SECA and the Office of Fossil Energy’s

Program Strategy

4th Annual SECA MeetingRita A. Bajura, Director

April 15, 2003

National Energy Technology LaboratoryOffice of Fossil Energy

Solid State Energy Conversion Alliance

SECA 4/15/03

World Primary Energy DemandProjected to Grow 66% by 2030

Natural Gas

Oil

Coal

02,0004,0006,0008,000

10,00012,00014,00016,000

1970 1980 1990 2000 2010 2020 2030

Mto

e

Non-hydro Renewable

Hydro

Nuclear

World Energy Outlook 2002. IEA

SECA 4/15/03

The ChallengeDefining a Path to World Energy Future

Future• Energy security• Economic development• Environmental

protection• Social welfare

02,0004,0006,0008,000

10,00012,00014,00016,000

1970 1980 1990 2000 2010 2020 2030

Mto

e

Non-hydro Renewable

HydroNuclear

Natural Gas

Oil

Coal

SECA 4/15/03

-5.0

0.0

5.0

10.0

15.0

20.0

1990 2015 2040 2065 2090 2115 2140 2165 2190 2215 2240 2265 2290

PgC

/yr

350 Ceiling450 Ceiling550 Ceiling650 Ceiling750 Ceilingis92a

Ultimately, Net Global GHG Emissions Must Sharply Decline and Even Approach Zero to

Achieve Stabilization

Source: PNNL

Emis

sion

s Pg

C/y

ear

20

15

10

5

0

- 51990 2140 2290

Year

Stabilization Levels

350 ppm

750 ppm

SECA 4/15/03

All Sectors and All Fossil Fuels Contribute to Carbon Emissions

CO2 Emissions from Fossil Fuel Combustion Year 2000 Emissions by Sector and Fuel Type

0

100

200

300

400

500

600

700

ResidentialCommercial

IndustrialTransportation

Electric

Mill

ion

Met

ric T

ons

Car

bon

Equi

vale

nt

Natural Gas

Petroleum

Coal

Relative Contributionby Fuel Type

U.S. Territories

SECA 4/15/03

The World Needs Affordable Energy

100

1,000

10,000

1,000 10,000 100,000 1,000,000 10,000,000

Affluence

Poverty

Annual Commercial Energy Consumption per Capita (kWh / person)

GD

P pe

r Cap

ita ($

/ yr

/ pe

rson

)Japan

World Resources Institute Database 1996-1997

BangladeshChina

Poland

MexicoSouth Korea

UK

France U.S.

100,000

SECA 4/15/03

FutureGen: A Presidential Initiative

One billion dollar, 10-year demonstration project to create world’s first, coal-based, zero-emission electricity and hydrogen plant

President Bush, February 27, 2003

One billion dollar, 10-year demonstration project to create world’s first, coal-based, zero-emission electricity and hydrogen plant

President Bush, February 27, 2003

• Produce electricity and hydrogen from coal using advanced technology

• Emit virtually no air pollutants

• Capture and permanently sequester CO2

SECA 4/15/03

“Traditional” Integrated Gasification Combined Cycle

CoalGasification

Central PowerGas Turbine Combined

Cycle

Central PowerGas Turbine Combined

Cycle

SyngasH2 + CO

Coal

SECA 4/15/03

IGCC in FutureGen

CoalGasification

Coal

TransportationFuel CellsIC Engine

TransportationFuel CellsIC EngineGeologic CO2

SequestrationGeologic CO2 Sequestration

Distributed Power

Fuel Cells

Distributed Power

Fuel Cells

“New” Part

Central PowerGas Turbine

or Hybrid Cycle

Central PowerGas Turbine

or Hybrid Cycle

HydrogenSyngasH2 + CO

SECA 4/15/03

Why Coal?

246

11.7 9.2

0

50

100

150

200

250

300Coal

Oil

NaturalGas

U.S. Fossil Fuels Reserves/Production Ratio Shows Years Supply at Current Production

• Abundant reserves• Low and stable

prices• Technology

improvements− Could enable near-

zero emissions of air pollutants/GHGs

EIA- U.S. Crude Oil, Natural Gas, and Natural Gas Liquids Reserves: 2001 Annual Report, November 2002;

Coal: BP Statistical Review, June 2002, World Energy Council

SECA 4/15/03

Why Sequestration?

• Compatible with existing energy infrastructures

• May prove to be lowest cost option

SECA 4/15/03

Options for Electricity & Hydrogen Production

Nuclear

Fossil/SequestrationFutureGen

Dream Source• Fusion• Thermochemical

Dream Source• Fusion• Thermochemical

RenewableEnergy

Conservation / Efficiency ImprovementConservation / Efficiency Improvement

SECA 4/15/03

SECA: A Route to Making Fuels Cells a Reality

2015• $400/kW• Hybrid systems

–60-70% efficient• Coal power plants

2010• $400/kW• Commercial products

–Residential, commercial, industrial CHP

–Transportation APUs

2005• 1st Generation products− Premium power– Truck APU’s– RV’s– Military

SECA 4/15/03

SECA SECA Program Structure

DOEDOEProgram Program

ManagementManagement

Univer-sities

Materials

Modeling & Simulation

Fuel Processing

Power Electronics

Control & Diagnostics

Manufacturing

TechnologyTechnologyTransferTransfer

Research

ResearchTopicsTopicsR&D

R&D

NeedsNeeds

Core Technology Program

Industry InputIndustry Input

Nat.Labs

+ + -- +- -Indus-try

SmallBus.

Industry Teams

SECA 4/15/03

Four SECA Industry Teams

General Electric Company

SECA 4/15/03

Cummins - SOFCo

Two 60-cell Stacks

5-cell Cross-flow Stack

Catalytic Partial

Oxidation

Images courtesy of Cummins & SOFCo

SECA 4/15/03

Delphi - Battelle

Generation 2 APUTwo 15-cell stacksReforWERBalance of Plant

Compact, light, low-cost systems for transportation

Compact, light, low-cost systems for transportation

Images courtesy of Delphi

SECA 4/15/03

General Electric

Unitized Cell

Design

1-kW Catalytic Partial Oxidation

ConceptualDesign

Images courtesy of GE

SECA 4/15/03

Siemens Westinghouse

Redesigned Tube

Tubularcell

5 kW Prototype

Images courtesy of Siemens Westinghouse

SECA 4/15/03

Different Approaches!

• Stack extrusion• Plasma spray

• Cathode supported• 800 C• Redesigned tubular• Seal-less stack

Siemens Westinghouse

• Tape calendering• 2–stage sintering

• Anode supported • 750 C• Hybrid compatible• Internal reforming

General Electric

• Tape casting• Screen printing• 2–stage sintering

• Anode supported • 750 C • Ultra compact• Rapid transient capability

Delphi-Battelle

• Tape casting • Screen printing• Co-sintering

• Electrolyte supported• 850 C• Thermally matched materials• Seal-less stack

Cummins-SOFCo

ManufacturingDesignTeam

SECA 4/15/03

Core Technology Program Raises All Boats

DelphiDelphiSiemens

WestinghouseSiemens

Westinghouse

GeneralElectricGeneralElectric

Cummins PowerGeneration

Cummins PowerGeneration

• Materials• Modeling and simulation• Fuel processing

• Power electronics• Controls and diagnostics• Manufacturing

SECA 4/15/03

Current Priorities: Core Technology Program

• Lower cost precursor processing • Cost model methodology

Material cost4

• Direct DC to AC conversion• DC to DC design for fuel cells

Powerelectronics

3

• Metal oxides with interface modification• Catalyst surface modification• Characterize thermodynamics/kinetics

Anode/fuel processing

2

• Micro structure optimization• Mixed conduction• Interface modification

Cathodeperformance

2

• Models with electrochemistry• Structural characterization

Modeling2

• Modifying components in alloys• Coatings

Interconnect1• Glass and compressive seals Gas seals1

HowWhat

SECA 4/15/03

Cross Cutting Technologies

Seals, Modeling And Analysis, Cathodes, Anodes, Interconnects, Fuel Processing• PNNL

Metallic Supported Cell Structure, Cathode Interface Modification• LBNL

Metallic Supported Cell Structure,Interconnects, Fuel Processing• ANL

Bipolar PlateCathodeElectrolyteAnodeEnd Plate

Current Flow

Fuel Flow

Oxidant Flow

SECA 4/15/03

Intermediate-temperature Inexpensive Interconnect Materials

• U. of Pittsburgh• Ceramatec• Southwest Research Institute• PNNL• ANL

Thin foil Interconnect

Seal

Cell

Spacer

Images courtesy of Delphi

SECA 4/15/03

Materials for 2- to 3-fold Improvement in Cathode Performance

• U. of Washington • U. of Missouri Rolla • U. of Utah• Functional Coating, LLC • Georgia Tech• PNNL

Images courtesy of NexTech

SECA 4/15/03

Structural, Performance, And Optimization Design Tools

• PNNL • NETL• ORNL• U. of Florida • Georgia Tech• TIAX

Image courtesy of PNNL

SECA 4/15/03

Fuel Processing

Tubular cPox Reformer

Carbon/Sulfur Resistant Anodes• Northwestern • GTI

Carbon/Sulfur Resistant Reforming Catalysts• LANL • ANL• NETL

Image courtesy of Delphi

SECA 4/15/03

Balance of Plant

Interaction Among Fuel Cell, Power Conditioning, Load

• U. of Illinois

DC-DC / DC-AC Converters• Texas A&M • VPI

High Temperature Sensors• NexTech Materials

SECA 4/15/03

Low Cost / Consistent Precursor Materials

• NexTech Materials • U. of Utah

Electrolyte

Supportelectrode

Supportelectrode

Bilayer

Tape forming Rolling Rolling

Thin electrolyte on support electrode layer

Tape Calendering

Image courtesy of Honeywell

SECA 4/15/03

Highlights: Core Technology Program

• Glass and mica compressive seal characterization• Inexpensive Ferritic alloy interconnect characterization• Fuel cell models available• Material structural characterization• Mixed conducting cathodes, LaSrFeOx• Cathode microstructure optimization• Cathode mechanism intermediates identified• Metal oxide anode material–promising S, C,O tolerance• Low temperature bi-layer and ultra-thin electrolytes• Efficient DC-DC converter designed• Developing lower cost consistent materials

SECA 4/15/03

SECA Performance TargetsPhase 1 FY2005/06

Cost $800/ kW, $600/ kW, $400/ kWCost $800/ kW, $600/ kW, $400/ kW

> 1,000 hour intervalMaintenance

Stationary: 40,000 hours, 100 cyclesAPU: 5,000 hours, 1,000 cycles

Design lifetime

Natural gasGasolineDiesel

Fuels (Current infrastructure)

Stationary: 40 - 60%APU: 30 - 50%

Efficiency(AC or DC/LHV)

3-10 kW (net)Power rating

SECA 4/15/03

NETL’s SECA Test Facility

FUEL STORAGE

RESEARCH AREA113

STAIR101

UP

Liquid Fuel

Storage

Propane Storage

Fuel Cell System

Elec. Load Banks-AC/DC-Grid Simulator

Facility Design by:Concurrent

Technologies Corp.

Co-Gen ThermalLoad Bank System

Control Room

SECA 4/15/03

SECA Budget ($M)

0

5

10

15

20

25

30

35

2000 2001 2002 2003 20040

5

10

15

20

25

30

35

2000 2001 2002 2003

RequestFunding

Industry TeamsCore Technology Program

SECA 4/15/03

Other Pathways to High VolumeWith Help from our Friends

SECA 4/15/03

SECA Program Status

• Program in place• Making technical progress• Implementation as planned

SECA 4/15/03

Hybrid-basedFutureGen

plants

SECA: Key Part of Larger Fossil Energy Program2002 2006 2010 2015

Dynamic control /component integration

Turbine adaptation for hybrids

SECA

1st Gen.SECA

Hybrids with SECA technology

$400 / kWSECA module

ready

IGCC coal-fueled SECA-based hybrids

SECA 4/15/03

FutureGen Power Plants

Gasification with Cleanup Separation System

Integration

CarbonSequestration

A Vision for 2015Putting the Pieces Together

Optimized Turbines

SECA-Based Hybrids

SECA 4/15/03

5-kW SOFC Cost Breakdown

Total Cost: $372/kWTotal Cost: $372/kW

Stack 32%

Insulation 2%

Reformer & Desulfurization 9%

Piping 5%

Controls & Power Electronics 11%

Labor, Depreciation, Indirects 10%

Fuel & Air Supply 32%

Source: Conceptual Design of POx SOFC 5kW net System, Arthur D. Little, Inc., October 12, 2000