fuel cell design
DESCRIPTION
Fuel Cell Design. Chemical Engineering Senior Design Spring 2005 UTC. Technical and Economic Aspects of a 25 kW Fuel Cell. Chris Boudreaux Wayne Johnson Nick Reinhardt. Technical and Economic Aspects of a 25 kW Fuel Cell. Chemical and Thermodynamic Aspects. Our Competence. - PowerPoint PPT PresentationTRANSCRIPT
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Fuel Cell Design
Chemical Engineering Senior DesignSpring 2005
UTC
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Technical and EconomicAspects of a 25 kW Fuel Cell
Chris BoudreauxWayne JohnsonNick Reinhardt
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Technical and EconomicAspects of a 25 kW Fuel Cell
Investigate the design of--a 25 kW Fuel Cell--Coproduce Hydrogen
--Grid parallel--Solid Oxide Electrolyte
• Chemical and Thermodynamic Aspects
Our Competence
Not Our Competence
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Outline
• Introduction to the project• Process Description• Process & Equip. Design• Economic Analysis
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Introduction
Overall Reaction
Methane + Air --> Electricity + Hydrogen
+ Heat + CO2
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Introduction
Pressure SwingAdsorption
Fuel Cell
ReformerGas
Hydrogen
ElectricityAirHeat
SynGas
POR
Water
Exhaust
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Fuel Cell-ChemistrySynGas
Air
O- O-
H2 H2O CO CO2
POR
O2 N2“Air”
Solid Oxide Electrolyte
is porous to O-
H2 + CO
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Fuel Cell-ElectricitySynGas
Air
O- O-
H2 H2O CO CO2
POR
O2 N2“Air”
Electrons
Load
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Fuel Cell-ChallengesSynGas
Air
O- O-
H2 H2O CO CO2
POR
O2 N2“Air”
H2 + COHot SynGas
Hot Air
Recover H2
Recover Heat
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Process Description
Turn it over to Nick Reinhardt
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Process Description
Fuel Preparation
Air Preparation
Post Processing
Fuel Cell
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Fuel Preparation
Air Preparation
Post Processing
Fuel Cell
Fuel Preparation - 100
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Fuel Preparation
Air Preparation
Post Processing
Fuel Cell
Air Preparation - 200
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Fuel Preparation
Air Preparation
Post Processing
Fuel Cell
Fuel Cell - 300
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Fuel Preparation
Air Preparation
Post Processing
Fuel Cell
Post Processing - 400
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Process and Equipment Design
Turn it over to Chris Boudreaux
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Pure Natural Gas25°C0.33 kmol/hrCH4 = 100%
Sulfur Purge25°C0.0002 kmol/hrH2S = 100%
Natural Gas Inlet25°C0.33 kmol/hrCH4 = 99.9%H2S = 0.001%
Desulfurizer
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Heat Exchangers
• A=q/UFΔTlm
• F = 0.9• U = 30 W/m2°C• ΔTlm = (ΔT2 – ΔT1) / [ ln(ΔT2 / ΔT1) ]
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Recycled Water5°C0.37 kmol/hrH2O = 100% Cooled POC
283°C3.51 kmol/hrN2 = 86%O2 = 9%H2O = 4%CO2 =1%
Humidified NG273°C0.67 kmol/hrH2O = 56% CH4 = 44%
Pure NG25°C0.3 kmol/hrCH4 = 100%
POC Vent26°C
Fuel Humidifier
Area = 2.6 m2
q = 1.8 kW
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Heated HNG840°C
Cooled POR479°C
POR850°C1.3 kmol/hrH2O = 47% H2 = 29%CO2 = 23%CO = 1%
Humidified NG273°C
Fuel Preheater
Area = 6.3 m2
q = 5.3 kW
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Heated HNG840°C0.67 kmol/hrH2O = 56%CH4 = 44%
SynGas734°C1.26 kmol/hrH2 = 73%CO = 21%H2O = 3%CO2 = 2%
ReformerR-104
q = 17 kW
R-104COMB-105
Heated HNG SynGas
POCDepleted AirPure NG
CH4 + H2O → CO + 3H2
CH4 + 2H2O → CO2 + 4H2
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CombustorCOMB-105
Depleted Air850°C3.48 kmol/hrN2 = 87%O2 = 11%H2O = 2%
POC784°C3.51 kmol/hrN2 = 86%O2 = 9%H2O = 4%CO2 =1%
Pure NG25°C0.03 kmol/hrCH4 = 100%
q = -17 kW
R-104COMB-105
CH4 + 2O2 → CO2 + 2H2O
SynGas
POC
Heated HNG
Depleted AirPure NG
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Cooled POR480°C1.3 kmol/hrH2O = 47%H2 = 29%CO2 = 23%CO = 1%
WGS Exhaust480°C1.26 kmol/hrH2O = 46.5%H2 = 30%CO2 = 23.2%CO = 0.3%
Water Gas Shift Reactor
CO + H2O → CO2 + H2
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POR850°C1.3 kmol/hrH2O = 47% H2 = 29%CO2 = 23%CO = 1%
Depleted Air850°C3.48 kmol/hrO2 = 11.5%
Heated Air650°C3.88 kmol/hrO2 = 21%
SynGas750°C1.26 kmol/hrH2 = 73%CO = 21%H2O = 3%CO2 = 2%
Fuel Cell
CO + ½ O2 → CO2
H2 + ½ O2 → H2O
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H Exhaust25°C0.38 kmol/hrH2 = 100%
Purge25°C0.43 kmol/hrCO2 = 68%
Uncondensed Gases5°C0.68 kmol/hrH2 = 56%CO2 = 43%
Air Inlet25°C0.13 kmol/hr
Pressure Swing Adsorber
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Economic Analysis
Turn it over to Wayne Johnson
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Economic Components
• Capital Costs• Operating Costs• Income Generated• Payback Period• Return on Investment
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Capital Cost Assumptions
• Cap Cost Program– Analysis, Synthesis, and Design of Chemical
Processes– Compares to Peters and Timmerhaus
• Stainless Steel
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Equipment CostsEquipment Name Capital Cost ($)
Solid Oxide Fuel Cell $10,000PSA $10,000
Reformer/Combustor $6,300Fuel Preheater $3,400
Chiller $3,000Fuel Humidifier $2,800
Desulfurizer $1,200Water Gas Shift Reactor $1,200
Air Compressor $950Air Side Heat Recovery $670
Air Preheater $290Water Condenser $150Water Purification $100
$40,000
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Lang Factor
• Fluid Processing = 4.74• Includes:
– Construction material and overhead– Labor– Contract engineering– Contingency– Site development
• $40,000 X 4.74 = $190,000
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Operating Costs
Fuel $17,000Utilties $1,000
Maintenance $1,000Labor $1,000Total $20,000
Operating Costs• Fuel: 0.33 kmol/hr
= 260,000 BTU/hr = 0.26 therms/hr
• Tennessee Valley industrial rate= $7.70/therm
• Labor included at site
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Income• Electricity = 25kW• Price = $0.10/kWhr
• Hydrogen = 0.38 kmol/hr= .76 kg/hr
• Tennessee Valley industrial rate
= $11.64/kg
Electricity $22,000Hydrogen $76,000
Total $98,000
Income
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Total Income vs. Expense
Costs $20,000Income $98,000Total $78,000
Income vs Expense
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Investment Results
Non-discounted Payback = 2.4 Years
Return on Investment = 41%
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Conclusions
• Rate of return and payback period are interesting
• Emerging technology means cost may decrease
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Questions for the Board
• What areas require more detail?• What locations should be investigated?• Should we enlist an electro-chemistry
team?• Should we enlist an electrical engineering
team?