SECA Coal-Based System Program library/events/2006/seca/Minh-SECA.pdf · SECA Coal-Based System...

SECA Coal-Based System Program

Nguyen MinhGE Global ResearchTorrance, CA

7th Annual SECA Workshop and Peer Review MeetingPhiladelphia, PASeptember 12-14, 2006

2SECA Coal Based Systems

7th SECA Annual Workshop September 2006

SECA Coal Based System Program

• Completed SECA SOFC Program Phase I September 2005 and started SECA Phase II

• Initiated SOFC Coal Based Power Systems Program September 2006• Combined the two programs into the program “SECA Coal based

System”



SECA Coal Based System Program -Overview

Program Summary

Period of Performance: Phase I: 2.75 years (1/2006 - 9/2008)Phase II: 2 years Phase III: 5 years

GE Team: GE - GE Global Research and GE EnergyUniversity of South CarolinaPacific Northwest National Laboratory

Program Objective• Resolve identified barrier issues concerning SOFC technology and demonstrate SECA prototype

systems and a SOFC building block stack for multi-MW system applications• Develop and optimize a design of a large-scale (>100 MW) integrated gasification fuel cell (IGFC) power

plant incorporating a SOFC and a gas turbine (GT) in a hybrid system that will produce electrical power from coal. The system will be:

- Highly efficient (>50% HHV), Environmentally friendly (90% CO2 separation), and Cost-effective ($400/kW projected factory cost, exclusive of coal gasification and

CO2 separation subsystems).• Design, manufacture and test a proof-of-concept (POC) system derived from the IGFC design that

demonstrates operation with the required performance characteristics.



Program Features

PHASE I PHASE II PHASE III

CostEstimate

CostEstimate Demo Of Stack

Suitable For Hybrid

IGFC & Proof-of-Concept Design

Concepts

SOFC Module Demo

IGFC & Proof-of-Concept

Designs

Installation of Proof-of-Concept System

Long-term Operation / Life Demo

Field test of Proof-of-Concept System

Resolution of SOFC technical barriers, performance, hybridization, scale-up,

degradation

IGFC & Proof-of-concept system design development

IGFC & Proof-of-concept designs

Technology improvement & SOFC module development

Manufacture, installation of Proof-of-concept system

Operation, demonstration, performance evaluation, and

long-term / life testing

PHASE I PHASE II PHASE III

CostEstimate

CostEstimate

CostEstimate

CostEstimate Demo Of Stack

Suitable For HybridDemo Of Stack

Suitable For Hybrid


Concepts


Concepts

SOFC Module Demo

SOFC Module Demo


Designs


Designs







Resolution of SOFC technical barriers, performance, hybridization, scale-up,

degradation

IGFC & Proof-of-concept system design development

IGFC & Proof-of-concept designs

Technology improvement & SOFC module development

Manufacture, installation of Proof-of-concept system

Operation, demonstration, performance evaluation, and

long-term / life testing

SECA Phase II Prototype Demo Prototype Demo

SECA Phase III

SECA Phase II Prototype SECA Phase III

Prototype



Presentation Outline

• SECA prototype demonstration• SOFC stack technology• System concept development



Prototype Demonstration - Highlights

1720 hrs1500 hrsTest Time

90%80%Availability

159Power Cycle

31Thermal cycle

1.8% per 500 hrs<2% per 500 hrsSteady State Degradation

5.4 kW3-10 kWDC Peak Power

41%35%DC Efficiency

RESULTSREQUIREMENTSPERFORMANCE PARAMETER

HIGHLIGHTS

• 2005: Demonstrated a SECA prototype system that met/exceeded key DOE minimum requirements

•41% peak efficiency•5.4 kW peak power, ATR fuel•Projected mfg cost < $800/kW•System tested ~1700h at GE

• 2006: Prototype system – 75% reduction in system volume

•49% peak efficiency•5.6 kW peak power, ATR fuel•ATR fuel•Projected mfg cost < $600/kW•System to be tested at NETL



Stack Technology - Highlights

0

0.2

0.4

0.6

0.8

1

0 400 800 1200 1600 2000 2400 2800 3200Time, Hours

Ave

rage

Cel

l Vol

tage

, V

3-cell stackTemperature: 800oC

Power outage

Degradation rate:: ~0.8%/1000 hrs

Degradation rate: ~1.3%/1000 hrs

HIGHLIGHTS

• Single cell performance improvement and cell size scaleup demonstration

• Performance degradation rate 1.0-1.5%/1000 hours

• Multicell stack demonstration (height and footprint area)

• Stack operation under pressures

0.5

0.6

0.7

0.8

0.9

0.2 0.3 0.4 0.5 0.6

Current Density, mA/cm2

Cel

l Vol

tage

, V

14.7 psia with SR29.4 psia with SR49.1 psia with SR58.8 psia with SR



System Concepts -Highlights

HIGHLIGHTS

• SOFC/GT hybrid systems• IGFC concepts incorporating

SOFC/GT hybrid• IGFC system concepts

• 500+MW• >50% efficiency (HHV)• 90% CO2 separation

GEGasifier

GT

HRSG/ST

CoalSyngas

Steam

Gas Cooling,Cleanup

Parasiticpower

NetPlant

PowerSOFC

IGFC-CO2 Isolation after SOFC

Exhaust(air)

An-ex Ca-ex

CO2Isolation CO2

CO2, H2O

O2fromASU

SECA Prototype Demonstration



SECA Prototype System Schematic

CathodeAir-Preheater

Fuel Processor

Stack

PH

SteamGenerator

Combustor

AIR

AIR

H2O

CH4

• Design features• Self contained unit• Anode supported planar SOFC,

4 stacks with 150 cm2 active area cells

• Autothermal reforming (ATR) fuel processor

• Operation features• Thermally self sustaining • Methane operation• Internal reforming

• Design features• Self contained unit• Anode supported planar SOFC,

4 stacks with 150 cm2 active area cells

• Autothermal reforming (ATR) fuel processor

• Operation features• Thermally self sustaining • Methane operation• Internal reforming



Prototype System

PROTOTYPE SYSTEMSOFC STACK

ATR FUEL PROCESSOR

CATHODE AIR BLOWER



Prototype System Test Plan

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Test Time (h)

Fuel

Cel

l Sys

tem

Net

Pow

er

Steady State Test 1

Transient Test and Scheduled Maintenance Steady State Test 2

Efficiency Demonstration, Peak Efficiency Operation

Peak Power Demonstration &

Operation

Efficiency Demonstration, Peak Efficiency

Operation

System Startup and Initial

Performance Test

Further testing as desired, and

system shutdown

End of Phase I Required Testing



Prototype System Operation



Prototype System Operating Parameters



Cell Voltages at Peak Efficiency Point

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0 5 10 15 20 25 30 35 40

Cell #

Cel

l Vol

tage

(V)

S1S2S3S4



Cell Voltages at Peak Power Point

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0 5 10 15 20 25 30 35 40

Cell #

Cel

l Vol

tage

(V)

S1S2S3S4



Prototype System TestResult Summary

1720 hrs1500 hrsTest Time

90%80%Availability

159Power Cycle

31Thermal cycle

1.8% per 500 hrs<2% per 500 hrsSteady State Degradation

5.4 kW3-10 kWDC Peak Power

41%35%DC Efficiency

RESULTSREQUIREMENTSPERFORMANCE PARAMETER



SECA Prototype System(2006 system)

Key Features

• Single stack with 600 cm2 active area cells

• 75% reduction in system volume

Key Features

• Single stack with 600 cm2 active area cells

• 75% reduction in system volume



Preliminary Test Results

PRELIMINARY RESULTS•Peak efficiency 49%

• Net DC power 3.2 kW• ATR fuel• Fuel utilization 80%• Air utilization 24%

•Peak power of 5.6 kW• Efficiency of 32%• ATR fuel• Fuel utilization 65%• Air utilization 21%

PRELIMINARY RESULTS•Peak efficiency 49%

• Net DC power 3.2 kW• ATR fuel• Fuel utilization 80%• Air utilization 24%

•Peak power of 5.6 kW• Efficiency of 32%• ATR fuel• Fuel utilization 65%• Air utilization 21%

SOFC Stack Technology



Single Cell Performance Improvement

Mod

ule

Pow

er D

ensi

ty a

t 0.7

V (W

/cm

2 ) 0.671

0.267 0.274

0.455

0.213

0.406

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

2002 2003 2004 2005

PD at 0.7V, 80%FU

PD at 0.7V, 88%FU



Cell Size Scaleup

2.5 cm10 cm 16 cm 31 cm 40 cm

Tape Calendering Plasma Spraying



Performance Degradation

1200 1600 2000Time, Hours

Ave

rage

Cel

l Vol

tage

, V

3-cell stackTemperature: 800oCCurrent density: 0.428 A/cm2

Power outage

Degradation rate:: ~0.8%/1000 hrs

Degradation rate: ~1.3%/1000 hrs

Interconnect Coating

1

0.8

0.6

0.4

0.2

00 400 800 2400 2800 3200



Performance of 20-Cell Stack

10.00

11.00

12.00

13.00

14.00

15.00

0.300 0.320 0.340 0.360 0.380 0.400 0.420

Stac

k Vo

ltage

(V

)

0.100

0.150

0.200

0.250

0.300

0.350

0.400

0.450

0.500

0.550

Pow

er D

ensi

ty (

W/c

m2 )

Stack Voltage, 64% H2 (V)

Stack Voltage, ATR Fuel (V)

Power Density, 64% H2 (W/cm2)

Power Density, ATR Fuel (W/cm2)

T=800C

16.00

Current Density (A/cm2)

0.600

600-cm2 active area cells



Multicell Stack Performance

0.100

0.200

0.300

0.400

0.500

0.600

0.700

0.800

0.900

Stac

k Vo

ltage

V

0.000

0.050

0.100

0.150

0.200

0.250

0.300

0.350

0.400

0.450

0.500

Pow

er D

ensi

ty

(W/c

m2 )

20cell 600 cm2 Stack, Stack Voltage V 40cell 150 cm2 Stack, Stack Voltage V 20cell 600 cm2 Stack, Power Density (W/cm2) 40cell 150 cm2 Stack, Power Density (W/cm2)

80% Fuel Utilization ATR Fuel, T=800C

0.100 0.150 0.200 0.250 0.300 0.350 0.400 0.450 0.500

Current Density (A/cm2)



Pressurized Stack Testing

0.5

0.6

0.7

0.8

0.9

0.2 0.3 0.4 0.5 0.6

Current Density, mA/cm2

Cel

l Vol

tage

, V

14.7 psia with SR29.4 psia with SR49.1 psia with SR58.8 psia with SR

T=8000CSR=Simulated steam reformateCell active area= 150 cm2



Pressurized OperationStack with 600 cm2 active area cells

0.0

0.2

0.4

0.6

0.8

1.0

1.2

0.00 0.20 0.40 0.60

Current Density, A/cm22

Ave

rage

Cel

l Vol

tage

, V

0%

10%

20%

30%

40%

50%

60%

Fuel

Util

izat

ion,

%

14.7 psia30 psia45 psia60 psiaFuel Utilization

0.5

0.6

0.7

0.8

0.9

0.10 0.20 0.30 0.40

Current Density, A/cm2A

vera

ge C

ell V

olta

ge, V

60%FU 37%H2

60%FU SR Fuel

70%FU SR Fuel

75%FU SR Fuel

System Concept Development



SOFC – GT Hybrid System Schematic

Solid Oxide Fuel Cell

Compr Turbine

PE

Generator

Recuperator

TG Burner

PE

GridAir

Exhaust gas

Pre-ReformerFuel

Gas Turbine20% to 35% of Power

65% to 80% of Power

Air

Exhaust gas

Fuel



Efficiency Improvements with Hybrid Configurations

5258 kW4585 kW3320 kWNet Plant Power

4.6 atm4.6 atm1.3 atmSOFC Pressure

(389 kW)

0

3709

44.8

Simple

(100 kW)

976

3709

61.1

Hybrid Hybrid with Recycle

(288 kW)Parasitic Power

1447GT Power* (kW)

4099SOFC Power* (kW)

71.0Efficiency (%)

• Natural gas

• 800C planar SOFC *After power conversion



IGFC System

IGFC System• System feautres

• SOFC/gas turbine hybrid• CO2 separation (with or

without•Key system components

• SOFC• Gasifier• Gas turbine and steam

turbine

IGFC System• System feautres

• SOFC/gas turbine hybrid• CO2 separation (with or

without•Key system components

• SOFC• Gasifier• Gas turbine and steam

turbine

Gasifier

Fuel Cells

HRSG

Water Gas Shift

Combustor

Gas Clean-upCoal Raw Syngas

Steam

Steam

Generator

Air

GT C

Steam

STGenerator

Exhaust

CO2 SeparationSpentFuel Recycle



IGFC Plant Concept

Targets and Features• 500+ MW• 50% Efficiency (HHV)• ~$400/kW mfg cost (power block)• 5-10% CoE advantage over IGCC• Low emissions• CO2 sequestration capable



IGFC ConceptsGE

Gasifier

GT

HRSG/ST

CoalSyngas

Steam

Gas Cooling,Cleanup

Parasiticpower

NetPlant

PowerSOFC

IGFC-CO2 Isolation after SOFC

Exhaust(air)

An-ex Ca-ex

CO2Isolation CO2

CO2, H2O

O2fromASU

GEGasifier

GT

HRSG/ST

Coal H2-richSyngas

Steam

Gas Cooling,Cleanup, CO Shift,

CO2 Removal

Parasiticpower

NetPlant

PowerSOFC

IGFC-CO2 Isolation before SOFC

Exhaust

CO2ALTERNATIVE CONFIGURATION• Syngas to SOFC via CO-shift and removal

before SOFC (like H2 from coal plant)• Conventional shift CO2 removal• Advanced shift CO2 membrane

• Potential efficiency ~50% • 90% of gasified carbon isolated pre-

SOFC• High H2 content to SOFC allows for high

cell voltage and conversion efficiency• CO2 isolated at P >> 1 atm

BASELINE CONFIGURATION• Potential efficiency >50% • 90% of gasified carbon isolated

after SOFC• CO2 isolated @ P = 1 atm



IGFC System PerformancePreliminary Results

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

PowerProducers

Cryogenic AirCompressor

Oxygencompressor

AGR, SRU,TGCU Power

SOFCRecycle

Compressor

Net Efficiency

Sys

tem

Effi

cien

cy (%

Coa

l HH

V)

SOFC

GT

ST

55.3%50.1%

-2.6% -1.3% -0.3% -1.0%

Syngas HHV = 82%Baseline SOFC settings:• 0.75 V/cell• 150° ∆T• 80% Uf (fuel utilization)• Air outlet T <800°C

AGR: acid gas removal, SRU: sulfur removal unit; TGCU: tail gas cleanup unit



Concluding Remarks

• Successful SECA prototype system demonstration• Significant progress on stack technology development for hybrid

SOFC/GT systems• Focus on IGFC system development



Acknowledgments

• Travis Shultz, Wayne Surdoval, Don Collins of DOE/NETL• GE Fuel Cell Team• The material presented was prepared with the support of the U.S.

Department of Energy, under Award No. DE-FC26-01NT41245 and DE-FC26-05NT42614. However, any opinions, findings, conclusions, or recommendations expressed herein are those of the author and do not necessarily reflect the views of the DOE.

Date post:	19-Feb-2018
Category:	Documents
Upload:	vophuc
View:	215 times
Download:	0 times

SECA Coal-Based System Program library/events/2006/seca/Minh-SECA.pdf · SECA Coal-Based System...

Documents