2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Precision Combustion, Inc.Compact, Diesel/Jet Fuel Processing Systems and SOFC Generators
Anthony Anderson, Subir Roychoudhury
Precision Combustion, Inc. (PCI), North Haven, CT
April 24, 2017
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
• Privately‐held small business/40 employees. Est 1986.
• High performance engineering team: • 9 PhDs, 31 engineers/technicians/admin., large/small co backgrounds
• Focus on Innovation and product development
• Catalytic reactors/systems for Energy sector
• Microlith® Catalytic Reactors, and RCL® Combustors
Reforming: Syngas, H2, Chemicals, W – MW scales
Sorption: Bio/Chem, Sulfur, trace contaminantsSmall Generators: Tactical Power, UAV, UGVCombustion: Gas turbines, burners, augmentation, down‐hole, Stirling
Prototypes: BOP, Controls, packaging
• Customers/partners: U.S. Govt., large & small companies, universities
Precision Combustion, Inc.
38,000 sq ft facility
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
PCI Technology‐Product‐Application Space
Power
Fuel Cell SystemsAPUs/GensetsVehicles/Ships/Soldier portable
IC EnginesTactical Gensets
UXV Fuel Cell Systems
Reformers for Industrial Systems
Combustion
Kitchen Burners
Stirling BurnersTEG Burners
Fuel Cell System Oxidizers
Catalytic Combustors
•Gas Turbines•Steam generators
Air Cleaning
Oxidizers
Adsorbers
Desulfurization
Other
H2 generation•Still Gas Processor
Catalytic ignitors
Chem. Manf.•Sabatier Methanation
•Shale Gas to Chem.•CO2 to Fuels
Chemical Sensors
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
PCI Jet Fuel, Diesel Power Generation Solutions
Fuel Cell
20 – 50 W (Wearable/Packable)
1 – 2 kW (APU, UAV)
10 kW
IC Engine
Included Technologies Won Army SBIR Achievement Awards in 2008 & 2010
350 W
1 kW
2 kW
Stirling
2 kW
135 W
3 kW
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Microlith® Reactor Technology
Small, durable, catalytically coated metal mesh with very high surface area
Continuous catalyst coating line with batched furnace and rigorous QA, QC in place
Microlith® Catalytic ReactorsLow cost
Ultra compact Short contact time
Rapid thermal responseHigh heat & mass transfer
High surface area/unit volume
PCI holds multiple patents on catalyst structure, reaction methods and apparatus.
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Microlith Substrate vs. Monolith
Cells/in 2
GSA (m 2/l)Channel Length (in)
Length to Diameter Ratio (L/d)Operating Temperature ( oC)
Frontal Open Area
4002.64
3.0 - 5.070 - 120
1050 - 120070
25006.3
0.0030.3
1050 - 120072
Microlith®Conventional MonolithConventional Monolith PCI’s Microlith Substrate
Monolith wall
Monolith wall
Monolith wall
Boundary layer formation
Mixing regions
Boundary layer formation
400 Cells / in2 25002.64 GSA (m2 / liter) 6.3
3.0 – 5.0 Channel Length (in) 0.0031200 Material Limit Temp (°C) 120070 Frontal Open Area (%) 72
Benefits of Microlith® substrate:
• High surface area per unit volume
• High heat & mass transfer rates
• Low catalyst usage & small size
• Lower ∆P vs. pellet catalyst bed
• Comparable ∆P vs. monoliths
• Design flexibility (e.g., planar, radial)
• Modular design, easily scalable
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Reforming (for Fuel Cells, H2 Gen)
1. Catalytic Partial Oxidation (CPOX)
2 CH4 + O2 4 H2 + 2CO {H2O + CO2 ‐ ∆H}
2. Catalytic Autothermal Reforming (ATR)
3 CH4 + O2 + H2O 7 H2 + 3 CO {H2O + CO2 ‐ ∆H}
3. Catalytic Steam Reforming (CSR)
CH4 + H2O 3 H2 + CO {H2O + CO2 + ∆H}
Application specific reformers, using Microlith® Technology
5 kWth DieselFor Automotive
5 MWth Nat. Gas
3 kWth Diesel/JP‐8 ATR Module 1 MWth Liquid HC Reformer
3 ‐ 10 kWth Diesel SR‐ Exo/Endo sections
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2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
PCI Innovation: Diesel/Jet‐A Reformer with Sulfur Cleanup
• Ultra‐compact, high efficiency, water‐neutral reformer for producing stack‐quality reformate
• Reformer includes catalyst, steam generator, HX, sulfur cleanup, fuel/air/steam mixer, igniter
• Value: • Allows SOFC’s to use diesel/Jet fuels (up to 3,000 ppmw Sulfur)• With PCI’s WGS, allows HT‐PEM fuel cells to use diesel/military fuels • With H2 separation, demonstrated to produce PEM quality hydrogen
We put the fuel in fuel cells®
100 We 1 kWe 1 kWe – High Sulfur 2 kWe 10 kWe 300 kWe
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2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Unique Approach for Reformation & Cleanup of High Sulfur JP‐8
A simple, compact, lightweight approach w. small logistic footprints & high efficiency
Approach: Microlith catalyst tailored w. optimum reactor design & operating conditionsSulfur Tolerant Reformer followed by gas phase desulfurization
• In‐situ sulfur cleanup (types of sulfur, fuel types, sensors,….)
• Produce SOFC‐quality reformate from JP‐8 w. up to 3000 ppmw sulfur
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2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
• High capacity, low DP sorbent bed removes sulfur from reformate stream (US Patent 7,964,023)
• High sulfur sorption capability due to increased sorbent surface area & dispersion High volumetric sorption capacity results in long life (200 cc for 3200 hrs. with ULSD) Implemented as non‐regenerative to avoid complexity
Sulfur Removal
Sharp breakthrough curve allows longer periods between change‐outs10
H2S breakthrough conc. = 3 ppmv
Low bed utilization
Improved bed utilization
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
H2 Purification
• Water Gas Shift Reactor (WGSR)CO + H2O H2 + CO2 {CH4 ‐ ∆H}
• Preferential Oxidation of CO (PROX)CO + ½ O2 {H2} CO2 {H2O ‐ ∆H}
• Membrane Separation IntegrationPd/Ag/Polymer on metal/ceramic supports
• Pressure Swing Adsorption (PSA)H2 selective sorbents
PCI has experience in HT‐PEM and LT‐PEM Quality Reformate Generation
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Commercial Applications
Aircraft APU Truck APU Marine APU
Fuel Cell Range Extenders RV APU Industrial Syngas
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
PCI Reformer Benefits
• Compact
• Lightweight
• Simple design & packaging
• Enables water neutral operation
• Readily integrated with Fuel Cells
• Modular components – readily serviceable
• Sulfur tolerant (ATR and CPOX) with sulfur cleanup cartridge filter
• Durable
• Stack‐quality reformate
• COTS BOP and controls
• Tested with different stacks
• Fuel flexible (distillate, biofuels, gaseous fuels)
• TRL 4‐8
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Fuel Reformer & Fuel Processor Test Carts
• Ultra‐compact high efficiency reformer able to convert fuels to sulfur‐free syngas (H2+CO) for SOFC stack testing
• Add WGS for HTPEM testing and Pd membranes for LTPEM testing
• Packaged with BOP, MFCs and software to enable push‐button operation
• CPOx, ATR and SR versions available
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Turnkey Syngas Generation Skids
Stand alone syngas generators with PLC controls operating on Natural Gas
Over 5,000 combined operating hours to date making over 60,000 Nm3 syngas
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
1 MWth Microlith® Autothermal Reformer to reform VOC compounds from process waste streams
Scale‐up: 1 MWth VOC Reformer
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
CPOX Scale‐up: 5 MW(th) Natural Gas Processor
• Performance testing successfully completed.
• 1000 hrs of sub‐scale durability completed (Target 8000 hrs).
5 MWth reactor to reform natural gas to produce syngas
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
• High heat flux due to conductive heat transfer enhanced by Microlith catalyst packing
• Microlith based design provides low DP and high bed utilization compared to packed beds
• Rapid thermal response coupled with high conductive heat transfer results in compact size
• Catalytic burner instead of flame‐stabilized improves thermal uniformity, distribution, durability, control
Microlith Based Thermally Integrated Steam Reformer
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Catalyzed Microlith
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Conductive vs. Convective Heat Transfer
Constant Heat Flux across the wall
Wire mesh packing
Empty channel
Chemical and Process Engineering, 2010, 31, 119‐134
Wire mesh packed channel
Empty channel
Wire mesh packed channel
Empty channel
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Significantly higher heat flux can be achieved via efficient conductive heat transfer
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
H2 Generation System
Feed Pretreat & Mixer Steam Reforming WGS Water Recovery
PSA / MembraneBurnerFuel
Heat Recovery
Tail Gas
Steam
Water
Heat integration for maximized efficiency
H2
AirBurner Exhaust
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Water
Steam
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
• Endothermic (CSR) fuel: natural gas, <5 ppmw sulfur distillate fuels
• Exothermic (burner) fuel: diesel, distillate fuels, waste fuels (e.g., High S fuels, Tail Gas)
• Readily scalable; Tested at up to 10 atm on endothermic side; includes heat integration & mixing
• Completed ~500‐hr durability testing and 250‐hr integrated testing w. H2 separator
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Integrated Steam Reformer Prototypes
H2 generationPower generation
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
H2 Generator
%65.7710021.5716.75100
(SLPM) H Reformate(SLPM) UPH%) ,Efficiency Separation(
2
Avg. Reformate composition (mole%, dry basis)
Reformate flow rate (SLPM) Raffinate composition (mole%, dry basis) Raffinate flow rate (SLPM)
H2 56.18 21.57 22.06 4.82
CH4 12.21 4.69 21.69 4.74
CO 8.06 3.09 15.57 3.4
CO2 18.34 7.04 31.52 6.89
N2 5.21 2 9.15 2
H2 Generation rate of ~17 slpm
Steam Reformer MembraneFuel + Water
H2, CO, CO2, CH4, H2O , N2
Permeate (UPH)
Raffina
te
H2COCO2CH4H2O N2
Reformate
N2 as internal standard
Heat
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Steam Reformer + H2 Separator Setup
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Modular SR and Separator
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Packaged 1 kWe Diesel/Jet Fuel Reformer/Desulfurizer
• Fully‐packaged 1 kWe Fuel Reformer System• Includes all balance‐of‐plant (BOP) components & control
• Capable of stand‐alone, facility independent operation• Includes safety interconnects & stack interface control
Approximate dimensions:7.5” (19 cm) x 15” (38 cm) x 18” (46 cm);
Includes Fuel Reformer, sulfur trap, fuel/water/air pumps, sensors/meters, fuel tank, water tank, HEX & control electronics.
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Maturation Timeline
BOP‐based Reformer Test Systemw. Lab Controls
MFC‐based Reformer Test Systemw. Lab Controls (2 ft x 2.5 ft x 3 ft)
c. 2012
Packaged Reformer w. BOP & single control board
National Instrument (NI) cRio
2015c. 2010
Facilities Supported Standalone Minimized, Packaged
2019
Integrated
Integrated Fuel reformer Fuel Cell System
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
1 kWe Reformer + SOFC Testing (Breadboard Integration)
• 1 kWe (3 kW thermal) reformer, desulfurizer with all BOP components used for test
• Powered 1 kW SOFC @ 25% Fuel to electric efficiency (gross).
• Operated fuel cell system for 500 hours with Jet fuels.
• Operated reformer for a total of 1500 hours on Jet fuels (containing up to 3000 ppmw sulfur).
1 kW Fuel Reformer, Desulfurizer
Compact, lightweight diesel/Jet fuel Fuel Cell Generator with high efficiency & long mission duration
SOFC:
1 kW SOFC
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Operation w. 400 ppmw Sulfur Jet Fuels
Performance Mapping of reformer @ 3, 2.25 & 1.5 kWth to evaluate turndown (0.5 – 1 kWe)
Reformate composition (mole %, wet basis) 3 kWth 2.25 kWth 1.5 kWth
H2 23.5 23.4 23.4
CO 14.0 13.1 11.9
CO2 5.8 6.5 7.5
N2 38.9 39.3 39.8
CH4 0.14 0.14 0.10
H2O 17.7 17.6 17.2
C2s (ppmv) 50 40 32
C3s (ppmv) 0 0 0
Fuel conversion to C1 products (%) 100 100 100
LHV‐based reforming efficiency (%) 81 79 78
• Increasing sulfur levels in fuel requires higher O/C, resulting in lower reforming efficiency.• Complete fuel conversion w. ≥~78% reforming efficiency & ≤50 ppmv HHC in reformate.
Stable operation, high reforming efficiency & turndown capability w. sulfur fuels
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
1 kWe Reformer Specifications
• Includes ATR, injector, steam generator, HEX, desulfurizer, Sensors, Controls, Pumps, blower.
• Compact & lightweight (<10 kg)
• Fuel flexible (diesel, Jet fuels, other distillates, alcohols, gaseous & bio‐fuels)
• Sulfur tolerance (up to 3000 ppmw fuel sulfur)
• Sulfur cleanup to <<0.5 ppm
• Non‐Regenerable high capacity sulfur trap (200 cc for 3,200 hrs. w. ULS diesel)
• Durable (1500‐hr w/o failure demonstrated with up to 3000 ppm S fuels)
• High reforming efficiency of 75 – 85% (LHV based)
• SOFC‐suitable reformate stream (<50 ppmv HHCs; <<1 ppmv sulfur)
Visit the PCI Booth (D33) for details.
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
2 kWe Fuel Cell Generator (Breadboard Integration)
• Operated 2 kWe Fuel Cell Generator @ Fuel to electric efficiency of 25%;
• Thermally‐integrated, water‐neutral system operated for 270 hrs w. Jet Fuels & Diesel.
Reformer + desulfurizer
Hotbox consisting of SOFC, burner & heat recuperators
Dual‐fuel Burner
2.25ʺ
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
SOFC Performance (w. Tier II Diesel)
• Fuel Cell System evaluation using Tier II Diesel for ~125 hrs.
• Steady state operation at 1.5 kWe demonstrated stable system performance (reformer, fuel cell & burner).
• Stack voltage was stable at ~60 V, 25 Amps; anode & cathode temperatures were also stable.
• Test was stopped after ~125 hrs to replace fuel with Jet‐A.
Stack Temp vs. Time Stack Power & Voltage vs. Time
Stack heat‐up & OCV
Stack OCV & cool‐down
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
SOFC Performance (w. 100 – 400 ppmw Sulfur Jet Fuel)
• Fuel Cell System evaluation using up to 400 ppmw sulfur Jet Fuels for ~50 hrs.
• Stable system operation (reformer, fuel cell & burner) at steady state, producing 1.5 kWe.
• Stack voltage was stable at ~60 V, 25 Amps; anode & cathode temperatures were also stable.
• System shutdown alarm triggered ~20 hrs; no observable performance degradation after re‐start.
Stack Temp vs. Time Stack Power & Voltage vs. Time
Stack heat‐up & OCV
Stack OCV & cool‐down
Shutdown due to mains power fluctuation
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Dual Fuel Burner
• Required for start‐up & steady state operation
• Liquid fuel (Jet fuels/diesel) for start‐up
• Anode Tail Gas + liquid fuel during steady state
• Integrated w. anode/cathode inlet/outlet HX
Features:
• Reliable start‐ups with consistent temperature profile;
• Stable temperature & simple controls;
• Dual fuel capability (i.e., starts with liquid fuel & then transitions to anode exhaust or co‐fuels).
8 kWth burner: weight = 0.9 kg, vol. = 0.8 L
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Sabatier Methanation Reactor
• Sabatier reactionCO2 + 4H2 CH4 + {2H2O ‐ ∆H}
• Demonstrated at laboratory scale
• Compact unit with less pressure drop than pellets or foams
Suitability for Power to Gas Systems
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
• Packaged reformer system demonstration: Reforming eff. ~75 – 84% (Fuel sulfur dependent)
• Advanced a simple approach for compact reformation & desulfurization of high sulfur fuels:• Avoids upstream liquid‐fuel desulfurization sub‐systems• Demonstrated durability for 1000 hrs w. 1000 ppmw sulfur Jet fuel; 1500 hrs w. various JP‐8• Near complete fuel conversion to C1 products (<150 ppmv C2s & C3s w. 1000 ppmw sulfur fuel)
• Developed BOP components & packaging:• Demonstrated stand‐alone operation with complete BOP system• Low steady state parasitic power needs demonstrated (70 We for 1 kWe Reformer System)• Automated startup, transient w. 3:1 turndown capability & shutdown• Demonstrated 1500 hours durability of BOP components
• Developed dual fuel burner capable for operation w. JP‐5/JP‐8/diesel & anode tail gas
• Successful demonstration of stack integrated solutions:• Flexible reformer design being integrated w. stacks• Successfully demonstrated stable reformer + stack operation with & without sulfur fuels• Packaged Jet fuel/Diesel generator systems being matured
Summary
2017 Hannover Messe Group Exhibit Hydrogen + Fuel Cells + Batteries April 24, 2017
Come See Us!
Precision Combustion, Inc.Booth# D33We put the fuel in fuel cells®
Subir RoychoudhuryVP Research and Engineering
sroychoudhury@precision‐combustion.com+1 203‐287‐3700 Ext.267
Tony AndersonDirector, Marketing & Business Development
aanderson@precision‐combustion.com+1 203‐287‐3700 Ext.290
http://www.precision‐combustion.com
Twitter: @_PCI
Linked In: www.linkedin.com/company/precision‐combustion‐inc.