Fuel Cells Technology: Opportunities and Challenges Dr. Daniel Kramer 937-229-1038 August 2, 2010.
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Transcript of Fuel Cells Technology: Opportunities and Challenges Dr. Daniel Kramer 937-229-1038 August 2, 2010.
OVERVIEW OF PRESENTATION
Why fuel cell technology is important? How do fuel cells work?
• Are they inherently dangerous-hydrogen? Are they real?
• Will I use them in my lifetime? Future affect on American Industries?
• Barriers to technology transition
• Some current materials/manufacturing issues
Over the last ~30 years U.S. domestic oil productionhas significantly decreased and imported oil now
accounts for >50% of total consumption
There has also been several major disruptions of the world’s oil supplyover the last several decades including recent events in Venezuela/Iraq/Iran
Fuel cell technology has the potential to decreaseU.S. dependency on imported oil
Shift from a petroleum to a hydrogen based economy Fuel cells “burn”:
• Hydrogen• Water
• Methanol
• Oxygen• Air
Fuel cells produce electricity• “Waste” mainly water
• Heat
OVERVIEW OF PRESENTATION
Why fuel cell technology is important? How do fuel cells work?
• Are they inherently dangerous-hydrogen? Are they real?
• Will I use them in my lifetime? Future affect on American Industries?
• Barriers to technology transition
• Some current materials/manufacturing issues
Sir William Grove, a Welsh born Oxford educated lawyer, demonstrated fuel cell technology ~1840
Sir Grove was initially investigating the electrolysis of water forming hydrogen and oxygen using electricity
He also reversed the experiment thus investigating the recombination of hydrogen and oxygen producing electricity and water
He was successful and his work makes him the “Father of Fuel Cell Technology”
Electrolysis uses electricity to split waterinto hydrogen and oxygen
2H2 + O2 2H2O + energy (electricity)?Sir Grove
energy (electricity) + 2H2O O2 + 2H2
The field advanced slowly over the next century
but it took a “giant leap” in the 1960’s
Who remembers the Apollo program?
Early in the program NASA recognized that the energy requirements for an eight day mission to the moon and back were demanding
• Batteries
• Size/weight concerns
• Solar panels
• Size/weight concerns
• Fuel cells? General Electric was given the contract to
produce alkaline fuel cells for the space missions
• Hydrogen/oxygen fuel
• By-product/drinkable water
What about the Apollo 13 accident?Wasn’t that caused by the “fuel cells”? No!
The oxygen tanks were designed for 28vDC“Changed” to also accept ground support at KSC to 65vDCHeater switch within tank was not upgradedSwitch damaged during ground support tests allowing high tempsResult – damage to the insulation on the electrical wires in tank #256 hours into mission exposed wires shorted
So what actually is a fuel cell?
Electrochemical reaction between a fuel and oxygen
Produces DC power Environmentally green
(effluent consists of mainly water and heat)
Present focus is on two types of fuel cells:• Proton exchange
membrane (PEM)
• Solid oxide fuel cell (SOFC)
FUEL
AIR
DC
WATERHEAT
ANODE -
CATHODE +ELECTROLYTE
PEM and SOFC based technologies maysee near term commercial application
Operates ~>800oC – 1000oCCan use a variety of fuelsElectrolyte-yttria stabilized zirconia~0.08(Y2O3)0.92(ZrO2)Cathode-lanthanum manganite (Sr doped)Anode-zirconia nickel cermetStationary power systems(?)
Operates at lower tempsNeeds “purer” fuelElectrolyte-Nafion® polymerCathode/Anode-Pt/CarbonTransportation systems(?)
The PEM electrolyte (Nafion®) material acts as a“solid-state switch” - it is an ionic (H+) conductor
but not an electronic (e-) conductor
AnodeGas Diffusion Layer
CathodeGas Diffusion Layer
H2
H2
H2H2
H2 Gas Flow
PEM Schematic
Air (O2) Gas Flow
O2
O2
O2
O2
O2
O2
O2
H2
H2 2H+ + 2e-
Pt1/2O2+2H++2e- H20
Pt
e-
H+
H+
H+
H+
H+
Nafion®
Pt
Pt
H2
Example of an integral Solid Oxide Fuel Cell (SOFC) anode/electrolyte/cathode assembly
Tape Cast Integral Assembly(Anode+Electrolyte+Cathode)
SOFC “Planer Unit Cell”
Individual fuel cells are connected togetherin the manufacturing of a fuel cell stack
Multiple fuel cell stacks interconnected with “Balance of Plant”components (fans, valves, controllers, etc.) form a fuel cell system
SOFC Stack
Multiple fuel cell stacks are integrated with Balance of Plant (BOP) to form a fuel cell system
BOP is everything else besides the fuel cell stack needed to fabricate a Fuel Cell System
Electrical Controllers
• Temperature
• Humidity
• Gas Flow Fans, Valves, Cabinet, Heat Exchangers, etc.
What about the safety issues associatedwith the application of hydrogen?
Hydrogen can be hazardous
• But it can be handled safely Possible storage plans:
• Solid storage using metal hydrides
• Compressed gas cylinders
• Liquid storage using a “salt”
Wait a minute I remember the Hindenburg accident and that disaster was due to hydrogen!!!!
The dopant painted on the skin was ignited by a static discharge(iron oxide/fine aluminum/cellulose acetate)
The Hindenburg (~813ft long/~7,200,000ft3 of H2)burning at Lakehurst, NJ in May 1937
(36 of 97 people on board are lost)
In 1998 research showed that hydrogen was not the cause!!! (Van Vorst/UCLA)
OVERVIEW OF PRESENTATION
Why fuel cell technology is important? How do fuel cells work?
• Are they inherently dangerous-hydrogen? Are they real?
• Will I use them in my lifetime? Future affect on American Industries?
• Barriers to technology transition
• Some current materials/manufacturing issues
Fuel cells are real and within 5 – 10 years theywill initially (my opinion) be commercialized
in two main market areas
Stationary electrical power systems (1w – 100Mw)
• Large hybrid cascading power plants• Conceptual designs approach ~60+% eff.
• Auxiliary power units (~20kw – 250kw)• Hospitals/Shopping centers/Schools
• Smaller power units (~1w – ~20kw)• Homes• Emergency applications• “Batteries”
Various transportation applications• Automobiles• Buses• Motorcycles• Golf carts/wheelchairs
Efficiency Comparisons
Examples where fuel cell systems willbe commercialized in the “near” future
Electrical Power Generation and in Transportation
STATIONARY/EMERGENCY POWER GENERATION
• HOSPITALS
• OFFICE COMPLEXES
250kWe PEM SYSTEM
SMALLER POWER SYSTEMSFOR RESIDENTIAL USE
3kWe IdaTech SYSTEM
havePower’s commercially available 500w PEM systememploys a number of swappable modular power cartridges
Prototype Casio laptop that can run for more than 20 hours on one refueling of its fuel cell power supply, shown here removed from the computer.
The portable electronics industry is exploringminiature fuel cells as a more powerful, longer
lasting replacement for batteries
UltraCell is developing a Reformed Methanol Fuel Cell (RMFC) that is being manufactured in the Dayton area
25 Watts continuous power output (enough power for most laptop computers, radios, and satellite phones)
Selectable voltage: 12V to 30V
Stores, starts, and operates to -20ºC
1 liter size, 1.2 kg weight
On/Off button and easy-to-read LCD
Orientation independent
Up to 18 hours of run time with hot swappable fuel cartridges
Built tough for military applications (designed for MIL-STD 810F, 461E/462D compliance)
System emissions: H2O, CO2,
and unconsumed air
System intake: Air
Power out
Reformer
CH3OH 2H2 + CO
CO + H2O H2 + CO2
Fuel Cell
Anode: H2 2H+ + 2e-
Cathode: 1/2O2 + 2H+ + 2e- H2O
Fuel cellStack180ºC
H2, CO2
Reformer
280ºC
Fuel cartridge
67% methanol, 33% water
(by vol.)
Some info on Reformed Methanol Fuel Cells(RMFC)
Small portable fuel cell power systems are entering the marketplace
25 Watts continuous power output (enough power for most laptop computers, radios, and satellite phones)
Selectable voltage: 12V to 30V
Stores, starts, and operates to -20ºC
1 liter size, 1.2 kg weight
On/Off button and easy-to-read LCD
Orientation independent
Built tough for military applications (designed for MIL-STD 810F, 461E/462D compliance)
Portable power for First Responders
FuelCell
Fuel cell power system has significant advantagesover batteries in various military applications
70% Weight Savings for 72-Hour Mission
XX25™ (with 7 spare cartridges)
72 hr mission wt. = 4.0 kg (8.8 lb)
BB-2590 (military version of Li-Ion)
72 hr mission wt. = 12.3 kg (27.0 lb) Communications
Electrical Power Generation and in Transportation: Most of the large automobile manufacturers have fuel cell
powered test vehicles on the road today
Honda FCX-V4 Fuel Cell Car
General Motors HydroGen 3 Fuel Cell Car
So are fuel cell powered vehicles reallyGREEN and POLLUTION FREE?
British Columbia Transportation Minister toasting fuelcell powered “zero emission” bus using
water from the bus exhaust
What the future may look like!GM’s AUTOnomy concept fuel cell vehicle could change the dynamics of automobile production
Skateboard platform prototype (~6” thick) would include both the
fuel cells and the power train
The Skateboard chassis would allow a variety of body types tobe economically mass-produced
Ohio Fuel Cell Symposium
Hydrogen on Demandtm systems have demonstrated a range of ~300 miles on a
single tank without refueling
DaimlerChryslerTown & Country NATRIUM
Ford Mercury Sable
Top Speed ~80 mph
The Hydrogen on Demandtm system storesthe hydrogen in liquid form
AS THE DRIVER “PRESSES THE PEDAL” NaBH4 + 2H2O 4H2 + NaBO2CAT
Solution of sodium borohydride in water
Would you let this guy driveyour $1,000,000+ fuel cell car?
Toyota Fuel Cell Hybrid Vehicle at Sinclair CC
Working on your own fuel cell car would be difficult
Requires entire repair infrastructure to be set-up
Some potential advantages offuel cell powered automobiles
Efficient – Fuel cells are generally more efficient than internal combustion engines
Simple – Fuel cells are typically “simple” with few if any moving parts
Low Emissions – mostly Water / Carbon Dioxide
Quiet – Mainly Balance of Plant (fans, pumps, etc.)
Some potential disadvantages offuel cell powered automobiles
Fuel Availability – Where do you fill-up?
Safety Questions - Ford has designed a fuel cell vehicle with a range of 380 miles using 5,000psi tanks
Reliability – Present fuel cells tend to exhibit performance degradation over time
Cost – Fuel cell cars are currently too costly
Can we store enough hydrogen on the vehicleto obtain “commercially” required range?
Hydrogen storage is a current challenge that is being addressed by research and technology demonstrations.
Conventional pressurized tanks yield enough range to meet niche markets that will be the entry point for fuel cell vehicles.
The best of today’s research vehicles report range of well more than 200 miles using conventional compressed hydrogen storage.
Ford designed a fuel cell vehicle with range of 380 miles using pressurized tanks (5,000 psi).
Several vehicles are operating on non-gaseous alternatives that achieve fully commercial range. (greater than 300 miles)
Increases in stack efficiency will help in the short term.
OVERVIEW OF PRESENTATION
Why fuel cell technology is important? How do fuel cells work?
• Are they inherently dangerous-hydrogen? Are they real?
• Will I use them in my lifetime? Future affect on American Industries?
• Barriers to technology transition
• Some current materials/manufacturing issues
Commercialization of most new technologies is a battle between two interacting forces
Market Pull vs. Technology Push
As technologists we don’t understand why consumers aren’t breakingdown our doors with bundles of cash to buy our latest and greatest
As consumers we don’t understand why technologists aren’tproviding us with what we want at a cost we are willing to pay
What is the major barrier to fuel celltechnology commercialization?
havePower 500w PEM system
Cost ~$5,000+
Coleman 5kw Powermate
Cost ~$500 at Home Depot
As a consumer which would you buy?
Short answer – Cost!
Fuel cell technology in transportation may representone of the largest opportunities or threats
for American companies
Large motor vehicle manufacturers:• Imagine the number of American companies and jobs that are
currently dependent on the auto industry• Imagine the economic impact in the USA of changing from internal
combustion engine powered to fuel cell powered vehicles!!• Application of fuel cell technology will change:
• Engines• Transmissions• Battery Systems• Electronic Control Systems
Now imagine the potential economic impact to our country’s economy and employment
What are some of the major cost barriers inhibiting fuel cell commercialization?
Infrastructure• Fuel handling/refilling issues?• Need Installers/trained repair technicians• Fuel cell testers?
Materials• PEM – Fuel/Electrolyte Related?• SOFC – Temperature/Electrolyte Related?
Manufacturing• Need for high volume manufacturing processes to lower
cost of fuel cell systems• Cells/Stack/System Assembly?• Balance of Plant?
The marketplace has real infrastructure barriers to the application of fuel cell technology
Automobile manufacturers have billions of dollars invested in internal combustion engine vehicles
• Engine plants
• Transmission plants OPEC as a cartel is able to “adjust” the price of oil
• Competing technologies may not be allowed to transition into the marketplace
Filling / Repair stations
• 1000’s of already in-service gas stations (FC stations?)
• Tens of Thousands of highly trained professionals
Fuel cell refueling stations will be similarto present day gas stations
HYDROGEN REFUELING STATION IN VANCOUVER, BC
METHANOL REFUELING FACILITY IN SACRAMENTO, CA
Lowering the manufacturing costs of fuel cell components represents a major challenge
Examples of manufacturing issues in the manufacturing of planer solid oxide fuel cells
Close flatness tolerances Ceramic machining Surface preparation of joined surfaces Metal interconnects Sealing systems Balance of plant issues Need for high speed manufacturing processes
Manufacturing costs are a Catch 22 loop?
Large quantity orders for fuel cell systems
will significantly lower individual unit costs
Large quantity orders for fuel cell systems may
not occur until the individual unit cost is lowered
Despite the challenges there is a good chance that fuel cell technology will be a part of your future
250KW POWER PLANT
UTC 5KW HOME UNIT
US ARMY FORK-LIFT
GM HydroGen 3