Kentucky Pioneer Energy IGCC

CCT Fuel Cell Demonstration

Cooperative Agreement No. DE-FC21-95MC31262

BASIS OF DESIGN

May 22, 2003

Submitted to:

Global Energy Inc.

312 Walnut St. Suite 2000
Cincinnati, OH 45202

and

U.S. Department of Energy

National Energy Technology Center
626 Cochrans Mill Road
P.O. Box 10940
Pittsburgh, PA 15236-0940

Submitted by:
G. Steinfeld, Project Director
FuelCell Energy Inc.
3 Great Pasture Road
Danbury, CT 06813
 DOE Intellectual Property Disclaimer

“This report was prepared as an account of work sponsored by an agency

of the United States Government. Neither the United States Government
nor any agency thereof, nor any of their employees, makes any warranty,
express or implied, or assumes any legal liability or responsibility for the
accuracy, completeness, or usefulness of any information, apparatus,
product, or process disclosed, or represents that its use would not infringe
privately owned rights. Reference herein to any specific commercial
product, process, or service by trade name, trademark, manufacturer, or
otherwise does not necessarily constitute or imply its endorsement,
recommendation, or favoring by the United States Government or any
agency thereof. The views and opinions of authors expressed herein do
not necessarily state or reflect those of the United States Government or
any agency thereof.”
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

TABLE OF CONTENTS

Page No.

Executive Summary 1

Design Basis 2

1.0 General Design Considerations 2

2.0 Site Data 5

3.0 Fuel Basis 6

4.0 Water Basis 8

5.0 Plant Interfaces 8

6.0 Plant Operating Requirements 9

7.0 Process Systems Design 9

8.0 Environmental Emissions and Effluents 12

9.0 Layout 13

i
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

LIST OF FIGURES

Figure No. Page No.

1 Fuel Cell Power Plant Simplified Process Flow Diagram 14

2 Fuel Cell Power Plant 16

LIST OF TABLES

Table No. Page No.

1 Site Data 6

2 Syngas Analysis 6

3 Natural Gas Analysis 7

4 Water Analysis 8

5 Plant Interfaces 9

6 Emissions Estimates Summary 13

ii
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

EXECUTIVE SUMMARY

The objective of this project is to demonstrate the significant improvement in efficiency

and environmental performance of carbonate fuel cell technology in coal based power
generation systems. As part of this project, FuelCell Energy (FCE) is designing and
constructing a Direct Fuel (DFC) Cell power plant to operate on coal-derived syngas.
The original site for this project was the Kentucky Pioneer Energy (KPE) Integrated
Gasification Combined Cycle (IGCC) project site in Trapp, Kentucky as part of the U.S.
Department of Energy (DOE) Clean Coal Technologies V Program. However, in order
to expedite the project schedule it was relocate to the Wabash River Energy Limited
(WREL) Gasification site in Terre Haute, Indiana, where the gasification plant is already
in operation. This will allow completion of the demonstration more than 2 years ahead
of the estimated current schedule at the Trapp Kentucky site.

Design of the syngas processing system for the original KPE site in Trapp, Kentucky
was initiated by preparation of a preliminary PFD and material and energy balances.
Due to the planned change of site to the Wabash River site and the differences in the
gasification/clean up system, the design of the syngas processing is being updated for
the new location.

1
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

DESIGN BASIS

The Fuel Cell Power Plant will be based on FCE’s standard natural gas-fueled two-
module Direct Fuel Cell (DFC) power plant design, adapted to operate on syngas after
its initial operation and checkout on natural gas. Its balance of plant (BOP) components
will be sized to enable plant power generation of up to 3.0 MW (net ac) using future
technology replacement Fuel Cell Stack Modules containing FCE’s “mature” generation
of fuel cell stacks. It will be highly modularized, and will feature high efficiency, quiet
operation, low emissions, and a small footprint.

The Syngas Fuel Preparation Facility will convert the treated syngas from the Wabash
gasification plant into fuel gas suitable for the Fuel Cell Stack Modules. This will be
accomplished by (1) Additional desulfurization of the syngas to lower its sulfur content
further, and (2) methanating the syngas (in order to utilize the cooling effect of the
endothermic methane reforming reactions within the fuel cell stacks). The Syngas Fuel
Preparation Facility will be located adjacent to the Fuel Cell Power Plant.

The Project’s operating characteristics and performance presented in this document

reflect fuel cell technology advances that FCE expects to achieve in the near future.
The majority of the Fuel Cell Power Plant’s balance of plant (BOP) equipment
(including the inverter system) and all of the Syngas Fuel Preparation Facility equipment
is based on proven and commercially available technology.

1.0 General Design Considerations

The plant will meet the following requirements:

• Location Terre Haute, Indiana

• Plant Fuel Capability:

Anode Fuel Gas Makeup: Coal/Pet Coke derived syngas, natural
gas (one at a time)
Oxidizer Burner Fuel: Natural gas or peak shave gas

• Overall Plant Performance Targets (Nominal Values)

Rated Power Output 2.0 MW (Net AC), lower on syngas due

to lower Btu value of syngas

Power Output Turndown 25% to 100% of Rated Sustainable

Output (stable operation below 25% and
islanding)

2
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

• Electrical Characteristics

Output Voltage 480 Volts Power Quality: IEEE Standard

519
Power Factor Range 0.90 Lag to 0.90 Lead at Rated Output
Power Output Phase 3 Phase, Wye, 4 Wire
Frequency, Hz 60
DC to AC conversion efficiency 95% or greater
Black Start Capability Not included; connection to grid will be
required or stand alone 480Vac
generator provided

• Plant Controls Designed for unattended operation with

local and remote dispatching/control

• Height 25 feet

• Plant Constructability Basis Modular (skidded) design. Truck-

transportable skids complete with pre-
installed piping, valves, insulation,
instrumentation, and electrical wiring.
The plant will be configured to minimize
number of skids to limit footprint
requirements and to limit
interconnectivities during installation.

• Plant Design Life Expectancy 35 years

• Equivalent Availability 95%

• Fuel Cell Stack Modules

Number required in Plant Two

Stack Module Design Internally Insulated Nearly-Cylindrical
Vessel, truck-transportable modules,
each containing four fuel cell stacks

Fuel Cell Type/Configuration Carbonate/DFC (Direct Internal

Reforming/Indirect Internal Reforming
(DIR/IIR)
Operating Temperature 1050-1194°F
Operating Pressure <1 psig
Stack Module Rated Output 1.0 MW (net ac) on natural gas
Design Service Life Expectancy 10,000 – 40,000 hours, based on fuel
cell stack generation

Replacement Philosophy Replacement fuel cell stack modules will

be available to meet the 35-year design
3
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

operating life of the plant, and will be

designed to fit into the plant without
requiring modifications to the balance of
plant components.

• Noise 60 dB(A) or less at 100 feet from the

plant boundary (fence).

Fuel Cell Stack Conditioning Requirements

All fuel cell stack modules will be preconditioned before being installed at the site.

Plant Control Requirements

The plant will be designed for unattended operation with local and remote
dispatching/control. The control system will be able to communicate with a remote
monitoring station located at FCE’s facilities in Danbury, CT for diagnostic purposes.

Control of the plant will be accomplished using a Scaleable Process Control System
(SPCS). The majority of control and monitoring interfaces to the process will be via
“Smart Type Transducers” communicating over Foundation Fieldbus segments, Modbus
Links to PLC’s controllers with classic I/O providing, motor control and multiplexor
interfaces to the non-smart instruments.

The SPCS controllers, power supplies, bus interface modules, I/O racks, data
historian/WEB server and an Engineering Operator Work Station with a laser printer (for
maintenance) will be housed inside the Electrical Equipment enclosure located inside
the plant Inside Boundary Limit (IBL).

The WEB server will interface via a telephone modem for remote communications and a
telephone pager for annunciating alarms.

Materials Selection Requirements

The metallurgy of piping and equipment will be selected to ensure the purity and
freedom from particulates (including pipe slag, rust, etc.) of the anode fuel gas and
cathode oxidant gas supplied to the fuel cell Stack Modules.

Electrical Classification (Preliminary, based on DFC Process Design Guide)

On-site equipment and controls will be designed for electrical classification per code
(e.g. Class 1, Division 2, Groups B & D).

FCE Provided Equipment

FCE will manufacture the fuel cell stack modules. The balance of plant equipment will
be manufactured by subcontractors and delivered to the site by FCE.

4
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

Global Energy Provided Process Gases, and Utilities

Global Energy is responsible for providing the following gases and utilities at a regulated
pressure to a tie-in location adjacent to the plant site: syngas, natural gas, electricity,
municipal water, and sewer connection for process waste water.

Process Safety Considerations

Special process safety considerations are listed below:

• The stack modules and balance of plant equipment (BOP), where applicable, will be
designed to withstand pressure spikes induced by internal deflagrations by adequate
structural design.

Special process safety hazards include the following:

• Leaks of treated syngas downstream from the Feed Treatment System and fuel gas
will not be detectable by smell. Strategically located combustible gas detectors will
be provided to detect methane gas and fuel gas leaks in the Fuel Gas Preparation
system.

• Carbon monoxide, present in significant concentrations in the fuel gas from the
Gasification facility and anode exhaust gas, is highly poisonous. Strategically
located combustible gas detectors will be provided to detect CO leaks in the fuel
gas, anode exhaust gas piping and the Oxidizer.

2.0 Site Data

Site and climatic design conditions for the WREL Gasification site are listed in Table 1.

5
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

TABLE 1. SITE DATA FOR THE WREL SITE

CONDITION DESIGN POINT1 SITE SPECIFIC DATA

Elevation 0 ft. above sea level 520 ft. above sea level
Avg ambient Temperature, °F 60 59
Min Ambient Temperature, °F -20 -20
Max Ambient Temperature, °F 104 100
Avg Ambient Pressure, in Hg 29.9
Avg Relative Humidity, %RH 60 60
Wind Loading @ 33 ft, PSF 302
Precipitation, in/hr 2.5 2.4 in-25 yr interval
Snow Load, PSF 303 20
Ambient Dust Loading, Avg/yr 27µgm/m3 Dust and Coal Dust
Ambient Gaseous Halide Conc, 20 ppbw
Avg/yr
Ambient Gaseous SOx Conc, <10 ppb
Avg/yr
Seismic Zone (US 4 2A
Height Limit, ft 25
Noise Limits, db(a) @ 100 ft 60 “Normal OSHA Work Place”

3.0 Fuel Basis

The Fuel Cell Power Plant will be supplied with treated syngas from the WREL
Gasification plant after acid gas removal. The gas analysis shown in Table 2 is
representative of the range of compositions estimated for the coal gasification plant.
When syngas is not available from the gasification plant, and during initial startup and
commissioning, natural gas will be used as feed to the fuel cell power plant.

TABLE 2. WREL Syngas Data

Component Coal operation Petroleum Coke Operation

H2 vol % 34.4 33.2
CO vol % 45.3 48.6
CO2 vol % 15.8 15.4
CH4 vol % 1.9 0.5
N2 vol % 1.9 1.9
Argon vol % 0.6 0.6
Total Sulfur ppmv 301 280
HHV, Btu/SCF 277 268

1
DFC basis used for plant performance projections and design of equipment.
2
This wind load of 30 PSF is based on a wind speed of <90 mph and Exposure C. Exposure C is defined
as “Open terrain and scattered obstructions have height generally <30 ft” (American Society of Civil
Engineers standard ASCE 7-88).
3
Snow load is equivalent to a ground snow load of 40 PSF and a snow exposure factor of 0.7 (Uniform
Building Code UBC-97)
6
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

Natural gas can be used as an alternate fuel for the fuel cell power plant and is used in
the thermal oxidizer for the pilot and as startup fuel to heat up the plant. The natural
gas analysis for the site is shown in Table 3. The reference gas and range/limit data
are the basis of design for the equipment in the DFC power plant.

TABLE 3. NATURAL GAS ANALYSIS

Fuel Cell Power Plant WREL Site Specific

Design Basis
Range Performance Range4 Performance
Gas Gas5
Composition
Methane, vol % 80 – 100 93.0 95.8-96.1 96.00
Ethane, vol % 0 – 10 1.9 2.13-2.23 2.17
Propane, vol % 0–3 0.6 0.28-0.33 0.30
Butanes, vol % 0 – 1.25 0.5 0.10-0.12 0.11
Pentanes+, vol % 0 – 0.5 0.0 0.10-0.12 0.1
Unsaturated Hydrocarbons None None None None

Inert Gases
Nitrogen, vol % 0–3 1.1 0.34-0.39 0.35
Carbon Dioxide, vol % 0–3 1.1 0.96-0.99 0.97
Total Inerts, vol % 0–6 2.2 1.3 - 1.38 1.32

Oxygen 0 – 0.2 0.0 0.0 0.0

Impurities
Total Sulfur, ppmv 0 – 12 6 6
Grains/100 SCF 0 – 0.7 0.36 0.36
H2S, ppmv 0 – 0.8 0 0
COS, ppmv 0–2 0 0
Odorants, ppmv 0 – 12 6 6

Halogens (Cl, etc) None None None

Dust, Gum, Solid Matter None None None

Water, lb/MMscf 0-7 Dry Dry

Physical Properties
Heating Value, Range
- LHV, Btu/scf 870 – 1000 933 933
- HHV, Btu/scf 970 – 1100 1035 1035

Pressure, psig 15 – 20 15 15
Temperature, °F 40 - 75 60 60

4
Source “Power Plant Needs List” E-mail from Jeff Stockton WREL to George Steinfeld (FCE), dated
6/24/02
5
The Performance Gas Composition is estimated from the average of the range.
7
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

4.0 Water Basis

Municipal potable water is supplied to the plant to meet its process water requirements.
The data in Table 4 shows the range of water compositions that the plant is designed
for. The performance water criteria listed in the table is the basis to be used for
estimating the plant’s water treatment requirement and flow at rated output and the
WREL water is representative of the municipal water supply at the WREL site.

TABLE 4 WATER ANALYSIS

RANGE / REFERENCE WREL

LIMITS WATER WATER
(DFC BASIS) (DFC RANGE
BASIS)
Quality
Calcium (Ca), mg/l as CaCO3 0 – 120 44
Magnesium (Mg), mg/l as CaCO3 0 – 30 16
Sodium (Na), mg/l N/A 16 < 24
Bicarbonate (HCO3), mg/l as CaCO3 0 – 90 50
Chloride (Cl), mg/l 0 – 50 17 < 31
Sulfate (SO4), mg/l 0 – 90 20 < 80

Total Dissolved Solids, mg/l 0 – 350 135 < 392

Total Hardness as CaCO3, mg/l 0 – 150 60 < 310

Silica (SiO2), mg/l 0 – 10 3 < 4.6

Iron (Fe), mg/l 0 - 0.1 0.03 < 2.0
Copper (Cu), mg/l 0 - 0.05 0.01 < 0.05

Silt Density Index 0–5 2

Specific Conductance, micromho/cm 0 – 580 205 < 563
PH 7 - 8.5 7.6 7–8

Properties
Temperature, °F 40 – 90 59
Pressure, psig 50 – 65 60

Notes: 1. Source: “Fuel Cell Power Plant Needs List”, E-mail from Jeff Stockton WREL to George
Steinfeld (FCE), dated 06/24/02.

5.0 Plant Interfaces

The process gases, utility services, and control interfaces listed in Table 5 will be
required for the fuel cell power plant. WREL is responsible for line sizing, pressure
relief, and pressure regulation up to the plant interface location.

8
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

TABLE 5. PLANT INTERFACES

PLANT INTERFACE REQUIREMENTS

Process Gases

Coal/Coke- Derived Syngas

Natural gas

Utility Services

Potable Water
Electricity
Sewer
Flare

Control Interfaces

Data communications link(s) to WREL control center/

dispatch facility & FCE monitoring Station

6.0 Plant Operating Requirements

The WREL Fuel Cell Power Plant will be designed to operate on syngas from the WREL
gasification facility when operating on either coal or pet coke or a blend of both. During
periods when syngas is not available the fuel cell power plant can operate on natural
gas.

7.0 Process Systems Design

The functionality of each of the major process systems is described below.

Syngas Preparation System

The design of the Syngas Preparation Unit is based on receiving a syngas from the
WREL gasification plant that has been desulfurized but can have up to 320 ppmv total
sulfur content. The sulfur is primarily a combination of H2S and COS and has to be
reduced to 0.1 ppm. A sorbent such as ZnO can be used to capture the H2S and the
COS can be either hydrogenated or hydrolyzed to form H2S, which can be captured by
ZnO. After desulfurization the syngas will be methanated in three stages with
intercooling. The resulting methane rich gas is fed to the fuel cell power plant.

Natural Gas Fuel Preparation System

The Natural Gas Fuel Preparation System will treat natural gas for use as a fuel within
the fuel cell plant as follows:

9
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

1. Preheat if required during cold weather in an optional heater,

2. Desulfurize and remove other contaminants from the gas at ambient temperature, in
the Cold Gas Desulfurizers;
3. Pre-reform to remove higher hydrocarbons

Nitrogen Gas Supply System

The Nitrogen Gas Supply System will provide low pressure nitrogen gas for purging
operations and protecting the Fuel Cell Stack Modules during Plant Shutdown/Trip
modes. The Nitrogen Gas Supply System consists of pressurized gas cylinders.
Additional nitrogen will be required for use in certain maintenance activities.

Nitrogen will be required in the plant for:

1. purging of the fuel gas piping and fuel cell anodes at the beginning of start-up,
2. purging of the fuel gas piping prior to maintenance activities,
3. purging of the Cold Gas Desulfurizer canisters before change-out,
4. providing an inert gas curtain of the fuel cell cathode exit line when the plant is
placed in Shutdown mode to avoid a vacuum condition in the stack module as the
module cools down,
5. purging of the fuel gas piping and fuel cell anodes when the plant is placed in
Shutdown mode to avoid Ni carbonyl formation (within the Prereformer and the RU)
and condensation of the moisture.

Heat Recovery System

The Heat Recovery System will:

1. Collect the cathode exhaust gas exiting the Fuel Cell Stack Modules
2. Utilize waste heat from the cathode exhaust gas to
a. superheat the anode fuel gas, and
b. humidify and preheat the feed natural (or peak shave) gas
3. Vent the cooled cathode exhaust gas to the atmosphere.

The system includes a portion of the cathode exhaust gas piping to the Heat Recovery
unit. The Heat Recovery System will include an internal bypass to limit the heat
addition in the humidifier and thus control the exit temperature of the humidified fuel gas
such that the operating temperature limit of the downstream Preconverter is not
exceeded.

Oxidizer Supply System

The Oxidizer Supply System will:

1. Compress ambient air for cathode oxidant makeup

2. Collect, mix with the pressurized air stream, and catalytically oxidize the anode
exhaust gas from the Fuel Cell Stack Module System
3. Generate cathode oxidant gas at the flow rate, composition, and temperature
required for fuel cell power generation, and
4. Deliver the oxidant gas to the Fuel Cell Stack Module System.
10
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

The Oxidant Supply System will also burn desulfurized natural gas in the pressurized air
stream to generate a hot effluent gas to achieve the temperatures and flow rates
required for controlled heating and cooling of the fuel cell stack modules during plant
startup, shutdown, and standby operation.

The Oxidant Supply System is designed to integrate the operation of the fuel cell
anodes and cathodes during power generation by:

1. Utilizing the residual fuel energy and sensible heat in the anode exhaust gas to heat
air to the required oxidant gas temperature, and
2. Recirculating the carbon dioxide generated in the fuel cell anodes back to the fuel
cell cathodes to support the cathode reactions. All components of the Oxidant
Supply System will be located on a single skid.

Fuel Cell Stack Module System

The Fuel Cell Stack Module System will:

1. Receive superheated anode fuel gas from the Fuel Gas Preparation System and hot
cathode oxidant gas from the Oxidant Supply System,
2. Generate dc electric power for the Inverters by converting the fuel energy in the
anode fuel gas to electrical energy, and
3. Discharge anode exhaust gas to the Oxidant Supply System and cathode exhaust
gas to the Heat Recovery System.

The Fuel Cell Stack Module System will include two Fuel Cell Stack Modules
(containing four fuel cell stacks each).

Inside the fuel cell stacks, anode fuel gas will be reformed and electrochemically
reacted with the cathode oxidant gas to generate dc power according to the following
reactions:

CH4 + H2O ↔ CO + 3 H2 (Methane Reforming Reaction)

H2O + CO ↔ H2 + CO2 (Shift Reaction)
H2 + CO3≡ → H2O + CO2 + 2e- (Anode Half-Cell Reaction)
CO2 + ½ O2 + 2e- → CO3≡ (Cathode Half-Cell Reaction)

The Fuel Cell Stack Module interfaces with the BOP process piping will be designed to
enable changeout of the Fuel Cell Stack Module.

Each initial generation stack module will be nominally rated at 1.0 MW (net ac) power
output based on natural gas fuel. The plant may be derated somewhat for operation
with a syngas fuel derived from gasification. The stack modules will be gas-tight to
provide environment containment at operating pressures up to 2 psig.

Water Treatment System

The Water Treatment System will:

11
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

(1) Purify chlorinated municipal water for use as fuel gas humidifier makeup; and
(2) Provide a 10-hour service capacity of treated water for use during water
purification equipment outages.

The system is designed for operation with makeup water that meets the performance
water criteria in Table 4, and will be easily amenable to upgrades to accommodate
makeup water qualities outside these design limits.

The Water Treatment system is designed for continuous, reliable, and automatic
operation.

Instrument Air System

The Instrument Air System will produce dry, compressed air and distribute it to
pneumatically operated control valves and panel purges in the balance of plant (BOP)
equipment. Oil-free, rotary type air compressors are used.

Electrical Balance of Plant

The Electrical Balance of Plant converts the DC electric power generated by the fuel
Cell Stack Modules to AC electric power. The Electrical Balance of Plant contains all
electrical system protective devices and the distribution and control devices for auxiliary
loads.

8.0 Environmental Emissions and Effluents

An estimate of the plant’s environmental emissions is listed in Table 6. Continuous

effluent streams from the plant during normal operation are:

1. The fuel cell’s cathode exhaust exiting the exhaust stack. Air emissions in the fuel
cell exhaust gas are nearly negligible. SOx emissions are essentially zero because
the fuel gas feed to the fuel cells contains less than 0.1 ppmv sulfur, and NOx
emissions are low due to the low operating temperatures in the Oxidizer and fuel
cells. VOC’s and carbon monoxide emissions are also very low.

2. The liquid effluent from the plant during normal operation includes
reject/regeneration/backwash water from the Water Treatment system. The quality
and temperature of the effluent water stream are expected to be satisfactory for their
disposal into a municipal sewer.

Solid wastes generated in the plant require disposal intermittently. These include spent
sulfur absorbent and deactivated catalysts. The spent material is collected in waste
bins prior to being shipped off-site. The Preconverter and oxidation catalysts are
suitable for recycle/sale to catalyst reclaimers. The spent sulfur sorbent will be returned
to the supplier for regeneration or disposal. Other intermittent wastes will occasionally
be generated, such as used lube oil that must be replaced per equipment vendor
specifications.

12
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

Rainwater or washdown water from the site can be directed to a stormwater drain. Oil
leakage beneath rotary equipment is contained to allow clean up during the regular
maintenance.

TABLE 6 EMISSIONS ESTIMATES SUMMARY (1)

Emission / Effluent Rated Output

Estimated Emissions
(ppmv)
Air Emissions
SO2 0.026
NOx (as NO2) 0.267
CO 0.2
VOC (as C) 2.4
PM (µg/acm) 249

Note: (1) Values listed are wet-basis based on concentrations measured on sub-MW
scale DFC operating on natural gas. PM concentration adjusted for stack temperature.

9.0 Layout

Most of the plant equipment is packaged in modules or skids, which are placed on
concrete foundations. The skidding philosophy consists of combining equipment on
common skids in order to minimize the plant footprint, and reduce the interconnection
activities in the field. The plant requires a rectangular footprint. The plant height will not
exceed 25 feet.

The plant’s piping and structural interfaces with the fuel cell stack modules are designed
to be identical to those planned for all other megawatt class DFC Fuel Cell Modules.

An access zone capable of supporting the module transporter and the crane used to
install and remove the Fuel Cell Stack Modules and other equipment skids, and which
enables access for catalyst/sorbent/brine salt removal and replacement, will be provided
adjacent to the physical plant boundary. A laydown area will be provided adjacent to
the plant during construction.

Process and Plant Configuration

The fuel cell power plant will first operate on natural gas then it will operate on clean
syngas supplied by the coal gasification plant. The design philosophy is to develop a
standard Direct Fuel Cell (DFC) power plant optimized for natural gas and rated for 2.0
MW, then determine its performance using syngas fuel. The syngas is treated in a fuel
preparation unit to increase the methane content. The plant can therefore use the
cooling effect of the endothermic methane reforming reactions within the DFC fuel cell
stacks.

A block diagram of the power plant configuration is shown in Figure 1. Fuel (natural
gas) (shown in dotted lines) enters an electric heater and then the cold gas desulfurizer.
The desulfurizer contains activated carbon beds to remove contaminants from the gas.
13
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

Low Temp
Desulfurizer

Syn Gas
Water Natural Gas
Processing
Unit
Fuel Cell
Modules
Water
Cathode Power Plant
Exhaust
Syn Gas from Anode
Gasification Plant
Preconverter
Cathode

Anode

Oxidizer
MO2788
Air Blower 42602

Figure 1. Fuel Cell Power Plant Simplified Process Flow Diagram

The desulfurized fuel is humidified and preheated using waste heat from the fuel cell
exhaust. The stream is fed to a deoxidizer (not shown in Fig 1) to remove O2 present in
natural gas and peak shave gas and then to a preconverter. The preconverter reforms
higher hydrocarbons generating hydrogen. The stream is superheated using the waste
heat from the fuel cell exhaust and fed to the anodes in the fuel cell modules.

The depleted fuel from the anodes goes to the oxidizer, where the unused fuel is
catalytically oxidized with air supplied by the air blower (shown in blue lines in Figure 1).
The exit stream from the oxidizer is fed to the cathodes in the fuel cell modules. The
exhaust from the fuel cell modules is used to supply heat for the fuel treatment
processes. These heat exchangers are located in the Heat Recovery Unit (HRU). A
catalytic polishing unit is also installed in the HRU to recover heat by oxidizing any
combustible gases that may be present in the cathode exhaust.

The plant also contains a startup system (an electric heater and blower) that is used to
initially raise the temperature of the fuel cell modules from ambient to about 150°F. A
nitrogen gas supply system provides low-pressure nitrogen for purging operations
during plant trips and shutdowns. A water treatment system supplies deionized water
for fuel gas humidification.

There are two fuel cell stack modules each containing four stacks. Inside the fuel cell,
the anode fuel gas is reformed and electrochemically reacted with the cathode oxidant
as to generate DC power:

CH4 + H2O → CO + 3 H2 (Methane Reforming Reaction)

H2O + CO → CO2 + H2 (Shit Reaction)
H2 + CO3= → CO2 + H2O + 2e- (Anode Half-Cell Reaction)
CO2 + ½O2 + 2e- → CO3= (Cathode Half-Cell Reaction)

14
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

The electrical equipment in the plant contains inverters to convert the DC electric power
generated by the fuel cell stack modules to AC electric power, transformers and
switchgear required for the plant. The electrical/control center incorporates a
Distributed Control System (DCS) required for operating the plant.

During syngas operation the fuel stream from the gasifier will pass through a syngas
processing unit that desulfurizes and methanates the syngas from the WREL
gasification system.

Power Plant Description

The overall plant footprint is 2935 ft2. The Clean Coal Fuel Cell Power Plant is highly
modularized, consisting of the Fuel Cell Stack Modules as well as mechanical and
electrical equipment skids. The skidding philosophy, combining equipment on common
skids, has resulted in a smaller plot plan. All components are designed for outdoor
installation and are truck-transportable to the site using standard or customized trailers.

Figure 2 depicts a 3-D model of the fuel cell demonstration power plant. This does not
yet include the syngas treatment facility to be built in two skids that will be placed next
to the fuel cell power plant.

There are four BOP skids, from left to right, the Fuel Processing skid, Anode Gas
Oxidizer/Heat Recovery skid, Water Treatment/Instrument Air skid, and the Power
Conditioning skid. Two fuel cell modules, shown in the cylindrical vessels, and a start-
up blower complete the power plant.

15
FuelCell Energy, Inc.
Cooperative Agreement No. DE-FC21-95MC31262

Figure 2. Fuel Cell Power Plant

The BOP equipment skids will be pre-assembled and tested at the fabrication shop
before shipment to the site. The Fuel Cell Stack Module will be assembled and
conditioned in the FCE Danbury, CT conditioning facility. Inter-connecting piping
between skids has been minimized in the plant design and will be fitted at the skid
fabricator to insure proper fit. The instrumentation and electrical components on the
skids will be pre-wired, with all connections terminating at junction boxes.

16