ers energy&resource solutions © 2003 ERS, Inc.

Assessment of Fuel Cell Applications for Assessment of Fuel Cell Applications for Critical Industrial ProcessesCritical Industrial Processes

presented byDan Birleanu

ERS

ACEEE Summer Study on Energy Efficiency in IndustryAugust 2003

ers energy&resource solutions © 2003 ERS, Inc.

Assessment of Fuel Cell Applications for Assessment of Fuel Cell Applications for Critical Industrial ProcessesCritical Industrial Processes

Power Quality and Critical Applications

Premium Power Equipment

Overview of Fuel Cell Technology

Fuel Cells Current Challenges

Feasibility Assessment Methodology

Case Study: Semiconductor Crystal Growth Facility

Conclusions

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High Voltage Spikes and Surges

Low Voltage Electrical Noise

Harmonics

Voltage Fluctuations

Power Outages and Interruptions

Power Quality and Critical ApplicationsPower Quality and Critical Applications

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Medical Treatment Facilities

Advanced Manufacturing Facilities

Communication and Data Centers

High-Security Facilities

Remote Sites

Air Traffic Control Facilities

Power Quality and Critical Applications Power Quality and Critical Applications (cont.)(cont.)

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RequirementsAvailability: Respond in Milliseconds without Significant Distortions

Reliability: 99.999…%

Maintainability: Easily Accessible while Maintaining Availability

TechnologiesEnergy Storage: Batteries, Flywheel, Super-capacitors, Super-conducting Magnetic Energy Storage (SMES), Compressed Air Storage (CAES)

Back-up Power: Generator Sets, Micro-turbines, Small Gas Turbines, Fuel Cells.

Premium Power EquipmentPremium Power Equipment

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PAFC PEMFC MCFC SOFC Size Range 100-200 kW 3-250 kW 250 kW - 10 MW 1 kW - 10 MW Fuel Hydrogen, Natural

Gas, Landfill Gas, Digester Gas, Propane

Natural Gas, Hydrogen, Propane,

Diesel

Natural Gas, Hydrogen

Natural Gas, Hydrogen, Landfill Gas, Fuel Oil

Capacity 0.1-0.3 W/cm2 0.6-0.8 W/cm2 0.1-0.2 W/cm2 0.3-0.5 W/cm2 Efficiency 36-42% 30-40% 45-55% 45-60% Environment Nearly zero emissions

(when running on H2) Nearly zero emissions (when running on H2)

Nearly zero emissions (when running on H2)

Nearly zero emissions (when running on H2)

Other Features

Cogeneration (Hot Water)

Cogeneration (Hot Water)

Cogeneration (Hot Water or Steam)

Cogeneration (Hot Water or Steam)

Estimative Cost

$4,000 per kW $5,000 per kW $2,000-$4,000 per kW

$1,300 per kW (Desired)

Commercial Status

Available Pre-commercial Pre-commercial Pre-commercial

Strengths Quiet Low Emissions High Efficiency

Proven Reliability

Quiet Low Emissions High Efficiency

Quiet Low Emissions High Efficiency

Quiet Low Emissions High Efficiency

Weaknesses High Cost High Cost Need to Demonstrate

Limited Field Test Experience

High Cost Need to Demonstrate

High Cost Need to Demonstrate

Overview of Fuel Cell TechnologyOverview of Fuel Cell Technology

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PAFC Reduction of manufacturing and operating costs Further improved durability and reliability Reducing space requirements Improving heat recovery potentials Staying economically competitive with other fuel cell technologies as they mature

PEMFC Reduction of manufacturing and operating costs Understanding the influences of operating conditions Understanding transient load response Improve fuel processing to accommodate different type of fuels Improve cold-start Catalyst loading

MCFC Reduction of manufacturing and operating costs Reducing the rate of cathode dissolution Improve retention of the electrolyte Improving resistance to catalyst poisoning

SOFC Reduction of manufacturing and operating costs Identifying configurations that require less stringent material purity specifications Use of less exotic alloys, which is directly related to the high operating temperature Maintenance of seals and manifolds under severe thermal stresses

Fuel Cells Current ChallengesFuel Cells Current Challenges

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Description of the Operation and Need for Premium PowerApplicable End Uses and Equipment

Utility Usage

Outage and Low Power Quality History

Technical Impacts of Downtime

Cost Impacts of Outage and Low Power Quality Incidents

Capital Project Financing and Investment Requirements

Assessment of Power QualityCritical Equipment Service Lines

Tolerance Range of Critical Equipment

Impact Assessment of Power Quality

Feasibility Assessment MethodologyFeasibility Assessment Methodology

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Assessment of Economic Losses Associated with Power Reliability and Power Quality Problems

Estimates of Economic Impacts

Technical and Economic Scenarios

Research and Review of the Premium Power Systems Technical Options

Review of Premium Power Systems

Considered Technologies: Features and Advantages

Preliminary Technical and Economic Screening of OptionsSimplified Estimates of Energy Impacts

Simplified Estimates of Costs

Simplified Estimates of Economic Impacts

Feasibility Assessment Methodology Feasibility Assessment Methodology (cont.)(cont.)

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Preparation of Conceptual Design for Cost-Effective Application

Site-Specific Systems Components

Desired Location Requirements

Detailed Conceptual Design

System Cost Estimation

Detailed Energy, Environmental and Economic AnalysesSystem Modeling

Environmental Impact

Life Cycle Cost Analyses

Feasibility Assessment Methodology Feasibility Assessment Methodology (cont.)(cont.)

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Molecular Beam Epitaxy (MBE) Process

Facility DescriptorsDemand: 2.5 MW

Critical Demand: 1.5 MW

Energy Usage: 20 million kWh annually

Two Separate Feeding Circuits from the Utility Network

UPS Batteries Capacity: 600 kW

Emergency Generators Capacity: 1.5 MW

Critical SystemsUltra-High Vacuum System

Heating System (Crystal Growth Process @ 1,700 F)

Cooling System (1,700 Tons)

Case Study: Semiconductor Crystal Case Study: Semiconductor Crystal Growth FacilityGrowth Facility

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Power Quality IncidentsSeven Separate Power Outages in 2001

Voltage Sags

Over Voltages

Impact of Power Quality IncidentsShutdown of Crystal Growth Process

Process Resume Takes Several Hours

Labor Costs: $50,000 per hour

Material Losses: up to $500,000 per hour

Case Study: Semiconductor Crystal Case Study: Semiconductor Crystal Growth Facility (cont.)Growth Facility (cont.)

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PAFC Proven reliability: installations in different locations all over the world with many hours of successful operation

Commercially available in sizes that are attractive for the facility (200 kW) For premium power, requires a reliable source of fuel To make it highly cost-effective, requires cogeneration opportunities - which

may not be present PEMFC Not sufficiently proven for this application

Commercially available in sizes too small (maximum 50 kW) For premium power, requires a reliable source of fuel To make it highly cost-effective, requires cogeneration opportunities - which

may not be present MCFC Not sufficiently proven for this application

Still in the pre-commercial stage For premium power, requires a reliable source of fuel Can produce steam, which could be used in absorption chillers – would require

chiller replacement SOFC Not sufficiently proven for this application

Still in the pre-commercial stage For premium power, requires a reliable source of fuel Can produce steam, which could be used in absorption chillers – would require

chiller replacement

Case Study: Semiconductor Crystal Case Study: Semiconductor Crystal Growth Facility (cont.)Growth Facility (cont.)

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Selected Fuel Cell System: UTC Fuel Cells PC25Rated electrical Capacity: 200 kW/235 kVA

Thermal Capacity: 900,000 Btu/h @ 140 F

Efficiency (LHV): 37% Electric and 50% Thermal

Natural Gas Consumption: 2,100 cu.ft./hour

Emissions: <2 ppm CO, <1 ppm NOx, negligible SOx

Proposed Premium Power System Characteristics and Cost Integration of the Fuel Cells with the Existing Back-up System

Eight (8) Fuel Cell Units

Fuel Cells Will Operate 8,000 hours/year

Total Estimated Cost: $9,600,000

Case Study: Semiconductor Crystal Case Study: Semiconductor Crystal Growth Facility (cont.)Growth Facility (cont.)

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Case Study: Semiconductor Crystal Case Study: Semiconductor Crystal Growth Facility (cont.)Growth Facility (cont.)

0

2

4

6

8

10

12

14

16

$500,000 $750,000 $1,000,000 $1,250,000 $1,500,000 $1,750,000 $2,000,000

Total Annual Cost of Losses Due to Power Q uality Issues

Payb

ack

Peri

od [y

ears

]

Payback Period for the Fuel Cell System vs. Cost of LossesAverage Prices (Northeast): Natural Gas – $6.38/ccf and Electricity – $0.0772/kWh

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PAFC and PEMFC Could Provide Clean and Reliable Power for Critical Industrial Applications

Installation Costs Represent a Considerable Barrier to Widespread Commercialization of the Available Fuel Cell Systems

Cost-effectiveness of the Large Fuel Cell Based Premium Power Application Rises in the Probability that Major Events with High Impact on Company’s Revenues Occur

Very Critical Operations (Communication/Data Centers, Financial Transaction Operations, High-Tech Manufacturing Facilities) are the most Suitable Applications for Future Implementation of These Systems

ConclusionsConclusions

ers energy&resource solutions © 2003 ERS, Inc.

Assessment of Fuel Cell Applications for Assessment of Fuel Cell Applications for Critical Industrial ProcessesCritical Industrial Processes

Thank you!

Questions?