This report includes the progress in development of Direct FuelCell/Turbine{reg_sign} (DFC/T{reg_sign}) power plants for generation of clean power at very high efficiencies. The DFC/T power system is based on an indirectly heated gas turbine to supplement fuel cell generated power. The DFC/T power generation concept extends the high efficiency of the fuel cell by utilizing the fuel cell's byproduct heat in a Brayton cycle. Features of the DFC/T system include: electrical efficiencies of up to 75% on natural gas, 60% on coal gas, minimal emissions, simplicity in design, direct reforming internal to the fuel cell, reduced carbon dioxide release to the environment, and potential cost competitiveness with existing combined cycle power plants. The operation of sub-MW hybrid Direct FuelCell/Turbine power plant test facility with a Capstone C60 microturbine was initiated in March 2003. The inclusion of the C60 microturbine extended the range of operation of the hybrid power plant to higher current densities (higher power) than achieved in previous tests using a 30kW microturbine. The design of multi-MW DFC/T hybrid systems, approaching 75% efficiency on natural gas, was initiated. A new concept was developed based on clusters of One-MW fuel cell modules as the building blocks. System analyses were performed, …

In this reporting period, a milestone was achieved by commencement of testing and operation of the sub-scale hybrid direct fuel cell/turbine (DFC/T{reg_sign}) power plant. The operation was initiated subsequent to the completion of the construction of the balance-of-plant (BOP) and implementation of process and control tests of the BOP for the subscale DFC/T hybrid system. The construction efforts consisted of finishing the power plant insulation and completion of the plant instrumentation including the wiring and tubing required for process measurement and control. The preparation work also included the development of procedures for facility shake down, conditioning and load testing of the fuel cell, integration of the microturbine, and fuel cell/gas turbine load tests. At conclusion of the construction, the process and control (PAC) tests of BOP, including the microturbine, were initiated.

Project activities were focused on the design and construction the sub-scale hybrid Direct Fuel Cell/turbine (DFC/T{reg_sign}) power plant and modification of a Capstone Simple Cycle Model 330 microturbine. The power plant design work included preparation of system flow sheet and performing computer simulations based on conservation of mass and energy. The results of the simulation analyses were utilized to prepare data sheets and specifications for balance-of-plant equipment. Process flow diagram (PFD) and piping and instrumentation diagrams (P&ID) were also completed. The steady state simulation results were used to develop design information for modifying the control functions, and for sizing the heat exchangers required for recuperating the waste heat from the power plant. Line and valve sizes for the interconnecting pipes between the microturbine and the heat recuperators were also identified.

This report includes the progress in development of Direct FuelCell/Turbine{reg_sign} (DFC/T{reg_sign}) power plants for generation of clean power at very high efficiencies. The DFC/T power system is based on an indirectly heated gas turbine to supplement fuel cell generated power. The DFC/T power generation concept extends the high efficiency of the fuel cell by utilizing the fuel cell's byproduct heat in a Brayton cycle. Features of the DFC/T system include: electrical efficiencies of up to 75% on natural gas, 60% on coal gas, minimal emissions, simplicity in design, direct reforming internal to the fuel cell, reduced carbon dioxide release to the environment, and potential cost competitiveness with existing combined cycle power plants. FCE successfully completed testing of the pre-alpha DFC/T hybrid power plant. This power plant was constructed by integration of a 250kW fuel cell stack and a microturbine. The tests of the cascaded fuel cell concept for achieving high fuel utilizations were completed. The tests demonstrated that the concept results in higher power plant efficiency. Also, the preliminary design of a 40 MW power plant including the key equipment layout and the site plan was completed.

This report summarizes the progress made in development of Direct FuelCell/Turbine{reg_sign} (DFC/T{reg_sign}) power plants for generation of clean power at very high efficiencies. The DFC/T power system is based on an indirectly heated gas turbine to supplement fuel cell generated power. The DFC/T power generation concept extends the high efficiency of the fuel cell by utilizing the fuel cell's byproduct heat in a Brayton cycle. Features of the DFC/T system include: electrical efficiencies of up to 75% on natural gas, 60% on coal gas, minimal emissions, simplicity in design, direct reforming internal to the fuel cell, reduced carbon dioxide release to the environment, and potential cost competitiveness with existing combined cycle power plants. Detailed design of the packaged sub-MW alpha DFC/T unit has been completed for mechanical and piping layouts and for structural drawings. Procurement activities continued with delivery of major equipment items. Fabrication of the packaged sub-MW alpha DFC/T unit has been initiated. Details of the process control philosophy were defined and control software programming was initiated.

The subMW hybrid DFC/T power plant facility was upgraded with a Capstone C60 microturbine and a state-of-the-art full size fuel cell stack. The integration of the larger microturbine extended the capability of the hybrid power plant to operate at high power ratings with a single gas turbine without the need for supplementary air. The objectives of this phase of subMW hybrid power plant tests are to support the development of process and control and to provide the insight for the design of the packaged subMW hybrid demonstration units. The development of the ultra high efficiency multi-MW power plants was focused on the design of 40 MW power plants with efficiencies approaching 75% (LHV of natural gas). The design efforts included thermodynamic cycle analysis of key gas turbine parameters such as compression ratio.