Manufacturing Cost and Installed Price Analysis of ...

1 1 Manufacturing Cost and Installed Price Analysis of Stationary Fuel Cell Systems 30 September 2015 By: Brian D. James Daniel A. DeSantis Revision 3 2 Sponsorship and Acknowledgements This research was conducted under Subcontract Number AGB-0-40628-01 and AGB-0-40628-03 to the National Renewable Energy Laboratory1 (NREL) under Prime Contract Number DE-AC36-08GO28308 to the US Department of Energy. The authors wish to thank Dr. Bryan Pivovar of NREL and Mr. Jason Marcinkoski of DOE s Office of Energy Efficiency and Renewable Energy (EERE), Fuel Cell Technologies Office (FCTO) for their technical and programmatic contributions and leadership.

2 Authors Contact Information Strategic Analysis Inc. may be contacted at: Strategic Analysis Inc. 4075 Wilson Blvd, Suite 200 Arlington VA 22203 (703) 527-5410 The authors may be contacted at: Brian D. James, (703) 778-7114 Document Revisions Rev 1 September 2015 Original document Rev 2 October 2015 Minor formatting corrections Rev 3 August 2016 Correction of installation costs as applied to all three fuel cell technologies 1 Actual subcontract is with the Alliance for Sustainable Energy, LLC which is the management and operating contractor for NREL.

3 3 Table of Abbreviations AC alternating current ATS automatic transfer switch BOL beginning of life BOM bill of material BOP balance of plant CCB customer critical bus CFCL Ceramic Fuel Cells Limited (of Australia) CO carbon monoxide CPU central processing unit DC direct current DFMA Design for Manufacturing and Assembly DI de-ionizing DOE US Department of Energy EOL end of life ELRB electrically resistive load bank ePTFE expanded polytetrafluoroethylene ESC electrical subsystem configuration FC fuel cell FCS fuel cell system FP fuel processor GDC gadolinia-doped ceria GDL gas diffusion layer HDPE high density polyethylene HHV higher heating value HT high temperature kWe kilowatts of electricity LB load bank LHV lower heating value LSCF lanthanum-strontium-cobalt-ferrite LT low

4 Temperature MCFC molten carbonate fuel cell MCO manganese cobalt oxide MEA membrane electrode assembly MPPT Maximum Power Point Tracking NiO nickel oxide Ni-Co nickel cobalt NLB No Load Bank Nm3 normal cubic meters NRE non-recurring engineering 4 NREL National Renewable Energy Laboratory NSTF nanostructured thin film PEM proton exchange membrane ppmv parts per million (by volume) PROX preferential oxidation Pt/Co/Mn platinum-cobalt-manganese PV photovoltaic SA Strategic Analysis , Inc. SMR steam methane reformer SOFC solid oxide fuel cell SR steam reforming TB tie bar TIG tungsten inert gas WGS water gas shift YSZ yttrium stabilized zirconia 5 Table of Contents 1 Executive Summary.

5 9 Abstract .. 9 Summary of System Configurations and Operating Conditions .. 10 Overview of Changes to the 2012 Fuel Cell System Cost Report .. 13 Summary of System Cost and Price Results .. 13 System Price Comparison as a function of Manufacturing Rate .. 13 Breakdown of Price results at subsystem level .. 15 Cumulative global Installed capacity .. 18 Additional Cost Comparisons of Fuel Cell Subsystems .. 19 Comparison of System Installed Price between the Three FC Types .. 21 Primary Findings .. 22 2 Introduction .. 25 Project Motivation .. 25 Fuel Cell System Summary.

6 25 Structure of Report .. 26 3 Analysis Methodology .. 28 System Conceptual Design .. 28 System Physical Design .. 29 Cost Modeling .. 29 Core System Components .. 29 Balance of Plant Components .. 32 Cost and Price Factors Included in Analysis .. 32 Iteration to Improve Analysis .. 33 4 System Design, Performance, and Manufacturing Details .. 34 System 34 Breakdown of Subsystems .. 34 Common Design and Cost Assumptions .. 35 Power levels and Manufacturing Rates .. 35 Gross Power vs. Net Power .. 35 System Efficiency .. 35 Air Supply .. 36 Fuel and Water Supply.

7 36 Desulfurization System .. 37 Fuel Processor .. 37 Stack Degradation .. 40 6 CHP Operation .. 41 System Housing .. 42 Grid-Dependent vs. Grid-Independent Operation .. 42 System Schematics .. 44 LT PEM .. 44 HT PEM .. 44 SOFC .. 44 Fuel Cell Subsystem .. 46 Fuel Cell Stack .. 46 LT PEM Stack 46 HT PEM Stack Parameters .. 48 SOFC Stack Parameters .. 49 Fuel Cell Balance of Plant .. 53 Common FC BOP Parts .. 53 Unique LT PEM BOP Components .. 56 Unique HT PEM BOP Components .. 56 Unique SOFC BOP Components .. 56 Fuel Cell Subsystem Assembly.

8 56 Fuel Processor Subsystem .. 56 Reactor .. 56 LT PEM .. 56 HT PEM .. 57 SOFC .. 57 Fuel Processor Balance of Plant .. 58 Common FP BOP Parts .. 58 Fuel Processing Reactor Assembly .. 59 5 System Performance Projections .. 60 6 Fuel Cell System Electrical Configurations .. 61 Electrical Subsystem Framework .. 61 ESC for Configuration 4a with fast ramping fuel cells .. 65 ESC for Configuration 4a with slow ramping fuel cells using a resistive load bank .. 66 Critical Power using Other Electrically Resistive Loads, Capacitors, or Batteries .. 68 ESC selected for cost Analysis .

9 69 7 Manufacturer Markup Rate (to Convert FCS Cost into FCS Price ) .. 70 8 Installation Cost .. 71 7 Installation Cost Analysis Methodology .. 71 Installation Cost Result Summary .. 75 9 System Cost and Price Results .. 77 LT PEM Costs .. 77 LT PEM System Price Projections .. 77 LT PEM System Projected Price as a Function of Subsystem and Component Costs .. 80 LT PEM FP Subsystem Costs .. 82 LT PEM FC Subsystem Costs .. 87 HT PEM Costs .. 89 HT PEM System Costs .. 89 HT PEM System Projected Price as a Function of Subsystem and Component Costs .. 90 HT PEM FP Subsystem Costs.

10 93 HT PEM FC Subsystem Costs .. 98 SOFC Costs .. 100 SOFC System Price 100 SOFC System Projected Price as a Function of Subsystem and Component Costs .. 101 SOFC FP Subsystem Results .. 103 SOFC FC Subsystem Costs .. 108 10 Summary and Comparison of Installed FCS Price Projections .. 110 Summary of FCS Installed Price Projections .. 110 Comparisons by Fuel Cell System Type .. 112 11 Fuel cell System Price Conclusions .. 115 12 Appendices of System Detailed Cost Results .. 118 Appendix A: Stack BOM .. 118 LT PEM Stack BOM .. 118 HT PEM Stack BOM.