compression~45% w/out CO2 Compression
Atmospheric SOFC
CO2Separation
To HRSG
Shift
To Fuel Cell Preheat
16 16
SECA Coal Based Systems Near Zero Water Requirement
99% Carbon Capture
Gas Cleaning
CO2,CO, H2, H2O
Coal
H2O
Marketable Ash/Slag
By-product
Air
O2
SulfurRecovery
MarketableSulfur
By-product
Anode
Cathode
CO2
Catalytic Gasification25% CH4
AirSeparation
EnhancedOil Recovery
Deep SalineAquifer
UnmineableCoal Beds Depleted Oil & Gas
Reservoirs
Sequestration
Air Heat Recoverye.g., Expander
Air
CO, H2, CH4
Pressurized SOFC
O2
CombustorO2
Combustor
O2
CO2
H2O
• Pressurized SOFC with catalytic gasification 25% Methane
• Separate Fuel and Air Streams: Oxy Combustion
• No steam cycle – minimal external water requirement
• Cycle Efficiency (HHV); 99% Capture
~56% with CO2 Compression
~60% w/out CO2 Compression
Heat Recoverye.g., Expander
CO, H2, CH4
17 17
Impact of Efficiency on COE
Advanced Power SystemsWith CO2 Capture, Compression and Storage
PC Baseline
IGCC Baseline
IGFC Atmos.
IGFC Press.
EfficiencyHHV (%)
27.2 32.5 42.8 57.3
Capital Cost$/kW
2,870 2,390 1,991 1,667
Steam Cycle% Power
100 37 26 2
Cost-of-Electricity¢/kW-hr
11.6 10.6 8.5 7.3
The Benefit of SOFC for Coal Based power Generation, Report Prepared for U. S. Office of Management and Budget, 30OCT07
18 18
1 System includes 100% carbon capture and CO2 compression to 2,215 psia2 System includes 90% carbon capture and CO2 compression to 2,215 psia
Raw Water Consumption Comparison
1
2
•Percentage of Power from Steam Plant is significantly reduced
•Higher fuel cell cycle efficiency reduces water use per unit of coal feed
•Separate fuel and oxidant streams in fuel cell permits use of substantially less cooling water to condense, recycle and reuse process H2O
From NETL Bituminous Baseline Study
0
200
400
600
800
1000
1200
1400
IGFC1
IGCC2
Gal
lons
/MW
h (n
et)
Supercritical PC2
Water Consumption (gal/MWh)PC plants: 1000 - 1200IGCC: 600-700Nuclear: 1600NGCC: 500
19 19
Current & Future IGCC Technologieswith Carbon Capture
Current & Future IGCC Technologies, DOE/NETL – 2008/1337, 16OCT2008
Case Description
14Reference: Slurry Feed Gasifier / Cryogenic ASU / Cold Gas Cleanup wcc / 7FB Syngas Turbine / 80 % Capacity Factor
15Coal Feed Pump / Cryogenic ASU / Cold Gas Cleanup wcc / 7FB Syngas Turbine / 80 % Capacity Factor
16Coal Feed Pump / Cryogenic ASU / Cold Gas Cleanup wcc / 7FB Syngas Turbine / 85 % Capacity Factor
17
Coal Feed Pump / Cryogenic ASU / Warm Gas Cleanup wcc / 7FB Syngas Turbine / 85 % Capacity Factor
18Coal Feed Pump / Cryogenic ASU / Warm Gas Cleanup wcc / 2010-AST Syngas Turbine / 85 % Capacity Factor
19Coal Feed Pump / Ion Transport Membrane (ITM) / Warm Gas Cleanup wcc / 2010-AST Syngas Turbine / 85 % Capacity Factor
20Coal Feed Pump / Ion Transport Membrane (ITM) / Warm Gas Cleanup wcc / 2015-AST Syngas Turbine / 85 % Capacity Factor
21Coal Feed Pump / Ion Transport Membrane (ITM) / Warm Gas Cleanup wcc / 2015-AST Syngas Turbine / 90 % Capacity Factor
24Catalytic Gasifier / Cryogenic ASU / Warm Gas Cleanup / Pressurized SOFC / 90 % Capacity Factor
20 20
Carbon CaptureEfficiency
30%
35%
40%
45%
50%
55%
60%
Refere
nce
Coal P
ump
85%
CF
War
m Clea
nup
Adv.
Turb
ine
ITM +
Adv
. Tur
bine
ITM +
Adv
. Tur
bine (
II)90
% C
FSO
FCEf
ficie
ncy
(%H
HV)
21 21
Carbon CaptureCapital Cost
1,2001,400
1,6001,8002,000
2,2002,4002,600
Refere
nce
Coal P
ump
85%
CF
War
m Clea
nup
Adv.
Turb
ine
ITM +
Adv.
Turb
ine
ITM +
Adv.
Turb
ine (I
I)90
% C
FSO
FC
Cap
ital C
ost (
2007
$/kW
)
22 22
Carbon CaptureCOE
456789
101112
Refere
nce
Coal P
ump
85%
CF
War
m Clea
nup
Adv.
Turb
ine
ITM +
Adv.
Turb
ine
ITM +
Adv.
Turb
ine (I
I)90
% C
FSO
FC
Cos
t of E
lect
ricity
(200
7 ce
nts/
kWh)
23 23
Key Points
• 25% Methane+
• Pressure
• Balance of Plant Cost Scales with Size
• Fuel Cell Stack Cost Scales with Power
• Separate Air & Fuel Streams / w/o Steam Plant
60% EfficiencyHHV
99 % Carbon CaptureNear Zero Water Use
24 24
Single Cell Module PerformancePlanar Cell - Atmospheric
0
200
400
600
800
2002 2003 2004 2005 2006 2007 2008
mW/cm2 System ($/kW)
250@ 0.6 V144 cm2
275@ 0.7V144cm2
500 @ 0.8V144 cm2
450@ 0.8V550 cm2
25 25
SECA Industry TeamsFY 2001 – FY 2007
5kW Systems - CompleteSECA Industry Team Location Prototype NETL Validation
General Electric Torrance, CA Complete Pass
Delphi Rochester, NY Complete Pass
Fuel Cell Energy Calgary, BC Complete Pass
Acumentrics Westwood, MA Complete Pass
Siemens Power Group Pittsburgh, PA Complete Pass
Cummins Power Gen. Minneapolis, MN Complete Pass
Size Efficiency Degradation Availability Cost
Target 3 – 10 kW 35 (LHV) 4%/1,000 hrs 90%
Aggregate Team Performance
3 – 7 kW 35.4 – 41 % 2%/1,000 hrs 97% $724 - $775/kW
26 26
SECA Industry Team Prototypes
27 27
Peterbilt - Delphi Auxiliary Power Unit
• Delphi’s SECA APU powered the Peterbilt Model 386’s electrical hotel loads, including air-conditioner, radio, CB, lights, battery, & start-up.
• The Delphi SECA APU provided an average of 800 watts of electricity on diesel.
• The Delphi SECA APU addresses anti-idling regulations.
28 28
SOFCs in Unmanned Undersea Vehicles (UUVs)
• Naval Undersea Warfare Center, Division Newport, (NUWCDIVNPT) successfully tested SECA SOFCs in extreme conditions. Used SECA Stacks (2 Developers) and SECA developed High Temperature Blower
• SOFC technology has the potential to greatly increase UUV mission time compared with current battery technology.
• Although SECA has a coal-based, central generation focus, spin-off applications are encouraged. Military applications like UUVs provide operating experience and independent validation for SECA.
• Cost and operational lifetime are not necessarily major concerns for military applications, as long as new mission capability can be delivered.
21UUV (2-5 kW)> 100 In-Water RunsFisher-TropschSECA Stacks and Blower
29 29
•NETL website:−www.netl.doe.gov
Wayne A. SurdovalTechnology Manager, Fuel CellsNational Energy Technology LaboratoryU. S. Department of Energy(Tel) 412 386-6002(Fax) 412 [email protected]
CDs available from the website•FE Fuel Cell Program Annual
Report _2007• 8th Annual SECA Workshop
Proceedings•Fuel Cell Handbook (7th ed.)
•Office of Fossil Energy website:
−ww.fe.doe.gov
For More Information About the DOE Office of Fossil Energy Fuel Cell Program
Reference Shelf
