TECHNOLOGY AND APPLICATION OVERVIEW OF FUEL CELLS

by

R.K.BHATTACHARYA General Manager(EM) Bharat Heavy Electricals Limited, Corporate Research & Development Division , Vikas Nagar,Hyderabad

.MILLIONS OF YEARS AGO, THERE WAS NO MAN KIND..

ONLY PRE-HISTORIC LIVING SPECIES..

CLIMATE/ENVIRONMENTAL CHANGE (NATURAL)

.RESULTED IN THE EVOLUTION OF MANKIND

ECOLOGICAL CHANGE (MAN-MADE)

..LOGICALLY WILL SEE THE EXTINCTION OF THE PRESENT LIVING FORMS

UNLESS WE DO SOMETHING ABOUT REVERSING WHAT WE ARE DOING

ENERGY IS THE PRIME MOVER FOR THE WHEELS OF LIFE

QUEST FOR NEW SOURCES & NEW CONVERSION TECHNOLOGIES TO USABLE FORMS EARTH-THE HOLDING POT OF SUM TOTAL OF ALL FORMS OF ENERGY STILL ECOLOGICAL CONDITIONS WILL DICTATE FORMS OF LIFE

WORLD POPULATION EXPECTED TO GROW TO 8 BILLION IN 2020 WILL REQUIRE 90 BILLION bpd OF OIL 7 B.TONS OF COAL/YR 40 TRILLION Cu.M/YR OF NG 50% OF THIS ENERGY WILL BE REQUIRED IN THE DEVELOPING WORLD

16% OF WORLD POPULATION WITH 0.6% OF OIL & 6% OF COAL RESOURCES.

IN 2000-01, ENERGY SHORTAGE - 7.8%, PEAK LOAD SHORTAGE -13%.

PER CAPITA ENERGY CONSUMPTION IS FAR LESS COMPARED TO GLOBAL STANDARDS (482 kWHr IN 1997 - CHINA 922 - WORLD 1562). BY 2025, INDIA WILL BE THE MOST POPULOUS COUNTRY IN THE WORLD. COUPLED WITH THE GDP GROWTH REQUIREMENTS, THE ADDITIONAL ENERGY REQUIREMENT WILL BE MIND BOGGLING.

HOW DO WE MANAGE THIS?

-------------------

----------- THE ANSWER WILL HAVE TO BE FOUND ON BOTH SIDES OF THE EQUATION.

ENERGY SUPPLY

ENERGY DEMAND

(SOURCE, TECHNOLOGY, EFFICIENCY)

(ALTERNATIVES, EQUIPMENT, LIFE STYLE)

------------STILL, WE CAN NOT AVOID THE INEVITABLE, BUT WE CAN DELAY THE SAME.

ELECTRIFICATION RATE ( %) WORLD DEV COUNTRIES OECD INDIA CHINA 72.8 64.2 99.2 43.0 98.6

SRILANKA
PAKISTAN BANGLADESH

62.0
52.9 20.4.

COAL FOSSIL FUEL OIL NATURAL GAS SOLAR PV / THERMAL RENEWABLES HYDRO WIND BIO - MASS OTHER NUCLEAR

FOCUS ON FUEL CELLS

OUR PRESENT LIFESTYLE CANNOT DO AWAY WITH FOSSIL FUEL ENERGY SOURCES IMMEDIATELY. BUT, ADOPTING ENERGY CONVERSION SYSTEMS WITH HIGHER EFICIENCY WILL REDUCE GH GAS GENERATION. FUEL CELLS MEET THIS REQUIREMENT ADEQUATELY. ALSO, BEING A COMBUTIONLESS SYSTEM THERE IS NO EMISSSION OF SOX/NOX.

Part I : Fuel Cell Technology- an Overview

Principle of Operation of a Typical Fuel Cell

Repeating elements used in a typical cell stack

Major sub-systems in a typical Fuel Cell Power Plant

Benefits of Fuel Cells Fuel cells provide a range of critical benefits that no other single power-generating technology can match.

Some of the key characteristics of fuel cells are :

Fuel Cells are Efficient even at part loads Fuel Cells are modular Fuel Cells provide high availability and reliability Fuel Cells can operate on a variety of fuels Fuel Cells are Clean & Quiet

Types of Fuel Cells

Fuel Cell Type
Alkaline Fuel Cell (AFC)

Temp of Operatio n [oC]

RT 100 RT 100

Unit Sizes [kWe]

< 100 0.1 100

Most likely applications

Space , Military recently terrestrial applications
Portable devices like Lap Tops, Cellular phones, Video Cameras etc Domestic & Dedicated Power (+ heat) Buses, Passenger Cars, Service Vehicles, Railway Locomotives & Streetcars etc

Proton Exchange Membrane Fuel Cell (PEMFC)

Phosphoric Acid Fuel Cell (PAFC) Molten Carbonate Fuel Cell (MCFC) Solid Oxide Fuel Cell (SOFC)

100 210

5 - 200 (also MW sized plants) 100 2,000 (plants up to 100 MW) 2.5 250 (plants up to 100 MW)

Dedicated Power (+ heat), Railways Dispersed Power & Utility Power (Combined Cycle with downstream Steam Turbine)
Domestic & Commercial (heat and power), Utility Power (combined cycle) Mobile applications for railways

650

800-1000

PEMFC
Electrolyte
Ion Exchange Membrane

AFC Potassium Hydroxide non platinum RT-80 50-60

PAFC Phosphoric Acid Platinum 180-205 36-42

MCFC Molten carbonates Nickel 650 45-60

SOFC Ceramic Oxides Perovskite 800-1000 50-60

Catalyst Operating Temp 0 C

Electrical Efficiency (%LHV)

Platinum RT-80 32-40

Applications Cogeneration Utility Power Distributed Power Passenger Vehicles Heavy Duty Vehicles Portable Power Specialty Power

PEMFC
Advantages High Power density, Light weight, quick response

AFC
Low cost high efficiency, Co tolerant

PAFC
Co tolerance up to 1.5% Multi fuel capability

MCFC
Inexpensi ve catalysts Multi fuel capability

SOFC
Efficienci es up to 60%

Disadvantages

Humidificati on required CO Intolerance Platinum& Membrane pushes the cost upwards

Requires inlet air scrubbers. Circulating Alkali requires toping up

Expensive platinum catalyst used. Low current& power. Large size& weight

High temperatures enhance corrosion and the breakdown of cell components.

Not yet available commercia lly

Alkaline Fuel Cell Applications

PEMFC applications

MCFC &DFC applications

SOFC tubular and planer design

Simple-cycle Atmospheric SOFC Cogeneration System

100 kW SOFC Cogeneration System formerly at Westervoort, the Netherlands, currently at Essen, Germany. As of January 2002 the system has operated in a total of 20,000+ hours. The system has a peak power of ~140 kW, typically feeding 109 kW into the local grid and 64 kW of hot water into the local district heating system, and is operating at an electrical efficiency of 46%.

World's First Fuel Cell-Gas Turbine Hybrid now Operating in California

220-kW hybrid system with a Solid Oxide Fuel Cell (SOFC) generator and a downstream micro-turbine

SOFC stack

Part II :

BHELs Activities in Fuel Cell Area

Fuel Cells at BHEL

(History of Development) 1987-1990: Started work on PAFC. Made single cells and small stacks (100-200 cm2) 1991: Demonstrated a 1 kW stack (chlor-alkali plant, 40 cells,with imported bipolar plates, ~400 cm2) 1995: Demonstrated 5 kW stacks (chlor-alkali plant, 80 cells, ~900 cm2, Laminated bipolar plates, 300*400 mm, Rolled electrodes) 2001: Demonstrated 2*25 kW stacks (chlor-alkali plant, 160 cells / stack, ~1600 cm2, molded bipolar plates, screen printed electrodes) 2002:Acquired basic PEMFC technology from IISc,single cell testing

The 50kW Power Pack during testing at BHEL R&D during December 2000

Salient features of 50 kW stack (2 x 25 kW fuel cell stack)

2 x 25 kW stacks Plate area 500mm x 400mm = 2000 sqcm

Effective Cell Area = 1500 sqcm

Number of cells in each stack = 160 Air cooling system Water to air Heat exchanger system Inverter and DC loading system Data acquisition and storage system Current densities achieved in the range of 200 to 250 mA/sqcm Operating voltage in the range of 550 to 600 mV per cell

200 kW PC 25 C PAFC Power Plant at BHEL R&D

Part III :Fuel Cell Application Opportunities in India

Fuel Cells Application in India Railways

Passenger Coaches lighting and fans 4 kW systems mounted on the passenger coach Requirement 4500 coaches Power cars for long distance Shatabdi & Rajdhani 200 kW systems / 2 per train / 25 trains Illumination of level crossing Up to 1 kW systems / Around 8000 to 10000 Lighting of isolated railway stations 5 to 10 kW systems / Up to 1000 stations Emergency power supply for control rooms 10-25 kW systems / Up to 200 - 500 control rooms

Fuel Cells Application in India Transportation

Two

Wheeler

4 kW systems / 75,000 to 1,00,000

Three Wheeler
6-8 kW systems / 25,000 to 50,000

Buses
100 kW systems / 1,000 to 5,000

Merchant Navy
100-200 kW / 100 to 200

Fuel Cells Application in India Strategic

Data Processing centres 1- 5 kW systems / around 5,000
Soft ware Companies 25 50kW / around 1,000

Communication Centres 1-5 kW systems / around 20,000

Remote Area Installations 1-2 kW systems / around 1,000

Off shore oil rig installations 25-50 kW systems up to 500

Fuel Cells Application in India

Commercial establishments

Shops in Malls and Underground bazaars 1 to 3 kW systems / around 1,00,000 Small Business Establishments 5-10 kW systems / 50,000 Entertainment Industry 25-50 kW systems / 500 to 1,000 Hotels, restaurants & Resorts 100-200 kW systems / up to 500 units Hospitals 200-500 kW systems / up to 200 units Residential Complexes 50-200 kW systems / 30,000 to 50,000

Part IV : Issues in Fuel Cell Application in DPG

Distributed Generation
-

Rural Urban

(Remote areas) ( Hotels ,Hospitals ,Ent.centres, Software dev. centres) Strategic (Communication centres, Defense,
Chemicals and Pharmaceutical plants)

Fuel options
Urban :- Hydrogen,NG,Methanol,LPG, Di-gas Rural :- Ethanol ,Biogas Strategic:- Hydrogen, NG, LPG, Methanol
Technology of fuel cells will depend upon the type of fuel available

Capacity /Duty cycle

Urban/Strategic
High Power Capacity

Base Load (High temp.Fuel Cells)

Rural
Low Power Capacity
Cyclic Load (Low temp.Fuel Cells) No.of start stops will determine the life cycle of HT fuel cells.

Other Issues

Starting power - Rural area (Black start) Others (Brown start) Cost Factor - Still not affordable without Govt.subsidy Market Size - Traditional tussle between cost and volume Op.& Maint. - Being high technology item requires careful handling

PART- V: AUTOMOTIVE APPLICATIONS OF FUEL CELLS

NEED VS GROUND REALITIES

WORLDWIDE, TRANSPORT VECHICLES ARE THE SINGLE LARGEST CONTRIBUTOR TO THE GH GASES. IC ENGINES CONVERT FUELS CHEMICAL ENERGY TO WHEEL POWER AT VERY LOW EFFICIENCIES. THOUGH THE NEED FOR HIGHER CONVERSION EFFICIENCY IS FELT AND THE DESIRABILITY OF FUEL CELLS IS VINDICATED, PEOPLE WOULD BE INFLUENCED BY: - COST - PERFORMANCE - CONVENIENCE (INFRASTRUCTURE)

FUEL - THE CRUCIAL FACTOR

ON BOARD PRESSURIZED GAS
HYDROGEN

FROM GROUND BASED FUEL INFRASTRUCTURE (EXTERNAL REFORMATION)

ON BOARD LIQUIFIED H2

FUEL CELL POWER STACK

VEHICLE PROPULSION SYSTEM

GASOLENE METHANOL

ON BOARD REFORMER

HYDRIDE REPLENISHMENT FROM GROUND SOURCES

ON -BOARD METAL HYDRIDES

ISSUES FOR EACH OPTION

1. ON -BOARD PRESSURIZED HYROGEN : COMPRESSION PRESS 10000 PSI ; LARGE SPACE REQUIREMENT ; OCCUPIES EIGHT TIMES THE VOLUME OF GASOLENE. 2. ON BOARD LIQUIFIED HYDROGEN:- HIGH ENERGY REQUIRED FOR COOLING THE GAS TO LIQUID IN CRYOGENIC TANKS (-2530C); HIGH COST OF CRYO TANKS. 3. METHANOL REFORMATION : REFORMATION AT 260 - 300 0C ; TOXIC AND POISONOUS WITH INVISIBLE FLAME ; EASY TRANSPORTABILITY AND HANDLING ; EXISTING FUEL INFRASTRUCTURE CAN BE USED.

ISSUES (CONTD)
4. GASOLENE REFORMATION : REFORMATION AT 6000C ; LESS EFFICIENT THAN METHANOL AND PRODUCES MORE EMISSIONS ; EXISTING INFRASTRUCTURE CAN BE USED. 5.METAL HYDRIDES : PRESENTLY RARE-EARTH METAL HYDRIDES ONLY STORE 1.5 - 2.0% HYDROGEN BY WEIGHT ; RESULTANT WEIGHT MAKES IT UNVIABLE FOR CARS WITH RANGE OF 300 KMs ; REQUIRES GROUND INFRASTRUCTURE FOR RECHARGING. 6. SODIUM BOROHYDRIDE : SAFE CARRIER OF HYDROGEN ; REQUIRES LESS VOLUME THAN COMPRESSED HYDROGEN ; REQUIRES GROUND INFRASTRUCTURE.

WHAT ARE AUTO MAJORS PURSUING ?

DAIMLER.CHRYSLER LIQUIFIED HYDROGEN COMPRESSED HYDROGEN - NECAR 4 - NECAR 4a

METHANOL
METAL HYDRIDE & SODIUM BOROHYDRIDE

- NECAR 5 & JEEP COMMANDER

- CHRYSLER NATRIUM

( A MODIFIED MERCEDES - BENZ A - CLASS WILL RUN ON COMP. H2 IN 2004)

TOYOTA HONDA GM

COMPRESSED HYDROGEN COMPRESSED HYDROGEN COMPRESSED HYDROGEN

FCHV (KLUGER V) FCX HydroGen 3

(ACHIEVED HIGHEST STACK POWER DENSITY OF 1.75 kW/litre)

FORD COMPRESSED HYDROGEN FOCUS FCV (HYBRID)

NEED FOR QUICK-STARTING, MULTI-FUEL COMPACT REFORMER

LOW-COST MATERIALS (SPECIALLY, ELECTROLYTIC MEMBRANE)

LOW-COST NON-NOBLE MATERIAL CATALYST LOW-COST MASS-PRODUCIBLE BIPOLAR PLATE SIMPLIFIED LOW-COST POWER CONDITIONER

The Future
Despite all these difficulties, the
Governments all over the world are

pouring in money for Breakthroughs

since this eco friendly technology could

be the ULTIMATE WINNER !

Thank You