03 JohannBergmair

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.
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)
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
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
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
Contents

• Gas upgrading
• FC test beds
• Conclusions
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)
The EFFECTIVE concept
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
EFFECTIVES approach
• 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
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
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
Biological gas upgrading: EFFECTIVES design
BUBBLE
COLUMN
Air
BIOGAS
BIOTRICKLING Air
FILTER
Fresh
Medium
CLEANED
GAS
NaOH
Recirculated
Liquid
Used Medium
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
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
Site for long term endurance tests
Biogas – fuel cell lab
Foto Gadus Foto Gadus
Biogasplant from the University of Nitra, Slovakia
Biological gas upgrading: EFFECTIVES design
Gas analytic for raw gas & cleaned gas, Biotricklingfilter coupled with MCFC
Micro GC for MCFC gas analytics testbed
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
Chemical gas upgrading: test cycle in Asten
MCFC
Testbed
and
chemical
biogas filter
in Asten
2003
(Austria)
EFFECTIVE
MCFC Testbeds
Designed and constructed

by MTU CFC Solutions
Right Control Unit

Center Operator
Left Operation Unit
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)
EFFECTIVE
The process of the MCFC test bed
Screenshot of
control unit
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
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
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
… 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
Contents

• Gas upgrading
• FC test beds
• Conclusions
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
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
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
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

• Duration: 1.5 years
• Financing: Austrian Government, German regional found
• Partners: Profactor (A), TU Vienna (A), Studia (A), MTU (D)
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)
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

• Duration: 2.5 years
• 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)
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
Biogas cleaning and reformer for PEM…
Bio-Hydrogen
Development of a Biogas Reformer for Production of Hydrogen for PEM Fuel Cells

• Duration: 2 years
• 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)
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
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 !


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Innovative Energy Systems

Field Test of MCFC Stacks operating with Biogas

3rd International Workshop on Fuel Cells

October 18 – 19, 2006

PROFACTOR Produktionsforschungs GmbH

• Biogas towards Fuel Cells

• Biogas Fuel Cells applications and other EU RTD projects

•If we are looking for sustainable and clean energy

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

• Biogas is a renewable energy with the highest potential for

• Decentralised energy production (approx.1MWel)

• Cost reduction of waste disposal and new income for the

• Closing of the nutrient cycle (agriculture)

• Several European directives encourage biogas utilisation

Low temperature FC High temperature FC

• High temperature FC – internal reforming

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

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

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

• Efficient and clean energy conversion of valuable RES

• High user potential for utilising the process heat which is

• Decentralised energy production

• Biogas towards Fuel Cells

• Biogas Fuel Cells applications and other EU RTD projects

• Project start: 07 / 2000

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

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

Organic Biogas Biogas Distribution

• Construction of two FC test beds:

• Tests (endurance and performance) with different gas

• Socio technical integration of biogas-FC technology in

• Biological biotrickling filter for

• 32 month endurance operation

• Capacity: 200 l/h

- Mixture of oxygen and biogas

Biological PPU - Biotrickling Filter at Biogas Plant Kolinany / Nitra

900 H2S in Raw

100 H2S Clean

Biogas – fuel cell lab

Foto Gadus Foto Gadus

Biogasplant from the University of Nitra, Slovakia

• Capacity: 200 l/h

Designed and constructed

Right Control Unit

(CIEMAT and MTU)

Linz, Austria, 1.500 •Austria:

Nitra, Slowak Republic, 2.400

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

• Posttest analyses of the FC stack indicate no severe

• NH3 reduction by catalytic decomposition in the fuel cell

• The key issue is the gas purification

Release: June 2004.

Relevant topics in over 200 pages are:

• Biogas towards Fuel Cells

• Biogas Fuel Cells applications and other EU RTD projects

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

• In Germany: Schmack Biogas test scale with 300 W

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

• Also in Japan und USA demo projects have been started

• In Switzerland: SULZER Hexis operated a full scale 1

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

• EFFECTIVE is a project that involves also own