A fleet of 91 residential-scale proton exchange membrane (PEM) fuel cells, ranging in size from 1 to 5 kW, was demonstrated at various U.S. federal facilities worldwide. This detailed analysis looks into the most prevalent means of failure in the PEM fuel cell systems as categorized from the stack, reformer, and power conditioning systems as well as the subsequent subsystems. Also evaluated are the lifespan and failure modes of selected fuel cell components, based on component type, age, and usage. The balance of plant, with the numerous pumps and filters, accounted for 60.6% of the total component outages, followed by the fuel cell stack system (20.4%), fuel processing system (10.7%), and the power conditioning system (8.2%). Hydrogen cartridges were the most prevalent component replaced (79), but various filters (RO, DI, air-intake, carbon) account for almost 25% (175) of the total component outages. The natural gas fuel cell stacks had the highest average operational lifetime; one stack reached a total of 10,250 h.
Fuel cells and hydrogen can play an important role in the rapidly emerging smart grid. The "soft" wind power can be converted to "hard", reliable utility power by using high temperature stationary fuel cells to co-produce baseload power plus hydrogen, and use of lower temperature fuel cells operating on hydrogen for the load following/peak power (DFC-H2 ® Peaker). If the stationary fuel cell operates on biogas, the hydrogen will be considered renewable and the overall system will be truly renewable power system. Demonstration of some of the major components of such as system is ongoing. A DFC-H2 ® plant in California has co-produced 125 kg/day of hydrogen and 250 kW of power, with a combined hydrogen, power and heat efficiency of 80-85% and ultra-low emissions. The DFC power plants currently installed or on order can support hardening of 500 MW of wind power. IntroductionAs more renewable energy becomes integrated into the US electrical grid, the need for efficient back-up power is becoming more urgent. Renewable wind and solar energy provide intermittent power which must be backed-up to maintain a reliable power grid. Ideally, such back-up power would be efficient, distributed, and low emissions. Distributed power improves efficiency by minimizing transmission losses, but requires low emissions in order to be permitted in densely populated areas where the power need is growing. When relatively higher cost biofuels are used for back-up power, higher efficiency becomes even more important to maximize the biofuel benefit.
The Federal government is the greatest consumer of electricity in the nation. Federal procurement and installation of higher efficiency energy sources promises many benefits, in terms of economy, employment, export, and environment. While distributed generation (DG) technologies offer many of the benefits of alternative, efficient energy sources, few DG systems can currently be commercially purchased "off the shelf," and complicated codes and standards deter potential users. Federal use of distributed generation demonstrates the technology, can help drive down costs, and an help lead the general public to accept a changing energy scheme. This work reviews and describes various distributed generation technologies, including fuel cells, microturbines, wind turbines, photovoltaic arrays, and Stirling engines. Issues such as fuel availability, construction considerations, protection controls are addressed. Sources of further information are provided. DISCLAIMER:The contents of this report are not to be used for advertising, publication, or promotional purposes. Citation of trade names does not constitute an official endorsement or approval of the use of such commercial products. All product names and trademarks cited are the property of their respective owners. The findings of this report are not to be construed as an official Department of the Army position unless so designated by other authorized documents. DESTROY THIS REPORT WHEN IT ISNO LONGER NEEDED. DO NOT RETURN IT TO THE ORIGINATOR. ERDC/CERL SR-03-18 iii Contents List of Figures and Tables .
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