DoD Climate Change Fuel Cell Program

The Los Angeles Department of Water and Power (LADWP) has developed one of the most recognized fuel cell demonstration programs in the United States. In addition to their high efficiencies and superior environmental performance, fuel cells and other generating technologies that can be located at or near the load, offers several electric utility benefits. Fuel cells can help further reduce costs by reducing peak electricity demand, thereby deferring or avoiding expenses for additional electric utility infrastructure. By locating generators near the load, higher reliability of service is possible and the losses that occur during delivery of electricity from remote generators are avoided. The potential to use renewable and locally available fuels, such as landfill or sewage treatment waste gases, provides another attractive outlook. In Los Angeles, there are also many oil producing areas where the gas by-product can be utilized. In June 2000, the LADWP contracted with FCE to install and commission the precommercial 250kW MCFC power plant. The plant was delivered, installed, and began power production at the JFB in August 2001. The plant underwent manufacturer's field trials up for 18 months and was replace with a commercial plant in January 2003. In January 2001, the LADWP contracted with FCE to provide two additional 250kW MCFC power plants. These commercial plants began operations during mid-2003. The locations of these plants are at the Terminal Island Sewage Treatment Plant at the Los Angeles Harbor (for eventual operation on digester gas) and at the LADWP Main Street Service Center east of downtown Los Angeles. All three carbonate fuel cell plants received partial funding through the Department of Defense's Climate Change Fuel Cell Buydown Program. This report covers the technical evaluation and benefit-cost evaluation of the Terminal Island 250kW MCFC power plant during its first year of operation from June 2003 to July 2004.

A 200 kW, natural gas fired fuel cell was installed at the Richard Stockton College of New Jersey. The purpose of this project was to demonstrate the financial and operational suitability of retrofit fuel cell technology at a medium sized college. Target audience was design professionals and the wider community, with emphasis on use in higher education. ''Waste'' heat from the fuel cell was utilized to supplement boiler operations and provide domestic hot water. Instrumentation was installed in order to measure the effectiveness of heat utilization. It was determined that 26% of the available heat was captured during the first year of operation. The economics of the fuel cell is highly dependent on the prices of electricity and natural gas. Considering only fuel consumed and energy produced (adjusted for boiler efficiency), the fuel cell saved $54,000 in its first year of operation. However, taking into account the price of maintenance and the cost of financing over the short five-year life span, the fuel cell operated at a loss, despite generous subsidies. As an educational tool and market stimulus, the fuel cell attracted considerable attention, both from design professionals and the general public.

Rod Borup is a Team Leader in the fuel cell program at Los Alamos National Lab in Los Alamos, New Mexico. He received his B.S.E. in Chemical Engineering from the University of Iowa in 1988 and his Ph.D. from the University of Washington in 1993. He has worked on fuel cell technology since 1994, working in the areas of hydrogen production and PEM fuel cell stack components. He has been awarded 12 U.S. patents, authored over 40 papers related to fuel cell technology, and presented over 50 oral papers at national meetings. His current main research area is related to water transport in PEM fuel cells and PEM fuel cell durability. Recently, he was awarded the 2005 DOE Hydrogen Program R&D Award for the most significant R&D contribution of the year for his team's work in fuel cell durability and was the Principal Investigator for the 2004 Fuel Cell Seminar (San Antonio, TX, USA) Best Poster Award. Jeremy Meyers is an Assistant Professor of materials science and engineering and mechanical engineering at the University of Texas at Austin, where his research focuses on the development of electrochemical energy systems and materials. Prior to joining the faculty at Texas, Jeremy workedmore » as manager of the advanced transportation technology group at UTC Power, where he was responsible for developing new system designs and components for automotive PEM fuel cell power plants. While at UTC Power, Jeremy led several customer development projects and a DOE-sponsored investigation into novel catalysts and membranes for PEM fuel cells. Jeremy has coauthored several papers on key mechanisms of fuel cell degradation and is a co-inventor of several patents. In 2006, Jeremy and several colleagues received the George Mead Medal, UTC's highest award for engineering achievement, and he served as the co-chair of the Gordon Research Conference on fuel cells. Jeremy received his Ph.D. in Chemical Engineering from the University of California at Berkeley and holds a Bachelor's Degree in Chemical Engineering from Stanford University. Bryan Pivovar received his B.S. in Chemical Engineering from the University of Wisconsin in 1994. He completed his Ph.D. in Chemical Engineering at the University of Minnesota in 2000 under the direction of Profs. Ed Cussler and Bill Smyrl, studying transport properties in fuel cell electrolytes. He continued working in the area of polymer electrolyte fuel cells at Los Alamos National Laboratory as a post-doc (2000-2001), as a technical staff member (2001-2005), and in his current position as a team leader (2005-present). In this time, Bryan's research has expanded to include further aspects of fuel cell operation, including electrodes, subfreezing effects, alternative polymers, hydroxide conductors, fuel cell interfaces, impurities, water transport, and high-temperature membranes. Bryan has served at various levels in national and international conferences and workshops, including organizing a DOE sponsored workshop on freezing effects in fuel cells and an ARO sponsored workshop on alkaline membrane fuel cells, and he was co-chair of the 2007 Gordon Research Conference on Fuel Cells. Minoru Inaba is a Professor at the Department of Molecular Science and Technology, Faculty of Engineering, Doshisha University, Japan. He received his B.Sc. from the Faculty of Engineering, Kyoto University, in 1984 and his M.Sc. in 1986 and his Dr. Eng. in 1995 from the Graduate School of Engineering, Kyoto University. He has worked on electrochemical energy conversion systems including fuel cells and lithium-ion batteries at Kyoto University (1992-2002) and at Doshisha University (2002-present). His primary research interest is the durability of polymer electrolyte fuel cells (PEFCs), in particular, membrane degradation, and he has been involved in NEDO R&D research projects on PEFC durability since 2001. He has authored over 140 technical papers and 30 review articles. Kenichiro Ota is a Professor of the Chemical Energy Laboratory at the Graduate School of Engineering, Yokohama National University, Japan. He received his B.S.E. in Applied Chemistry from the University of Tokyo in 1968 and his Ph.D. from the University of Tokyo in 1973. He has worked on hydrogen energy and fuel cells since 1974, working on materials science for fuel cells and water electrolysis. He has published more than 150 original papers, 70 review papers, and 50 scientific books. He is now the president of the Hydrogen Energy Systems Society of Japan, the chairman of the Fuel Cell Research Group of the Electrochemical Society of Japan, and the chairman of the National Committee for the Standardization of the Stationary Fuel Cells. ABSTRACT TRUNCATED« less

The purpose of this work was to assess the performance of high temperature membranes and observe the impact of different parameters, such as water-to-carbon ratio, carbon formation, hydrogen formation, efficiencies, methane formation, fuel and oxidant utilization, sulfur reduction, and the thermal efficiency/electrical efficiency relationship, on fuel cell performance. A 250 KW PEM fuel cell model was simulated [in conjunction with Argonne National Laboratory (ANL) with the help of the fuel cell computer software model (GCtool)] which would be used to produce power of 250 kW and also produce steam at 120oC that can be used for industrial applications. The performance of the system was examined by estimating the various electrical and thermal efficiencies achievable, and by assessing the effect of supply water temperature, process water temperature, and pressure on thermal performance. It was concluded that increasing the fuel utilization increases the electrical efficiency but decreases the thermal efficiency. The electrical and thermal efficiencies are optimum at ~85% fuel utilization. The low temperature membrane (70oC) is unsuitable for generating high-grade heat suitable for useful cogeneration. The high temperature fuel cells are capable of producing steam through 280oC that can be utilized for industrial applications. Increasing the supply water temperature reduces the efficiency of the radiator. Increasing the supply water temperature beyond the dew point temperature decreases the thermal efficiency with the corresponding decrease in high-grade heat utilization. Increasing the steam pressure decreases the thermal efficiency. The environmental impacts of fuel cell use depend upon the source of the hydrogen rich fuel used. By using pure hydrogen, fuel cells have virtually no emissions except water. Hydrogen is rarely used due to problems with storage and transportation, but in the future, the growth of a “solar hydrogen economy” has been projected. Photovoltaic cells convert sunlight into electricity. This electricity can be used to split water (electrolysis) into hydrogen and oxygen, to store the sun's energy as hydrogen fuel. In this scenario, fuel cell powered vehicles or generating stations have no real emissions of greenhouse or acid gases, or any other pollutants. It is predominantly during the fuel processing stage that atmospheric emissions are released by a fuel cell power plant. When methanol from biomass is used as a fuel, fuel cells have no net emissions of carbon dioxide (CO2, a greenhouse gas) because any carbon released was recently taken from the atmosphere by photosynthetic plants. Any high temperature combustion, such as that which would take place in a spark ignition engine fueled by methanol, produces nitrous oxides (NOx), gases which contribute to acid rain. Fuel cells virtually eliminate NOx emissions because of the lower temperatures of their chemical reactions. Fuel cells, using processed fossil fuels, have emissions of CO2 and sulfur dioxide (SO2) but these emissions are much lower than those from traditional thermal power plants or spark ignition engines due to the higher efficiency of fuel cell power plants. Higher efficiencies result in less fuel being consumed to produce a given amount of electricity or to travel a given distance. This corresponds to lower CO2 and SO2 emissions. Fuel cell power plants also have longer life expectancies and lower maintenance costs than their alternatives.

Fuel Cells. Fuel cells are electrochemical devices that convert the chemical energy of a fuel directly into electrical and thermal energy. In a typical fuel cell, gaseous fuels are fed continuously to the anode (negative electrode) compartment, and an oxidant, eg, oxygen or air, is fed continuously to the cathode (positive electrode) compartment. The electrochemical reactions take place at the electrodes to produce an electric (direct) current. The fuel cell theoretically has the capability of producing electrical energy for as long as the fuel and oxidant are fed to the electrodes. In reality, degradation or malfunction of components limits the practical operating life of fuel cells. Besides the direct production of electricity, heat is also produced in fuel cells. This heat can be effectively utilized for the generation of additional electricity or for other purposes, depending on the temperature. A practical consideration for fuel cells is compatibility with the available fuels and oxidants. One of the main attractive features of fuel cell systems is the expected high fuel‐to‐electricity efficiency. This efficiency, which runs from 40–60% based on the lower heating value (LHV) of the fuel, is higher than that of almost all other energy conversion systems. The two primary impediments to the widespread use of fuel cells are high initial cost and short operational lifetime. A variety of fuel cells has been developed for terrestrial and space applications. Fuel cells are usually classified according to the type of electrolyte used in the cells as polymer electrolyte fuel cell (PEFC), alkaline fuel cell (AFC), phosphoric acid fuel cell (PAFC), molten carbonate fuel cell (MCFC), and solid oxide fuel cell (SOFC). Fuel cells operating on pure H 2 and O 2 provide a useful power source in remote areas such as in space or under the sea where system weight and volume are important parameters. On the other hand, fuel cell power plants operating on fossil fuels and air offer the potential for environmentally acceptable, highly efficient, and low cost power generation. The minimum technical requirements for fuel cells for four different types of applications, ie, for buildings, industry, transportation, and utilities are given. From the standpoint of commercialization of fuel cell technologies, there are two challenges: initial cost and reliable life. Several activities, would strongly boost the prospects for fuel cell technology and include the development of (1) an active electrocatalyst for the direct electrochemical oxidation of methanol; (2) improved electrocatalysts for oxygen reduction; and (3) a more CO‐tolerant electrocatalyst for hydrogen.

Polymers for Electrolyte Membrane Fuel Cells

The primary focus is on the development of commercial Phosphoric Acid Fuel Cell (PAFC) powerplant systems because the PAFC, which has undergone extensive development, is currently the closest fuel cell system to commercialization. Shorter discussions are included on the high temperature fuel cell systems which are not as mature in their development, such as the Molten Carbonate Fuel Cell (MCFC) and the Solid Oxide Fuel Cell (SOFC). The alkaline and the Solid Polymer Electrolyte (SPE) fuel cell systems, are also included, but their discussions are limited to their prospects for commercial development. Currently, although the alkaline fuel cell continues to be used for important space applications there are no commercial development programs of significant size in the USA and only small efforts outside. The market place for fuel cells and the status of fuel cell programs in the USA receive extensive treatment. The fuel cell efforts outside the USA, especially the large Japanese programs, are also discussed.

Fuel cell is the technology that, nowadays, is deemed having a great potential to be used in supplying energy. Basically, fuel cells can be categorized particularly by the kind of employed electrolyte. Several fuel cells types which are currently identified having huge potential to be utilized, namely, Solid Oxide Fuel Cells (SOFC), Molten Carbonate Fuel Cells (MCFC), Alkaline Fuel Cells (AFC), Phosphoric Acid Fuel Cells (PAFC), Polymer Electron Membrane Fuel Cell (PEMFC), Direct Methanol Fuel Cells (DMFC) and Regenerative Fuel Cells (RFC). In general, each of these fuel cells types has their own characteristics and specifications which assign the capability and suitability of them to be utilized for any particular applications. Stationary power generations and transport applications are the two most significant applications currently aimed for the fuel cell market. It is generally accepted that there are lots of advantages if fuel cells can be excessively commercialized primarily in context of environmental concerns and energy security. Nevertheless, this is a demanding task to be accomplished, as there is some gap in fuel cells technology itself which needs a major enhancement. It can be concluded, from the previous study, cost, durability and performance are identified as the main limitations to be firstly overcome in enabling fuel cells technology become viable for the market.

Robust progress has been made in fuel cell technology since the previous edition of the Fuel Cell Handbook was published in January 1994. This Handbook provides a foundation in fuel cells for persons wanting a better understanding of the technology, its benefits, and the systems issues that influence its application. Trends in technology are discussed, including next-generation concepts that promise ultra high efficiency and low cost, while providing exceptionally clean power plant systems. Section 1 summarizes fuel cell progress since the last edition and includes existing power plant nameplate data. Section 2 addresses the thermodynamics of fuel cells to provide an understanding of fuel cell operation at two levels (basic and advanced). Sections 3 through 6 describe the four major fuel cell types and their performance based on cell operating conditions. The section on polymer electrolyte membrane fuel cells has been added to reflect their emergence as a significant fuel cell technology. Phosphoric acid, molten carbonate, and solid oxide fuel cell technology description sections have been updated from the previous edition. New information indicates that manufacturers have stayed with proven cell designs, focusing instead on advancing the system surrounding the fuel cell to lower life cycle costs. Section 7, Fuel Cell Systems, has been significantly revised to characterize near-term and next-generation fuel cell power plant systems at a conceptual level of detail. Section 8 provides examples of practical fuel cell system calculations. A list of fuel cell URLs is included in the Appendix. A new index assists the reader in locating specific information quickly.

The recent awareness on the environmental issues related to global warming is leading to the search for always more efficient energy conversion systems and, mainly, with very low carbon dioxide emissions. In fact, they are strictly related to the combustion reaction of fossil fuels which is the main process of the actual power generation technology. In this regard, fuel cells are energy conversion systems which are characterized by higher efficiency and near-zero CO2 emissions. Their novel integration with conventional power plants participates to the concept of the decarbonization of the economy. In this work, the integration of two high temperature fuel cells (HTFC) with a gas turbine power plant has been proposed and investigated, thanks to the combination of a physical model of the fuel cells and a numerical one of the components involved in the gas turbine cycle. In the layout studied, fresh air is compressed, pre-heated and used in a Solid Oxide Fuel Cell (SOFC), where the high operating temperature and the exothermic process give exhaust gases at very high temperatures, suitable for an expansion in a turbine. After the expansion, the gases are rich of CO2 and, so, they can be sent to the cathode side of a Molten Carbonate Fuel Cell (MCFC). Hence, the so-defined integrated plant is composed by three power units: a turbine, a SOFC and a MCFC; operating pressure, fuel need, oxygen and carbon dioxide utilizations in the fuel cells are parameterized in order to optimize the whole plant and find additional room of energy exploitation. Moreover, the MCFC acts as an active device for carbon separation, introducing further environmental benefits.

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The concept of hybrids combining fuel cell and gas turbine systems is without question neoteric, and probably is less than eight years old. However, this concept is in a sense a logical development derived from the many early systems that embodied the key features of rotating machinery to compress air. It was the introduction of high temperature fuel cells such as the solid oxide fuel cell (SOFC) that allowed the concept of hybrid gas turbine fuel cell systems to take root. The SOFC with an operating temperature circa 1000° C matched well with small industrial gas turbines that had firing temperatures on the same order. The recognition that the SOFC could be substituted for the gas turbine combustor was the first step into the realm of fuel cell topping systems. Fuel cells in general were recognized as having higher efficiencies at elevated pressures. Thus the hybrid topping system where the gas turbine pressurized the fuel cell and the fuel cell supplied the hot gases for expansion over the turbine promised to provide a high level of synergy between the two systems. Bottoming systems using the exhaust of a gas turbine as the working fluid of a fuel cell such as the molten carbonate fuel cell (MCFC) have been identified and are potential future power generation hybrid systems. The MCFC is especially well suited to the bottoming role because of the need to have carbon dioxide present in the inlet air stream. The carbon dioxide in the gas turbine exhaust allows the high temperature blower, normally used to recirculate and inject exhaust products into the inlet air, to be eliminated. Hybrid systems have the potential of achieving fossil fuel to electricity conversion efficiencies on the order of 70% and higher. The costs of hybrid systems in dollars per kilowatt are generally higher than say an advanced gas turbine that is available today but not by much. The net energy output over the life of a hybrid topping system is similar to that of a recuperated gas turbine but possibly lower than a high-efficiency simple-cycle machine, depending on the efficiency of the hybrid. Methodologies to aid in the selection of the hybrid system for future development have to be developed and used consistently. Life cycle analyses (LFA) provide a framework for such selection processes. In particular the concept of net energy output provides a mechanism to assign relative worth to competing concepts.

The fuel cell industry, which has experienced continued increases in sales, is an emerging clean energy industry with the potential for significant growth in the stationary, portable, and transportation sectors. Fuel cells produce electricity in a highly efficient electrochemical process from a variety of fuels with low to zero emissions. This report describes data compiled in 2008 on trends in the fuel cell industry for 2007 with some comparison to two previous years. The report begins with a discussion of worldwide trends in units shipped and financing for the fuel cell industry for 2007. It continues by focusing on the North American and U.S. markets. After providing this industry-wide overview, the report identifies trends for each of the major fuel cell applications -- stationary power, portable power, and transportation -- including data on the range of fuel cell technologies -- polymer electrolyte membrane fuel cell (PEMFC), solid oxide fuel cell (SOFC), alkaline fuel cell (AFC), molten carbonate fuel cell (MCFC), phosphoric acid fuel cell (PAFC), and direct-methanol fuel cell (DMFC) -- used for these applications.

Economic analysis of CO2 capture from natural gas combined cycles using Molten Carbonate Fuel Cells

High temperature fuel cell stacks of commercially significant power (>100 kW) have emerged during the last 10 years. Five US programs, two Molten Carbonate and three Solid Oxide were recently awarded feasibility study funding from US Department of Energy (DOE) to define products which could achieve at least 70% efficiency to electricity. The Department of Energy believes that these pressurized fuel cell systems will become an important part of the future power generation soruces. In support of these views, Rolls-Royce has joined fuel cell manufacturers to develop pressurized fuel cell plants which can be marketed successfully to end users. In selecting technology which should be supported, RR-Allison considered the following critical issues: technology with US business focus; technology with potential for near term commercialization; and technology which would lead into second generation fuel cell system development over long term. The Rolls-Royce plan is to join the DOE initiative through the pressurized Molten Carbonate program which has been funded as “Molten Carbonate Fuel Cell (MCFC) Product Design and Improvement.” The paper outlines the functional and commercial issues to be evaluated during the proof of concept tests of the first pressurized MCFC power generation package. The key factors to be evaluated during the test program in current order of priority are: • operational stability • power output and system availability • cost reduction potential • system simplification for commercial power generation application • enhanced reliability • power quality • grid interconnection