![Case Study: Semiconductor Crystal
Growth Facility (cont.)
16
Payback Pe riod [ye ars]
14
12
10
8
6
4
2
0
$500,000
$750,000
$1,000,000
$1,250,000
$1,500,000
$1,750,000
$2,000,000
Total Annual Cost of Losse s Due to Power Q uality Issue s
Payback Period for the Fuel Cell System vs. Cost of Losses
Average Prices (Northeast): Natural Gas – $6.38/ccf and Electricity – $0.0772/kWh
ers
energy&resource solutions
© 2003 ERS, Inc.](https://image.slidesharecdn.com/fuelcellapplicationspresentation-140303154416-phpapp01/85/Fuelcellapplicationspresentation-15-320.jpg)
Fuelcellapplicationspresentation
- 1. Assessment of Fuel Cell Applications for Critical Industrial Processes presented by Dan Birleanu ERS ACEEE Summer Study on Energy Efficiency in Industry August 2003 ers energy&resource solutions © 2003 ERS, Inc.
- 2. Assessment of Fuel Cell Applications for Critical Industrial Processes Power Quality and Critical Applications Premium Power Equipment Overview of Fuel Cell Technology Fuel Cells Current Challenges Feasibility Assessment Methodology Case Study: Semiconductor Crystal Growth Facility Conclusions ers energy&resource solutions © 2003 ERS, Inc.
- 3. Power Quality and Critical Applications High Voltage Spikes and Surges Low Voltage Electrical Noise Harmonics Voltage Fluctuations Power Outages and Interruptions ers energy&resource solutions © 2003 ERS, Inc.
- 4. Power Quality and Critical Applications (cont.) Medical Treatment Facilities Advanced Manufacturing Facilities Communication and Data Centers High-Security Facilities Remote Sites Air Traffic Control Facilities ers energy&resource solutions © 2003 ERS, Inc.
- 5. Premium Power Equipment Requirements Availability: Respond in Milliseconds without Significant Distortions Reliability: 99.999…% Maintainability: Easily Accessible while Maintaining Availability Technologies Energy Storage: Batteries, Flywheel, Super-capacitors, Super-conducting Magnetic Energy Storage (SMES), Compressed Air Storage (CAES) Back-up Power: Generator Sets, Micro-turbines, Small Gas Turbines, Fuel Cells. ers energy&resource solutions © 2003 ERS, Inc.
- 6. Overview of Fuel Cell Technology Size Range Fuel Capacity Efficiency Environment Other Features Estimative Cost Commercial Status Strengths Weaknesses ers PAFC 100-200 kW Hydrogen, Natural Gas, Landfill Gas, Digester Gas, Propane 0.1-0.3 W/cm2 36-42% Nearly zero emissions (when running on H2) Cogeneration (Hot Water) $4,000 per kW PEMFC 3-250 kW Natural Gas, Hydrogen, Propane, Diesel 0.6-0.8 W/cm2 30-40% Nearly zero emissions (when running on H2) Cogeneration (Hot Water) $5,000 per kW Available Quiet Low Emissions High Efficiency Proven Reliability High Cost energy&resource solutions MCFC 250 kW - 10 MW Natural Gas, Hydrogen SOFC 1 kW - 10 MW Natural Gas, Hydrogen, Landfill Gas, Fuel Oil 0.3-0.5 W/cm2 45-60% Nearly zero emissions (when running on H2) Cogeneration (Hot Water or Steam) $1,300 per kW (Desired) Pre-commercial 0.1-0.2 W/cm2 45-55% Nearly zero emissions (when running on H2) Cogeneration (Hot Water or Steam) $2,000-$4,000 per kW Pre-commercial Quiet Low Emissions High Efficiency Quiet Low Emissions High Efficiency Quiet Low Emissions High Efficiency High Cost Need to Demonstrate Limited Field Test Experience High Cost Need to Demonstrate High Cost Need to Demonstrate Pre-commercial © 2003 ERS, Inc.
- 7. Fuel Cells Current Challenges PAFC PEMFC MCFC SOFC ers Reduction of manufacturing and operating costs Further improved durability and reliability Reducing space requirements Improving heat recovery potentials Staying economically competitive with other fuel cell technologies as they mature Reduction of manufacturing and operating costs Understanding the influences of operating conditions Understanding transient load response Improve fuel processing to accommodate different type of fuels Improve cold-start Catalyst loading Reduction of manufacturing and operating costs Reducing the rate of cathode dissolution Improve retention of the electrolyte Improving resistance to catalyst poisoning Reduction of manufacturing and operating costs Identifying configurations that require less stringent material purity specifications Use of less exotic alloys, which is directly related to the high operating temperature Maintenance of seals and manifolds under severe thermal stresses energy&resource solutions © 2003 ERS, Inc.
- 8. Feasibility Assessment Methodology Description of the Operation and Need for Premium Power Applicable End Uses and Equipment Utility Usage Outage and Low Power Quality History Technical Impacts of Downtime Cost Impacts of Outage and Low Power Quality Incidents Capital Project Financing and Investment Requirements Assessment of Power Quality Critical Equipment Service Lines Tolerance Range of Critical Equipment Impact Assessment of Power Quality ers energy&resource solutions © 2003 ERS, Inc.
- 9. Feasibility Assessment Methodology (cont.) Assessment of Economic Losses Associated with Power Reliability and Power Quality Problems Estimates of Economic Impacts Technical and Economic Scenarios Research and Review of the Premium Power Systems Technical Options Review of Premium Power Systems Considered Technologies: Features and Advantages Preliminary Technical and Economic Screening of Options Simplified Estimates of Energy Impacts Simplified Estimates of Costs Simplified Estimates of Economic Impacts ers energy&resource solutions © 2003 ERS, Inc.
- 10. Feasibility Assessment Methodology (cont.) Preparation of Conceptual Design for Cost-Effective Application Site-Specific Systems Components Desired Location Requirements Detailed Conceptual Design System Cost Estimation Detailed Energy, Environmental and Economic Analyses System Modeling Environmental Impact Life Cycle Cost Analyses ers energy&resource solutions © 2003 ERS, Inc.
- 11. Case Study: Semiconductor Crystal Growth Facility Molecular Beam Epitaxy (MBE) Process Facility Descriptors Demand: 2.5 MW Critical Demand: 1.5 MW Energy Usage: 20 million kWh annually Two Separate Feeding Circuits from the Utility Network UPS Batteries Capacity: 600 kW Emergency Generators Capacity: 1.5 MW Critical Systems Ultra-High Vacuum System Heating System (Crystal Growth Process @ 1,700 F) Cooling System (1,700 Tons) ers energy&resource solutions © 2003 ERS, Inc.
- 12. Case Study: Semiconductor Crystal Growth Facility (cont.) Power Quality Incidents Seven Separate Power Outages in 2001 Voltage Sags Over Voltages Impact of Power Quality Incidents Shutdown of Crystal Growth Process Process Resume Takes Several Hours Labor Costs: $50,000 per hour Material Losses: up to $500,000 per hour ers energy&resource solutions © 2003 ERS, Inc.
- 13. Case Study: Semiconductor Crystal Growth Facility (cont.) PAFC PEMFC MCFC SOFC ers Proven reliability: installations in different locations all over the world with many hours of successful operation Commercially available in sizes that are attractive for the facility (200 kW) For premium power, requires a reliable source of fuel To make it highly cost-effective, requires cogeneration opportunities - which may not be present Not sufficiently proven for this application Commercially available in sizes too small (maximum 50 kW) For premium power, requires a reliable source of fuel To make it highly cost-effective, requires cogeneration opportunities - which may not be present Not sufficiently proven for this application Still in the pre-commercial stage For premium power, requires a reliable source of fuel Can produce steam, which could be used in absorption chillers – would require chiller replacement Not sufficiently proven for this application Still in the pre-commercial stage For premium power, requires a reliable source of fuel Can produce steam, which could be used in absorption chillers – would require chiller replacement energy&resource solutions © 2003 ERS, Inc.
- 14. Case Study: Semiconductor Crystal Growth Facility (cont.) Selected Fuel Cell System: UTC Fuel Cells PC25 Rated electrical Capacity: 200 kW/235 kVA Thermal Capacity: 900,000 Btu/h @ 140 F Efficiency (LHV): 37% Electric and 50% Thermal Natural Gas Consumption: 2,100 cu.ft./hour Emissions: <2 ppm CO, <1 ppm NOx, negligible SOx Proposed Premium Power System Characteristics and Cost Integration of the Fuel Cells with the Existing Back-up System Eight (8) Fuel Cell Units Fuel Cells Will Operate 8,000 hours/year Total Estimated Cost: $9,600,000 ers energy&resource solutions © 2003 ERS, Inc.
- 15. Case Study: Semiconductor Crystal Growth Facility (cont.) 16 Payback Pe riod [ye ars] 14 12 10 8 6 4 2 0 $500,000 $750,000 $1,000,000 $1,250,000 $1,500,000 $1,750,000 $2,000,000 Total Annual Cost of Losse s Due to Power Q uality Issue s Payback Period for the Fuel Cell System vs. Cost of Losses Average Prices (Northeast): Natural Gas – $6.38/ccf and Electricity – $0.0772/kWh ers energy&resource solutions © 2003 ERS, Inc.
- 16. Conclusions PAFC and PEMFC Could Provide Clean and Reliable Power for Critical Industrial Applications Installation Costs Represent a Considerable Barrier to Widespread Commercialization of the Available Fuel Cell Systems Cost-effectiveness of the Large Fuel Cell Based Premium Power Application Rises in the Probability that Major Events with High Impact on Company’s Revenues Occur Very Critical Operations (Communication/Data Centers, Financial Transaction Operations, High-Tech Manufacturing Facilities) are the most Suitable Applications for Future Implementation of These Systems ers energy&resource solutions © 2003 ERS, Inc.
- 17. Assessment of Fuel Cell Applications for Critical Industrial Processes Thank you! Questions? ers energy&resource solutions © 2003 ERS, Inc.