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Molten Carbonate Fuel
Cells
www.MoltenCarbonateFuelCells.com
We provide "Cooler, Cleaner, Greener"
power and energy solutions that also include "Pollution Free
Power" and "Carbon Free
Energy" systems, and all provide "Renewable
Energy Credits." We also offer energy-saving
technologies that may include; Absorption
Chillers, Adsorption Chillers,
Automated Demand Response, Cogeneration,
Demand Response Programs, Demand
Side Management, Energy Master
Planning, Engine Driven
Chillers, Trigeneration and Energy
Conservation Measures.
Cooler,
Cleaner, Greener Power & Energy Solutions
project development services are one of our many specialties.
These projects are Kyoto Protocol compliant and generate clean energy
and significantly fewer greenhouse gas emissions. Unlike most companies,
we are equipment supplier/vendor neutral. This means we help our clients
select the best equipment for their specific application. This approach
provides our customers with superior performance, decreased operating
expenses and increased return on investment.
Renewable
Energy Technologies provides
project development services that generate clean energy and
significantly reduce greenhouse
gas emissions and carbon
dioxide emissions. Included in this are our
turnkey "ecogeneration"
products and services which includes renewable
energy technologies, waste to
energy, waste to watts and waste
heat recovery solutions. Other project development
technologies include; Anaerobic
Digester, Anaerobic Lagoon, Biogas
Recovery, BioMethane, Biomass
Gasification, and Landfill Gas
To Energy, project development services.
Products and services provided by Renewable Energy Technologies includes
the following power and energy project development services:
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Project
Engineering Feasibility & Economic Analysis Studies
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Engineering,
Procurement and Construction
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Environmental
Engineering & Permitting
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Project
Funding & Financing Options; including Equity Investment, Debt
Financing, Lease and Municipal Lease
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Shared/Guaranteed
Savings Program with No Capital Investment from Qualified Clients
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Project
Commissioning
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3rd
Party Ownership and Project Development
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Long-term
Service Agreements
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Operations
& Maintenance
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Green
Tag (Renewable Energy Credit, Carbon Dioxide Credits, Emission
Reduction Credits) Brokerage Services; Application and Permitting
For
more information: call us at: 832-758-0027
We
are Renewable Energy
Technologies specialists and develop clean power and energy projects
that will generate a "Renewable
Energy Credit," Carbon
Dioxide Credits and Emission
Reduction Credits. Some of our products and services solutions
and technologies include; Absorption
Chillers, Adsorption Chillers,
Automated Demand Response, Biodiesel
Refineries, Biofuel Refineries,
Biomass Gasification, BioMethane,
Canola Biodiesel, Coconut
Biodiesel, Cogeneration, Concentrating
Solar Power, Demand Response
Programs, Demand Side
Management, Energy
Conservation Measures, Energy
Master Planning, Engine Driven
Chillers, Geothermal Heatpumps,
Groundsource Heatpumps, Solar
CHP, Solar Cogeneration, Rapeseed
Biodiesel, Solar Electric
Heat Pumps, Solar
Electric Power Systems, Solar
Heating and Cooling, Solar
Trigeneration, Soy Biodiesel, Trigeneration,
and Watersource Heat Pumps.
Types of Fuel Cells
Fuel
cells are classified primarily by the kind of electrolyte they employ.
This determines the kind of chemical reactions that take place in the
cell, the kind of catalysts required, the temperature range in which the
cell operates, the fuel required, and other factors. These
characteristics, in turn, affect the applications for which these cells
are most suitable. There are several types of fuel cells currently under
development, each with its own advantages, limitations, and potential
applications.
What
are Molten Carbonate Fuel Cells?
Molten Carbonate Fuel Cells (MCFC) evolved from work in the 1960's aimed
at producing a fuel cell which would operate directly on coal. While
direct operation on coal seems less likely today, operation on
coal-derived fuel gases or natural gas is viable.
Molten
Carbonate Fuel Cell Design
and Operation
Molten Carbonate Fuel Cells use a molten carbonate salt mixture as its
electrolyte. The composition of the electrolyte varies, but usually
consists of lithium carbonate and potassium carbonate. At the operating
temperature of about 1200°F (650°C), the salt mixture is liquid and a
good ionic conductor. The electrolyte is suspended in a porous,
insulating and chemically inert ceramic (LiA102) matrix.
The
Molten Carbonate Fuel Cell reactions that occur are:
The
anode process involves a reaction between hydrogen and carbonate ions
(CO3=) from the electrolyte which produces water and carbon dioxide
(CO2) while releasing electrons to the anode. The cathode process
combines oxygen and CO2 from the oxidant stream with electrons from the
cathode to produce carbonate ions which enter the electrolyte. The need
for CO2 in the oxidant stream requires a system for collecting CO2 from
the anode exhaust and mixing it with the cathode feed stream.
As
the operating temperature increases, the theoretical operating voltage
for a fuel cell decreases and with it the maximum theoretical fuel
efficiency. On the other hand, increasing the operating temperature
increases the rate of the electrochemical reaction and thus the current
which can be obtained at a given voltage. The net effect for the
Molten Carbonate Fuel Cell is that the real operating voltage is higher than
the operating voltage for the Phosphoric
Acid Fuel Cell at the same current density.
The
higher operating voltage of the Molten
Carbonate Fuel Cell means that
more power is available at a higher fuel efficiency from a Molten
Carbonate Fuel Cell than from a Phosphoric
Acid Fuel Cell of the same electrode area. As size
and cost scale roughly with electrode area, this suggests that a Molten
Carbonate Fuel Cell should be smaller and less expensive than a
"comparable" Phosphoric
Acid Fuel Cell.
The
Molten
Carbonate Fuel Cell also produces excess heat at a temperature
which is high enough to yield high pressure steam which may be fed to a
turbine to generate additional electricity. In combined cycle operation,
electrical efficiencies in excess of 60% (HHV) have been suggested for
mature Molten
Carbonate Fuel Cell systems.
The
Molten
Carbonate Fuel Cell operates at between 1110°F (600°C) and 1200°F
(650°C) which is necessary to achieve sufficient conductivity of the
electrolyte. To maintain this operating temperature, a higher volume of
air is passed through the cathode for cooling purposes.
As
mentioned above, the high operating temperature of the Molten
Carbonate Fuel Cell offers the possibility that it could operate directly on
gaseous hydrocarbon fuels such as natural gas. The natural gas would be
reformed to produce hydrogen within the fuel cell itself.
The
need for CO2 in the oxidant stream requires that CO2 from the spent
anode gas be collected and mixed with the incoming air stream. Before
this can be done, any residual hydrogen in the spent fuel stream must be
burned. Future systems may incorporate membrane separators to remove the
hydrogen for recirculation back to the fuel stream.
At
cell operating temperatures of 1200°F (650°C) noble metal catalysts
are not required. The anode is a highly porous sintered nickel powder,
alloyed with chromium to prevent agglomeration and creep at operating
temperatures. The cathode is a porous nickel oxide material doped with
lithium. Significant technology has been developed to provide electrode
structures which position the electrolyte with respect to the electrodes
and maintain that position while allowing for some electrolyte boil-off
during operation. The electrolyte boil-off has an insignificant impact
on cell stack life. A more significant factor of life expectancy has to
do with corrosion of the cathode.
The
Molten
Carbonate Fuel Cell
operating temperature is about 1200°F (650°C). At this temperature the
salt mixture is liquid and is a good conductor. The cell performance is
sensitive to operating temperature. A change in cell temperature from
1200°F (650°C) to 1110°F (600°C) results in a drop in cell voltage
of almost 15%. The reduction in cell voltage is due to increased ionic
and electrical resistance and a reduction in electrode kinetics. Molten
Carbonate Fuel Cells (MCFCs) are currently being developed for natural
gas and coal-based power plants for electrical utility, industrial, and
military applications. Molten
Carbonate Fuel Cells are high-temperature fuel cells that use an
electrolyte composed of a molten carbonate salt mixture suspended in a
porous, chemically inert ceramic lithium aluminum oxide (LiAlO2)
matrix. Since they operate at extremely high temperatures of 650°C
(roughly 1,200°F) and above, non-precious metals can be used as
catalysts at the anode and cathode, reducing costs.
Improved
efficiency is another reason Molten
Carbonate Fuel Cells offer significant cost reductions
over Phosphoric Acid Fuel Cells
(PAFCs). Molten Carbonate Fuel
Cells can
reach efficiencies approaching 60 percent, considerably higher than the
37-42 percent efficiencies of a phosphoric acid fuel cell plant. When
the waste heat is captured and used, overall fuel efficiencies can be as
high as 85 percent.
Unlike
alkaline, phosphoric acid, and polymer electrolyte membrane fuel cells, Molten
Carbonate Fuel Cells don't require an external reformer to convert more energy-dense
fuels to hydrogen. Due to the high temperatures at which Molten
Carbonate Fuel Cells operate,
these fuels are converted to hydrogen within the fuel cell itself by a
process called internal reforming, which also reduces cost.
Molten
Carbonate Fuel Cells are not prone to carbon monoxide or carbon dioxide
"poisoning" —they can even use carbon oxides as
fuel—making them more attractive for fueling with gases made from
coal. Because they are more resistant to impurities than other fuel cell
types, scientists believe that they could even be capable of internal
reforming of coal, assuming they can be made resistant to impurities
such as sulfur and particulates that result from converting coal, a
dirtier fossil fuel source than many others, into hydrogen.
The
primary disadvantage of current Molten
Carbonate Fuel Cell technology is durability. The high
temperatures at which these cells operate and the corrosive electrolyte
used accelerate component breakdown and corrosion, decreasing cell life.
Scientists are currently exploring corrosion-resistant materials for
components as well as fuel cell designs that increase cell life without
decreasing performance.
Phosphoric Acid Fuel Cells
Phosphoric
Acid Fuel Cells use liquid phosphoric acid as an electrolyte—the acid
is contained in a Teflon-bonded silicon carbide matrix—and porous
carbon electrodes containing a platinum catalyst. The chemical reactions
that take place in the cell are shown in the diagram to the right.
The
Phosphoric Acid Fuel Cell (PAFC) is considered the "first
generation" of modern fuel cells. It is one of the most mature cell
types and the first to be used commercially, with over 200 units
currently in use. This type of fuel cell is typically used for
stationary power generation, but some phosphoric
acid fuel cells have been used to power
large vehicles such as city buses.
Phosphoric
Acid Fuel Cells are more tolerant of impurities in fossil fuels that have been reformed
into hydrogen than Proton
Exchange Membrane Fuel Cells, which are easily "poisoned" by
carbon monoxide—carbon monoxide binds to the platinum catalyst at the
anode, decreasing the fuel cell's efficiency. They are 85 percent
efficient when used for the co-generation of electricity and heat, but
less efficient at generating electricity alone (37 to 42 percent). This
is only slightly more efficient than combustion-based power plants,
which typically operate at 33 to 35 percent efficiency. Phosphoric
acid fuel cells
are also
less powerful than other fuel cells, given the same weight and volume.
As a result, these fuel cells are typically large and heavy. Phosphoric
acid fuel cells
are
also expensive. Like Proton
Exchange Membrane Fuel Cells, Phosphoric
acid fuel cells
require an expensive platinum
catalyst, which raises the cost of the fuel cell. A typical phosphoric
acid fuel cell costs between $4,000 and $4,500 per kilowatt to operate.
Alkaline Fuel Cells
Alkaline
Fuel Cells (AFCs) were one of the first fuel cell technologies
developed, and they were the first type widely used in the U.S. space
program to produce electrical energy and water onboard spacecraft. These
fuel cells use a solution of potassium hydroxide in water as the
electrolyte and can use a variety of non-precious metals as a catalyst
at the anode and cathode. High-temperature Alkaline
Fuel Cells operate at temperatures
between 100°C and 250°C (212°F and 482°F). However, newer AFC
designs operate at lower temperatures of roughly 23°C to 70°C (74°F
to 158°F)
Alkaline
Fuel Cells' high performance is due to the rate at which chemical reactions take
place in the cell. They have also demonstrated efficiencies near 60
percent in space applications.
The
disadvantage of this fuel cell type is that it is easily poisoned by
carbon dioxide.
In fact, even the small amount of CO2
in the air can affect this cell's operation, making it necessary to
purify both the hydrogen and oxygen used in the cell. This purification
process is costly. Susceptibility to poisoning also affects the cell's
lifetime (the amount of time before it must be replaced), further adding
to cost.
Cost
is less of a factor for remote locations such as space or under the sea.
However, to effectively compete in most mainstream commercial markets,
these fuel cells will have to become more cost-effective. Alkaline
Fuel Cells have been shown to maintain sufficiently stable operation for more than
8,000 operating hours. To be economically viable in large-scale utility
applications, these fuel cells need to reach operating times exceeding
40,000 hours, something that has not yet been achieved due to material
durability issues. This is possibly the most significant obstacle in
commercializing this fuel cell technology.
Direct Methanol Fuel Cells
Most
fuel cells are powered by hydrogen, which can be fed to the fuel cell
system directly or can be generated within the fuel cell system by
reforming hydrogen-rich fuels such as methanol, ethanol, and hydrocarbon
fuels. Direct Methanol Fuel
Cells (DMFCs), however, are powered by pure
methanol, which is mixed with steam and fed directly to the fuel cell
anode.
Direct
Methanol Fuel Cells do not have many of the fuel storage problems
typical of some fuel cells since methanol has a higher energy density
than hydrogen—though less than gasoline or diesel fuel. Methanol is
also easier to transport and supply to the public using our current
infrastructure since it is a liquid, like gasoline.
Direct
Methanol Fuel Cell technology is relatively new compared to that of fuel
cells powered by pure hydrogen, and Direct
Methanol Fuel Cell research and development are
roughly 3-4 years behind that for other fuel cell types.
Proton
Exchange Membrane (PEM) Fuel Cells
Proton
Exchange Membrane Fuel Cells - sometime called a Polymer
Electrolyte Membrane Fuel Cell — deliver high power density and offer the
advantages of low weight and volume, compared to other fuel cells. Proton
Exchange Membrane Fuel Cells use a solid polymer as an electrolyte and porous carbon
electrodes containing a platinum catalyst. They need only hydrogen,
oxygen from the air, and water to operate and do not require corrosive
fluids like some fuel cells. They are typically fueled with pure
hydrogen supplied from storage tanks or onboard reformers.
Proton
Exchange Membrane Fuel Cells operate at relatively low temperatures,
around 80°C (176°F). Low temperature operation allows them to start
quickly (less warm-up time) and results in less wear on system
components, resulting in better durability. However, it requires that a
noble-metal catalyst (typically platinum) be used to separate the
hydrogen's electrons and protons, adding to system cost. The platinum
catalyst is also extremely sensitive to CO poisoning, making it
necessary to employ an additional reactor to reduce CO in the fuel gas
if the hydrogen is derived from an alcohol or hydrocarbon fuel. This
also adds cost. Developers are currently exploring platinum/ruthenium
catalysts that are more resistant to CO.
Proton
Exchange Membrane Fuel Cells are used primarily for transportation applications and some
stationary applications. Due to their fast startup time, low sensitivity
to orientation, and favorable power-to-weight ratio, Proton
Exchange Membrane Fuel Cells are
particularly suitable for use in passenger vehicles, such as cars and
buses.
A
significant barrier to using these fuel cells in vehicles is hydrogen
storage. Most fuel cell vehicles (FCVs) powered by pure hydrogen must
store the hydrogen onboard as a compressed gas in pressurized tanks. Due
to the low energy density of hydrogen, it is difficult to store enough
hydrogen onboard to allow vehicles to travel the same distance as
gasoline-powered vehicles before refueling, typically 300-400 miles.
Higher-density liquid fuels such as methanol, ethanol, natural gas,
liquefied petroleum gas, and gasoline can be used for fuel, but the
vehicles must have an onboard fuel processor to reform the methanol to
hydrogen. This increases costs and maintenance requirements. The
reformer also releases carbon dioxide (a greenhouse gas), though less
than that emitted from current gasoline-powered engines.
Solid Oxide Fuel Cells
Solid
Oxide Fuel Cells (SOFCs) use a hard, non-porous ceramic compound as the
electrolyte. Since the electrolyte is a solid, the cells do not have to
be constructed in the plate-like configuration typical of other fuel
cell types. Solid Oxide Fuel Cells
are expected to be around 50-60 percent efficient at
converting fuel to electricity. In applications designed to capture and
utilize the system's waste heat (co-generation), overall fuel use
efficiencies could top 80-85 percent.
Solid
Oxide Fuel Cells operate at very high temperatures—around 1,000°C
(1,830°F). High temperature operation removes the need for
precious-metal catalyst, thereby reducing cost. It also allows Solid
Oxide Fuel Cells
to
reform fuels internally, which enables the use of a variety of fuels and
reduces the cost associated with adding a reformer to the system.
Solid
Oxide Fuel Cells are also the most sulfur-resistant fuel cell type; they can tolerate
several orders of magnitude more sulfur than other cell types. In
addition, they are not poisoned by carbon monoxide (CO), which can even
be used as fuel. This allows Solid
Oxide Fuel Cells to use gases made from coal.
High-temperature
operation has disadvantages. It results in a slow startup and requires
significant thermal shielding to retain heat and protect personnel,
which may be acceptable for utility applications but not for
transportation and small portable applications. The high operating
temperatures also place stringent durability requirements on materials.
The development of low-cost materials with high durability at cell
operating temperatures is the key technical challenge facing this
technology.
Scientists
are currently exploring the potential for developing lower-temperature Solid
Oxide Fuel Cells operating at or below 800°C that have fewer durability problems
and cost less. Lower-temperature Solid
Oxide Fuel Cells produce less electrical power,
however, and stack materials that will function in this lower
temperature range have not been identified.
What
are Regenerative Fuel Cells?
Regenerative Fuel Cells produce electricity from hydrogen and oxygen and
generate heat and water as byproducts, just like other fuel cells.
However,
Regenerative Fuel Cells can also use electricity from
solar power or some other source to divide the excess water into oxygen
and hydrogen fuel—this process is called "electrolysis."
This is a comparatively young fuel cell technology being developed by
NASA and others.
For
more information: call Monty Goodell at: (832) 758 - 0027
* Some of the above information from the Department
of Energy website with permission.
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