TECHNOLOGY AND APPLICATION OVERVIEW OF

FUEL CELLS

by

MANMOHAN SINGH CHANDOLIYARTU KOTA,YIT JAIPUR

Ref. - 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)

ECOLOGICAL CHANGE (MAN-MADE)

……….RESULTED IN THE EVOLUTION OF MANKIND

……..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.

(SOURCE, TECHNOLOGY, EFFICIENCY) (ALTERNATIVES, EQUIPMENT, LIFE STYLE)

------------STILL, WE CAN NOT AVOID THE INEVITABLE, BUT WE CAN

DELAY THE SAME.

ENERGY SUPPLY = ENERGY DEMAND

ELECTRIFICATION RATE ( %)

WORLD - 72.8

DEV COUNTRIES - 64.2

OECD - 99.2

INDIA - 43.0

CHINA - 98.6

SRILANKA - 62.0

PAKISTAN - 52.9

BANGLADESH - 20.4.

FOSSIL FUEL

RENEWABLES

OTHER

COAL

OIL

NATURAL GAS

SOLAR PV / THERMAL

HYDRO

WIND

NUCLEAR

BIO - MASS

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

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

Benefits of Fuel Cells

Fuel Cell Type Temp of Operatio

n [oC]

Unit Sizes [kWe]

Most likely applications

Alkaline Fuel Cell (AFC) RT – 100 < 100 Space , Military recently

terrestrial applications

Proton Exchange Membrane Fuel Cell (PEMFC)

RT – 100 0.1 - 100

Portable devices like Lap Tops, Cellular phones, Video Cameras etcDomestic & Dedicated Power (+ heat) Buses, Passenger Cars, Service Vehicles, Railway Locomotives & Streetcars etc

Phosphoric Acid Fuel Cell (PAFC)

100 – 2105 - 200 (also MW sized plants)

Dedicated Power (+ heat), Railways

Molten Carbonate Fuel Cell (MCFC)

650100 - 2,000 (plants up to 100 MW)

Dispersed Power & Utility Power (Combined Cycle -with downstream Steam Turbine)

Solid Oxide Fuel Cell (SOFC)

800-10002.5 – 250(plants up to 100 MW)

Domestic & Commercial (heat and power), Utility Power (combined cycle) Mobile applications for railways

 

Types of Fuel Cells

  PEMFC AFC PAFC MCFC SOFC

Electrolyte Ion ExchangeMembrane

PotassiumHydroxide

Phosphoric Acid

Molten carbonates

CeramicOxides

Catalyst Platinum non platinum

Platinum Nickel Perovskite

Operating Temp 0 C

RT-80 RT-80 180-205 650 800-1000

ElectricalEfficiency(%LHV)

32-40  

50-60 36-42 45-60 50-60

Applications

Cogeneration √ √ √Utility Power     √ √ √

Distributed Power

√ √   √ √

Passenger Vehicles

√ √      

Heavy DutyVehicles 

    √ √  

Portable Power

√ √      

Specialty Power 

√ √      

  PEMFC AFC PAFC MCFC SOFC

Advantages High Power density,Light weight, quick response

Low cost high efficiency,Co tolerant 

Co tolerance up to 1.5%Multi fuel capability

Inexpensive catalystsMulti fuel capability

Efficiencies up to 60%  

Disadvantages Humidification requiredCOIntolerancePlatinum&Membrane pushes the cost upwards 

Requires inlet air scrubbers.CirculatingAlkali 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 commercially 

 

Alkaline Fuel Cell Applications

PEMFC applications

MCFC &DFC applications

SOFC tubular and planer design

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%.

Simple-cycle Atmospheric SOFC Simple-cycle Atmospheric SOFC Cogeneration SystemCogeneration System

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

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

SOFC stack

Part II : BHEL’s Activities in Fuel Cell Area

Fuel Cells at BHELFuel Cells at BHEL (History of Development(History of Development))

1987-1990:1987-1990: Started work on PAFC. Made single cells and Started work on PAFC. Made single cells and small stacks (100-200 cm small stacks (100-200 cm22))

1991: Demonstrated a 1 kW stack (chlor-alkali plant, 40 1991: Demonstrated a 1 kW stack (chlor-alkali plant, 40 cells,with imported bipolar plates, ~400 cmcells,with imported bipolar plates, ~400 cm22))

1995: Demonstrated 5 kW stacks (chlor-alkali plant, 1995: Demonstrated 5 kW stacks (chlor-alkali plant, 80 80 cells, ~900 cm2, Laminated bipolar plates, cells, ~900 cm2, Laminated bipolar plates, 300*400 300*400 mm, Rolled electrodes)mm, Rolled electrodes)

2001: Demonstrated 2*25 kW stacks (chlor-alkali plant, 2001: Demonstrated 2*25 kW stacks (chlor-alkali plant, 160 160 cells / stack, ~1600 cmcells / stack, ~1600 cm22, molded bipolar plates, screen printed , molded bipolar plates, screen printed electrodes) electrodes)

2002:Acquired basic PEMFC technology from IISc,single cell 2002:Acquired basic PEMFC technology from IISc,single cell testing 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 IndiaRailways

•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 IndiaTransportation

 Two Wheeler4 kW systems / 75,000 to 1,00,000

Three Wheeler6-8 kW systems / 25,000 to 50,000

Buses100 kW systems / 1,000 to 5,000

Merchant Navy100-200 kW / 100 to 200

Fuel Cells Application in IndiaStrategic

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 IndiaCommercial establishments

Shops in Malls and Underground bazaars1 to 3 kW systems / around 1,00,000

Small Business Establishments5-10 kW systems / 50,000

Entertainment Industry25-50 kW systems / 500 to 1,000

Hotels, restaurants & Resorts100-200 kW systems / up to 500 units

Hospitals 200-500 kW systems / up to 200 unitsResidential Complexes

50-200 kW systems / 30,000 to 50,000

Part IV : Issues in Fuel Cell Application in DPG

Distributed GenerationDistributed Generation

- Rural (Remote areas)Rural (Remote areas)- Urban ( Hotels ,Hospitals ,Ent.centres, Urban ( Hotels ,Hospitals ,Ent.centres,

Software dev. centres)Software dev. centres)- Strategic (Communication centres, Defense,Strategic (Communication centres, Defense,

Chemicals and Pharmaceutical plants)Chemicals and Pharmaceutical plants)

Fuel options Fuel options

Urban :- Hydrogen,NG,Methanol,LPG,Urban :- Hydrogen,NG,Methanol,LPG,

Di-gasDi-gas

Rural :- Ethanol ,BiogasRural :- Ethanol ,Biogas

Strategic:- Hydrogen, NG, LPG, Methanol Strategic:- Hydrogen, NG, LPG, Methanol

Technology of fuel cells will depend upon the type of fuel availableTechnology of fuel cells will depend upon the type of fuel available

Capacity /Duty cycleCapacity /Duty cycleUrban/StrategicUrban/Strategic – – High Power CapacityHigh Power Capacity

– – Base Load Base Load (High temp.Fuel Cells)(High temp.Fuel Cells)

Rural Rural – – Low Power Capacity Low Power Capacity

– – Cyclic Load Cyclic Load (Low temp.Fuel Cells)(Low temp.Fuel Cells)

No.of start stops will determine the life cycle of HT fuel cells.

Other IssuesOther Issues Starting power - Rural area (Black start)Starting power - Rural area (Black start) Others (Brown start)Others (Brown start) Cost Factor - Still not affordable Cost Factor - Still not affordable

without Govt.subsidy without Govt.subsidy Market Size - Traditional tussle between Market Size - Traditional tussle between cost and volumecost and volume Op.& Maint. - Being high technology itemOp.& Maint. - Being high technology item requires careful handlingrequires 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 FUEL’S

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

ON BOARD LIQUIFIED H2

ON BOARD REFORMER

ON -BOARD METAL HYDRIDES

FUEL CELL POWER STACK

VEHICLE PROPULSION

SYSTEM

FROM GROUND BASED FUEL

INFRASTRUCTURE (EXTERNAL REFORMATION)

GASOLENEMETHANOL

HYDRIDE REPLENISHMENT FROM GROUND SOURCES

HYDROGEN

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 - NECAR 4

COMPRESSED HYDROGEN - NECAR 4a

METHANOL - NECAR 5 & JEEP COMMANDER

METAL HYDRIDE & - CHRYSLER NATRIUM SODIUM BOROHYDRIDE

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

TOYOTA COMPRESSED HYDROGEN - FCHV (KLUGER V)

HONDA COMPRESSED HYDROGEN - FCX

GM COMPRESSED HYDROGEN - 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 FutureThe Future

Despite all these difficulties, the Despite all these difficulties, the

Governments all over the world are Governments all over the world are

pouring in money for pouring in money for BreakthroughsBreakthroughs

since this eco friendly technology could since this eco friendly technology could

be the ULTIMATE WINNER !be the ULTIMATE WINNER !

Thank You