Challenges in Fuel Cell Technology: Indias Perspective for - - PowerPoint PPT Presentation

Challenges in Fuel Cell Technology: India’s Perspective

for presentation at the National Seminar Organized by the

Indian Institute of Technology, Delhi

December 1 – 2, 2006

Shailendra Sharma, AGM (Fuel Cells Lab), BHEL, Corporate R&D Division, Vikas Nagar, Hyderabad – 500 093 (Phone: 040 - 23775861) e-mail: shailendra@bhelrnd.co.in

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Hydrogen Energy & Fuel Cells Production of Hydrogen Storage of H2 Means to deliver H2 Utilization of H2 for Transport application Utilization of H2 for Power Generation

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Power Generation using H2 -

Using Internal Combustion Engines - both Spark ignition (petrol) & Compression ignition (diesel) engines may be adapted for use with H2. Using Fuel Cells - All types of fuel cells,

• perating at low, medium & high temperatures

(AFC, PAFC, PEMFC, MCFC & SOFC) can be used for power generation. When used in Combined Heat & Power (CHP) mode, very high

• verall conversion efficiencies (80 - 85%) can

be achieved.

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Principle of Operation - Schematic for PEMFC / PAFC

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Repeating Elements used in a typical cell stack

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Major sub-systems in a typical Fuel Cell Power Plant

In addition to the above, a number of other sub-systems (viz.: Fuel storage & delivery system, Air supply system, Thermal Management system, C&I systems etc) are also needed

A glimpse of Fuel Cell Developments @ BHEL

(Inter-disciplinary approach followed for Fuel Cells Development)

Anodes, Cathodes, Membra ne Electrode Assemblies etc (Fuel Cells Lab) Bipolar & Cooling plates (Fuel Cells Lab) Stack Hardware & Assembly (Design Analysis & V alue Engg) Reactants & Coolant Supply (Turbo Ma chinery Lab) Stack Heating & Cooling (Heat Transfer Lab)

Fuel Cell Development

Data Acquisition, display & Controls (Control Instrumentation Lab) Inverter System (Power Electronics Lab) Skid Design (Renew able Energy Systems Lab)

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Fuel Cells - Major Challenges / Disadvantages Performance loss with time (few mV / 1000 hrs) Short life span (~ 5000 hrs to 40,000 hours) High Capital costs (~ $ 3000 to $ 10,000 / kW) Few technology developers / providers Limited commercial availability Limited fuel infrastructure

A glimpse of Fuel Cell Developments @ BHEL

(PAFC & PEMFC components - Electrodes, bi-polar plates etc, 1998 - 2005)

A glimpse of Fuel Cell Developments @ BHEL

Multiple Cells - connected in series 8 Cells PAFC stack, 100 x 200 mm; (PAFC, 60x60 mm, 1989) (1990)

A glimpse of Fuel Cell Developments @ BHEL

India’s first kW rated Fuel Cell Stack India’s first Multi kW Fuel Cell Stack (PAFC, 120x360 mm, 40 Cells, 1 kW) (PAFC, 300x400 mm, 80 Cells, 5 kW) (1991) (1995)

A glimpse of Fuel Cell Developments @ BHEL

(5 kW PAFC stack under testing, Active Area 865 cm2, 1995)

A glimpse of Fuel Cell Developments @ BHEL

2x25 kW PAFC stacks, 400x500 mm 200 kW, Performance Evaluation of PAFC (2000 - 2001) based Power Plant (PC25C-IFC/Toshiba) (1997 - 2000)

A glimpse of Fuel Cell Developments @ BHEL

(PEMFC single cell test set up, 60x60 mm) (4 Cells PEMFC education-cum-demo (2003 - 2006) stack, 100 x 90 mm; 2004 - 2005)

A glimpse of Fuel Cell Developments @ BHEL

(PEMFC, 20 cells’ stack under testing - Nov 2005)

A glimpse of Fuel Cell Developments @ BHEL

50 Cells, 150x300 mm, PEMFC 1 kW modular stack (under testing - January 2006)

A glimpse of Fuel Cell Developments @ BHEL

50 Cells, 150x300 mm, PEMFC 1 kW modular stacks

150 x 300 mm; ExfoGrap BP's; 5 cells' PEMFC Stack # 7 19 Aug 2005 (0900 - 1455 Hrs; 26 - 49°C)

600 650 700 750 800 850 900 950 1000 1050 1100 0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 55.0

Stack Current (A) In d iv id u a l C e ll V o lt a g e s ( m V )

1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0

S t a c k V o lt a g e ( V )

cell#1 cell#2 cell#3 cell#4 cell#5

Stack

A glimpse of Fuel Cell Developments @ BHEL

(V - I characteristics of a typical PEMFC stack)

A glimpse of Fuel Cell Developments @ BHEL

C&I system - developed under NMITLI program

Monitor Cubicle DAS PC Controller & Relay cards Keyboard, mouse

A glimpse of Fuel Cell Developments @ BHEL

Power Conditioner Under testing

Power Generation - using Fuel Cells

(Likely markets for different ratings of Fuel Cell Power Packs)

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Few identified technology gaps for PEMFCs

• Development of Indigenous Cathode Catalyst

Powders

• Development of Porous C / Graphite paper for use

as substrates

• Development of cost-effective Bi-polar plates
• 4. Development of electrode edge sealing materials

(PTFE tapes etc)

• 5. Development of proton conducting membranes

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Few identified technology gaps (contd)

• 1. Development of robust dc-dc converters & dc-ac Inverters
• 2. Development of compact Reformers & Heat Exchangers
• 3. Development of a C&I to impart ‘stand-alone’ capability
• 4. Developing tools & fixtures for ensuring alignment while

assembling large stacks

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Robust dc-dc converters & dc-ac Inverters

• Usual ‘battery’ based inverters face ~ 10 - 20% variation in

the input dc voltage.

• In contrast, inverters for fuel cells have to face very large

fluctuation – of the order of 40 - 50%. Most of this drop, however, is limited to the initial ‘no load’ – ‘load’ transition. Use of ‘dummy’ resistor or fan load etc have been tried.

• With the use of dc-dc boosters (~ 600 V for 3 phase, ~ 300

V for single phase) very high inverter efficiency can be achieved (>90%).

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Compact Reformers & Heat Exchangers

• Before we think of commercializing fuel cell based power

packs, infrastructure for the most appropriate Fuel needs to be established. Different fuels can be identified for different areas / applications. Ethanol, LPG, NG etc

• Suitable reformers for different fuels are needed. Some

expertise already available (Methanol reformers - NMRL & IICT; LPG – NCL)

• Development of compact heat exchangers needed to tap

‘excess’ or ‘waste’ heat as hot water or low-grade steam for use at customer end. – with low power pumps/fans

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

C&I package for ‘stand-alone’ capability

• All FCPPs thus far have been operated by experts only.

OK for developmental phase. Robust, cost effective C&I system to ensure auto start-up, safe operation & auto-

• stop. Should also log & store critical data for experts to

analyze initially,& for self diagnostics, later-on.

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Ensuring alignment during stack assembly

• Ensuring alignment of components (cells, bi-polar, cooling,

dummy & pressure plates etc) poses many problems, especially in larger stacks. Special tools & fixtures were designed for the 25 kW PAFC stack (160 cells, >2 m high)

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Stack Compression

• Apply & retain required compressive load over the

entire useful life of the stack – a mechanism using active loading components (springs), is shown below

Challenges in Fuel Cell Technology – India’s perspective

IIT Delhi, December 1-2, 2006

Thank You Thank You