SS AWMA 2007 August 9, 2007 Sea Palms Resort Southeastern Air & Waste Management Association...

SS AWMA 2007August 9, 2007 Sea Palms Resort

Southeastern Air & Waste Management Association Conference

Stationary Fuel Cells: Power Generation Applications for Industry and Government Tom Militello, Executive DirectorFuelCellSouth Partners Forum, Inc.


Mission Fostering Awareness and Creating Market Opportunities for Fuel Cell Industry Growth

FuelCellSouth Partners Forum, Inc.

Programs- Southeastern Hydrogen and Fuel Cell Conference- Crystal Flame Innovation Awards- Quarterly Partners Forums- Webcasts and Newsletters- Business and Economic Development


Background• FuelCellSouth was officially founded in May 2003, starting with

South Carolina companies, researchers and entrepreneurs.• In 2004 we added participation from Georgia and North Carolina; held

our inaugural FuelCellSouth Conference.• From 2005-2007 we have broadened our reach by:

– Organizing as a 501 (c) (6) non-profit corporation– Expanding to serve twelve (12) Southeastern States– Launching Quarterly FCS Partners Forums – Offering a bimonthly newsletter– Conducting FuelCellSouth Seminars– Researching Opportunities for Sponsored Demonstration

Programs• In 2008 – 2010 we will grow to include representation and events in

Texas, Oklahoma, Missouri, West Virginia, Maryland and Delaware.


The Chemistry

*A catalyst like FuelCellSouth is needed to make the reactions go!

IndustrySupport

State & FederalSupport

H+

H+

H+

H+

* FuelCellSouth Partners Forum

RegionalEnd User Markets

ResearchNational and

RegionalSpecial Interest

Groups

e- e-


Industrial / Research Advisory*Showa Denko Carbon

Finnish Chemicals

Savannah River National Lab

Columbian Chemicals

Sequentus

Fuji

Center for Hydrogen Research

Concurrent Technologies Corp.

NSF Center for Fuel Cell Research

North Carolina Advanced Vehicle Research Center

Swagelok

BellSouth

Oak Ridge National Lab

U.S. Department of Energy

LOGAN Energy

Plug Power

Fuel Cell Energy

Clemson ICAR

NC State College of Textiles

MPT

University of South Carolina


• Oil & Chemical

• Utilities – Electrical, Gas, Telephony, Water

• Manufacturing

• Healthcare

• Hospitality / Hotels

• Education (Public & Private)

• Government

Targeted Industries


Process, Programs & Project Teams

• Researches Region for Special Projects of Interest• Advise Executive Committee on Projects & Funding.• Develops, Delivers and Manages Programs / Projects• Supports and Participates in National / International

Conferences and Market Education Events.• Develops and Delivers Quarterly FuelCellSouth

Partners Forums and Annual Conference.


Fuel Cell BasicsFuel Cell Basics- The Chemistry- The Components

Fuel Cell Technologies- Proton Exchange Membrane (PEM)- Molten Carbonate (MCFC)- Phosphoric Acid (PAFC)- Solid Oxide (SOFC)- Direct Methanol (DMFC)


The Chemistry• Anode: H2 = 2H+ + 2e-

• Cathode: O2 (Air) + 2H+ + 2e- = H2O

*A catalyst like Platinum is needed to make the reactions go!

Anode(negative side)

Cathode(positive side)

H+

H+

H+

H+

Electrode

Catalyst

O2

H2

H2O

Electric Circuit

e- e-


Fuel Cell Technologies

• Proton Exchange Membrane (PEM)

• Molten Carbonate (MCFC)

• Phosphoric Acid (PAFC)

• Solid Oxide (SOFC)

• Direct Methanol (DMFC)


PEM Fuel Cells• Named for their electrolyte

– Proton Exchange Membrane

• Like a battery, but supplied with external fuel

• Generally use hydrogen from a reformer converting:– Natural Gas, Propane or Methanol

• Products are:– DC Power

– Heat

– Water

• Power: 1 to 100 kWIdatech PEMFuel Cell Stack


Molten Carbonate Fuel Cells (MCFC)

• Named for their electrolyte– Molten alkali carbonate mixture (Molten carbonate salt that becomes a

liquid and a good ionic conductor.)

• Operate at a temperature of about 650 degrees Centigrade.

• Produces heat and water vapor• Fuel is typically Reformed Natural Gas• Utilized for Large-scale power

generation (> 250 to 2,000 kW)– Heat– Water Photo Credit: American Society of Mechanical Engineers.


Phosphoric Acid Fuel Cell (PAFC)• Named for their electrolyte

– phosphoric acid

• Able to reform methane or industrial waste gases to a hydrogen rich gas with the waste heat from the fuel cell stack.

• Heat may be used for heating or hot water.

• Scale – a few kilowatts to several megawatts.

Photo Credit: HydroGEN LLC


Solid Oxide Fuel Cell (SOFC)• Uses yttria-stabalized zirconia as its

electrolyte.– Runs at a temperature of around

1000 degrees centigrade.

• Three Designs for SOFCs– Tubular, Planar and Monolithic

• Produces heat for use in cogeneration applications or steam turbines to produce electricity.

• Fuel Sources:– Pure Hydrogen – Methane– Carbon Monoxide

Photo Courtesy of Siemens Westinghouse.


Direct Methanol Fuel Cell (DMFC)• Based on Solid Polymer

Technology that uses methanol directly as the fuel.

• Benefits – reduces the need for storage or generation of hydrogen.

• Prototype products exist, but research and development is still early stage.

Toshiba 100 milliwatts embedded DMFC


Types of Fuel Cells

Portable


Types of Fuel Cells

Transportable


Types of Fuel Cells

Stationary


Types of Fuel Cells

Transportation


Timing and Industry Cost Curve

FUEL CELL MARKET ESTIMATION

100,000

10,000

1,000

100

10

202020102000

ResidentialCHP(1)

Stationary Mass Markets

Automotive

RemoteStationary

Peak Shaving

Backup & Standby

Micro fuel cells

Syste

m C

ost ($

/ k

W)

Source: Plug Power (J uly 2003)(1) CHP: Combined Heating and Power

Timing and Industry Cost Curve

FUEL CELL MARKET ESTIMATION

100,000

10,000

1,000

100

10

202020102000

ResidentialCHP(1)

Stationary Mass Markets

Automotive

RemoteStationary

Peak Shaving

Backup & Standby

Micro fuel cells

Syste

m C

ost ($

/ k

W)

Source: Plug Power (J uly 2003)(1) CHP: Combined Heating and Power

2005


Fuel Cell Implementations:Backup & Distributed Power Solutions

Source: Ballard Fuel Cell Power Plug Power, Inc.

Commercial Power Residential / Small Business


What is Distributed Generation?

Distributed generation is a concept where smaller, highly efficient power plants are installed along the existing grid, close to the end-user customer. It is similar in concept to the move from large central computers to desktop computers on a network.


Why is Distributed Generation Occurring?

• There are localized shortages of electricity in this country, particularly in California and the Northeast. The ability to quickly build power plants to provide needed power is attractive.

• It is getting increasingly difficult to site new power plants near population centers due to air quality concerns.

• Deregulation is opening up new markets and new players on those markets, all of whom are looking for tools that will make them as competitive as possible.

• National Security


Distributed Generation in the Southeast?

• Electricity in the Southeast is relatively inexpensive, but recognized as being less clean then alternative energy sources. Distributed Fuel Cells are one potential source for clean power, but not cost competitive today with fossil fuel plants.

• Today, renewable energy implementations are relatively few in the Southeast, but do exist… utilizing landfills and reciprocating engines… participating in the Green Power Program.

e.g. Santee Cooper - Horry County Landfill Anderson County

Landfill


Distributed Generation in the Southeast?

• We need more reliable power alternatives for business and mission critical environments. Power security and inclement weather (ice, wind, thunder & lightning, etc.) present economic and security threats to our region.

• The Southeast has many feed stocks for biomass and large-scale wastewater management facilities upon which to leverage for green power. These environments present opportunities for research, demonstration, public awareness and ultimately lower cost implementations.


Distributed GenerationFuel Cell Economics

Economics Work in High Energy Cost Regions…e.g. Northeast, California,Arizona, Japan, etc.

US DoE, EPA, DoD, State and Private Programs

Source: Fuel Cell Energy, Inc.


Power Generation

South Carolina Power Sources

The Southeast is predominately a nuclear / fossil fuel powered region – our power is relatively inexpensive…

Source: Green Power Alliance


Power EconomicsLocal Situational Analysis

Average Price/kWh Sold

Santee CooperS.C. Investor

Owned UtilitiesNationalAverage

Residential ¢/kWh 6.98 7.91 8.62

Commercial ¢/kWh 6.17 6.65 7.79

Industrial ¢/kWh 3.45 4.11 4.94

Other ¢/kWh 6.29 6.33 7.05

Total Retail ¢/kWh 4.35 6.00 7.32

Note: Data obtained from the Energy Information Administration and Platts' POWERdat database


Emissions Criteria

Average US Fossil Fuel Plant 24.09

Micro-turbine 1.2

Combined Cycle Gas Turbine 0.6

Fuel Cell (Molten Carbonate/DFC) 0.04

Source: http://www.eere.energy.gov/

Pounds of emissions per 1,000 kW hours of NOx, CO, Sox, Hydrocarbons, Particulates


National Security• Growing Concern about Power Security

– Reliability of National Grid (Blackouts)

– Vulnerability of National and Regional Grid, in particular Generation and Transmission Facilities.

• Business Operations are vulnerable to power availability fluctuations due to weather and local load factors.– Not just a big business concern anymore… an “Internet connected

society” needs reliable power… in the home, in the office – 7 x 24.


Distributed Generation ScenariosEnd-User • Remote Generation (on or off grid)• Export to System Side (sell the excess power back to the

utility)• Backup Generation (replacement of diesel generators)

System Side• Energy and Capacity (e.g. green power program)• Ancillary Services (in support of distributed generation)• Local Reliability Generation Services (in mission critical

areas, e.g. hospitals).


End User Scenarios – Remote Generation

On Grid - Residential• Generate power locally and feed back

unused power to the local utility.• Feed Stock: Natural Gas• Contains an on-board reformer

Utility Company Requirements• Must not compromise system reliability.

– Create or extend an outage.– Decrease the life of or damage equipment.– Reduce reliability to other customers.

• Must not shift costs to other customers.• Safety concerns

– Back feed onto the grid.

5 kW Unit with combined Heat and Power

Single Phase 110/208 VAC

22,000 BtuH 135 Deg FSource: Logan Energy


On Grid - Commercial• Generate power locally and

feed back unused power to the local utility.

• Scale: 250 to 2,000 kW• Heat Utilized for HAVC.• Feed Stock: Natural Gas,

Methane (no onboard reformer required).

250-kilowatt MCFC fuel cell power plant

Source: FuelCell Energy, Inc.

Higher fuel efficiency than micro-turbines, turbines, reciprocating engines and low temp fuel cells.


Note: similar models could apply for future Phosphoric Acid Fuel Cells

Source: FuelCell Energy, Inc.


Sample Direct Fuel Cell Implementations

• Coast Guard• University• City Municipal Power• Manufacturing• Hotel• Hospital

• Wastewater Treatment Facility


Typical Project Goals

• Grid Independence

• Environmentally Friendlier Power

• High Quality Power

• Reliable Emergency Power

• Cost Effectiveness


Sample Funding Sources

• Sponsor Programs (1.07 million)

• DOE program (250K)

• State Technology Fund (406K)

• Partner Energy Company ($100K)

• Total Contract $1.83 million

Source: Mass Coast Guard.

Mass. Coast Guard Implementation


Budget

Cost Breakdown– Fuel Cell $1,250 K– Heat Recovery Unit $150K– Engineering / Project Management $143K– Site Preparation $100K– Installation / Start-up $66K– Interconnect $60K– Modifications $66K (Mod. Rate: 4%)




Utility Company Interface• Determine the appropriate

utility interface– Customer representative

– Distribution engineer

– Substation engineer

• Involve them in the project from the beginning

• The utility focus will be on safety, reliability and cost allocation

Typical Requirements

• Single line diagram

• Load flow study

• Loss of phase protection

• Loss of power sequencing

• Certification protocol

• Testing protocol

Commercial and Residential Implementations Alike


Project Scope

• Engineering & Design

• Design Review

• Final Design

• Site Preparation (slab, piping, etc)

• Fuel Cell Configured, Tested and Delivered

• Installation & Start Up

• Acceptance Test

• Fuel Cell Online

60 days

2 days

15 days

30 days

15 days

10 days

15 days

2 days

149 days



Note: a program delay set back the project almost ½ year… expectthe unexpected to occur.


Long Island Power Authority…


or City of Westerville, Ohio• "The 250-kilowatt (kW) DFC

power plant creates the hydrogen it needs from a readily available fuel, natural gas. The unit is manufactured by FuelCell Energy and distributed by Caterpillar through its dealer Ohio Cat.

• The fuel cell power plant is

located at Westerville's electric substation #2, and will produce enough energy to power approximately 180 homes in Westerville.


Commercial Installations

Food Processing Plant Yale University


Hotel and Hospitality Business

Sheraton Hotel – Edison NJ

Starwood began using fuel-cell energy in 2003 at its Parsippany and Edison, N.J., properties,

They have cut about 5% from the hotels' energy costs.

The DFC300A uses natural gas that is supplied by New Jersey Natural Gas of Wall, N.J. H.T. Lyons, a PPL subsidiary based in Allentown, Pa., was responsible for the installation.

The New Jersey Clean Energy Program provided $860,000 in funding to PPL as part of its incentive program to encourage the use of clean and efficient technology.

Other Sites:Starwood NYCSheraton San Diego

4 x 250 kW power plant 1,044 Rooms


Wastewater Treatment Facilities• Industrial and municipal wastewater treatment facilities with

anaerobic gas digesters present an important opportunity.• The methane generated from the anaerobic gas digestion

process is used as fuel for the fuel cell power plants, which in turn generates the electricity to operate wastewater treatment equipment at the facility.

• Wastewater treatment gas is a renewable fuel eligible for government incentive funding for project installations throughout the world.

• There are over 550 municipal wastewater treatment facilities in the U.S. that are capable of producing enough methane from anaerobic gas digestion to fuel a 250-kilowatt or larger fuel cell power plant.


FuelCell Energy DFC 1500 Power Plant

• Using digester gas from King County's South Treatment Plant in Renton, Wash., the Company's DFC1500 power plant provides one megawatt of electricity for the wastewater treatment facility, enough to power 1,000 households.

• The electricity generated by the Direct FuelCell (DFC) power plant is used to run some of the treatment plant equipment and the waste heat is used to produce hot water for the treatment facility.


Molten Carbonate Fuel CellWastewater Treatment Application

Site: Renton, WA ( King County Wastewater Treatment Facility)

Project Cost: $22 million, with $12.5 million provided in the form of a grant from the US EPA.

Two (2) Year DemonstrationProject; 5 years from concept to Go live (including DOE bid)

Fuel: digester gas Solution: On Grid

Power Generation: 1 MW Fuel Cell ModuleElectrical Enclosure

Source: FuelCell Energy, Inc.Heat Recovery

And Stack

MethaneConditioning

Air Blower& Oxidizer


Obstacles to Adoption• Low volume production results in high initial capital

equipment costs. • Interconnection standards, exit / stand-by charges, net

metering. • No clear correlation between spot market natural gas prices

and grid-delivered electricity rates, making business unfavorable for distributed generation.

• Rate definition process can cause delays or lags in fuel price impact on utility rates.

• Government incentive programs can be overly complex.

Public and industry awareness of reduced emissions unrecognized…

… understanding of risk mitiga-tion from on-grid dependencyand overall power security risksnot understood or quantified.


Questions


Contact UsPhone / Fax: 888.481.8433

[email protected]


Sample ExerciseOffered at FuelCellSouth Seminars


ExerciseExercise - Plan, Install and Manage an Off-Grid Solution - Plan, Install and Manage an Off-Grid Solution

Mountain Home

Single Phase 110/208 VAC/GP/GI

22,000 BtuH 135 Deg F

On or Off Grid Solution?• Remote power generation

– CNG / Natural Gas or– Bio-renewable Gas / Methane

• Generate power locally as needed in your Mtn. Home

• Account for Safety and Operational concerns – Remote ManagementGas Meter

Natural Gas Line

Thermal Loop

Phone Line

Fuel

Cell Equipment Room

120 Volts

HWH

Main PowerPanel

Data Logger

Drain

Foundation

Water Line


Probable Early Commercial Product Proforma Assumptions Early Commercial Residentrial UnitsRFC Installed Cost 10,000$ 6,000$ New 3500 Sq. Ft Home, Gas & Electric AppliancesAverage Hourly kWH 2 kWhAnnual KWh 16,644 kWhGas Cost $6.00 MCF $1,648 $1,648Annual Maintenance 8 Hrs $640 $64020 Year Amortization $949 $569Waste Heat Available @ 2kW 0.22 mmBtuHEst. Waste Heat Recovery 30 % ($350) ($350)Annual Operating Cost $2,887 $2,507

Cost Per kWH $0.17 $0.15

Source: Logan Energy

Economic Analysis


Fuel: Natural Gas - Fuel cell will require a ¾” Natural Gas supply line. Delivery pressure same as typical home appliance.

Water - Fuel cell will require a ¼” water supply line. A water treatment panel will be installed inside the residence or business, and the installer will run an additional ¼” line to each fuel cell from this water treatment panel.

Drain - The unit produces a small amount of condensate. This condensate will drip from a ¼” diameter plastic hose. The condensate can drain to the ground or a nearby sanitary line.

Electric - Fuel cell must be connected to an existing 120/240V electric panel. This is where the fuel cell will import power into the residence or business. A 1-1/2” conduit must be run from the fuel cell to the panel. This conduit will carry grid-sensing and power conductors. An FC disconnect is installed near the unit which serves to isolate the fuel cell for service or in the event of a power outage.

Heating System - For a Combined Heat and Power Configuration (CHP), a separate CHP heating loop will be needed. This loop is typically a 1-1/4” insulated copper line that will circulate a water-glycol mixture to and from the fuel cells. This loop is called the CHP loop. It will carry heat from the fuel cell to a water storage tank that will be located inside the residence or business. The tank is similar to a residential hot water heater and will supplement your existing hot water heater or boiler.

Phone Line - A dedicated analog phone line will be required to allow the fuel cell to relay data to the manufacturer.

Foundation - Fuel cell can sit on any stable and level surface. A concrete pad is optimum, but a concrete paver, asphalt, or gravel base is acceptable.

Exercise - install a residential PEMFC solution


Gas MeterNatural Gas Line

Thermal Loop

DI with Heat Trace

Phone Line

Fuel

Cell EquipmentRoom

24V Control Wires to Relay Panel

DI Solenoid Wires

Data Logger Wires

Data Logger Wires

Data Logger Ambient Temp Sensor

Small Scale PEM : RFC Single Line with CHP Detailed Diagram

Line

Critical Load

120 Volts

DPDTSwitch

Meter

Critical Load Panel

HWH

DI Panel

Main Panel

Btu Meter

Control conduit

Data Logger

* Diagram courtesy of Logan Energy

Solution

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SS AWMA 2007 August 9, 2007 Sea Palms Resort Southeastern Air & Waste Management Association...

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