Fuel Cells: electrifying chemistry! - WSU Labs | … fuel cell hybrid loco PRWLYH´$ 5 0LOOHU . 6...

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2/63© Clean Energy Systems Integration Lab, 2016

Fuel Cells: electrifying chemistry!

What are they & How they work

Automotive Future

Other Fuel Cell Applications

CESI Lab Research interests


Traditional energy conversion device (combustion)

CH4 →

O2, N2 →

Reduction and Oxidation occur at the same place & time

Fuel cell energy conversion device

CH4 →

O2, N2 →

Reduction and Oxidation separated in space:Oxidation: CH4 + 2 H2O CO2 + 8 H+ + 8 e–

Reduction: 2 O2 + 8 e– + 8 H+ 4 H2O

– 8 e–

+ 4 e– + 4 e–

CH4 + 2 O2 CO2 + 2 H2O

oxidation

reduction

Load8 e–


Internal Energy

U=TS-pV

U = Energy needed to create a system

Energy change with

constant S and V

UHelmhotlz

Free Energy

F=U-TS

F = Energy needed to create a system –energy provided by environment

Energy change with

constant T and V

F

Gibbs

Free Energy

G=U-TS+pV

G = Energy to create system + work – environmentEnergy change with constant T and P

GEnthalpy

F=U+pV

H = Energy to create a system + work needed to make room for it.Energy change with

constant S and P

H

+pV

-TS

-pV

+TS

𝑰𝒅𝒆𝒂𝒍 𝑽𝒐𝒍𝒕𝒂𝒈𝒆 =∆𝑮

𝒏𝑭

0

0.25

0.5

0.75

1

1.25

1.5

0 200 400 600 800 1000

Vo

ltag

e

Temperature

Ideal Voltage

Lower Temp. = Higher Ideal Efficiency

Lower Temperature = Slower Reactions

∆𝑮 of 1kg H2 ≈ 33kWh

5,000

iPhone

batteries

(6.9Wh)

@ atmospheric pressure


Limitations:a) Activation energy (giving a push)

b) Ohmic Losses (drag)

c) Concentration losses (traffic jam)

1.23 V

Higher Power Density =

Less Efficient

Heat

PowerMore Power


Loade

Product Gases

Residual Fuel

Fuel Oxidant

Anode CathodeElectrolyte

(Ion Conductor)

Product Gases

Residual Oxidant

ee

Phosphoric Acid: PAFC &Proton Exchange

Membrane: PEMFCH2

H2O

O2H+

Molten Carbonate: MCFCH2

CO2

H2O

CO3

CO2

O2

200C

90C

650C

Alkaline: AFC H2

H2OO2 80COH

–

Solid Oxide: SOFCH2

H2OO O2

700 -

1000C


Loade

Product Gases

Residual Fuel

Fuel Oxidant


(Ion Conductor)

Residual Oxidant

ee

AFCH2

O2 80CH2O

OH–

H2O

Space shuttle alkaline fuel cell

14”x15”x40” & weighs 255 lb

12kW peak, 7kW continuous

3 modules per shuttle


http://h2forum2008.ru/docs/pdf/23/s2/p3/4.pdf


Loade

Residual Fuel

Fuel Oxidant

Anode CathodeElectrolyte(Ion Conductor)

Product Gases

Residual Oxidant

ee

PAFC H2H2O

O2H+

~200C

PAFC: H3PO4, SiC silicone carbide support, 150ºC and 210ºC

* Electrical efficiency of between 37% & 42% --higher with CHP

* 10 year lifespan

440KW PAFC – Doosan

Fuel Cell America


Loade

Residual Fuel

Fuel Oxidant

Anode CathodeElectrolyte(Ion Conductor)

Product Gases

Residual Oxidant

ee

PEM H2H2O

O2H+

~90C

PEM fuel cells can be easily ruined by impurities.

Hydrogen purity is required at 99.999 %.

Some degradation in performance due to poisons is reversible and

some is fatal.


Gas

dif

fusi

on

layer

Electro

lyte

Carbon supported catalyst

Water collects around the

clusters of hydrophylic

sulfonate side chains

Sulphonated

fluoroethylene


Loade

Product Gases

Residual Fuel

Fuel


(Ion Conductor)

Residual Oxidant

ee

Oxidant

(O2, CO2)

O2

MCFC

H2

CO2

H2O

CO3

CO2

550-

650C


Loade

Product Gases

Residual Fuel

Fuel


(Ion Conductor)

Residual Oxidant

eeOxidant

SOFCH2

H2OO O2

700 -

1000C


Two geometry types primarily used in SOFC technology


» BloomEnergy, Versa Power, CFCL, SOFC Power, Ceres, SolidPower, NexCeris…

» Stacking with interconnect and manifold plates


A single fuel cell will typically produce between 0.5 to 0.8V.

In order to meet application reasonable voltages fuel cells

are connected in series.


» PEM fuel cells˃ Low temperature – require catalyst & pure H2

˃ Great for transportation applications (fast start)

˃ Goal is 5,000 hour lifespan

» MCFC & SOFC˃ High temperature – fuel flexible

˃ Stationary power

˃ Goal is 80,000 hour lifespan




Automotive Future




Honda Clarity

Toyota Mirai

Hyundai Tucson

BPEV.XLS; 'Compound' AS146 5/13 /2009

-

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

0 50 100 150 200 250 300 350 400

Range (miles)

Vehicle Test Mass

(kg)

PbA Battery EV

Li-Ion Battery EV

NiMH Battery EV

Fuel Cell Electric Vehicle

Grid Mix: US BPEV.XLS; 'Compound' AQ200 5/13 /2009

-

200

400

600

800

1,000

0 50 100 150 200 250 300 350 400

Range (miles)

Greenhouse Gas Emissions (CO2 -equivalent grams/mile) PbA Battery EV

Li-Ion

Battery

EV

NiMH

Battery EV

Fuel Cell Electric Vehicle

Conventional

Gasoline

VehicleBatteries

• Weigh more

• Take up space

• Don’t reduce GHG

• Charge for 4+

hours


High Voltage Junction Box

Motor Control Unit

Air Blower

Fuel Cell Stack

Humidifier

Demineralizer

Fuel Processing System

Controller

To Radiator

Hydrogen Recirculation

Blower

From Radiator

Air Filter


Traction MotorGear Reduction

Unit

Heater

3 way valveWater pump

Silencer


Sedan

SUV


CSULA hosted Mercedes

Benz F-Cell World Drive

with Cristian Maier, March

8, 2011


•Asia Toyota –Hino [dual automotive FC]

Hyundai

China ---in 4th generation

development, said to be well funded

•Europe Daimler

Van Hool/UTC/AC Transit

VDL/Kiepe/Ballard –18M flex bus

Hydrogenics –mini-bus

H2 Bus (HICE, in development)?

Skoda [“triple hybrid”, 85kW Proton

motor, U-cap

Wright/ISE

•USA • New Flyer/ISE/Ballard [150kW or

75kW, battery or U-Cap]

• E-Bus [22’, 20kW?]

• Proterra [35’, 32kW]

• El Dorado/BAE/Ballard –“American

FCB”


• All-Electric Drive Rooftop Cooling

• All Electric HVAC System

• Electric-Drive Power Steering

and Air Compressor

• Active Regenerative Braking

• Liquid Cooled Lithium-Ion

Battery System

• Rooftop 40 Kg H2 Storage

• Two 85 kW Siemens Drive Motors

• 164,000 miles (since Aug 2010)

• > 10,500 Fuel Cell Hours (for fleet)

AC Transit Fueled Bus




Automotive Power Past & Future




September 2009, Ohio State University Buckeye Bullet 2 set the world

record of 302 mph http://www.buckeyebullet.com/press.html

Intelligent Energy

Cal State Los Angeles

fuel cell racer

In 2007, a team of Ford engineers retrofitted the production Ford Fusion into

Hydrogen vehicle with fuel cells and set a world record of 200 mph

http://www.buckeyebullet.com/press.html


• Liquid oxygen and hydrogen is stored

in metal-hydride outside of the

pressure hull.

• The 120 kW BZM 120 Siemens fuel

cell has dimensions of 176x53x50 cm

and mass of 900 kg.


Figure 1. BNSF 1205, the largest fuel cell powered shunt locomotive and land vehicle, June 2009

(http://www.fuelcellpropulsion.org/projects.html) (left). Fuel cell locomotive principal systems layout (“System design of a

large fuel cell hybrid locomotive” A. R. Miller, K. S. Hess, D. L. Barnes, and T. L. Erickson, “System design of a large fuel

cell hybrid locomotive.” Journal of Power Sources, 173 (2007) 935-942) (right).


Figure 1. “PowerCar” developed by Russian National Railroads for working in enclosed conditions such as tunnels

(http://fotki.yandex.ru/users/serokoy/view/436236/?page=1).

Alkaline, leftovers from the space program


Fuel Cell APU applied to landing gear

http://www.dlr.de

The Boeing designed the very first manned fuel

cell airplane 2008 (Photo Credit: Boeing photo)

http://www.airbus.com/fileadmin/media_gallery/photoga

llery/big/800x600_1347473821_ILA-Berlin_Fuel-cell-

tailcone.jpg


Early 2000’s, Helios project: The 247

foot wingspan plane is capable of

generating up to 37 kW while

needing only 10 kW to operate its 14

propeller motors. Regenerative cells.

Global Observer: Remote Sensing &

Persistent Communications up to 65,000 ft

Endurance/RangeUp to 1 week

Payload Up to 400 lbs. for GO-1

Liquid hydrogen powered


• Large Distribution Centers

• Up to 2 million sq. ft.

• As many as 300 trucks

• Usually sited along major

highways away from large cities

(cheap land)

• E.g., grocery DC’s


Class 1

Sit-down lift trucks: Handle heavy loads in large

manufacturing operations

Stand-up reach trucks:Provide flexibility and

maximum floor space

Utilization in large

distribution centers

Rider pallet trucks:Select goods within large

distribution centers before

delivery to retail stores

Class 3Class 2

Courtesy: Plug Power, 2013


Backup & Transportable Power

Ballard Power

Systems

Plug Power

Smart Fuel Cell

Intelligent Energy

Ball Aerospace

Manhattan Scientifics

Plug Power

Plug Power

Plug Power

Ballard

IdaTech

Altergy

JadooIntelligent Energy

http://www.mobilecomms-technology.com/contractors/powersupply/plug-power/

http://www.mobilecomms-technology.com/contractors/powersupply/plug-power/

http://images.google.com/imgres?imgurl=http://www.casfcc.org/2/AboutUs/images/CapitolandTree.jpg&imgrefurl=http://www.casfcc.org/2/AboutUs/Projects.aspx&h=436&w=450&sz=274&hl=en&start=4&um=1&tbnid=x6sCb1ZPlG4G5M:&tbnh=123&tbnw=127&prev=/images?q=photo+altergy+fuel+cell&um=1&hl=en

http://images.google.com/imgres?imgurl=http://www.casfcc.org/2/AboutUs/images/CapitolandTree.jpg&imgrefurl=http://www.casfcc.org/2/AboutUs/Projects.aspx&h=436&w=450&sz=274&hl=en&start=4&um=1&tbnid=x6sCb1ZPlG4G5M:&tbnh=123&tbnw=127&prev=/images?q=photo+altergy+fuel+cell&um=1&hl=en

http://www.goodcleantech.com/batteries/?p=3

http://www.goodcleantech.com/batteries/?p=3

http://www.fuelcellstore.com/cgi-bin/tornado/view=Item/cat=1046/product=1131

http://www.fuelcellstore.com/cgi-bin/tornado/view=Item/cat=1046/product=1131


» Cellular Communications Equipment

http://energy.gov/sites/prod/files/2014/10/f19/ftco_early_mkts_fc_backup_power_fact_sheet.pdf


http://energy.gov/sites/prod/files/2014/03/f12/mt_moreland_apco_presentation.pdf


» Cellular Communications Equipment (most popular)

http://energy.gov/sites/prod/files/2014/10/f19/ftco_early_mkts_fc_backup_power_fact_sheet.pdf


» Google» eBay» Microsoft» Apple» JPMorgan Chase» Verizon» Fujitsu» NTT» Williams-Sonoma

Apple


Distributed & Central Power Generation˃ Significant markets emerging

+ Landfill/digester

+ Combined heating and power

Siemens Power

Santa Rita Jail, CA

San Diego Sheraton, CACal State Northridge

Sierra Nevada Brewery, CA

King County, WAEarly DFC 1500®,

Danbury, CT

Residential

Power


» Japan’s Ene-Farm has most # of units sold

» Korea leads in large stationary power, but US is gaining˃ Primarily FuelCell Energy and Bloom

» Europe, even with many FC companies, lags behind


Ceres power (UK)




Automotive Power Past & Future




Farming

Manufacturing/Industry

Electricity

GenerationTransport

of Goods

Services/Offices

http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=boeogfAuthyBNM&tbnid=HrmKUAz7u60ivM:&ved=0CAgQjRwwADh2&url=http://www.clker.com/clipart-24110.html&ei=ePB3UrDvGs6ajALl34GgBg&psig=AFQjCNH2IiSx_xT1ill7z5J5ORclFqES2Q&ust=1383678456592925


http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=5AiQcpm1U8O_DM&tbnid=PNiTLXjzKLD-tM:&ved=0CAgQjRwwAA&url=http://clipart-finder.com/clipart/Houseicon14.html&ei=uPB3UuGvFYW8igLa3YC4BQ&psig=AFQjCNEhC-rxQyCDO5OY0WMqI-xsc_EYZA&ust=1383678520399931


http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=L4UWv6Bw8oVqzM&tbnid=PRIZJ4LEfZbaZM:&ved=0CAgQjRwwAA&url=http://www.clker.com/clipart-car-icon-2.html&ei=x_B3UrDnBpCWjALfjoCYCg&psig=AFQjCNEP3CcgFN1-w6sU8l6RrBJ6YzFyzA&ust=1383678535166544


http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=AJfG8vxYwZP6rM&tbnid=bzFsw6kEduTdEM:&ved=0CAgQjRwwADgm&url=http://icons.mysitemyway.com/legacy-icon-tags/coal/&ei=f_N3UsCFIeaZiAK1_ICQAQ&psig=AFQjCNH1PbCRXbvJSUg6gUEIhUqWi6tn9Q&ust=1383679231588239


http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=4RzQlJ7G3M9ygM&tbnid=Xlg4R1q-pUaY5M:&ved=0CAgQjRwwADhY&url=http://www.thermeau.com/en/index.php/energy-efficiency-charts&ei=IfR3UuzJKs3rigKIvoDABA&psig=AFQjCNHBWT1n1PpeIWn2s-N6kBUWwdVSbg&ust=1383679393756410


http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=F30Ao1LNxHiAaM&tbnid=K6QtO2HM62iNOM:&ved=0CAgQjRwwADgj&url=http://openclipart.org/detail/170536/nuclear-power-plant-symbol-3-by-qubodup-170536&ei=jfR3Uov2GsrAigKr34HwAw&psig=AFQjCNEJySq0cUuim3NWeZoli4XQHuphMw&ust=1383679501484601


http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=qSFC0L1TczkkmM&tbnid=MdEUHL4e0uJIMM:&ved=0CAgQjRwwAA&url=http://www.off-gridelectric.com/faq.html&ei=Ofd3UrKHAqPkiwK3qICYBA&psig=AFQjCNFoP13FQo3ikzrqiO2YF7e6lCIxlQ&ust=1383680185080491


http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=jNZNqt14iD-VOM&tbnid=Y74sGom_pB1jBM:&ved=0CAgQjRwwAA&url=http://www.westernpower.com.au/residents/connections/movingequipment.html&ei=sf13UpOiMsOKjAK104H4BA&psig=AFQjCNFzvHG5QEQ_mrPvjlcls_DHOUDsVw&ust=1383681841876172



Farming

Manufacturing/Industry

Electricity

Generation

Transport

of Goods

Services/Offices


















» Capture curtailed renewable energy in a convenient storage medium H2

Electrolyzer Fuel Cell

O2

H2

Fuel

Cell

Storage








Inlet Flow

Manifold

Inlet Flow Manifold

McLarty et al. International Journal of Hydrogen Energy 2013


% Self Generation

Baseline Grid Cost

Co

st

Max

Best NPC savings

Largest CHP for break-even

(best emissions reduction)


Choose A Building

Select State/Utility

Add Chillers/TES

View Results Choose Dispatch

Edit Costs

Pick A Fuel Cell

Add Wind/Solar

16 16 5


0

10

20

30

40

50

60

70

2000

2500

3000

3500

4000

4500

5000

5500

De

man

d m

et b

y D

G (

%)

Inst

alle

d F

C c

ost

($

/kW

)


McLarty, D., and J. Brouwer. “Poly-generating closed cathode fuel cell with carbon capture.” Applied Energy, 131, 108-116

Differences from standard SOFC:• Pressurized, pure O2 cathode increases FC efficiency • Higher anode H2 concentration increases FC efficiency• Waste heat captured in chemical potential of H2

• Cryogenic air separation synergistically produces O2 for FC and liquid N2 for the carbon liquefaction and H2 recovery


Reformer

Anode

Cathode

N2l 77K

+-

ASU

HSUCond-enser WGS

Fuel

Air

800K

1000K

900K

O2g 298K 900K

Heat, 1000K

(H2, CO2) 298K

(H2, CO2, H2O) 485K

H2gLiquid CO2

Recovery

(H2, CO2, H2O, CO)473K

Ammonia Production

N2g Liquid Ammonia

(NH3) Production

Heat, 500K

Oxy-FC can provide ultra-efficient, carbon free, fertilizer production!• The Oxy-FC concept is readily integrated with the standard Haber-Bosch process of ammonia

synthesis by passing the exhaust N2 and H2 streams over a catalyst bed to form NH3

• Ammonia production consumes 3% of the worlds fossil fuel at less than 50% thermal efficiency• Eliminates steam reforming, partial oxidation, shift reactors, and gas refining from ammonia plant


C T

Air Exhaust

ExhaustAir

Heat

100kW700kW

400kW

FC-GT Hybrid Challenges:1. Air flow rate & temperatures must match2. Off-design, GT flow doesn’t change, FC does3. Large plenum volume, stall/surge risk


Standard

FC-GT

Air @ 15 barITM

O2 at 15bar

(H2, CO2, H2O, CO)

Reformer

Anode

Cathode+-

Fuel800K

1000K

900K

Exhaust

Compressor Turbine

Air

O2 at 0.5bar

Combustor

Fuel

Depleted

Air

Generator

New De-Coupled FC-GT

Differences from standard FC-GT• Potential for retrofit to existing

systems• Eliminates costly high

temperature heat exchangers• FC not directly in working flow

risking surge/stall• Independent control of GT flow

and FC flow• Higher efficiency operating

condition for fuel cell• Potential for low emission

combustion

Fuel Cells: electrifying chemistry! - WSU Labs | … fuel cell hybrid loco PRWLYH´$ 5 0LOOHU . 6...

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Transcript of Fuel Cells: electrifying chemistry! - WSU Labs | … fuel cell hybrid loco PRWLYH´$ 5 0LOOHU . 6...