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Fuel Cell Power Plant Experience Naval Applications

US Department of Energy/Office of Naval ResearchShipboard Fuel Cell Workshop

Washington, DCMarch 29, 2011

FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.

•FuelCell Energy, Inc.

•Renewable and Liquid Fuels Experience

•HTPEM Fuel Cell Stack for Shipboard APU

•Solid Oxide Experience and Applications

DOE-ONR Workshop


FuelCell Energy, Inc.

• Premier developer of fuel cell technology — founded in 1969

• Over 50 power installations in North America, Europe, and Asia

• Industrial, commercial, utility products

• 300 KW to 50 MW and beyond• Research and development in

MCFC, SOFC, PEM and Fuels


High electrical and CHP efficiencyNear zero NOX, SOX and lower CO2

emissions Reliable, Secure powerClean & Quiet Operation Ideal Shore Capacity - Low Profile,

Easy SitingConnects to existing electricity and

fuel infrastructureMultiple fuels

29 Palms Marine Corps Base

Naval Station Groton (Planned)

DFC Naval Facilities Applications


Renewable and Liquid Fuels

DOE-ONR Workshop


FCE Liquid Fuels Experience

• Silent tactical 3/5 kW fuel cells (US Army) – M 232 methanol PAFC• Remote site 3 kW DFC power unit plant (USCG) – M 232 methanol PAFC• 32 kW DFC Demonstration power plant (DARPA) – DF2, JP-8 • 500 kW Ship Service DFC Demo Plant (Navy) – JP-5 • DFC300 Commercial Design Power Plant (US Army CERL) propane• 5 kW adiabatic fuel processor (US Army CERL) – B-100 bio diesel• Bench scale adiabatic reactor - ethanol

3 kW methanol fueled fuel cell power units were constructed and delivered to the US Army

This 3 kW methanol fuel DFC power plant operated unattended at Virginia Beach, VA site for 6 months

DFC300 power plant operated for 6 months on Propane with seamless transition to NG


Logistic Fuel DFC Power Plant

A 0.5 MW fuel processor was integrated with an FCE Direct Fuel Cell Stack and operated with high sulfur naval logistic fuel (JP-5 jet fuel)• Over 1000 Hours of Fuel System Operation• Over 300 Hours of Operation on Load with Water Recovery • Power Output up to 125 kW (50% of Stack Rating)• Over 17,600 kWh Generated with Navy Logistic Fuel• 17 Tons of Logistic Fuel Processed by HDS During Factory Test• Sulfur Reduced in JP-5 from 1,100 ppm to 0.1 ppm


Pilot Scale Prereformer Operated over 1000 hr with Biodiesel fuel

Reformate Composition(dry basis)

CH4 40.3%H2 32.0%CO 0.7%CO2 27.0%

Reformate Composition(dry basis)

CH4 37.4%H2 37.0%CO 0.0%CO2 25.6%

Bench Scale Prereformer Tested with Ethanol

Renewable Liquid Fuel ProcessingHigh Temperature Fuel Cells


HTPEM Fuel Cell Stack for Shipboard APU

DOE-ONR Workshop


400

500

600

700

800

900

0 50 100 150 200 250 300 350

Current Density, mA/cm2

Cel

l Vol

tage

, mV

1.2 stoic Fuel/2 stoic Air, 30%H2, 65% N2, 5% H2OCell HT-001

Atmospheric Pressure

3 Atmospheres PressureV- I Characteristic for PBI Cell 1atm/3atm

50 kW PBI Stack Module

Endurance Test of BASF P-2100 MEA



50 kW PBI Stack ModuleFour 144-cell stacks incommon gas enclosure

144-Cell PBI Stack Performance - 3 atm

90

95

100

105

110

115

0 50 100 150 200 250

Stack Current (A)

Stac

k Vo

ltage

(V)

0

5

10

15

20

Stac

k Po

wer

(kW

)

Projected Module Power OutputThe 4-stack module generates 50.4 kW at 125 A

PBI 2KW Short Stack with 24 600cm2 Cells

Temperature: 180°C

Pressure: 0 - 30 psig

CO Tolerant to 2%

Two phase liquid cooling



35"

30"

12"

10"

1.5"

3"

OXIDANT MANIFOLD

FUEL

MA

NIF

OLD

FUE

L MAN

IFOLD

INSULATION INSULATED SUPPORTCHANNEL

Estimated Dimensions and Performance of a 50 kW PBI Stack Module Meets Navy’s Shipboard Fuel Cell Goals


Solid Oxide Experience and Applications

DOE-ONR Workshop


• Planar anode supported cells (up to 33 x 33 cm2)• Capable of operating from 650°C to 800°C• Ferritic stainless steel sheet metal interconnect • Cross-flow gas delivery , manifolds integrated into the interconnect but not through the cell• Compressible ceramic gasket seals • Standardized stack blocks configurable into stack towers for various power applications

A node

Cathode

Electrolyte

A node

Cathode

Electrolyte

FCE SOFC Systems Background

SOFC MW Module

FCE utilizes VPS (Versa Power Systems) fuel cell technology in FCEs SOFC stack modules and systems.

FCE/VPS team is engaged in Phase II of Solid State Conversion Alliance (SECA) Program for development of MW-scale SOFC systems


10-20 kW Stack

1 kW Stack

SOFC Stack Module

Stack Tower

Develop SOFC stack technology that meets performance & cost objectives, is scalable, and is used as the building block for assembling stack towers and large-scale power modules.

Modular

Endurance

Performance Cost

Scal

abl

e

Prime Power and Auxiliary Applications

SECA SOFC Development Path

2006

2008

2010


Stack Tower (SO-30-3) Test

• Demonstration of stack tower operation in a simulated power plant environment, using 2x92-cell stack blocks.

• A Power Rating of 30 kW was established during the operation.

0

5000

10000

15000

20000

25000

30000

35000

40000

45000

50000

0 200 400 600 800 1000 1200Runtime/ Hr

Pow

er/ W

0

50

100

150

200

250

Stac

k Vo

ltage

/ V

PowerTotal Voltage


Hybrid System for Underwater Vehicles and Weapons

• Project Support by Office of Naval Research (ONR) through STTR programs:– Phase I STTR, “Hybrid Propulsion System for Undersea Weapons” (N00014-05-M-0183)– Phase II STTR, “Hybrid Propulsion System”(N00014-06-C-0406 )


SOFC Based Torpedo System Design

• Very compact• Designed to fit in

torpedo cross section • Length depends on

power/stack size

13” for 5 kW

18” for 8 kW

22” for 10.7 kW

33” for 16 kW


SOFC/T Hybrid System

Black Start CapabilityBlack Start CapabilityFast Ramp RateFast Ramp Rate

Flexible Fuel Processing TechnologyFlexible Fuel Processing TechnologyUltra High Efficiency Ultra High Efficiency

GenC

AnodeCathode

Recuperator

T

Out

Gas Turbine

Fuel

AGO

Water

C

Water Recovery

Air

Supp. FuelPower Ramp/Startup

Solid Oxide Fuel CellInverter

~

Fuel Processing(SR or ATR)


Summary

FCE DFC Fuel Cells ready now to provide shore based power

FCE has multiple process Liquid Fuels Experience

HTPEM Stack Experience can be Advanced to Demonstration

Solid Oxide (SOFC/T) holds promise as high efficiency cycle

DOE-ONR Workshop

fuel cell power plant experience naval applications · fuelcell energy, the fuelcell energy logo,...

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