Fuel cell cost analysis

The results of this stationary PEM fuel cell cost analysis are compared with cost projections for PEM vehicle fuel cell systems for a 50 kW stationary fuel cell system cost is projected at 490/kW for 1(X) units, decreasing to 310/kW for 10,000 units, while the 50 kW mobile fuel cell system cost is estimated at 36/ kW in automotive production volumes. 

This section presents sample calculations to aid the reader in understanding the calculations behind the development of a fuel cell power system. The sample calculations are arranged topically with unit operations in Section 10.1, system issues in Section 10.2, supporting calculations in Section 10.3, and cost calculations in Section 10.4. A list of conversion factors common to fuel cell systems analysis is presented in Section 10.5 ans a sample automotive design calculation is presented in Section 10.6. 

Task 4. R D Gap Analysis Determine the current gaps among fuel cell cost, performance and application requirements (look at 2005-2006 technology). Develop a timeline for technology development and commercialization, and extract R D needs and opportunities for DOE involvement. Project benefits to the nation from technology introduction (e g. oil displaced, emission reductions, noise reduction, and safety benefits)... 

Vehicle cost estimates based on a detailed bottom-up analysis consistent with TIAX s automotive fuel cell costing study. 

It must be noted that the DoE analysis has some tentative aspects. New materials are taken into account in the cost figures without the guarantee that these will actually survive the operating conditions over the full lifetime of the fuel cell. On a cell level, these materials might have survived relevant accelerated tests, but that does not mean that in combination with stack and system hardware, and used under real-life conditions, these materials will qualify. It is at present the only publicly known assessment of fuel cell costs that is regularly updated, and that takes into account all fuel cell stack and system components on an equal basis. 

A detailed analysis published for fuel-cell drive systems by Schirrmeister et al. (2002) showed a specific cost breakdown of the added value of a fuel-cell drive system powered by methanol (a methanol reformer was a reasonable alternative at that time)... 

These cost considerations have to rely on some risk analysis if the risks of producing smaller series for stationary markets, which can absorb fuel-cell systems at a specific cost of some 500/kWel are smaller, it seems likely that stationary fuel cells will enter the market earlier than mobile fuel cells in cars at a specific cost of 50 to 80/kWel, but with much larger production series. 

Another important parameter that has to be taken into account when choosing the appropriate diffusion layer is the overall cost of the material. In the last few years, a number of cost analysis studies have been performed in order to determine fuel cell system costs now and in the future, depending on the power output, size of the system, and number of xmits. Carlson et al. [1] reported that in 2005 the manufacturing costs of diffusion layers (for both anode and cathode sides) corresponded to 5% of the total cost for an 80 kW direct hydrogen fuel cell stack (assuming 500,000 units) used in the automotive sector. The total value for the DLs was US 18.40 m-, which included two carbon cloths (E-TEK GDL LT 1200-W) with 27 wt% P ILE, an MPL with PTFE, and Cabot carbon black. Capital, manufacturing, tooling, and labor costs were included in the total. 

E. J. Carlson, P. Kopf, J. Sinha, S. Sriramulu, and Y. Yang. Cost analysis of PEM fuel cell systems for transportation, NREL report no. SR-560-39104, 2005. 

Development of MCFC cell, stack and system components. Improvement of efficiency and durability and cost reduction of MCFC systems through optimization of cell and stack components cost-benefit analysis to overcome the technical and economic barriers to the development and employment of MCFC. Budget 2.6 million. Partners ENEA, Ansaldo Fuel Cells Co, CNR-ITAE, CESI, Universities of Perugia, Messina and Genova. 

Many potential applications are under study. Miniature chemical reactors could be used for portable applications in which they provide advantages of rapid startup and shutdown and of increased safety (intensification by requiring only small quantities of hazardous materials). The development of chip-scale chemical and biological analysis systems has the potential to reduce the time and cost associated with conventional laboratory methods. These devices could be used as portable analysis systems for detection of hazardous chemicals in air and water. There is considerable interest in using a microreactor to provide in situ production of hydrogen for small-scale fuel-cell power applications by conducting a reformation reaction from some liquid hydrocarbon raw material (e.g., methanol). 

Many studies have shown that the potential market is enormous. For instance, a 2000 study for the doe s Energy Information Administration found that the technical market potential for combined heat and power (chp) at commercial and institutional facilities was 75,000 mw, of which more than 60 percent was in systems less than 1 mw in size. This sub-MW market is a very good match for fuel cell technologies. The remaining technical potential in the industrial sector is about 88,000 mw. That analysis did not look at the opportunity created by heat-driven chillers to expand the market for cogeneration, nor did it contemplate cost-effective systems in sizes below 100 kW, as are being pursued by a number of fuel-cell (and other) companies.37... 

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