Direct Fuel Cell Stack Module Evolution

The direct carbonate fuel cell (DFC®) power plant is an emerging high efficiency, ultra-clean electric power generation system utilizing a variety of gaseous, liquid, and solid carbonaceous fuels. The power-producing block of this system is the carbonate fuel cell stack. One of its key characteristics is the ability to generate electricity directly from a hydrocarbon fuel, by reforming the fuel inside the fuel cell to produce hydrogen. FCE has placed approximately 75 units ranging from 250kW to 2.4 MW around the world, achieving an electric efficiency of 45 to 49%. FCE currently has 50 MW/year manufacturing capacity, and plans are in place to increase production capacity as demand increases from domestic and Asian markets. The manufacturing cost has been improved through implementing lean manufacturing, process improvements, and strategic sourcing for vendor purchased items. The stack output has been increased from 250kW to 350 kW. An overall stack cost reduction of ~50% has been achieved over the past five years. Concerted efforts to improve performance, lower cost and increase service life are continuing. This paper will describe FCE's DFC stack technology evolution in advancing output and lowering manufacturing cost.