Project #38 Hydrogen, Fuel Cells

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Project #38 Hydrogen, Fuel Cells Powered By Docstoc
					Low Cost, High Efficiency Reversible
        Fuel Cell Systems
              DE-FC36-99GO-10455
               POC: Doug Hooker



            Dr. Robert Ruhl
          Vice President, Technology


     Technology Management, Inc.
   9718 Lakeshore Blvd, Cleveland, OH 44108
        (216) 541 -1000, tmi@stratos.net
                 May 19, 2003
                  Berkeley, CA
                                                                           Slide 2

                                                        Outline

                     •    Objectives
                     •    Approach
                     •    Time Line
                     •    Accomplishments
                     •    Interactions
                     •    Plans
            Responses to last year’s reviewer comments are
                included throughout this presentation

Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000    May 19 , 2003
                                                                                Slide 3


                                                   Objectives

   • Develop Enabling Technology for Low Cost
     Production of Hydrogen for Vehicles
                − natural gas
                − photovoltaic or wind power utilized when available
                − up to 80 MPa (11,600 psi)
                − residential or filling station sites
                − negligible CO and H2O
                − negligible emissions of NOx and other pollutants
                − cost < $1.50/kg




Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000         May 19 , 2003
                                                                                                     Slide 4

                             Approach: System Concept
                                                  Exhaust                  Water

                                           Heat
                                         Recovery            Useful Heat
                                                                                    High
             Natural Gas                                Oxygen                    Pressure
                                    Fuel Cell                        Electrolyzer    H2      H2
                                   Subsystem                         Subsystem             Storage
                    Air

                                                                  High
                   PV               DC                           Voltage
                                           Converter             DC Bus
                  Array
                                                                       Inverter
                                                                                      AC Power
                                                                      Subsystem
                                    Battery
                                   Subsystem

Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000                              May 19 , 2003
                                                                          Slide 5

                                    Approach: Challenges


                       • Electrolyzer Subsystem Efficiency
                       • Fuel Cell Subsystem Efficiency
                       • Moderate Installed Capital Cost
                       • Other




Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000   May 19 , 2003
                                                                          Slide 6

           Approach: Novel Solid Oxide Technology


      • Reversible Solid Oxide Stacks
            – target feed utilization: 100% (staged)
            – target average fuel cell voltage: 750 mV
            – target average electrolysis cell voltage: 1500 mV
      • Stack Cost Target: $100./kW
      • Stack Life Target: 5 years
      • Integrated Subsystems


Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000   May 19 , 2003
                                                                                                 Slide 7


                           Approach - Cell Configuration

                                                                     Alloy Separator
        • Radial Flow
                                                                 Cathode Distribution Layer
        • Diffusional
                                                                        Electrolyte
        • Small Diameter                                                               Seal




                                                                  Anode Distribution layer


                                                                                      Seal




Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000                          May 19 , 2003
                                                                                                        Slide 8


                                                    Time Line

                                   Phase 1 Start
              2000                   Phase 1 Completion (conceptual & cost studies,
                                     reversible cell demonstration)
Phase 2 Start
                              2001
   Phase 2 Completion                                            Phase 3 Starts (5/1/02)
   (cell & 2 to 5 cell stack studies)         2002
                                                                             Phase Test Stand and
                                                                             Hot Subassembly Completed
                                                             2003            Phase 3 Completion (10/31/03)
                                                                             (Stack Subassembly Demonstration &
                                                                             Cost Projections)




Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000                                 May 19 , 2003
                                                                                      Slide 9


                   Cell Development Accomplishments


      Parameters                                                 Goal       Status
                                                                      -5         -6
      Seal Cv                                                    < 10       < 10
      Power Decline (Watts/1000 hr)                              < 5%       < 5%
                                      2
      Area Specific Resistance (Ω - cm )                         < 1.0      1.1 to 2.3
      Cells/Stack                                                up to 50   up to 20




Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000               May 19 , 2003
                                                                                            Slide 10

                   Fuel Cell System Accomplishments



       • 50 cell Reversible SOFC                                          Hot
                                                                          Subassembly
           System Design
                                                                 Controls &
                                                                 Instrumentation
       • Natural Gas or
           Water Feed




Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000                     May 19 , 2003
                                                                          Slide 11


                   Fuel Cell System Accomplishments


             • 51% Stack LHV Efficiency on natural gas
                   − 20-cell stack

             • less than 5% per 1000 hr power decline
                   − natural gas, 19-cell stack

             • additional reversible stack tests



Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000   May 19 , 2003
                                                                                                 Slide 12

                            Fuel Cell System Accomplishments

                                                       1050

                                                                 3-cell Solid Oxide Stack
                                                       1000
                                                                           900C
                                                                     35% H2O in H2
              mV per cell




                                                         950


                                                         900


                                                         850
                                Electrolysis                           Fuel Cell
                                                        800
                   -100 -80        -60       -40      -20   0   20     40    60    80   100
                                                         mA/cm2

Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000                          May 19 , 2003
                                                                          Slide 13


     Engineering & Cost Studies Accomplishments


                         Example Residential System
                         • Annual Hydrogen 480 kg
                         • Annual AC 15000 kWh
                         • Annual Heat Recovery 18000 MJ
                         • Natural Gas LHV 925 BTU/scf




Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000   May 19 , 2003
                                                                                   Slide 14


     Engineering & Cost Studies Accomplishments

                         Example Residential System
                         projections for large annual quantities

                   Fuel Cell Modules (2 x 3 kW)                  $2281.
                   Electrolyzer Module (3 kW)                     1178.
                   Inverter Subsystem (20 kVA surge)               317.
                   Battery Subsystem (20 kW surge)                 388.
                   Photovoltaic Converter (3 kW)                    49.
                   Heat Recovery (2 kW)                            243.
                   Hydrogen Storage (10 kg)                        261.
                   Total Manufacturing Costs                     $4717.


Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000            May 19 , 2003
                                                                                      Slide 15


     Engineering & Cost Studies Accomplishments


       Manufacturing Cost                                               $ 4717.
       Manufacturing & Distribution Margins 75%                           3538.
       Installation Costs                                                 1843.
       Subtotal                                                         $10098.

       Sales Taxes 5%                                                       505.
       Total Installed Cost (end-user)                                  $ 10603.

       Annual Rate (assumption)                                  8.0%
       Annual Capital                                                     $ 848.

       Annual Maintenance (20 yr. Avg.)                                   $ 425.


Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000               May 19 , 2003
                                                                                                              Slide 16

     Engineering & Cost Studies Accomplishments

                                $3.00                                                  4.0

                                                                                       3.5
                                $2.50
                                            Fuel + Maintenance + Capital               3.0
              Hydrogen per kg




                                                                                             Cents per Mile
                                $2.00
                                                                                       2.5

                                $1.50               Fuel + Maintenance                 2.0

                                                                            Fuel       1.5
                                $1.00
                                                                                       1.0
                                $0.50
                                                                                       0.5

                                $0.00                                                  0.0
                                    $2.00   $3.00       $4.00    $5.00    $6.00    $7.00
                                                    Natural Gas per MCF

Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000                          May 19 , 2003
                                                                                      Slide 17


     Engineering & Cost Studies Accomplishments

                           Example Residential System
                   AC Power (using Natural Gas @ $6.00/MCF)

                                                                 Cents/kWh
                          Fuel                                         2.2
                          Maintenance                                  1.4
                          Subtotal Cash                                3.6
                          Capital                                      2.8
                          Total                                        6.4


Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000               May 19 , 2003
                                                                          Slide 18

     Engineering & Cost Studies Accomplishments


         H2 and Electricity Cost Depend on:
         • Fuel Cost
         • Maintenance Costs
         • Photovoltaic or Wind Inputs
         • Sale and/or Purchase of Electricity
         • Annual Capacity Factors
         • Accounting Assumptions



Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000   May 19 , 2003
                                                                          Slide 19


                                                 Interactions
           •     NIST/ATP (Nat’l Institute of Standards & Technology -
                 Advanced Technology) Program
                 - Delco Remy International
           •     DoD/Air Force, Dual Use Science & Technology
                 (DUS&T) Program
                  - Electricore
                  - Delco Remy International
                  - NASA Glenn Research Center
           •      State of Ohio 3rd Frontier Action Fund
                  - NASA Glenn Research Center
                  - Boeing
                  - Catacel

Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000   May 19 , 2003
                                                                           Slide 20

                                                          Plans

                       • Phase 3 completion: 10/31/03
                       • Cell and Stack Demonstration
                              –   Reduce ASR to 1.0 ohm-cm2
                              –   Demonstrate Stacks up to 50 Cells
                              –   Preserve Power Loss < 5%/1000 hr
                              –   Preserve Cv < 10-5
                       • Engineering and Cost Studies
                              – Complete Work



Technology Management, Inc.,
                                                      541-
9718 Lake Shore Blvd., Cleveland, Ohio 44108, - (216) 541-1000    May 19 , 2003

				
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