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Combined Heat,
Hydrogen and Power
from DFC® Fuel Cell
FCE Information Towards Design:
Hydrogen Education Foundation’s
2011-2012 CHHP Contest
Joseph Daly, Fred Jahnke
Pinakin Patel
November 4, 2011
1
Outline
� Background
� Fuel cell operation
� H2 recovery system
�Conclusions / Next Steps
2
Integrated Fuel Cell Company
2
Manufacture Sell (direct & via partners) Install Services
Delivering Ultra-Clean Baseload Distributed Generation Globally
1.4 MW plant at a municipal
building
2.4 MW plant owned by an
Independent power producer
600 kW plant at a food
processor
11.2 MW plant - largest
fuel cell power plant in
the world
Scalable On-site Power and Utility Grid Support Solutions
3
Global Market Leader
3
Multi- MW DFC-
ERG in Canada
Utility grid support
in South Korea
On-site power in
London, England* On-site power for
Jakarta, Indonesia*
• 182 MW installed and in backlog - 5 year average growth rate of 48%
• Over 80 Direct FuelCell® (DFC®) plants generating power at more than 50 sites globally
• South Korea & California are leading markets
• Expanding opportunities in N.E. USA, Canada, Europe and Southeast Asia
On-site power in
ConnecticutUtility owned in
California
* In backlog
Americas
AsiaEurope
44
Market Leadership
Natural gas - Utility
& IPP, 79%
Renewable
baseload power,
11%
Natural gas -
Commercial,
Government, etc,
10%
Installed Base & Backlog
1.4 MW at a municipal building 2.4 MW plant owned by an IPP600 kW plant at a food processor11.2 MW plant owned by an IPP
• More than 900 Million kW-Hrs of Electricity Produced.
• Operating models
– On-site power
– Utility & Independent Power Producers (IPP)
• All DFC Products Employ Internal Reforming Technology
5
Background – Fuel Cell Technologies
PerovskitesNickelPlatinumPlatinumCatalyst
CeramicStainless SteelGraphiteCarbon /Metal
BasedCell Hardware
O=CO3=H+H+Charge Carrier
18001200400200Operating
Temp. °F
Yttria Stabilized
ZirconiaAlkali CarbonatePhosphoric Acid
Ion Exchange
MembraneElectrolyte
Future
Solid Oxide
Carbonate
Direct Fuel
Cell®
Phosphoric
Acid
Polymer
Electrolyte
Membrane
Fuel Cell Type
6
STEAM
Internal Reforming DFC® Technology
CATHODE
½O2+ CO
2+ 2e-� CO
3=
INTERNAL REFORMING
CH4+ 2H
2O ���� 4H
2+ CO
2
ANODE
H2+ CO
3= ���� H
2O +CO
2+2e-
CATALYST
CATALYST
ELECTROLYTE
HYDROCARBON FUEL
(e.g. Natural Gas)
AIR + CO2
Opportunity
25-35% Excess H2,CO
+ CO2
Exhaust
CO2
H2 Co-production expands market for fuel cells
7
Operation Features
� Hydrogen formed in fuel cell (no reforming
unit needed)
� Normal operation only 70 - 80% of fuel
consumed in fuel cell
� 20 - 40% of feed can be available from fuel
cell as H2
� Currently need CO2 transfer to air side for
cathode reaction
� H2 export impacts exhaust heat
production, not fuel cell operation
8
H2 Purification
A/E Cooling
E-BOP
M-BOP
DFC300
Current Prototype DFC-H2 System: SubMW Unit
9
Configuration – Simple Cycle
WATERWATER
FUELAIR
HEX
CO-GEN HEAT
A
C
DFC
H2, CO, CO2, H2O
HEX
WATER
FUELAIR
AGO
10
``
HEX W.G. SHIFT
Configuration – H2 Recovery
AIR
A
C
DFC
H2,CO,CO2,H2O
H2, CO2
H2Separator
WATER
HEX
CO-GEN HEAT
HEXPreheated
Air
CO2 with a
fractional
amount of H2
H2
WATER
FUEL
AGO
Optional
Supplemental Fuel
11
Anode Outlet Gas (H2 Source)
Composition
(at fuel utilization of 65%)
Dry / Shifted
� H2 10% 23%
� H2O 40% -
� CO 5% < 1%
� CO2 45% 77%
Anode Gas needs to be cooled, pressurized and purified, but extracted H2
represents an additional “free” revenue stream for combined H2 + Power solution
12
� Hydrogen DFC-H2 configuration
- Hydrogen vehicle fueling- Industrial uses
H2 Energy Station in California
12
Renewable biogas fueled
DFC300-H2 in CA providing
hydrogen for vehicle fueling
under DOE demonstration
program
.
First of a Kind Unit in the World
13
Hydrogen Energy Station Fountain
Valley, California
Co-product
2,4001,200300Fuel Cell Cars, 0.5 kg/day
Refueling Capacity
4.02.00.5Heat, mmBtu/hr
1,000500125Hydrogen, kg/day
2,0001,000250Power, kW
DFC300 DFC1500 DFC3000
4,0002,000500Peak Power (8 hrs/day), kW
Peaker Capacity
Co-product
2,4001,200300Fuel Cell Cars, 0.5 kg/day
Refueling Capacity
2,4001,200300Fuel Cell Cars, 0.5 kg/day
Refueling Capacity
4.02.00.5Heat, mmBtu/hr
1,000500125Hydrogen, kg/day
2,0001,000250Power, kW
DFC300 DFC1500 DFC3000DFC300 DFC1500 DFC3000
4,0002,000500Peak Power (8 hrs/day), kW
Peaker Capacity
4,0002,000500Peak Power (8 hrs/day), kW
Peaker Capacity
14
High Efficiency
Low Emissions
54500.016DFC Fuel Cell –
CHP 80% efficiency
96700.016DFC Fuel Cell
47% efficiency
1,24400.467Small Gas Turbine (250 kW)
1,86200.490Microturbine (60 kW)
2,0179.214.200Average US Fossil Fuel
Plant
CO2
(lb/MWh)
SOX
(lb/MWh)
NOX
(lb/MWh)
54500.016DFC Fuel Cell –
CHP 80% efficiency
96700.016DFC Fuel Cell
47% efficiency
1,24400.467Small Gas Turbine (250 kW)
1,86200.490Microturbine (60 kW)
2,0179.214.200Average US Fossil Fuel
Plant
CO2
(lb/MWh)
SOX
(lb/MWh)
NOX
(lb/MWh)
NOx and SOx are Negligible
Compared to Conventional Technologies
10.0% 10.0%
1.4%5.2%
0%
20%
40%
60%
80%
100%
120%
NOx CO
% of CARB Lim
it_
CARB 2007 Limit (California Air Resources Board)
U87 Emissions Plots.x ls
DFC
DFC-H2
DFCDFC-H2
Test Results for DFC-H2®:
Validated Emissions <90% of CARB 2007 Limit
High Efficiency for Hydrogen Co-production
Engines
Direct FuelC
ell®
0.1 1 10 100 1000
10
30
50
70
EFFICIENCY, %(LHV)
Gas Turbin
es
Combined
Cycle
0.01
Microtu
rbines
SYSTEM SIZE (MW)
PA/PEM FC
Average
U.S.
Fossil Fuel
Plant = 33%
Coal/
Steam
DFC-H2/PEM
Peaker
DFC-T®DFC-H2
®
Engines
Direct FuelC
ell®
0.1 1 10 100 1000
10
30
50
70
EFFICIENCY, %(LHV)
Gas Turbin
es
Combined
Cycle
0.01
Microtu
rbines
SYSTEM SIZE (MW)
PA/PEM FC
Average
U.S.
Fossil Fuel
Plant = 33%
Coal/
Steam
DFC-H2/PEM
Peaker
DFC-H2/PEM
Peaker
DFC-T®
DFC-T®DFC-H2
®DFC-H2
®
60%+ Efficiency
Before Waste Heat Recovery
15
Conclusions
� Distributed co-production of Hydrogen and Power
with a Carbonate (DFC®) fuel cell is attractive
� Current technology is competitive with small scale /
distributed H2 production
� Future developments have potential to make fuel
cell produced hydrogen the preferred method of
supply
16
CHHP System:
Enabler for FCV, EV, Smart Grid
GRIDLoad Following
Fuel Cell
Hydrogen
Storage
Base Load
Fuel Cell
Co-Produced
Hydrogen
Fuel Cell Cars
Heat
Power
Micro-GRID
Fuel
(NG/BioGas/Propane)
• Enhanced Energy Security
• Maximize Green Energy
Use
• Water Independent
• Load Following
• Fuel Flexible
• Ultra Clean
• Provides Distributed H2
for Multiple Uses
• Compensates for
Intermittent Supplies
Wind and Solar Power
(Intermittent)
17
Potential for DFC H2 Production
KWs to electric load: 50%
Hydrogen: 20%
Heat to buildingsthermal load: 15%
DFC-H2 POWER PLANT
H2 – REFUELING STATION
COMMERCIAL/INDUSTRIAL BUILDING