1. The impact of distributed micro-CHP on energy efficiency
David Peck
Sustainable Energy 2005
27th April 2005

2. Introduction
CFCL background
Micro-CHP vision
Distributed energy
Efficiency
Micro-CHP technology
Why Utilities are interested
CFCL product development

3. CFCL Background
Based in Noble Park (Melbourne), Australia
Established 1992 – ASX IPO July 2004
9000m2 of R&D and prototyping facilities
Pilot solid oxide fuel cell (SOFC) production
100 employees
European subsidiary established Sept 2004

4. Micro-CHP vision
“In the future we can also expect to see far more ‘micro-CHP’ – efficient, small- scale heating and electricity generation systems in homes as well as businesses.”
UK Energy White Paper 2003
“MicroMap calculates different scenarios with up to 12 million micro-CHP systems delivered in Europe by 2020.”
WWF/Fuel Cell Europe 2003

5. Micro-CHP domestic distributed generation
CFCL 1kW micro-CHP

6. Distributed energy resources
Source: European Commission, 2003

7. Energy efficiency of CFCL micro-CHP
CFCL’s micro-CHP unit – heat and
power produced on site
Transmission losses 0 kW, 0%
Energy used to power CHP system 0.5 kW, 20%
Heat recovered used for hot water 1 kW, 40%
45% energy saving using CFCL’s CHP unit instead of a central power plant and gas fired domestic water heater
Electricity generated for use on site 1 kW, 40%
Wasted heat 2.15 kW, 66%
Switchyard
Transmission losses 0.1kW, 10%
Conventional power station
Electrical energy for use on site
1 kW, 30.8%
Electrical energy 1.1 kW, 33.8%
Plus
Domestic gas hot water unit
Wasted heat energy 0.25 kW, 20%
Heat energy 1 kW, 80%
Source: ABARE 2004

8. Micro-CHP technologies
Internal combustion
External combustion
Stirling cycle
Steam - Rankine cycle
PEMFC
SOFC
Fuel cells
CFCL - SOFC

9. Micro-CHP performance
Micro-CHP technology
Electrical efficiency
Power to Heat ratio
Solid Oxide Fuel Cell
40-50%
1:1
PEM Fuel Cell
30-40%
1:2
Internal Combustion
20-30%
1:3
Stirling Engine
10-20%
1:6

10. Commercial micro-CHP units
Make
Country
Type
Price – A$
Senertec
Germany
5 kW IC engine
23,000
Ecopower
4.7 kW IC engine
21,500
Honda Ecowil
Japan
1 kw IC engine
12,500
Whispergen
NZ/UK
0.8 kW Stirling
7,500

11. Why Utilities are interested in micro-CHP
Hedge against losing revenue from micro-CHP emergence
Customer retention in competitive markets
Synergies between electricity and gas businesses
Increase gas sales and reduced seasonality
Reduce peak demand
Relieve network congestion
Energy efficiency / CO2 benefit
Provide customers with lower cost energy
Provide additional services which may be unregulated
Provide higher reliability service
Services to off-grid customers
Support green credentials
Deferred capital investment
Source: Platts, Micropower Conference, UK 2004

12. Government support for micro-CHP
Germany
€5.11c/kwh in-feed bonus
Exemption from mineral oil tax on NG for heating
Energy efficiency targets for new houses UK
VAT reduced from 17.5% to 5%
Recognition of micro-CHP in energy policy
Carbon Trust funding for field trials
Modification of network regulations for small DG
Australia
Energy efficiency targets for new houses – 5 Star, BASIX

13. Fuel Cell Technology (SOFC)
Efficient
Clean
Silent
Electrolyte
(SOFC)
Anode
Cathode
Methane fuel
input
Internal reforming of
methane into hydrogen
and carbon monoxide
Reaction with oxygen ions generates
electricity and forms water vapour
and carbon dioxide exhaust
Air input
Valuable high temperature exhaust heat
DC Electricity Output
800°C Operating Temperature
O2- oxygen ions
Air exhaust
Load
Wide fuel range – NG, LPG, bio-methane, ethanol
High Efficiency – 40 to 50% electrical
Reduced greenhouse gas – up to 60% vs coal

14. CFCL’s SOFC Stack Technology
Stack components – Layer Set
Made up of only 4 components for ease of manufacture and economies of scale
Air Seal:
Glass-ceramic seal
Cell:
Zirconia electrolyte with printed electrodes and gas distribution structure
Pictures of layer set components appear with each mouse click – starting from the bottom
Fuel Seal:
Glass-ceramic seal
Interconnector:
Zirconia plate with electric feed-throughs and printed contact layers

15. CFCL’s SOFC Operation

16. CFCL’s SOFC Stack Technology
Level 1 Sub-stack
Consists of 28 Layer Sets
150 Watt DC electricity output
Versatile building block
Quality control step prior to assembly into larger stacks
28 Layer Sets
in a Level 1

17. CFCL’s SOFC Stack Technology
Level 2 Stack
Consists of up to 14 Level 1’s (total 1~2 kW electrical output)
Multiple stacks can be manifolded together
Suitable for capacities up to 200 kW
Up to 14 Level 1’s
in a Level 2

18. CFCL Product Development
Combined Heat & Power micro-CHP concept
Proof-of-concept prototype
Prototype with it’s covers fitted
Pre-commercial demonstrator

19. CFCL Product Development
Combined Heat & Power micro-CHP concept
Proof-of-concept prototype
Prototype with it’s covers fitted
Pre-commercial demonstrator

20. CFCL Product Development
Combined Heat & Power micro-CHP concept
Proof-of-concept prototype
Prototype with it’s covers fitted
Pre-commercial demonstrator

21. CFCL Product Development
Combined Heat & Power micro-CHP concept
Proof-of-concept prototype
Prototype with it’s covers fitted
Pre-commercial demonstrator

22. Micro-CHP Demonstrator Prototype

23. Micro-CHP prototype on test
Fuel cell stack
Hot water tank
Waste heat recovery
Steam generator & burner
Fuel processor & heat exchanger
Mains power converter

24. Commercialisation of fuel cell micro-CHP
PEMFC & SOFC at advanced stage of development
SOFC uses readily available fuels
PEMFC requires pure hydrogen or on- board reformer with NG
Mass production will reduce cost
Micro-CHP trials – Europe & Japan
CFCL trials – Australia, NZ, Europe