UNESCO UNESCO DesireDesire – Net project – Net project

Molten Carbonate Fuel Cells:Molten Carbonate Fuel Cells:

an opportunity for decentralized generationan opportunity for decentralized generation

Angelo Moreno, Viviana Cigolotti Angelo Moreno, Viviana Cigolotti ENEA – ENEA – HydrogenHydrogen and Fuel Cell Project and Fuel Cell Project

moreno@casaccia.enea.itmoreno@casaccia.enea.itviviana.cigolotti@casaccia.enea.itviviana.cigolotti@casaccia.enea.it

UNESCOUNESCORome, 16Rome, 16thth April 2007 April 2007

PART A

FC lessons programme

6 June 2006Hydrogen as energy carrier

ENEA Moreno

8 June 2006 Fuel Cells ENEA Moreno

13 March 2007 MCFC ENEAMoreno

McPhail

14 March 2007 MCFCAnsaldo Fuel Cell

Parodi

29 March 2007 MCFCAnsaldo Fuel Cell

Capobianco

16 April 2007MCFC System configurations

ENEAMoreno

Cigolotti

PEM/SOFC lessons in planning

SummaryPART APART A

• MCFC: synthesis of main characteristicsMCFC: synthesis of main characteristics

• Distributed GenerationDistributed Generation

• MCFC: innovative solution for distributed MCFC: innovative solution for distributed

generation and for generation and for energy independence in energy independence in

rural economyrural economy

PART BPART B

• Sustainable Strategies based on Best Sustainable Strategies based on Best

Practices and Best Available TechnologiesPractices and Best Available Technologies

• Case StudiesCase Studies

Hydrogen and Fuel Cells

Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

No thermal cycles

Fuel Cells – principle

No thermodynamic limitations (Carnot)

Electric power

Hydrogen(Fuel)

Oxygen(air - oxidant)+

heat

water

Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

MCFC – stack

Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

MCFC – system

Fuel

Treatment

Heat

Recovery

MCFC

Stack

System

Control

Fuel

Heat

Heat

Heat

H2O

H2, CO

DC

AC

Air

Power

Cond.

Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

˙Temperature: 600-650 °C˙Efficiency: 45-55%˙State of the art technology: 100 kW - 3 MW ˙Applications: CHP, distributed generation

(plants up to 20 MW)

MCFC System Characteristics

Main characteristics of fuel cells plants

• High conversion efficiency

• Efficiency almost independent from load and plant size

• Rapid load following capability

• Low environmental impact, low noise and negligible emissions

• Modular installation to match load and increase reliability

• Site and Fuel flexibility

Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

Emissions from different plants

CO2 (g/kWh)

NOx (mg/kWh)

SO2 (mg/kWh)

Powders (mg/kWh)

Hydrocarbons (mg/kWh)

1400

1200

1000

800

600

400

200

0 Coal Plant Oil Plant Gas Plant Fuel Cell Plant

2400

Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

Key Technological Targets Current and Expected

CCuurrrreenntt SSttaattuuss

OObbjjeeccttiivvee ooff DDeemmoo PPhhaassee

LLoonngg--tteerrmm CCoommmmeerrcciiaall TTaarrggeett

Stack Life (hours)

> 12,000* > 30,000 > 40,000

Electrical Efficiency (%)

> 47.0% > 49.0% > 55.0%

Efficiency Using Cogen (%)

> 80.0% > 80.0% > 80.0%

Decay Rate (% mV/1000h)

1.0% < 0.5% < 0.2%

Production Cost (€/kW)

> 5,800 < 2,300 1,200

* Demonstrated at cell level

Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

Current and future cost of Stationary Fuel Cell

CurrentCurrent

$5.000 to $8.000/kW installed

$0,085 to $0,065/kWh

40% to 50% efficiency

Source: DOE Oak Ridge Nat’l lab, Federal CHP Market and Fuel Cells

Future GoalFuture Goal

$1.500/kW installed

$0,015/kWh

>50% efficiency

1500

1000

500

€/kW

MW

0,3 10,1 3 10 30 100 300 1000

Gas Piston Engine

42 %

30 %

Gas Turbine

25 %

40 %

50 %

58 %Gas and Steam

Fuel Cell50 % 54 %

Performance, efficiencies and Costs

Source: MTU

New Energy Vision

Desire-Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic

How CHP Saves Energy

Desire-Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic

It is an Integrated System that: – Supplies electrical or mechanical power

– Uses thermal output for space or water heating,

dehumidification, or process heat

– Is located at/or near user

– Can serve a single facility or district energy system

– Can range in size from a few kW to 100+MW

Combined Heat and Power

Desire-Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic

USEFUL HEATCOOLELECTRICAL POWER

Combined Cool Heat & Power: CCHP

Desire-Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic

Realize Decentralized Stationary Consumable Energy Supply

To demonstrate Stationary Energy Supply based on Fuel Cells

Production on demand of consumable energies

• Electrical power• Heat Trigeneration• Cold

using decentralized energy sources

• natural gas• other gasified energy carriers• regenerative and secondary fuels from biomass and waste

It is a Prime Mover

which transfers

chemical energy of a fuel

to electrical energy (LHV efficiency ~ 50%)

and high useful heat (LHV efficiency ~ 45%)

FUEL CELL

It is characterized by

Fuel Flexibility

Fuel Flexibility• Primary fuels:

• natural gas, gasified primary energy carriers, e. g. gasoline, diesel, etc.

• coal gas (synthesis gas)

• Secondary gaseous or gasified Hydrocarbons:

• biogas from anaerobic digestion (CH4, CO2)

• sewage gas, landfill gas, coal mine gas (CH4, CO2)

• gasified liquid and solid hydrocarbons, methanol, ethanol, plastic material, etc.

• biodiesel

• Synthesis gases (H2, CO, CH4, CO2):

• gases from thermal gasification processes (pyrolysis) using biomass and even waste material

• purge gases e. g. from refineries, chemical industry

Secondary FuelsCharacteristics

• Mostly renewable

• High Contents of inert components: N2, CO2, H2O

• Low heating value

• Decentrally available, but not everywhere

• Fluctuating properties

• Variety of different contaminants

High efficiency of fuel cells could optimise the use of secondary fuels

High quality utilization of secondary fuels: • Trigeneration – electrical energy, thermal energy, cooling

energy

Saving primary energy sources:• Reduction of dependence on primary energy sources• Reduction of pollution by greenhouse gases and

contaminants• Reduction of transport losses by utilization of energy sources

in situ and production of consumable energy forms in situ

Energy supply for Remote Areas

Why Combine Fuel Cell withSecondary Energy Sources

MCFC – Fuelling

Fuel:

• H2

• CO (< 20%)

Possible sources:

• Natural gas• Light hydrocarbons (butane, methanol, …)

Yield: • H2 75%• CO 10%• CO2 15% Traces of NH3, CH4, SOx…

Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

MCFC – Fuelling

Fuel:

• H2

• CO (< 20%)

Possible sources:

• Biomass (gasification)• Heavy hydrocarbons (distillate, oil)

Yield: • H2 20%• CO 25%• CO2 10%• N2 40% CH4, NH3, SOx, H2S, HCl, …

Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

MCFC – FuellingFuel:

• CHCH44

Possible sources:

• Animal manure, sewage sludge• Organic fraction of municipal solid waste• Residue, By- product• Organic industrial waste

Yield: • CH4 55-75%• CO2 25-45%• H2S 0-1,5%• N2 0-10%

Traces of H2 ,CO, Halogens, Siloxane

Reforming

Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

H2 + CO

MCFC – Fuelling

Fuel:

• H2

Possible sources:

• Animal manure, sewage sludge• Organic fraction of municipal solid waste• Residue, By- product

Yield: • H2 70-90%• CO2 10-30%

Traces of sulphidesTechnology under development

Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

MCFC – Fuelling

• High efficiency conversion• CO is a fuel: it will be shifted into H2 in reforming step• MCFC operates efficiently with CO2 – containing fuels

Source: MTU

Biomass gasification, Waste pyrolisis, anaerobic digestion,…

MCFC ideal for green electricity generation

Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

MCFC – Fuelling

• High efficiency conversion• CO is a fuel: it will be shifted into H2 in reforming step• MCFC operates efficiently with CO2 – containing fuels

BUT

Fuel gas clean-up is still restrictive: low tolerance and high cost

MCFC ideal for green electricity generation

Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

MCFC – Fuelling

• High efficiency conversion• CO is a fuel: it will be shifted into H2 in reforming step• MCFC operates efficiently with CO2 – containing fuels

MCFC – FuellingContaminations

Sulphur Containing Compounds H2S, THT, Mercaptanes, Thioester,

Thioether, COS, (SO2)

Nitrogen Containing Compounds NH3, NOx, Amines, N2 (Gasification)

Olefinic Hydrocarbons, Tar R2C=CR2, aromatic HC, undefined products from cracking reactions

Halogens F, Cl, Br, I, aliphatic, aromatic

Volatile metal organic Compounds R3-Si-O-Si-R3 (Siloxanes)

If present most of them can limit the lifetime of the fuel cell system

Cell type Tolerance limits

AFC 0% CO2, 0% H2S

PEFC CO < 10 ppm

PAFCCO < 1%v

H2S + COS < 50 ppm

MCFCH2S < 10 ppm, COS < 1 ppm

HCl < 1 ppm, NH3* < 4%v

SOFC H2S < 1 ppm, HCl < 1 ppm

NH3 < 1000 ppm *Under this % NH3 is a fuel Desire-Net Lesson: Fuel Cell, 8 June 200 – Angelo Moreno ENEA

Available Clean-up Systems

Conventional Systems:

• derived from methods used in chemical industry; technical mature, but expensive in small scales adapted to decentralized CHP systems:

Cooling down - drying – condensing – washing – adsorption on activated carbon.

H2S removal:

• Adsorption• Chemical scrubbers• Catalytic oxidation• Membrane separation• Bio-filters• Bio-scrubbers

Cost estimations clean-up

Gas Clean-up Costs:

0.4 to 8.0! €cts/kWhel

regenerative/non-regenerative systems

Source: MTU

WARNING: Clean-up is a tricky system

Methanol MCFCLandfill Gas

Coal Mine Gas

Coal Gas

Synthesis Gas

Biogas

Natural Gas

Sewage Gas

MCFC suitable forRegenerative andRegenerative andsecondary fuels secondary fuels

Gaseous Gaseous hydrocarbons hydrocarbons

BIOMASSWASTE MCFC

DECENTRALIZED HEAT & POWER

GENERATION

• reducing transmission losses• reducing dependence from availability of fuel and/or

electricity grid • reducing emissions of GHG and pollutant• reducing dependence on primary energy carriers imports

From the production to the end use

Rural economy

Energy independence

CHP System Sizes

MCFC

MCFC

Desire- Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic

Institutional Hospitals Universities

Commercial Hotels Data Centers Office/Shopping

Industrial Waste Water Telecom Food & Beverage Chemical Manufacturing Utility Grid-support

MCFC: Target Customers

Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

* - Allied Business Intelligence’s 2001 Study, “Stationary Fuel Cells: U.S. and Global Early Market Opportunities.”

Uses anaerobic digester gas from industrial and municipal waste water treatment facilities

Use of “biogas makes this a “renewable” application.

Favorable economics – fuel generated by application

King County, Kirin Brewery, Terminal Island, City of Fukuoka

Over 500 MW Waste Water Fuel Cell Installations by 2011*Over 500 MW Waste Water Fuel Cell Installations by 2011*

MCFC: Waste Water Treatment FacilitiesA Unique Opportunity for market entry

Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

Wabash River Energy Ltd., Terre Haute, Indiana

DFC® 3000

Headquarters Building (LADWP)Los Angeles, California

DFC® 300

Multi-megawatt systems

FCE main realizations

King County Wastewater Treatment FacilityRenton, Washington

DFC® 1500

Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

FCE experience: King Country 1 MW power plant

First Fuel Switching ApplicationOperated on Natural Gas and Digester Gas Source: FCE

King Country 1 MW power plant

Overall process flow Source: FCE

Types of Gases used by the King Country Fuel Cell

Digester Gas Natural Gas

• 90 -100% CH4

• 9,3 - 10,3 kWh/Nm3

• Odorised for safety, typically 3 ppm Sulphur, max 20 ppm

• 50 -80% CH4 (60% typically)

• 5,2 - 8,3 kWh/Nm3

• Sulphur present naturally at tens to hundred of ppm

• It contains Siloxanes

Source: FCE

Types of Gases used by the King Country Fuel Cell

Source: FCE

MTU experience: Leonberg Germany

Source: MTU

AFCO

MCFC – Plant

Source: AFCO

AFCo Demonstration Program

Source: AFCO

Size (Class) Fuel Market segmentFirst of a kind Series 2TW Natural gas Stationary DGTecnodemo Series 100 Natural gas Stationary DGHybrid Cycle Series 100 Natural gas DGNaval Application Series 2TW Diesel Naval

Biomass Appication Series 100Biomass

Gassification Waste to Energy

H2 /CO2 Series 2TW Hydrogen

MC-WAP NAVAL APU

Series 2TW Diesel Naval

BICEPS 1 MW-class Digester gasBICEPS 1 MW-class Landfill GasPRIOLO Series 100 SyngasH2 FILSTAT Series 2TW Natural gas DGFURTHER DEMOS MW-class various various

Waste to EnergyWaste to Energy

AFCOOngoing Field Tests: MCFC-NAV

• Installed at Marmara Research Center, Istanbul (Turkey)

• Fuelled with NATO F76 Diesel Oil

• Conceived for future boarding on military ships and for “stand alone” use in remote areas and military bases

• Fuel Processing System successfully tested

• Installed at Marmara Research Center, Istanbul (Turkey)

• Fuelled with NATO F76 Diesel Oil

• Conceived for future boarding on military ships and for “stand alone” use in remote areas and military bases

• Fuel Processing System successfully tested

Source: AFCO

• BICEPS – 2 “MW-Class” plants running on biogas:

• 1 MW in Terni (Italy) on ADG (beg. 2008)• 1MW in Murcia (Spain) on landfill gas (2008)

– Project cost shared by the European Commission

• PULP&PAPER– An integrated waste AND energy solution for the P&P industry:

• Reforming/Gasification of “pulper” waste and conversion to power and heat with MCFC.

– Framework agreement in place with Italian P&P industrial ass.n and Italian Government:

• 1 MW prototype in 2007• 2 x 4MW plants from 2008/9

AFCOField Tests: Ongoing projects

Source: AFCO

• REFINERY WASTE

– Agreement with a major Italian Oil&Gas Company for a demo plant running on tar gasification plant to be installed in 2007

• OTHER WASTE TO ENERGY PROJECTS

– Conversion of Chicken Manure through gasification and MCFC

• REFINERY WASTE

– Agreement with a major Italian Oil&Gas Company for a demo plant running on tar gasification plant to be installed in 2007

• OTHER WASTE TO ENERGY PROJECTS

– Conversion of Chicken Manure through gasification and MCFC

AFCOField Tests: Ongoing projects

Source: AFCO

CONCLUSIONSPART A

• MCFC is a viable, clean, sustainable power generation alternative

• Very HIGH EFFICIENT TECHNOLOGY

suitable for DISTRIBUTED GENERATION AND RURAL ECONOMY

and characterized by FUEL FLEXIBILITY

PART B

• Sustainable Strategies based on Best Practices and

Best Available Technologies

• WASTE TO ENERGY Case Studies