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Fuel Cells for Stationary Power Fuel Cells for Stationary Power Generation Generation A Comprehensive Analysis of Technology, Plant Construction, and A Comprehensive Analysis of Technology, Plant Construction, and Marketing Strategy for Small
The University of Oklahoma Fuel Cell Corporation Fuel Cell Corporation
April 29, 2004
A Comprehensive Analysis of Technology, Plant Construction, and A Comprehensive Analysis of Technology, Plant Construction, and Marketing Strategy for Small Buildings Marketing Strategy for Small Buildings
Business Overview and Market Analysis Kristen Martinez Technology Overview Thu Nguyen Fuel Cell Analysis Caroline Ihejiawu Fuels and Gas Reforming Justice Diven Process Flowsheet and Equipment Costs Eric Daugherty Tax, Labor, and Transportation Analysis Jennifer Treece Mathematical Model and Economic Analysis Lola Soyebo Uncertainty and Risk Analysis Caroline Ihejiawu
Business Overview and Market Analysis Kristen Martinez Technology Overview Thu Nguyen Fuel Cell Analysis Caroline Ihejiawu Fuels and Gas Reforming Justice Diven Process Flowsheet and Equipment Costs Eric Daugherty Tax, Labor, and Transportation Analysis Jennifer Treece Mathematical Model and Economic Analysis Lola Soyebo Uncertainty and Risk Analysis Caroline Ihejiawu
– All fuel cell “plant” parts (reformer, power conditioner, etc.) – On-site consultation to suggest infrastructure changes, determine the best source of fuel, and help customer choose fuel cell type.
Phosphoric Acid Fuel Cell (PAFC) Solid Oxide Fuel Cell (SOFC) Proton Exchange Membrane Fuel Cell (PEMFC)
– Delivery – Trial-period of one year – Warranty period of two years The OUFCC offers the following services with the purchase
The OUFCC will fill the need of supplying a source
– High efficiency and cogeneration applications – Reliable – Independent of a power grid – Optionally dependent on fossil fuel – Few maintenance costs – Clean
– Hospitals – Banks – Post Offices – Police Stations Main customers: Most Probable Location: – High No. of Businesses – High Air Pollution Levels – High Electricity Price – Away from markets already targeted Our largest market is in the Southwest (AZ, NM, OK, TX)
No Yes Yes Yes Yes Yes Cogen Available? Low 45-200 150-300 50 NOx Emissions (ppm) 20-40% 1000 Yes Wind Systems 5-15% 6000-10,000 Yes Photovoltaic Systems 12-20% 2000-50,000 No Stirling Engines 25-45% 300-900 Yes Reciprocating Engines (Generators) 20-45% 300-1000 Yes Combustion Turbines 20-30% 700-1100 Yes Microturbines 60-85% 4000-4800 Yes Fuel Cells Efficiency (%) Cost ($/kW) Commercially Available? Technology
Current Goals: Enter the stationary fuel cell market, make a profit, and establish a name and reputation. Future Goals: Develop a niche market. Eventually, as fuel cell technology becomes more widely accepted, compete as a leading provider of stationary fuel cells.
Business Overview and Market Analysis Kristen Martinez Technology Overview Thu Nguyen Fuel Cell Analysis Caroline Ihejiawu Fuels and Gas Reforming Justice Diven Process Flowsheet and Equipment Costs Eric Daugherty Tax, Labor, and Transportation Analysis Jennifer Treece Mathematical Model and Economic Analysis Lola Soyebo Uncertainty and Risk Analysis Caroline Ihejiawu
electricity and produce heat, with the help of catalyst
fuel cells produce electricity
device was developed.
system was demonstrated.
energy has been expected to replace traditional power sources.
Catalyst
2H2 4H+ + 4e- O2 + 4H+ +4e- 2H2O 2H2 + O2 2H2O
→ Catalyst → Catalyst
Heat Hydrogen Oxygen Proton Electron
Courtesy of National Fuel Cell Research Center Solid Oxide Fuel Cell Phosphoric Acid and Proton Exchange Membrane Fuel Cells Molten Carbonate Fuel Cell
Block Diagram of Fuel Cell System
Courtesy of DoDFuelCell-Library Resources
Produces H2-rich gas Produces DC electricity Converts DC to AC electricity
Business Overview and Market Analysis Kristen Martinez Technology Overview Thu Nguyen Fuel Cell Analysis Caroline Ihejiawu Fuels and Gas Reforming Justice Diven Process Flowsheet and Equipment Costs Eric Daugherty Tax, Labor, and Transportation Analysis Jennifer Treece Mathematical Model and Economic Analysis Lola Soyebo Uncertainty and Risk Analysis Caroline Ihejiawu
PHOSPHORIC ACID FUEL CELL (PAFC)
for 10 yrs
SOLID OXIDE FUEL CELL (SOFC)
Courtesy of Global Thermoelectric Inc.
PROTON EXCHANGE MEMBRANE FUEL CELL (PEMFC)
MOLTEN CARBONATE FUEL CELL (MCFC)
carbonate salt
Catalyst poisoned @ low temp. No poison
Electrode corrodes @ high temp. Catalyst poisoned @ low temp.
Durability/Corrosion Issues
6 min 5 – 10 hr 8 – 10 hr 1 – 4 hr
Start-Up Time
~ 700 mW/cm2 ~ 200 mW/cm2 ~ 160 mW/cm2 ~ 200 mW/cm2
Peak Power Density
pure H2 flexible flexible pure H2
Fuel
$750/kW $377/kW $780/kW $560/kW
Cost of Raw Materials
Massachusetts Ohio limited Massachusetts
Availability of Raw Materials
175°F 1800°F 1200°F 370 - 410°F
Operating Temp.
50% 50% - 60% 50% - 55% 37% - 42%
Efficiency
Proton Exchange Solid Oxide Molten Carbonate Phosphoric Acid Criteria
Business Overview and Market Analysis Kristen Martinez Technology Overview Thu Nguyen Types of Products Manufactured Caroline Ihejiawu Fuels and Gas Reforming Justice Diven Process Flowsheet and Equipment Costs Eric Daugherty Tax, Labor, and Transportation Analysis Jennifer Treece Mathematical Model Lola Soyebo Uncertainty and Risk Analysis Caroline Ihejiawu
Halias Natural Gas Reformer for 7.5 kW PEMFC, ChevronTexaco
– Center of reforming process convert CH4 to H2 using steam.
– High Temperature ~ 800 ºC – Use H2O to push equilibrium towards products – Nickel Oxide 4 hole cylinders
2 2 2 2 2 4
3 H CO O H CO H CO O H CH + → + + → +
– Convert Carbon Monoxide Byproduct of Steam Reforming
– Two reactors with different…
pellets, copper-zinc oxide pellets)
2 2 2
H CO O H CO + ↔ +
– Reduce Sulfur content of gas
– Cobalt-Molybdenum extrudes – ZnO spheres to remove H2S – 300-400 °C
( )
O H ZnS ZnO S H S H H C H S H C
2 2 2 6 2 2 2 5 2
2 2 + → + + → +
– Sulfur reduction to less than 1 ppm
– Sulfur to less than 50 ppm – CO to less than 0.5 mole %
– Sulfur to less than 1 ppb – CO to less than 10 ppm
Benefits
Lower Per Unit Cost Opportunities for Process Integration Increased Design Flexibility
Disadvantages
Increased Capital Investment Catalyst Regeneration and Handling Diffuse Market Focus
– East Coast – Flexible Fuel Stocks
– 4000 SCF H2 produced per hour. – 2 m by 4 m by 2 m – Estimated cost of $125,000 based upon Department of Energy study.
– West Coast – Fuel Stocks
– Currently under scaled
per hour
Business Overview and Market Analysis Kristen Martinez Technology Overview Thu Nguyen Fuel Cell Analysis Caroline Ihejiawu Fuels and Gas Reforming Justice Diven Process Flowsheet and Equipment Costs Eric Daugherty Tax, Labor, and Transportation Analysis Jennifer Treece Mathematical Model and Economic Analysis Lola Soyebo Uncertainty and Risk Analysis Caroline Ihejiawu
Fuel Cell Manufacturing Processes Processes
– Teflon bonded silicon carbide matrix suspends the phosphoric acid
– MEA is created through polymer processes
– Cathode, anode, and electrolyte are all produced from powder solutions
– Solvents – Binders – Plastisisers – Cr Alloy
Process Flowchart for SOFC
Binder Solvent ZrO2(Y2O3) Ball Milling Tape Casting Drying Sintering Solvent Binder ELECTROLYTE Triple Roll Milling Screen Printing Drying Sintering Solvent Solvent Binder Binder ELECTROLYTE AND CATHODE Doped LaMnO3 Triple Roll Milling Screen Printing Drying Sintering Solvent Binder Ni-ZrO2(Y2O3) Solvent Binder ELECTROLYTE, CATHODE, AND ANODE PEN AND INTERCONNECT Cr Alloy Metal Forming INTERCONNECT Brazing
BALL MILLING TAPE CASTING SCREEN PRINTING
Factors: Labor, Power, Raw Materials
Layer Assembly 52% Anode, Cathode, Electrolyte 33% Interconnect 15%
$300,000 Tape Caster Electrolyte Automated Tape Casting $20,000 Manual Station Anode, Cathode Screen Printing $22,000 Ball Mill, Roll Mills Anode, Cathode, Electrolyte Milling $400,000 Brazing Furnace Interconnect IC joining -Heat Treatment $500,000 Sintering Furnace Fabrication Continuous Sinter $300,000 Inspection Machine Fabrication Vacuum Leak Test
Equipment Cost Equipment Description Component Process Description
Total SOFC Equipment Cost = $2.4 million
Courtesy of Department of Energy-Federal Energy Technology Center
Business Overview and Market Analysis Kristen Martinez Technology Overview Thu Nguyen Fuel Cell Analysis Caroline Ihejiawu Fuels and Gas Reforming Justice Diven Process Flowsheet and Equipment Costs Eric Daugherty Tax, Labor, and Transportation Analysis Jennifer Treece Mathematical Model with Economic Analysis Lola Soyebo Uncertainty and Risk Analysis Caroline Ihejiawu
MA and OH
Amount of Pollution Electricity Prices
Property, Sales, Federal, and State Taxes
Median Hourly Wage
Labor
Taxes
Two options – American Freight Company or The OUFCC fleet If AFC is contracted:
the Shipments
If The OUFCC purchases own fleet:
Maintenance
Business Overview and Market Analysis Kristen Martinez Technology Overview Thu Nguyen Fuel Cell Analysis Caroline Ihejiawu Fuels and Gas Reforming Justice Diven Process Flowsheet and Equipment Costs Eric Daugherty Tax, Labor, and Transportation Analysis Jennifer Treece Mathematical Model and Economic Analysis Lola Soyebo Uncertainty and Risk Analysis Caroline Ihejiawu
– Consider multiple design options simultaneously. – Prediction of sales and added production
(GAMS)
– Determine plant and market locations – Determine annual production rate of each type – Maximize our objective function: NPW
Deterministic Model
– Raw Materials – Utilities costs – Transportation – Taxes – Market demands – Maximum capacity – Selling price of fuel cells
– Production rate – Increase production – Revenue – Cash Flow – FCI,TCI – Objective Function: NPW
Deterministic Model
–Decision variable for plant location –Maximum Capacity –Market demand
Parameters
– AZ, CA,FL,MA,MO,NE,NV,NY,OH,OK,TX,WA, WY
– $1.0 million for PAFC – $1.1 million for SOFC – $1.2 million for PEMFC
200,000 400,000 600,000 800,000 1,000,000 1,200,000 1,400,000
2 6 2 7 2 8 2 9 2 1 2 1 1 2 1 2 2 1 3 2 1 4 2 1 5
P AFC SOFC P E M FC
Project Lifetime Selling Price ($)
Mathematical Equations
) int 1 /( ) (
,
t
Time i i t t i
TCI CF NPW + − = ∑ ∑
t i i i t i t i t i
TOC Tax FCI Dep v v CF
, , , ,
] * ) * (Re [Re − − − =
) ) , , , ( * ) ( ( Re
, , t i j t i
TOC t k j i x k Sell v − = ∑
t k i k t i i
FxCost FCI
, , ,
AddProd *
+ = α
50 100 150 200 250 300 350 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
PEMFC SOFC PAFC
Project Lifetime Number of Fuel Cells
Project Lifetime Number of Fuel Cells
20 40 60 80 100 120 140 160 180 200 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
PEMFC SOFC PAFC
Cash Flow Predictions
0.00 10.00 20.00 30.00 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
TCI
Project Lifetime
Cashflow (million $)
20 40 60 80 100 120 140 160
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Time Cumulative Cashflow (million $)
Breakeven Point TCI
Deterministic Model Results
Business Overview and Market Analysis Kristen Martinez Technology Overview Thu Nguyen Fuel Cell Analysis Caroline Ihejiawu Fuels and Gas Reforming Justice Diven Process Flowsheet and Equipment Costs Eric Daugherty Tax, Labor, and Transportation Analysis Jennifer Treece Mathematical Model and Economic Analysis Lola Soyebo Uncertainty and Risk Analysis Caroline Ihejiawu
Uncertain Parameters
Examined 3 Scenarios Deviated 20% around the mean values
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
0.E+00 1.E+08 2.E+08 3.E+08 4.E+08 5.E+08 6.E+08 High Medium Low
NPW ($) Probability
MAXIMIZE Net Present Value considering all possible scenarios of the uncertain parameters
.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00% 100.00%
121063714 139592458 184526327 201564245 342581655 357054225 389039274 483837044
NPW ($) Probability
Courtesy of Global Thermoelectric Inc.
Process for PEMFC
2,700 Catalyst 17,400 Electrode 187,500 Hardware Cost ($) Component
Total manufacturing cost = $576,600
50 100 150 200 250
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Project Lifetime Revenue (million $)