2004 FUEL CELL SEMINAR

Technology, Markets and Commercialization

ABSTRACTS

In Cooperation with

UMTED STATESL'.S. Department of Energy

U.S. Army Corps of EngineersAdvanced Technology Program

EPRIFederal Transit Administration

Gas Technology InstituteNational Aeronautics and Space Administration

U.S. Fuel Cell Council

EUROPEEuropean Commission

Energy Research Centre or' The \etheriands

IA PASFuel Cell Development Information Center

? November 1-5, 2004San Antonio, Texas

Henry B. Gonzalez Convention Center

Fuel Cell Seminar 2004Table of Contents

Session 1A "The Global View"

Electric Utility Experiences in Demonstrating Stationary Fuel Cells 1D. Rastler, EPRI, Palo Alto, CA, Y. Kishinevsky, New York Power Authority, K. Ostensen, LosAngeles Department Water & Power, M. Tinkler, Ontario Power Generation, E. Shaw, FirstEnergy,E. Palomino, Salt River Project, P. Poray, Chugach Electric, D. Schigoda, We Energies

The Finnish Public SOFC Research Program 5J. Kiviaho, R. Rosenberg, VTT Technical Research Centre of Finland, Espoo, FINLAND

Fuel Cell Commercialization: Differences in Approach Between Industrial Labsand Private-Sector Companies 9D. Richardson, Alberta Research Council Inc, Edmonton, Alberta, CANADA

The Hydrogen Fuel Initiative and the International Partnership for the HydrogenEconomy: Working Towards a Hydrogen Fuel Cell Future 11V. Lightner, C. Bordeaux, P. Davis, U. S. Department of Energy, Washington, DC, L. Inouyc,Sentech, Inc., Bethesda, MD

International Energy Agency Hydrogen Implementing Agreement: 25 Years ofCooperation Toward the Next Generation of Hydrogen R&D 15A. Iocabazzi, ENEA, Rome, ITALY, T. Riis, Research Council of Norway, Oslo, NORWAY,N. Beck, Natural Resources Canada, Ottawa, CANADA, N. Rossmeissl, U.S. Department of Energy,Washington, D.C., H. Barten, Netherlands Agency for Energy and the Enviroment (NOVEM),Utrecht, NETHERLANDS, M-R. de Valladares, Hydrogen Implementing Agreement Secretariat,Bethesda, MD

State-of-the-Art of the Development of Fuel Cell Power Generation Systems inKorea 19B-K. Lee, D-W. Yoo, G-H. Rim, Korea Electrotechnology Research Institute, Changwon,REPUBLIC OF KOREA, J-M. Won, Korea Energy Management Corporation, Yongin, REPUBLICOF KOREA, J. Hur, Korea Electonics Technology Institute, Puchon, REPUBLIC OF KOREA,C-Y. Won, Sungkyunkwan University, Suwon, REPUBLIC OF KOREA

US DOE FE Stationary 23M. Williams, U.S. Department of Energy, NETL, Morgantown, WV, J. Strakey, W. Surdoval,U.S. Department of Energy, NETL, Pittsburgh, PA

Session IB "Fuel Processing"

Development of a 2 kW PEMFC System for Defense Applications Operating onKerosene and Diesel Fuels 27D. Edlund, IdaTcch, LLC, Bend, OR

Development of a MicroChannel Fuel Processor for Complex Hydrocarbon Fuels 29Q. Ming, P. Irving, J. Harrison, InnovaTek, Richland, WA

Fuel Reforming Over Microlith Reactors .„ - _ ,„„.••• .•••••.••••.•^ 33S. Roychoudhury, M. Lyubovsky, Precision Combust :>n,Inc.,f* ' " ""*"

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Future Directions for DOE Fuel Processing R&D: Results of the On-Board FuelProcessing Go/No-Go Decision for DOE's Office of Hydrogen, Fuel Cells &Infrastructure Technologies 37D. Ho, V. Lightner, U.S. Department of Energy, Washington, DC

Hydrogen Production from Biofuels for PEM Fuel Cell Applications 41A. Chellappa, T. Vencill, D. LaMont, Mesofuel Inc, Albuquerque, NM

Modeling and Test Results of Plate Reactors for a Gasoline Fuel ProcessingSystem 45J. Nicole, H. Liu, Y. Liu, D. Yee, C. Pickett, Catalytica Energy Systems, Inc., Mountain View, CA

New Steam Reforming Catalytic Reactors for Smaller, More Efficient Fuel CellSystems 46Y. Liu, R. Farrauto, Engelhard Corp, Iselin, United States Minor Outlying Islands

Session 2A "SOFC Research Progress"

Developments in Microporous Insulation for SOFCs 50M. Mortimer, A. Cawley, Microtherm International Ltd., Wirral, UNITED KINGDOM

Dynamic Simulation of an IT-SOFC 5 kW System 53P. Aguiar, C. Adjiman, N. Brandon, Imperial College London, London, UNITED KINGDOM,R. Leah, Ceres Power Ltd., Crawley, UNITED KINGDOM

Evaluation of the Potential for Fuel Cell APUs 57S. Lasher, K. Isherwood, S. Sriramulu, TIAX LLC, Cambridge, MA, C-J Brodrick, University ofCalifornia, Davis, CA

Experimental Simulation of Temperature-Distributions in Different SOFC-StackLayouts in View of Individual Cell Performance 61P. Prenninger, M. Schuessler, AVL List GmbH, Graz, AUSTRIA

Interaction of Interconnect Materials with SOFC Cathodes 65T. Cruse, T. Kaun, M. Krumpelt, M. Hash, Argonne National Laboratory, Argonne, IL

Scale-Up of SOFC Stacks: Approaches and Impact on Performance and Cost 69J. Thijssen, J. Thijssen, LLC, Redmond, WA, D. Rastler, EPRI, Palo Alto, CA

Solid Oxide Fuel Cell Development Activities at Pacific Northwest NationalLaboratory 73J. Stevenson, M. Khaleel, D. King, G. McVay, P. Singh, Pacific Northwest National Laboratory,Richland, WA

Session 2B "PEM I (MEAs)"

Development of a Low Cost, Durable Membrane and Membrane ElectrodeAssembly for Stationary and Mobile Fuel Cell Applications 77K. Adjemian, M. Foure, S. Gaboury, L. Hedhli, P. Piccione, Atofina Chemicals Inc., King ofPrussia, PA, S. Mullapudi, J. Rcinkingh, Johnson Matthey Fuel Cells, West Chester, M. Petch,Johnson Matthey Fuel Cells, Reading, UNITED KINGDOM

Enabling PEM Fuel Cell Commercialization with Breakthrough LifetimeImprovements 81T. Jarvi, UTC Fuel Cells, South Windsor, CT, E. Teather, DuPont Fuel Cells, Wilmington, DE

MEA Failure Mechanisms in PEM Fuel Cells Operated on Hydrogen and Oxygen 85V. Stanic, Teledyne Energy Systems, Inc, West Palm Beach, M. Hoberecht, NASA Glenn ResearchCenter, Cleveland, OH

Membrane-Electrode-Assemblies for Reformed Hydrogen Fuel Cells (RHFC) 89J. Pawlik, C. Henschel, PEMEAS GmbH, Frankfurt, GERMANY

The Use of Heteropoly Acids in Composite Membranes for Elevated TemperaturePEM Fuel Cell Operation; Lessons Learn from Three Different Approaches 93A. Herring, S. Dec, J. Malers, F. Meng, J. Horan, Colorado School of Mines, Golden, CO, J. Turner,M-A Sweikart, J. Pern, D. Vernon, National Renewable Energy Laboratory, Golden, CO

The Use of Pt-alloy/C Catalysts to Enhance ORR Activity and AchieveAutomotive Cost Targets for PEMFCs 97S. Kocha, H. Gasteiger, General Motors Corp, Fuel Cell Activities, Honcoye Falls, NY

Session 3A "SOFC Development Progress"

Development of a Residential Combined Heat and Power (CHP) System atCeramic Fuel Cells Limited 101J. Dinsdale, A. Conduit, K. Foger, Ceramic Fuel Cells Limited, Nobal Park, AUSTRALIA

Development of MOLB Type SOFC 105A. Nakanishi, M. Hattori, Y. Sakaki, K. Kimura, Electric Power Research & Development Center,Chubu Electric Power Company, Inc., Nagoya, JAPAN, H. Miyamoto, Takasago Research &Development Center, Mitsubishi Heavy Industries, LTD., Takasago, JAPAN, S. Kanehira,K. Takenobu, M. Nishiura, H. Oozawa, Kobe Shipyard and Machinery Works, Mitsubishi HeavyIndustries, LTD., Kobe, JAPAN

Development of SOFC Power Systems Using Multi-Layer Ceramic Interconnects 109K. Kneidel, C. DeBellis, M. Kantak, SOFCo-EFS Holdings LLC, Alliance, OH, D. Norrick,C. Vesely, B. Palmer, Cummins Power Generation, Minneapolis, MN

Intermediate Temperature SOFC Modules and System 113T. Inagaki, F. Nishiwaki, J. Kanou, Y. Miki, The Kansai Electric Power Co., Inc., Amagasaki,JAPAN, K. Hosoi, T. Miyazawa, N. Komada, Mitsubishi Materials Corporation, Naka-gun, JAPAN

Power Enhancement in Seal-Less SOFCs 117S. Vora, Siemens Wcstinghouse Power Corporation, Pittsburgh, PA

Recent Results of Solid Oxide Fuel Cell Development at ForschungszentrumJuelich 120R. Steinberger-Wilckens, B. de Haart, H-P. Buchkrcmcr, H. Nabiclck, J. Quadakkcrs, U. Rcisgcn,R. Steinbrech, F. Tietz, I. Vinke, Forschungszentrum Juelich, Juelich, GERMANY

SOFC Development Program at Haldor Topsee/Rise National Laboratory -Progress Presentation 124N. Christiansen, J. Hanscn, S. Kristcnscn, H. Holm-Larscn, Haldor Topsec A/S, Lyngby,DENMARK, S. Linderoth, P. Hendriksen, P. Larsen, M. Mogensen, Rise National Laboratory,Roskildc, DENMARK

Solid Oxide Fuel Cell Technology - Development Status 128N. Minh, GE Energy, Torrance, CA

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Thermally Integrated Power System (TIPS), High Power Density SOFCGenerator 132P. Patel, H. Maru, Fuel Cell Energy, Danbury, CT, B. Borglum, Fuel Cell Energy SOFC Division,Calgary, Alberta, CANADA, R. Stokes, R. Petri, Versa Power Systems, Des Plaines, IL, R. Remick,C. Sishtla, K. Krist, Gas Technology Institute, Des Plaines, IL, T. Armstrong, A. Virkar,MSRI/University of Utah, Salt Lake City, UT

Session 3B "PEM II"

Air, Water and Thermal Management for PEM Fuel Cell Systems 136M. Gee, C. Liu, Honeywell Engines, Systems & Services, Torrance, CA

Approaches for Low Cost Components and MEAs for PEFCs: Current andFuture Directions 140E. De Castro, Y-M. Tsou, C. Hou, L. Cao, E-TEK division, De Nora N.A. Inc., Somerset, NJ

Evolution of a Manifold Solution for a PEM Stationary Fuel Cell Application 144B. Arriola, Entegris, Inc, Chaska, MN, T. Siciliano, Plug Power, Inc, Latham, NY

Hydrogen Odorants for Fuel Cell Vehicles 148D. Imamura, M. Akai, S. Watanabe, Japan Automobile Research Institute, Tsukuba, JAPAN

Scenario Analysis of the Commercialization of Proton Exchange Membrane(PEM) Fuel Cells for Stationary Applications in the U.S. by the Year 2015 152S. Millett, K. Mahadevan, Battelle Memorial Institute, Columbus, OH

Technology Advances at Ballard Power Systems 156C. Stone, Ballard Power Systems, Burnaby, BC, CANADA

Session 4A "Field Demonstrations"

The Department of Defense Residential Proton Exchange Membrane (PEM) FuelCell Demonstration Program 160M. White, M. Binder, F. Holcomb, N. Josefik, US Army Corps of Engineers - ERDC-CERL,Champaign, IL

Development of Residential PEFC System at Toshiba International Fuel Cells 164T. Kaneko, H. Miyahara, S. Shimotori, Toshiba International Fuel Cells, Kanagawa, JAPAN

Performance of a 1 kW Methanol-Fired Fuel Cell for Remote Applications 168C. Chamberlin, P. Lehman, G. Chapman, M. Marshall, A. Reis, D. Rommel, M. Winkler, SchatzEnergy Research Center, Arcata, CA, D. Witmer, T. Johnson, Arctic Energy TechnologyDevelopment Laboratory, Fairbanks, AK

Reliability of Plug Power GenSys™ Fuel Cell Systems 172A. Feitelbcrg, J. Stathopoulos, Z. Qi, C. Smith, J. Eltcr, Plug Power Inc., Latham, NY

Sulzer Hexis SOFC-Fuel Cell Appliance for Single-Family Homes - TechnologyStatus and Steps on the Road to Commercialization 176H. Raak, R. Diethclm, B. Pictzak, Sulzer Hcxis AG, Wintcrthur, SWITZERLAND

Session 4B "PEM III (Transportation)"

Controlled Hydrogen Fleet and Infrastructure Demonstration and ValidationProject Abstract 180J. Garbak, S. Gronich, US Department of Energy, Washington, DC

IV

Development of a Fuel Cell Hybrid-Electric Transit Bus 181T. Tyler, ISE Corp, San Diego, CA, D. Byrne, S. Thompson, AC Transit, Oakland, CA

Fuel Cell Vehicle Deployment and Hydrogen Infrastructure Development inSouthern California 185J. Mauzey, J. Brouwer, S. Samuelsen, National Fuel Cell Research Center, Irvine, CA

Fuel Economy of Hybrid Fuel Cell Vehicles 189R. Ahluwalia, X. Wang, A. Rousseau, Argonne National Laboratory, Argonne, IL

New Leads for Future FC Vehicles: Intermediate Temperature Fuel Cell and NewHydrogen Storage Materials 193S. Iguchi, N. Ito, K. Kimura, K. Tange, H. Suzuki, Toyota Motor Corporation, Susono, JAPAN

Performance and Durability Characteristics of Hydrogenics HyPM™ 10 kW FuelCell Power Module 197N. Joos, R. Abouatallah, R. Del Core, S. Sorbera, Hydrogenics Corporation, Mississauga,Ontario, CANADA

Session 5A "Specialty Markets"

European Certification of Hydrogen Generators and Fuel Cell Systems 201F. Thuis, Gastec Certification BV, Apeldoorn, NETHERLANDS

Fuelcell Locomotive for Commerical and Military Railways 205A. Miller, D. Barnes, Vehicle Projects LLC, Denver, CO, O. Velev, L. Sheppard, AeroVironment,Inc, Monrovia, CA , P. Chintawar, Nuvera Fuel Cells, Cambridge, MA , A. Delfrate, Nuvera FuelCells Europe, Milano, ITALY, M. Golben, HERA, Hydrogen Storage Systems, Longueuil, Quebec,CANADA, T. Vencill, Intelligent Energy/MesoFuel, Albuquerque, NM

Fuel Cells on the Grid 209P. Kelly, J. Yarbrough, J. Afghani, US EPA - Region 6, Dallas, TX

Improved, Low Temperature Selective PROX Catalyst for CO Conversion 213W. Helfman, M. Goldstein, M. Oum, D. Blackburn, E. Panaguiton, Quantum Group Inc., San Diego,CA, K. Spilker, P. Ricci, ChcvronTexaco Energy Technology Company, Houston, TX

NASA Fuel Cell Development for Aerospace Applications 217A. Liang, M. Hoberecht, NASA Glenn Research Center, Cleveland, OH

Recycling of Precious Metals from Fuel Cell Components 220R. Zuber, C. Hagelueken, K. Seitz, K. Fehl, Umicore AG&Co KG, Hanau, GERMANY, R. Privette,Umicore Autocat USA Inc., Auburn Hills, MI

Status of Direct FuelCell/Turbine Systems Development 224H. Ghezcl-Ayagh, J. Walzak, D. Patel, J. Daly, H. Mara, R. Sanderson, W. Livingood, Fuel CellEnergy, Inc., Danbury, CT

US Navy Ship Service Fuel Cell Program 228A. Nickcns, Office of Naval Research, Arlington, VA, M. Ccrvi, D. Hoffman, NAVSEA,Philadelphia, PA, S. Abcns, FuelCcll Energy, Inc., Danbury, CT

Session 5B "Hydrogen"

A Breakthrough Technology for Hydrogen Production 232P. Bcrlowitz, F. Hcrshkowitz, ExxonMobil Corporate Strategic Research, Annandale, NJ

The Development Permitting Process: Next Challenge for Fuel Cell andHydrogen Technology Technology, Markets and Commercialization 236M-R. de Valladares, M.R.S. Enterprises, LLC, Bethesda, MD

Hydrogen Fuel Pilot Plant and Hydrogen ICE Vehicle Testing 240J. Francfort, Idaho National Engineering and Environmental Laboratory, Idaho Falls, ID, D. Karner,Electric Transportation Applications, Phoenix, AZ

Hydrogen Infrastructure: Energy, Costs, and Transition 244S. Lasher, TIAX LLC, Cambridge, MA, S. Unnasch, TIAX LLC, Cupertino, CA

Hydrogen Quality Standard for Fuel Cell Vehicles 248S. Watanabe, M. Tatsumi, M. Akai, Japan Automobile Research Institute, Tsukuba, JAPAN

Impact of Recently Adopted Hydrogen Building Codes and Standards on FuelCell Commercialization 252Y. Khayyat, Parsons Brinckerhoff, Newark, NJ

A New Type of Hydrogen Generator HHEG (High-compressed Hydrogen EnergyGenerator) 256H. Harada, K. Tojima, T. Nakazawa, H3 Energy Ltd., Vancouver, BC, CANADA

The President's Hydrogen Fuel Initiative: Update on DOE Programs AddressingHydrogen Production and On-board Hydrogen Storage 260C. Read, A. Bouza, S. Satyapal, J. Milliken, R. Danz, P. Devlin, Department of Energy, Washington,DC, J. Petrovic, Los Alamos National Laboratory, station assignment at DOE, Washington, DC

Session 6A "Portable"

75 W Portable SOFC Generator 264J. Martin, Mesoscopic Devices, LLC, Broomfield, CO, A. Virkar, University of Utah, Salt LakeCity, UT, T. Armstrong, Materials and Systems Research, Inc., Salt Lake City, UT

Advances in Compact Pure Hydrogen Generation Systems for Fuel Cells 268A. Chellappa, T. Vencill, D. LaMont, Z. Wilson, Mesofuel Inc, Albuquerque, NM

Development and Commercialization of DMFC Power Sources for Hand HeldElectronic Devices 272S. Gottesfeld, MTI MicroFuel Cells, Albany, NY

Diesel and Jet Fuel Desulfurization and Reforming for Fuel Cell Applications 276M. Namazian, S. Sethuraman, W. Elder, G. Venkataraman, W. Wan, J. Kelly, Altex TechnologiesCorporation, Sunnyvale, CA , X. Ma, V. Subramani, J. Strohm, C. Song, The Pennsylvania StateUniversity, University Park, PA

Formic Acid Fuel Cells: New Possibilities for Portable Power 280B. Adams, Y. Zhu, Renew Power, Champaign, II, S. Ha, R. Larsen, A. Wieckowski, M. Shannon,R. Mascl, University of Illinois, Urbana, IL

Microchannel-Based Fuel Processors for Portable Power Applications: Soldier-Portable Fuel Cell Portable Battery Charger 283D. Palo, J. Holladay, R. Daglc, M. Donnelly, P. Boyd, B. Roberts, V. Viswanathan, PacificNorthwest National Lab, Richland, WA

Production of Portable PEM Fuel Cells: Breaking the Cost Barrier 287M. Enayetullah, P. Osenar, P. Sabin, R. Formato, Protonex Technology Corp., Southborough, MA

VI

Session 6B "PEM IV / DMFC"

0.5W/cm2 PCM-Based Methanol-Air Fuel Cell 291E. Peled, V. Livshits, A. Blum, T. Duvdevani, A. Aharon, A. Ulus, M. Philosph, Tel AvivUniversity, Tel Aviv, ISRAEL, M. Rakhman, T. Feiglin, Israel Plastics & Rubber Center,Haifa, ISRAEL

Development of lkW Residential PEFC Cogeneration Systems at Tokyo Gas 295T. Takahashi, Y. Nishizaka, K. Ito, N. Osaka, K. Kobayashi, H. Horinouchi, R. Toriumi, T. Miura,K. Nishizaki, Tokyo Gas Co., Ltd., Tokyo, JAPAN

DuPont Direct Methanol (DMFC) MEA's 299M. Abdou, DuPont, Wilmington, DE

Establishing a Standardized Single Cell Testing Procedure Through IndustryParticipation, Consensus, and Experimentation 303D. Lane, W.L. Gore and Associates, Elkton, MD, E. Teathcr, DuPont Fuel Cells, Wilmington, DE,T. Rockward, F. Uribe, Los Alamos National Laboratory, Los Alamos, NM , D. McNeil, TeledyncEnergy Systems, Inc, Hunt Valley, MD, R. Bailey, Greenlight Power Technologies, Burnaby, BC,CANADA, M. Picn, Electrochem, Inc, Woburn, MA

Performance Durability of Direct Methanol Fuel Cells 307P. Piela, M. Neergat, P. Zelenay, Los Alamos National Laboratory, Los Alamos, NM

Study of Fuel Cell Structure and Heating Method for the Standardization ofSingle Cells 311Y. Hashimasa, T. Numata, K. Moriya, S. Watanabe, Japan Automobile Research Institute,Tsukuba, JAPAN

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