Office of Fossil EnergySECA Solid State Fuel CellsClean Economic Energy in a Carbon/Water Challenged World

Wayne A. SurdovalTechnology Manager, Fuel CellsNational Energy Technology LaboratoryNational Energy Technology LaboratoryUnited States Department of Energy

Revolutionizing Power Production & Use SECA as a key part of DOE’s Strategy to Reduce Electrical Energy LossesSECA as a key part of DOE s Strategy to Reduce Electrical Energy Losses

Coal GenerationTransmission &

Distribution End-UseLight

CurrentCurrent Technology

35% Efficiency(65% Loss)

31% Efficiency(11% Loss)

4% Efficiency(87% Loss)

SECA SOFC Systems

Solid-State Lighting

SMARTGRID

DOE Programsfor Tomorrow

Coal Generation

>40% Effi i

SECA and other DOE programs can realistically increase

60% Efficiency(40% Loss)

55% Efficiency(8% Loss)

>40% Efficiency(27% Loss)

2

end-use efficiency by more than 10x! (from 4 to >40)

Adapted from AEP, Ohio Fuel Cell Coalition, June 2009

Raw Water Withdrawal Comparison•Percentage of Power from Steam Plant is significantly reduced

1400

•Percentage of Power from Steam Plant is significantly reduced

•Higher fuel cell cycle efficiency reduces water use per unit of coal feed

•Separate fuel and oxidant streams in fuel cell permits use of substantially less cooling water to condense, recycle and reuse process H2O

1200

W t C ti ( l/MWh)

From NETL Bituminous Baseline Study

800

1000

(net

)

Water Consumption (gal/MWh)PC plants: 1000 - 1200IGCC: 600-700Nuclear: 1600NGCC: 500

600

800

Gal

lons

/MW

h (

Supercritical PC2

400

G

2

0

200

IGFC1

IGCC2

3

1 System includes 100% carbon capture and CO2 compression to 2,215 psia2 System includes 90% carbon capture and CO2 compression to 2,215 psia

10

FY 09 Fossil Energy Fuel Cell Program Solid State Energy Conversion AllianceSolid State Energy Conversion Alliance

(SECA)$70

$40

$50

$60

$10

$20

$30SECA FY 09…...$58,000,000

SECA Cost ReductionIndustry SECA Coal Based Systems

Industry

$02000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Request Appropriation

Universities, Small Business

National Laboratories

4

Intellectual PropertyIntellectual PropertyCornerstone of the AllianceCornerstone of the AllianceCornerstone of the AllianceCornerstone of the Alliance

Industry Teams Develop Proprietary Technologies

Research

Non-Exclusive LicensesExceptional Circumstance to Bayh-Dole Act

P t C ll b ti I d t k it ill b fit

ResearchCore Technology Program

• Promotes Collaboration – Industry knows it will benefit

• Limits Research Redundancy – Less Government Dollars

5

• Technology in best designs – Technology isn’t “locked up”

SECA Industry Teams & Major SubcontractorsSubcontractorsCalgary

VersaPowerSystems

6

00076A 10-22-08 WAS

2009 SECA Core Technology & Other Partners

NEXTECH

MATERIALS

NEXTECH

MATERIALS

ANL

7

00076C 6-03-09 WAS

Solid State Energy Conversion Alliance Performance Assessment Rating Tool (OMB)

2010

Stack Cost ~ $175/kW stackStack Cost $175/kW stack

Capital Cost < $700/kW system

Maintain Economic Power Density with Increased Scale ~ 300mW/cm2Increased Scale 300mW/cm2

Mass customization – stacks used in multiple li ti l d ll t

Ref: 2007Goal: 2010

8

applications….large and small systems

SECA Industry TeamsFY 2001 FY 2007FY 2001 – FY 2007

5kW Systems - CompleteSECA Ind str Team Location Protot pe NETL ValidationSECA Industry Team Location Prototype NETL Validation

General Electric Torrance, CA Complete Pass

Delphi Rochester, NY Complete Passp p

Fuel Cell Energy Calgary, BC Complete Pass

Acumentrics Westwood, MA Complete Pass

Si P G Pitt b h PA C l t PSiemens Power Group Pittsburgh, PA Complete Pass

Cummins Power Gen. Minneapolis, MN Complete Pass

Size Efficiency Degradation Availability CostSize Efficiency Degradation Availability Cost

Target 3 – 10 kW 35 (LHV) 4%/1,000 hrs 90%

Aggregate Team Performance

3 – 7 kW 35.4 – 41 % 2%/1,000 hrs 97% $724 - $775/kW

9

Single Cell Module PerformancePlanar Cell - AtmosphericPlanar Cell - Atmospheric

250mw/cm2@ 0 6 V

275mw/cm2@ 0 7V

400mw/cm2@ 0 7V

450mw/cm2@ 0 7V

600mw/cm2@ 0 7V

500mw/cm2@ 0 8V

(x10)

450mw/cm2@ 0.85V

800

0.6 V144 cm2

0.7V144cm2

0.7V144cm2

0.7V144cm2

0.7V144cm2

0.8V144 cm2 550 cm2

200

400

600

800

0

200

2002 2003 2004 2005 2006 2007 2008

System ($/kW) ref 2002

10

How Big are the U.S. Markets?C lCoal

EIA/AEO 2007 New Capacity Forecast

200.0250.0300.0350.0

e A

dditi

ons

W)

0.050.0

100.0150.0

2010 2015 2020 2025 2030

Cum

ulat

ive

(GW

2010 2015 2020 2025 2030

YEAR

New Coal Capacity All New Capacity

SECA Fuel Cells available for installation in 2018New Coal Capacity, 2018 – 2030…….110 GWAverage SECA Fuel Cell Production …. 9.2 GW/yr

11

EIA Annual Energy Outlook (AEO) for 2007 pp. 82-83

Solid State Energy conversion Alliance Fuel Cells Technology TimelineFuel Cells Technology Timeline

2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 20202005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2020

SECA R&DTechnology Solutions and Enabling Technology

SECA Cost Reduction

Validation test Validation test

SECA Coal Based Systems Operate

Single Module Operate Multiple Module (5 MW)

SECA Manufacturing

g(1 MW) Scale

( )Scale with Turbines

$700/kWRef: 2007

250 – 500 MW IGFC

12

Ref: 2007Coal-Based Fuel Cell

Objective

SECA Coal Based Systems near-zero water requirement

99% carbon captureAir AirSeparation

Dry Gas Cleaning

CO2,CO, H2, H2O

Coal

H2O

O2

Anode

Catalytic Gasification

CH4 CO, H2, CH4 O2

CombustorO2

Combustor

O2

CO2

CO, H2, CH4

SulfurRecovery

Anode

Cathode

Air

AirAtmospheric SOFCH2O

Marketable Ash/Slag

By-productMarketable

SulfurBy-product

CO2

Sequestration

Heat Recoverye.g., Expander

• Atmospheric SOFC with catalytic gasification 25 % Methane

EnhancedOil Recovery

Deep SalineAquifer

UnmineableCoal Beds Depleted Oil & Gas

Reservoirs

q• Atmospheric SOFC with catalytic gasification 25 % Methane

• Separate Fuel and Air Streams: Oxy Combustion

• Cycle Efficiency (HHV); 99% Capture

~50% with CO2 Compression

13

~53% w/out CO2 Compression

SECA Coal Based Systems near-zero water requirement

99% carbon captureAir AirSeparation

Gas Cleaning

CO2,CO, H2, H2O

Coal

H2O

O2

Anode

Catalytic Gasification25% CH4 CO, H2, CH4 O2

CombustorO2

Combustor

O2

CO2

CO, H2, CH4

SulfurRecovery

Anode

Cathode

Air

AirPressurized SOFC

Combustor

H2O

Marketable Ash/Slag

By-productMarketable

SulfurBy-product

CO2

Sequestration

Heat Recoverye.g., Expander

• Pressurized SOFC with catalytic gasification 25% Methane

EnhancedOil Recovery

Deep SalineAquifer

UnmineableCoal Beds Depleted Oil & Gas

Reservoirs

q• Pressurized SOFC with catalytic gasification 25% Methane

• Separate Fuel and Air Streams: Oxy Combustion

• No steam cycle – minimal external water requirement

• Cycle Efficiency (HHV); 99% Capture

14

~56% with CO2 Compression

~60% w/out CO2 Compression

Impact of Efficiency on COE

Advanced Power SystemsWith CO2 Capture, Compression and Storage

PC Baseline

IGCC Baseline

IGFC Atmos.

IGFC Press.

Efficiency27 2 32 5 50 0 57 3

yHHV (%)

27.2 32.5 50.0 57.3

Capital Cost2 870 2 390 1 991 1 667

$/kW2,870 2,390 1,991 1,667

Steam Cycle100 37 26 2

% Power100 37 26 2

Cost-of-Electricity¢/kW-hr

11.6 10.6 8.5 7.3

15

¢/kW hrThe Benefit of SOFC for Coal Based power Generation, Report Prepared for U. S. Office of Management and Budget, 30OCT07

Raw Water Withdrawal Comparison•Percentage of Power from Steam Plant is significantly reduced

1400

•Percentage of Power from Steam Plant is significantly reduced

•Higher fuel cell cycle efficiency reduces water use per unit of coal feed

•Separate fuel and oxidant streams in fuel cell permits use of substantially less cooling water to condense, recycle and reuse process H2O

1200

W t C ti ( l/MWh)

From NETL Bituminous Baseline Study

800

1000

(net

)

Water Consumption (gal/MWh)PC plants: 1000 - 1200IGCC: 600-700Nuclear: 1600NGCC: 500

600

800

Gal

lons

/MW

h (

Supercritical PC2

400

G

2

0

200

IGFC1

IGCC2

16

1 System includes 100% carbon capture and CO2 compression to 2,215 psia2 System includes 90% carbon capture and CO2 compression to 2,215 psia

10

For More Information About the DOE Office of Fossil Energy Fuel Cell Program

Websites:www.netl.doe.gov

of Fossil Energy Fuel Cell Program

www.fe.doe.govwww.grants.gov

CDs available from the websiteCDs available from the websiteFE Fuel Cell Program Annual

Report _20089th Annual SECA Workshop

P di

Wayne A Surdoval

ProceedingsFuel Cell Handbook (7th ed.)

Wayne A. SurdovalTechnology Manager, Fuel CellsNational Energy Technology LaboratoryU. S. Department of Energy(Tel) 412 386-6002(Fax) 412 386-4822

17

wayne.surdoval@netl.doe.gov