1. UNESCO Desire – Net project Molten Carbonate Fuel Cells: an opportunity for decentralized generation an opportunity for decentralized generation Angelo Moreno, Viviana Cigolotti ENEA – Hydrogen and Fuel Cell Project moreno@casaccia.enea.itviviana.cigolotti@casaccia.enea.itUNESCO Rome, 16 th April 2007 PART A

2. FC lessons programme 6 June 2006 Hydrogen as energy carrier ENEAMoreno 8 June 2006Fuel CellsENEAMoreno 13 March 2007MCFCENEA Moreno McPhail 14 March 2007MCFC Ansaldo Fuel Cell Parodi 29 March 2007MCFC Ansaldo Fuel Cell Capobianco 16 April 2007 MCFC System configurations ENEA Moreno Cigolotti PEM/SOFC lessons in planning

3. Summary PART A MCFC: synthesis of main characteristicsMCFC: synthesis of main characteristics Distributed GenerationDistributed Generation MCFC: innovative solution for distributed generation and for energy independence in rural economyMCFC: innovative solution for distributed generation and for energy independence in rural economy PART B Sustainable Strategies based on Best Practices and Best Available TechnologiesSustainable Strategies based on Best Practices and Best Available Technologies Case StudiesCase Studies

4. Hydrogen and Fuel Cells Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

5. No thermal cycles Fuel Cells – principle No thermodynamic limitations (Carnot) Electric power Hydrogen (Fuel) Oxygen (air - oxidant) + heat water Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

6. MCFC – stack Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

7. MCFC – system Fuel Treatment Heat Recovery MCFC Stack System Control Fuel Heat H2OH2O H 2, CO DC AC Air Power Cond. Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

8. ˙ Temperature: 600-650 °C ˙ Efficiency: 45-55% ˙ State of the art technology: 100 kW - 3 MW ˙ Applications: CHP, distributed generation (plants up to 20 MW) MCFC System Characteristics

9. Main characteristics of fuel cells plants High conversion efficiency Efficiency almost independent from load and plant size Rapid load following capability Low environmental impact, low noise and negligible emissions Modular installation to match load and increase reliability Site and Fuel flexibility Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

10. Emissions from different plants CO 2 (g/kWh) NO x (mg/kWh) SO 2 (mg/kWh) Powders (mg/kWh) Hydrocarbons (mg/kWh) 1400 1200 1000 800 600 400 200 0 Coal PlantOil PlantGas PlantFuel Cell Plant 2400 Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

11. Key Technological Targets Current and Expected Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

12. Current and future cost of Stationary Fuel Cell Current $5.000 to $8.000/kW installed $0,085 to $0,065/kWh 40% to 50% efficiency Source: DOE Oak Ridge Nat’l lab, Federal CHP Market and Fuel Cells Future Goal $1.500/kW installed $0,015/kWh >50% efficiency

13. Performance, efficiencies and Costs Source: MTU

14. New Energy Vision Desire-Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic

15. How CHP Saves Energy Desire-Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic

16. It is an Integrated System that: – Supplies electrical or mechanical power – Uses thermal output for space or water heating, dehumidification, or process heat – Is located at/or near user – Can serve a single facility or district energy system – Can range in size from a few kW to 100+MW Combined Heat and Power Desire-Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic

17. USEFUL HEAT COOL ELECTRICAL POWER Combined Cool Heat & Power: CCHP Desire-Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic

18. Realize Decentralized Stationary Consumable Energy Supply To demonstrate Stationary Energy Supply based on Fuel Cells Production on demand of consumable energies Electrical power HeatTrigeneration Cold using decentralized energy sources natural gas other gasified energy carriers regenerative and secondary fuels from biomass and waste

19. It is a Prime Mover which transfers chemical energy of a fuel to electrical energy (LHV efficiency ~ 50%) and high useful heat (LHV efficiency ~ 45%) FUEL CELL It is characterized by Fuel Flexibility

20. Primary fuels: natural gas, gasified primary energy carriers, e. g. gasoline, diesel, etc. coal gas (synthesis gas) Secondary gaseous or gasified Hydrocarbons: biogas from anaerobic digestion (CH 4, CO 2 ) sewage gas, landfill gas, coal mine gas (CH 4, CO 2 ) gasified liquid and solid hydrocarbons, methanol, ethanol, plastic material, etc. biodiesel Synthesis gases (H 2, CO, CH 4, CO 2 ): gases from thermal gasification processes (pyrolysis) using biomass and even waste material purge gases e. g. from refineries, chemical industry

21. Secondary Fuels Characteristics Mostly renewable High Contents of inert components: N 2, CO 2, H 2 O Low heating value Decentrally available, but not everywhere Fluctuating properties Variety of different contaminants

22. High efficiency of fuel cells could optimise the use of secondary fuels High quality utilization of secondary fuels: Trigeneration – electrical energy, thermal energy, cooling energy Saving primary energy sources: Reduction of dependence on primary energy sources Reduction of pollution by greenhouse gases and contaminants Reduction of transport losses by utilization of energy sources in situ and production of consumable energy forms in situ Energy supply for Remote Areas Why Combine Fuel Cell with Secondary Energy Sources

23. MCFC – Fuelling Fuel: H 2 CO (< 20%) Possible sources: Natural gas Light hydrocarbons (butane, methanol, …) Yield: H 2 75% CO 10% CO 2 15% Traces of NH 3, CH 4, SO x … Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

24. MCFC – Fuelling Fuel: H 2 CO (< 20%) Possible sources: Biomass (gasification) Heavy hydrocarbons (distillate, oil) Yield: H 2 20% CO 25% CO 2 10% N 2 40% CH 4, NH 3, SO x, H 2 S, HCl, … Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

25. MCFC – Fuelling Fuel: CH 4 CH 4 Possible sources: Animal manure, sewage sludge Organic fraction of municipal solid waste Residue, By- product Organic industrial waste Yield: CH 4 55-75% CO 2 25-45% H 2 S 0-1,5% N 2 0-10% Traces of H 2,CO, Halogens, Siloxane Reforming Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA H 2 + CO

26. MCFC – Fuelling Fuel: H 2 Possible sources: Animal manure, sewage sludge Organic fraction of municipal solid waste Residue, By- product Yield: H 2 70-90% CO 2 10-30% Traces of sulphides Technology under development Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA

27. MCFC – Fuelling High efficiency conversion CO is a fuel: it will be shifted into H 2 in reforming step MCFC operates efficiently with CO 2 – containing fuels Source: MTU

28. Biomass gasification, Waste pyrolisis, anaerobic digestion,… MCFC ideal for green electricity generation Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA MCFC – Fuelling High efficiency conversion CO is a fuel: it will be shifted into H 2 in reforming step MCFC operates efficiently with CO 2 – containing fuels

29. BUT Fuel gas clean-up is still restrictive: low tolerance and high cost MCFC ideal for green electricity generation Desire-Net Lesson: Molten Carbonate Fuel Cell, 13 March 2007 – Moreno, McPhail ENEA MCFC – Fuelling High efficiency conversion CO is a fuel: it will be shifted into H 2 in reforming step MCFC operates efficiently with CO 2 – containing fuels

30. MCFC – Fuelling Contaminations Sulphur Containing Compounds H 2 S, THT, Mercaptanes, Thioester, Thioether, COS, (SO 2 ) Nitrogen Containing Compounds NH 3, NOx, Amines, N 2 (Gasification) Olefinic Hydrocarbons, Tar R2C=CR2, aromatic HC, undefined products from cracking reactions HalogensF, Cl, Br, I, aliphatic, aromatic Volatile metal organic Compounds R3-Si-O-Si-R3 (Siloxanes) If present most of them can limit the lifetime of the fuel cell system

31. Cell typeTolerance limits AFC 0% CO 2, 0% H 2 S PEFC CO < 10 ppm PAFC CO < 1% v H 2 S + COS < 50 ppm MCFC H 2 S < 10 ppm, COS < 1 ppm HCl < 1 ppm, NH 3 * < 4% v SOFC H 2 S < 1 ppm, HCl < 1 ppm NH 3 < 1000 ppm * Under this % NH 3 is a fuel Desire-Net Lesson: Fuel Cell, 8 June 200 – Angelo Moreno ENEA

32. Available Clean-up Systems Conventional Systems: derived from methods used in chemical industry; technical mature, but expensive in small scales adapted to decentralized CHP systems: Cooling down - drying – condensing – washing – adsorption on activated carbon. H 2 S removal: Adsorption Chemical scrubbers Catalytic oxidation Membrane separation Bio-filters Bio-scrubbers

33. Cost estimations clean-up Gas Clean-up Costs: 0.4 to 8.0! €cts/kWh el regenerative/non-regenerative systems Source: MTU WARNING: Clean-up is a tricky system

34. Methanol MCFC Landfill Gas Coal Mine Gas Coal Gas Synthesis Gas Biogas Natural Gas Sewage Gas MCFC suitable for Regenerative and secondary fuels Gaseous hydrocarbons

35. BIOMASS WASTE MCFC DECENTRALIZED HEAT & POWER GENERATION reducing transmission losses reducing dependence from availability of fuel and/or electricity grid reducing emissions of GHG and pollutant reducing dependence on primary energy carriers imports From the production to the end use Rural economy Energy independence

36. CHP System Sizes  MCFC  MCFC Desire- Net Lesson: Micro and distributed generation and trigeneration, 6 Nov 2006 - Prof. dr. Marija Todorovic

37. Institutional  Hospitals  Universities Commercial  Hotels  Data Centers  Office/Shopping Industrial  Waste Water  Telecom  Food & Beverage  Chemical  Manuf a cturing  Utility  Grid-support MCFC: Target Customers Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

38. * - Allied Business Intelligence’s 2001 Study, “Stationary Fuel Cells: U.S. and Global Early Market Opportunities.” Uses anaerobic digester gas from industrial and municipal waste water treatment facilities Use of “biogas makes this a “renewable” application. Favorable economics – fuel generated by application King County, Kirin Brewery, Terminal Island, City of Fukuoka Over 500 MW Waste Water Fuel Cell Installations by 2011* MCFC: Waste Water Treatment Facilities A Unique Opportunity for market entry Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

39. Wabash River Energy Ltd., Terre Haute, Indiana DFC ® 3000 Headquarters Building (LADWP) Los Angeles, California DFC ® 300 Multi-megawatt systems FCE main realizations King County Wastewater Treatment Facility Renton, Washington DFC ® 1500 Desire-Net Lesson: Fuel Cell, 8 June 2006 – Angelo Moreno ENEA

40. FCE experience: King Country 1 MW power plant First Fuel Switching Application Operated on Natural Gas and Digester Gas Source: FCE

41. King Country 1 MW power plant Overall process flow Source: FCE

42. Types of Gases used by the King Country Fuel Cell Digester GasNatural Gas 90 -100% CH 4 9,3 - 10,3 kWh/Nm 3 Odorised for safety, typically 3 ppm Sulphur, max 20 ppm 50 -80% CH 4 (60% typically) 5,2 - 8,3 kWh/Nm 3 Sulphur present naturally at tens to hundred of ppm It contains Siloxanes Source: FCE

43. Types of Gases used by the King Country Fuel Cell Source: FCE

44. MTU experience: Leonberg Germany Source: MTU

45. AFCO MCFC – Plant Source: AFCO

46. AFCo Demonstration Program Source: AFCO Size (Class)FuelMarket segment First of a kind Series 2TWNatural gas Stationary DG Tecnodemo Series 100Natural gas Stationary DG Hybrid Cycle Series 100Natural gasDG Naval Application Series 2TWDieselNaval Biomass Appication Series 100 Biomass Gassification Waste to Energy H 2 /CO 2 Series 2TWHydrogen MC-WAP NAVAL APU Series 2TWDieselNaval BICEPS 1 MW-classDigester gas BICEPS 1 MW-classLandfill Gas PRIOLO Series 100Syngas H 2 FILSTAT Series 2TWNatural gasDG FURTHER DEMOS MW-classvarious Waste to Energy

47. AFCO Ongoing Field Tests: MCFC-NAV Installed at Marmara Research Center, Istanbul (Turkey) Fuelled with NATO F76 Diesel Oil Conceived for future boarding on military ships and for “stand alone” use in remote areas and military bases Fuel Processing System successfully tested Installed at Marmara Research Center, Istanbul (Turkey) Fuelled with NATO F76 Diesel Oil Conceived for future boarding on military ships and for “stand alone” use in remote areas and military bases Fuel Processing System successfully tested Source: AFCO

48. BICEPS –2 “MW-Class” plants running on biogas: 1 MW in Terni (Italy) on ADG (beg. 2008) 1MW in Murcia (Spain) on landfill gas (2008) –Project cost shared by the European Commission PULP&PAPER –An integrated waste AND energy solution for the P&P industry: Reforming/Gasification of “pulper” waste and conversion to power and heat with MCFC. –Framework agreement in place with Italian P&P industrial ass.n and Italian Government: 1 MW prototype in 2007 2 x 4MW plants from 2008/9 AFCO Field Tests: Ongoing projects Source: AFCO

49. REFINERY WASTE –Agreement with a major Italian Oil&Gas Company for a demo plant running on tar gasification plant to be installed in 2007 OTHER WASTE TO ENERGY PROJECTS –Conversion of Chicken Manure through gasification and MCFC REFINERY WASTE –Agreement with a major Italian Oil&Gas Company for a demo plant running on tar gasification plant to be installed in 2007 OTHER WASTE TO ENERGY PROJECTS –Conversion of Chicken Manure through gasification and MCFC AFCO Field Tests: Ongoing projects Source: AFCO

50. CONCLUSIONS PART A MCFC is a viable, clean, sustainable power generation alternative Very HIGH EFFICIENT TECHNOLOGY suitable for DISTRIBUTED GENERATION AND RURAL ECONOMY and characterized by FUEL FLEXIBILITY PART B Sustainable Strategies based on Best Practices and Best Available Technologies WASTE TO ENERGY Case Studies