Open Competition 3 - Chemistry and Materials

Development of a Highly Reliable and Low Cost Fuel Processing System for Stationary PEM Fuel Cell Applications

Sponsor: Plug Power, Inc.

• Project Performance Period: 11/1/2001 - 4/30/2004
• Total project (est.): $1,999,898.00
• Requested ATP funds: $799,959.00

Hydrocarbon fuels, such as natural gas, methanol, or liquid petroleum gas, must be reformed to produce hydrogen rich product gas (reformate) in order for a polymer electrolyte membrane (PEM) fuel cell to utilize them. The reforming process converts the hydrocarbon fuel to useful hydrogen (H2), plus harmful species such as H2S, SO2, NH3. These harmful species must be reduced or eliminated before entering the fuel cell stack. Existing processes to eliminate the contaminants are complicated, expensive, and not reliable. There are three commercial reforming methods in use today including steam reforming (SR), catalytic partial-oxidation (CPO), and autothermal reforming (ATR). Each method is capable of reforming hydrocarbon fuel, but at a very high cost for a small fuel cell system. Although significant efforts have been devoted to improving the performance and reliability of fuel processors, there are many outstanding difficult issues that influence the development of a fuel processor, such as robust catalyst, thermal integration, automated control, and engineering for low cost manufacturing. Due to the high quality reformate required by the fuel cell stack, today's fuel processors cost $1000s/kW for small fuel cell systems. To truly commercialize fuel cell systems, one must drastically reduce the complexity of the fuel processor, increase its operability, and reduce its cost. To achieve this important goal, Plug Power proposes major innovations to develop a compact, well-integrated, low cost and mass-manufacturable fuel processor that, when combined with the recent advancement in the stack technology as a result of a previous ATP program, will create a marketable robust fuel cell system.

For project information:

Cynthia M. Mahoney, (518) 782-7700
Cynthia_Mahoney@plugpower.com

ATP Project Manager

Jean-Louis Staudenmann, (301) 975-4866
jstaudenmann@nist.gov