The Fuel Cell Expertise Network is an initiative of Kiwa and Energy Matters
FCEN Member meeting
26 March 2012, Apeldoorn
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Program
12.00 – 12.45 Lunch
12.45 – 13.00 Introduction & goals13.00 – 13.30 Short updates from Members
13.30 – 14.30 Market research results - FC Expertise Network
14.30 – 14.45 Short break
14.45 – 15.15 Innovation in thermal storage - Flamco
15.15 – 15.45 Fuel Cell test projects - Alliander15.45 – 16.30 Discussion – focus & strategy FCEN
16:30 – 17:30 Drinks
Introduction
Fuel cell Expertise Network today
We invite you to:participate and share your latest updates on technology, market and/or policy issues
Learn about first research results FCEN
Discuss tomorrows challenges & activities FCEN
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FEN first results
Basis for comparison – three FC mCHP systems
Technical issues
Market potentialMarket sizes
Cost price development
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Energetic performances of FC mCHP in general
Electrical vs. thermal efficiency
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PEMSOFCStirlingGas Engine100%
Fuel cells compared to other technologies
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Anonymous systems overview
System A B C D E F G H I J K
Type PEM SOFC
E-power [kW] 1 1 0.75 0.7 1 1 1.5 1 0.8 1 0.7
Th-power [kW] 1.2 1.3 1.1 1 1.7 0.74 0.5 2.5 1.1 2 0.7
E-efficiency [%] 33 37 35 36 32 50 60 28 34 30 45
Total efficiency [%] 80 89 85 86 85 87 80 90 85 88 87
System current lifetime design
N/A N/A 40k 60k >20k 60k N/A N/A N/A N/A 30k
Expected current stack lifetime
N/A N/A 40k 30k >40k 30k N/A N/A N/A >16k 30k
Modulation [%] 25 30 N/A 35 30 15 30 30 N/A N/A N/A
Annual start/stops 50 N/A N/A 1000 100 N/A 0 3 Several Several N/A
System volume [l] 450 270 290 250 580 170 440 480 N/A N/A 160
Weight [kg] 200 125 125 104 230 105 195 170 N/A N/A 90
Auxiliary boiler integrated?
No No No No Yes No No Yes Yes No No
Three typical FC mCHP systems
Why three systems?To compare different systems and to give an accurate representation of the available technologies in our calculations
Systems can be distinguished by:Electrical efficiency
Thermal efficiency
Control / load strategy
Modulation rate
Flow temperature available heat @ 30ºC return temperature
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PEMFC SOFC
Modulation Yes limited
Cold start time < 2 hours >20 hours
Thermal cycles over 50 / year 0 - few / year
Electrical efficiency 30-38% 28-60%
Max. temp coolant 65 ºC 100 ºC
Current life time 20k-40k hour (goal: >60k) 6k-25k hour (goal: >60k)
Three typical FC mCHP systems
General requirements;DHW: ca. 3500 kWh = 400 watt continuously
Thermal output of FC’s is too low to provide heating by itself à auxiliary heating is always necessary.
Space heating: is the temperature level high enough for conventional systems?
Our proposalElectricity load following, domestic hot water production, DHW + space heating
Default values for calculation: electrical efficiency 35% and 50% @ overall 85%
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System 1: Electricity following heating system
Heating system
High electricity production
Much modulation required
Requires thermal storage
Example: Ceres SOFC
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System 2: Domestic hot water production
Add-on electricity generator to existing heating system
High electricity production adapted to demand
Steady operation, might depend on thermal storage capacity
Example: CFCL BlueGen
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System 3: Heating system
Heat demand following
Auxiliary boiler
Electricity is by-product
Relative steady operation, average
modulation required
Bottleneck: low heat demand in summers
Requires modulation / start & stop / thermal storage
Example:
Baxi Gamma 1.0
Thermal (integration) considerations
DHW and space heating? Dependents on efficiency.
Optimizing thermal efficiency:Retrieve thermal losses of components (inverter, controller, blowers,…)
Optimize heat exchanger
Coolant flow temperature control improves thermal efficiency andstorage capacity
Return temperature affects thermal efficiency
High flow temperature is more usable and better for storage
Low flow and small ΔT improves heat transfer in storage
Maintain temperature level by smart buffer configurationMake optimal use of thermal layering/temperature levels
New storage techniques can reduce size and increase capacity (PCM)
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Areas of attention
Compact system (wall-hung?)
Heat storage: reduce required storage sizeSmart integration in dwellings
Improved storage techniques.
Reduce thermal output by increasing electrical efficiency
Varying gas qualityIncreasingly feed-in of biogas, LNG, Hydrogen, various types of NG
Gas quality measurement required? (small scale Wobbe meter)
L-gas: NH3 removing (PEMFC tolerates <1ppm NH3).
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Market potential
Technical market potential dependent on several factors:Availability gas infrastructure (also hydrogen)
Type of fuel cell application, dependent on temperature level usable heat
Available space à space for buffer?
Wall hung / floor standing
Outdoor / indoor application
Weight (attic installation)
Implementation other system options (solar thermal, PV, heat pump)
Market potentialOperational revenues
Policy: energy neutral buildings and subsidies
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Floor standing or wall hung?
Wall hung (x1000)
Total 52.72M
Floor standing (x1000)
Total 14.97MData from 2004. Source: Eco-design Boilers, Task 2, final | 30 September 2007 | VHK for European Commission
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Market potential FC in Europe
First focus; NL, DE, UKMature markets for boilers
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NL DE UK
Number of households # 7 572 727 38 928 571 27 147 826
Gas connected HH % 84% 37% 71%
Number of gas connected HH # 6 361 091 14 403 571 19 274 957
Number of boilers installed # 6 000 000 9 000 000 20 000 000
Wall hung boilers % 96% 40% 75%
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Market potential FC in Europe
Heat consumption households
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NL DE UK
Heat consumption toe/year*HH 0,95 1,45 1,00
GJ/year*HH 39,8 60,7 41,9
Space heating % 80% 86% 70%
Water heating % 18% 11% 26%
Cooking/other % 2% 3% 4%
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Market potential
Discussion: market potential:
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DHWElectricity following
DHW + space heating
+ add-on-Combisystems + large heat
replacement market+ Combi systems+ >> CO2-impact Large stack optional
+ E-capacity needed- Less operating hours? New business model- Combi systems
Market potential
Economic potential -> primarily driven by cash flow generation
Simulation of 3 control strategies;1. Electricity load following, heat vented when not usable
2. Domestic hot water (DHW) load following, electricity can be exported
3. DHW + space heating load following, electricity can be exported
Assumptions;1 kWe stack à 35% and 50% electrical and 85% overall
Individual house2400 m3 gas consumption for heat use à 21600 kWh
400 m3 gas consumption for domestic hot water à 3600 kWh
5000 kWh
All produced electricity is used behind-the-meter
No costs effects of reduced (local) grid losses
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• Control strategy determines # of full load hours à cash flow
• DHW + Space heating controlled most beneficial in both cases à best heat use
• Overcapacity thermal of 35% FC leads to a relative low cash flow
• Domestic hot water demand important factor
Market potential
Overall efficiency % 85%Electrical efficiency FC % 35% 50%Full load hours Electricity controlled hr/year 5000 5000
Domestic Hot water hr/year 3077 6280DHW + Space heating hr/year 5672 7412
Savings on energy costs (excl. subsidies) Electricity controlled €/year € 473 € 643 Domestic Hot water €/year € 360 € 807 DHW + Space heating €/year € 666 € 954
Market potential
Effect of higher overall efficiencyIn electricity controlled operation
Higher energy savings due to more heat production FC and less heat requirement of boiler
In heat controlled operation Lower energy savings due to less full load hours, less electricity production
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Overall efficiency % 90%Electrical efficiency FC % 35% 50%Full load hours Electricity controlled hr/year 5000 5000
Domestic Hot water hr/year 2797 5495DHW + Space heating hr/year 5520 6986
Savings on energy costs (excl. subsidies) Electricity controlled €/year € 490 € 675 Domestic Hot water €/year € 353 € 742 DHW + Space heating €/year € 699 € 944
Overall efficiency % 85%Electrical efficiency FC % 35% 50%Full load hours Electricity controlled hr/year 5000 5000
Domestic Hot water hr/year 3077 6280DHW + Space heating hr/year 5672 7412
Savings on energy costs Electricity controlled €/year € 473 € 643 Domestic Hot water €/year € 360 € 807 DHW + Space heating €/year € 666 € 954
Market potential
Effect of subsidy on electricity production 5 €ct/kWhIn all cases beneficial
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Overall efficiency % 85%Electrical efficiency FC % 35% 50%Full load hours Electricity controlled hr/year 5000 5000
Domestic Hot water hr/year 3077 6280DHW + Space heating hr/year 5672 7412
Savings on energy costs Electricity controlled €/year € 729 € 898 (incl. subsidy 5,11€ct/kWh) Domestic Hot water €/year € 517 € 1 128
DHW + Space heating €/year € 956 € 1 332
Overall efficiency % 85%
Electrical efficiency FC % 35% 50%
Full load hours Electricity controlled hr/year 5000 5000
Domestic Hot water hr/year 3077 6280
DHW + Space heating hr/year 5672 7412
Savings on energy costs Electricity controlled €/year € 473 € 643
Domestic Hot water €/year € 360 € 807
DHW + Space heating €/year € 666 € 954
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Cost price development
What is a feasible mass produced cost price across different manufacturers?
How is the cost price build up in components?Assumptions need to be challenged
Cells < 5% cost price?
stack 30% cost price?
Rare earth metals < 2%, depending on type?
What learning curves have we already seen?
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Cost price learning curve
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Cost price development
FCEN wants to establish a more accurate vision on possible cost price development in perspective of mass production.
We want to gather information concerning:Global indication material costs
Global indication of cost reduction options
Cell price development
Output: an (anonymous) substantiation of fuel cell development
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Program
12.00 – 12.45 Lunch
12.45 – 13.00 Introduction & goals13.00 – 13.30 Short updates from Members
13.30 – 14.30 Market research results - FC Expertise Network
14.30 – 14.45 Short break
14.45 – 15.15 Innovation in thermal storage - Flamco
15.15 – 15.45 Fuel Cell test projects - Alliander15.45 – 16.30 Discussion – focus & strategy FCEN
16:30 – 17:30 Drinks
Discussion
What is needed for the next step?Strengthening technology concepts
Creating demand in (niche) markets
Attracting new capital for expansion
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Are policy makers and investors convinced already? Energy potential
Fossil based generation
Energy neutral options
Technological feasibility
Niche markets: Combining FC mCHP with sustainable technologies?E-vehicles
E-heat pumps