1. Assessment of Fuel Cell Applications for
Critical Industrial Processes
presented by
Dan Birleanu
ERS
ACEEE Summer Study on Energy Efficiency in Industry
August 2003
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2. Assessment of Fuel Cell Applications for
Critical Industrial Processes
Power Quality and Critical Applications
Premium Power Equipment
Overview of Fuel Cell Technology
Fuel Cells Current Challenges
Feasibility Assessment Methodology
Case Study: Semiconductor Crystal Growth Facility
Conclusions
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3. Power Quality and Critical Applications
High Voltage Spikes and Surges
Low Voltage Electrical Noise
Harmonics
Voltage Fluctuations
Power Outages and Interruptions
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4. Power Quality and Critical Applications
(cont.)
Medical Treatment Facilities
Advanced Manufacturing Facilities
Communication and Data Centers
High-Security Facilities
Remote Sites
Air Traffic Control Facilities
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5. Premium Power Equipment
Requirements
Availability: Respond in Milliseconds without Significant Distortions
Reliability: 99.999…%
Maintainability: Easily Accessible while Maintaining Availability
Technologies
Energy Storage: Batteries, Flywheel, Super-capacitors, Super-conducting
Magnetic Energy Storage (SMES), Compressed Air Storage (CAES)
Back-up Power: Generator Sets, Micro-turbines, Small Gas Turbines, Fuel
Cells.
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6. Overview of Fuel Cell Technology
Size Range
Fuel
Capacity
Efficiency
Environment
Other
Features
Estimative
Cost
Commercial
Status
Strengths
Weaknesses
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PAFC
100-200 kW
Hydrogen, Natural
Gas, Landfill Gas,
Digester Gas, Propane
0.1-0.3 W/cm2
36-42%
Nearly zero emissions
(when running on H2)
Cogeneration (Hot
Water)
$4,000 per kW
PEMFC
3-250 kW
Natural Gas,
Hydrogen, Propane,
Diesel
0.6-0.8 W/cm2
30-40%
Nearly zero emissions
(when running on H2)
Cogeneration (Hot
Water)
$5,000 per kW
Available
Quiet
Low Emissions
High Efficiency
Proven Reliability
High Cost
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MCFC
250 kW - 10 MW
Natural Gas,
Hydrogen
SOFC
1 kW - 10 MW
Natural Gas, Hydrogen,
Landfill Gas, Fuel Oil
0.3-0.5 W/cm2
45-60%
Nearly zero emissions
(when running on H2)
Cogeneration (Hot
Water or Steam)
$1,300 per kW (Desired)
Pre-commercial
0.1-0.2 W/cm2
45-55%
Nearly zero emissions
(when running on H2)
Cogeneration (Hot
Water or Steam)
$2,000-$4,000 per
kW
Pre-commercial
Quiet
Low Emissions
High Efficiency
Quiet
Low Emissions
High Efficiency
Quiet
Low Emissions
High Efficiency
High Cost
Need to Demonstrate
Limited Field Test
Experience
High Cost
Need to Demonstrate
High Cost
Need to Demonstrate
Pre-commercial
© 2003 ERS, Inc.

7. Fuel Cells Current Challenges
PAFC
PEMFC
MCFC
SOFC
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Reduction of manufacturing and operating costs
Further improved durability and reliability
Reducing space requirements
Improving heat recovery potentials
Staying economically competitive with other fuel cell technologies as they mature
Reduction of manufacturing and operating costs
Understanding the influences of operating conditions
Understanding transient load response
Improve fuel processing to accommodate different type of fuels
Improve cold-start
Catalyst loading
Reduction of manufacturing and operating costs
Reducing the rate of cathode dissolution
Improve retention of the electrolyte
Improving resistance to catalyst poisoning
Reduction of manufacturing and operating costs
Identifying configurations that require less stringent material purity specifications
Use of less exotic alloys, which is directly related to the high operating temperature
Maintenance of seals and manifolds under severe thermal stresses
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8. Feasibility Assessment Methodology
Description of the Operation and Need for Premium Power
Applicable End Uses and Equipment
Utility Usage
Outage and Low Power Quality History
Technical Impacts of Downtime
Cost Impacts of Outage and Low Power Quality Incidents
Capital Project Financing and Investment Requirements
Assessment of Power Quality
Critical Equipment Service Lines
Tolerance Range of Critical Equipment
Impact Assessment of Power Quality
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9. Feasibility Assessment Methodology
(cont.)
Assessment of Economic Losses Associated with Power
Reliability and Power Quality Problems
Estimates of Economic Impacts
Technical and Economic Scenarios
Research and Review of the Premium Power Systems
Technical Options
Review of Premium Power Systems
Considered Technologies: Features and Advantages
Preliminary Technical and Economic Screening of Options
Simplified Estimates of Energy Impacts
Simplified Estimates of Costs
Simplified Estimates of Economic Impacts
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10. Feasibility Assessment Methodology
(cont.)
Preparation of Conceptual Design for Cost-Effective
Application
Site-Specific Systems Components
Desired Location Requirements
Detailed Conceptual Design
System Cost Estimation
Detailed Energy, Environmental and Economic Analyses
System Modeling
Environmental Impact
Life Cycle Cost Analyses
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11. Case Study: Semiconductor Crystal
Growth Facility
Molecular Beam Epitaxy (MBE) Process
Facility Descriptors
Demand: 2.5 MW
Critical Demand: 1.5 MW
Energy Usage: 20 million kWh annually
Two Separate Feeding Circuits from the Utility Network
UPS Batteries Capacity: 600 kW
Emergency Generators Capacity: 1.5 MW
Critical Systems
Ultra-High Vacuum System
Heating System (Crystal Growth Process @ 1,700 F)
Cooling System (1,700 Tons)
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12. Case Study: Semiconductor Crystal
Growth Facility (cont.)
Power Quality Incidents
Seven Separate Power Outages in 2001
Voltage Sags
Over Voltages
Impact of Power Quality Incidents
Shutdown of Crystal Growth Process
Process Resume Takes Several Hours
Labor Costs: $50,000 per hour
Material Losses: up to $500,000 per hour
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13. Case Study: Semiconductor Crystal
Growth Facility (cont.)
PAFC
PEMFC
MCFC
SOFC
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Proven reliability: installations in different locations all over the world with
many hours of successful operation
Commercially available in sizes that are attractive for the facility (200 kW)
For premium power, requires a reliable source of fuel
To make it highly cost-effective, requires cogeneration opportunities - which
may not be present
Not sufficiently proven for this application
Commercially available in sizes too small (maximum 50 kW)
For premium power, requires a reliable source of fuel
To make it highly cost-effective, requires cogeneration opportunities - which
may not be present
Not sufficiently proven for this application
Still in the pre-commercial stage
For premium power, requires a reliable source of fuel
Can produce steam, which could be used in absorption chillers – would require
chiller replacement
Not sufficiently proven for this application
Still in the pre-commercial stage
For premium power, requires a reliable source of fuel
Can produce steam, which could be used in absorption chillers – would require
chiller replacement
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14. Case Study: Semiconductor Crystal
Growth Facility (cont.)
Selected Fuel Cell System: UTC Fuel Cells PC25
Rated electrical Capacity: 200 kW/235 kVA
Thermal Capacity: 900,000 Btu/h @ 140 F
Efficiency (LHV): 37% Electric and 50% Thermal
Natural Gas Consumption: 2,100 cu.ft./hour
Emissions: <2 ppm CO, <1 ppm NOx, negligible SOx
Proposed Premium Power System Characteristics and Cost
Integration of the Fuel Cells with the Existing Back-up System
Eight (8) Fuel Cell Units
Fuel Cells Will Operate 8,000 hours/year
Total Estimated Cost: $9,600,000
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15. Case Study: Semiconductor Crystal
Growth Facility (cont.)
16
Payback Pe riod [ye ars]
14
12
10
8
6
4
2
0
$500,000
$750,000
$1,000,000
$1,250,000
$1,500,000
$1,750,000
$2,000,000
Total Annual Cost of Losse s Due to Power Q uality Issue s
Payback Period for the Fuel Cell System vs. Cost of Losses
Average Prices (Northeast): Natural Gas – $6.38/ccf and Electricity – $0.0772/kWh
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16. Conclusions
PAFC and PEMFC Could Provide Clean and Reliable
Power for Critical Industrial Applications
Installation Costs Represent a Considerable Barrier to
Widespread Commercialization of the Available Fuel Cell
Systems
Cost-effectiveness of the Large Fuel Cell Based Premium
Power Application Rises in the Probability that Major
Events with High Impact on Company’s Revenues Occur
Very Critical Operations (Communication/Data Centers,
Financial Transaction Operations, High-Tech
Manufacturing Facilities) are the most Suitable
Applications for Future Implementation of These Systems
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17. Assessment of Fuel Cell Applications for
Critical Industrial Processes
Thank you!
Questions?
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