Combined Heat,

Hydrogen and Power

from DFC® Fuel Cell

FCE Information Towards Design:

Hydrogen Education Foundation’s

2011-2012 CHHP Contest

Joseph Daly, Fred Jahnke

Pinakin Patel

November 4, 2011

1

Outline

� Background

� Fuel cell operation

� H2 recovery system

�Conclusions / Next Steps

2

Integrated Fuel Cell Company

2

Manufacture Sell (direct & via partners) Install Services

Delivering Ultra-Clean Baseload Distributed Generation Globally

1.4 MW plant at a municipal

building

2.4 MW plant owned by an

Independent power producer

600 kW plant at a food

processor

11.2 MW plant - largest

fuel cell power plant in

the world

Scalable On-site Power and Utility Grid Support Solutions

3

Global Market Leader

3

Multi- MW DFC-

ERG in Canada

Utility grid support

in South Korea

On-site power in

London, England* On-site power for

Jakarta, Indonesia*

• 182 MW installed and in backlog - 5 year average growth rate of 48%

• Over 80 Direct FuelCell® (DFC®) plants generating power at more than 50 sites globally

• South Korea & California are leading markets

• Expanding opportunities in N.E. USA, Canada, Europe and Southeast Asia

On-site power in

ConnecticutUtility owned in

California

* In backlog

Americas

AsiaEurope

44

Market Leadership

Natural gas - Utility

& IPP, 79%

Renewable

baseload power,

11%

Natural gas -

Commercial,

Government, etc,

10%

Installed Base & Backlog

1.4 MW at a municipal building 2.4 MW plant owned by an IPP600 kW plant at a food processor11.2 MW plant owned by an IPP

• More than 900 Million kW-Hrs of Electricity Produced.

• Operating models

– On-site power

– Utility & Independent Power Producers (IPP)

• All DFC Products Employ Internal Reforming Technology

5

Background – Fuel Cell Technologies

PerovskitesNickelPlatinumPlatinumCatalyst

CeramicStainless SteelGraphiteCarbon /Metal

BasedCell Hardware

O=CO3=H+H+Charge Carrier

18001200400200Operating

Temp. °F

Yttria Stabilized

ZirconiaAlkali CarbonatePhosphoric Acid

Ion Exchange

MembraneElectrolyte

Future

Solid Oxide

Carbonate

Direct Fuel

Cell®

Phosphoric

Acid

Polymer

Electrolyte

Membrane

Fuel Cell Type

6

STEAM

Internal Reforming DFC® Technology

CATHODE

½O2+ CO

2+ 2e-� CO

3=

INTERNAL REFORMING

CH4+ 2H

2O ���� 4H

2+ CO

2

ANODE

H2+ CO

3= ���� H

2O +CO

2+2e-

CATALYST

CATALYST

ELECTROLYTE

HYDROCARBON FUEL

(e.g. Natural Gas)

AIR + CO2

Opportunity

25-35% Excess H2,CO

+ CO2

Exhaust

CO2

H2 Co-production expands market for fuel cells

7

Operation Features

� Hydrogen formed in fuel cell (no reforming

unit needed)

� Normal operation only 70 - 80% of fuel

consumed in fuel cell

� 20 - 40% of feed can be available from fuel

cell as H2

� Currently need CO2 transfer to air side for

cathode reaction

� H2 export impacts exhaust heat

production, not fuel cell operation

8

H2 Purification

A/E Cooling

E-BOP

M-BOP

DFC300

Current Prototype DFC-H2 System: SubMW Unit

9

Configuration – Simple Cycle

WATERWATER

FUELAIR

HEX

CO-GEN HEAT

A

C

DFC

H2, CO, CO2, H2O

HEX

WATER

FUELAIR

AGO

10

``

HEX W.G. SHIFT

Configuration – H2 Recovery

AIR

A

C

DFC

H2,CO,CO2,H2O

H2, CO2

H2Separator

WATER

HEX

CO-GEN HEAT

HEXPreheated

Air

CO2 with a

fractional

amount of H2

H2

WATER

FUEL

AGO

Optional

Supplemental Fuel

11

Anode Outlet Gas (H2 Source)

Composition

(at fuel utilization of 65%)

Dry / Shifted

� H2 10% 23%

� H2O 40% -

� CO 5% < 1%

� CO2 45% 77%

Anode Gas needs to be cooled, pressurized and purified, but extracted H2

represents an additional “free” revenue stream for combined H2 + Power solution

12

� Hydrogen DFC-H2 configuration

- Hydrogen vehicle fueling- Industrial uses

H2 Energy Station in California

12

Renewable biogas fueled

DFC300-H2 in CA providing

hydrogen for vehicle fueling

under DOE demonstration

program

.

First of a Kind Unit in the World

13

Hydrogen Energy Station Fountain

Valley, California

Co-product

2,4001,200300Fuel Cell Cars, 0.5 kg/day

Refueling Capacity

4.02.00.5Heat, mmBtu/hr

1,000500125Hydrogen, kg/day

2,0001,000250Power, kW

DFC300 DFC1500 DFC3000

4,0002,000500Peak Power (8 hrs/day), kW

Peaker Capacity

Co-product

2,4001,200300Fuel Cell Cars, 0.5 kg/day

Refueling Capacity

2,4001,200300Fuel Cell Cars, 0.5 kg/day

Refueling Capacity

4.02.00.5Heat, mmBtu/hr

1,000500125Hydrogen, kg/day

2,0001,000250Power, kW

DFC300 DFC1500 DFC3000DFC300 DFC1500 DFC3000

4,0002,000500Peak Power (8 hrs/day), kW

Peaker Capacity

4,0002,000500Peak Power (8 hrs/day), kW

Peaker Capacity

14

High Efficiency

Low Emissions

54500.016DFC Fuel Cell –

CHP 80% efficiency

96700.016DFC Fuel Cell

47% efficiency

1,24400.467Small Gas Turbine (250 kW)

1,86200.490Microturbine (60 kW)

2,0179.214.200Average US Fossil Fuel

Plant

CO2

(lb/MWh)

SOX

(lb/MWh)

NOX

(lb/MWh)

54500.016DFC Fuel Cell –

CHP 80% efficiency

96700.016DFC Fuel Cell

47% efficiency

1,24400.467Small Gas Turbine (250 kW)

1,86200.490Microturbine (60 kW)

2,0179.214.200Average US Fossil Fuel

Plant

CO2

(lb/MWh)

SOX

(lb/MWh)

NOX

(lb/MWh)

NOx and SOx are Negligible

Compared to Conventional Technologies

10.0% 10.0%

1.4%5.2%

0%

20%

40%

60%

80%

100%

120%

NOx CO

% of CARB Lim

it_

CARB 2007 Limit (California Air Resources Board)

U87 Emissions Plots.x ls

DFC

DFC-H2

DFCDFC-H2

Test Results for DFC-H2®:

Validated Emissions <90% of CARB 2007 Limit

High Efficiency for Hydrogen Co-production

Engines

Direct FuelC

ell®

0.1 1 10 100 1000

10

30

50

70

EFFICIENCY, %(LHV)

Gas Turbin

es

Combined

Cycle

0.01

Microtu

rbines

SYSTEM SIZE (MW)

PA/PEM FC

Average

U.S.

Fossil Fuel

Plant = 33%

Coal/

Steam

DFC-H2/PEM

Peaker

DFC-T®DFC-H2

®

Engines

Direct FuelC

ell®

0.1 1 10 100 1000

10

30

50

70

EFFICIENCY, %(LHV)

Gas Turbin

es

Combined

Cycle

0.01

Microtu

rbines

SYSTEM SIZE (MW)

PA/PEM FC

Average

U.S.

Fossil Fuel

Plant = 33%

Coal/

Steam

DFC-H2/PEM

Peaker

DFC-H2/PEM

Peaker

DFC-T®

DFC-T®DFC-H2

®DFC-H2

®

60%+ Efficiency

Before Waste Heat Recovery

15

Conclusions

� Distributed co-production of Hydrogen and Power

with a Carbonate (DFC®) fuel cell is attractive

� Current technology is competitive with small scale /

distributed H2 production

� Future developments have potential to make fuel

cell produced hydrogen the preferred method of

supply

16

CHHP System:

Enabler for FCV, EV, Smart Grid

GRIDLoad Following

Fuel Cell

Hydrogen

Storage

Base Load

Fuel Cell

Co-Produced

Hydrogen

Fuel Cell Cars

Heat

Power

Micro-GRID

Fuel

(NG/BioGas/Propane)

• Enhanced Energy Security

• Maximize Green Energy

Use

• Water Independent

• Load Following

• Fuel Flexible

• Ultra Clean

• Provides Distributed H2

for Multiple Uses

• Compensates for

Intermittent Supplies

Wind and Solar Power

(Intermittent)

17

Potential for DFC H2 Production

KWs to electric load: 50%

Hydrogen: 20%

Heat to buildingsthermal load: 15%

DFC-H2 POWER PLANT

H2 – REFUELING STATION

COMMERCIAL/INDUSTRIAL BUILDING