This document provides an overview of fuel cell technology and applications. It discusses the basic principles of how fuel cells work and the major components of a typical fuel cell power plant. It describes the different types of fuel cells, including their operating temperatures, unit sizes, applications, advantages and disadvantages. The document also discusses BHEL's activities and demonstrations with phosphoric acid fuel cells. It outlines potential application opportunities for fuel cells in India, including in the transportation, railways, commercial, strategic and distributed power generation sectors. It covers issues related to fuel options, system sizing, operating conditions, costs and infrastructure requirements for fuel cell deployment in India.

1. TECHNOLOGY AND
APPLICATION OVERVIEW OF
FUEL CELLS
by
MANMOHAN SINGH CHANDOLIYA
RTU KOTA,YIT JAIPUR
Ref. - Bharat Heavy Electricals Limited,
Corporate Research & Development Division ,
Vikas Nagar,Hyderabad

2. ……….MILLIONS OF YEARS AGO, THERE WAS NO MAN KIND..……
ONLY PRE-HISTORIC LIVING SPECIES..
CLIMATE/ENVIRONMENTAL CHANGE
(NATURAL)
ECOLOGICAL CHANGE
(MAN-MADE)
……….RESULTED IN THE EVOLUTION OF MANKIND
……..LOGICALLY WILL SEE THE EXTINCTION OF THE PRESENT LIVING FORMS
UNLESS WE DO SOMETHING ABOUT REVERSING WHAT WE ARE DOING

3. •ENERGY IS THE PRIME MOVER FOR THE WHEELS OF LIFE
•QUEST FOR NEW SOURCES & NEW CONVERSION TECHNOLOGIES
TO USABLE FORMS
•EARTH-THE HOLDING POT OF SUM TOTAL OF ALL FORMS OF ENERGY
•STILL ECOLOGICAL CONDITIONS WILL DICTATE FORMS OF LIFE
-

4. •WORLD POPULATION EXPECTED TO GROW TO 8 BILLION IN 2020
•WILL REQUIRE 90 BILLION bpd OF OIL
7 B.TONS OF COAL/YR
40 TRILLION Cu.M/YR OF NG
•50% OF THIS ENERGY WILL BE REQUIRED IN THE DEVELOPING WORLD

5. •16% OF WORLD POPULATION WITH 0.6% OF OIL & 6% OF COAL
RESOURCES.
•IN 2000-01, ENERGY SHORTAGE - 7.8%, PEAK LOAD SHORTAGE -13%.
•PER CAPITA ENERGY CONSUMPTION IS FAR LESS COMPARED TO
GLOBAL STANDARDS (482 kWHr IN 1997 - CHINA 922 - WORLD 1562).
•BY 2025, INDIA WILL BE THE MOST POPULOUS COUNTRY IN THE
WORLD.
•COUPLED WITH THE GDP GROWTH REQUIREMENTS, THE ADDITIONAL
ENERGY REQUIREMENT WILL BE MIND BOGGLING.
HOW DO WE MANAGE THIS? -------------------

6. ----------- THE ANSWER WILL HAVE TO BE FOUND ON BOTH SIDES OF
THE EQUATION.
(SOURCE, TECHNOLOGY, EFFICIENCY) (ALTERNATIVES, EQUIPMENT, LIFE STYLE)
------------STILL, WE CAN NOT AVOID THE INEVITABLE, BUT WE CAN
DELAY THE SAME.
ENERGY SUPPLY = ENERGY DEMAND

7. ELECTRIFICATION RATE ( %)
WORLD - 72.8
DEV COUNTRIES - 64.2
OECD - 99.2
INDIA - 43.0
CHINA - 98.6
SRILANKA - 62.0
PAKISTAN - 52.9
BANGLADESH - 20.4.

8. FOSSIL FUEL
RENEWABLES
OTHER
COAL
OIL
NATURAL GAS
SOLAR PV / THERMAL
HYDRO
WIND
NUCLEAR
BIO - MASS

9. FOCUS ON FUEL CELLS
OUR PRESENT LIFESTYLE CANNOT DO AWAY WITH FOSSIL
FUEL ENERGY SOURCES IMMEDIATELY.
BUT, ADOPTING ENERGY CONVERSION SYSTEMS WITH
HIGHER EFICIENCY WILL REDUCE GH GAS GENERATION.
FUEL CELLS MEET THIS REQUIREMENT ADEQUATELY.
ALSO, BEING A COMBUTIONLESS SYSTEM THERE IS NO
EMISSSION OF SOX/NOX.

10. Part I : Fuel Cell Technology- an
Overview

11. Principle of Operation of a Typical Fuel C

12. Repeating elements used in a typical cell stack

13. Major sub-systems in a typical Fuel Cell Power Plant

14. Fuel cells provide a range of critical benefits that no
other single power-generating technology can match.
Some of the key characteristics of fuel cells are :
•Fuel Cells are Efficient – even at part loads
•Fuel Cells are modular
•Fuel Cells provide high availability and reliability
•Fuel Cells can operate on a variety of fuels
•Fuel Cells are Clean & Quiet
Benefits of Fuel Cells

15. Fuel Cell Type
Temp of
Operatio
n [o
C]
Unit
Sizes
[kWe
]
Most likely
applications
Alkaline Fuel Cell
(AFC)
RT – 100 < 100
Space , Military recently
terrestrial applications
Proton Exchange
Membrane Fuel Cell
(PEMFC)
RT – 100
0.1 -
100
Portable devices like Lap Tops, Cellular
phones, Video Cameras etc
Domestic & Dedicated Power (+ heat)
Buses, Passenger Cars, Service
Vehicles, Railway Locomotives &
Streetcars etc
Phosphoric Acid
Fuel Cell
(PAFC)
100 – 210
5 - 200
(also MW
sized
plants)
Dedicated Power (+ heat),
Railways
Molten Carbonate
Fuel Cell
(MCFC)
650
100 -
2,000
(plants
up to 100
MW)
Dispersed Power & Utility
Power (Combined Cycle
-with downstream Steam
Turbine)
Solid Oxide Fuel
Cell
(SOFC)
800-1000
2.5 – 250
(plants
up to 100
MW)
Domestic & Commercial (heat
and power), Utility Power
(combined cycle)
Mobile applications for railways
Types of Fuel Cells

16. PEMFC AFC PAFC MCFC SOFC
Electrolyte Ion Exchange
Membrane
Potassium
Hydroxide
Phosphoric
Acid
Molten
carbonates
Ceramic
Oxides
Catalyst Platinum non
platinum
Platinum Nickel Perovskite
Operating
Temp 0
C
RT-80 RT-80 180-205 650 800-1000
Electrical
Efficiency
(%LHV)
32-40
50-60 36-42 45-60 50-60
Applications
Cogeneration
√ √ √
Utility Power √ √ √
Distributed
Power
√ √ √ √
Passenger
Vehicles
√ √
Heavy Duty
Vehicles
√ √
Portable
Power
√ √
Specialty
Power
√ √

17. PEMFC AFC PAFC MCFC SOFC
Advantages High
Power
density,
Light
weight,
quick
response
Low cost
high
efficiency,
Co
tolerant
Co
tolerance
up to 1.5%
Multi fuel
capability
Inexpensi
ve
catalysts
Multi fuel
capability
Efficienci
es up to
60%
Disadvantages Humidificati
on required
CO
Intolerance
Platinum&
Membrane
pushes the
cost upwards
Requires
inlet air
scrubbers.
Circulating
Alkali
requires
toping up
Expensive
platinum
catalyst used.
Low
current&
power.
Large size&
weight
High
temperatures
enhance
corrosion and
the
breakdown of
cell
components.
Not yet
available
commercial
ly

18. Alkaline Fuel Cell Applications

19. PEMFC applications

20. MCFC &DFC applications

21. SOFC tubular and planer design

22. 100 kW SOFC Cogeneration System formerly at Westervoort,
the Netherlands, currently at Essen, Germany. As of January
2002 the system has operated in a total of 20,000+ hours. The
system has a peak power of ~140 kW, typically feeding 109 kW
into the local grid and 64 kW of hot water into the local district
heating system, and is operating at an electrical efficiency of
46%.
Simple-cycle Atmospheric SOFCSimple-cycle Atmospheric SOFC
Cogeneration SystemCogeneration System

23. World's First Fuel Cell-Gas Turbine HybridWorld's First Fuel Cell-Gas Turbine Hybrid
now Operating in Californianow Operating in California
220-kW hybrid system with a Solid Oxide
Fuel Cell (SOFC) generator and a down-
stream micro-turbine
SOFC stack

24. Part II : BHEL’s Activities in Fuel Cell
Area

25. Fuel Cells at BHELFuel Cells at BHEL
(History of Development(History of Development))
 1987-1990:1987-1990: Started work on PAFC. Made single cells andStarted work on PAFC. Made single cells and
small stacks (100-200 cmsmall stacks (100-200 cm22
))
 1991: Demonstrated a 1 kW stack (chlor-alkali plant, 401991: Demonstrated a 1 kW stack (chlor-alkali plant, 40
cells,with imported bipolar plates, ~400 cmcells,with imported bipolar plates, ~400 cm22
))
 1995: Demonstrated 5 kW stacks (chlor-alkali plant,1995: Demonstrated 5 kW stacks (chlor-alkali plant, 8080
cells, ~900 cm2, Laminated bipolar plates,cells, ~900 cm2, Laminated bipolar plates, 300*400300*400
mm, Rolled electrodes)mm, Rolled electrodes)
 2001: Demonstrated 2*25 kW stacks (chlor-alkali plant,2001: Demonstrated 2*25 kW stacks (chlor-alkali plant, 160160
cells / stack, ~1600 cmcells / stack, ~1600 cm22
, molded bipolar plates, screen printed, molded bipolar plates, screen printed
electrodes)electrodes)
 2002:Acquired basic PEMFC technology from IISc,single cell2002:Acquired basic PEMFC technology from IISc,single cell
testingtesting

26. The 50kW Power Pack during testing at
BHEL R&D during December 2000

27. Salient features of 50 kW stack
(2 x 25 kW fuel cell stack)
•2 x 25 kW stacks
•Plate area 500mm x 400mm = 2000 sqcm
•Effective Cell Area = 1500 sqcm
•Number of cells in each stack = 160
•Air cooling system
•Water to air Heat exchanger system
•Inverter and DC loading system
•Data acquisition and storage system
•Current densities achieved in the range of 200 to 250
mA/sqcm
•Operating voltage in the range of 550 to 600 mV per cell

28. 200 kW PC 25 C PAFC Power Plant at BHEL
R&D

29. Part III :Fuel Cell Application Opportunities
in India

30. Fuel Cells Application in India
Railways
•Passenger Coaches’ lighting and fans
4 kW systems mounted on the passenger coach
Requirement 4500 coaches
•Power cars for long distance Shatabdi & Rajdhani
200 kW systems / 2 per train / 25 trains
•Illumination of level crossing
Up to 1 kW systems / Around 8000 to 10000
•Lighting of isolated railway stations
5 to 10 kW systems / Up to 1000 stations
•Emergency power supply for control rooms
10-25 kW systems / Up to 200 - 500 control rooms

31. Fuel Cells Application in India
Transportation
 Two Wheeler
4 kW systems / 75,000 to 1,00,000
Three Wheeler
6-8 kW systems / 25,000 to 50,000
Buses
100 kW systems / 1,000 to 5,000
Merchant Navy
100-200 kW / 100 to 200

32. Fuel Cells Application in India
Strategic
Data Processing centres 1- 5 kW systems / around 5,000
Soft ware Companies 25 – 50kW / around 1,000
Communication Centres 1-5 kW systems / around 20,000
Remote Area Installations 1-2 kW systems / around 1,000
Off shore oil rig installations 25-50 kW systems up to
500

33. Fuel Cells Application in India
Commercial establishments
Shops in Malls and Underground bazaars
1 to 3 kW systems / around 1,00,000
Small Business Establishments
5-10 kW systems / 50,000
Entertainment Industry
25-50 kW systems / 500 to 1,000
Hotels, restaurants & Resorts
100-200 kW systems / up to 500 units
Hospitals
200-500 kW systems / up to 200 units
Residential Complexes
50-200 kW systems / 30,000 to 50,000

34. Part IV : Issues in Fuel Cell Application in
DPG

35. Distributed GenerationDistributed Generation
- Rural (Remote areas)Rural (Remote areas)
- Urban ( Hotels ,Hospitals ,Ent.centres,Urban ( Hotels ,Hospitals ,Ent.centres,
Software dev. centres)Software dev. centres)
- Strategic (Communication centres, Defense,Strategic (Communication centres, Defense,
Chemicals and Pharmaceutical plants)Chemicals and Pharmaceutical plants)

36. Fuel optionsFuel options
Urban :- Hydrogen,NG,Methanol,LPG,Urban :- Hydrogen,NG,Methanol,LPG,
Di-gasDi-gas
Rural :- Ethanol ,BiogasRural :- Ethanol ,Biogas
Strategic:- Hydrogen, NG, LPG, MethanolStrategic:- Hydrogen, NG, LPG, Methanol
Technology of fuel cells will depend upon the type of fuel availableTechnology of fuel cells will depend upon the type of fuel available

37. Capacity /Duty cycleCapacity /Duty cycle
Urban/StrategicUrban/Strategic
–– High Power CapacityHigh Power Capacity
–– Base LoadBase Load
(High temp.Fuel Cells)(High temp.Fuel Cells)
RuralRural
–– Low Power CapacityLow Power Capacity
–– Cyclic LoadCyclic Load
(Low temp.Fuel Cells)(Low temp.Fuel Cells)
No.of start stops will determine the life cycle of HT fuel cells.

38. Other IssuesOther Issues
 Starting power - Rural area (Black start)Starting power - Rural area (Black start)
Others (Brown start)Others (Brown start)
 Cost Factor - Still not affordableCost Factor - Still not affordable
without Govt.subsidywithout Govt.subsidy
 Market Size - Traditional tussle betweenMarket Size - Traditional tussle between
cost and volumecost and volume
 Op.& Maint. - Being high technology itemOp.& Maint. - Being high technology item
requires careful handlingrequires careful handling

39. PART- V: AUTOMOTIVE APPLICATIONS OF
FUEL CELLS

40. NEED VS GROUND REALITIES
• WORLDWIDE, TRANSPORT VECHICLES ARE THE SINGLE LARGEST
CONTRIBUTOR TO THE GH GASES. IC ENGINES CONVERT FUEL’S
CHEMICAL ENERGY TO WHEEL POWER AT VERY LOW EFFICIENCIES.
• THOUGH THE NEED FOR HIGHER CONVERSION EFFICIENCY IS FELT
AND THE DESIRABILITY OF FUEL CELLS IS VINDICATED, PEOPLE
WOULD BE INFLUENCED BY:
- COST
- PERFORMANCE
- CONVENIENCE (INFRASTRUCTURE)

41. FUEL - THE CRUCIAL FACTOR
ON BOARD
PRESSURIZED
GAS
ON BOARD
LIQUIFIED
H2
ON BOARD
REFORMER
ON -BOARD
METAL
HYDRIDES
FUEL CELL
POWER
STACK
VEHICLE
PROPULSION
SYSTEM
FROM GROUND
BASED FUEL
INFRASTRUCTURE
(EXTERNAL
REFORMATION)
GASOLENE
METHANOL
HYDRIDE
REPLENISHMENT
FROM GROUND
SOURCES
HYDROGEN

42. ISSUES FOR EACH OPTION
1. ON -BOARD PRESSURIZED HYROGEN : COMPRESSION PRESS
10000 PSI ; LARGE SPACE REQUIREMENT ; OCCUPIES EIGHT
TIMES THE VOLUME OF GASOLENE.
2. ON BOARD LIQUIFIED HYDROGEN:- HIGH ENERGY
REQUIRED FOR COOLING THE GAS TO LIQUID IN CRYOGENIC
TANKS (-2530
C); HIGH COST OF CRYO TANKS.
3. METHANOL REFORMATION : REFORMATION AT 260 - 300 0
C ;
TOXIC AND POISONOUS WITH INVISIBLE FLAME ; EASY
TRANSPORTABILITY AND HANDLING ; EXISTING FUEL
INFRASTRUCTURE CAN BE USED.

43. ISSUES (CONTD)
4. GASOLENE REFORMATION : REFORMATION AT 6000
C ; LESS
EFFICIENT THAN METHANOL AND PRODUCES MORE
EMISSIONS ; EXISTING INFRASTRUCTURE CAN BE USED.
5.METAL HYDRIDES : PRESENTLY RARE-EARTH METAL
HYDRIDES ONLY STORE 1.5 - 2.0% HYDROGEN BY WEIGHT ;
RESULTANT WEIGHT MAKES IT UNVIABLE FOR CARS WITH
RANGE OF 300 KMs ; REQUIRES GROUND INFRASTRUCTURE
FOR RECHARGING.
6. SODIUM BOROHYDRIDE : SAFE CARRIER OF HYDROGEN ;
REQUIRES LESS VOLUME THAN COMPRESSED HYDROGEN ;
REQUIRES GROUND INFRASTRUCTURE.

44. WHAT ARE AUTO MAJORS PURSUING ?
DAIMLER.CHRYSLER
LIQUIFIED HYDROGEN - NECAR 4
COMPRESSED HYDROGEN - NECAR 4a
METHANOL - NECAR 5 &
JEEP COMMANDER
METAL HYDRIDE & - CHRYSLER NATRIUM
SODIUM BOROHYDRIDE
( A MODIFIED MERCEDES - BENZ A - CLASS WILL RUN ON COMP. H2
IN 2004)

45. TOYOTA COMPRESSED HYDROGEN - FCHV (KLUGER V)
HONDA COMPRESSED HYDROGEN - FCX
GM COMPRESSED HYDROGEN - HydroGen 3
(ACHIEVED HIGHEST STACK POWER DENSITY OF 1.75 kW/litre)
FORD COMPRESSED HYDROGEN - FOCUS FCV
(HYBRID)

47. •NEED FOR QUICK-STARTING, MULTI-FUEL COMPACT REFORMER
•LOW-COST MATERIALS (SPECIALLY, ELECTROLYTIC MEMBRANE)
•LOW-COST NON-NOBLE MATERIAL CATALYST
•LOW-COST MASS-PRODUCIBLE BIPOLAR PLATE
•SIMPLIFIED LOW-COST POWER CONDITIONER

48. The FutureThe Future
Despite all these difficulties, theDespite all these difficulties, the
Governments all over the world areGovernments all over the world are
pouring in money forpouring in money for BreakthroughsBreakthroughs
since this eco friendly technology couldsince this eco friendly technology could
be the ULTIMATE WINNER !be the ULTIMATE WINNER !

49. Thank You