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

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

3. Where Do We Get Our Electrical Power From?

4. Where Do We Get Our Electrical Power From?

5. Where Does Our Energy Go?

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

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

8. FUEL CELL VS BATTERY

9. 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

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

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

12. FUEL CELL CONCEPT

13. FUEL CELL TYPES

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

15. Oxygen Reduction Catalyst Structure
GAS DIFFUSION ELECTRODE
SUPPORTED ORR CATALYST

16. FUEL CONSTITUENTS EFFECTS

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

18. 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.

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

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

21. 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

22. 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

23. PHOSPHORIC ACID FUEL CELL

24. 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)

25. 1 kW PEM FUEL CELL

26. CHRYSLER’S FUEL CELL CONCEPT CAR

27. SOLID OXIDE FUEL CELL

28. MOLTEN CARBONATE FUEL CELL
LOAD e
DEPLETED FUEL AND
DEPLETED OXIDANT
PRODUCT GASES OUT
½ O2 + CO2 + 2e CO3
H2 + CO 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-

29. U.S. Coast Guard Bourne, Mass.

30. FCE 1 MW Plant
King County Sewage Treatment Plant

31. 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

32. High Efficiency for Distributed Generation70
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)

33. 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(

34. 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

35. DFC/T Power Plant

36. DFC/T Main Menu Screen

37. 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

38. SSFC DEMONSTRATOR SCHEMATIC

39. ASSEMBLED BALANCE OF PLANT MODULE
PORT SIDE VIEW
STARBOARD SIDE VIEW

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

41. 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

42. 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

43. 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.

44. 1 MW Fuel Cell Module at FCE Manufacturing Facility
(Torrington, CT)
250 kW Direct Fuel Cell Stack

45. 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

46. 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.

47. Phase I Stack Deliverables
A tall kW 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.

48. Atmospheric System Concept

50. 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

51. Future Gen