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Coal-Based SECA Program - FuelCell Energy Inc. 11 th Annual SECA Workshop Pittsburgh, PA July 27-29, 2010 Hossein Ghezel-Ayagh, FuelCell Energy, Inc. Brian Borglum, Versa Power Systems
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Coal-Based SECA Program - FuelCell Energy Inc.

11th Annual SECA WorkshopPittsburgh, PA

July 27-29, 2010

Hossein Ghezel-Ayagh, FuelCell Energy, Inc. y g , gy,Brian Borglum, Versa Power Systems

Presentation Outline

Introduction FCE SECA program team members

SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development

Metric Tests

Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses

Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate

Conclusions

FuelCell Energy (FCE)

• Premier developer of fuel cell technology for stationary power applications• Headquarters in Danbury, CT (USA), with 65,000 ft2 manufacturing facility in

Torrington, CT (USA) • Delivering Direct FuelCell power plants to commercial, industrial and utility g p p , y

customers• Developing large-scale coal-based power plants as well as natural gas

distributed generation (DG) systems utilizing planar SOFC • Established commercial relationships with major distributors in the p j

Americas, Europe, and Asia

MW Cl F l C ll P d tTorrington, CT - Manufacturing Facility MW-Class Fuel Cell Products

SECA Coal-Based Systems Program

Program ObjectivesDevelopment of large scale (>100 MWe) coal-based SOFC systems with:systems with:

At least 50% electrical efficiency from coal (higher heating value) Performance to meet DOE specified metrics for power output, degradation availability and reliabilitydegradation, availability, and reliability Fuel cell power island factory cost <$400/kW (2002 USD) More than 90% of carbon capture from coal syngas as CO2, for sequestration

Program Status FCE team successfully completed Phase I of the Coal Based SECA

Reduced water consumption as compared to the existing coal power plant technologies

FCE team successfully completed Phase I of the Coal Based SECA Program in December 2008. Phase II work is focused on further development of cost-effective, multi-MW size SOFC power plant system to operate on coal syngas fuel, with y y gnear zero emissions.

Phase II SECA Coal-Based Program Team

The FCE team is comprised of diverse organizations with expertise in key functional areas:

FuelCell Energy Inc. (FCE), Danbury, CT Manufacturing and commercialization of fuel cell power plant systems in sizes ranging from 300kW to Multi-MWto Multi MW.

Versa Power Systems Inc. (VPS), Littleton, CO Solid Oxide Fuel Cell (SOFC) development and manufacturing technologies.

Pacific Northwest National Laboratory (PNNL), Richland, WA SOFC cell and stack computational modeling.

WorleyParsons Inc. (WP), Reading, PA Design of the power plant, including: integration with gasifier and syngas clean-up technologies, system levelgasifier and syngas clean up technologies, system level costing, and system performance analysis.

VPS Planar SOFC Cell and Stack Technology

• Anode supported cells (up to 33 x 33 cm2)• Capable of operating from 650°C to 800°C

F iti t i l t l h t t l i t t• Ferritic stainless steel sheet metal interconnect • Cross-flow gas delivery with manifolds integrated into

the interconnect but not through the cell• Compressible ceramic gasket sealsCompressible ceramic gasket seals • Standardized stack blocks configurable into stack

towers for various power applications

CathodeCathode

Anode

Electrolyte

Anode

Electrolyte

Presentation Outline

Introduction FCE SECA program team members

SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development

Metric Tests

Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses

Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate

Conclusions

SECA Coal Based Program Plan for IGFC Development

• FCE is currently engaged in development of stack tower and SOFC power module configurations suitable for large scale coal based power plants.

5 MW Proof of Concept

≥ 250 kWModule Demonstration Unit

>25 kW Stack Tower

10 kW Stack

Unit

2008 2010 2012 2015

Ph IIIPhase IIPhase I Phase IIIPhase IIPhase I

SECA SOFC Development Path

Develop SOFC stack technology that meets the performance & cost objectives, is scalable, and is used as the building block for assembling

t k t d l l d l

Endurance

Performance

Stack

stack towers and large-scale power modules.

MW-scale Proof-of-Concept Plant

2010

Stack Tower

Scal

able

of-Concept Plant

10-20 kW Stack SOFC Stack

Module2006

2008

1 kWStack

Module2006

Modular

Presentation Outline

Introduction FCE SECA program team members

SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development

Metric Tests

Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses

Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate

Conclusions

Cell Development Objectives

• Performance:> High performance over a wide operating

window> Capability for in-stack reforming (DIR)> Accommodation of load following

• Durability: > Degradation rate of less than 0.2% per

1000 hours over a wide operating window (temperature, fuel utilization and current density)

Cost

Durabilit

Performany)

> Robustness for thermal cycles and rapid load transients

• Cost:

ty nce

> Scalability to facilitate large stack and power module

> Reduction of materials usage> Improvements in cell fabrication process> Improvements in cell fabrication process

technology

Recent Achievements in Cell Fabrication Process

• Established fabrication process capabilities for large area cells

C ll t 1000 2 (33 33 2) i i

Tape Casting

> Cells up to 1000 cm2 (33 x 33 cm2) in size were produced using TSC cell manufacturing process

• Developed and implemented the nextDeveloped and implemented the next generation of cell fabrication processes

> Cell thickness was reduced by more than 40%

Screen Printing• Fabricated > 4000 cells (25 x 25 cm2)

> Production volume of 500 kW (annual) was established

USLLSL

Process Capability Analysis for Y-ave

StDev (Overall)StDev (Within)Sample NMeanLSLTargetUSL

0.8756790.749099

750253.243250.000

*258.000

Process Data

Within

Overa

Co-sintering258256254252250

PPM TotalPPM > USLPPM < LSL

PPM TotalPPM > USLPPM < LSL

PPM TotalPPM > USLPPM < LSL

PpkPPLPPUPp

Cpm

CpkCPLCPUCp

( )

106.1 0.0

106.1

7.46 0.00 7.46

1333.33 0.00

1333.33

1.231.231.811.52

*

1.441.442.121.78

Exp. "Overall" PerformanceExp. "Within" PerformanceObserved PerformanceOverall Capability

Potential (Within) Capability

Third Generation of Cell Technology (TSC-3)

0.7

0.8 Cell Performance at 740 mA/cm2: TSC2 vs. TSC3

850

900

950

16%

18%

20%

Cell Performance at 740 mA/cm2: TSC2 vs. TSC3

850

900

950

16%

18%

20%

0 5

0.6

650

700

750

800

Volta

ge (m

V)

8%

10%

12%

14%

Impr

ovem

ent

650

700

750

800

Volta

ge (m

V)

8%

10%

12%

14%

Impr

ovem

ent

T

0.4

0.5

ASR

(ohm

.cm

2) TSC 2

500

550

600

650

650°C 700°C 750°C 800°C0%

2%

4%

6%

500

550

600

650

650°C 700°C 750°C 800°C0%

2%

4%

6%

TSC 3

TSC 2

0.2

0.3

A

TSC 3

TemperaturesTemperatures

0.1 Significant ASR reduction below 700°C

0650 670 690 710 730 750 770 790

Temperature (°C)

Single Cell Performance Enhancement

Performance Curves

1.100.70

10 X 10 cm2 Cell. Stainless Steel Current Collectors. Cross-Flow Gas Delivery.Fuel: H2 + 3%H2O; Oxidant: Air, 650 – 800°C

0 90

1.00

0.50

0.60

cm2

0.80

0.90

olta

ge, V 0.40

Den

sity

, W/c

0.60

0.70Vo

0.20

0.30

Pow

er D

0.40

0.50

0.00

0.10800 - V 750 - V 700 - V 650 - V800 - P 750 - P 700 - P 650 - P

0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80

Current Density, A/cm2

Single Cell Stability Achievements

1.200

OVERALL:21 V 7392 h

0.800

1.00021 mV over 7392 hrs2.84 mV or 0.28% / 1000 hrs

0.600

Volta

ge, V

0.400

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature: 750°C

0.000

0.200Furnace Temperature: 750 CFuel: 55 H2:45 N2 + 3% H2O, Uf = 50%Oxidant: Air, Ua = 25%Current: 40.5 A (0.5 A/cm2)

0 1000 2000 3000 4000 5000 6000 7000 8000

Elapsed Time, hrs

Progress in Cell Scale-Up

33 x 33 cm2

550 cm2

25 x 25 cm2

350 cm2

10 x 10 cm212.5 x 12.5 cm2

20 x 20 cm2

81 cm2 121 cm210 x 10 cm2

Presentation Outline

Introduction FCE SECA program team members

SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development

Metric Tests

Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses

Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate

Conclusions

Stack Design Approach

• Utilized a model-driven design approach using both CFD and FEA to resolve thermo-mechanical challenges

• Followed a progressive modeling path from single cell, short stack, full size stack block, and finally to stack towerValidated the models using component and stack test results• Validated the models using component and stack test results

• Provided valuable information for engineering team to accomplish component development

°C

Fi

Ai

SOFC Stack Evolution

10 kW64-CellPhase 1(2008)

18 kW92-CellPhase 2

25 kW120 C ll

16 inches(41 cm)

24 inches(61 cm)(2008) Phase 2

(2010)120-CellPhase 2(2010)

(61 cm)

Stack Scale-up and Maufacturing Progression

Phase 1StackSize

Power (kW/stack) Quantity Total Power

(kW)

6 cells 1 21 21

16 cells 2.5 18 45

64 cells 10 6 60

Total 45 126

Stack Power Total PowerStackSize

Power (kW/stack) Quantity Total Power

(kW)

16 cells 2.5 42 105

32 cells 5 1 5

Phase 2

92 cells 18 7 126

120 cells 25 1 25

Total 51 261

Stack Performance Enhancement16-Cell Stack

1.1 100%Uf (%) Phase 1 Phase 2 Gain

50 0.823 0.886 7.7%

60 0 817 0 879 7 6%

1

80%

90%60 0.817 0.879 7.6%

70 0.804 0.866 7.7%

80 0.785 0.847 7.9%

0.9

tage

(V)

70%

80%

lizat

ion

(%)

Volt

60%

Fuel

Uti

0.8

50%Cell 01 Cell 02 Cell 03Cell 04 Cell 05 Cell 06Cell 07 Cell 08 Cell 09Cell 10 Cell 11 Cell 12

Test Stand Temperature: 700°C Cell Active Area: 550 cm2

25% In-stack reforming

0.723.50 24.50 25.50 26.50 27.50 28.50 29.50

Elapsed Time (hours)

40%

Cell 13 Cell 14 Cell 15Cell 16 uf

25% In stack reformingCurrent Density: 0.388 A/cm2

Stack Peak Power AchievementGT057235-0057 TC1

16-cell StackCell Active Area: 550 cm2

500 6

400

450

4.5

5

5.5

300

350

rent

(A)

3

3.5

4

wer

(kW

)

200

250Cur

r

1.5

2

2.5 Pow

Peak Power Testing – Coal Syn GasFurnace Temperature: 700°C

Peak Power Testing – NG-basedFurnace Temperature: 685°CFuel: 33.6% H2, 21.5% N2, 12.5% NG, 32.4% H2OIn-stack reforming = 60%, Uf = 70%Oxidant: Air, Ua = 15%C t 320 A (0 582 A/ 2 0 467 W/ 2)

100

150

0

0.5

1Furnace Temperature: 700 CFuel: 29.5% H2, 1.6% N2, 38.2%CO2, 6.7% NG, 24.1% H2O, In-stack reforming = 48%, Uf = 54%Oxidant: Air, Ua = 15%Current: 250 A (0.455 A/cm2, 0.365 W/cm2)

Current: 320 A (0.582 A/cm2, 0.467 W/cm2)

2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00

Elapsed Time (hours)

1 200

Stack Endurance Achievement

1.000

1.200

All Cells TC0 +TC15.6mV (0.64%) / 1000hrs @4206 hrs

0.800

tage

(V)

( %) @

0 400

0.600

Ave

rage

Cel

l Vol

0.200

0.400A

Thermal CycleCell Count: 32Cell Active Area: 550 cm2

Furnace Temperature: 700°CFuel: In-stack reforming = 25% Uf = 61 5%

0.000

0

500

1000

1500

2000

2500

3000

3500

4000

4500

Fuel: In-stack reforming = 25%, Uf = 61.5%Oxidant: Air, Ua = 13.5%Current: 213 A (0.390 A/cm2)

2 2 3 3 4 4

Elapsed Time (hours)

Stack Scale-Up Status (Phase II)92-Cell Stack (GT058011-1)

1

1.2

Thermal Cycle1.2

Thermal Cycle

0.8

1

olta

ge (V

)

80% Fuel Utilization

0.8

1

tage

(V)

C ll Si 25 25 2

0.4

0.6

Ave

rage

Cel

l Vo

Cell Count: 92

80% Fuel Utilization

0.4

0.6

vera

ge C

ell V

ol 80% Fuel Utilization

Cell Size 25 x 25 cm2

Active Area 550 cm2

Number of Cells 92

0

0.2

A Cell Count: 92Cell Active Area: 550 cm2

Furnace Temperature: 710°CFuel: In-stack reforming = 25%, Uf = 61.5%Oxidant: Air, Ua = 13%Current: 200 A (0.364 A/cm2)

(June 2010)

92-Cell Stack (GT058011-1)0.2

Av

Cell Count: 92Cell Active Area: 550 cm2

Furnace Temperature: 710°CFuel: In-stack reforming = 25%, Uf = 61.5%Oxidant: Air, Ua = 13%Current: 200 A (0.364 A/cm2)

(June 2010)

92-Cell Stack (GT058011-2)

35.00 40.00 45.00 50.00 55.00 60.00 65.00 70.0000.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00

Elapsed Time (hours)

00.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00 55.00 60.00 65.00 70.00

Elapsed Time (hours)

Stack Development Status

80

Fuel Utilization100%

40

60 In-Stack Reforming100%

Cost @ SECA Volume100$/kW

20060

80150

20

200

20

10

40

15

5

250

300

Stack Block Power25 kW

Current Density

2

1000 mA/cm2

600

0 8

420

0.7

15

30.75

400

800

Phase 2 TargetPhase 2 Status

Phase 1 Level

Degradation0%/1000 h

Operating Cell Voltage – BOL0.9 V

0.8

10.85

Stack Tower Testing

2009 2010

3 x 64-cell stacks 2 x 92-cell stacks

• Thermally self-sustaining test environment (gas preheated only)

SO-30-1 Tower Assembly SO-30-3 Tower Assembly

• Thermally self-sustaining test environment (gas preheated only)• Provisions for simulated anode gas representative of both syngas and

natural gas fueled systems• Providing valuable lessons for future larger stack module designsg g g

Stack Tower (SO-30-3) Test

35000

40000

45000

50000

200

250PowerTotal Voltage

20000

25000

30000

35000

Pow

er/ W

100

150

Stac

k Vo

ltage

/ V

0

5000

10000

15000

0

50

• Demonstration of stack tower operation in a simulated power plant environment,

0 200 400 600 800 1000 1200Runtime/ Hr

using 2x92-cell stack blocks.• A Power Rating of 30 kW was established

during the operation.

Next Steps – Metric Tests

SECA Phase II Metric Test Minimum Requirements:• Stack power rating 25 kW• Degradation rate < 2%/1000 hrs• Endurance tests: 1,500h in Phase II plus 3,500h in Phase III (5000h total)

2x92-Cell Stack Tower

120-Cell Stack

20 inches(51 cm)

120-Cell Stack

24 inches(61 cm)

Two pronged approach:Two pronged approach: A 120-cell stack block at VPS and a 2x92-cell stack tower at FCE

Initial Performance (June 2010) 120-Cell Stack (GT058027-1)

GT058027-0001120-cell Stack

Cell Active Area: 550 cm2

300 30

250 27.5

150

200

Cur

rent

(A)

22.5

25

wer

(kW

)

0.455 A/cm2

Furnace T: 700°CPeak Power Testing

Furnace Temperature: 700°CFuel: 33.6% H2, 21.5% N2, 12.5% NG, 32.4% H2O

100Stac

k C

20

Pow

0.364 A/cm2Normal Operating Conditions (NOC)

Furnace Temperature: 715°C

In-stack reforming = 60%, Uf = 65%Oxidant: Air, Ua = 15%Current: 250 A (0.455 A/cm2)

0

50

15

17.5Furnace T: 715°Cp

Fuel: 25.2% H2, 22.4% N2, 14.5% NG, 37.8% H2OIn-stack reforming = 70%, Uf = 68%Oxidant: Air, Ua = 15%Current: 200 A (0.364 A/cm2)

Future5000 hr Tests

130 132 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 164

Elapsed Time (hours)

Phase II Stack Tower Metric Test at FCE

250

32.5

35CurrentPower

Peak Power200

A 27 5

30

ea o e

Start of long term hold @ NOC

100

150

ack

Cur

rent

/ A

25

27.5

Pow

er/ k

W

g @

Future5000 hr Tests

50

100Sta

20

22.5

0

50

15

17.5Fuel: Simulated Syngas System Fuel, 6.5% CH4, 24.0% H2, 45.3% CO2, 22.4% H2O, 1.8% N2

150 160 170 180 190 200 210 220 230 240 250Runtime/ hr

Presentation Outline

Introduction FCE SECA program team members

SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development

Metric Tests

Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses

Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate

Conclusions

SOFC Module Evolution

30 kW2-Stack Tower

30-kW Tower Assembly (Phase II)

Stack Block

SOFC Stack Modules Assembly (Phase III)

250 kW2 Q d

125 kW4 Stack Tower

60 kW4 Stack 2-Quad

Module4-Stack Tower Quad

4-Stack Quad

250kW SOFC Power Plant

MW-Class SOFC Module Design

Presentation Outline

Introduction FCE SECA program team members

SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development

Metric Tests

Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses

Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate

Conclusions

Improved Coal-Based SOFC System with Catalytic Gasification

POWER GENERATION SUMMARY kW % Q input % MW grossFuel Gas Expandors Gross Power @ 20 kV 49 750 7 04% 10 96%Fuel Gas Expandors Gross Power @ 20 kV 49,750 7.04% 10.96%Fuel Cell Inverter AC Gross Power @ 20 kV 362,134 51.28% 79.78%WGCU Off Gas Expander Gross Power @ 20 kV 7,024 0.99% 1.55%Steam Turbine Gross Power at Generator Terminals @ 20 kV, 35,019 4.96% 7.71%

Total Gross Power Generation @ 20 kV 453,927 64.27% 100.00%

Total Auxiliary Load 39,342 5.57% 8.67%

Net Power Output at 345 kV 414,585 58.70% 91.33%Net Efficiency Excluding CO2 Compression & Thermal InputCoal feed lb/h 202 980Coal feed, lb/h 202,980Coal HHV (AF), Btu/lb 11,872Coal Thermal Input, kWth 706,255 100.00% 155.59%Net Plant Efficiency (HHV) 58.70%

Combined with high methane producing gasification, coal based atmospheric-pressure SOFC systems are capable of achieving ~ 59% efficiency and 99+% carbon captureefficiency and 99+% carbon capture.

Baseline SOFC Power Plant Electrical Efficiency vs. Competing Technologies

60%

70%

al)

58.70%Value of CO2 Compression

30%

40%

50%

ncy

(% H

HV c

oa

32.50% 31.70% 32.00% 28.20%

54.79%

27.20%10%

20%

30%

Net E

ffici

en

0%IGCC

GE-E w/SelexolCO2 cap.

IGCCCoP w/Selexol

CO2 cap.

IGCCShell w/Selexol

CO2 cap.

PCSupercritical

w/Amine

PCSupercriticalw/Oxy-comb.

AdvancedIGFC

Cat. Gasifier

Baseline coal based SOFC system is >22 percentage points more efficient than IGCCs and Pulverized Coal (PC) Steam plants.

References for Competing Technologies:

CO2 cap. CO2 cap. CO2 cap. w/AmineCO2 cap.

w/Oxy comb.CO2 cap.

Cat. GasifierZnO

* Cost and Performance Baseline for Fossil Energy Plants, Volume 1 - Bituminous Coal and Natural Gas to Electricity, DOE/NETL-2007/1281, Revision 1, August 2007** Pulverized Coal Oxycombustion Power Plants, Volume 1 - Bituminous Coal to Electricity, DOE/NETL-2007/1291, Final Report, August 2007

Baseline SOFC Power Plant Water Consumption vs. Competing Technologies

1,139

1000

1200

h ne

t

683 672721

792

600

800

mpt

ion

Gal

/MW

h

260

200

400

Wat

er C

onsu

m

0IGCC

GE-E w/SelexolCO2 cap

IGCCCoP w/Selexol

CO2 cap

IGCCShell w/Selexol

CO2 cap

PCSupercritical

w/Amine

PCSupercriticalw/Oxy-comb

AdvancedIGFC

Cat Gasifier

Baseline coal based SOFC system requires significantly less water than IGCCs and Pulverized Coal (PC) Steam Turbine Power Plants.

References for Competing Technologies:

CO2 cap. CO2 cap. CO2 cap. w/AmineCO2 cap.

w/Oxy comb.CO2 cap.

Cat. GasifierZnO

* Cost and Performance Baseline for Fossil Energy Plants, Volume 1 - Bituminous Coal and Natural Gas to Electricity, DOE/NETL-2007/1281, Revision 1, August 2007** Pulverized Coal Oxycombustion Power Plants, Volume 1 - Bituminous Coal to Electricity, DOE/NETL-2007/1291, Final Report, August 2007

H2 Co-Generation System Concept

• 138 ton/day H2 Produced• 48.2% Net Electrical Efficiency• 67.4% Total Efficiency (Electrical + H2)y ( 2)

Stack Cost Reduction

SOFC Stack Block Cost Reduction (2002 USD)

$197$210

$250

$/kW t AC

96-cell Stack:

$2,857 (2002 USD)

$197

$119

$153

$116$150

$200$/kW net AC$/kW gross DC

$93

$116

$50

$100

Labor $148

Other, $52018%

$0Phase I 2009 Interim 2010

Thi C ll D l tLabor, $1485%

Stack Block Scale Up

Stack Materials Reduction

Thin Cell Development

Materials, $2,18977%

Stack Block Scale Up

Power Density Improvements

Factory Equipment Cost Estimate

Steam Turbine18 $/kWFuel Cell Piping

Fuel Cell Enclosure 17 $/kW

6%

HRSG63 $/kW

22%

Phase I Cost Estimate: 597 $/kW (2002 USD)

Fuel Cell

BOP Water Systems7 $/kW

2%

$6%

Fuel Cell Piping36 $/kW

9%

Blowers

Fuel Cell Stacks

$197/kW,33%

Balance-of-Plant (BOP)

$400/kW, 67%

Electric Accessories10 $/kW

3%

2%o e s6 $/kW

2%

Expanders40 $/kW

67%

Heaters & Coolers44 $/kW

15%Inverter48 $/kW

16%

Instrumentation & Control8 $/kW

3%

40 $/kW13%

Phase II Interim Cost Estimate: 390 $/kW (2002 USD)

Balance-of-

Fuel Cell Stacks$93/kW,

29%

Cost estimation is based on two 570 MW nominal power plants manufactured per year (2002 USD).

Estimate includes Factory Equipment costs for the Power Island, exclusive of gasification, syngas l d CO ti / i tBalance of

Plant (BOP) $297/kW,

71%

cleanup, and CO2 separation/compression systems.

Baseline SOFC Power Island

SOFC power island includes:> 8 Sections of 42 fuel cell stack modules > Steam turbine> Two syngas expanders

Layout of 42-Module SOFC Cluster

SOFC Stack Module

Air Heater

Anode Recycle Blowers

& ExhaustBlowers

Air

DC-AC Inverters

Air Blower

SOFC cluster design takes advantage of modularity of fuel cells.

IGFC Site Layout

Representative Foot Print Comparison: IGFC & IGCC

IGFC IGCC

• A similarly sized (MW) IGCC and IGFC will be comparable in real estate requirement.real estate requirement.

Presentation Outline

Introduction FCE SECA program team members

SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development

Metric Tests

Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses

Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate

Conclusions

Summary of Recent Achievements

• Demonstrated new TSC3 cell with ASR less than 0.35 ohm·cm2 at 650°C and a degradation rate of less than 0.3% per 1000 h at 750°C (on-going test of over 7,000 h)

• Established cell manufacturing processes for the new baseline TSC3 cell with an active

f 550 2 (25 25 2)area of 550 cm2 (25 x 25 cm2)

• Demonstrated performance and pendurance improvements in scaled up stacks with TSC3 cells

• Developed a 92-cell stack block that produces 18 kW and has beenproduces 18 kW and has been successfully tested in a 2 x 92-cell stack tower

• Demonstrated 25 kW from a 120-cell stack

Summary of Recent Achievements

• Baseline Systems with Catalytic Gasifier were developed which could achieve electrical efficiency (HHV) of 59% and remove more than 99% carbon from syngas.B li 400 600MW l t l t d F t C t E ti t• Baseline 400-600MW power plant layout and Factory Cost Estimates were developed resulting in an interim cost estimate of $390/kW (in 2002 dollars) for the SOFC power island.

• The developed IGFC system showed significantly lower water consumption p y g y pas compared to IGCC and other coal fueled power plants.

Acknowledgements

Support for FCE’s SECA Coal Based Program provided by the US Department of Energy (DOE) through the co operati e agreement DE FC26 04NT41837co-operative agreement DE-FC26-04NT41837

Support and guidance by the management team at NETL

Thank You!


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