stationary fuel cell evaluation - energy.gov · 2015. 6. 16. · nrel is a national laboratory of...

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

Stationary Fuel Cell Evaluation

Genevieve Saur (PI), Jennifer Kurtz, Chris Ainscough, Sam Sprik

National Renewable Energy Laboratory

June 11, 2015Project ID TV016

This presentation does not contain any proprietary, confidential, or otherwise restricted information.

2

Overview

• Project start date: October 2011• Project end date: Sept 2015*• FY14 DOE funding: $100k • FY15 planned DOE funding: $100• Total DOE funds received to date:

$465k

• B. Lack of Data on Stationary Fuel Cells in Real-World Applications

• E. Codes & Standards

Timeline and Budget Barriers

• California Stationary Fuel Cell Collaborative (review results)

• National Fuel Cell Research Center (UCI)(subcontractor)

• Five OEM data providers• Connecticut Department of Transportation

(data provider through TIGGER)**

Partners

* Project continuation and direction determined annually by DOE

** Separately funded project

3

Relevance - Objectives

Independently assess, validate, and report operation targets and stationary fuel cell system performance under real operating conditions.

B. Lack of Data on Stationary Fuel Cells in Real-World Applications

Addressing the gap in knowledge as stationary fuel cell installations have increased dramatically

E. Codes & Standards Providing data and context to C&S activities.

3

4

CDPs

DDPs

Public

Composite Data Products (CDPs) • Aggregated data across multiple systems,

sites, and teams• Publish analysis results every six months

without revealing proprietary data

Detailed Data Products (DDPs) • Individual data analyses

• Identify individual contribution to CDPs• Shared every six months only with the

partner who supplied the data

www.nrel.gov/hydrogen/proj_tech_validation.html

Approach: NFCTEC Analysis and Reporting of Real-World Operation Data

Results

Bundled data (operation & maintenance/safety) delivered

to NREL quarterlyInternal analysis

completed quarterlyin NFCTEC

National Fuel Cell Technology Evaluation Center

5

Approach – Data Sources and ScopeProject is reliant on voluntary data sharing – partner development is

ongoing.• Deployment and cost dataoPublically available data from California SGIP (Self Generation Incentive Program)

(2001-present)o Includes systems providing prime, continuous, or regular power to a site (not

backup power)o Includes multiple fuel cell types - proton exchange membrane (high and low

temperature), solid oxide, phosphoric acid, and molten carbonateo Includes fuel types for fuel cells (natural gas, biomass, digester gas, landfill gas)oSmall, kilowatt-scale to large, megawatt-scaleoCost data for projects including incentives

• Operations dataoAll data voluntarily supplied

• 33 total CDPsoQuarterly data analysis (based on available data), biannual publications

5

6

Approach - Data Processing, Analysis, and Reporting Tools

• NREL Fleet Analysis Toolkit (NRELFAT)— Developed first under fuel cell vehicle Learning

Demonstration— Restructured architecture and interface to

effectively handle new applications and projects and for flexible analysis

— Leverage analyses already created

• Report results– Detailed and composite results– Target key stakeholders such as fuel cell and hydrogen developers, and

end users

Public results available at http://www.nrel.gov/hydrogen/proj_fc_systems_analysis.html

6

7

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 20140

50

100

150

200

250

300

Proj

ect C

ount

Cumulative Deployment Count by Year*

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 20140

100

200

300

400

Total = 397 unitsFuel Cell CHP = 118 unitsFuel Cell Electric = 279 units

Proj

ect C

ount

Tot

al

Fuel Cell CHPFuel Cell ElectricTotal

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 20140

50

100

150

Cap

acity

[MW

]

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 20140

50

100

150

200

Total = 161 MWFuel Cell CHP = 35 MWFuel Cell Electric = 126 MW

Tota

l Cap

acity

[MW

]

Cumulative Capacity by Year

Fuel Cell CHPFuel Cell ElectricTotal

NREL cdp_stat_01Created: Apr-21-15 11:09 AM | Data Range: 2001Q2-2014Q4

*Data from the CA SGIP.

Accomplishments: CA SGIP - Deployment

4%9%

9%

79%

Site Count by Fuel Type*

Biomass [1]

Digester Gas [1]

Landfill Gas [1]

Natural Gas

3%

17%

11%

69%

Installed Capacity by Fuel Type


Includes Status Categories:Application Review [2]Project Execution Review [3]Incentive Claim Review [4]Project In Operation [5]Project Completed [6]

Total Capacity: 161 MWTotal Sites: 397

Installations by Fuel Type(All Fuel Cell Systems)

[1] The renewable fuels exclude those defined as conventional in Section 2805 of the California Public Utilities Code and are categorizedhere as gas derived from biomass, digester gas, or landfill gas.Definition of Included Status: [2] Includes CA SGIP projects in Reservation Request Form (RRF) phases.[3] Includes CA SGIP projects in Proof of Project Milestone (PPM) phases.[4] Projects are in operation and pending confirmation of incentive claims, including CA SGIP Incentive Claim Form (ICF) phases.[5] Includes projects that are receiving perfomance based incentives, includes CA SGIP Performance Based Incentives (PBI) In Progress.[6] Includes installed projects with unknown operation status, includes CA SGIP Payment Completed and Payment Recalled status.


California SGIP - Deployment Deployment of fuel cells in the

California SGIP have been ramping up more rapidly than in the past several years, 25% increase in 2014.

Natural gas sites dominate, but renewable fuels have a greater capacity compared to the number of projects.

• The California SGIP will continue run through at least January 1, 2019.

• Renewable fuels exclude those defined as conventional in Section 2805 of the California Public Utilities Code and are categorized here as gas derived from biomass, digester gas, or landfill gas.

8

Accomplishments: CA SGIP – Fuel cell costs

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 20140

20

40

60

80

100

120

140

160

180

Cum

ulat

ive

Cap

acity

[MW

]

Year1500

2000

2500

3000

3500

4000

4500

5000

5500

Ince

ntiv

e Sp

endi

ng ($

2010

) Per

kW

Inst

alle

d

Stationary Fuel Cell - Total Incentive ($2010) per kW by Year*


In 2014 incentive rates for emerging technologies(including fuel cells) and biogas will decline 10% and allother technologies 5% annually. (2014 SGIP Handbook)


0

10

20

30

Average Prices No Incentive, Incentive0-50 kW = $11,275/kW, $8,782/kWAverage Prices No Incentive, Incentive

51-200 kW = $10,927/kW, $6,715/kW

Average Prices No Incentive, Incentive

201-400 kW = $10,022/kW, $6,220/kW


401+ kW = $9,537/kW, $5,620/kWData points with less than 2 projects filtered.

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proj

ect c

ount

Price [$2010/kW] No Incentive

Stationary Fuel Cell - Installed Eligible Cost Per kW By Capacity*Adjusted To 2010 Dollars

0-50kW

51-200 kW

201-400 kW

>400 kW

DOE 2020 Target†

0

10

20

30

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Price [$2010/kW] With IncentiveNREL cdp_stat_26Created: Apr-21-15 11:27 AM | Data Range: 2001Q2-2014Q4


Eligible Costs May Include: Planning & Feasibility Study,Engineering & Design, Permitting, Self-GenerationEquipment, Waste Heat Recovery Costs, Construction &Installation Costs, Gas & Electric Interconnection, Warranty,Maintenance Contract, Metering, Monitoring & DataAcquisition System, Emission Control Equipment Capital,Gasline Installation, Fuel Gas Clean-up Equipment,Electricity Storage Devices, Bond to Certify RenewableFuel, Sales Tax, Fuel Supply (digesters, gas gathering, etc.),Thermal Load, & Other Eligible Costs

†installed cost for the year 2020, operating on naturalgas. May not include all costs reported in CA SGIP.

A few larger (>200 kW) projects meet the DOE target of $1,500/kW* with incentives

Fuel cell incentive spending as $/kW has steadily declined since 2010

Larger projects generally cost less on a per kilo-watt basis than smaller projects.

Project Size (kW)

Cost without Incentive ($/kW)

Cost with Incentive ($/kW)

0-50 11,275 8,782

51-200 10,927 6,715

201-400 10,022 6,220

> 400 9,537 5,620

* DOE target may not include all costs reported in CA SGIP.

9

Accomplishments: CA SGIP – CHP Costs

0 200 400 600 800 1000 1200 1400 >1400(max 2800)0

10

20

30

40

50

60

70Distribution of Capacity and Average Eligible Cost $2010/kW (CHP Fuel Cell)*

Capacity (kW)

% o

f sys

tem

s

0 200 400 600 800 1000 1200 1400 >1400(max 2800)0

2,000

4,000

6,000

8,000

10,000

12,000

Ave

rage

$/k

W(A

djus

ted

to 2

010

dolla

rs)

$/kW w/o Incentive$/kW w/ Incentive2020 DOE Target†

0 200 400 600 800 1000 1200 1400 >1400(max 2800)0

10

20

30

40

50

Capacity (kW)

% o

f sys

tem

s

Detailed Capacity Distribution

01020304050

Num

ber o

f sys

tem

s

0 10 20 30 40 500

20406080

Capacity (kW)

% o

f sys

tem

s<=

50 k

W


†installed cost for the year 2020, operatingon natural gas. May not include all costsreported in CA SGIP.

*Data from the CA SGIP.Eligible Costs May Include: Planning & Feasibility Study, Engineering & Design, Permitting, Self-Generation Equipment, WasteHeat Recovery Costs, Construction & Installation Costs, Gas & Electric Interconnection, Warranty, Maintenance Contract,Metering, Monitoring & Data Acquisition System, Emission Control Equipment Capital, Gasline Installation, Fuel Gas Clean-upEquipment, Electricity Storage Devices, Bond to Certify Renewable Fuel, Sales Tax, Fuel Supply (digesters, gas gathering,etc.), Thermal Load, & Other Eligible Costs

0

10

20

30

0

1000

20

00

3000

40

00

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60

00

7000

80

00

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1000

011

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013

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1400

015

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021

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proj

ect c

ount

Price without incentives [$2010/kW]

Installed Eligible Cost Per kW (CHP Fuel Cell)*Adjusted To 2010 Dollars

Avg** = $10,408 $/kW

CurrentDOE 2020 Target†Mean without Incentives± 1σ ($3,065)

0

10

20

30

40

0

1000

20

00

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00

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ect c

ount

Price with incentives [$2010/kW]

Avg** = $7,545 $/kW

CurrentDOE 2020 Target†Mean with Incentives± 1σ ($3,224)



**Data bins with less than 2projects filtered.†installed cost for the year 2020,operating on natural gas. May notinclude all costs reported in CA SGIP.

A few larger (>400 kW) projects meet the DOE target of $1,500/kW* with incentives

Costs decline with size of project

Project Size (kW)

Cost without Incentive ($/kW)

Cost with Incentive ($/kW)

0-50 11,303 8,809

201-400 9,165 5,316

> 400 7,608 3,706

* DOE target may not include all costs reported in CA SGIP.

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11

Accomplishments: Load Profile (>100 kW units)

How stationary fuel cells are used changes the operation profiles.• At base load most operation is 90-

100% load fraction of rated capacity• Some fuel cells may even be

operated for significant time above rated capacity

Fuel cell sizing• For base load the fuel cells are sized for

minimum load.• For load following the fuel cells may be

sized for near peak load.

0 10 20 30 40 50 60 70 80 90 100 110 120 Inf0

5

10

15

20

25

30

35

40

45

Load Fraction (%) [2]

Ope

ratio

n Ti

me

(%)

Stationary Fuel Cell - Histogram of Load Fractions (Base Load Units) [1]

NREL cdp_stat_31Created: Apr-24-15 11:37 AM | Data Range: 2001Q2-2014Q4 [1] Voluntarily supplied data for units > 100 kW, fuel cells running as building base load generation

[2] Load fraction is the ratio of electrical output per rated capacity of the fuel cell unit.

Units >100 kW

0 10 20 30 40 50 60 70 80 90 100 110 120 Inf0

5

10

15

20

25

30

Load Fraction (%) [2]

Ope

ratio

n Ti

me

(%)

Stationary Fuel Cell - Histogram of Load Fractions (Load Following Units) [1]

NREL cdp_stat_32Created: Apr-24-15 11:37 AM | Data Range: 2001Q2-2014Q4 [1] Voluntarily supplied data for units > 100 kW, fuel cells running as building load following generation

[2] Load fraction is the ratio of electrical output per rated capacity of the fuel cell unit.

Units >100 kW

Histogram of Load Profile – Base Load Units

Histogram of Load Profile – Load Following Units

12

10 15 20 25 30 35 40 45 50 55 600

5

10

15

20

25

30

35

40

45

% o

f Uni

ts

Mean Unit Electrical Efficiency (% HHV)

Stationary Fuel Cell - Unit Lifetime Mean Electrical Efficiency (HHV)*†


Overall Mean = 28 %

Units <100 kW

* Voluntarily supplied data†Includes startup, shutdown, transient andpartial power operation

Accomplishments: Mean Electrical Efficiency

Electrical efficiency for fuel cells > 100 kW are exceeding the 2015 DOE technology validation target of 43% LHV (39% HHV)

Electrical efficiency for units < 100 kW is improving, but does not meet target

Sizing• Commercial are > 100 kW• Residential are 0-10 kW

20

25

30

35

40

45

50 75 90 100 110Load Fraction (%) [2]

Mea

n El

ectr

ical

Effi

cien

cy H

HV

(%) [

3]

Stationary Fuel Cell - Electrical Efficiency by Load Fraction [1]

Median25/75th percentileMeanDOE Target Efficiency 2015 (HHV)

NREL cdp_stat_33Created: Apr-24-15 1:19 PM | Data Range: 2001Q2-2014Q4

Units >100 kW

[1] Voluntarily supplied data for units > 100 kW[2] Load fraction is the ratio of electrical output per rated capacity of the fuel cell unit. Efficiency data points for each load fraction are +/- 2% of the target load fraction.[3] Mean efficiencies by unit are calculated as the percentage of electrical power output to higher heating value of fuel input. The natural gas higher heating value used is48.956 MJ/kg and the lower heating value used is 44.294 MJ/kg.

Electrical Efficiency – Units > 100 kW

Electrical Efficiency – Units < 100 kW

13

Accomplishments: Availability and MTBS* (<100 kW units)

40 45 50 55 60 65 70 75 80 85 90 95 1000

5

10

15

20

25

30

35

40

% o

f Uni

ts

Mean Unit Availability (%)

Stationary Fuel Cell - Unit Mean Availability*


Overall Mean = 92 %

* Voluntarily supplied data

Units <100 kW

Availability (<100 kW units) Mean availability is 92% ~60% of units are > 90% availabilityMBTS* (<100 kW units) Overall MBTS is 2407 hours >80% are 3000 or less

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 140000

5

10

15

20

25

30

35

% o

f Uni

ts

Mean Time (hr) between Stoppages

Stationary Fuel Cell - Mean Time Between Stoppage (hours)*


Overall Mean = 2407 hours

* Voluntarily supplied data

Units <100 kW

* Mean Time Between Stoppages

14

Accomplishments and Progress:Responses to Previous Year Reviewers’ Comments

• What is the purpose of collecting data?o The purpose is to look at the current state of the technology for stationary fuel cells

for the consideration by fuel cell OEMS, developers, state and federal agencies; better understand project deployments, costs, and incentives and the changes over time; compare performance to DOE targets for the technology; and provide other value-added analysis for stationary OEMs, developers, and other key stake-holders.

• Can data be segmented by power and application more? o We have developed several new CDPs which start to segment the capacity ranges and

therefore stationary applications. In some cases we have data that we do not show due to data sensitivity. We also have some cross-app CDPs which compare across applications, ie. vehicle, material handling, lab-scale, etc.

• Can missing data be included through literature or benchmark data points?o We typically do not include literature data in CDPs because by definition we work with

real data sets and may not have enough confidence in literature data sources though some of this could be included as text or footnote references.

15

Collaborations• Partners for data delivered at the end of 2014

o National Fuel Cell Research Centero California Stationary Fuel Cell Collaborativeo Five fuel cell OEMs

• Communicating with several organizations to establish agreements for sharing data with NRELo Connecticut Department of Transportation (through TIGGER - separately

funded project)o NJ Clean Energy Fund/NJ Economic Development Authority (public data,

deployment and incentives only) o California Public Utilities Commissiono Verizono State and regional fuel cell organizationso Fuel cell developers

16

Proposed Future Work

• Q3 2015 milestone: Update all CDPs with current data and publish technical report

• Remainder of FY2015: o Continue to analyze current California SGIP deployment datao Collect additional operations datao Expand analysis

– Further segmentation of the data (CHP/non-CHP, competing technologies, load following/base load, fuel sources) and trends over time

– New operations CDPs for availability/capacity factor

o Continue to develop other data partners (state and federal programs)

o Work with fuel cell OEMs for possibility of additional data sets

17

Summary• NREL is leveraging a large pool of technology validation analyses and

knowledge• CA SGIP

o Deployment of fuel cells is increasing steadily, 25% increase since 2013.o Incentive spending ($/kW) for fuel cells has been steadily decreasingo There has been a resurgence of digester gas projects in 2014o Average fuel cell CHP costs ($/kW) are close to that of gas turbines and below with

incentives.o Some larger fuel cell projects are meeting the DOE target of $1,500/kW with incentiveso Digester gas projects have the lowest average and median costs ($/kW), but also the

largest range

• Operations Datao Units >100 kW: The mean fuel cell efficiency exceeds the DOE target of 43% LHVo Stationary fuel cells being used for both base load and load following applicationso Units <100 kW: The mean availability is 92% with ~60% over 90% availability.o Units <100 kW: The mean time between stoppages is 2407 hours with >80% less than

3000 hours

Technical Back-Up Slides

19

Biomass Digester Gas Landfill Gas Natural Gas

4000

6000

8000

10000

12000

$201

0/kW

of In

stal

led

Cap

acity

Stationary Fuel Cell - Eligible Cost $2010/kW of Installed Capacity by Fuel Type*

Avg. Without IncentiveAvg. With Incentive


75% Percentile

Median

25% Percentile

Mean

Note: Refer to CA SGIPHandbook for on-site vsdirected digester gas (biogas)qualifications.


Accomplishments: CA SGIP – Fuel Types

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 20140

10

20

30

40

50

60

Year

Tota

l Ann

ual I

nsta

lled

Cap

acity

(MW

)

Stationary Fuel Cell - Installed Fuel Type By Year*

BiomassDigester GasLandfill GasNatural Gas

NREL cdp_stat_13Created: Apr-21-15 11:16 AM | Data Range: 2001Q2-2014Q4 Note: Refer to CA SGIP Handbook for on-site vs

directed digester gas (biogas) qualifications.


California SGIP – Fuel Types Annual installed capacity has been

steadily climbing since recession dip Digester gas projects have made a

comeback in 2014, but still lag natural gas in total capacity

Digester gas projects have the lowest average and median costs ($/kW), but also the largest range

20

CDP-STAT-27Installed Eligible Cost per kW By Capacity (CHP Fuel Cell)

0

10

20

30

Average Prices No Incentive, Incentive0-50 kW = $11,303/kW, $8,809/kWAverage Prices No Incentive, Incentive

51-200 kW = $NaN/kW, $NaN/kW


201-400 kW = $9,165/kW, $5,316/kW


401+ kW = $7,608/kW, $3,706/kWData points with less than 2 projects filtered.

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011

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Price [$2010/kW] No Incentive

Installed Eligible Cost Per kW By Capacity (CHP Fuel Cell)*Adjusted To 2010 Dollars

0-50kW

51-200 kW

201-400 kW

>400 kW

DOE 2020 Target†

0

10

20

30

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Price [$2010/kW] With IncentiveNREL cdp_stat_27Created: Apr-21-15 11:27 AM | Data Range: 2001Q2-2014Q4


Eligible Costs May Include: Planning & Feasibility Study,Engineering & Design, Permitting, Self-GenerationEquipment, Waste Heat Recovery Costs, Construction &Installation Costs, Gas & Electric Interconnection, Warranty,Maintenance Contract, Metering, Monitoring & DataAcquisition System, Emission Control Equipment Capital,Gasline Installation, Fuel Gas Clean-up Equipment,Electricity Storage Devices, Bond to Certify RenewableFuel, Sales Tax, Fuel Supply (digesters, gas gathering, etc.),Thermal Load, & Other Eligible Costs

†installed cost for the year 2020, operating on naturalgas. May not include all costs reported in CA SGIP.

21

CDP-STAT-14Distribution of Capacity by Equipment Type

0 200 400 600 800 1000 1200 1400 1600 1800 2000 >20000

50

100

150

200

250Distribution of Capacity by Equipment Type*

Capacity (kW)

Tota

l # o

f Sys

tem

s

Fuel Cell CHPFuel Cell ElectricGas TurbineInternal CombustionMicroturbine


(max 9200)*Data from the CA SGIP.

22

CDP-STAT-06Fuel Cell Stationary Capacity and Average Prices

0 200 400 600 800 1000 1200 1400 >1400(max 4200)0

10

20

30

40Stationary Fuel Cell - Distribution of Capacity and Average Eligible Cost $2010/kW*

Capacity (kW)

% o

f sys

tem

s

0 200 400 600 800 1000 1200 1400 >1400(max 4200)0

2,000

4,000

6,000

8,000

10,000

12,000

Ave

rage

$/k

W(A

djus

ted

to 2

010

dolla

rs)

$/kW w/o Incentive$/kW w/ Incentive2020 DOE Target†

0 200 400 600 800 1000 1200 1400 >1400(max 4200)0

10

20

30

Capacity (kW)

% o

f sys

tem

s

Detailed Capacity Distribution

0 10 20 30 40 50 60 70 80 90100110

Num

ber o

f sys

tem

s

0 10 20 30 40 500

20406080

Capacity (kW)%

of s

yste

ms

<=50

kW


†installed cost for the year 2020, operatingon natural gas. May not include all costsreported in CA SGIP.


23

CDP-STAT-07Distribution of Stationary Fuel Cell Install Price with and without Incentives

0

20

40

60

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Price without incentives [$2010/kW]

Stationary Fuel Cell - Installed Eligible Cost Per kW*Adjusted To 2010 Dollars

Avg** = $10,429 $/kW

CurrentDOE 2020 Target†Mean without Incentives± 1σ ($2,506)

0

20

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60

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Price with incentives [$2010/kW]

Avg** = $6,929 $/kW

CurrentDOE 2020 Target†Mean with Incentives± 1σ ($2,736)



**Data bins with less than 2projects filtered.†installed cost for the year 2020,operating on natural gas. May notinclude all costs reported in CA SGIP.

stationary fuel cell evaluation - energy.gov · 2015. 6. 16. · nrel is a national laboratory of...

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