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Critical Components for Direct Fuel Cell/Turbine Ultra-Efficiency System
Hossein Ghezel-Ayagh
Project Manager, Senior Scientist Phone: (203) 825-6048 Fax : (203) 825-6273
e-mail: [email protected]
Joseph M. Daly Manager, Test Operations Phone: (203) 825-6487 Fax : (203) 825-6273 e-mail: [email protected]
Mohammad Farooque Vice President, Stationary
Systems Phone: (203) 825-6092
Fax: (203) 825 6273 e-mail: [email protected]
FuelCell Energy, Inc. 3 Great Pasture Road
Danbury, CT 06813 FuelCell Energy Inc. (FCE) is developing ultra high efficiency fuel cell/Turbine (DFC/T®) hybrid power plants. The DFC/T power system is based on an innovative power cycle utilizing an indirectly heated gas turbine to supplement fuel cell generated power. Features of the DFC/T system include: electrical efficiencies of up to 75% on natural gas, minimal emissions, simplicity in design, direct reforming internal to the fuel cell, reduced carbon dioxide release to environment, and potential cost competitiveness with existing combined cycle power plants. The combined fuel cell and turbine system does not require any combustion in the turbine. Emissions from DFC/T systems are expected to be less than 0.001 lb/million BTU for sulfur and nitrogen oxides, a significant improvement over existing power plants. The DFC/T system development is being conducted under the Department of Energy’s Vision 21 Program through the Office of Fossil Energy and managed by the National Energy Technology Laboratory (NETL). The project objectives are the design of a 40 MW system utilizing the internally reformed Direct FuelCell (DFC) technology being commercialized by FCE. The development, design and testing of the key components for the DFC/T are the focus of the Vision 21 project.
An important aspect of the hybrid fuel cell/turbine system design is the synergistic operation of the fuel cell stack, which is an electrochemical device, and the gas turbine, which is a mechanical power generator. In order to address this issue, the DFC/T development project includes construction and testing of a subMW DFC/T power plant prototype at FCE headquarters. To date, significant progress have been achieved in proof-of-concept tests of the sub-scale power plant built around a state-of-the-art DFC stack integrated with a modified Capstone Model 330 Microturbine. The objectives of this effort are to investigate the integration aspects of the fuel cell and turbine and to obtain design information and operational data that will be utilized in the design of a 40-MW high efficiency Vision 21 power plant. Additionally, these tests are providing the valuable insight for DFC/T power plant potential for load following, increased reliability, and enhanced operability. The results from the sub-scale hybrid tests along with any experience gained in operating the fuel cell and microturbine will be utilized in the development of larger (MW scale) Vision 21 power plants. Acknowledgements The development of Direct Fuel Cell /Turbine hybrid power system is being performed as a cost-shared Vision 21 project supported by the US Department of Energy through the National Energy Technology Laboratory (NETL). The technical guidance of Mr. Richard Dennis, the DOE Contracting Officer’s Representative (COR) is acknowledged. This project has also substantially benefited from the guidance and directions of Mr. Tom J. George and Ms. Abbie Layne of NETL.
FuelCell Energy, Inc.
Critical Components for Direct Fuel Cell/Turbine Ultra-Efficiency System
Presented at :
Turbine Power Systems Conference and Condition Monitoring Workshop
Galveston, Texas
February 25-27, 2002
HOSSEIN GHEZEL-AYAGH
FuelCell Energy, Inc.3 Great Pasture Road
Danbury, CT 06813-1305
FuelCell Energy, Inc.
INTRODUCTIONDirect FuelCellDirect FuelCell® ® / Turbine/ Turbine
FUELCELL ENERGY, INC (FCE) IS CURRENTLY INVOLVED IN THE DEVELOPMENT OF FUEL CELL/TURBINE HYBRID POWER PLANTS UNDER A VISION 21 PROJECT SUPPORTED BY THE US DEPARTMENT OF ENERGY ( DE-FC26-00NT40798)
Technology development is focused on the integration of FCE’s Direct FuelCell® (DFC® ) with Gas Turbines in an ultra high efficiency power plant configuration.
FuelCell Energy, Inc.
VISION 21 PROJECT
OBJECTIVES
• DESIGN OF 40 MW HYBRID POWER PLANT
• SYSTEM EFFICIENCY > 75%
• COST COMPETITIVE WITH OTHER ENERGY SYSTEMS
• ULTRA LOW EMISSIONS: <.01 lbs/MMBTU of SOx and NOx
FuelCell Energy, Inc.
VISION 21 PROJECT
PROJECT PLAN
• DESIGN OF 40-MW DFC®/TURBINE POWER PLANT• SUB-SCALE FUEL CELL/TURBINE INTEGRATION TESTS
• HIGH EFFICIENCY FUEL CELL DESIGN
• BOP COMPONENTS FOR 40 MW POWER PLANT:
• HIGH TEMPERATURE ANODE EXHAUST OXIDIZER
• RECUPERATORS
• GAS TURBINE
OVERVIEW
OF
ULTRA HIGH EFFICIENCY
DFC/T TECHNOLOGY
FuelCell Energy, Inc.
FUEL
~
700 to 800 F High Quality
Waste Heat for Cogen / Cooling
ApplicationsDIRECT FUEL CELL
CatalyticOxidizer
Anode
HRUCathodeAIR
BlowerCathode Exit Gas is used
for Fuel Preheat and Water Vaporization
Residual 20 - 25% Fuel in Anode Exhaust is Used in
Catalytic Oxidizer to Preheat Cathode Air
DC to AC INVERTER
Internal Reforming Fuel Cell
Optimal Temperature for Cogen Application
SIMPLIFIED SYSTEM DIAGRAMBaseline Simple-Cycle DFC® Power Plant
WATER
EXHAUST
AIR
GENERATORGAS TURBINE
Efficiencies of ~ 75% are possible
Low Cost of Electricity Compared to Combined Cycles
HIGH EFFICIENCY HYBRID DFC® / TURBINE POWER PLANT
MO2595A
FuelCell Energy, Inc.
ADVANTAGES OF DFC/T® SYSTEM
• FUEL CELL IS PRIMARY SOURCE OF POWER GENERATION
• TURBINE PRESSURE RATIO INDEPENDENT OF AMBIENT PRESSURE FUEL CELL
• FLEXIBILITY IN OPERATION OF FUEL CELL AND TURBINE
• SIMPLICITY OF DFC® DESIGN AND INTERNAL REFORMING FEATURE RETAINED
• NO NATURAL GAS COMPRESSION REQUIRED (UNLESS A SUPPLEMENTAL DIRECT FIRING OF TURBINE IS DESIRED)
• PROJECTED LOW COST AND HIGH EFFICIENCY
FuelCell Energy, Inc.
Comparative Efficiencies of Electric Power Plants
Engines
Direct FuelCell®
Coal/Steam
SYSTEM SIZE (MW)0.1 1 10 100 1000
DFC®/Turbine
EFFI
CIE
NC
Y, %
(LH
V)
PA/PEM FCGas Turbines
Combined
Cycle
0.01
Microturbines
70
50
30
10
MO1402CMO1402C
FuelCell Energy, Inc.
NOx EMISSIONS PRODUCED BY VARIOUS TECHNOLOGIES
Microturbine Low Emission Conventional DFC/TurbineDesign Design
Recip Engine Recip Engine
Microturbine Low Emission Conventional DFC/TurbineDesign Design
Recip Engine Recip Engine
** At 95% Capacity Factor, ISO Conditions** At 95% Capacity Factor, ISO Conditions
0
5,000
10,000
15,000
20,000
25,000
0
25
50
75
100
125
150
NOx(ppm)
NOx**(lbs/MW-Yr)
17, 200 lb/MW-Yr78 ppm
4, 100 lb/MW-Yr9 ppm
4,000550,000
17 lb/MW-Yr< 0.1 ppm
543,500 lb/MW-Yr3,750 ppm
NOx (ppm)NOx (ppm) NOx (lb/MW-Yr)NOx (lb/MW-Yr)
DFC®/TURBINE Systems Have Negligible NOx Emissions
FuelCell Energy, Inc.
Product Development for 10-50 MW Applications
20 MW Ultra–High Efficiency DFC® /Turbine Power Plant
FuelCell Energy, Inc.
COST OF ENERGY: Comparison of GT Combined Cycle with DFC/Turbine Hybrid
3.03.54.04.55.05.56.06.57.07.5
2.0 3.0 4.0 5.0 6.0 7.0FUEL COST, $/MMBTU
CO
E, C
ENTS
/kW
hr
DFC/TURBINE HYBRID
GAS TURBINE COMBINED CYCLE
DR301101899
VISION 21
SUBSCALE DFC®/TURBINE
INTEGRATION TEST
FuelCell Energy, Inc.
SUBSCALE DFC®/MICROTURBINE INTEGRATION TESTS
OBJECTIVES
• Proof-of-concept of DFC/T® system by integrating a 250kW DFC® stack with a microturbine in a sub-MW power plant
• Gain operational and design experience
• Develop and identify the design of critical components for 40 MW DFC/T® system
FuelCell Energy, Inc.
SUB-MW CLASS DFC/T POWER PLANT OPERATING MODES
The power plant is designed to operate in dual mode
FUEL CELL CONDITIONING
DUAL MODE OF OPERATION
- FUEL CELL ONLY
- INTEGRATED FUEL CELL/TURBINE
RESTART / SHUTDOWN
FuelCell Energy, Inc.
FULL-SIZE STACK ACCOMPLISHMENT
FA-100-2 BUILT WITH LOW COST NON-REPEAT COMPONENTS
FuelCell Energy, Inc.
MODIFICATIONS OF MICROTURBINE FOR DFC/T TESTS
MECHANICAL / DESIGN MODIFICATIONS
MATERIALS
CONTROL / DATA COMMUNICATION
CAPSTONE MODEL 330 (Simple Cycle)
FuelCell Energy, Inc.
MECHANICAL / DESIGN MODIFICATIONS OF MICROTURBINE
IMPROVED THRUST BEARING CAPABLE OF >20 IWG
INLET/OUTLET PORT CONNECTIONS TO THE BALANCE-OF-PLANT
MODIFIED CASING
FuelCell Energy, Inc.
CONTROL/ SOFTWARE MODIFICATIONS OF MICROTURBINE
• COMMUNICATION OF MICROTURBINE’S CONTROLLER / DATA ACQUISITION HARDWARE TO FCE’S CONTROL SYSTEM
• MICROTURBINE CONTROL SOFTWARE MODIFICATIONS
• Speed Control
• Expander Inlet Temperature Control
• SURGE AND TRIP CONTROL
FuelCell Energy, Inc.
MODIFIED CAPSTONE SIMPLE CYCLE MicroTurbineTM
Capstone Simple Cycle Model 330 MicroTurbineTM at FCE Test Area
POWER PLANT CONSTRUCTION AND TESTING
FuelCell Energy, Inc.
Vision 21 Project Milestone
250kW DFC® stack integrated with a Capstone 330 Microturbine
MO251273000
FuelCell Energy, Inc.
Objectives Met
Verified DFC/T® Concept Modes of Operation Tested:– Fuel Cell Only– Fuel Cell with Turbine Integrated and Operated at
Various Operating ConditionsThermal Management Confirmed– Fuel Cell Operating Temperature– MT Expander Inlet Temperature
Trip/Emergency Scenarios Tested and SuccessfulRefinement of Control Strategies thru Operational Experience– Validation of Control Philosophy for Commercial
Production
FuelCell Energy, Inc.
FUTURE WORK PLANS
Continue sub-scale DFC/T power plant tests and
implement refinements for optimal power and
efficiency
Complete design of the 40 MW DFC/T power plant
Investigate suitable gas turbine and recuperator
technologies for the 40MW plant
Develop design of fuel cells for operation at high
fuel utilization
