Innovative Energy Systems

Field Test of MCFC Stacks operating with Biogas

3rd International Workshop on Fuel Cells

WICaC 2006
Brazilian Reference Center for Hydrogen Energy

October 18 – 19, 2006

Campinas/SP/Brazil

Johann Bergmair
Profactor, Austria Steven Trogisch

PROFACTOR Produktionsforschungs GmbH

A-4400 Steyr | Austria | Im Stadtgut A2
Tel +43(0)7252/885-403 | Fax +43(0)7252/885-101
sekretariat@profactor.at | www.profactor.at
 Contents

• Biogas towards Fuel Cells

• Why Molten Carbonate Fuel Cell (MCFC) ?
• Synergies for the combination of MCFC and biogas as fuel
• The EFFECTIVE project – EU RTD project
• Gas upgrading
• FC test beds
• Conclusions

• Biogas Fuel Cells applications and other EU RTD projects

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 2
Biogas towards Fuel Cells
Fuel cell scenario – clean energy future

•If we are looking for sustainable and clean energy

future and we choose for effective energy conversion
fuel cells as a tool, then we have to think about where
we get our hydrogen or prime fuel from.

•This prime fuel has to be, up to a certain extent, from a

renewable energy source and be as far as possible
directly suitable for its energy transformation in fuel cells
in order to avoid a neutralisation of it advantages.

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 3
Biogas – renewable energy
Advantages

• Biogas is a renewable energy with the highest potential for

green house gas reduction1

• Decentralised energy production (approx.1MWel)

• Cost reduction of waste disposal and new income for the

agricultural sector

• Closing of the nutrient cycle (agriculture)

• Several European directives encourage biogas utilisation

1Greenhouse gas emissions (IEA Bioenergy Task 25, G. Jungmeier gerfried.jungmeier@joanneum.ac.at)

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 4
 Why MCFC?
High temperature versus low temperature

Low temperature FC High temperature FC

FC Type PEMFC AFC PAFC MCFC ITSOFC TSOFC
80 100 200 °C 650 800 1000 °C
H2 F F F F F F
CH4 & CnHm IG poison IG IG/F F F
CO2 IG poison IG React. IG IG
CO poison poison poison F F F
(<50ppm) (<500ppm)
H2S, COS nd poison poison poison poison poison
(<50ppm) (<0.5ppm) (<1.0ppm)
NH3 poison F poison F F F
Analysis on siloxanes
siloxanes, halides, tar, dust, and other contaminants are still unsure!
F.....Fuel, IG…. Inert gas, Reactant ....... Takes part in electrode reaction
rd
3 International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 5
 Why MCFC

• High temperature FC – internal reforming

• Ideally suitable for biogas (due to the biogas composition:

CO2 and CH4)

• High electrical efficiency (~49%), due to the beneficial impact

of carbon dioxide
MCFC
• Near to market
H2 O2
CO2 CO3 --

H2O CO2
MTUs
Hot Module Stack Operating temperature MCFC: ~ 650 °C,
(250 kW el) enabling internal CH4 reforming

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 6
 Synergies MCFC - Biogas

• Utilisation of RES in FC technology – leading to a better

sustainable energy production

• Efficient and clean energy conversion of valuable RES

• High user potential for utilising the process heat which is

released from the MCFC-process

• Decentralised energy production

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 7
 Contents

• Biogas towards Fuel Cells

• Why Molten Carbonate Fuel Cell (MCFC) ?
• Synergies for the combination of MCFC and biogas as fuel
• The EFFECTIVE project – EU RTD project
• Gas upgrading
• FC test beds
• Conclusions

• Biogas Fuel Cells applications and other EU RTD projects

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 8
 The EFFECTIVE project
Biogas usage in fuel cells

EFFECTIVE
Holistic integration of MCFC technology towards a most EFFECTIVE systems
compound using biogas as a renewable source of energy.

• Project start: 07 / 2000

• Duration: 4 years
• Budget: ~ 3.5 Mio Euro

• Financing: Own contribution, EU - Commission, bm:bwk

• Partners: Profactor (A), Studia (A), Linz Strom GmbH (A),

MTU (D), Seaborne (D), Uni Nitra (SK), Ciemat (E),
Urbaser (E)
3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 9
 The EFFECTIVE concept
Biogas usage in fuel cells

Organic Biogas Biogas Distribution

Production of
resudues production upgrading Electricity and heat
Biogas Biogas Fuel cell for
Production upgrading electricity and heat

Gas upgrading is
a key issue

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 10
 EFFECTIVES approach
Biogas usage in fuel cells
• Development and construction of 2 gas purification
systems for H2S removal

• Construction of two FC test beds:

• One mobile system to be installed in Germany,
Austria and Spain
• One stationary system in which long term tests are
made at the Univ. of Nitra (Slovakia)

• Tests (endurance and performance) with different gas

qualities on basis of six lab scale stacks (300 W)

• Socio technical integration of biogas-FC technology in

Spain and Slovakia
3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 11
 EFFECTIVES gas upgrading
Biological gas upgrading

• Biological biotrickling filter for

H2S removal, built by
Profactor:

• 32 month endurance operation

in Nitra, Slovakia, achieving
the aim of less than 10 ppm
H2S in the outlet gas

• Capacity: 200 l/h

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 12
 EFFECTIVES gas upgrading
Biological gas upgrading: basic concept

BASIC PROBLEMS:

- Mixture of oxygen and biogas

at 650°C - safety problems
- Oxygen damages anode
of fuel cells
- N2 from air dilutes the biogas

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
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 EFFECTIVES gas upgrading
Biological gas upgrading: EFFECTIVES design

BUBBLE
COLUMN
Air
BIOGAS

BIOTRICKLING Air
FILTER

Fresh
Medium
CLEANED
GAS

NaOH
Recirculated
Liquid

Used Medium
3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 14
 EFFECTIVE Test Periode 2003

Biofilter performance

Biological PPU - Biotrickling Filter at Biogas Plant Kolinany / Nitra

Period January - June 2003

1000

900 H2S in Raw

Gas [ppm]
H2S in Raw Gas [ppm]

800

700

600

500

400

300

200

100

120
110
Biogas out of Small Stack 1 in operation Big Stack 2 in operation
H2S Clean Gas [ppm]

100 H2S Clean

90 Biogas Plant Biogas Gas [ppm]
80 Plant
70
January to mid of February
60
50 Biotrickling filter not in operation
40
30
20
10
0
1

6
.0

.0

.0

.0

.0

.0

.0

.0

.0

.0

.0

.0

.0

.0

.0

.0

.0

.0

.0
01

11

21

31

10

20

02

12

22

01

11

21

01

11

21

31

10

20

30
January - June 2003

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 15
 EFFECTIVE Test Periode 2003

Biofilter performance

Biological PPU – Biotrickling Filter at Biogas Plant Kolinany / Nitra - period 2003

Month H2S raw gas H2S cleaned gas H2S loading rate Elimination capacity
[ppm] [ppm] [ppm] [ppm] [gH2S/m³h] [gS/m³h]
average max. average max. average max. average max.
Feb 03 587 796 1 1 2,3 6,6 4,6 6,2
Mar 03 410 868 0 3 4,2 7,2 4,0 6,8
Apr 03 44 257 0 1 0,6 3,4 0,5 3,2
*)
May 03 132 811 4 109 0,7 5,1 0,4 3,7
June 03 92 291 2 32**) 1,2 3,6 1,1 3,4
July 03 75 168 2 7 1,2 2,6 1,1 2,5
Aug 03 46 186 1 1 0,7 2,8 0,6 2,8
Sept 03 59 315 1 1 0,8 3,7 0,7 3,5
Oct 03 1 24 0 0 0 0 0 0
Nov 03 828 4212 11 *) 64***) 3,3 9,7 3,1 0,9
Dec 03 189 621 1 1 2,3 9,8 2,1 9,1
*)
Too quick change of H2S loading rate switching from the big to the small fermenter
**)
Surrounding temperature of measurement instrument very high (summer period) – failure possible
***)
In November 2003 the FC test bed was out of operation

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 16
 EFFECTIVES gas upgrading
Site for long term endurance tests

Biogas – fuel cell lab

Foto Gadus Foto Gadus

Biogasplant from the University of Nitra, Slovakia

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 17
 EFFECTIVES gas upgrading
Biological gas upgrading: EFFECTIVES design

Gas analytic for raw gas & cleaned gas, Biotricklingfilter coupled with MCFC
Micro GC for MCFC gas analytics testbed

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 18
 EFFECTIVES gas upgrading
Chemical gas upgrading

• Chemical H2S-filter,
based on Ironoxide,
built by Seaborne:

• 6 month endurance
operation in Germany and
2 months in Austria, also
achieving the aim of less
than 10 ppm H2S in the
outlet gas

• Capacity: 200 l/h

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 19
 EFFECTIVES gas upgrading
Chemical gas upgrading: test cycle in Asten

MCFC
Testbed
and
chemical
biogas filter
in Asten
2003
(Austria)

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 20
 EFFECTIVE
MCFC Testbeds

Designed and constructed

by MTU CFC Solutions

Right Control Unit

Center Operator
Left Operation Unit

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 21
 EFFECTIVE
MCFC Stack used for the project (300W)

• 300 W stack
• With 10 cells each
• Six units available for
the project
• After each of the 6
test cycles the used
stacks are removed
and undergo a series
of material analysis EFFECTIVES 300W Stack, manufactured by MTU

(CIEMAT and MTU)

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 22
 EFFECTIVE
The process of the MCFC test bed

Screenshot of
control unit

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 23
 Locations for Biogas – MCFC test
EFFECTIVES approach
cycles in EFFECTIVE Test locations for the
Chemical gas upgrading EFFECTIVE Testbeds in:

•Slovakia:
agricultural biogas
•Germany:
Owschlag, Germany,
2.200 hours operation
industrial waste
(Industrial research biogas
center, Seaborne GmbH)

Linz, Austria, 1.500 •Austria:

hours operation (Waste
water treatment plant in waste water
Asten, Linz AG)
treatment biogas
•Spain:
landfill gas

Nitra, Slowak Republic, 2.400

hours in operation in first cycle,
over 3.300 hours in the 2nd
(Agricultural Biogas plant at
rd
Pinto,
3 International Workshop on Fuel Cells, Spain,
WICaC 2.000
2006, hours
Campinas/SP/Brazil,
Uni Nitra)
October 18 – 19, 2006
© PROFACTOR 2006 Page 24
operation (Waste
treatment plant, Urbaser)
 EFFECTIVE
Technical conclusions
• Biogas operation of MCFC is possible without any problems
(after more than 15.000h operating experience) provided a
suitable biogas purification is available

• el. efficiency of MCFC stack of 50% achieved (Seaborne)

• Posttest analyses of the FC stack indicate no severe

interaction between biogas and fuel cell system components

• NH3 reduction by catalytic decomposition in the fuel cell

system happens and serves as fuel

• The key issue is the gas purification

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 25
 EFFECTIVE
General conclusions
•The synergy potential for biogas and fuel cell systems seems to
be enormous with view of an sustainable energy supply
•Using biogas as renewable fuel for FC is a very promising clean
application. A specific legal framework should promote this
technology.
•Biogas - MCFC technology for CHP is in competition with gas
engines. Justification must be found in environmental issues.
•Demonstration sites should be set up in different sectors.
Today a proximity to R&D locations as well as transfer points to
modern business is preferable

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 26
… EFFECTIVE publishes a book !

Release: June 2004.

Relevant topics in over 200 pages are:

• Hydrogen and fuel cell perspectives for
Europe
• Synergies of biogas and fuel cell application
• Marketability analysis of biogas-FC in Spain
• A quality approach for Biogas-FC in Austria,
Slovakia and Spain: a site selection
•More info under www.profactor.at

•ISBN 3-85487-626-2
3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 27
 Contents

• Biogas towards Fuel Cells

• Why Molten Carbonate Fuel Cell (MCFC) ?
• Synergies for the combination of MCFC and biogas as fuel
• The EFFECTIVE project – EU RTD project
• Gas upgrading
• FC test beds
• Conclusions

• Biogas Fuel Cells applications and other EU RTD projects

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 28
 Biogas – Fuel Cell applications
Several European demonstration activities…

•In Germany: full scale PC25C (200 kW PAFC) in the

waste water treatment plant of Köln-Rodenkirchen,
achieving el. efficiencies of 39%.

• In Germany: Schmack Biogas test scale with 300 W

MCFC test bed with agricultural biogas

• In Germany: Biogas – PEM project at the FAL institute

with co-fermentation gas at testing scale (~300 W)

• Also in Japan und USA demo projects have been started

or are starting soon, mainly with full scale PAFC operated
with waste water treatment gas
3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 29
 Biogas – Fuel Cell applications
Several European demonstration activities …

• In Switzerland: SULZER Hexis operated a full scale 1

kW SOFC Pilot plant at an agricultural biogas plant in Lully.
achieving el. efficiencies of 35%. Operating time: approx.
5.000 h

• In Germany: MTU CFC-Solution MCFC „Hot Module“

since 2006, fuel: biogas of co-fermentation plant, 245 kWel,
170 kWth, el. efficiency: stack: 55%, total: up to 47%

• EFFECTIVE is a project that involves also own

development of gas upgrading and that gathers that large
experience with different gas qualities

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 30
 Biogas – Fuel Cell applications
Main applications:…

• Decentralized: Biogas from agricultural and industrial wastes

• Stationary energy production
• Size >200kWel
• Mainly with high temperature fuel cells (MCFC & SOFC)
• Different source gases possible provided a suitable
gas purification is available
• If mobile applications, then with stationary reforming and
gas upgrading for PEM

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 31
 Biogas – Fuel Cells EU RTD projects
MCFC other renewable fuels…

BioVision
Energy supply in form of electricity, heat and cold using high temperature fuel cells

• Project start: 03 / 2006

• Duration: 1.5 years
• Budget: ~ 0.5 Mio Euro

• Financing: Austrian Government, German regional found

• Partners: Profactor (A), TU Vienna (A), Studia (A), MTU (D)

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 32
 Biogas – Fuel Cells EU RTD projects
MCFC other renewable fuels…

BioVision
Energy supply in form of electricity, heat and cold using high temperature fuel cells

gaseous fuels
liquid fuels

 Biogas  Biodiesel
Energy plants  Glycerin
Co-fermentation  Bioethanol
 Sewage plant gas  Vegetable oil
 Natural gas  Diesel

Fuel transport  Methanol
 no/optional
Fuel transport
 yes (high energy density)

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 33
 Biogas – Fuel Cells EU RTD projects
Different biogas qualities for testing a SOFC…

BioSOFC
Design and demonstration of 4 CHP Plants using two 5 kW Solid Oxide Fuel Cells
(SOFC) working with landfill gas and biogas from anaerobic digestion

• Project start: 10 / 2006

• Duration: 2.5 years
• Budget: ~ 2.5 Mio Euro
• Financing: Own contribution, EU - Commission
• Partners: Hera (E), Biogas Fuel Cell (E), Profactor (A),
Protecma (E), KIBZ Stuttgart (D), SOGAMA (E), Patrimonia
Natural (E), INEGA (E)

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 34
 Biogas – Fuel Cells EU RTD projects
Different biogas qualities for testing a SOFC…

BioSOFC
Design and demonstration of 4 CHP Plants using two 5 kW Solid Oxide Fuel Cells
(SOFC) working with landfill gas and biogas from anaerobic digestion

Biogas test sites

 Landfill Biogas Plant Catalonia landfill
 Biogas Plant in Asturias slaughterhouse waste
 Landfill Biogas Plant in Galicia landfill
 Biogas Plant in CyL. landfill or mining facility

Biogas conditioning and purification

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 35
 Biogas – Fuel Cells EU RTD projects
Biogas cleaning and reformer for PEM…

Bio-Hydrogen
Development of a Biogas Reformer for Production of Hydrogen for PEM Fuel Cells

• Project start: 07 / 2005

• Duration: 2 years
• Budget: ~ 1.7 Mio Euro

• Financing: Partner contribution, EU - Commission

• Partners: Profactor (A), Besel (E), Schmack (D), Bitter (A),

Udomi (D), Proton Motor (D), Fronius (A), Uni Duisburg (D),
Uni Nitra (SK)

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 36
 Biogas – Fuel Cells EU RTD projects
Biogas cleaning and reformer for PEM…

Bio-Hydrogen
Development of a Biogas Reformer for Production of Hydrogen for PEM Fuel Cells

biogas cleaning reforming PEM

biological steam
H2S- removal reformer

biological
siloxane CO-shift
removal

activated CO-removal
carbon filter 5 kW biogas reformer Uni Duisburg

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 37
 Contact Details

PROFACTOR Produktionsforschungs GmbH

A-4400 Steyr | Austria | Im Stadtgut A2
That´s all for now ... Tel +43(0)7252/885-403
Fax +43(0)7252/885-101

johann.bergmair@profactor.at
www.profactor.at

Acknowledgement
EFFECTIVE is supported by
5th Framework Program of
the European Commission
N°ERK5-CT-1999-00007

… thanks for your attention !

3rd International Workshop on Fuel Cells, WICaC 2006, Campinas/SP/Brazil, October 18 – 19, 2006
© PROFACTOR 2006 Page 38