SYSTEM DESIGN Lessons Learned
Generic Concepts
Characteristics & ImpactsCharacteristics & Impacts
Don HoffmanDon Hoffman Ship Systems &
Engineering Research Division
March 2011
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Ship Service Fuel Cell Program Lessons Learned
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625 Molten Carbonate Ship Service Fuel Cell (NATO F76/JP5 Logistics Fuel)
Ship Service Fuel Cell Program
• MCFC with steam reformer • Fuel reformer built for methane production • 302 Hours On Load Operation • 48% Efficiency
PREREFORMER ZNO HDS
TURBO EXPANDER
FUEL CONDENSER
FUEL
EXHAUST
H2 FUEL
H2
A C FUEL CELL
STACK
WATER RECOVERY
CATALYTIC OXIDIZER
WATER
ELECTROLYZER
STEAM START BURNER
AIR
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500 kWe Integrated Fuel Processor (NATO F76/JP5 Logistics Fuel)
Ship Service Fuel Cell Program
• Low Temperature PEM with ATR reformerLow Temperature PEM with ATR reformer • Gas clean up process • Waste heat recovery to pressurize process •• Process stability issues preventedProcess stability issues prevented significant integrated operation
Autothermal Guard Desulfurizer / LowRegenerable Reformer High Temperature Temperature Desulfurizer(s) Shift Reactor Shift Reactor
Selective Air
Oxidizer
Water Preheater
Steam Superheaters
Fuel Vaporizer
Water Simulated Fuel Cell
Fuel
Exhaust
Spent Fuel Burner
Air Heater
To Regen Burner
To Selective Oxidizer
Spent Air and Spent Reformate Recuperators
Multi Stream Steam Generator
To Regen Burner
Fuel
Condensate
Exhaust Exhaust
AirAir
Fuel Processor Turbocompressor
Main Turbocompressor
N2
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•
SSFC Design Issues & Lessons
• High Complexity with Auxiliaries • Industrial reforming method adapted
for shippboard use • Low space velocity reactors • Component accessibility • Imbedded Instrumentation • Greatest impact on overall density
• High Pressure Gas Storage • High pressure combustible ggasg p • Shipboard vent requirements
• Start Time • Fuel Cell & reformer requirements –• Fuel Cell & reformer requirements
large thermal mass • Heat up technique – direct vs
indirect start process
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Learned • Marinization
• Design for shipboard operation requires integgrated packaggingg
• Design methods for inherently safe operation are different (industrial vs shipboard use)
•• Control and dynamic operation needs Control and dynamic operation needs to be accounted for up front in overall design
Price Point Price Point • Total system design will affect overall
price point (parts count) • Need to follow existing model for
incorporation off power generation (gas turbine/diesels) into fleet
5
Navy Fuel Cell Processor Development
Ship Service Demonstration Fuel Cell S&T Modular Fuel Cell Systems
High Power Shipboard System
625kW SSFC Demo 45-50% Efficient
System
Low Power High Efficiency Low Power, High Efficiency Tactical Power System
• Enable 3X improvement in Ship Service Fuel Cell l t i d it SSFC Future Full Scale Modular Fuel Cell Ship Service Fuel Cell volumetric density over SSFC
demonstrators System Design for Multi Platform Program Lessons Application• Risk Reduction of Fuel CellLearned Subsystems through scaled
breadboard demonstrationbreadboard demonstration
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Solid Oxide Fuel Cell Tactical Power Low Sulfur JP8 Fuel
Total Power 5 kW ------------------------------------- 5 MW 10kW Total Power 5 kW 5 MW Efficiency 25 % ------------------------------------- 50 % Airborne Noise 50 db ------------------------------------- 110 db
10kW
30-40%
60db
Volumetric Density 20 w/l ------------------------------------- 35 w/l Gravimetric Density 20 w/kg ------------------------------------- 40 w/kg Start Time 15 min ------------------------------------- 24 hrs
25w/l
35w/kg
30min
Life (MTBO) 1000 hrs ------------------------------------- 10000 hrs Hours per year operating 500 hrs ------------------------------------- 9000 hrs Scheduled Maintenance 250 hrs 9000 hrs
1250hr
750hrs
250hrs Scheduled Maintenance 250 hrs ------------------------------------- 9000 hrs Water Neutrality 0 ------------------------------------- 100% Electric System Interface 450VAC, 3Phase
250hrs
100%
Power Quality Mil-Std-1332 Environmental Mil-Std-810 Emissions No Std Identified EMI Mil-Std-461 Shock & Vibration Mil-Std-810
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Solid Oxide Fuel Cell Tactical Power Low Sulfur JP8 Fuel
Towable Power SOFC System Vehicle Based APU
MMeasure D t ti G l @ TRL 6 Demonstration Goal @ TRL 6
Power Output 10 kW
Efficiency 30-40%
System Weight 35 W/Kg
System Volume 20-30 W/liter (Power Core)
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Shipboard Fuel Cell System Bioffuel
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Heavy Vehicle
Commercial Commercial MarineSmall Marine
Residential, APU A t ti
Electronics
Industrial, Dist. Gen
.01 .1 1 10 100 1,000 10,000
Automotive Locomotive
SOFC MCFC
POWER (kWe)
PEM/HT PEMFC
SOFC Multiple Modules
PAFC DMFC
UV/Small Craft/ Soldier Power
Ship Service , Large MEP
Vehicles, Small MEPPortable
PowerMilitary
UV/Small Craft/ Submersible
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Shipboard Fuel Cell System Biofuel
Total Power Total Power 5 kW 5 kW ------------------------------------- 5 MW 5 MW Efficiency 25 % ------------------------------------- 50 % Airborne Noise 50 db ------------------------------------- 110 db Volumetric Density 20 w/l ------------------------------------- 35 w/l Gravimetric Density 20 w/kg ------------------------------------- 40 w/kg Start Time 15 min ------------------------------------- 24 hrs Life (MTBO) 1000 hrs ------------------------------------- 10000 hrs Hours per year operating 500 hrs ------------------------------------- 9000 hrs Scheduled Maintenance Scheduled Maintenance 250 hrs 250 hrs ------------------------------------- 9000 hrs 9000 hrs Water Neutrality 0 ------------------------------------- 100% Electric System Interface Power Quality Environmental Emissions EMI Shock & Vibration
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Other Criteria to Consider
• Exhaust temperaturesExhaust temperatures • Airflow
M i t l• Maintenance envelope • Equipment removal concept • Duty Cycle • Structureborne NoiseStructureborne Noise
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Power Electronics
Notional Electric Architecture
Power Generation HTS Generator Adaptive Fault & Recovery Technology
Motor / Motor Drive
Permanent Magnet HTS
Service Loads
Adv. Induction Homopolar
Power Generation Bidirectional Power Conversion
Module (PCM)
Pulse Loads
DCDC DCDC
Energy Storage
R t ti M hi C it
Distributed Power Generation/ Fuel Cells
DCDC
Rotating Machine Capacitor
Battery
DC or 60DC or 60 --DC or 60DC or 60 240 Hz240 Hz
High Speed Generator
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Shipboard Fuel Cell
Characteristics & ImpactsCharacteristics & Impacts
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1st Step: Shipboard Power Needs Operating w Biofuel
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2nd Step: Specification Prioritization
Action: Prioritize & identify shipboard fuel cell characteristic information based information based on Shipboard Power Need Power Need
Total Power
Efficiency
Airborne Noise
Volumetric DensityVolumetric Density
Gravimetric Density
Start Time
Life (MTBO)
Hours per year operating
Scheduled Maintenance
Water Neutrality
Electric System Interface
P Q litPower Quality
Environmental
Emissions
EMI
Shock & Vibration
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e o ate
Fuel Cell Types
Electrolyte Cell Temp Fuel
Proton Exchange Membrane (PEM)
Polymer Membrane (Solid)
70-90 C Pure Hydrogen
Phosphoric Acid Phosphoric Acid (PAFC)
Phosphoric Acid Phosphoric Acid (Liquid)
120 180 C 120-180 C Hydrogen Hydrogen rich
reformate
High Temp PEM (HTPEM)(HTPEM)
Phosphoric Acid Polymer (Solid) Polymer (Solid)
120-180 C Hydrogen richrich
reformate
Molten Carbonate (MCFC)
Potassium Lithium Carbonate (Liquid)
650 C Methane rich
reformate
Solid Oxide (SOFC) (Tubular, planar)
Solid Zirconium Oxide Ceramic
(Solid)
700-900 C Hydrogen rich
reformate
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Low Temperature PEM System
Ballard Fuel Cell
Fuel Cell Stack Characteristics •Manufacturer: GM, Ballard etc. ••Fuel:Fuel: Pure H2 Pure H2 •Temperature: 60 C
GM Automotive Fuel Cell
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Phosphoric Acid Fuel Cell System
Fuel Cell Stack Characteristics •Manufacturer: United Technologies Company •Fuel: H2 rich reformate •Temperature: 180 C
UTC PureCell 400
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High Temperature PEM/PBI System
Fuel Cell Energy
Stack test Module Stack test Module
Fuel Cell Stack Characteristics •Manufacturer: Enercell, FCE etc. •Fuel:Fuel: H2 rich reformate H2 rich reformate •Temperature: 180 C
Enercell HT PEM
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Molten Carbonate Fuel Cell System
Hot Box
MCFC Stack
Fuel Cell Characteristics •Manufacturer:Manufacturer: Fuel Cell Energy Fuel Cell Energy •Fuel: CH4 rich reformate •Temperature: 650 C
FCE SSFC Module
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Solid Oxide Fuel Cell System
Versa 25 kW SOFC Stack
Fuel Cell Stack Characteristics •Manufacturers: Versa, Delphi, RR etc. ersa, Delphi, RR etc.Manufacturers: V•Fuel: H2 rich reformate •Temperature: 800 C
250 kW SOFC ModuleFCE Conceptual
250 kW SOFC Module
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3rd Step: Technology Assessment for Shipboard Fuel Cell System - Biofuel
Ship Service Demonstration Fuel Cell Components Modular Fuel Cell Systems
625kW SSFC Demo 45-50% Efficient
• Technical Challenges Ship Service Fuel Cell of Advanced Fuel Cell High Power
Program Lessons ShipboardCompponents Opperatingg SystemLearned on Biofuel
• System Integration of Advanced Fuel CellAdvanced Fuel Cell Components based on Shipboard Power Need
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QQuestions?
Shipboard Fuel Cell System Installation
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