Clean Economic Energy in a Carbon Challenged World

Wayne A SurdovalWayne A. SurdovalTechnology Manager, Fuel CellsNational Energy Technology LaboratoryUnited States Department of Energy

30SEPTEMBER08, International Pittsburgh Coal Conference, Pittsburgh, PA

United States Department of Energy

Department of EnergySecretary

Dr. Steven ChuDeputy Secretary

Federal EnergyRegulatory

CommissionChief of Staff

Office of theUnder Secretary for Nuclear Security / Administrator for National Nuclear Security

Administration

Associate Administrator Assistant Secretary

Office of theUnder Secretary

D t Ad i i t t

Assistant Secretaryfor Policy &

International Affairs

Assistant Secretaryfor Congressional &Intergovernmental

Affairs

General Counsel Health, Safety & Security

Bonneville Power Administration

Southeastern Power

Administration

Office of theUnder Secretary for

Science

Associate Administratorfor Emergency

Operations

Associate Administratorfor Infrastructure& Environment

Associate Administrator

Assistant Secretaryfor Energy Efficiency &

Renewable Energy

Assistant Secretary for Environmental

Management

Advanced Scientific Computing Research

Deputy Administratorfor Defense Programs

Deputy Administratorfor Defense Nuclear

Nonproliferation

D t Ad i i t t

Economic Impact & Diversity

Inspector General

Chief FinancialOfficer

Chief InformationOfficer

Southwestern Power

Administration

Western Area Power

Administration

Office of Science

Associate Administratorfor Defense Nuclear

Security

Associate Administratorfor Management& Administration

Assistant Secretary for Nuclear Energy

Assistant Secretaryfor Fossil Energy

Biological & Environmental

Research

Basic Energy Sciences

Deputy Under Secretaryfor Counter-terrorism

Deputy Administrator for Naval Reactors

Assistant Secretary F i E

Intelligence and Counterintelligence

Hearings & Appeals

Human CapitalManagement

Management

Energy Information

Administration

Assistant Secretary for Electricity Delivery & Energy Reliability

Civilian Radioactive Waste Management

Fusion Energy Science

High Energy Physics

Public Affairs

2

From energy.gov, 02/02/2009

Legacy Management Nuclear Physics

Workforce Development for

Teachers & Scientists

FY 09 Fossil Energy Fuel Cell Program Solid State Energy Conversion AllianceSolid State Energy Conversion Alliance

(SECA)$70

$40

$50

$60

$10

$20

$30SECA FY 09…...$58,000,000

SECA Cost ReductionIndustry SECA Coal Based Systems

Industry

$02000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Request Appropriation

Universities, Small Business

National Laboratories

3

SECA Industry Teams & Major SubcontractorsSubcontractorsCalgary

VersaPowerSystems

4

00076A 10-22-08 WAS

2009 SECA Core Technology & Other Partners

NEXTECH

MATERIALS

NEXTECH

MATERIALS

ANL

5

00076C 6-03-09 WAS

DOE’s Office of Fossil EnergyAdvanced (Coal) Power Systems GoalsAdvanced (Coal) Power Systems Goals

• 2010: – 45-50% Efficiency (HHV)y ( )– 99% SO2 removal– NOx< 0.01 lb/MM Btu

90% Hg removal– 90% Hg removal• 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)

6

Solid State Energy Conversion Alliance Performance Assessment Rating Tool (OMB)

2010

Stack Cost ~ $175/kW stackStack Cost $175/kW stack

Capital Cost < $700/kW system

Maintain Economic Power Density with Increased Scale ~ 300mW/cm2Increased Scale 300mW/cm2

Mass customization – stacks used in multiple li ti l d ll t

Ref: 2007Goal: 2010

7

applications….large and small systems

Solid State Energy conversion Alliance Fuel Cells Technology TimelineFuel Cells Technology Timeline

2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 20202005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2020

SECA R&DTechnology Solutions and Enabling Technology

SECA Cost Reduction

Validation test Validation test

SECA Coal Based Systems Operate

Single Module Operate Multiple Module (5 MW)

SECA Manufacturing

g(1 MW) Scale

( )Scale with Turbines

$700/kWRef: 2007

250 – 500 MW IGFC

8

Ref: 2007Coal-Based Fuel Cell

Objective

SECA Coal Based Systems reduced water requirement

> 90% carbon captureAir AirSeparation

Gas CleaningCoal

H2O

O2

Anode

Gasification

H2,CO2S ti

Shift

Combustor

SulfurRecovery

Anode

Cathode

CO2Air Atmospheric SOFC

Separation

To HRSG

To Fuel Cell Preheat

Marketable Ash/Slag

By-productMarketable

SulfurBy-product Sequestration

Heat Recoverye.g., HRSG

Preheat

EnhancedOil Recovery

Deep SalineAquifer

UnmineableCoal Beds Depleted Oil & Gas

Reservoirs

Sequest at o

• Atmospheric SOFC with conventional coal gasification• Combined Fuel and Air Streams• Steam cycle – reduced external water requirement• Cycle Efficiency (HHV); 90% Capture

9

~42% with CO2 Compression~45% w/out CO2 Compression

SECA Coal Based Systems reduced water requirement

>90% carbon captureAir AirSeparation

Water Gas Shift;Dry

Gas CleaningCoal

H2O

O2

Anode

Gasification H2,Rich Syngas

CO2S ti

Combustor

SulfurRecovery

Anode

Cathode

CO2Air Pressurized SOFC

Separation

To HRSG

To Fuel Cell Preheat

Marketable Ash/Slag

By-productMarketable

SulfurBy-product Sequestration

Heat Recoverye.g., HRSG

Preheat

EnhancedOil Recovery

Deep SalineAquifer

UnmineableCoal Beds Depleted Oil & Gas

Reservoirs

Sequest at o

• Pressurized SOFC with conventional coal gasification• Combined Fuel and Air Streams• Steam cycle – reduced external water requirement• Cycle Efficiency (HHV); 90% Capture

10

~47% with CO2 Compression~50% w/out CO2 Compression

SECA Coal Based Systems near-zero water requirement

99% carbon captureAir AirSeparation

Dry Gas Cleaning

CO2,CO, H2, H2O

Coal

H2O

O2

Anode

Catalytic Gasification

CH4 CO, H2, CH4 O2

CombustorO2

Combustor

O2

CO2

CO, H2, CH4

SulfurRecovery

Anode

Cathode

Air

AirAtmospheric SOFCH2O

Marketable Ash/Slag

By-productMarketable

SulfurBy-product

CO2

Sequestration

Heat Recoverye.g., Expander

• Atmospheric SOFC with catalytic gasification 25 % Methane

EnhancedOil Recovery

Deep SalineAquifer

UnmineableCoal Beds Depleted Oil & Gas

Reservoirs

q• Atmospheric SOFC with catalytic gasification 25 % Methane

• Separate Fuel and Air Streams: Oxy Combustion

• Cycle Efficiency (HHV); 99% Capture

~50% with CO2 Compression

11

~53% w/out CO2 Compression

SECA Coal Based Systems near-zero water requirement

99% carbon captureAir AirSeparation

Gas Cleaning

CO2,CO, H2, H2O

Coal

H2O

O2

Anode

Catalytic Gasification25% CH4 CO, H2, CH4 O2

CombustorO2

Combustor

O2

CO2

CO, H2, CH4

SulfurRecovery

Anode

Cathode

Air

AirPressurized SOFC

Combustor

H2O

Marketable Ash/Slag

By-productMarketable

SulfurBy-product

CO2

Sequestration

Heat Recoverye.g., Expander

• Pressurized SOFC with catalytic gasification 25% Methane

EnhancedOil Recovery

Deep SalineAquifer

UnmineableCoal Beds Depleted Oil & Gas

Reservoirs

q• Pressurized SOFC with catalytic gasification 25% Methane

• Separate Fuel and Air Streams: Oxy Combustion

• No steam cycle – minimal external water requirement

• Cycle Efficiency (HHV); 99% Capture

12

~56% with CO2 Compression

~60% w/out CO2 Compression

Impact of Efficiency on COE

Advanced Power SystemsWith CO2 Capture, Compression and Storage

PC Baseline

IGCC Baseline

IGFC Atmos.

IGFC Press.

Efficiency27 2 32 5 42 8 57 3

yHHV (%)

27.2 32.5 42.8 57.3

Capital Cost2 870 2 390 1 991 1 667

$/kW2,870 2,390 1,991 1,667

Steam Cycle100 37 26 2

% Power100 37 26 2

Cost-of-Electricity¢/kW-hr

11.6 10.6 8.5 7.3

13

¢/kW hrThe Benefit of SOFC for Coal Based power Generation, Report Prepared for U. S. Office of Management and Budget, 30OCT07

Raw Water Withdrawal Comparison•Percentage of Power from Steam Plant is significantly reduced

1400

•Percentage of Power from Steam Plant is significantly reduced

•Higher fuel cell cycle efficiency reduces water use per unit of coal feed

•Separate fuel and oxidant streams in fuel cell permits use of substantially less cooling water to condense, recycle and reuse process H2O

1200

W t C ti ( l/MWh)

From NETL Bituminous Baseline Study

800

1000

(net

)

Water Consumption (gal/MWh)PC plants: 1000 - 1200IGCC: 600-700Nuclear: 1600NGCC: 500

600

800

Gal

lons

/MW

h (

Supercritical PC2

400

G

2

0

200

IGFC1

IGCC2

14

1 System includes 100% carbon capture and CO2 compression to 2,215 psia2 System includes 90% carbon capture and CO2 compression to 2,215 psia

10

C b C tCarbon CaptureEfficiency

45%

50%

55%

60%(%

HH

V)

30%

35%

40%

45%

Effic

ienc

y

Refere

nce

Coal P

ump

85%

CF

War

m Clea

nup

Adv.

Turb

ine

+Ad

v. Tu

rbine

dv. T

urbin

e (II)

90%

CF

SOFC

Wa Ad

ITM +

AIT

M + A

dv

15

Carbon CaptureCapital Cost

2,2002,4002,600

2007

$/kW

)

1,2001,400

1,6001,8002,000

apita

l Cos

t (2

Refere

nce

Coal P

ump

85%

CF

War

m Clea

nup

Adv.

Turb

ine

+Ad

v. Tu

rbine

Adv.

Turb

ine (I

I)90

% C

FSO

FC

Ca

W AIT

M + IT

M + Ad

16

Carbon CaptureCOE

Wh) COE

1112

cent

s/kW

789

1011

ty (2

007

c

4567e mp F up e ne (II

)

F Cf Ele

ctric

it

Refere

nce

Coal P

ump

85%

CF

War

m Clea

nup

Adv.

Turb

ine

Adv.

Turb

ine

dv. T

urbin

e (I

90%

CF

SOFC

Cos

t of

Wa Ad

ITM +

AIT

M + Ad

v

17

Key Points

• 25% Methane+ 60% Efficiency

• Pressure

C t S l ith Si

HHV

• Balance of Plant Cost Scales with Size

• Fuel Cell Stack Cost Scales with Power

S t Ai & F l St / / St Pl t• Separate Air & Fuel Streams / w/o Steam Plant

99 % Carbon CaptureN Z W t U

18

Near Zero Water Use

Single Cell Module PerformancePlanar Cell - AtmosphericPlanar Cell - Atmospheric

250mw/cm2@ 0 6 V

275mw/cm2@ 0 7V

400mw/cm2@ 0 7V

450mw/cm2@ 0 7V

600mw/cm2@ 0 7V

500mw/cm2@ 0 8V

(x10)

450mw/cm2@ 0.85V

800

0.6 V144 cm2

0.7V144cm2

0.7V144cm2

0.7V144cm2

0.7V144cm2

0.8V144 cm2 550 cm2

200

400

600

800

0

200

2002 2003 2004 2005 2006 2007 2008

System ($/kW) ref 2002

19

Research Priorities: SECA Cost Reduction and Coal Systems

Gas SealsGas Seals Glass and Compressive Seals Glass and Compressive Seals Compliant SealsCompliant SealsSelfSelf--healing Materialshealing Materials

f Sf SHigh Temperature Refractive SealHigh Temperature Refractive SealFailure AnalysisFailure Analysis Models with Electrochemistry & EMFModels with Electrochemistry & EMF

Define Operating Window (Not possible experimentally)Define Operating Window (Not possible experimentally)Structural Failure Analysis & Design Criteria (ASME)Structural Failure Analysis & Design Criteria (ASME)

Risk Level

CathodeCathodeperformanceperformance

Understand MechanismUnderstand MechanismAdAd--atom Modification of Surfacesatom Modification of SurfacesModification through InfiltrationModification through Infiltration

InterconnectInterconnect CoatingsCoatingsElectrode to Interconnect InterfaceElectrode to Interconnect Interface Contact MaterialContact Material

Medium

Low

Electronic Effect versusDefect Chemistry

Electrode to Interconnect Interface Electrode to Interconnect Interface -- Contact MaterialContact Material

Anode /Anode /fuel processingfuel processing

Establish Fuel SpecificationEstablish Fuel SpecificationCharacterize Thermodynamics/Kinetics/ ContaminantsCharacterize Thermodynamics/Kinetics/ Contaminants

//

High

Heat Exchangers/ Heat Exchangers/ High Temperature High Temperature BlowersBlowers

Cost and ReliabilityCost and ReliabilityDesign GuidelinesDesign Guidelines

20

SECA Peer Review 2008Project Average Score ResultsProject Average Score Results

All Projects Overall AverageAll Projects -- Overall Average

4.00

5.00

2.00

3.00

Scor

e

0.00

1.00

4 49 4 52 2 82 4 43 4 35 4 19 4 64 4 40 4 59 4 53 4 51 4 49 4 78 4 59 4 33 4 53 4 62 4 60 4 75

Industry Team

Industry Team

CDP Industry Team

CDP Industry Team

Inter-connects

Material Seals Cathode Cathode Cathode Cathode Cathode Fuel Process

Models Fuel Process

Coal Contam.

Power Electro.

4.49 4.52 2.82 4.43 4.35 4.19 4.64 4.40 4.59 4.53 4.51 4.49 4.78 4.59 4.33 4.53 4.62 4.60 4.75

21

OMB cited SECA as Leading the Way in Government-Industry PartnershipsGovernment-Industry Partnerships

The Office of Management and Budget cited the SECA program as leading the way in Government-industry partnerships. “Theas leading the way in Government industry partnerships. The SECA program leverages private-sector ingenuity by providing Government funding to Industry Teams developing fuel cells, as long as the Teams continue to exceed a series of stringent technical performance hurdles. This novel incentive structure has generated a high level of competition between the Teams and an impressive array of technical approaches. The SECA program also develops certain core technologies that can be used by all the Industry Teams to avoid duplication of effort. The program exceeded its 2005 performance targets, and it is on track to meet its goal for an economically competitiveon track to meet its goal for an economically competitive technology by 2010.”

22

SECA Industry TeamsFY 2001 FY 2007FY 2001 – FY 2007

5kW Systems - CompleteSECA Ind str Team Location Protot pe NETL ValidationSECA Industry Team Location Prototype NETL Validation

General Electric Torrance, CA Complete Pass

Delphi Rochester, NY Complete Passp p

Fuel Cell Energy Calgary, BC Complete Pass

Acumentrics Westwood, MA Complete Pass

Si P G Pitt b h PA C l t PSiemens Power Group Pittsburgh, PA Complete Pass

Cummins Power Gen. Minneapolis, MN Complete Pass

Size Efficiency Degradation Availability CostSize Efficiency Degradation Availability Cost

Target 3 – 10 kW 35 (LHV) 4%/1,000 hrs 90%

Aggregate Team Performance

3 – 7 kW 35.4 – 41 % 2%/1,000 hrs 97% $724 - $775/kW

23

Peterbilt - Delphi Auxiliary Power Unit

• Delphi’s SECA APU powered the Peterbilt Model 386’s electrical hotel loads including air conditioner radio CB lights batteryhotel loads, including air-conditioner, radio, CB, lights, battery, & start-up.

• The Delphi SECA APU provided an average of 800 watts of electricity on diesel.

24

• The Delphi SECA APU addresses anti-idling regulations.

SOFCs in Unmanned Undersea Vehicles (UUVs)SOFCs in Unmanned Undersea Vehicles (UUVs)21UUV (2-5 kW)

Fisher-TropschpSECA Stacks and Blower

• Naval Undersea Warfare Center, Division Newport, (NUWCDIVNPT) successfully tested SECA SOFCs in extreme conditions. Used SECA Stacks (2 Developers) and SECA developed High Temperature Blower

• SOFC technology has the potential to greatly increase UUV mission• SOFC technology has the potential to greatly increase UUV mission time compared with current battery technology.

• Although SECA has a coal-based, central generation focus, spin-off applications are encouraged. Military applications like UUVs provide operating experience and independent validation for SECAoperating experience and independent validation for SECA.

• Cost and operational lifetime are not necessarily major concerns for military applications, as long as new mission capability can be delivered.

25

For More Information About the DOE Office of Fossil Energy Fuel Cell Program

Websites:www.netl.doe.gov

2009 SECA Workshop 2009 SECA Workshop thth thth

of Fossil Energy Fuel Cell Program

www.fe.doe.govwww.grants.gov

CDs available from the website

July 14July 14thth –– 1616thth

Pittsburgh, PAPittsburgh, PACDs available from the website

•FE Fuel Cell Program Annual Report _2008

•9th Annual SECA Workshop P di

Wayne A Surdoval

Proceedings•Fuel Cell Handbook (7th ed.)

Wayne A. SurdovalTechnology Manager, Fuel CellsNational Energy Technology LaboratoryU. S. Department of Energy(Tel) 412 386-6002(Fax) 412 386-4822

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wayne.surdoval@netl.doe.gov