Fuel Cell Primer Presented to Ridgefield High School December 15,2006

Who is Fuel Cell Energy? IPO in 1992 Corporate Offices in Danbury, CT Manufacturing in Torrington, CT 300+ Employees

Where Do We Get Our Electrical Power From?

Where Do We Get Our Electrical Power From?

Where Does Our Energy Go?

Power Demand, High Power Cost, Grid Constraints & Environmental Impact

WHAT IS A FUEL CELL? “Fuel cells are electrochemical devices that convert chemical energy of reaction directly into electrical energy”

FUEL CELL VS BATTERY

FUEL CELL HISTORY SIR WILLIAM GROVE, 1839, REVERSE HYDROLYSIS SIR FRANCIS BACON, 1950s, FUEL CELL STACK LATE 1950s, ALKALINE FUEL CELL FIRST USED IN SPACE PROGRAM 1960s TO PRESENT: USED IN EVERY MANNED SPACE PROGRAM

FUEL CELL CONCEPT CONTINUOUS BATTERY FUEL AND OXIDANT (AIR) SUPPLIED - NEVER NEEDS CHARGING REVERSE HYDROLYSIS - CONVERT HYDROGEN TO WATER

FUEL CELL CONCEPT INCREASE VOLTAGE TO USEFUL LEVELS BUNDLE OR STACK MANY ELECTRODE/ELECTROLYTE ASSEMBLIES TOGETHER BUILD “STACK”

FUEL CELL CONCEPT

FUEL CELL TYPES

Governing Theoretical Background Typical Fuel Cell “V-I Curve”

Oxygen Reduction Catalyst Structure GAS DIFFUSION ELECTRODE SUPPORTED ORR CATALYST

FUEL CONSTITUENTS EFFECTS

FUEL CELL POWER PLANT FUEL CELL POWER PLANT INCLUDES: FUEL CELL STACK FUEL PROCESSING DC-TO-AC POWER CONVERSION

FUEL PROCESSING HYDROGEN IS NOT READILY AVAILABLE AS A NATURAL RESOURCE FuelCell Energy Inc developed molten carbonate fuel cells to utilize existing NG infrastructure and enable combined cycle operation.

FUEL PROCESSING FUEL OF CHOICE NATURAL GAS LNG PROPANE BIOMASS (Anaerobic Digester Gas, ADG) COAL GASIFICATION OTHER

STEAM REFORMING CH3OH + H2O CO2+ 3H2 METHANOL REFORMING ENDOTHERMIC

ALKALINE FUEL CELL Used on Gemini and Apollo missions Still Used on Space Shuttle missions KOH Electrolyte 100C - 200C Not Contaminant Tolerant – CO and CO2 Pure Hydrogen Pure Oxygen Uses less Expensive catalysts, but Fuel Cell Materials are more Exotic due to Corrosive KOH Electrolyte

Apollo Fuel Cells Over 10,000 hours of operation in 18 missions 1.5 kW Apollo Alkaline Fuel Cell power plant Three Fuel Cells operated in parallel

PHOSPHORIC ACID FUEL CELL

IFC’s 200 kW PAFC UNIT Rated Capacity - 200kW / 235kVA Electrical Operation - Grid-connected or Grid-independent Thermal Energy Available - 700,000 Btu/hr Thermal Energy Temperature - 140F hot water (60C) Electrical Efficiency - 40% Total Efficiency (Electric + Heat)- 80% Pollutant Emissions - less than 6 ppmv (total)

1 kW PEM FUEL CELL

CHRYSLER’S FUEL CELL CONCEPT CAR

SOLID OXIDE FUEL CELL

MOLTEN CARBONATE FUEL CELL LOAD e DEPLETED FUEL AND DEPLETED OXIDANT PRODUCT GASES OUT ½ O2 + CO2 + 2e CO3 H2 + CO3 H2O + CO2 + 2e CO3 FUEL IN OXIDANT IN (H2) (O2 , CO2) ANODE CATHODE (POROUS Ni) (POROUS NiO) ELECTROLYTE ION CONDUCTOR Li/K CO3 OVER ALL REACTION: H2 + ½O2 H2O + 2e-

U.S. Coast Guard Bourne, Mass.

FCE 1 MW Plant King County Sewage Treatment Plant

Future Products Designed to Enhance Customer Value Proposition DFC/T MW Grid support Marine/Diesel Ship service, islands DFC/H2 Hydrogen generation SOFC Multiple units, <100 kW

High Efficiency for Distributed Generation 70 DFC®/Turbine Combined Cycle Direct FuelCell® 50 PA/PEM FC EFFICIENCY, %(LHV)) Average U.S. Fossil Fuel Plant = 33% Coal/ Steam Engines Gas Turbines 30 Microturbines 10 0.01 0.1 1 10 100 1000 SYSTEM SIZE (MW)

Unmatched Emissions Performance of DFC Power Plants Average US fossil fuel plant Combined cycle gas turbine Microturbine Fuel cell 24.89 1.2 0.6 0.04 (Pounds of emissions per 1000 kWh NOx, CO, SOx, Hydrocarbon, Particulates) 0.5 1.0 1.5 24.5 25.0 Source: NETL(http://www.eren.doe.gov/der/pdfs/mid_atlantic_conf_02/williams.pdf)

Process Flow Diagram of Sub-MW DFC/T Power Plant Humidifier Natural Gas Anode Cathode DC/AC Inverter Water Fuel Cell Sub-System Oxidizer ~ Exhaust LTR HTR Ambient Air G C T Gas Turbine Sub-System

DFC/T Power Plant

DFC/T Main Menu Screen

FUEL CELL BENEFITS TO US NAVY Greater System Efficiencies Reduced Maintenance Cost Enables Spiral Development Reduced IR and Acoustic Signature Distributed Power Generation Modular Approach to Ship Power Multi-Platform Applicable

SSFC DEMONSTRATOR SCHEMATIC

ASSEMBLED BALANCE OF PLANT MODULE PORT SIDE VIEW STARBOARD SIDE VIEW

PRE-REFORMER PERFORMANCE Exit Gas Composition, % (Dry Basis) 10 kW Scale Lab Reactor(1) 500 kW SSFC Demonstrator(2) H2 23.4 CH4 51.8 CO2 24.2 CO 0.6 Total 100 26.4 50.8 22.4 0.4 100 Desulfurized DF-2 FC-2 FT

Coal-Based SOFC/T Power Plant Objectives Development of large (>100 MWe) SOFC combined cycle fuel cell power plant systems with: At least 50% overall efficiency from coal (higher heating value) Performance to meet DOE specified metrics for degradation, availability, transient testing Power plant cost <$400/kW Include 90% of CO2 separation for carbon sequestration

Cell and Stack Technology Anode Supported, Planar Cell Design Internally Manifolded Stacked Design 28 Cells Per Stack 121cm2 Cell Area This building block approach provides a cost effective process for SOFC power plant fabrication. Four Stacks per 3kW Tower

Coal Based Hybrid SOFC/T System Block Flow Diagram SOFC - Combined Cycle System This innovative SOFC/Turbine hybrid concept is anticipated to provide high system efficiencies > 50% (HHV) using coal derived fuels while sequestering CO2 for low emissions.

1 MW Fuel Cell Module at FCE Manufacturing Facility (Torrington, CT) 250 kW Direct Fuel Cell Stack

SECA 3kW SOFC Prototype System Demonstration Packaged 3-1 System In Operation At NETL Thermally integrated power system Pipeline natural gas fuel Autonomous control Grid connected (parallel) Designed towards applicable codes and standards compliance Packaged 3-1 System

3-1 System Test Demonstration at NETL 3-1 System demonstration at NETL, Morgantown ongoing having operated ~1600 hours. No stack and system related issues identified under this real life, customer environment.

Phase I Stack Deliverables A tall 80-100kW stack tower consisting of these building block units will be constructed to validate design components associated with a multi-stack tower. A stack building block unit representative of the platform area will be fabricated, assembled and tested on simulated coal syngas in accordance with the Fuel Cell Coal-Based Systems Phase I Minimum Requirements. Test results from this representative building block unit will serve as the basis for the phase I performance metric.

Atmospheric System Concept

Carbon Sequestration (Capture) Future Gen Coal Fuel Cell Power Plant C + H2O  CO + H2 Gasification CO + H2O  CO2 + H2 H2O Gas Shift Carbon Sequestration (Capture) Grid Support

Future Gen