Simulated coal-gas fueled carbonate fuel cell power plant system verification. Final report, September 1990--June 1995

This report summarizes work performed under U.S. Department of Energy, Morgantown Energy Technology Center (DOE/METC) Contract DE-AC-90MC27168 for September 1990 through March 1995. Energy Research Corporation (ERC), with support from DOE, EPRI, and utilities, has been developing a carbonate fuel cell technology. ERC`s design is a unique direct fuel cell (DFC) which does not need an external fuel reformer. An alliance was formed with a representative group of utilities and, with their input, a commercial entry product was chosen. The first 2 MW demonstration unit was planned and construction begun at Santa Clara, CA. A conceptual design of a 10OMW-Class dual fuel power plant was developed; economics of natural gas versus coal gas use were analyzed. A facility was set up to manufacture 2 MW/yr of carbonate fuel cell stacks. A 100kW-Class subscale power plant was built and several stacks were tested. This power plant has achieved an efficiency of {approximately}50% (LHV) from pipeline natural gas to direct current electricity conversion. Over 6,000 hours of operation including 5,000 cumulative hours of stack operation were demonstrated. One stack was operated on natural gas at 130 kW, which is the highest carbonate fuel cell power produced to date, at 74% fuel utilization, with excellent performance distribution across the stack. In parallel, carbonate fuel cell performance has been improved, component materials have been proven stable with lifetimes projected to 40,000 hours. Matrix strength, electrolyte distribution, and cell decay rate have been improved. Major progress has been achieved in lowering stack cost