N131-067 TITLE: Bio-fuel Reforming for High-Efficiency Solid Oxide Fuel Cell Generators

TECHNOLOGY AREAS: Ground/Sea Vehicles

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is "ITAR Restricted". The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: Develop and demonstrate an innovative fuel reforming process, utilizing bio-fuel, scalable for a 10kW and greater solid oxide fuel cell system.

DESCRIPTION: Fuel cells offer a viable means to provide distributed ship service pier side as well as tactical electrical power. In tactical and shipboard applications there are benefits such as high efficiencies and lower heat/noise signatures compared to traditional generators. Also, fuel cells provide modular design options that dramatically improve the ease with which to perform general maintenance and to conform to a variety of platforms and applications. Compared to typical diesel generators, further benefits can be obtained through the use of fuel cells providing environmental benefits due to reduced NOx, soot, and greenhouse gas emissions. Beyond the basic benefits provided by fuel cell operation, the impact of using bio-fuel on these fuel cell systems, as compared to the use of existing Navy logistics fuel, include the potential to improve overall fuel cell system size, weight, efficiency, life cycle cost, and acquisition cost.

Bio-fuels are assumed to be similar to a paraffin-based fuel with no sulfur and negligible aromatic constituents. Paraffin fuels are easier to reform and require less energy to break the fuel bonds as compared to complex Navy distillate fuels. Because of this, the overall process efficiency of reformer and stack is expected to improve. This is due to the ability to operate the reformer at an optimum temperature and operating ratios, reduction of process parasitics, and the reduction of the potential to produce carbon deposition on the reformer catalyst material and increase overall catalyst life. In addition, operation with this fuel will theoretically enable reformer reactors to function at a wider operating range and still maintain complete fuel conversion. Finally, it enables the ability to operate with innovative fuel reforming processes which can operate as a stand-alone reformer or further integrate with the fuel cell stack in ways that were previously restricted due to the properties of logistic fuels such as JP8, JP5, and NATO F76.

It is desired to develop an innovative fuel reforming process which operates at high efficiency within a solid oxide fuel cell system to produce electric power from bio-fuel. The overall reforming process shall be thermally integrated to produce an effective package with minimal balance of plant components such as pipes, heat exchangers and valves. The unit shall also utilize simple control concepts to properly manage thermal balance during both start up, shut down, steady state, and transient operating conditions. Emphasis shall be placed on the design which reduces production cost goals of the power unit. The solid oxide fuel cell power unit concept shall be designed to achieve or exceed the following performance goals:

� System Efficiency: >40% based on LHV of bio-fuel
� Volumetric Density: 25 watts/liter
� Gravimetric Density: 20 watts/kg
� Stack Durability: >10,000 hours with less than 5% degradation
� Unit Power: 10 kWe, scalable to 100 kWe
� Airborne Noise: <70 dB � Water Neutral

Proposals are encouraged to include a development plan and projected performance utilizing bio-fuel. Technologies with tested stack assemblies that have previously demonstrated the ability to operate within a power generation system are desired.

PHASE I: Develop a conceptual design of a fuel reformer for a Solid Oxide Fuel Cell (SOFC) power unit, operating on bio-fuel, and scalable in the range of 10�100 kWe per modular power unit. Emphasize system performance and complexity benefits by using bio-fuel. The 10 kWe conceptual SOFC power unit design shall include performance models for steady state operation and 3D layouts of the power unit. The concept shall include a basis for operation of the fuel reformer and power unit including startup, shutdown, load pickup, and reduction. A proof-of-concept of the notional reformer in a sub-scale demonstration would be beneficial.

PHASE II: Conduct a full scale development and demonstration test of the thermally integrated bio-fuel reforming process at a 10 kW level to demonstrate process benefits, operability, and controllability. Develop a detailed design for a complete 10 kW power unit incorporating the reformer previously developed. The power unit design should take advantage of the system benefits provided by the fuel characteristics. Refine the steady state process model and 3D conceptual layouts for both a 10 kWe tactical power unit and larger shipboard applications. Develop a dynamic model based upon the efforts of the Phase I concept, and the Phase II prototype design, that simulates the operability and transient performance of the fuel cell power unit. This reformer shall be demonstrated with a fuel cell, but does not require military environmental packaging.

PHASE III: Update the detailed design for a complete 10 kW power unit incorporating the reformer previously developed in Phase II. Build and demonstrate a unit for a tactical application including military packaging which demonstrates the technology advancements developed during Phase I and II. The unit will be delivered to a military facility for demonstration testing in a relevant environment.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: This technology can be utilized for any commercial fuel cell application that uses biofuel as a source.

REFERENCES:
1. Hoffman, Don. 2011. "Fuel Cell 101", DOE-DOD Shipboard APUl Workshop, March 2011, http://www1.eere.energy.gov/hydrogenandfuelcells/pdfs/apu2011_2_hoffman.pdf.

2. Devlin, Pete. 2011. "Fuel Cell Commercial Outlook", DOE-DOD Shipboard APUl Workshop, March 2011, http://www1.eere.energy.gov/hydrogenandfuelcells/pdfs/apu2011_3_devlin.pdf.

3. Hoffman, Don. 2011. "System Design", DOE-DOD Shipboard APUl Workshop, March 2011, http://www1.eere.energy.gov/hydrogenandfuelcells/pdfs/apu2011_11_hoffman.pdf.

4. Devlin, Pete and John Christensen. 2011. "Fuel Cell Technologies Program", 2011 Joint Service Power Expo, May 2011, http://www.dtic.mil/ndia/2011power/Session3_12303_Christensen.pdf.

KEYWORDS: Fuel Cells; bio-fuel

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