Challenges in Fuel Cell Technology: Indias Perspective for - PowerPoint PPT Presentation

Challenges in Fuel Cell Technology: India’s Perspective for presentation at the National Seminar Organized by the Indian Institute of Technology, Delhi December 1 – 2, 2006 Shailendra Sharma, AGM (Fuel Cells Lab), BHEL, Corporate R&D Division, Vikas Nagar, Hyderabad – 500 093 (Phone: 040 - 23775861) e-mail: shailendra@bhelrnd.co.in

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Hydrogen Energy & Fuel Cells � Production of Hydrogen � Storage of H 2 � Means to deliver H 2 � Utilization of H 2 for Transport application � Utilization of H 2 for Power Generation

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Power Generation using H 2 - � Using Internal Combustion Engines - both Spark ignition (petrol) & Compression ignition (diesel) engines may be adapted for use with H 2 . � Using Fuel Cells - All types of fuel cells, operating at low, medium & high temperatures (AFC, PAFC, PEMFC, MCFC & SOFC) can be used for power generation. When used in Combined Heat & Power (CHP) mode, very high overall conversion efficiencies (80 - 85%) can be achieved.

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Principle of Operation - Schematic for PEMFC / PAFC

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Repeating Elements used in a typical cell stack

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Major sub-systems in a typical Fuel Cell Power Plant In addition to the above, a number of other sub-systems (viz.: Fuel storage & delivery system, Air supply system, Thermal Management system, C&I systems etc) are also needed

A glimpse of Fuel Cell Developments @ BHEL (Inter-disciplinary approach followed for Fuel Cells Development) Anodes, Cathodes, Membra ne Electrode Skid Design Assemblies etc (Renew able (Fuel Cells Lab) Energy Systems Bipolar & Lab) Cooling plates (Fuel Cells Lab) Inverter System (Power Fuel Cell Stack Hardware Electronics Lab) Development & Assembly (Design Analysis & V alue Engg) Data Acquisition, display & Controls (Control Reactants & Stack Heating Instrumentation Lab) Coolant Supply & Cooling (Turbo Ma chinery (Heat Transfer Lab) Lab)

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Fuel Cells - Major Challenges / Disadvantages � Performance loss with time (few mV / 1000 hrs) � Short life span (~ 5000 hrs to 40,000 hours) � High Capital costs (~ $ 3000 to $ 10,000 / kW) � Few technology developers / providers � Limited commercial availability � Limited fuel infrastructure

A glimpse of Fuel Cell Developments @ BHEL (PAFC & PEMFC components - Electrodes, bi-polar plates etc, 1998 - 2005)

A glimpse of Fuel Cell Developments @ BHEL Multiple Cells - connected in series 8 Cells PAFC stack, 100 x 200 mm; (PAFC, 60x60 mm, 1989) (1990)

A glimpse of Fuel Cell Developments @ BHEL India’s first kW rated Fuel Cell Stack India’s first Multi kW Fuel Cell Stack (PAFC, 120x360 mm, 40 Cells, 1 kW) (PAFC, 300x400 mm, 80 Cells, 5 kW) (1991) (1995)

A glimpse of Fuel Cell Developments @ BHEL (5 kW PAFC stack under testing, Active Area 865 cm 2 , 1995)

A glimpse of Fuel Cell Developments @ BHEL 2x25 kW PAFC stacks, 400x500 mm 200 kW, Performance Evaluation of PAFC (2000 - 2001) based Power Plant (PC25C-IFC/Toshiba) (1997 - 2000)

A glimpse of Fuel Cell Developments @ BHEL (PEMFC single cell test set up, 60x60 mm) (4 Cells PEMFC education-cum-demo (2003 - 2006) stack, 100 x 90 mm; 2004 - 2005)

A glimpse of Fuel Cell Developments @ BHEL (PEMFC, 20 cells’ stack under testing - Nov 2005)

A glimpse of Fuel Cell Developments @ BHEL 50 Cells, 150x300 mm, PEMFC 1 kW modular stack (under testing - January 2006)

A glimpse of Fuel Cell Developments @ BHEL 50 Cells, 150x300 mm, PEMFC 1 kW modular stacks

A glimpse of Fuel Cell Developments @ BHEL (V - I characteristics of a typical PEMFC stack) 150 x 300 mm; ExfoGrap BP's; 5 cells' PEMFC Stack # 7 19 Aug 2005 (0900 - 1455 Hrs; 26 - 49°C) 1100 6.0 In d iv id u a l C e ll 1050 5.5 S t a c k V o lt a g e 1000 5.0 V o lt a g e s 950 4.5 ( m V ) 900 4.0 ( V ) 850 3.5 800 3.0 750 2.5 700 2.0 650 1.5 600 1.0 0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 55.0 Stack Current (A) Stack cell#1 cell#2 cell#3 cell#4 cell#5

A glimpse of Fuel Cell Developments @ BHEL C&I system - developed under NMITLI program Monitor Controller Cubicle & Relay cards Keyboard, mouse DAS PC

A glimpse of Fuel Cell Developments @ BHEL Power Conditioner Under testing

Power Generation - using Fuel Cells (Likely markets for different ratings of Fuel Cell Power Packs)

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Few identified technology gaps for PEMFCs • Development of Indigenous Cathode Catalyst Powders • Development of Porous C / Graphite paper for use as substrates • Development of cost-effective Bi-polar plates 4. Development of electrode edge sealing materials (PTFE tapes etc) 5. Development of proton conducting membranes

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Few identified technology gaps (contd) 1. Development of robust dc-dc converters & dc-ac Inverters 2. Development of compact Reformers & Heat Exchangers 3. Development of a C&I to impart ‘stand-alone’ capability 4. Developing tools & fixtures for ensuring alignment while assembling large stacks

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Robust dc-dc converters & dc-ac Inverters • Usual ‘battery’ based inverters face ~ 10 - 20% variation in the input dc voltage. • In contrast, inverters for fuel cells have to face very large fluctuation – of the order of 40 - 50%. Most of this drop, however, is limited to the initial ‘no load’ – ‘load’ transition. Use of ‘dummy’ resistor or fan load etc have been tried. • With the use of dc-dc boosters (~ 600 V for 3 phase, ~ 300 V for single phase) very high inverter efficiency can be achieved (>90%).

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Compact Reformers & Heat Exchangers • Before we think of commercializing fuel cell based power packs, infrastructure for the most appropriate Fuel needs to be established. Different fuels can be identified for different areas / applications. Ethanol, LPG, NG etc • Suitable reformers for different fuels are needed. Some expertise already available (Methanol reformers - NMRL & IICT; LPG – NCL) • Development of compact heat exchangers needed to tap ‘excess’ or ‘waste’ heat as hot water or low-grade steam for use at customer end. – with low power pumps/fans

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 C&I package for ‘stand-alone’ capability • All FCPPs thus far have been operated by experts only. OK for developmental phase. Robust, cost effective C&I system to ensure auto start-up, safe operation & auto- stop. Should also log & store critical data for experts to analyze initially,& for self diagnostics, later-on.

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Ensuring alignment during stack assembly • Ensuring alignment of components (cells, bi-polar, cooling, dummy & pressure plates etc) poses many problems, especially in larger stacks. Special tools & fixtures were designed for the 25 kW PAFC stack (160 cells, >2 m high)

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Stack Compression • Apply & retain required compressive load over the entire useful life of the stack – a mechanism using active loading components (springs), is shown below

Challenges in Fuel Cell Technology – India’s perspective IIT Delhi, December 1-2, 2006 Thank You Thank You