DOE Experiences with Fuel Cell Environmental Performance

1
DOE Experiences with Fuel Cell Environmental
Performance
Charles Zeh and Mark Williams, NETL, U.S.
Department of Energy
Strategic Center for Natural Gas
2
National Energy Technology Laboratory (NETL)

• What We Are
• One of US DOEs 15 National Laboratories
• Government Owned and Operated
• What We Do
• Shape, fund, and manage DOE Stationary Fuel Cell
  Program
• Conduct on-site science and technology research
• Conduct analyses to support DG policy

3
US DOE and Canadian Fuel Cell Related Federal
Budgets (FY 2001)
4
Types of Fuel Cells

• TYPE TEMP
  CHARGE CARRIER
• Solid Oxide 2000 F O--
• Carbonate 1250 F CO3--
• Phosphoric Acid 400 F H
• Polymer 160 F H
• Alkaline 180 F OH-

5
Advanced Technologies Will Play a Crucial Role in
Mitigating Climate Change
6
Greenhouse Gas Emissions

• Electric Power Produces
• 35 of the US CO2 emissions
• 33 of the US NOx emissions
• 72 of US SO2 emissions
• Kyoto Protocol
• 7 reduction in the 1990 level of greenhouse
  gases
• starting 2008 through 2012
• Impact on the economy - 30-33 billion (1992 )
  loss in
• the gross domestic product
• Impact on the energy market - higher energy
  prices
• Clean Air Act is ratcheting down - Phase II
• Affects all new and existing generators 25 MWe
  or larger
• Sulfur dioxide emissions for electricity
  generators
• capped at 8.95 million tpy in 2010 and
  thereafter
• Proposed NOx standards

7
Greenhouse Gas Emissions
Reduced emissions from Molten Carbonate Fuel
Cell SOx 0.001 Kg/MWhr
NOx 0.0002 Kg/MWhr Reduced emissions from
Siemens Westinghouse Solid Oxide Fuel Cell

NOx 0.004 Kg/MWhr (0.635 Kg/MWhr
allowable)
CO2 440 Kg/MWhr (now 1450 Kg/MWhr)
SOx,
VOCs, VHCs, and CO are undetectable 100 to 1,000
times better than conventional technologies
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Environmental/Sociological Concerns

• Building of dams and wind farms
• Commercial sprawl
• Siting utilities and right-of-ways
• High land use
• Solid waste disposal
• High water use
• Contamination of groundwater
• Threat to endangered species

9
Environmental/Sociological Solution

• Natural gas fuel cell distributed generation
  means
• No building of dams
• No commercial sprawl
• No siting or right-of-way issues
• Reduced footprint
• No solid waste generation
• Net (clean) water production rather than water
  use
• Exemptions from air permitting
• Lowest possible emissions
• Low Noise

10
Fuel Cell Emissions and Efficiency

24.89
1.2
0.6
2700
1862
1164
911
610
Average US fossil fuel plant
Combined cycle gas turbine
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Environmental and Economic Benefits Fuel Cells

• Economic
• Potential 100GW/year new/replacement generation
  global market
• Sales/Exports in 40GW/year global DG market by
  2010
• Potential Truck APU sales 4 billion/year
• Ultimate Longterm Impact - 55 million
  vehicles/year global transportation market
• Environmental
• Lower emissions
• 50-60 efficient fuel cell and hybrid systems cut
  CO2 by half
• fuel cells virtually eliminate NOx in stationary
  and transportation

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PEM Fuel Cells

• 2004-2008
• Near-term DG market
• 30-40 efficiency
• 900-1,500/kW
• 500 W to 250 kW

• 2001
• 24 - 32 efficiency
• gt 10,000/kW
• 1 to 250 kW
• Stationary and Transportation Initiatives

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North American PEM Developers

• Ballard (Canada)
• Enable/DCH
• Avista
• IdaTech
• Schatz (Humbolt State)
• IGT/Mosaic
• Millenium
• Hydrogenics (Canada)
• Reliant (TAM)

• Nuvera
• IFC
• Dais-Analytic
• Energy Partners
• Plug Power
• H Power
• Honeywell/GE
• Stuart (Canada)
• Gore

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Molten Carbonate Fuel Cells

• 2001
• Demonstration
• 47 efficiency
• 8,000/kW
• 250kW
• Internal reforming
• FCE Manufacturing 50MW/year

• 2003-2008
• Near-term DG market
• 55 efficiency
• 1,000-1,500/kW
• 250kW-3MW

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Solid Oxide Fuel Cells

• 2004-2008
• Near-term DG market
• 47-63 efficiency
• 1,000-1,500/kW
• 250kW - 1MW

• 2001
• 47 efficiency
• gt 10,000/kW
• 100kW
• Internal/coupled reforming

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North American SOFC Players

• SWPC (German/US)
• Delphi
• NexTech
• Honeywell
• McDermott
• TMI
• PNNL, NETL, ANL, ORNL, LANL, LBL, LLNL
• Universities

• Global Thermoelectric (Canadian)
• FCT (Canadian)
• IFC
• Ceramtec
• IGT
• Zetek
• Accumetrics
• MSRI
• American Fuel Cell

(Note SECA-funded in red)
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Tubular SOFC Demonstration Status EDB-ELSAM 100
kWe CHP System
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SOFC Demonstration StatusPlanned Tubular SOFC
Field Units
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FCT 5 kWe SOFC Power SystemFront View-Open
Access Panel
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Fuel Cell/Turbine HybridsHighest Efficiency Ever

• 2004-2015
• DG market
• 1,000-1,200/kW
• 70 efficiency
• 1-20MW
• Vision 21

• 2001
• gt 10,000/kW
• 57-59 efficiency
• 220kW

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SOFC Demonstration StatusSCE 220 kWe PSOFC/MTG
Installation
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High Efficiency Hybrid DFCTM/Turbine Power
PlantCompressed Air is Heated with Fuel Cell
Waste Heat, Expanded, and then Used as the Fuel
Cell Oxidant
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SOFC Demonstration StatusMWe-class PSOFC/GT
System Drawing
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SOFC Demonstration Status300 kWe-class PSOFC/GT
CHP System Illustration
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Honeywell Hybrid System Schematic
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Solid State Energy Conversion Alliance
(SECA)Core Module for Multiple Applications
Stationary
Transportation
Core Module
Military
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SECA Development Progressive Applications

• 2005
• 800/kW
• Prototype (?-Unit)3 - 10 kW

2015

• Vision 21 Power Plants
• 70-80 efficient plants
• Propulsion lt200?/kW

• 2010
• 400/kW
• Commercial

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Environmental Permitting History

• CX and EA under NEPA for DOE and DoD Research and
  Demonstrations
• Exemption from air permitting in CA MA
• Emissions at detection levels

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Materials and Manufacturing

• Materials for High-temperature Fuel Cells
• Nickel
• Stable Naturally Occurring Oxides
• Carbonates
• Not organically based
• Manufacturing processes and materials business
  sensitive

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Life Cycle Cost Comparisons

• Compare among relevant technology and processes
• Include recycle
• Use advanced, mature, commercial manufacturing
  processes
• Fairness and accuracy