1
The U. S. Department of Energy Fossil Energy Fuel Cell Program Solid State Energy Conversion Alliance
Goals and Challenges
Technology Manager, Fuel Cells National Energy Technology Laboratory
U. S. Department of Energy
8th SECA Workshop
Wayne A. Surdoval
7 August 2007
Atoms for Peace1953
Department of Eneregy
October 22, 1953:The Atomic Energy Commission announces that an AEC-owned demonstration power plant of 60 MW will be built at Shippingport, PA, jointly by Westinghouse Electric Corporation and Pittsburgh’s Duquesne Light Company under the direction of the U.S. Navy/AEC Naval Reactors Branch.
The more important responsibility of this atomic energy agency would be to devise methods whereby this fissionable material would be allocated to serve the peaceful pursuits of mankind. Experts would be mobilized to apply atomic energy to the needs of agriculture, medicine and other peaceful activities. A special purpose would be to provide abundant electrical energy in the power-starved areas of the world.
Dwight D. Eisenhower, President of the United States of America, to the 470th Plenary Meeting of the United Nations General AssemblyTuesday, 8 December 1953
Photograph of the Shippingport Atomic Power Station in Shippingport, Pennsylvania, the first full-scale nuclear power generating station in the United States which began operating in 1957.
Clean Coal Power Initiative
"More than half of the electricity generated in America today comes from coal. If we weren't blessed with this natural resource, we would face even greater [energy] shortages and higher prices today. Yet, coal presents an environmental challenge. So our plan funds research into new, clean coal technologies."
Statement by President George W. Bush National Energy Policy May 17, 2001
“Today I am pleased to announce that the United States will sponsor a $1 billion, 10-year demonstration project to create the world's first coal-based, zero-emissions electricity and hydrogen power plant . . . .”
Statement by the PresidentFebruary 27, 2003
FutureGen2003
DOE’s Office of Fossil EnergyAdvanced (Coal) Power Systems Goals
• 2010: −45-50% Efficiency (HHV)−99% SO2 removal−NOx< 0.01 lb/MM Btu−90% Hg removal−$1,000/kW (2002 $)
• 2012:−90% CO2 capture−<10% increase in COE with
carbon sequestration• 2015
−Multi-product capability (e.g, power + H2)−60% efficiency (measured without carbon capture)
Why Fuel Cells in a Coal Plant (FutureGen)?
• Permits high efficiency gasification • Multiple options for Carbon Capture, remove > 90%• High Power Station Efficiency _60% HHV?• Near Zero Emissions _ NOx or < 0.5ppm• No Impact on Cost of Electricity with SECA goals• Meet environmental regulations; able to site and
produce energy from coal in any state in the U.S.
• Permits high efficiency gasification • Multiple options for Carbon Capture, remove > 90%> 90%• High Power Station Efficiency _60%60% HHV?• Near Zero Emissions _ NOxNOx or < 0.5ppmor < 0.5ppm•• No Impact on Cost of Electricity with SECA goalsNo Impact on Cost of Electricity with SECA goals•• Meet environmental regulations; able to site and Meet environmental regulations; able to site and
produce energy from coal in any state in the U.S.produce energy from coal in any state in the U.S.
SECA Coal Based Systems (IGFC)
Gas Cleaning
CO2,CO, H2, H2O
Coal
H2O
Marketable Ash/Slag
By-product
Air
O2
SulfurRecovery
MarketableSulfur
By-product
Anode
Cathode
CO2
Gasifier
AirSeparation
EnhancedOil Recovery
Deep SalineAquifer
UnmineableCoal Beds Depleted Oil & Gas
Reservoirs
Sequestration
SolventCO2
Separation
Air
SOFCCO, H2
Heat Recoverye.g.,Turbine
Air
H2O purge
SECA Project ScheduleManufacture –10 MWs per System
Full Scale Balance of Plant >50% HHVWith Carbon Capture
Operation
40,000 Hours
Sub-Module Prototype ~ 1MWLocation – TBD
$400/kW System
Conceptual System Design including Carbon Capture
NEPA – Manufacturing & Site
SECA Module –< $225/kW
*Deputy Secretary also serves as Chief Operating Officer
Department of EnergySecretary
Dr. Samuel BodmanDeputy Secretary*
Clay Sell
SecretaryDr. Samuel BodmanDeputy Secretary*
Clay Sell
Federal EnergyRegulatory
Commission
Federal EnergyRegulatory
Commission
Under Secretary for Nuclear Security/Administrator for National Nuclear Security
AdministrationThomas P. D’Agostino, Acting
Under Secretary for Nuclear Security/Administrator for National Nuclear Security
AdministrationThomas P. D’Agostino, Acting
Assistant Secretaryfor Policy &
International Affairs
Assistant Secretaryfor Policy &
International Affairs
Assistant Secretaryfor Congressional &Intergovernmental
Affairs
Assistant Secretaryfor Congressional &Intergovernmental
Affairs
General Counsel General Counsel
Energy InformationAdministration
Energy InformationAdministration
Economic Impact & Diversity
Economic Impact & Diversity
ManagementManagement
Health, Safety & Security
Health, Safety & Security
Intelligence and CounterintelligenceIntelligence and
Counterintelligence
Inspector GeneralInspector General
Chief InformationOfficer
Chief InformationOfficer
Public AffairsPublic Affairs
Hearings & AppealsHearings & Appeals
Bonneville Power Administration
Bonneville Power Administration
Associate Administratorfor Emergency
Operations
Associate Administratorfor Emergency
Operations
Associate Administratorfor Defense Nuclear
Security
Associate Administratorfor Defense Nuclear
Security
Associate Administratorfor Infrastructure& Environment
Associate Administratorfor Infrastructure& Environment
Associate Administratorfor Management& Administration
Associate Administratorfor Management& Administration
Assistant Secretaryfor Energy
Efficiency & Renewable Energy
Assistant Secretaryfor Energy
Efficiency & Renewable Energy
Assistant Secretary for Environmental
Management
Assistant Secretary for Environmental
Management
Assistant Secretary for Nuclear Energy
Assistant Secretary for Nuclear Energy
Assistant Secretaryfor Fossil Energy
Assistant Secretaryfor Fossil Energy
Advanced Scientific Computing Research Advanced Scientific
Computing Research
Biological & Environmental
Research
Biological & Environmental
Research
Basic Energy SciencesBasic Energy Sciences
Office of ScienceOffice of Science
Under Secretary
Dennis R. Spurgeon(Acting)
Under Secretary
Dennis R. Spurgeon(Acting)
Deputy Administratorfor Defense ProgramsDeputy Administratorfor Defense Programs
Deputy Under Secretaryfor Counter-terrorism
Deputy Under Secretaryfor Counter-terrorism
Deputy Administratorfor Defense Nuclear
Nonproliferation
Deputy Administratorfor Defense Nuclear
Nonproliferation
Deputy Administrator for Naval Reactors
Deputy Administrator for Naval Reactors Chief Financial
OfficerChief Financial
Officer
Human CapitalManagement
Human CapitalManagement
10/26/2005
Southeastern Power
Administration
Southeastern Power
Administration
Southwestern Power
Administration
Southwestern Power
Administration
Western Area Power
Administration
Western Area Power
Administration
Under Secretary forScience
Dr. Raymond L. Orbach
Under Secretary forScience
Dr. Raymond L. Orbach
Civilian Radioactive Waste ManagementCivilian Radioactive Waste Management
Electricity Delivery & Energy Reliability
Electricity Delivery & Energy Reliability
Legacy Management
Legacy Management
Fusion Energy Science
Fusion Energy Science
High Energy PhysicsHigh Energy Physics
Nuclear PhysicsNuclear Physics Workforce Development for
Teachers & Scientists
Workforce Development for
Teachers & Scientists
Solid State Energy Conversion Alliance (SECA)
Historical Budget
$0
$10
$20
$30
$40
$50
$60
$70
2000 2001 2002 2003 2004 2005 2006 2007 2008
Request Appropriation
Mill
ions
Solid State Energy Conversion Alliance (SECA) FY 08 Request ….$62.025 Million
SECA FY 08….. .$62,025,000
Universities, Small Business
NETL
SECA Cost ReductionIndustry
SECA Coal Based SystemsIndustry
National Laboratories
SECA ManufacturingIndus try
SECA Program Structure
Industry Input Program Management
Industry Integration Teams
Core Technology Program
Project Management
SECA Cost Reduction
SECA Coal Based Systems
NATIONAL
LAB
NATIONAL
LAB
UNIVERSITY
UNIVERSITY
INDUSTRY
INDUSTRY
SMALL
BUSINESS
SMALL
BUSINESS
Research TopicsNeeds
TechnologyTransfer
FuelProcessing
FuelFuelChemistryChemistry
ManufacturingManufacturingManufacturing
Balance of PlantBalance of Plant
Coal Contaminants
Coal Coal ContaminantsContaminants
Modeling &SimulationModeling &Modeling &SimulationSimulation
MaterialsMaterials
SECA Manufacturing
SECA Industry Teams & Major Subcontractors
VersaPowerSystems
00076 7-13-07 WAS
Calgary Global Research
SECA Industry TeamsFY 2001 – FY 2007
Complete
PassCompleteMinneapolis, MNCummins Power Gen.
PassCompletePittsburgh, PASiemens Power Group
PassCompleteWestwood, MAAcumentrics
PassCompleteCalgary, BCFuel Cell Energy
PassCompleteRochester, NYDelphi
PassCompleteTorrance, CAGeneral Electric
NETL ValidationPrototypeLocationSECA Industry Team
3 – 7 kW
3 – 10 kW
Size
90%4%/1,000 hrs35 (LHV)Target
$724 - $775/kW97%2%/1,000 hrs35.4 – 41 %Aggregate Team Performance
CostAvailabilityDegradationEfficiency
Short Stack Performance Example
0
100
200
300
400
500
600
700
2002 2003 2004 2005 2006
Pow
er D
ensi
ty (m
W/c
m2 )
0.6 V80% Uf
0.7 V88% Uf
0.7 V88% Uf
0.7 V88% Uf
0.7 V88% Uf
257 274
404
451
618SECA Target:
500 mW/cm2, 0.7 V, 80% Uf
2007 SECA Core Technology & Other Partners
ANL
NEXTECH
MATERIALS
NEXTECH
MATERIALS
00076 7-13-07 WAS
UTSA
Research Priorities: SECA Cost Reduction
CoatingsCoatingsElectrode to Interconnect Interface Contact MaterialElectrode to Interconnect Interface Contact MaterialInexpensive Processing/Removal of Tramp ElementsInexpensive Processing/Removal of Tramp Elements
InterconnectInterconnect
Cost and ReliabilityCost and ReliabilityDesign GuidelinesDesign Guidelines
Heat Exchangers/ Heat Exchangers/ High Temperature High Temperature BlowersBlowers
Optimize MicrostructureOptimize MicrostructureMixed ConductionMixed ConductionNew Active MaterialsNew Active MaterialsUnderstand MechanismUnderstand Mechanism
AdAd--atom Modification of Surfaceatom Modification of SurfaceModification through InfiltrationModification through Infiltration
CathodeCathodeperformanceperformance
Models with ElectrochemistryModels with ElectrochemistryDefine Operating WindowDefine Operating WindowStructural Failure Analysis & Design CriteriaStructural Failure Analysis & Design Criteria
Failure AnalysisFailure Analysis
Glass and Compressive Seals Glass and Compressive Seals Compliant SealsCompliant SealsSelfSelf--healing Materialshealing MaterialsHigh Temperature SealHigh Temperature SealBrazesBrazes
Gas SealsGas Seals
Moderate
Low
High
Risk Level
Research Priorities: SECA Coal Based Systems
Improve EfficiencyImprove EfficiencyReduce Cooling RequirementReduce Cooling RequirementOptimize TopologyOptimize Topology
Power ElectronicsPower Electronics
Enable High EfficiencyEnable High EfficiencyReduce Stack Cooling RequirementReduce Stack Cooling RequirementRecover High Quality Heat Recover High Quality Heat
Reliability of Components Reliability of Components
High Temperature High Temperature Heat Exchangers/ Heat Exchangers/
High Temperature High Temperature Blowers/CompreBlowers/Compressorsssors
Catalyst Surface ModificationCatalyst Surface ModificationCharacterize Thermodynamics/Kinetics/ ContaminantsCharacterize Thermodynamics/Kinetics/ ContaminantsMultiMulti--component Catalystscomponent CatalystsPressure EffectsPressure Effects
Anode /Anode /Coal ContaminantsCoal Contaminants
Combined Phenomenological Models with Combined Phenomenological Models with ElectrochemistryElectrochemistryStructural failure Analysis & Design Criteria Structural failure Analysis & Design Criteria
Maximum Cell SizeMaximum Cell SizeMaximum Thermal GradientsMaximum Thermal GradientsTransient Operating ConditionsTransient Operating Conditions
Pressure EffectsPressure Effects
Failure AnalysisFailure Analysis
Moderate
Low
High
Risk Level
Electrical Performance of Surface-Treated 441Electrical Performance of Surface-Treated 441
LSM cathode, LSM contact paste, 800oC, air
SECA Fuel Cells in DOD Applications
• DOD Requirements−Extend mission length−Quiet−Combined functions – power, heat and water −Volume and weight
• Operate with High Specific Energy Fuels – Liquids• DOE’s power density targets (based on cost) minimize
stack size and volume to diminishing returns. • Further size and weight improvements – Focus on the
Balance of Plant.
Anil Virkar2007 National Academy of Engineering
Anil Virkar was elected a member of the National Academy of Engineering on February 9, 2007, for his contributions to the development of high-temperature ionic and electronic materials for fuel cells and batteries. Election to the National Academy of Engineering is among the highest of professional distinctions with a U.S. membership of 2,217
Dr. Virkar is the Distinguished Professor and Chair of the Department of Materials Science & Engineering at the University of Utah, the Vice President of Materials and Systems Research, Inc. (MSRI), and a board member of Versa Power Systems (VPS)
Nguyen Minh 2007 Francis T. Bacon Medal
Nguyen Minh is the recipient of the 2nd Francis T. Bacon Medal presented at the 5th Annual International Conference on Fuel Cell Science, Engineering and Technology held this past June in New York City. The medal is awarded for "outstanding contributions to the technological achievements and commercialization of fuel cell systems".
The medal is preesented by ASME and named after Francis T. Bacon inventor of the Bacon cell. Pratt & Whitney licensed his work for the Apollo spacecraft.
Dr. Minh is shown shaking hands with Mr. Edward Bacon, F. T. Bacon's son; he lives in London and he and his wife came to New York to present the medal. (photo courtesy ASME)
Subhash Singhal2007 Fuel Cell Seminar & Exposition Award
The Fuel Cell Seminar & Exposition honored Mr. John Trocciola and Dr. Subhash Singhalwith the 2007 Fuel Cell Seminar & Exposition Award. This award is given annually to those who have achieved outstanding leadership and innovation in the promotion of and overall advancement of fuel cell technology.
New SolicitationSECA Coal-Based Systems
• Draft released for public comment Monday, August 6, 2007.• DE-PS26-07NT43136-DRAFT• https://e-center.doe.gov/• Closes August 20, 2007.
• Formal release scheduled for August 27, 2007, with an application due date of October 2, 2007.
• December 31, 2007 award date.• 1-2 awards.
• Same structure and objectives as existing Coal-Based Systems projects.
• Phase I: 12/07 - 9/08, $12.5MM DOE • Phase II: 10/08 - 9/10, $30MM DOE • Phase III: 10/10 - 10/15, $33MM DOE
SECA Coal-Based Systems Minimum Requirements
Phase I Phase II Phase III
40% 45-50% 45-50%
Cost (2002 $) $600/kW $400/kW $400/kW
Deliverable Scaled Stack Module POC
Deliverable Size >10-15kW ~5 MW
Steady-State Test 5000 hr 5000 hr >25,000 hrSS Degradation 4%/khr 2%/khr 0.2%/khrFuel Composite Composite Coal Syngas
Baseline System Efficiency (>100MWe IGFC, calculated)
250 – 1000 kW
•NETL website:−www.netl.doe.gov
Wayne A. SurdovalTechnology Manager, Fuel CellsNational Energy Technology LaboratoryU. S. Department of Energy(Tel) 412 386-6002(Fax) 412 [email protected]
CDs available from the website•FE Fuel Cell Program Annual
Report _2007• 8th Annual SECA Workshop
Proceedings (Coming Soon)
•Fuel Cell Handbook (7th ed.)
•FutureGen Alliance website:− www.futuregenalliance.org
•Office of Fossil Energy website:−ww.fe.doe.gov
For More Information About the DOE Office of Fossil Energy Fuel Cell Program
Reference Shelf
