fuel cell power plant experience naval applications · 3/29/2011 · logistic fuel dfc power...
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reliable, efficient, ultra-clean
Fuel Cell Power Plant Experience Naval Applications
US Department of Energy/Office of Naval ResearchShipboard Fuel Cell Workshop
Washington, DCMarch 29, 2011
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
•FuelCell Energy, Inc.
•Renewable and Liquid Fuels Experience
•HTPEM Fuel Cell Stack for Shipboard APU
•Solid Oxide Experience and Applications
DOE-ONR Workshop
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
FuelCell Energy, Inc.
• Premier developer of fuel cell technology — founded in 1969
• Over 50 power installations in North America, Europe, and Asia
• Industrial, commercial, utility products
• 300 KW to 50 MW and beyond• Research and development in
MCFC, SOFC, PEM and Fuels
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
High electrical and CHP efficiencyNear zero NOX, SOX and lower CO2
emissions Reliable, Secure powerClean & Quiet Operation Ideal Shore Capacity - Low Profile,
Easy SitingConnects to existing electricity and
fuel infrastructureMultiple fuels
29 Palms Marine Corps Base
Naval Station Groton (Planned)
DFC Naval Facilities Applications
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
Renewable and Liquid Fuels
DOE-ONR Workshop
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
FCE Liquid Fuels Experience
• Silent tactical 3/5 kW fuel cells (US Army) – M 232 methanol PAFC• Remote site 3 kW DFC power unit plant (USCG) – M 232 methanol PAFC• 32 kW DFC Demonstration power plant (DARPA) – DF2, JP-8 • 500 kW Ship Service DFC Demo Plant (Navy) – JP-5 • DFC300 Commercial Design Power Plant (US Army CERL) propane• 5 kW adiabatic fuel processor (US Army CERL) – B-100 bio diesel• Bench scale adiabatic reactor - ethanol
3 kW methanol fueled fuel cell power units were constructed and delivered to the US Army
This 3 kW methanol fuel DFC power plant operated unattended at Virginia Beach, VA site for 6 months
DFC300 power plant operated for 6 months on Propane with seamless transition to NG
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
Logistic Fuel DFC Power Plant
A 0.5 MW fuel processor was integrated with an FCE Direct Fuel Cell Stack and operated with high sulfur naval logistic fuel (JP-5 jet fuel)• Over 1000 Hours of Fuel System Operation• Over 300 Hours of Operation on Load with Water Recovery • Power Output up to 125 kW (50% of Stack Rating)• Over 17,600 kWh Generated with Navy Logistic Fuel• 17 Tons of Logistic Fuel Processed by HDS During Factory Test• Sulfur Reduced in JP-5 from 1,100 ppm to 0.1 ppm
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
Pilot Scale Prereformer Operated over 1000 hr with Biodiesel fuel
Reformate Composition(dry basis)
CH4 40.3%H2 32.0%CO 0.7%CO2 27.0%
Reformate Composition(dry basis)
CH4 37.4%H2 37.0%CO 0.0%CO2 25.6%
Bench Scale Prereformer Tested with Ethanol
Renewable Liquid Fuel ProcessingHigh Temperature Fuel Cells
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
HTPEM Fuel Cell Stack for Shipboard APU
DOE-ONR Workshop
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
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Current Density, mA/cm2
Cel
l Vol
tage
, mV
1.2 stoic Fuel/2 stoic Air, 30%H2, 65% N2, 5% H2OCell HT-001
Atmospheric Pressure
3 Atmospheres PressureV- I Characteristic for PBI Cell 1atm/3atm
50 kW PBI Stack Module
Endurance Test of BASF P-2100 MEA
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
50 kW PBI Stack Module
50 kW PBI Stack ModuleFour 144-cell stacks incommon gas enclosure
144-Cell PBI Stack Performance - 3 atm
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Stack Current (A)
Stac
k Vo
ltage
(V)
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Stac
k Po
wer
(kW
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Projected Module Power OutputThe 4-stack module generates 50.4 kW at 125 A
PBI 2KW Short Stack with 24 600cm2 Cells
Temperature: 180°C
Pressure: 0 - 30 psig
CO Tolerant to 2%
Two phase liquid cooling
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
50 kW PBI Stack Module
35"
30"
12"
10"
1.5"
3"
OXIDANT MANIFOLD
FUEL
MA
NIF
OLD
FUE
L MAN
IFOLD
INSULATION INSULATED SUPPORTCHANNEL
Estimated Dimensions and Performance of a 50 kW PBI Stack Module Meets Navy’s Shipboard Fuel Cell Goals
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
Solid Oxide Experience and Applications
DOE-ONR Workshop
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
• Planar anode supported cells (up to 33 x 33 cm2)• Capable of operating from 650°C to 800°C• Ferritic stainless steel sheet metal interconnect • Cross-flow gas delivery , manifolds integrated into the interconnect but not through the cell• Compressible ceramic gasket seals • Standardized stack blocks configurable into stack towers for various power applications
A node
Cathode
Electrolyte
A node
Cathode
Electrolyte
FCE SOFC Systems Background
SOFC MW Module
FCE utilizes VPS (Versa Power Systems) fuel cell technology in FCEs SOFC stack modules and systems.
FCE/VPS team is engaged in Phase II of Solid State Conversion Alliance (SECA) Program for development of MW-scale SOFC systems
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
10-20 kW Stack
1 kW Stack
SOFC Stack Module
Stack Tower
Develop SOFC stack technology that meets performance & cost objectives, is scalable, and is used as the building block for assembling stack towers and large-scale power modules.
Modular
Endurance
Performance Cost
Scal
abl
e
Prime Power and Auxiliary Applications
SECA SOFC Development Path
2006
2008
2010
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
Stack Tower (SO-30-3) Test
• Demonstration of stack tower operation in a simulated power plant environment, using 2x92-cell stack blocks.
• A Power Rating of 30 kW was established during the operation.
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0 200 400 600 800 1000 1200Runtime/ Hr
Pow
er/ W
0
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200
250
Stac
k Vo
ltage
/ V
PowerTotal Voltage
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
Hybrid System for Underwater Vehicles and Weapons
• Project Support by Office of Naval Research (ONR) through STTR programs:– Phase I STTR, “Hybrid Propulsion System for Undersea Weapons” (N00014-05-M-0183)– Phase II STTR, “Hybrid Propulsion System”(N00014-06-C-0406 )
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
SOFC Based Torpedo System Design
• Very compact• Designed to fit in
torpedo cross section • Length depends on
power/stack size
13” for 5 kW
18” for 8 kW
22” for 10.7 kW
33” for 16 kW
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
SOFC/T Hybrid System
Black Start CapabilityBlack Start CapabilityFast Ramp RateFast Ramp Rate
Flexible Fuel Processing TechnologyFlexible Fuel Processing TechnologyUltra High Efficiency Ultra High Efficiency
GenC
AnodeCathode
Recuperator
T
Out
Gas Turbine
Fuel
AGO
Water
C
Water Recovery
Air
Supp. FuelPower Ramp/Startup
Solid Oxide Fuel CellInverter
~
Fuel Processing(SR or ATR)
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
Summary
FCE DFC Fuel Cells ready now to provide shore based power
FCE has multiple process Liquid Fuels Experience
HTPEM Stack Experience can be Advanced to Demonstration
Solid Oxide (SOFC/T) holds promise as high efficiency cycle
DOE-ONR Workshop