1. Main Headquarters: 120 Water Street, Suite 350, North Andover, MA 01845 With offices in: NY, ME, TX, CA, OR www.ers-inc.com
ASSESSMENT OF FUEL CELL
APPLICATIONS FOR CRITICAL
INDUSTRIAL PROCESSES
presented by
Dan Birleanu
ENERGY & RESOURCE SOLUTIONS

2.  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
ASSESSMENT OF FUEL CELL APPLICATIONS
FOR CRITICAL INDUSTRIAL PROCESSES
6/9/2014 2

3.  High Voltage Spikes and Surges
 Low Voltage Electrical Noise
 Harmonics
 Voltage Fluctuations
 Power Outages and Interruptions
POWER QUALITY AND CRITICAL
APPLICATIONS

4.  Medical Treatment Facilities
 Advanced Manufacturing Facilities
 Communication and Data Centers
 High-Security Facilities
 Remote Sites
 Air Traffic Control Facilities
POWER QUALITY AND CRITICAL
APPLICATIONS (CONT.)

5.  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.
PREMIUM POWER EQUIPMENT

6. PAFC PEMFC MCFC SOFC
Size Range 100-200 kW 3-250 kW 250 kW - 10 MW 1 kW - 10 MW
Fuel H ydrogen, Natural
Gas, Landfill Gas,
Digester Gas, Propane
Natural Gas,
H ydrogen, Propane,
Diesel
Natural Gas,
H ydrogen
Natural Gas, H ydrogen,
Landfill Gas, Fuel Oil
Capacity 0.1-0.3 W/cm2
0.6-0.8 W/cm2
0.1-0.2 W/cm2
0.3-0.5 W/cm2
Efficiency 36-42% 30-40% 45-55% 45-60%
Environment Nearly zero emissions
(when running on H 2)
Nearly zero emissions
(when running on H 2)
Nearly zero emissions
(when running on H 2)
Nearly zero emissions
(when running on H 2)
Other
Features
Cogeneration (H ot
Water)
Cogeneration (H ot
Water)
Cogeneration (H ot
Water or Steam)
Cogeneration (H ot
Water or Steam)
Estimative
Cost
$4,000 per kW $5,000 per kW $2,000-$4,000 per
kW
$1,300 per kW (Desired)
Commercial
Status
Available Pre-commercial Pre-commercial Pre-commercial
Strengths Quiet
Low Emissions
H igh Efficiency
Proven Reliability
Quiet
Low Emissions
H igh Efficiency
Quiet
Low Emissions
H igh Efficiency
Quiet
Low Emissions
H igh Efficiency
Weaknesses H igh Cost H igh Cost
Need to Demonstrate
Limited Field Test
Experience
H igh Cost
Need to Demonstrate
H igh Cost
Need to Demonstrate
OVERVIEW OF FUEL CELL
TECHNOLOGY

7. PAFC 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
PEMFC 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
MCFC Reduction of manufacturing and operating costs
Reducing the rate of cathode dissolution
Improve retention of the electrolyte
Improving resistance to catalyst poisoning
SOFC 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
FUEL CELLS CURRENT
CHALLENGES

8.  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
FEASIBILITY ASSESSMENT METHODOLOGY

9.  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
FEASIBILITY ASSESSMENT METHODOLOGY
(CONT.)

10.  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
FEASIBILITY ASSESSMENT METHODOLOGY
(CONT.)

11.  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)
CASE STUDY: SEMICONDUCTOR CRYSTAL GROWTH FACILITY

12.  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
CASE STUDY: SEMICONDUCTOR CRYSTAL
GROWTH FACILITY (CONT.)

13. PAFC  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
PEMFC  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
MCFC  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
SOFC  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
CASE STUDY: SEMICONDUCTOR CRYSTAL
GROWTH FACILITY (CONT.)

14.  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
CASE STUDY: SEMICONDUCTOR CRYSTAL
GROWTH FACILITY (CONT.)

15. CASE STUDY: SEMICONDUCTOR CRYSTAL
GROWTH FACILITY (CONT.)
0
2
4
6
8
10
12
14
16
$500,000 $750,000 $1,000,000 $1,250,000 $1,500,000 $1,750,000 $2,000,000
Total Annual Cost of Losses Due to Power Quality Issues
PaybackPeriod[years]
Payback Period for the Fuel Cell System vs. Cost of Losses
Average Prices (Northeast): Natural Gas – $6.38/ccf and Electricity – $0.0772/kWh

16.  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
CONCLUSIONS