FCEN Member meeting - Fuel Cell Expertise Network · The Fuel Cell Expertise Network is an...

The Fuel Cell Expertise Network is an initiative of Kiwa and Energy Matters

FCEN Member meeting

26 March 2012, Apeldoorn

Fuel Cell Expertise Network © 2012 2

Program

12.00 – 12.45 Lunch

12.45 – 13.00 Introduction & goals13.00 – 13.30 Short updates from Members

13.30 – 14.30 Market research results - FC Expertise Network

14.30 – 14.45 Short break

14.45 – 15.15 Innovation in thermal storage - Flamco

15.15 – 15.45 Fuel Cell test projects - Alliander15.45 – 16.30 Discussion – focus & strategy FCEN

16:30 – 17:30 Drinks

Introduction

Fuel cell Expertise Network today

We invite you to:participate and share your latest updates on technology, market and/or policy issues

Learn about first research results FCEN

Discuss tomorrows challenges & activities FCEN


FEN website

Ready next month

FEN first results

Basis for comparison – three FC mCHP systems

Technical issues

Market potentialMarket sizes

Cost price development



Energetic performances of FC mCHP in general

Electrical vs. thermal efficiency

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Electrical efficiency [%]

Ther

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PEMSOFCStirlingGas Engine100%

Fuel cells compared to other technologies


Anonymous systems overview

System A B C D E F G H I J K

Type PEM SOFC

E-power [kW] 1 1 0.75 0.7 1 1 1.5 1 0.8 1 0.7

Th-power [kW] 1.2 1.3 1.1 1 1.7 0.74 0.5 2.5 1.1 2 0.7

E-efficiency [%] 33 37 35 36 32 50 60 28 34 30 45

Total efficiency [%] 80 89 85 86 85 87 80 90 85 88 87

System current lifetime design

N/A N/A 40k 60k >20k 60k N/A N/A N/A N/A 30k

Expected current stack lifetime

N/A N/A 40k 30k >40k 30k N/A N/A N/A >16k 30k

Modulation [%] 25 30 N/A 35 30 15 30 30 N/A N/A N/A

Annual start/stops 50 N/A N/A 1000 100 N/A 0 3 Several Several N/A

System volume [l] 450 270 290 250 580 170 440 480 N/A N/A 160

Weight [kg] 200 125 125 104 230 105 195 170 N/A N/A 90

Auxiliary boiler integrated?

No No No No Yes No No Yes Yes No No

Three typical FC mCHP systems

Why three systems?To compare different systems and to give an accurate representation of the available technologies in our calculations

Systems can be distinguished by:Electrical efficiency

Thermal efficiency

Control / load strategy

Modulation rate

Flow temperature available heat @ 30ºC return temperature


PEMFC SOFC

Modulation Yes limited

Cold start time < 2 hours >20 hours

Thermal cycles over 50 / year 0 - few / year

Electrical efficiency 30-38% 28-60%

Max. temp coolant 65 ºC 100 ºC

Current life time 20k-40k hour (goal: >60k) 6k-25k hour (goal: >60k)

Three typical FC mCHP systems

General requirements;DHW: ca. 3500 kWh = 400 watt continuously

Thermal output of FC’s is too low to provide heating by itself à auxiliary heating is always necessary.

Space heating: is the temperature level high enough for conventional systems?

Our proposalElectricity load following, domestic hot water production, DHW + space heating

Default values for calculation: electrical efficiency 35% and 50% @ overall 85%



System 1: Electricity following heating system

Heating system

High electricity production

Much modulation required

Requires thermal storage

Example: Ceres SOFC


System 2: Domestic hot water production

Add-on electricity generator to existing heating system

High electricity production adapted to demand

Steady operation, might depend on thermal storage capacity

Example: CFCL BlueGen


System 3: Heating system

Heat demand following

Auxiliary boiler

Electricity is by-product

Relative steady operation, average

modulation required

Bottleneck: low heat demand in summers

Requires modulation / start & stop / thermal storage

Example:

Baxi Gamma 1.0

Thermal (integration) considerations

DHW and space heating? Dependents on efficiency.

Optimizing thermal efficiency:Retrieve thermal losses of components (inverter, controller, blowers,…)

Optimize heat exchanger

Coolant flow temperature control improves thermal efficiency andstorage capacity

Return temperature affects thermal efficiency

High flow temperature is more usable and better for storage

Low flow and small ΔT improves heat transfer in storage

Maintain temperature level by smart buffer configurationMake optimal use of thermal layering/temperature levels

New storage techniques can reduce size and increase capacity (PCM)


Areas of attention

Compact system (wall-hung?)

Heat storage: reduce required storage sizeSmart integration in dwellings

Improved storage techniques.

Reduce thermal output by increasing electrical efficiency

Varying gas qualityIncreasingly feed-in of biogas, LNG, Hydrogen, various types of NG

Gas quality measurement required? (small scale Wobbe meter)

L-gas: NH3 removing (PEMFC tolerates <1ppm NH3).


Market potential

Technical market potential dependent on several factors:Availability gas infrastructure (also hydrogen)

Type of fuel cell application, dependent on temperature level usable heat

Available space à space for buffer?

Wall hung / floor standing

Outdoor / indoor application

Weight (attic installation)

Implementation other system options (solar thermal, PV, heat pump)

Market potentialOperational revenues

Policy: energy neutral buildings and subsidies

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Floor standing or wall hung?

Wall hung (x1000)

Total 52.72M

Floor standing (x1000)

Total 14.97MData from 2004. Source: Eco-design Boilers, Task 2, final | 30 September 2007 | VHK for European Commission


Market potential FC in Europe

First focus; NL, DE, UKMature markets for boilers

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NL DE UK

Number of households # 7 572 727 38 928 571 27 147 826

Gas connected HH % 84% 37% 71%

Number of gas connected HH # 6 361 091 14 403 571 19 274 957

Number of boilers installed # 6 000 000 9 000 000 20 000 000

Wall hung boilers % 96% 40% 75%


Market potential FC in Europe

Heat consumption households

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NL DE UK

Heat consumption toe/year*HH 0,95 1,45 1,00

GJ/year*HH 39,8 60,7 41,9

Space heating % 80% 86% 70%

Water heating % 18% 11% 26%

Cooking/other % 2% 3% 4%


Market potential

Discussion: market potential:

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DHWElectricity following

DHW + space heating

+ add-on-Combisystems + large heat

replacement market+ Combi systems+ >> CO2-impact Large stack optional

+ E-capacity needed- Less operating hours? New business model- Combi systems

Market potential

Economic potential -> primarily driven by cash flow generation

Simulation of 3 control strategies;1. Electricity load following, heat vented when not usable

2. Domestic hot water (DHW) load following, electricity can be exported

3. DHW + space heating load following, electricity can be exported

Assumptions;1 kWe stack à 35% and 50% electrical and 85% overall

Individual house2400 m3 gas consumption for heat use à 21600 kWh

400 m3 gas consumption for domestic hot water à 3600 kWh

5000 kWh

All produced electricity is used behind-the-meter

No costs effects of reduced (local) grid losses

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• Control strategy determines # of full load hours à cash flow

• DHW + Space heating controlled most beneficial in both cases à best heat use

• Overcapacity thermal of 35% FC leads to a relative low cash flow

• Domestic hot water demand important factor

Market potential

Overall efficiency % 85%Electrical efficiency FC % 35% 50%Full load hours Electricity controlled hr/year 5000 5000

Domestic Hot water hr/year 3077 6280DHW + Space heating hr/year 5672 7412

Savings on energy costs (excl. subsidies) Electricity controlled €/year € 473 € 643 Domestic Hot water €/year € 360 € 807 DHW + Space heating €/year € 666 € 954

Market potential

Effect of higher overall efficiencyIn electricity controlled operation

Higher energy savings due to more heat production FC and less heat requirement of boiler

In heat controlled operation Lower energy savings due to less full load hours, less electricity production

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Savings on energy costs (excl. subsidies) Electricity controlled €/year € 490 € 675 Domestic Hot water €/year € 353 € 742 DHW + Space heating €/year € 699 € 944



Savings on energy costs Electricity controlled €/year € 473 € 643 Domestic Hot water €/year € 360 € 807 DHW + Space heating €/year € 666 € 954

Market potential

Effect of subsidy on electricity production 5 €ct/kWhIn all cases beneficial

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Savings on energy costs Electricity controlled €/year € 729 € 898 (incl. subsidy 5,11€ct/kWh) Domestic Hot water €/year € 517 € 1 128

DHW + Space heating €/year € 956 € 1 332

Overall efficiency % 85%

Electrical efficiency FC % 35% 50%

Full load hours Electricity controlled hr/year 5000 5000

Domestic Hot water hr/year 3077 6280

DHW + Space heating hr/year 5672 7412

Savings on energy costs Electricity controlled €/year € 473 € 643

Domestic Hot water €/year € 360 € 807

DHW + Space heating €/year € 666 € 954



What is a feasible mass produced cost price across different manufacturers?

How is the cost price build up in components?Assumptions need to be challenged

Cells < 5% cost price?

stack 30% cost price?

Rare earth metals < 2%, depending on type?

What learning curves have we already seen?

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Cost prices - examples


Cost price learning curve

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Pric

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# of products

Price development manufacturer X



FCEN wants to establish a more accurate vision on possible cost price development in perspective of mass production.

We want to gather information concerning:Global indication material costs

Global indication of cost reduction options

Cell price development

Output: an (anonymous) substantiation of fuel cell development

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Program

12.00 – 12.45 Lunch

12.45 – 13.00 Introduction & goals13.00 – 13.30 Short updates from Members

13.30 – 14.30 Market research results - FC Expertise Network

14.30 – 14.45 Short break

14.45 – 15.15 Innovation in thermal storage - Flamco

15.15 – 15.45 Fuel Cell test projects - Alliander15.45 – 16.30 Discussion – focus & strategy FCEN

16:30 – 17:30 Drinks

Discussion

What is needed for the next step?Strengthening technology concepts

Creating demand in (niche) markets

Attracting new capital for expansion

..

Are policy makers and investors convinced already? Energy potential

Fossil based generation

Energy neutral options

Technological feasibility

Niche markets: Combining FC mCHP with sustainable technologies?E-vehicles

E-heat pumps

Focus FCEN

On what kind of issues would you like a more detailed analysis?Space heating options

Added value electricity markets

Technical overview

Market potential

Technical challenges

Policy measures EU

Demonstration projects

…


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