Fuel Cell

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Fuel Cell

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Fuel Cell Heat.JMH -- 20/april/05 3:30 pm I ve rearranged some of the nick s -- it is more in line with the flow of the process. I ve taken some things ... – PowerPoint PPT presentation

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Title: Fuel Cell


1
Fuel Cell
Heat
.JMH -- 20/april/05 330 pm Ive rearranged some
of the nick slides -- it is more in line with the
flow of the process. Ive taken some things
out. Ive made the background with header
footer on all but Title slide I added the PFD
repeatedly in nicks section to bring the viewer
back home Ive partially covered the non-circled
parts of the PFD when showing a new section Ive
enlarged all the PFD images to max I put some of
your pictures here there Ive added the Turn
it over introductions Ive revised and corrected
the fuel cell details
2
Fuel Cell Design
  • ENCH 340
  • Spring, 2005
  • UTC

3
Technical and EconomicAspects of a 25 kW Fuel
Cell
  • Chris Boudreaux
  • Jim Henry, P.E.
  • Wayne Johnson
  • Nick Reinhardt

4
Technical and EconomicAspects of a 25 kW Fuel
Cell
  • Chemical and Thermodynamic Aspects
  • Investigate the design of
  • --a 25 kW Fuel Cell
  • --Coproduce Hydrogen
  • --Grid parallel
  • --Solid Oxide Electrolyte

Our Competence
Not Our Competence
5
Outline
  • Introduction to the project
  • Process Description
  • Process Equip. Design
  • Economic Analysis

6
Introduction
  • Overall Reaction
  • Methane Air --gt Electricity
  • Hydrogen

Heat CO2
7
Introduction
Gas
Reformer
Water
SynGas
Electricity
Air
Fuel Cell
Heat
POC
Hydrogen
Pressure Swing Absorption
Exhaust
8
Fuel Cell-Chemistry
SynGas
POC
H2
H2
CO
H2O
CO2
CO
O-
O-
Air
Air
O2 N2
Solid Oxide Electrolyte Is porous to O-
9
Fuel Cell-Electricity
Electrons
SynGas
POC
H2
H2O
CO2
CO
Load
O-
O-
Air
Air
O2 N2
10
Fuel Cell-Challenges
SynGas
POC
H2
Hot SynGas
H2
CO
H2O
CO2
CO
Recover H2
O-
O-
Air
Air
O2 N2
Hot Air
Recover Heat
11
Process DescriptionTurn it over to Nick
Reinhardt
12
SOFC PFD
13
Fuel Preparation - 100
14
Desulfurizer (DS 101)
  • 2 ppm H2S in natural gas feed
  • H2S removed in DS-101 with disposable carbon
    filters
  • 10 of CH4 fed to combustor
  • 90 of CH4 fed fuel humidifier

15
Fuel Humidifier (FH 102)
  • 1.25 Kmol H20 per Kmol CH4 fed to FH-102
  • Heat provided from combustor exhaust

16
Fuel Preheater (HX 103)
  • Heat provided from fuel cell exhaust

17
Reformer (R 104)
  • Equilibrium determined to be
  • 85 CH4 ? CO
  • 15 CH4 ? CO2
  • CH4 H2O ? CO 3H2
  • CH4 2H2O ? CO2 4H2
  • Heat provided from reaction in combustor

18
Combustor (COMB 105)
  • Extent of reaction for combustion assumed to be
    100
  • CH4 2O2 ? CO2 2H2O
  • Necessary O2 provided from fuel cell air exhaust

19
SOFC PFD
20
Air Handling and WGS - 200
21
Air Compressor (COMP 224)
  • Air intake for the system
  • 6.65 standard cubic meters per minute flow

22
Air Preheater (HX 223)
  • Heat provided by water gas shift exhaust

23
Water Gas Shift (WGS 222)
  • CO H2O ? CO2 H2
  • Equilibrium determined to be 94

24
Air Side Heat Recovery (HX 221)
  • Heat provided by combustor exhaust

25
SOFC PFD
26
Fuel Cell - 300
27
Fuel Cell (FC 331)
28
SOFC PFD
29
Post Processing
30
Fuel Exhaust Condenser (HX 443)
  • Uses external cooling source
  • Condenses process water from exhaust gases
  • Condensed water flows to WP-441
  • Non-condensible exhaust flows to comp-445 and PSA
    system
  • 99.5 of water is condensed

31
Chiller (Ref 446)
  • Provides cold water utility for HX-443
  • Supply temp 0C
  • Return temp 50C
  • Rate 1.8 gpm
  • Cooling 35,500 kJ/hr (9.9kW)
  • Power 2.4 kW to run

32
PSA Compressor (COMP 445)
  • Provides dried, compressed exhaust gas to the PSA
    system.
  • 2 stage compressor

33
Pressure Swing Adsorber (PS 442)
  • Uses custom adsorbant to purify hydrogen
  • 80-90 recovery possible
  • 99.9 purity on the product gas achievable with
    slight recovery cost
  • Delivery pressure 20 bar
  • Recovered Hydrogen .177 kmol/hr _at_ 90

34
Hydrogen Compressor (COMP 447)
  • Produced compressed hydrogen for sale
  • Multi-stage compressor
  • Pressure input 2-20 bar
  • Pressure output 200 bar

35
Water Purifier (WP 441)
  • Basic cartridge filtration of incoming water
    (either city supply or process supply)
  • Excess process water discharged to city sewer

36
Water Pump (P 444)
  • Supplies water to section 100 fuel humidifier

37
Process and Equipment DesignTurn it over to
Chris Boudreaux
38
SOFC PFD
39
(No Transcript)
40
(No Transcript)
41
Equipment Assumptions
  • All equipment was assumed to be stainless steel

42
Heat Exchangers
  • 10 approach temperature was used
  • q UAF?Tlm
  • F 0.9
  • U 30 W/m2C
  • ?Tlm (?T2 ?T1) / ln(?T2 / ?T1)

43
Pumps and Compressors
  • Power mz1RT1(P2/P1a 1)/a
  • T1 inlet temp
  • R Gas Constant
  • Z1 compressibility
  • m molar flow rate
  • a (k-1)/k
  • k Cp / Cv

44
Other
  • PSA, WGS, and desulfurizer have purchased
    internals

45
Economic AnalysisTurn it over to Wayne Johnson
46
Economic Components
  • Capital Costs
  • Operating Costs
  • Income Generated
  • Payback Period
  • Return on Investment

47
Capital Cost Assumptions
  • Cap Cost Program
  • Stainless Steel
  • Minimum Size Basis for all components

48
Capcost Output
49
Capital Costs
50
Sizing Adjustments
  • Equation from Text
  • Ca/Cb (Aa/Ab)n
  • Ca Cost of Desired Equipment
  • Cb Cost of Base Equipment
  • Aa Desired Cost Attribute
  • Ab Base Cost Attribute
  • n Cost Exponent (0.6)

51
Sizing Adjustments
  • Ab 450 kilowatts Cb 150,000
  • Aa 1.2 kilowatts n 0.6
  • Total adjusted cost 4,282

52
Adjusted Costs
53
Total Installation
  • Total Equipment cost 51,474
  • Lang factor 4.74 for fluid processing plant
  • Total Installation 243,985

54
Operating Costs
  • Fuel 158,000 BTU/hr
  • 0.158 therms/hr
  • Fuji Hunt price 7.7/therm
  • Labor 24 hr coverage with 4 shifts
  • Average salary 30K
  • Benefits 2x salary
  • Total 240,000 annually
  • Use contract labor

55
Income
  • Electricity 25kW
  • Price 0.05/kWhr
  • Hydrogen 0.18 kmol/hr
  • .35 kg/hr
  • Fuji Hunt price 11.64/kg

56
Total Income vs. Expense
57
Investment Results
  • Non-discounted Payback
  • 7.4 Years
  • Return on Investment
  • 13.5

58
Conclusions
  • Materials are expensive
  • Operation is expensive
  • Electricity costs are low
  • Fuel cell not recommended at this time

59
Questions?
60
Alternative
  • CH4 2H2O CO2 4H2
  • Currently 0.2kmol CH4 0.18kmol of H2
  • Revenue 35,000 in H2 sales
  • Potential revenue at 50 H2 recovery
    70,000

61
Alternative
  • Remove fuel cell
  • Optimize reformer and WGS for H2 generation
  • H2 is only product

62

63
Fuel Cell
Heat
. Objective Develop and demonstrate a 25 kW, grid
parallel, solid oxide fuel cell system that
coproduces hydrogen. , the installation be
configured to simultaneously and efficiently
produce hydrogen from a commercial natural gas
feedstream in addition to electricity. This
ability to produce both hydrogen and electricity
at the point of use provides an early and
economical pathway to hydrogen production. .
Ceramic processing and challenges in the design
and manufacturing process of SOFCs will be
addressed . The amount of hydrogen that the
unit produces may be controlled by the adjusting
the natural gas flow at steady power production
(i.e., adjusting the fuel utilization). A nominal
production rate of 25 kg of hydrogen per day
falls within the expected upper and lower
utilization limits for 25 kW electricity
production. The system produces a hydrogen-rich
exhaust stream that will be purified using a
Pressure Swing Absorption (PSA) unit. The
hydrogen flow and purity are interdependent. It
is expected that purity gt98 is achievable for
flows of 2-3 kg/day. Critical impurities, such as
CO and CO2 will be measured. It is not clear
that this size system makes sense for commercial
production. We are looking at a 25 kW module as a
building block for commercial production to begin
in 2006. The size of the 25 kW module is
estimated to be smaller than a 5 ft cube. The
cost of early commercial systems is expected to
be lt10K/kW
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