TECHNOLOGY AND APPLICATION OVERVIEW OF FUEL CELLS
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Transcript of TECHNOLOGY AND APPLICATION OVERVIEW OF FUEL CELLS
TECHNOLOGY AND APPLICATION OVERVIEW OFFUEL CELLS
by
R.K.BHATTACHARYAGeneral Manager(EM)
Bharat Heavy Electricals Limited,Corporate Research & Development Division ,
Vikas Nagar,Hyderabad
……….MILLIONS OF YEARS AGO, THERE WAS NO MAN KIND..……ONLY PRE-HISTORIC LIVING SPECIES..
CLIMATE/ENVIRONMENTAL CHANGE(NATURAL)
ECOLOGICAL CHANGE (MAN-MADE)
……….RESULTED IN THE EVOLUTION OF MANKIND
……..LOGICALLY WILL SEE THE EXTINCTION OF THE PRESENT LIVING FORMS
UNLESS WE DO SOMETHING ABOUT REVERSING WHAT WE ARE DOING
•ENERGY IS THE PRIME MOVER FOR THE WHEELS OF LIFE
•QUEST FOR NEW SOURCES & NEW CONVERSION TECHNOLOGIES
TO USABLE FORMS
•EARTH-THE HOLDING POT OF SUM TOTAL OF ALL FORMS OF ENERGY
•STILL ECOLOGICAL CONDITIONS WILL DICTATE FORMS OF LIFE
-
•WORLD POPULATION EXPECTED TO GROW TO 8 BILLION IN 2020
•WILL REQUIRE 90 BILLION bpd OF OIL
7 B.TONS OF COAL/YR
40 TRILLION Cu.M/YR OF NG
•50% OF THIS ENERGY WILL BE REQUIRED IN THE DEVELOPING WORLD
•16% OF WORLD POPULATION WITH 0.6% OF OIL & 6% OF COAL
RESOURCES.
•IN 2000-01, ENERGY SHORTAGE - 7.8%, PEAK LOAD SHORTAGE -13%.
•PER CAPITA ENERGY CONSUMPTION IS FAR LESS COMPARED TO
GLOBAL STANDARDS (482 kWHr IN 1997 - CHINA 922 - WORLD 1562).
•BY 2025, INDIA WILL BE THE MOST POPULOUS COUNTRY IN THE
WORLD.
•COUPLED WITH THE GDP GROWTH REQUIREMENTS, THE ADDITIONAL
ENERGY REQUIREMENT WILL BE MIND BOGGLING.
HOW DO WE MANAGE THIS? -------------------
----------- THE ANSWER WILL HAVE TO BE FOUND ON BOTH SIDES OF THE
EQUATION.
(SOURCE, TECHNOLOGY, EFFICIENCY) (ALTERNATIVES, EQUIPMENT, LIFE STYLE)
------------STILL, WE CAN NOT AVOID THE INEVITABLE, BUT WE CAN DELAY
THE SAME.
ENERGY SUPPLY = ENERGY DEMAND
ELECTRIFICATION RATE ( %)
WORLD - 72.8
DEV COUNTRIES - 64.2
OECD - 99.2
INDIA - 43.0
CHINA - 98.6
SRILANKA - 62.0
PAKISTAN - 52.9
BANGLADESH - 20.4.
FOSSIL FUEL
RENEWABLES
OTHER
COAL
OIL
NATURAL GAS
SOLAR PV / THERMAL
HYDRO
WIND
NUCLEAR
BIO - MASS
FOCUS ON FUEL CELLS
OUR PRESENT LIFESTYLE CANNOT DO AWAY WITH FOSSIL FUEL
ENERGY SOURCES IMMEDIATELY.
BUT, ADOPTING ENERGY CONVERSION SYSTEMS WITH HIGHER
EFICIENCY WILL REDUCE GH GAS GENERATION.
FUEL CELLS MEET THIS REQUIREMENT ADEQUATELY.
ALSO, BEING A COMBUTIONLESS SYSTEM THERE IS NO
EMISSSION OF SOX/NOX.
Part I : Fuel Cell Technology- an Overview
Principle of Operation of a Typical Fuel Cell
Repeating elements used in a typical cell stack
Major sub-systems in a typical Fuel Cell Power Plant
Fuel cells provide a range of critical benefits that no other single power-generating technology can match.
Some of the key characteristics of fuel cells are :
•Fuel Cells are Efficient – even at part loads
•Fuel Cells are modular
•Fuel Cells provide high availability and reliability
•Fuel Cells can operate on a variety of fuels
•Fuel Cells are Clean & Quiet
Benefits of Fuel Cells
Fuel Cell TypeTemp of
Operation [oC]
Unit Sizes [kWe]
Most likely applications
Alkaline Fuel Cell (AFC)
RT – 100 < 100Space , Military recently terrestrial applications
Proton Exchange Membrane Fuel Cell (PEMFC)
RT – 100 0.1 - 100Portable devices like Lap Tops, Cellular phones, Video Cameras etcDomestic & Dedicated Power (+ heat) Buses, Passenger Cars, Service Vehicles, Railway Locomotives & Streetcars etc
Phosphoric Acid Fuel Cell (PAFC)
100 – 210
5 - 200 (also MW sized plants)
Dedicated Power (+ heat), Railways
Molten Carbonate Fuel Cell (MCFC)
650100 - 2,000 (plants up to 100 MW)
Dispersed Power & Utility Power (Combined Cycle -with downstream Steam Turbine)
Solid Oxide Fuel Cell (SOFC)
800-10002.5 – 250(plants up to 100 MW)
Domestic & Commercial (heat and power), Utility Power (combined cycle) Mobile applications for railways
Types of Fuel Cells
PEMFC AFC PAFC MCFC SOFC
Electrolyte Ion ExchangeMembrane
PotassiumHydroxide
Phosphoric Acid
Molten carbonates
CeramicOxides
Catalyst Platinum non platinum
Platinum Nickel Perovskite
Operating Temp 0 C
RT-80 RT-80 180-205 650 800-1000
ElectricalEfficiency(%LHV)
32-40
50-60 36-42 45-60 50-60
Applications
Cogeneration Utility Power
Distributed Power
Passenger Vehicles
Heavy DutyVehicles
Portable Power
Specialty Power
PEMFC AFC PAFC MCFC SOFC
Advantages High Power density,Light weight, quick response
Low cost high efficiency,Co tolerant
Co tolerance up to 1.5%Multi fuel capability
Inexpensive catalystsMulti fuel capability
Efficiencies up to 60%
Disadvantages Humidification requiredCOIntolerancePlatinum&Membrane pushes the cost upwards
Requires inlet air scrubbers.CirculatingAlkali requires toping up
Expensive platinum catalyst used.Low current& power.Large size& weight
High temperatures enhance corrosion and the breakdown of cell components.
Not yet available commercially
Alkaline Fuel Cell Applications
PEMFC applications
MCFC &DFC applications
SOFC tubular and planer design
100 kW SOFC Cogeneration System formerly at Westervoort, the Netherlands, currently at Essen, Germany. As of January 2002 the system has operated in a total of 20,000+ hours. The system has a peak power of ~140 kW, typically feeding 109 kW into the local grid and 64 kW of hot water into the local district heating system, and is operating at an electrical efficiency of 46%.
Simple-cycle Atmospheric SOFC Simple-cycle Atmospheric SOFC Cogeneration SystemCogeneration System
World's First Fuel Cell-Gas Turbine World's First Fuel Cell-Gas Turbine Hybrid now Operating in CaliforniaHybrid now Operating in California
220-kW hybrid system with a Solid Oxide Fuel Cell (SOFC) generator and a down-stream micro-turbine
SOFC stack
Part II : BHEL’s Activities in Fuel Cell Area
Fuel Cells at BHELFuel Cells at BHEL (History of Development(History of Development))
1987-1990:1987-1990: Started work on PAFC. Made single cells and Started work on PAFC. Made single cells and small stacks (100-200 cmsmall stacks (100-200 cm22))
1991: Demonstrated a 1 kW stack (chlor-alkali plant, 40 1991: Demonstrated a 1 kW stack (chlor-alkali plant, 40 cells,with imported bipolar plates, ~400 cmcells,with imported bipolar plates, ~400 cm22))
1995: Demonstrated 5 kW stacks (chlor-alkali plant, 1995: Demonstrated 5 kW stacks (chlor-alkali plant, 80 cells, ~900 cm2, Laminated bipolar plates, 80 cells, ~900 cm2, Laminated bipolar plates, 300*400 300*400 mm, Rolled electrodes)mm, Rolled electrodes)
2001: Demonstrated 2*25 kW stacks (chlor-alkali plant, 2001: Demonstrated 2*25 kW stacks (chlor-alkali plant, 160 cells / stack, ~1600 cm160 cells / stack, ~1600 cm22, molded bipolar plates, screen , molded bipolar plates, screen printed electrodes) printed electrodes)
2002:Acquired basic PEMFC technology from IISc,single cell 2002:Acquired basic PEMFC technology from IISc,single cell testing testing
The 50kW Power Pack during testing at
BHEL R&D during December 2000
Salient features of 50 kW stack (2 x 25 kW fuel cell stack)
•2 x 25 kW stacks
•Plate area 500mm x 400mm = 2000 sqcm
•Effective Cell Area = 1500 sqcm
•Number of cells in each stack = 160
•Air cooling system
•Water to air Heat exchanger system
•Inverter and DC loading system
•Data acquisition and storage system
•Current densities achieved in the range of 200 to 250 mA/sqcm
•Operating voltage in the range of 550 to 600 mV per cell
200 kW PC 25 C PAFC Power Plant at BHEL R&D
Part III :Fuel Cell Application Opportunities in India
Fuel Cells Application in IndiaRailways
•Passenger Coaches’ lighting and fans
4 kW systems mounted on the passenger coach
Requirement 4500 coaches•Power cars for long distance Shatabdi & Rajdhani
200 kW systems / 2 per train / 25 trains•Illumination of level crossing
Up to 1 kW systems / Around 8000 to 10000 •Lighting of isolated railway stations
5 to 10 kW systems / Up to 1000 stations•Emergency power supply for control rooms
10-25 kW systems / Up to 200 - 500 control rooms
Fuel Cells Application in IndiaTransportation
Two Wheeler4 kW systems / 75,000 to 1,00,000
Three Wheeler6-8 kW systems / 25,000 to 50,000
Buses100 kW systems / 1,000 to 5,000
Merchant Navy100-200 kW / 100 to 200
Fuel Cells Application in IndiaStrategic
Data Processing centres 1- 5 kW systems / around 5,000
Soft ware Companies 25 – 50kW / around 1,000
Communication Centres 1-5 kW systems / around 20,000
Remote Area Installations 1-2 kW systems / around 1,000
Off shore oil rig installations 25-50 kW systems up to 500
Fuel Cells Application in IndiaCommercial establishments
Shops in Malls and Underground bazaars1 to 3 kW systems / around 1,00,000
Small Business Establishments5-10 kW systems / 50,000
Entertainment Industry25-50 kW systems / 500 to 1,000
Hotels, restaurants & Resorts100-200 kW systems / up to 500 units
Hospitals 200-500 kW systems / up to 200 unitsResidential Complexes
50-200 kW systems / 30,000 to 50,000
Part IV : Issues in Fuel Cell Application in DPG
Distributed GenerationDistributed Generation
- Rural (Remote areas)Rural (Remote areas)- Urban ( Hotels ,Hospitals ,Ent.centres, Urban ( Hotels ,Hospitals ,Ent.centres,
Software dev. centres)Software dev. centres)- Strategic (Communication centres, Defense,Strategic (Communication centres, Defense,
Chemicals and Pharmaceutical plants)Chemicals and Pharmaceutical plants)
Fuel options Fuel options
Urban :- Hydrogen,NG,Methanol,LPG,Urban :- Hydrogen,NG,Methanol,LPG,
Di-gasDi-gas
Rural :- Ethanol ,BiogasRural :- Ethanol ,Biogas
Strategic:- Hydrogen, NG, LPG, Methanol Strategic:- Hydrogen, NG, LPG, Methanol
Technology of fuel cells will depend upon the type of fuel availableTechnology of fuel cells will depend upon the type of fuel available
Capacity /Duty cycleCapacity /Duty cycleUrban/StrategicUrban/Strategic – – High Power CapacityHigh Power Capacity
– – Base Load Base Load
(High temp.Fuel Cells)(High temp.Fuel Cells)
Rural Rural – – Low Power Capacity Low Power Capacity
– – Cyclic Load Cyclic Load
(Low temp.Fuel Cells)(Low temp.Fuel Cells)
No.of start stops will determine the life cycle of HT fuel cells.
Other IssuesOther Issues Starting power - Rural area (Black start)Starting power - Rural area (Black start) Others (Brown start)Others (Brown start) Cost Factor - Still not affordable Cost Factor - Still not affordable
without Govt.subsidy without Govt.subsidy Market Size - Traditional tussle between Market Size - Traditional tussle between cost and volumecost and volume Op.& Maint. - Being high technology itemOp.& Maint. - Being high technology item requires careful handlingrequires careful handling
PART- V: AUTOMOTIVE APPLICATIONS OF
FUEL CELLS
NEED VS GROUND REALITIES
• WORLDWIDE, TRANSPORT VECHICLES ARE THE SINGLE LARGEST
CONTRIBUTOR TO THE GH GASES. IC ENGINES CONVERT FUEL’S
CHEMICAL ENERGY TO WHEEL POWER AT VERY LOW EFFICIENCIES.
• THOUGH THE NEED FOR HIGHER CONVERSION EFFICIENCY IS FELT
AND THE DESIRABILITY OF FUEL CELLS IS VINDICATED, PEOPLE
WOULD BE INFLUENCED BY:
- COST
- PERFORMANCE
- CONVENIENCE (INFRASTRUCTURE)
FUEL - THE CRUCIAL FACTOR
ON BOARD PRESSURIZED GAS
ON BOARD LIQUIFIED H2
ON BOARD REFORMER
ON -BOARD METAL HYDRIDES
FUEL CELL POWER STACK
VEHICLE PROPULSION
SYSTEM
FROM GROUND BASED FUEL
INFRASTRUCTURE (EXTERNAL REFORMATION)
GASOLENEMETHANOL
HYDRIDE REPLENISHMENT FROM GROUND SOURCES
HYDROGEN
ISSUES FOR EACH OPTION
1. ON -BOARD PRESSURIZED HYROGEN : COMPRESSION PRESS 10000 PSI ; LARGE SPACE REQUIREMENT ; OCCUPIES EIGHT TIMES THE VOLUME OF GASOLENE.
2. ON BOARD LIQUIFIED HYDROGEN:- HIGH ENERGY REQUIRED FOR COOLING THE GAS TO LIQUID IN CRYOGENIC TANKS (-2530C); HIGH COST OF CRYO TANKS.
3. METHANOL REFORMATION : REFORMATION AT 260 - 300 0C ; TOXIC AND POISONOUS WITH INVISIBLE FLAME ; EASY TRANSPORTABILITY AND HANDLING ; EXISTING FUEL INFRASTRUCTURE CAN BE USED.
ISSUES (CONTD)
4. GASOLENE REFORMATION : REFORMATION AT 6000C ; LESS EFFICIENT THAN METHANOL AND PRODUCES MORE EMISSIONS ; EXISTING INFRASTRUCTURE CAN BE USED.
5.METAL HYDRIDES : PRESENTLY RARE-EARTH METAL
HYDRIDES ONLY STORE 1.5 - 2.0% HYDROGEN BY WEIGHT ;
RESULTANT WEIGHT MAKES IT UNVIABLE FOR CARS WITH
RANGE OF 300 KMs ; REQUIRES GROUND INFRASTRUCTURE
FOR RECHARGING.
6. SODIUM BOROHYDRIDE : SAFE CARRIER OF HYDROGEN ;
REQUIRES LESS VOLUME THAN COMPRESSED HYDROGEN ;
REQUIRES GROUND INFRASTRUCTURE.
WHAT ARE AUTO MAJORS PURSUING ?
DAIMLER.CHRYSLER
LIQUIFIED HYDROGEN - NECAR 4
COMPRESSED HYDROGEN - NECAR 4a
METHANOL - NECAR 5 & JEEP COMMANDER
METAL HYDRIDE & - CHRYSLER NATRIUM SODIUM BOROHYDRIDE
( A MODIFIED MERCEDES - BENZ A - CLASS WILL RUN ON COMP. H2 IN 2004)
TOYOTA COMPRESSED HYDROGEN - FCHV (KLUGER V)
HONDA COMPRESSED HYDROGEN - FCX
GM COMPRESSED HYDROGEN - HydroGen 3
(ACHIEVED HIGHEST STACK POWER DENSITY OF 1.75 kW/litre)
FORD COMPRESSED HYDROGEN - FOCUS FCV(HYBRID)
•NEED FOR QUICK-STARTING, MULTI-FUEL COMPACT REFORMER
•LOW-COST MATERIALS (SPECIALLY, ELECTROLYTIC MEMBRANE)
•LOW-COST NON-NOBLE MATERIAL CATALYST
•LOW-COST MASS-PRODUCIBLE BIPOLAR PLATE
•SIMPLIFIED LOW-COST POWER CONDITIONER
The FutureThe Future
Despite all these difficulties, the Despite all these difficulties, the
Governments all over the world are Governments all over the world are
pouring in money for pouring in money for BreakthroughsBreakthroughs
since this eco friendly technology could since this eco friendly technology could
be the ULTIMATE WINNER !be the ULTIMATE WINNER !
Thank You