NONRENEWABLE AND RENEWABLE RESOURCES. Renewable vs Non renewable.
Renewable Energy for Minnesota - Electrical and Computer...
Transcript of Renewable Energy for Minnesota - Electrical and Computer...
Renewable Energy for Minnesota
Progress in Fuel Cell Research at CPG
2
World Headquarters, Central Engineering, and Manufacturing for the Americas In Fridley Minnesota
1,000,000 ft2 1500 employees
Who are we?Cummins Power Generation (AKA Onan)
3
Stationary Power Markets
Residential Telecommunications
Portables Recreational Vehicle
Commercial Mobile
Rental
Mobile Power Markets
Technologies
Engine Gensets
Standby / Interruptible Distributed Generation
Fuel Cell ProgramControls, Switch Gear
Marine
GenSet
Variable Speed and Hybrid
Gensets
Cummins Power Generation Products and Markets
4
Cummins v. CompetitionCummins v. Competition
Diesel Engines Gas Engines AlternatorsControls & Switchgear
Gensets TurbochargersFiltration & Air-
Handling Systems
Cummins
CAT
Detroit Diesel/ MTU
Kohler
Others
Diesel Engines Gas Engines AlternatorsControls & Switchgear
Gensets TurbochargersFiltration & Air-
Handling Systems
Cummins
CAT
Detroit Diesel/ MTU
Kohler
Others
to 200 kWto 200 kW
Power of One: Single Source SupplyPower of One: Single Source Supply
Gen-sets from 2.0kW to 2.8MW, parallelable to many Mega Watts.
5
How is a Fuel Cell Different From a Battery?
Both cause an electrical potential through oxidation of materials
Batteries
Internal materials transform during charging and discharging (power and energy limited by the cell size)
Fuel Cells
Internal materials act as catalysts and only the fuel oxidizes (power limited by cell size, energy by the fuel tank size)
6
Anode Electrolyte Cathode
Fuel or reducing electrode
+ Positive
Ion conductor
Not electrically conductive
Oxidizing electrode
Electron flow
Basic elements of a battery or fuel cell
- Negative
FC Ion flow
7
Proton Exchange Membrane’sThe Hydrogen Economy Fuel Cell
Proton Exchange Fuel Cell– Protons
(Hydrogen Nuclei) Cross Electrolyte
– Solid Electrolyte– Requires ultra-
pure Hydrogen.– Chemical to
Electrical conversion efficiencies
• ~50%– System
efficiencies• 35% - 45%
8
Solid OxideFuel Cell(SOFC)
Oxygen Ions Cross the ElectrolyteOperating Temperature 700-800 oCWell suited to run on gasified coal or Bio-FuelsSystem Efficiencies ~40-50%
Solid Oxide Fuel CellsThe Omnivorous Fuel Cell
9
Why Solid Oxide Fuel Cells (SOFC’s)?
– Simplified fuel reformation for HC fuels (CO is fuel constituent, some Sulfur tolerance)
– No water management in stacks– Potential for low cost / no precious metals– No external cooling required– High quality waste heat stream– High efficiencyChallenges– Thermal management (start up, shut down, transients) – startup time– Degradation– Seals– Cost, cost, cost
10
DOE Solid State Energy Conversion Alliance (SECA) Fuel Cell Program
SECA helps bridge cost of moving from Lab to
Commercialization Process
SECA drives research needed to get cost to a commercially competitive level -- $400 / kWe
SECA funding enables the process
11
Fuel Cells and Cummins
SECA(Solid State Energy Conversion Alliance)10 kWe SOFC Power System Commercialization
Develop a SOFC system includingSOFC stack, reformer, heat exchangerBalance of PlantControls and Power ElectronicsPackaging and integrationFactory cost of $400/ kWe net by end of Phase IIICommercialized at earliest possible date
Objective:
12
Target MarketsObjective:
Commercialization
Recreational Vehicle
Truck APUMarin
eCommercial
Mobile
Military
Telecommunications
Diesel Diesel
Diesel
Diesel
Natural Gas or Propane
Diesel
13
Team Arrangements
• System integration• Electronic controls• Power electronics • Fuel systems• Air handling systems• Heat transfer• Reformer technology• Noise and vibration• Manufacturing• Marketing, sales, distribution
• Planar SOFC technology • Planar stack manufacturing• Reformer technology• Reformer manufacturing• Material sciences
Strategic Strategic PartnersPartners
14
What are the advantages?
Advantages of fuel cells–Can have greater conversion efficiency.
•Particularly for the conversion to electrical energy.
–SOFC can provide 50% open cycle and potentially 70% with bottoming cycle vs. 40% for heat engines open cycle.
•One of the leading arguments for fuel cells. Makes more costly renewable energy, affordable.
15
0.10
0.20
0.30
0.40
0.50
0.60
10 100 1000 10000Power (kW)
Ther
mal
Eff
icie
ncy
Gas Turbine(Non-recuperated)
Gas TurbineRecuperated
Current Fuel Cells
Diesel Recip
Natural Gas Recip(Stoichiometric)
Natural Gas Recip(Lean Burn)
DOE Advanced Gas Genset Target
Fuel Cell/ Microturbine Target 60-70%
Efficiency Vs. Technology
Higher efficiency plus high fuel costs favor evolving technology, fuel cells
16
What are the advantages?
Advantages of fuel cells–Can have near zero harmful emissions on
carbon based fuels (SOFC’s).•Heat engines running on Hydrogen also have near zero emissions.
•No NOx, if you are careful. –Fuel Cells are quiet with no vibration. –Fuel Cells can have a reduced IR signature.
•The military likes em.
17
0.76
0.40
0.01
0.45
0.42
0.273
0.164
0.030
0.015
0.015
0.3
0.00 0.20 0.40 0.60 0.80 1.00
Tier 1 Diesel
Tier 2 Diesel
Tier 3 Diesel
US Utility Average
Lean Burn Gas Recip
ARES Gas Recip
Gas Turbine
Microturbine
Fuel Cell
Rich Burn Gas Recip + TWC
Tier 1 Diesel+ SCR
Tier 2 Diesel + SCR
Tier 3 Diesel+ SCR
Lean burn gas recip + SCR
ARES Gas Recip + SCR
Gas Turbine+ SCR
NOx (lb/MWe-hr)
MOH - Mobile Off-Highway
SCR - Selective Catalytic Reduction
TWC - Three-Way Catalyst
Base Plant
MOH Regulations
1.5
3.4
8.2
13.6
20.9
Generating Equipment Exhaust Emissions
All technologies are evolving into a tight bandUltra low FC emissions may drive BACT regulations that favor fuel cells
in non containment areas
18
What are the disadvantages?
Disadvantages of fuel cells–Presently more costly.
•Not a mature technology.•Ceramics are relatively fragile.•Can be difficult to seal.
–Start up issues.•SOFC’s will always take tens of minutes to start.
•Transient response, Fuel must lead load.
19
0
500
1000
1500
2000
2500
3000
1 10 100 1000 10000 100000Power (Kw)
Pric
e ($
/kW
)Current Fuel Cells
Natural Gas Recip
Gas Turbine(Non-recuperated)
Microturbine(Recuperated)
Industry Fuel Cell Target
DOE SECA Fuel Cell Targets Long Term ($400/kW mfg. cost)
Diesel Recip
High Eq. costs drive total ownership costs, particularly in less than base load applications
Published Equipment Prices
Equipment Cost/KW vs. Power
20
Fuel Cells and Cummins
Solid State Energy Conversion Alliance (SECA)– Public (DOE), Private partnership to develop low cost SOFC’s.
• Cummins Power Generation is one of the industry teams.– DOE Target System Cost of $400 / kW by 2010
21
Phase 1 Reality
NOC = normal operating conditionsNotes:
– Peak efficiency is not a specific test - it is normal operation– $/kW calculation is based on peak power which will be done at end of test– All operation on pipeline natural gas with facility desulphurizer
> 90%
< 1%
~ 1-2 %
~ 35 - 44% DC Net~ 750 – 775
~ 3.3 kWDC NET (NOC)~ 5.4 kW DC NET (Peak)
Phase 1 Reality
> 80%
< 1 %
< 2 %
> 25% mobile< 800
3 – 10 kW
Phase 1 Program Requirements
Availability
Transient Degradation (/ 10 cycles)
Efficiency (net electrical LHV)
Steady State Degradation (/ 500 hrs.)
Cost ($/kW @ 50k/a.)
System Size (net)
22
Initial Phase 1 System Testing: Stack Current & Voltage vs. Time
0
10
20
30
40
50
60
70
80
90
100
110
0 120 240 360 480 600 720 840
Time Since Start [Hours]
Tota
l Sta
ck V
olta
ge [V
]
0
10
20
30
40
50
60
70
80
90
100
110
Cur
rent
[A]
Stack Tower Voltage, to BoostEOL Voltage LimitStack CurrentAugust 4 – September 5, 2006
System characterization NOC Hold
10 Transients
NOC Hold
Peak Power@80 A (450 mW/cm2)@100 A (500 mW/cm2)
23
Initial Phase 1 System Testing: Peak Power
0
1000
2000
3000
4000
5000
6000
7000
625 631 637 643 649 655 661 667 673
Time Since Start (Hours)
Pow
er (W
)
20%
25%
30%
35%
40%
45%
50%
55%
Effic
ienc
y (%
)
Gross DC Power Net DC Output Power Gross DC Efficiency Net DC Output Efficiency
5.5kWn DC @ 100ADC (1.5hrs)
5.4 kW net DC @ 80ADC (22 hrs)
Two hard transitions 80ADC to e-stop due to test errors
At 42 ADC Steady-state
At 42 ADC Steady-state
24
SOFC Planar Construction– Solid electrolyte, supported
by Anode material.– Cell interconnects made of
stainless steel.
Anode
Cathode
Electrolyte
•Anode – nickel-zirconia cermet, ~ 1 mm thick•Electrolyte – yttria-stabilized zirconia (YSZ), ~ 5 µm thick•Cathode – conducting ceramic, ~ 50 µm thick
All Courtesy of Versa Power
SOFC Cells
SOFC Stacks
25
Ceramics manufacturing
26
Low cost, high volume ceramics manufacturing
27
The SystemFuel Cell Stacks center piece of a larger system.– Fuel Cells by themselves are clean, balance of plant
may not be.– Balance of Plant (BOP)
• Thermal, fluid management– Control flows to match current demand, and fuel utilization
requirements. – Control stack average temperature.– Control stack temperature gradients.
• Combustor cleans up exhaust– MUST BE CAREFUL WITH DESIGN OF COMBUSTOR.
– Fuel processor• Other than Natural Gas, SOFC needs some fuel processing• Greatly simplified versus a PEM, however.
28
Mobile SOFC Balance of Plant
29
Stationary SOFC BOP
30
The System PEPower Electronics–Load management
– Fuel Must Lead ON Load, and Must Lag OFF Load
–Supply a buffer between required load power and fuel cell dynamics (Fuel processor limits transient performance).•Control stack loading to a safe rate.•Maintain supplemental energy storage.
– Battery based hybrid system•Generate stable AC power to user.
31
Fuel Cell Power Electronics
Onan Hybrid QD Electronics
32
Affordable Hybrid Fuel Cell SystemAffordable Hybrid Fuel Cell System
Ceramic solid-oxide technology – Clean, efficient, silent power– 10 kW power system– Improved emissions– Improved efficiency– Maintenance benefits over engine
gensets– Longer life– Lower costs over longer term
Key Markets– RV– Commercial mobile– Telecommunications standby– Distributed Generation– Residential
Ceramic solid-oxide technology – Clean, efficient, silent power– 10 kW power system– Improved emissions– Improved efficiency– Maintenance benefits over engine
gensets– Longer life– Lower costs over longer term
Key Markets– RV– Commercial mobile– Telecommunications standby– Distributed Generation– Residential
Packaged SystemPackaged SystemFuel Cell ModuleFuel Cell Module
33
Fuel Cell System Mock-Up
Operator controls
Power Module
Fuel cell boost
BOP Section
635mm(25”)
915mm(36”)
635mm(25”)
34
Fuel Cell System Components
Power Unit
Display Panel Inverter / Charger
Transfer Switch
35
36
37
SECA is a vital part of the DOE’s ultimate goal, called Vision 21
– Clean, efficient electric power generation with ~60% Efficiency on coal ~70% on natural gas 2015.
– Think about it, ~60% efficient electric power production on Coal or Renewable Bio-Fuels!
– Can also include Hydrogen separation.
Ultimate Goal of SECA Clean Coal and/or Clean Renewables
Fuel Cell
38