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Coal-Based SECA Program - FuelCell Energy Inc.
11th Annual SECA WorkshopPittsburgh, PA
July 27-29, 2010
Hossein Ghezel-Ayagh, FuelCell Energy, Inc. y g , gy,Brian Borglum, Versa Power Systems
Presentation Outline
Introduction FCE SECA program team members
SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development
Metric Tests
Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses
Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate
Conclusions
FuelCell Energy (FCE)
• Premier developer of fuel cell technology for stationary power applications• Headquarters in Danbury, CT (USA), with 65,000 ft2 manufacturing facility in
Torrington, CT (USA) • Delivering Direct FuelCell power plants to commercial, industrial and utility g p p , y
customers• Developing large-scale coal-based power plants as well as natural gas
distributed generation (DG) systems utilizing planar SOFC • Established commercial relationships with major distributors in the p j
Americas, Europe, and Asia
MW Cl F l C ll P d tTorrington, CT - Manufacturing Facility MW-Class Fuel Cell Products
SECA Coal-Based Systems Program
Program ObjectivesDevelopment of large scale (>100 MWe) coal-based SOFC systems with:systems with:
At least 50% electrical efficiency from coal (higher heating value) Performance to meet DOE specified metrics for power output, degradation availability and reliabilitydegradation, availability, and reliability Fuel cell power island factory cost <$400/kW (2002 USD) More than 90% of carbon capture from coal syngas as CO2, for sequestration
Program Status FCE team successfully completed Phase I of the Coal Based SECA
Reduced water consumption as compared to the existing coal power plant technologies
FCE team successfully completed Phase I of the Coal Based SECA Program in December 2008. Phase II work is focused on further development of cost-effective, multi-MW size SOFC power plant system to operate on coal syngas fuel, with y y gnear zero emissions.
Phase II SECA Coal-Based Program Team
The FCE team is comprised of diverse organizations with expertise in key functional areas:
FuelCell Energy Inc. (FCE), Danbury, CT Manufacturing and commercialization of fuel cell power plant systems in sizes ranging from 300kW to Multi-MWto Multi MW.
Versa Power Systems Inc. (VPS), Littleton, CO Solid Oxide Fuel Cell (SOFC) development and manufacturing technologies.
Pacific Northwest National Laboratory (PNNL), Richland, WA SOFC cell and stack computational modeling.
WorleyParsons Inc. (WP), Reading, PA Design of the power plant, including: integration with gasifier and syngas clean-up technologies, system levelgasifier and syngas clean up technologies, system level costing, and system performance analysis.
VPS Planar SOFC Cell and Stack Technology
• Anode supported cells (up to 33 x 33 cm2)• Capable of operating from 650°C to 800°C
F iti t i l t l h t t l i t t• Ferritic stainless steel sheet metal interconnect • Cross-flow gas delivery with manifolds integrated into
the interconnect but not through the cell• Compressible ceramic gasket sealsCompressible ceramic gasket seals • Standardized stack blocks configurable into stack
towers for various power applications
CathodeCathode
Anode
Electrolyte
Anode
Electrolyte
Presentation Outline
Introduction FCE SECA program team members
SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development
Metric Tests
Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses
Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate
Conclusions
SECA Coal Based Program Plan for IGFC Development
• FCE is currently engaged in development of stack tower and SOFC power module configurations suitable for large scale coal based power plants.
5 MW Proof of Concept
≥ 250 kWModule Demonstration Unit
>25 kW Stack Tower
10 kW Stack
Unit
2008 2010 2012 2015
Ph IIIPhase IIPhase I Phase IIIPhase IIPhase I
SECA SOFC Development Path
Develop SOFC stack technology that meets the performance & cost objectives, is scalable, and is used as the building block for assembling
t k t d l l d l
Endurance
Performance
Stack
stack towers and large-scale power modules.
MW-scale Proof-of-Concept Plant
2010
Stack Tower
Scal
able
of-Concept Plant
10-20 kW Stack SOFC Stack
Module2006
2008
1 kWStack
Module2006
Modular
Presentation Outline
Introduction FCE SECA program team members
SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development
Metric Tests
Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses
Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate
Conclusions
Cell Development Objectives
• Performance:> High performance over a wide operating
window> Capability for in-stack reforming (DIR)> Accommodation of load following
• Durability: > Degradation rate of less than 0.2% per
1000 hours over a wide operating window (temperature, fuel utilization and current density)
Cost
Durabilit
Performany)
> Robustness for thermal cycles and rapid load transients
• Cost:
ty nce
> Scalability to facilitate large stack and power module
> Reduction of materials usage> Improvements in cell fabrication process> Improvements in cell fabrication process
technology
Recent Achievements in Cell Fabrication Process
• Established fabrication process capabilities for large area cells
C ll t 1000 2 (33 33 2) i i
Tape Casting
> Cells up to 1000 cm2 (33 x 33 cm2) in size were produced using TSC cell manufacturing process
• Developed and implemented the nextDeveloped and implemented the next generation of cell fabrication processes
> Cell thickness was reduced by more than 40%
Screen Printing• Fabricated > 4000 cells (25 x 25 cm2)
> Production volume of 500 kW (annual) was established
USLLSL
Process Capability Analysis for Y-ave
StDev (Overall)StDev (Within)Sample NMeanLSLTargetUSL
0.8756790.749099
750253.243250.000
*258.000
Process Data
Within
Overa
Co-sintering258256254252250
PPM TotalPPM > USLPPM < LSL
PPM TotalPPM > USLPPM < LSL
PPM TotalPPM > USLPPM < LSL
PpkPPLPPUPp
Cpm
CpkCPLCPUCp
( )
106.1 0.0
106.1
7.46 0.00 7.46
1333.33 0.00
1333.33
1.231.231.811.52
*
1.441.442.121.78
Exp. "Overall" PerformanceExp. "Within" PerformanceObserved PerformanceOverall Capability
Potential (Within) Capability
Third Generation of Cell Technology (TSC-3)
0.7
0.8 Cell Performance at 740 mA/cm2: TSC2 vs. TSC3
850
900
950
16%
18%
20%
Cell Performance at 740 mA/cm2: TSC2 vs. TSC3
850
900
950
16%
18%
20%
0 5
0.6
650
700
750
800
Volta
ge (m
V)
8%
10%
12%
14%
Impr
ovem
ent
650
700
750
800
Volta
ge (m
V)
8%
10%
12%
14%
Impr
ovem
ent
T
0.4
0.5
ASR
(ohm
.cm
2) TSC 2
500
550
600
650
650°C 700°C 750°C 800°C0%
2%
4%
6%
500
550
600
650
650°C 700°C 750°C 800°C0%
2%
4%
6%
TSC 3
TSC 2
0.2
0.3
A
TSC 3
TemperaturesTemperatures
0.1 Significant ASR reduction below 700°C
0650 670 690 710 730 750 770 790
Temperature (°C)
Single Cell Performance Enhancement
Performance Curves
1.100.70
10 X 10 cm2 Cell. Stainless Steel Current Collectors. Cross-Flow Gas Delivery.Fuel: H2 + 3%H2O; Oxidant: Air, 650 – 800°C
0 90
1.00
0.50
0.60
cm2
0.80
0.90
olta
ge, V 0.40
Den
sity
, W/c
0.60
0.70Vo
0.20
0.30
Pow
er D
0.40
0.50
0.00
0.10800 - V 750 - V 700 - V 650 - V800 - P 750 - P 700 - P 650 - P
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80
Current Density, A/cm2
Single Cell Stability Achievements
1.200
OVERALL:21 V 7392 h
0.800
1.00021 mV over 7392 hrs2.84 mV or 0.28% / 1000 hrs
0.600
Volta
ge, V
0.400
1 Cell Stack - 81 cm2 Active AreaFurnace Temperature: 750°C
0.000
0.200Furnace Temperature: 750 CFuel: 55 H2:45 N2 + 3% H2O, Uf = 50%Oxidant: Air, Ua = 25%Current: 40.5 A (0.5 A/cm2)
0 1000 2000 3000 4000 5000 6000 7000 8000
Elapsed Time, hrs
Progress in Cell Scale-Up
33 x 33 cm2
550 cm2
25 x 25 cm2
350 cm2
10 x 10 cm212.5 x 12.5 cm2
20 x 20 cm2
81 cm2 121 cm210 x 10 cm2
Presentation Outline
Introduction FCE SECA program team members
SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development
Metric Tests
Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses
Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate
Conclusions
Stack Design Approach
• Utilized a model-driven design approach using both CFD and FEA to resolve thermo-mechanical challenges
• Followed a progressive modeling path from single cell, short stack, full size stack block, and finally to stack towerValidated the models using component and stack test results• Validated the models using component and stack test results
• Provided valuable information for engineering team to accomplish component development
°C
Fi
Ai
SOFC Stack Evolution
10 kW64-CellPhase 1(2008)
18 kW92-CellPhase 2
25 kW120 C ll
16 inches(41 cm)
24 inches(61 cm)(2008) Phase 2
(2010)120-CellPhase 2(2010)
(61 cm)
Stack Scale-up and Maufacturing Progression
Phase 1StackSize
Power (kW/stack) Quantity Total Power
(kW)
6 cells 1 21 21
16 cells 2.5 18 45
64 cells 10 6 60
Total 45 126
Stack Power Total PowerStackSize
Power (kW/stack) Quantity Total Power
(kW)
16 cells 2.5 42 105
32 cells 5 1 5
Phase 2
92 cells 18 7 126
120 cells 25 1 25
Total 51 261
Stack Performance Enhancement16-Cell Stack
1.1 100%Uf (%) Phase 1 Phase 2 Gain
50 0.823 0.886 7.7%
60 0 817 0 879 7 6%
1
80%
90%60 0.817 0.879 7.6%
70 0.804 0.866 7.7%
80 0.785 0.847 7.9%
0.9
tage
(V)
70%
80%
lizat
ion
(%)
Volt
60%
Fuel
Uti
0.8
50%Cell 01 Cell 02 Cell 03Cell 04 Cell 05 Cell 06Cell 07 Cell 08 Cell 09Cell 10 Cell 11 Cell 12
Test Stand Temperature: 700°C Cell Active Area: 550 cm2
25% In-stack reforming
0.723.50 24.50 25.50 26.50 27.50 28.50 29.50
Elapsed Time (hours)
40%
Cell 13 Cell 14 Cell 15Cell 16 uf
25% In stack reformingCurrent Density: 0.388 A/cm2
Stack Peak Power AchievementGT057235-0057 TC1
16-cell StackCell Active Area: 550 cm2
500 6
400
450
4.5
5
5.5
300
350
rent
(A)
3
3.5
4
wer
(kW
)
200
250Cur
r
1.5
2
2.5 Pow
Peak Power Testing – Coal Syn GasFurnace Temperature: 700°C
Peak Power Testing – NG-basedFurnace Temperature: 685°CFuel: 33.6% H2, 21.5% N2, 12.5% NG, 32.4% H2OIn-stack reforming = 60%, Uf = 70%Oxidant: Air, Ua = 15%C t 320 A (0 582 A/ 2 0 467 W/ 2)
100
150
0
0.5
1Furnace Temperature: 700 CFuel: 29.5% H2, 1.6% N2, 38.2%CO2, 6.7% NG, 24.1% H2O, In-stack reforming = 48%, Uf = 54%Oxidant: Air, Ua = 15%Current: 250 A (0.455 A/cm2, 0.365 W/cm2)
Current: 320 A (0.582 A/cm2, 0.467 W/cm2)
2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00
Elapsed Time (hours)
1 200
Stack Endurance Achievement
1.000
1.200
All Cells TC0 +TC15.6mV (0.64%) / 1000hrs @4206 hrs
0.800
tage
(V)
( %) @
0 400
0.600
Ave
rage
Cel
l Vol
0.200
0.400A
Thermal CycleCell Count: 32Cell Active Area: 550 cm2
Furnace Temperature: 700°CFuel: In-stack reforming = 25% Uf = 61 5%
0.000
0
500
1000
1500
2000
2500
3000
3500
4000
4500
Fuel: In-stack reforming = 25%, Uf = 61.5%Oxidant: Air, Ua = 13.5%Current: 213 A (0.390 A/cm2)
2 2 3 3 4 4
Elapsed Time (hours)
Stack Scale-Up Status (Phase II)92-Cell Stack (GT058011-1)
1
1.2
Thermal Cycle1.2
Thermal Cycle
0.8
1
olta
ge (V
)
80% Fuel Utilization
0.8
1
tage
(V)
C ll Si 25 25 2
0.4
0.6
Ave
rage
Cel
l Vo
Cell Count: 92
80% Fuel Utilization
0.4
0.6
vera
ge C
ell V
ol 80% Fuel Utilization
Cell Size 25 x 25 cm2
Active Area 550 cm2
Number of Cells 92
0
0.2
A Cell Count: 92Cell Active Area: 550 cm2
Furnace Temperature: 710°CFuel: In-stack reforming = 25%, Uf = 61.5%Oxidant: Air, Ua = 13%Current: 200 A (0.364 A/cm2)
(June 2010)
92-Cell Stack (GT058011-1)0.2
Av
Cell Count: 92Cell Active Area: 550 cm2
Furnace Temperature: 710°CFuel: In-stack reforming = 25%, Uf = 61.5%Oxidant: Air, Ua = 13%Current: 200 A (0.364 A/cm2)
(June 2010)
92-Cell Stack (GT058011-2)
35.00 40.00 45.00 50.00 55.00 60.00 65.00 70.0000.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00
Elapsed Time (hours)
00.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00 55.00 60.00 65.00 70.00
Elapsed Time (hours)
Stack Development Status
80
Fuel Utilization100%
40
60 In-Stack Reforming100%
Cost @ SECA Volume100$/kW
20060
80150
20
200
20
10
40
15
5
250
300
Stack Block Power25 kW
Current Density
2
1000 mA/cm2
600
0 8
420
0.7
15
30.75
400
800
Phase 2 TargetPhase 2 Status
Phase 1 Level
Degradation0%/1000 h
Operating Cell Voltage – BOL0.9 V
0.8
10.85
Stack Tower Testing
2009 2010
3 x 64-cell stacks 2 x 92-cell stacks
• Thermally self-sustaining test environment (gas preheated only)
SO-30-1 Tower Assembly SO-30-3 Tower Assembly
• Thermally self-sustaining test environment (gas preheated only)• Provisions for simulated anode gas representative of both syngas and
natural gas fueled systems• Providing valuable lessons for future larger stack module designsg g g
Stack Tower (SO-30-3) Test
35000
40000
45000
50000
200
250PowerTotal Voltage
20000
25000
30000
35000
Pow
er/ W
100
150
Stac
k Vo
ltage
/ V
0
5000
10000
15000
0
50
• Demonstration of stack tower operation in a simulated power plant environment,
0 200 400 600 800 1000 1200Runtime/ Hr
using 2x92-cell stack blocks.• A Power Rating of 30 kW was established
during the operation.
Next Steps – Metric Tests
SECA Phase II Metric Test Minimum Requirements:• Stack power rating 25 kW• Degradation rate < 2%/1000 hrs• Endurance tests: 1,500h in Phase II plus 3,500h in Phase III (5000h total)
2x92-Cell Stack Tower
120-Cell Stack
20 inches(51 cm)
120-Cell Stack
24 inches(61 cm)
Two pronged approach:Two pronged approach: A 120-cell stack block at VPS and a 2x92-cell stack tower at FCE
Initial Performance (June 2010) 120-Cell Stack (GT058027-1)
GT058027-0001120-cell Stack
Cell Active Area: 550 cm2
300 30
250 27.5
150
200
Cur
rent
(A)
22.5
25
wer
(kW
)
0.455 A/cm2
Furnace T: 700°CPeak Power Testing
Furnace Temperature: 700°CFuel: 33.6% H2, 21.5% N2, 12.5% NG, 32.4% H2O
100Stac
k C
20
Pow
0.364 A/cm2Normal Operating Conditions (NOC)
Furnace Temperature: 715°C
In-stack reforming = 60%, Uf = 65%Oxidant: Air, Ua = 15%Current: 250 A (0.455 A/cm2)
0
50
15
17.5Furnace T: 715°Cp
Fuel: 25.2% H2, 22.4% N2, 14.5% NG, 37.8% H2OIn-stack reforming = 70%, Uf = 68%Oxidant: Air, Ua = 15%Current: 200 A (0.364 A/cm2)
Future5000 hr Tests
130 132 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 164
Elapsed Time (hours)
Phase II Stack Tower Metric Test at FCE
250
32.5
35CurrentPower
Peak Power200
A 27 5
30
ea o e
Start of long term hold @ NOC
100
150
ack
Cur
rent
/ A
25
27.5
Pow
er/ k
W
g @
Future5000 hr Tests
50
100Sta
20
22.5
0
50
15
17.5Fuel: Simulated Syngas System Fuel, 6.5% CH4, 24.0% H2, 45.3% CO2, 22.4% H2O, 1.8% N2
150 160 170 180 190 200 210 220 230 240 250Runtime/ hr
Presentation Outline
Introduction FCE SECA program team members
SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development
Metric Tests
Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses
Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate
Conclusions
SOFC Module Evolution
30 kW2-Stack Tower
30-kW Tower Assembly (Phase II)
Stack Block
SOFC Stack Modules Assembly (Phase III)
250 kW2 Q d
125 kW4 Stack Tower
60 kW4 Stack 2-Quad
Module4-Stack Tower Quad
4-Stack Quad
Presentation Outline
Introduction FCE SECA program team members
SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development
Metric Tests
Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses
Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate
Conclusions
Improved Coal-Based SOFC System with Catalytic Gasification
POWER GENERATION SUMMARY kW % Q input % MW grossFuel Gas Expandors Gross Power @ 20 kV 49 750 7 04% 10 96%Fuel Gas Expandors Gross Power @ 20 kV 49,750 7.04% 10.96%Fuel Cell Inverter AC Gross Power @ 20 kV 362,134 51.28% 79.78%WGCU Off Gas Expander Gross Power @ 20 kV 7,024 0.99% 1.55%Steam Turbine Gross Power at Generator Terminals @ 20 kV, 35,019 4.96% 7.71%
Total Gross Power Generation @ 20 kV 453,927 64.27% 100.00%
Total Auxiliary Load 39,342 5.57% 8.67%
Net Power Output at 345 kV 414,585 58.70% 91.33%Net Efficiency Excluding CO2 Compression & Thermal InputCoal feed lb/h 202 980Coal feed, lb/h 202,980Coal HHV (AF), Btu/lb 11,872Coal Thermal Input, kWth 706,255 100.00% 155.59%Net Plant Efficiency (HHV) 58.70%
Combined with high methane producing gasification, coal based atmospheric-pressure SOFC systems are capable of achieving ~ 59% efficiency and 99+% carbon captureefficiency and 99+% carbon capture.
Baseline SOFC Power Plant Electrical Efficiency vs. Competing Technologies
60%
70%
al)
58.70%Value of CO2 Compression
30%
40%
50%
ncy
(% H
HV c
oa
32.50% 31.70% 32.00% 28.20%
54.79%
27.20%10%
20%
30%
Net E
ffici
en
0%IGCC
GE-E w/SelexolCO2 cap.
IGCCCoP w/Selexol
CO2 cap.
IGCCShell w/Selexol
CO2 cap.
PCSupercritical
w/Amine
PCSupercriticalw/Oxy-comb.
AdvancedIGFC
Cat. Gasifier
Baseline coal based SOFC system is >22 percentage points more efficient than IGCCs and Pulverized Coal (PC) Steam plants.
References for Competing Technologies:
CO2 cap. CO2 cap. CO2 cap. w/AmineCO2 cap.
w/Oxy comb.CO2 cap.
Cat. GasifierZnO
* Cost and Performance Baseline for Fossil Energy Plants, Volume 1 - Bituminous Coal and Natural Gas to Electricity, DOE/NETL-2007/1281, Revision 1, August 2007** Pulverized Coal Oxycombustion Power Plants, Volume 1 - Bituminous Coal to Electricity, DOE/NETL-2007/1291, Final Report, August 2007
Baseline SOFC Power Plant Water Consumption vs. Competing Technologies
1,139
1000
1200
h ne
t
683 672721
792
600
800
mpt
ion
Gal
/MW
h
260
200
400
Wat
er C
onsu
m
0IGCC
GE-E w/SelexolCO2 cap
IGCCCoP w/Selexol
CO2 cap
IGCCShell w/Selexol
CO2 cap
PCSupercritical
w/Amine
PCSupercriticalw/Oxy-comb
AdvancedIGFC
Cat Gasifier
Baseline coal based SOFC system requires significantly less water than IGCCs and Pulverized Coal (PC) Steam Turbine Power Plants.
References for Competing Technologies:
CO2 cap. CO2 cap. CO2 cap. w/AmineCO2 cap.
w/Oxy comb.CO2 cap.
Cat. GasifierZnO
* Cost and Performance Baseline for Fossil Energy Plants, Volume 1 - Bituminous Coal and Natural Gas to Electricity, DOE/NETL-2007/1281, Revision 1, August 2007** Pulverized Coal Oxycombustion Power Plants, Volume 1 - Bituminous Coal to Electricity, DOE/NETL-2007/1291, Final Report, August 2007
H2 Co-Generation System Concept
• 138 ton/day H2 Produced• 48.2% Net Electrical Efficiency• 67.4% Total Efficiency (Electrical + H2)y ( 2)
Stack Cost Reduction
SOFC Stack Block Cost Reduction (2002 USD)
$197$210
$250
$/kW t AC
96-cell Stack:
$2,857 (2002 USD)
$197
$119
$153
$116$150
$200$/kW net AC$/kW gross DC
$93
$116
$50
$100
Labor $148
Other, $52018%
$0Phase I 2009 Interim 2010
Thi C ll D l tLabor, $1485%
Stack Block Scale Up
Stack Materials Reduction
Thin Cell Development
Materials, $2,18977%
Stack Block Scale Up
Power Density Improvements
Factory Equipment Cost Estimate
Steam Turbine18 $/kWFuel Cell Piping
Fuel Cell Enclosure 17 $/kW
6%
HRSG63 $/kW
22%
Phase I Cost Estimate: 597 $/kW (2002 USD)
Fuel Cell
BOP Water Systems7 $/kW
2%
$6%
Fuel Cell Piping36 $/kW
9%
Blowers
Fuel Cell Stacks
$197/kW,33%
Balance-of-Plant (BOP)
$400/kW, 67%
Electric Accessories10 $/kW
3%
2%o e s6 $/kW
2%
Expanders40 $/kW
67%
Heaters & Coolers44 $/kW
15%Inverter48 $/kW
16%
Instrumentation & Control8 $/kW
3%
40 $/kW13%
Phase II Interim Cost Estimate: 390 $/kW (2002 USD)
Balance-of-
Fuel Cell Stacks$93/kW,
29%
Cost estimation is based on two 570 MW nominal power plants manufactured per year (2002 USD).
Estimate includes Factory Equipment costs for the Power Island, exclusive of gasification, syngas l d CO ti / i tBalance of
Plant (BOP) $297/kW,
71%
cleanup, and CO2 separation/compression systems.
Baseline SOFC Power Island
SOFC power island includes:> 8 Sections of 42 fuel cell stack modules > Steam turbine> Two syngas expanders
Layout of 42-Module SOFC Cluster
SOFC Stack Module
Air Heater
Anode Recycle Blowers
& ExhaustBlowers
Air
DC-AC Inverters
Air Blower
SOFC cluster design takes advantage of modularity of fuel cells.
Representative Foot Print Comparison: IGFC & IGCC
IGFC IGCC
• A similarly sized (MW) IGCC and IGFC will be comparable in real estate requirement.real estate requirement.
Presentation Outline
Introduction FCE SECA program team members
SECA Coal-Based SOFC Program OutlineProgress in SOFC TechnologyStack Development
Metric Tests
Module Demonstration Unit DevelopmentModule Demonstration Unit DevelopmentBaseline System Design and Cost Analyses
Integrated Gasification Fuel Cell (IGFC) System Configurationg ( ) y gBaseline Power Plant Cost Estimate
Conclusions
Summary of Recent Achievements
• Demonstrated new TSC3 cell with ASR less than 0.35 ohm·cm2 at 650°C and a degradation rate of less than 0.3% per 1000 h at 750°C (on-going test of over 7,000 h)
• Established cell manufacturing processes for the new baseline TSC3 cell with an active
f 550 2 (25 25 2)area of 550 cm2 (25 x 25 cm2)
• Demonstrated performance and pendurance improvements in scaled up stacks with TSC3 cells
• Developed a 92-cell stack block that produces 18 kW and has beenproduces 18 kW and has been successfully tested in a 2 x 92-cell stack tower
• Demonstrated 25 kW from a 120-cell stack
Summary of Recent Achievements
• Baseline Systems with Catalytic Gasifier were developed which could achieve electrical efficiency (HHV) of 59% and remove more than 99% carbon from syngas.B li 400 600MW l t l t d F t C t E ti t• Baseline 400-600MW power plant layout and Factory Cost Estimates were developed resulting in an interim cost estimate of $390/kW (in 2002 dollars) for the SOFC power island.
• The developed IGFC system showed significantly lower water consumption p y g y pas compared to IGCC and other coal fueled power plants.
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