SECA and the Office of Fossil Energy’s
Program Strategy
4th Annual SECA MeetingRita A. Bajura, Director
April 15, 2003
National Energy Technology LaboratoryOffice of Fossil Energy
Solid State Energy Conversion Alliance
SECA 4/15/03
World Primary Energy DemandProjected to Grow 66% by 2030
Natural Gas
Oil
Coal
02,0004,0006,0008,000
10,00012,00014,00016,000
1970 1980 1990 2000 2010 2020 2030
Mto
e
Non-hydro Renewable
Hydro
Nuclear
World Energy Outlook 2002. IEA
SECA 4/15/03
The ChallengeDefining a Path to World Energy Future
Future• Energy security• Economic development• Environmental
protection• Social welfare
02,0004,0006,0008,000
10,00012,00014,00016,000
1970 1980 1990 2000 2010 2020 2030
Mto
e
Non-hydro Renewable
HydroNuclear
Natural Gas
Oil
Coal
SECA 4/15/03
-5.0
0.0
5.0
10.0
15.0
20.0
1990 2015 2040 2065 2090 2115 2140 2165 2190 2215 2240 2265 2290
PgC
/yr
350 Ceiling450 Ceiling550 Ceiling650 Ceiling750 Ceilingis92a
Ultimately, Net Global GHG Emissions Must Sharply Decline and Even Approach Zero to
Achieve Stabilization
Source: PNNL
Emis
sion
s Pg
C/y
ear
20
15
10
5
0
- 51990 2140 2290
Year
Stabilization Levels
350 ppm
750 ppm
SECA 4/15/03
All Sectors and All Fossil Fuels Contribute to Carbon Emissions
CO2 Emissions from Fossil Fuel Combustion Year 2000 Emissions by Sector and Fuel Type
0
100
200
300
400
500
600
700
ResidentialCommercial
IndustrialTransportation
Electric
Mill
ion
Met
ric T
ons
Car
bon
Equi
vale
nt
Natural Gas
Petroleum
Coal
Relative Contributionby Fuel Type
U.S. Territories
SECA 4/15/03
The World Needs Affordable Energy
100
1,000
10,000
1,000 10,000 100,000 1,000,000 10,000,000
Affluence
Poverty
Annual Commercial Energy Consumption per Capita (kWh / person)
GD
P pe
r Cap
ita ($
/ yr
/ pe
rson
)Japan
World Resources Institute Database 1996-1997
BangladeshChina
Poland
MexicoSouth Korea
UK
France U.S.
100,000
SECA 4/15/03
FutureGen: A Presidential Initiative
One billion dollar, 10-year demonstration project to create world’s first, coal-based, zero-emission electricity and hydrogen plant
President Bush, February 27, 2003
One billion dollar, 10-year demonstration project to create world’s first, coal-based, zero-emission electricity and hydrogen plant
President Bush, February 27, 2003
• Produce electricity and hydrogen from coal using advanced technology
• Emit virtually no air pollutants
• Capture and permanently sequester CO2
SECA 4/15/03
“Traditional” Integrated Gasification Combined Cycle
CoalGasification
Central PowerGas Turbine Combined
Cycle
Central PowerGas Turbine Combined
Cycle
SyngasH2 + CO
Coal
SECA 4/15/03
IGCC in FutureGen
CoalGasification
Coal
TransportationFuel CellsIC Engine
TransportationFuel CellsIC EngineGeologic CO2
SequestrationGeologic CO2 Sequestration
Distributed Power
Fuel Cells
Distributed Power
Fuel Cells
“New” Part
Central PowerGas Turbine
or Hybrid Cycle
Central PowerGas Turbine
or Hybrid Cycle
HydrogenSyngasH2 + CO
SECA 4/15/03
Why Coal?
246
11.7 9.2
0
50
100
150
200
250
300Coal
Oil
NaturalGas
U.S. Fossil Fuels Reserves/Production Ratio Shows Years Supply at Current Production
• Abundant reserves• Low and stable
prices• Technology
improvements− Could enable near-
zero emissions of air pollutants/GHGs
EIA- U.S. Crude Oil, Natural Gas, and Natural Gas Liquids Reserves: 2001 Annual Report, November 2002;
Coal: BP Statistical Review, June 2002, World Energy Council
SECA 4/15/03
Why Sequestration?
• Compatible with existing energy infrastructures
• May prove to be lowest cost option
SECA 4/15/03
Options for Electricity & Hydrogen Production
Nuclear
Fossil/SequestrationFutureGen
Dream Source• Fusion• Thermochemical
Dream Source• Fusion• Thermochemical
RenewableEnergy
Conservation / Efficiency ImprovementConservation / Efficiency Improvement
SECA 4/15/03
SECA: A Route to Making Fuels Cells a Reality
2015• $400/kW• Hybrid systems
–60-70% efficient• Coal power plants
2010• $400/kW• Commercial products
–Residential, commercial, industrial CHP
–Transportation APUs
2005• 1st Generation products− Premium power– Truck APU’s– RV’s– Military
SECA 4/15/03
SECA SECA Program Structure
DOEDOEProgram Program
ManagementManagement
Univer-sities
Materials
Modeling & Simulation
Fuel Processing
Power Electronics
Control & Diagnostics
Manufacturing
TechnologyTechnologyTransferTransfer
Research
ResearchTopicsTopicsR&D
R&D
NeedsNeeds
Core Technology Program
Industry InputIndustry Input
Nat.Labs
+ + -- +- -Indus-try
SmallBus.
Industry Teams
SECA 4/15/03
Cummins - SOFCo
Two 60-cell Stacks
5-cell Cross-flow Stack
Catalytic Partial
Oxidation
Images courtesy of Cummins & SOFCo
SECA 4/15/03
Delphi - Battelle
Generation 2 APUTwo 15-cell stacksReforWERBalance of Plant
Compact, light, low-cost systems for transportation
Compact, light, low-cost systems for transportation
Images courtesy of Delphi
SECA 4/15/03
General Electric
Unitized Cell
Design
1-kW Catalytic Partial Oxidation
ConceptualDesign
Images courtesy of GE
SECA 4/15/03
Siemens Westinghouse
Redesigned Tube
Tubularcell
5 kW Prototype
Images courtesy of Siemens Westinghouse
SECA 4/15/03
Different Approaches!
• Stack extrusion• Plasma spray
• Cathode supported• 800 C• Redesigned tubular• Seal-less stack
Siemens Westinghouse
• Tape calendering• 2–stage sintering
• Anode supported • 750 C• Hybrid compatible• Internal reforming
General Electric
• Tape casting• Screen printing• 2–stage sintering
• Anode supported • 750 C • Ultra compact• Rapid transient capability
Delphi-Battelle
• Tape casting • Screen printing• Co-sintering
• Electrolyte supported• 850 C• Thermally matched materials• Seal-less stack
Cummins-SOFCo
ManufacturingDesignTeam
SECA 4/15/03
Core Technology Program Raises All Boats
DelphiDelphiSiemens
WestinghouseSiemens
Westinghouse
GeneralElectricGeneralElectric
Cummins PowerGeneration
Cummins PowerGeneration
• Materials• Modeling and simulation• Fuel processing
• Power electronics• Controls and diagnostics• Manufacturing
SECA 4/15/03
Current Priorities: Core Technology Program
• Lower cost precursor processing • Cost model methodology
Material cost4
• Direct DC to AC conversion• DC to DC design for fuel cells
Powerelectronics
3
• Metal oxides with interface modification• Catalyst surface modification• Characterize thermodynamics/kinetics
Anode/fuel processing
2
• Micro structure optimization• Mixed conduction• Interface modification
Cathodeperformance
2
• Models with electrochemistry• Structural characterization
Modeling2
• Modifying components in alloys• Coatings
Interconnect1• Glass and compressive seals Gas seals1
HowWhat
SECA 4/15/03
Cross Cutting Technologies
Seals, Modeling And Analysis, Cathodes, Anodes, Interconnects, Fuel Processing• PNNL
Metallic Supported Cell Structure, Cathode Interface Modification• LBNL
Metallic Supported Cell Structure,Interconnects, Fuel Processing• ANL
Bipolar PlateCathodeElectrolyteAnodeEnd Plate
Current Flow
Fuel Flow
Oxidant Flow
SECA 4/15/03
Intermediate-temperature Inexpensive Interconnect Materials
• U. of Pittsburgh• Ceramatec• Southwest Research Institute• PNNL• ANL
Thin foil Interconnect
Seal
Cell
Spacer
Images courtesy of Delphi
SECA 4/15/03
Materials for 2- to 3-fold Improvement in Cathode Performance
• U. of Washington • U. of Missouri Rolla • U. of Utah• Functional Coating, LLC • Georgia Tech• PNNL
Images courtesy of NexTech
SECA 4/15/03
Structural, Performance, And Optimization Design Tools
• PNNL • NETL• ORNL• U. of Florida • Georgia Tech• TIAX
Image courtesy of PNNL
SECA 4/15/03
Fuel Processing
Tubular cPox Reformer
Carbon/Sulfur Resistant Anodes• Northwestern • GTI
Carbon/Sulfur Resistant Reforming Catalysts• LANL • ANL• NETL
Image courtesy of Delphi
SECA 4/15/03
Balance of Plant
Interaction Among Fuel Cell, Power Conditioning, Load
• U. of Illinois
DC-DC / DC-AC Converters• Texas A&M • VPI
High Temperature Sensors• NexTech Materials
SECA 4/15/03
Low Cost / Consistent Precursor Materials
• NexTech Materials • U. of Utah
Electrolyte
Supportelectrode
Supportelectrode
Bilayer
Tape forming Rolling Rolling
Thin electrolyte on support electrode layer
Tape Calendering
Image courtesy of Honeywell
SECA 4/15/03
Highlights: Core Technology Program
• Glass and mica compressive seal characterization• Inexpensive Ferritic alloy interconnect characterization• Fuel cell models available• Material structural characterization• Mixed conducting cathodes, LaSrFeOx• Cathode microstructure optimization• Cathode mechanism intermediates identified• Metal oxide anode material–promising S, C,O tolerance• Low temperature bi-layer and ultra-thin electrolytes• Efficient DC-DC converter designed• Developing lower cost consistent materials
SECA 4/15/03
SECA Performance TargetsPhase 1 FY2005/06
Cost $800/ kW, $600/ kW, $400/ kWCost $800/ kW, $600/ kW, $400/ kW
> 1,000 hour intervalMaintenance
Stationary: 40,000 hours, 100 cyclesAPU: 5,000 hours, 1,000 cycles
Design lifetime
Natural gasGasolineDiesel
Fuels (Current infrastructure)
Stationary: 40 - 60%APU: 30 - 50%
Efficiency(AC or DC/LHV)
3-10 kW (net)Power rating
SECA 4/15/03
NETL’s SECA Test Facility
FUEL STORAGE
RESEARCH AREA113
STAIR101
UP
Liquid Fuel
Storage
Propane Storage
Fuel Cell System
Elec. Load Banks-AC/DC-Grid Simulator
Facility Design by:Concurrent
Technologies Corp.
Co-Gen ThermalLoad Bank System
Control Room
SECA 4/15/03
SECA Budget ($M)
0
5
10
15
20
25
30
35
2000 2001 2002 2003 20040
5
10
15
20
25
30
35
2000 2001 2002 2003
RequestFunding
Industry TeamsCore Technology Program
SECA 4/15/03
SECA Program Status
• Program in place• Making technical progress• Implementation as planned
SECA 4/15/03
Hybrid-basedFutureGen
plants
SECA: Key Part of Larger Fossil Energy Program2002 2006 2010 2015
Dynamic control /component integration
Turbine adaptation for hybrids
SECA
1st Gen.SECA
Hybrids with SECA technology
$400 / kWSECA module
ready
IGCC coal-fueled SECA-based hybrids
SECA 4/15/03
FutureGen Power Plants
Gasification with Cleanup Separation System
Integration
CarbonSequestration
A Vision for 2015Putting the Pieces Together
Optimized Turbines
SECA-Based Hybrids
SECA 4/15/03
5-kW SOFC Cost Breakdown
Total Cost: $372/kWTotal Cost: $372/kW
Stack 32%
Insulation 2%
Reformer & Desulfurization 9%
Piping 5%
Controls & Power Electronics 11%
Labor, Depreciation, Indirects 10%
Fuel & Air Supply 32%
Source: Conceptual Design of POx SOFC 5kW net System, Arthur D. Little, Inc., October 12, 2000