joe heinzmann fuelcell energy, inc., danbury, ct efficient, ultra-clean stationary fuel cell status...
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reliable, efficient, ultra-clean
Stationary Fuel Cell StatusDirect FuelCell®
Power Systems
Joe HeinzmannFuelCell Energy, Inc., Danbury, CT
Chemical Management ServicesSan Francisco, CAOctober 2007
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
Overview
•• FuelCell Energy ProductsFuelCell Energy Products
• Product Cost Reduction
• Market Trends and Product Mix Direction
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
FuelCell Energy: Profile• Premier developer of stationary fuel cell
technology
• More than 30 years of fuel cell development and commercialization experience
• Delivering Ultra-Clean Direct FuelCell power plants to commercial and industrial customers
• Headquarters in Danbury, CT (USA), with 65,000 square foot manufacturing facility in Torrington, CT (USA)
• Established commercial relationships with major distributors in the Americas, Europe, and Asia
Danbury, CT – Headquarters, R&D, Stack Conditioning
Torrington, CT - Manufacturing Facility
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
Core Product: DFC Cells and Stack Modules• FCE Manufactures complete Direct FuelCell® cells and stack modules from raw
materials and purchased parts in our Torrington, CT manufacturing facility
Electrode, Matrix and Bipolar Plate Manufacturing Assembled Cell Package
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
Building Block Approach to Product Line
Cell Package and Stack
Single-Stack Module
Four-Stack Module
DFC300 Single Module Powerplant
DFC3000: Two 4- Stack Modules
DFC1500A Four Module Powerplant
DFC1500B One 4-Stack Module
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
Average U.S. Fossil Fuel Plant = 33%
0
10
20
30
40
50
60
70
0.1 1 10 100 1000System Size, MW
Effic
ienc
y, %
(LH
V) Direct FuelCell ® Combined Cycle
Gas TurbineLow Temp FC
Coal/Steam
Micro-
Turbine
Engines
DFC/T Hybrid
DFC Benefits: High Efficiency - Drives low CO2 emissions, low fuel costs
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
DFC Benefits: Environmental• Emits virtually zero pollutants (NOx, SOx)
• Significantly reduced CO2
• Quiet operation suitable for almost any location
0
500
1000
1500
2000
2500
Lbs/MWh
Centra
l Coal
Genera
tion
Averag
e US G
enera
tion
Small Tu
rbine
DFC
DFC w
ith C
HP
CO2 Greenhouse Gas Emissions
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
Lbs/MWh
NOx SOx PM10
Pollutant, Particulate, CO Emissions
Central Coal GenerationGas TurbineDFC
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
Direct FuelCell Certifications• Powerplants that are certified to or comply with commercial standards:
– CSA-FC1 Certified– UL 1741 Certified– CARB 2007 Certified– IEEE 1547 Compliant– (NEC) NFPA 70 Compliant– California Rule 21 Compliant– ASME Compliant– OSHA 29 CFR Part 1910 Compliant– New York City MEA Approved
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
Overview
• FuelCell Energy Products
•• Product Cost ReductionProduct Cost Reduction
• Market Trends and Product Mix Direction
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
20,0
00
9,77
2
8,25
9
6,25
4
4,80
04,
300
3,25
0
3,84
03,
440
$-
$4,000
$8,000
$12,000
$16,000
$20,000
$/kW
1996-97 2003 2004 2005 2006 2007 2008e
Sub-MW 1.2 MW 2.4 MW
Cost Reduction Progress
Increasing annual production volume to 50 MW/yr. can yield an additional cost reduction of 25-30 percent
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
Cost Reduction Example: Lower Cost Stack Module• Change from round to square
enclosure:– Lower cost enclosure – Use of lower cost standard
insulation– Simplified Module assembly
• Transitioned machined components to castings or simple welded components
• Reduced cost internal piping design and fabrication
• Instrumentation optimized• Design-for-manufacturability
improvements
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
Overview
• FuelCell Energy Products
• Product Cost Reduction
•• Market Trends and Product Mix DirectionMarket Trends and Product Mix Direction
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
On-Site Self Generation• Combined heat and power
• Hotels, Universities, Hospitals, Manufacturing
• Wastewater treatment facilities on biogas
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
FuelCell Energy Power Plant Locations
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
4 DFC300MA units at Cal State Univ., Northridge
1MW of DFC300MA units with condensing heat recovery for pool heating: >80% Total Efficiency
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
Biogas Applications• Food and beverage processing
• Municipal wastewater treatment
• Eliminate emissions from flaring
• Utilize a Renewable energy source
• Carbon Neutral fuel
• For DFC Operation vs. Engines:– Increased electrical efficiency– Lower emissions– Improved economics
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
DFC1500 Santa Rita Corrections Facility, California
Combining DFC 1500 with Solar PV to further reduce Carbon Footprint
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
Power Magazine Plants of the Year Award Sierra Nevada Brewery, Chico, California
Bio-solid waste to Power and Heat for Reduced Environmental Emissions
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
Ford Paint Shop Fumes for DFC® 300 Fuel• Unit to start up in early 2008 at the Ford; Oakville, Ontario (Canada) Auto Plant
• VOC’s from the basecoat and clear coat paint lines for the Ford Edge and Lincoln MKX to fuel DFC 300 fuel cell power plant
• System will turn 200 lb/hr VOC’s into the 300kW of Electricity
• Eliminates NOx, SOx, and greatly reduces CO2 Emissions
• At part VOC load the unit will blend Natural Gas to maintain full electrical output
• Ten year cost is estimated to be half the cost to incinerate traditionally
• Funded by Ontario Government, Ford, and FuelCell Energy
VOC Emissions into Power and Heat reducing CO2, NOx and SOx
FuelCell Energy, the FuelCell Energy logo, Direct FuelCell and “DFC” are all registered trademarks (®) of FuelCell Energy, Inc.
www.fuelcellenergy.com
Market Trends and Product Direction• On Site Self Generation
– Trend is for larger installations, multiple subMW or MW-scale
– Natural gas, ADG and Opportunity Fuels– Combined heat and power
• Grid Support– Expanding market for distributed Multi-
MW grid support applications– Driven by T&D constraints, RPS
standards and declining product costs– Multiple DFC3000 systems, DFC-ERG™
systems, or systems with ORC bottoming
• Future Products: Other papers at seminar
– High efficiency hybrid systems– Co-production of power and hydrogen
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