Cleantech Blog

Tuesday, June 19, 2007

Fuel Cell 2007 Conference Highlights

By John Addison (6/19/07). Several hundred engineers, researchers, and managers shared fuel cell technology, trends, and market success at the Fuel Cell 2007 Conference. In some areas, fuel cells generate millions in revenues from commercial deployment; in other areas, fuel cells are early in research and development. A number of commercial products involve hydrogen PEM fuel cells. Business is steady for molten carbonate and phosphoric acid fuel cells. There was optimism about solid oxide fuel cells using a variety of fuels including landfill methane, natural gas, diesel, JP-8, and biomass.

In 2006, Ballard (BLDP) shipped 147 PEM fuel cells to replace lead-acid batteries in fork lifts. In large distribution and manufacturing environments, every minute counts. Fuel cells are cost justified in improving the productivity of moving goods. Fuel cells are more heat and cold tolerant, providing competitive advantage in many distribution centers.

Plug Power (PLUG) is aggressively pursuing the fork lift business. Plug recently acquired General Hydrogen, an early leader in Class 1 and 2 forklifts. Plug also acquired Celex, a leader in Class 3 forklifts. Contrary to concerns of some investors, it appears that Plug’s acquisitions may help Ballard who supplies fuel cell stacks to the acquired companies. Plug Power’s business model appears to be migrating towards integrated products and services for specific markets and applications. Ballard is a leader, in supplying fuel cell stacks; a field of growing and intensifying competition.

Toyota is also active in the hydrogen PEM forklift business since its acquisition of Raymond, a long-time provider of forklifts and material handling systems. Hydrogenics (HYGS) continues to see traction in fork lifts. Fuel cell forklift solutions are hybrid, also involving batteries for regenerative braking. Presentations forecasted 5,000 fuel cell sales in 2009 for forklifts and 20,000 in 2010.

Thanks to the sponsorship of Intelligent Energy, I was at the conference presenting One Million Hydrogen Riders in California by 2020 – An Optimistic Scenario. Free Report.

Hydrogen fuel cells are making progress in cars and heavy-vehicles. Several auto makers will be adding more vehicles in demonstration fleets this year. Several have ranges of 250-miles and more. General Motors recently demonstrated a 300-mile range with its Sequel. GM is rumored to also start demonstrating vehicles running hydrogen in internal combustion machines (HICE). GM was to speak at the conference, but cancelled at the last minute. The reason, perhaps, was a GM reorganization.

General Motors thinks its hydrogen fuel cell is ready to move out of the research lab. GM is shifting responsibility for the work from its research labs to engineering groups that develop engines and vehicles for commercial production. 500 people are being reassigned.

The shift is a sign of GM's increasing determination to have a fuel cell vehicle on the market by around 2011. "We're transitioning from science and research to developing real propulsion systems," Larry Burns, GM vice president for research and strategic planning, said in an interview.

Another area of hydrogen fuel cell success is providing remote stand-by power for the telecommunications industry. Batteries in temperature-sensitive areas have failed to often. The financial stakes are too high in telecommunications to continue depending on unreliable batteries. Telecoms such as Verizon and Sprint are buying from PlugPower and ReliOn. The Western States Alliance is buying from Altergy and Hydrogenics for stand-by back-up.

Big and hot fuel cells have a growing pipeline in the 250kW to multi-MW space. FuelCell Energy (FCEL) and Fuji offer molten carbonate energy solutions with by-product heat. Projects are using natural gas, propane, biogas, and anaerobic digester (AD) gas. POSCO, a Korean steel manufacturer, ordered a 7.5MW from FCEL to reduce their heavy use of 28 cents/kWh grid electricity. Linde will distribute FuelCell Energy for water treatment.

Long-term, molten carbonate growth may be threatened by solid-oxide fuel cells (SOFC). Keenly aware of this, FuelCell Energy finalized terms with the U.S. Department of Energy (DOE) for a $36.2 million Phase I award to develop a coal-based, multi-megawatt solid oxide fuel cell-based hybrid system.

Six industry teams have successfully completed tests of the first solid oxide fuel cell prototypes that can be manufactured at costs approaching those of conventional stationary power-generation technology. Part of the U.S. Department of Energy's Solid State Energy Conversion Alliance (SECA) program, these results reflect progress towards commercially-viable solid oxide fuel cell (SOFC) systems.

The six industry teams, led by Acumentrics, Cummins Power Generation, Delphi Automotive Systems, FuelCell Energy, General Electric, and Siemens Power Generation, designed and manufactured SOFC electrical power generators in the 3-10 kilowatt range. The industry teams' prototypes surpassed the Department of Energy (DOE) Phase I targets. The prototypes demonstrated:

Average efficiency of 38.5 percent and a high of 41 percent, exceeding the DOE target of 35 percent.
Average steady-stage power degradation of 2 percent per 1,000 hours, besting the DOE target of 4 percent per 1,000 hours.
System availabilities averaging 97 percent, topping the 90 percent DOE target across the board.
Projected system costs ranging from $724 to $775 per kilowatt, which eclipsed the DOE intermediate target for an annual production of 250 megawatts and positions the teams to meet the 2010 target of $400 per kilowatt target.

For home stationary power applications, it will require combined heat and power (CHP) to financially justify fuel cell installations. Adaptation is predicted in markets where utility-delivered costs are high for heat and electricity, such as in Japan and Korea. Ballard will be delivering a higher temperature PEM to address the CHP market.

In the long-run, conference attendees showed more enthusiasm for SOFCs which can use existing fuels, such as kerosene in Japan and natural gas in other markets. For example, Ceres Power (CWR.L) is developing low cost and robust fuel cells that will be combined into stacks capable of generating between 1kWe and 25kWe. EDF Energy Networks, the UK’s largest electricity distributor, will be offering Ceres for home CHP.

SOFC may be the fuel cell of choice for auxiliary power on trucks and military vehicles. Delphi Automotive Systems has SOFCs in development for on vehicle use of diesel and JP-8. Cost effective removal of sulfur is a major issue, especially for the DOD’s JP-8.

Surprisingly, there was little discussion of micro fuel cells. Major Japanese consumer electronic companies were at the conference, but no products were presented. Continued reduction in power demand plus advancements in batteries and ultracapacitors may obviate micro fuel cell adoption.

The Fuel Cell 2008 Conference is planned to be in Long Beach, California, in June 2008.

John Addison publishes the Clean Fleet Report which tracks clean transportation in California. His articles have appeared in print and electronic magazines with over one million readers: Yahoo Finance, The Auto Blog, The Auto Channel, EV World, Cleantech, Green Post, Seeking Alpha, Hydrogen Nation and others. Mr. Addison is a popular speaker, conducting over 1,000 workshops in Europe, Asia and the Americas.

Labels: alternative energy, autos, Batteries, cars, cleantech, Cleantech Blog, energy, fuel cell, green tech, greentech, hydrogen

Tuesday, May 15, 2007

Gas Misers or Corn Guzzlers

By John Addison (5/15/07)

People buying new cars are asking if they should get a high mileage hybrid that runs on gasoline, or a flex-fuel vehicle that could run on E85 ethanol. The United States DOE’s and EPA’s fueleconomy.gov, made it easy for car buyers to compare choices.

When you drive, there is most likely ethanol in your fuel tank. Ethanol is a fuel from a plant source that is normally mixed with gasoline. The percentage varies widely. All current U.S. vehicles can run on a blend of up to 10% ethanol (E10).

GM launched a national campaign, "Live Green Go Yellow." GM and Ford (F) have sold millions of flex fuel vehicles (FFV) on the road. GM is prepared to make up to half its vehicles ethanol capable by 2012.

Although FFVs are hot sellers in the USA, most have never had a drop of E85 in their tank. They are only fueled with standard gasoline blends. There are over 6 million vehicles on the U.S. streets that could run E85. Most never have.

Most FFVs are fuel guzzlers; fueled with E85, they are corn guzzlers. In 2007 the best rated car running on E85 was the Chevrolet Impala, with a United States EPA mileage rating of 16 miles per gallon in the city and 23 on the highway when fueled with E85. For a typical U.S. year of driving, the annual fuel cost would be at $1,657 and 6 tons of CO2 would be emitted by this FFV when running on E85.

By contrast, the EPA rating for a Toyota (TM) Prius running on gasoline was 60 miles per gallon in the city and 51 on the highway. The Prius would have an annual fuel cost of $833 and only emit 3.4 tons of CO2, compared to 6 tons from the most fuel efficient E85 offering.

A big problem is that ethanol cuts miles per gallon by about 27%. The energy content of E85 is 83,000 BTU/gallon, instead of 114,000 BTU/gallon for gasoline. Even by 2030, the U.S. Energy Information Administration (EIA) projects that only 1.4% of ethanol use will be E85. The vast majority will be for small percentage blending with gasoline.

The EIA forecasts that ethanol use will grow from 4 billion gallons in 2005 to 14.6 billion gallons in 2030 (about 8 percent of total gasoline consumption vs. today’s 2%). Ethanol use for gasoline blending grows to 14.4 billion gallons and E85 consumption to only 0.2 billion gallons in 2030. In other words, agriculture will be a big winner without any need to spend millions of tax dollars funding E85 stations.

There is a heated debate about whether ethanol helps the environment. In the U.S., the vast majority of ethanol is processed from corn. There is no current environmental benefit if the source-to-wheels use of ethanol includes diesel farm equipment, fertilizer from fossil fuel, coal produced electricity, diesel delivery trucks hauling ethanol over 1,000 miles to refineries, and then fueling a vehicle with poor mileage.

The amount of U.S. corn that became ethanol exceeds 20 percent. The Corn Growers Association says that by 2015 a third of all the corn grown - or 5.5 billion bushels - likely will be for ethanol. Food prices have increased.

World Watch Institute warns “Conventional biofuels will be limited by their land requirements: producing half of U.S. automotive fuel from corn-based ethanol, for example, would require 80 percent of the country’s cropland.” Thus, large-scale reliance on ethanol fuel will require new conversion technologies and feedstock.

A broad coalition is more enthusiastic about cellulosic rather than corn ethanol. Ethanol and other biofuels can be made from a wide range of plant fiber and waste. Currently corn kernels are more easily processed into fuel than cellulosic corn stover, but new enzyme technology can change that. Future stalk for ethanol may include prairie grasses, Miscanthus, Poplar, Willow and algae. Cellulosic sources could produce ten times the yield per acre of corn.

Cellulosic ethanol could account for all 14.6 billion of forecasted consumption, and even more, without needing special E85 pumps. It could all be blended with existing gasoline and fueled into current and future gasoline vehicles. Such blended cellulosic ethanol creates major opportunities for farmers in the United States and the world. It is incremental business, rather than business that competes with existing food business.

The Natural Resources Defense Council has concluded that with “an aggressive plan to develop cellulosic biofuels between now and 2015, America could produce the equivalent of nearly 7.9 billion barrels of oil per day by 2050. That is equal to more than 50 percent of our current total oil use in the transportation sector and more than three times as much as we import from the Persian Gulf alone.”

Increasingly biofuel will not be made from food; rather it will be made from sources such as waste, grasses, fast growth trees, algae, and biotechnology.

Fueling all current high-mileage cars with E10 helps reduce global warming when the ethanol is from cellulosic sources. Putting E85 ethanol in a vehicle with poor mileage does not help. It does not even help the nation with energy independence.

Until flex-fuel vehicles offer the same high mileage as many current cars, do not buy a FFV. The FFV will not help your pocketbook, the nation’s energy security, nor will it help the environment. When you buy your next vehicle, get high miles per gallon.

John Addison is the author of the upcoming book Save Gas, Save the Planet and publishes the Clean Fleet Report http://www.cleanfleetreport.com. This article is copyright John Addison with permission to publish or excerpt with attribution.

Labels: alternative energy, cars, clean fleet, cleantech, Cleantech Blog, energy, ethanol, green tech, greentech, Hybrid