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Molten carbonate fuel cell (MCFC)-based hybrid


propulsion systems for a liquefied hydrogen tanker

Junkeon Ahn a,*, Sung Ho Park b, Sanghyuk Lee a, Yeelyong Noh a,


Daejun Chang a,**
a
Department of Mechanical Engineering, Korea Advanced Institute of Science and Technology, Daehak-ro 291,
Yuseong-gu, Daejeon 34141, Republic of Korea
b
Plant Engineering Center, Institute for Advanced Engineering, 175-28, Goan-ro 51 Beon-gil, Baegam-myeon,
Cheoin-gu, Yongin, Gyeonggi-do 449-863, Republic of Korea

article info abstract

Article history: This study proposes a molten carbonate fuel cell (MCFC)-based hybrid propulsion system
Received 9 January 2018 for a liquefied hydrogen tanker. This system consists of a molten carbonate fuel cell and a
Received in revised form bottoming cycle. Gas turbine and steam turbine systems are considered for recovering heat
27 February 2018 from fuel cell exhaust gases. The MCFC generates a considerable propulsion power, and the
Accepted 5 March 2018 turbomachinery generates the remainder of the power. The hybrid systems are evaluated
Available online xxx regarding system efficiency, economic feasibility, and exhaust emissions. The MCFC with a
gas turbine has higher system efficiency than that with a steam turbine. The air
Keywords: compressor consumes substantial power and should be mechanically connected to the gas
Liquefied hydrogen tanker turbine. Although fuel cell-based systems are less economical than other propulsion sys-
Hybrid system tems, they may satisfy the environmental regulations. When the ship is at berth, the MCFC
MCFC systems can be utilized as distributed generation that is connected to the onshore-power
Gas turbine grid.
EEDI © 2018 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.
Emission

Mitigating exhaust emissions remains a challenge in the


Introduction shipping industry [3]. Marine transportation annually ac-
counts for 80e90% of world trade [4,5]. The shipping industry,
Global warming and climate change are both intensifying. as an anthropogenic source of emissions, emits 3%, 15%, and
Greenhouse gases are causing sea-level increases as well as 13% of the global emissions of CO2 (carbon dioxide), NOX (ni-
temperature increases in the atmosphere and in the oceans; trogen oxides), and SOX (sulfur oxides), respectively [6].
these phenomena are threatening the sustainable develop- The legislation framework for greener shipping has led to
ment of the international society [1]. With increasing energy considerable changes in the shipping industry [6,7]. The ship-
consumption, the depletion of fossil fuels, high energy costs, ping exhaust emissions excluded from the Montreal Protocol
and atmospheric pollution have become important economic, are the responsibility of the IMO (International Maritime Or-
environmental, and social concerns [2]. ganization) under the Kyoto Protocol [5]. The IMO has gradually

* Corresponding author.
** Corresponding author.
E-mail addresses: jkahn@kaist.ac.kr (J. Ahn), djchang@kaist.ac.kr (D. Chang).
https://doi.org/10.1016/j.ijhydene.2018.03.015
0360-3199/© 2018 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.

Please cite this article in press as: Ahn J, et al., Molten carbonate fuel cell (MCFC)-based hybrid propulsion systems for a liquefied
hydrogen tanker, International Journal of Hydrogen Energy (2018), https://doi.org/10.1016/j.ijhydene.2018.03.015
2 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 8 ) 1 e1 3

enforced the CO2 and anti-pollution regulations [8]. The EEDI organic hydride in the Euro-Quebec Hydro-Hydrogen Pilot
(energy efficiency design index) and ECA (emission control Project; however, no applicable propulsion machinery was
area) are typical regulations [9]. Because greener shipping and studied. Ahn et al. [9] evaluated the economic feasibility of
high ship propulsion efficiency are required, a great trans- maritime hydrogen transport and considered using a stand-
formation is underway, including the emergence of new alone MCFC to satisfy the enhanced EEDI requirements.
shipping concepts, increased demand for larger and special- This study proposes MCFC-based hybrid systems as pro-
ized ships, and the diversification of propulsion systems. pulsion machinery for a 140K LH2 tanker. The system, which
Energy commerce is continuously expanding and changing utilizes the high-temperature exhaust from an MCFC to drive
because of the rapid increase in global demand for energy. a bottoming cycle, consists of an MCFC and turbomachinery.
Environmental issues have led to the development of new and Energy efficiency and economic and environmental aspects
renewable energy sources to replace fossil fuel-based energy are significant factors that must be considered for a marine
sources [9]. The development and use of solar, wind, hydro, fuel cell system. The remainder of this paper is organized as
geothermal, tidal, wave, and biomass power are expanding. follows. Section Hybrid MCFC-based systems describes the
Hydrogen has become an alternative fuel and a new energy MCFC principles and the configurations of the hybrid systems.
source for the distributed generation [10] and transportation Section System modeling describes the thermodynamic
sectors [11]. modeling of the hybrid systems. The performance analyses
Hydrogen is a clean fuel for fuel cells. The technology of are described in Section Performance analyses. The compar-
fuel cells is innovative and shows promise for use in next- ative results are described and discussed in Section Results
generation power systems that emit few pollutants [12,13]. and discussion. Section Conclusions concludes this paper.
Fuel cells convert the chemical energy of a gaseous fuel into
electricity via electrochemical reactions [14]. Fuel cells can
operate using various fuels. High-temperature fuel cells, in Hybrid MCFC-based systems
particular, enable the recovery of high-quality exhaust heat
[10]. The heat recovery is a major concern for the design of MCFCs employ molten salt electrolytes. The electrolyte ma-
energy systems and is directly linked to fuel consumption and terials are eutectic mixtures of Li2CO3, Na2CO3, and K2CO3 [31].
exhaust emissions [6]. The Li2CO3 (62 mol%) and K2CO3 (38 mol%) eutectic has been
High-temperature fuel cells are classified into two types: widely adopted [32]. These carbonates melt at approximately
MCFC (molten carbonate fuel cell) and SOFC (solid oxide fuel 500  C, and the molten carbonates transfer ions. A stable
cell). Because SOFCs operate at temperatures approximately operating temperature that prevents electrolyte solidification
200  C higher than the operating temperature of MCFCs, they or volatilization is a significant condition [33]. MCFCs normally
enable the recovery of higher temperature waste heat [2,8,15]. operate at 923 K (650  C).
The electrolyte of an SOFC poses challenges in the An MCFC generates electricity via electrochemical re-
manufacturing process and increases costs. In addition, poor actions. The SMR (steam methane reforming) and WGS (water-
mechanical properties and excessive thermal expansion gas shift) reactions sequentially occur to produce H2 and CO in
remain challenges for the high-temperature operation of the MCFC stack [34]. Because the reforming reaction is a highly
SOFCs [16]. Alternatively, the practical application of MCFCs intensive endothermic process, it removes the heat generated
has been demonstrated for large-scale power plants [10] and by the hydrogen oxidation [35]. Fig. 1 illustrates the MCFC
ship propulsion systems [17]. Because MCFC technology is principle via the following electrochemical reactions [14]:
more mature than SOFC technology [10], MCFCs are respon-
0
sible for a substantial portion of the power generated in South  SMR: CH4 þ H2 O/CO þ 3H2 ðDh298K ¼ 206 kJ=molÞ
Korea, the United States, Europe, and Japan [18].  WGS: CO þ H2 O/CO2 þ H2 0
ðDh298K ¼ 41 kJ=molÞ
Marine fuel cells have been adopted as auxiliary power

units [19]. Representative marine fuel cells are the PEMFC H2 þ CO2
3 4CO2 þ H2 O þ 2e
 Anode: 
(proton exchange membrane fuel cell) used in the 212-class CO þ CO2
3 42CO2 þ 2e
submarines [20], the MCFC of the USCG Vindicator [21], the
25 kW PEMFC of the DESIRE project [22], the 20 kW SOFC of the
METHAPU project [23], the 330 kW MCFC of the Viking Lady
[14], the 500 kW MCFC for a ferry ship [24], and the 625 kW
SOFC of an offshore supply vessel [25]. With improvements in
the related technologies, fuel cells have become the main
propulsion system for many large ships [17].
With the introduction of LH2 (liquefied hydrogen) tankers, a
propulsion system based on an MCFC has become feasible [9].
A tanker that transports LH2 in bulk is a gas carrier. The pro-
pulsion system of a gas carrier depends on whether the BOG
(boil-off gas) is consumed as fuel [9,26]. Petersen et al. [27] and
Abe et al. [28] proposed the concept design of an LH2 tanker
while using hydrogen BOG as fuel, but they did not suggest a
specific propulsion system. Gretz et al. [29,30] considered
transatlantic hydrogen transport in liquid form or as liquid Fig. 1 e MCFC configuration with inlet and outlet flows.

Please cite this article in press as: Ahn J, et al., Molten carbonate fuel cell (MCFC)-based hybrid propulsion systems for a liquefied
hydrogen tanker, International Journal of Hydrogen Energy (2018), https://doi.org/10.1016/j.ijhydene.2018.03.015
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 8 ) 1 e1 3 3

 Cathode: 0:5O2 þ CO2 þ 2e 4CO2


3
turbine; Rankine cycle) system. The MCFC, as the primary
 Overall: H2 þ 0:5O2 þ CO2 4H2 O þ CO2 machinery, produces considerable propulsion power,
0
ðDh298K ¼ 242 kJ=molÞ whereas the turbomachinery, as the secondary machinery,
generates the remainder of the propulsion power. Because
In addition to these reactions, methanation, CO hydroge- these hybrid systems drive the electric motors linked to the
nation, and the Boudouard reaction may occur at the anode propeller, they can be classified as electric propulsion type.
[36] and peroxide, superoxide, and polycarbonate may form at Both MCFC-based hybrid systems commonly consume the
the cathode [32]. feed stream and hydrogen BOG as fuel. The NG blower and
After the electrochemical reactions, the anode emits the water pump supply natural gas and water, respectively. These
streams are mixed as the feed stream for the internal reformer.
unreacted fuel and byproducts, such as water and CO2,
The hydrogen BOG is supplied from the cargo tanks to the anode
whereas the cathode emits excess air. The CO2 is consumed to
side, and it is heated by two heat exchangers for the operating
form molten carbonates.
The advantage of the MCFC technology is that it utilizes the temperature. A small amount of BOG goes to the catalytic
exhaust gas at high temperature, unlike the low-temperature combustor to increase the TIT (turbine inlet temperature).
fuel cell, such as the PEMFC [17]. A system using cogeneration The main distinctions between the systems are associated
or integration to recover waste heat via a thermodynamic with the air supply and exhaust streams. In the MCFC-GT
cycle is called a “hybrid” system [37]. system, the air is supplied through the gas turbine to the
MCFC-based hybrid systems have led to high energy effi- cathode side. Because the exhaust stream directly heats the
ciency and improved economic performance. Such systems air stream via the heat exchanger, heat recovery is made in
have been developed for use in large-scale power plants, e.g., the power turbine as well as the hydrogen BOG can be heated,
as shown in Fig. 2. In the MCFC-ST system, air is supplied by
distributed generation and marine propulsion [10,12,14,24].
the air blower, and hydrogen BOG is heated by the exhaust. In
Hybrid systems are classified as either indirect heating or
addition, heat recovery is made via the closed Rankine cycle,
direct firing according to the heat recovery method [10]. The
direct hybrid system uses the MCFC exhaust to drive a gas as shown in Fig. 3.
turbine, where the operating pressure is 3e4 barg [38e40]. By
contrast, the exhaust heats the working fluid of a bottoming
cycle in an indirect hybrid system, which is suitable for MCFC
System modeling
operation at atmospheric pressure [41e43].
The process simulation is performed using AspenPLUS®. The
This study considers an indirect hybrid system with a
simulation is carried out under the following assumptions
28 MW propulsion system on a 140K LH2 tanker. The operating
[44,45]:
time is 204 h for a trip when the service speed is 20 knots [9].
Fig. 2 illustrates the MCFC-GT (MCFC-gas turbine; Brayton
1) All chemical reactions are in equilibrium.
cycle) system, and Fig. 3 shows the MCFC-ST (MCFC-steam

Fig. 2 e Schematic diagram of MCFC-GT system.

Please cite this article in press as: Ahn J, et al., Molten carbonate fuel cell (MCFC)-based hybrid propulsion systems for a liquefied
hydrogen tanker, International Journal of Hydrogen Energy (2018), https://doi.org/10.1016/j.ijhydene.2018.03.015
4 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 8 ) 1 e1 3

Fig. 3 e Schematic diagram of MCFC-ST system.

2) The temperature, pressure, and composition of the gas are considering the Nernst loss, activation polarizations, and
uniform. concentration loss [16]. Eq. (1) presents the cell voltage Vcell of
3) The temperatures of the anode and the cathode are the an MCFC [31]:
same.
4) The SMR and WGS occur rapidly and sequentially. Vcell ¼ E0  hNernst  jðRan þ Rca þ Rohm Þ ½V (1)
5) The kinetic and potential energy changes are negligible.
where E0 is the reversible potential at standard conditions and
6) All system components, except for the fuel cell and cata-
hNernst is the Nernst loss. The Nernst potential involves the
lytic combustor, are adiabatic.
summation of E0 and hNernst; this potential is the maximum
7) The system operates at steady state.
potential achieved through the electrochemical reaction.
When the current is zero, the Nernst potential becomes the
The thermodynamic properties depend on the SRK (Soave-
open-circuit voltage (OCV). Parameter j is the current density
Redlich-Kwong) equation of state. This equation, together
in mA/cm2, Ran and Rca represent the activation losses of the
with the Peng-Robinson equation of state, is the most widely
anode and cathode, respectively, and Rohm is the ohmic loss.
accepted equation for modern chemical processes [46]. These
The standard reversible potential is defined by the Gibbs free
equations are recommended for modeling gas mixtures in
energy:
non-polar real components [47]. The SRK equation of state is
more suitable than the Peng-Robinson equation for consid- Dg
E0 ¼  ½V (2)
ering properties at high temperatures and pressures [48]. In nF
addition, the equation of state accurately predicts the PVT
(pressure, volume, and temperature) behaviors of small mol- where Dg is the Gibbs free energy in J/mol; n is the molecular
ecules with high critical compressibility factors (ZC), such as number of H2; and F is the Faraday constant [52]. Parameter T
H2 (0.32) and CH4 (0.286) [49e51]. is the MCFC stack temperature in K.

Dg ¼ 0:002474T2 þ 48:996Te243730 ½J=mol (3)


MCFC stack
The Nernst loss in Eq. (4) is a function of the concentrations
The electrochemical phenomenon of a unit fuel cell follows
of the species of the reactants and products:
the following equations. The cell voltage is calculated by

Please cite this article in press as: Ahn J, et al., Molten carbonate fuel cell (MCFC)-based hybrid propulsion systems for a liquefied
hydrogen tanker, International Journal of Hydrogen Energy (2018), https://doi.org/10.1016/j.ijhydene.2018.03.015
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 8 ) 1 e1 3 5

!
RT PH2 O;an PCO2 ;an 
hNernst ¼ ln pffiffiffiffiffiffiffiffiffiffiffi ½V (4) _ PUMP ¼ m_ hout  hin
nF PH2 ;an PO2 ;ca PCO2 ;ca W ½kW (10)

where R is the molar gas constant in J/mol-K, and P is the Heat exchanger
partial pressure at each electrode.
The activation polarization losses occur by breaking the Heat exchange occurs between the hot stream and the cold
chemical bonds of H2 and O2 molecules in the electrochemical stream in a heat exchanger. The energy balance of the heat
reaction. Yuh and Selman suggested the following loss models exchanger is calculated by Eq. (11):
[53]:
! m_ hot;in hhot;in þ m_ cold;in hcold;in ¼ m_ hot;out hhot;out þ m_ cold;out hcold;out ½kW
Dhan 
Ran ¼ 2:27  105  exp  P0:42
H2 P0:17 1:0
CO2 PH2 O ½Ucm2 (5) (11)
RT

0 1 Turbine
Dh 
6
 exp@ A  P0:43 P0:09
ca
Rca ¼ 7:505  10 o2 co2 ½U  cm 2
(6)
RT The turbine power output is calculated by the enthalpy
change between the inlet and the outlet:
where Dhan and Dhca are the activation energy values in the 
anode and cathode, respectively. Table 1 summarizes the W_ T ¼ m_ hin  hout ½kW (12)
parameters of the above equations.
The ohmic loss involves ionic and electronic conduction at
the electrodes and the contacts. This resistance is normally Performance analyses
called the internal resistance and is calculated by the
following Arrhenius-type equation [53]: System efficiency
  
1 1 
Rohm ¼ 0:5  exp 3016  ½U  cm2 (7) Reforming and electrical efficiencies were used to evaluate
T 923
system performance. The reforming efficiency represents the
The resultant power output of an MCFC is presented in Eq. ratio between the hydrocarbon heating value and the H2
(8): heating value. A higher reforming efficiency corresponds to
greater H2 production. Because the SMR is an endothermic
W_ MCFC;AC ¼ j,Acell ,Vcell ,N,xDCAC ½W (8) reaction in an MCFC stack, the quantity of heat for the reac-
where Acell is the total active area of a fuel cell in cm , N is the 2 tion is included in Eq. (13):
number of cells, and xDC-AC is the inverter efficiency from
m_ H2  LHVH2
direct current (DC) to alternating current (AC) (0.95) [44]. xRF ¼ (13)
Q_ SMR þ m_ NG  LHVNG

Compressors where Q_ SMR is the quantity of heat for the SMR, m_ H2 and m_ NG
are the molar flow rates of produced H2 and the consumed
The compressors supply the fuel and air to the MCFC. The CH4 in mol/sec, respectively. LHV denotes lower heating
power required is calculated by the following equation: values.
 Electrical efficiency is an intuitive metric of fuel cell per-
W_ COMP ¼ m_ hout  hin ½kW (9) formance. A fuel cell system includes not only the cell stack
but also the BOP (balance of plant). The electrical efficiency of
where m_ is the molar flow rate in mol/sec and hin and hout are hybrid systems must consider the power outputs of a fuel cell
the specific enthalpy in J/mol at the inlet and outlet of a and the bottoming cycle. Eq. (14) represents the electrical
compressor, respectively. efficiency:

Pump W _ MCFC;AC  W_ BOPs þ W_ Recovery


xelec ¼ (14)
m_ NG  LHVNG þ m_ H2  LHVH2
The pump feeds water into the internal reformer. The power
where W _ MCFC;AC is the AC power output of an MCFC in kW,
required is calculated by the following equation:
_
WBOPs is the required power of the BOP, and W _ Recovery is the
power output of the turbomachinery.
Table 1 e Performance parameters of MCFC.
Parameter Unit Value Economic evaluation
Operating pressure barg 1
Operating temperature K 923 The economic evaluation of the system is based on the B/C
Current density, j mA/cm2 150 (benefit-cost) ratio and the NPV (net present value). The B/C
Molar gas constant, R J/mol-K 8.314 ratio is the ratio between the social benefit and the cost. The
Faraday constant, F C/mol 96,485 NPV is estimated by subtracting the cost from the benefit
Anode activation energy, Dhan J/mol 53,500 considering the discount rate. Eqs. (15) and (16) present the B/
Cathode activation energy, Dhca J/mol 77,300 C ratio and the NPV:

Please cite this article in press as: Ahn J, et al., Molten carbonate fuel cell (MCFC)-based hybrid propulsion systems for a liquefied
hydrogen tanker, International Journal of Hydrogen Energy (2018), https://doi.org/10.1016/j.ijhydene.2018.03.015
6 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 8 ) 1 e1 3

The reference and attained EEDI values for LH2 tankers


, have yet to be defined [9]. Because the LH2 tanker is similar to
X
L
Bt X
L
Ct
B=C ¼ 1 (15) an LNG carrier, the EEDI calculation refers to the LNG carrier in
t¼0 ð1 þ rÞt t¼0 ð1 þ rÞt
Eqs. (18) and (19). The attained EEDI must be lower than the
reference value.
X
L
Bt XL
Ct
NPV ¼ t  0 (16) 
t¼0 ð1 þ rÞ t¼0 ð1 þ rÞt Reference value ¼ 2253:7  ðDWTÞ0:474 ½g  CO2 =ton  NM
(18)
The total cost of a hybrid system is calculated on the basis
of the LCC (life-cycle cost) shown in Eq. (17) [9]:

PME;MCFC  CF;LNG  SFCLNG þ CF;H2  SFCH2
EEDI ¼
X
L
Ct XL
OPEXt fc  VRef  DWT
LCC ¼ t ¼ CAPEXjt¼0 þ t (17) 
t¼0 ð1 þ rÞ t¼0 ð1 þ rÞ ½g  CO2 =ton  NM (19)

where the cost of the system components is the CAPEX (cap- where PME is 75% of the MCR (maximum continuous rating) for
ital expenditure) and the cost of the system operation is the an LH2 tanker, CF is a non-dimensional conversion factor of
OPEX (operating expenditure). Table 2 summarizes the cost CO2 emission from hydrocarbon fuel, SFC is the specific fuel
functions of the system components [2,44,54e56]. consumption in kg/kWh, and the DWT (deadweight) is 27,600
ton [61].
Energy efficiency design index
NOX emission
With the development and innovation of eco-friendly tech-
nology, the philosophy of eco-efficiency has spread widely NOX, SOX, and particulate matter are significant pollutants
[57]. Eco-efficiency is the ability to produce goods and services among the shipping emissions. The IMO regulates NOX and
efficiently with the least environmental impact [58], which SOX by declaring the ECA. In particular, the amount of NOX
implies that economic activity is directly linked to sustainable emitted should be in compliance with the NOX technical code
development [59]. established in 2008. After January 2016, all propulsion systems
The EEDI is a representative index of the eco-friendly phi- of merchant ships must satisfy the Tier III requirement [61].
losophy in the shipping industry; it indicates the relationship NOX is generated by oxidizing nitrogen in a catalytic
between the social benefit and the environmental cost [5]. The combustor. NO (nitric oxide) accounts for the highest
IMO adopted the EEDI as a mandatory requirement in July, component of NOX [62]. The amount of NOX emitted is esti-
2011. The concept of EEDI has been developed under the MEPC mated by Eq. (20):
57th-59th sessions and the Working Group on Greenhouse
3600  MNOX  m_ NOX
Gases since 2008 [60] as a method to evaluate the energy ef- NOX ¼ ½g=kWh (20)
W_ MCFC;AC
ficiency of marine equipment and the propulsion systems of
newly built ships with a gross tonnage greater than 400 tons where MNOX and m_ NOX are the molar mass in g/mol and the
[5]. The EEDI is defined as the amount of CO2 emissions molar flow rate in mol/sec in the exhaust gases, respectively.
generated when a ship transports one ton of cargo for one
nautical mile, in units of g-CO2/ton-NM.
Results and discussion

This section compares the performance of the MCFC-based


hybrid systems and discusses the results on the basis of en-
Table 2 e Cost functions of system components in MCFC-
ergy efficiency, economic feasibility, and environmental
based hybrid system.
measures. The results provide background information for
System Cost model, US$ selecting the appropriate propulsion system.
component
MCFC stack ZMCFC ¼ 2600  W _ MCFC;AC Energy analysis
 
Catalytic 46:08m_ in
ZCC ¼ 0:995  ½1 þ expð0:018  TOUT  26:4Þ
combustor
!0:67 MCFC-based hybrid systems consume both H2 and CH4. The
Compressor ZCOMP ¼ 91562  W_ COMP steam-to-carbon ratio determines the amount of the inlet CH4
445
 
stream fed to the internal reformer of an MCFC. The mole
Pump ZPUMP ¼ 705:48  W_ PUMP  1þ 0:2 fraction of CH4 excluding water must be greater by 50% than
1xPUMP
!0:7 the mole fractions of the other components; this condition is
W_ MCFC;DC required for the endothermic reaction in the MCFC stack.
Inverter ZINV ¼ 105  500
Approximately 50e70% of CH4 is converted by the SMR pro-
Gas turbine ZGT ¼ W_ GT  ½1318:5  98:328  lnðW_ GT Þ
cess [63].
Steam turbine ZST ¼ 3744:3  W_ 0:7  61:3  W_ ST The reforming reaction gradually occurs where the feed
ST
Generator ZGEN ¼ 26:18  W_ 0:95
T
stream of CH4 and water is heated to 473 K (200  C). As the
 0:78
AHX
mole fractions of the feed stream decrease, the mole fractions
Heat exchanger ZHX ¼ 130  0:093
of H2, CO, and CO2 increase; as a result, the products are

Please cite this article in press as: Ahn J, et al., Molten carbonate fuel cell (MCFC)-based hybrid propulsion systems for a liquefied
hydrogen tanker, International Journal of Hydrogen Energy (2018), https://doi.org/10.1016/j.ijhydene.2018.03.015
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 8 ) 1 e1 3 7

Fig. 5 illustrates the performance curves for a unit cell of


the MCFC according to the operating temperature. The pecu-
liarity is the linear relationship between the current density
and cell voltage while accounting for all of the losses [33]. In
general, other fuel cells exhibit an exponential decrease in the
low-current-density region [65]. The observed linear rela-
tionship implies that the activation polarizations are negli-
gible [66].
The OCV is 1.026 V when the MCFC operates at 923 K. The
cell voltage is high in the low-current-density region [33]. At a
current density of 150 mA/cm2, the cell voltage and power
density are 0.879 V and 0.132 W/cm2, respectively. The area of
a single cell is 0.67 m2. One MCFC stack has 400 cells. The
number of stacks is 67 and 75 for the MCFC-GT and MCFC-GT
systems, respectively.
Table 5 summarizes the performance of both systems. The
voltage efficiencies are 53%; note that the efficiency is nor-
Fig. 4 e Results of reforming reaction in internal reformer.
mally ca. 50% for an MCFC. On the one hand, the electrical
efficiency of the stand-alone MCFC is 41e44% on the basis of
generated. If the temperature reaches 923 K (650  C), the mole the LHV. With respect to achieving high electrical efficiency,
fractions of H2 and CH4 will be 55% and 1%, respectively [64]. the gas turbine is better than the steam turbine as the bot-
Fig. 4 depicts the changes between the reactants and products toming cycle. Because the MCFC-GT system supplies the tur-
according to the temperature increase. bine exhaust directly to the cathode, no air compressor is
Tables 3 and 4 summarize the stream data of the MCFC-GT exclusively required; otherwise, the MCFC-ST system must
in Fig. 2 and MCFC-ST in Fig. 3 systems, respectively. The include an air compressor because of the separation between
reforming process supplies 90% of H2; the others are H2 BOG. the Rankine cycle and MCFC streams. Because the air
Because the LH2 tanker operates 204 h for one trip [9], the LNG compressor consumes considerable power, it results in a low
consumptions are 1328 m3 and 1674 m3 for the MCFC-GT and electrical efficiency of the hybrid system.
MCFC-ST systems, respectively. The H2 fuel is consumed in The heat release from the MCFC is a significant matter. The
the MCFC as well as a catalytic combustor of the MCFC-GT MCFC normally operates at 923 K while cooling the stack by
system, as shown in Fig. 2 and Table 3. The fired stream at the endothermic SMR reaction. The heat release in a single cell
high temperature will improve the turbine output. can be obtained from Fig. 5. The ideal voltage is 1.25 V on the

Table 3 e Stream data for MCFC-GT system.


Stream Temp., K Pressure, bar Mole flow, mol/sec Mole fraction
CH4 N2 CO CO2 H2 O2 H2O NO NO2
Hydrogen 73 1 60 0.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000
H2-01 94 2 60 0.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000
H2-02 297 1 60 0.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000
H2-03 923 1 60 0.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000
H2-04 923 1 18 0.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000
H2-05 923 1 42 0.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000
Natural gas 203 1 50 0.980 0.020 0.000 0.000 0.000 0.000 0.000 0.000 0.000
NG-01 250 2 50 0.980 0.020 0.000 0.000 0.000 0.000 0.000 0.000 0.000
Water 298 1 147 0.000 0.000 0.000 0.000 0.000 0.000 1.000 0.000 0.000
Water-01 298 3 147 0.000 0.000 0.000 0.000 0.000 0.000 1.000 0.000 0.000
Feed-01 291 2 197 0.249 0.005 0.000 0.000 0.000 0.000 0.746 0.000 0.000
Feed-02 673 2 197 0.249 0.005 0.000 0.000 0.000 0.000 0.746 0.000 0.000
An-01 923 2 275 0.036 0.004 0.063 0.080 0.506 0.000 0.312 0.000 0.000
An-02 923 1 1446 0.007 0.591 0.003 0.039 0.047 0.084 0.230 0.000 0.000
Air 298 1 920 0.000 0.790 0.000 0.000 0.000 0.210 0.000 0.000 0.000
Air-01 543 6 920 0.000 0.790 0.000 0.000 0.000 0.210 0.000 0.000 0.000
Air-02 1423 6 920 0.000 0.790 0.000 0.000 0.000 0.210 0.000 0.000 0.000
Air-03 1021 1 920 0.000 0.790 0.000 0.000 0.000 0.210 0.000 0.000 0.000
Ca-01 923 1 920 0.000 0.790 0.000 0.000 0.000 0.210 0.000 0.000 0.000
Ca-02 923 1 122 0.003 0.873 0.001 0.000 0.019 0.103 0.000 0.000 0.000
CC-01 1438 1 1147 0.000 0.623 0.000 0.046 0.000 0.045 0.286 0.000 0.000
Ex-01 825 1 1147 0.000 0.623 0.000 0.046 0.000 0.045 0.286 0.000 0.000
Ex-02 552 1 1147 0.000 0.623 0.000 0.046 0.000 0.045 0.286 0.000 0.000
Ex-03 542 1 1147 0.000 0.623 0.000 0.046 0.000 0.045 0.286 0.000 0.000

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8 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 8 ) 1 e1 3

Table 4 e Stream data for MCFC-ST system.


Stream Temp., K Pressure, bar Mole flow, mol/sec Mole fraction
CH4 N2 CO CO2 H2 O2 H2O NO NO2
Hydrogen 73 1 60 0.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000
H2-01 94 2 60 0.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000
H2-02 297 1 60 0.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000
H2-03 923 1 60 0.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000
H2-04 923 1 18 0.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000
H2-05 923 1 42 0.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000
Natural gas 203 1 55 0.980 0.020 0.000 0.000 0.000 0.000 0.000 0.000 0.000
NG-01 250 2 55 0.980 0.020 0.000 0.000 0.000 0.000 0.000 0.000 0.000
Water 298 1 162 0.000 0.000 0.000 0.000 0.000 0.000 1.000 0.000 0.000
Water-01 298 3 162 0.000 0.000 0.000 0.000 0.000 0.000 1.000 0.000 0.000
Feed-01 291 2 217 0.249 0.005 0.000 0.000 0.000 0.000 0.746 0.000 0.000
Feed-02 673 2 217 0.249 0.005 0.000 0.000 0.000 0.000 0.746 0.000 0.000
An-01 923 2 303 0.036 0.004 0.063 0.080 0.506 0.000 0.312 0.000 0.000
An-02 923 1 1383 0.008 0.559 0.003 0.044 0.054 0.063 0.269 0.000 0.000
Air 298 1 760 0.000 0.790 0.000 0.000 0.000 0.210 0.000 0.000 0.000
Air-01 379 2 760 0.000 0.790 0.000 0.000 0.000 0.210 0.000 0.000 0.000
Ca-01 923 2 760 0.000 0.790 0.000 0.000 0.000 0.210 0.000 0.000 0.000
Ca-02 923 1 96 0.003 0.896 0.001 0.000 0.024 0.075 0.000 0.000 0.000
CC-01 1677 1 1007 0.000 0.597 0.000 0.054 0.000 0.022 0.327 0.000 0.000
Ex-01 1361 1 1007 0.000 0.597 0.000 0.054 0.000 0.022 0.327 0.000 0.000
Ex-02 1334 1 1007 0.000 0.597 0.000 0.054 0.000 0.022 0.327 0.000 0.000
Ex-03 1054 1 1007 0.000 0.597 0.000 0.054 0.000 0.022 0.327 0.000 0.000
Ex-04 589 1 1007 0.000 0.597 0.000 0.054 0.000 0.022 0.327 0.000 0.000
Ex-05 578 1 1007 0.000 0.597 0.000 0.054 0.000 0.022 0.327 0.000 0.000
R-01 298 0.4 260 0.000 0.000 0.000 0.000 0.000 0.000 1.000 0.000 0.000
R-02 298 60 260 0.000 0.000 0.000 0.000 0.000 0.000 1.000 0.000 0.000
R-03 788 60 260 0.000 0.000 0.000 0.000 0.000 0.000 1.000 0.000 0.000
R-04 349 0.4 260 0.000 0.000 0.000 0.000 0.000 0.000 1.000 0.000 0.000

basis of the LHV. Each single cell produces 0.056 W/cm2 of the MCFC-ST system is 252 MUS$. These costs are approximately
heat release by the electrochemical reaction. Considering the 25% greater than the costs of DFDE (dual-fuel diesel engine)
open circuit voltage and the current density, the theoretical systems [9]. The LCCs of both systems show small differences.
power output is estimated as 34,688 kW and 38,813 kW for the The MCFC-GT system becomes the most economical config-
MCFC-GT and MCFC-ST systems, respectively. These values uration. Moreover, the NPV of the MCFC-GT system is 1.85
must match the sum of the reforming heat duty and the stack times greater than that of the stand-alone MCFC; hence, the
power output. LH2 tanker equipped with the MCFC-GT system provides a
The LH2 tanker also requires electric power while mooring substantial profit.
in a port. The MCFC-based hybrid system should supply Because the B/C ratios are greater than 1, the MCFC-based
electricity for the ship hoteling service as well as for cargo propulsion systems are economically feasible. However, these
loading and unloading. The cargo unloading requires 7.5 MW, ratios are prominently lower than those of the DFDE system
and the loading (including the hoteling service) requires (1.92) or the MGO (marine gas oil)- and H2-fueled steam tur-
4 MW. When the eight cryogenic pumps unload LH2 cargo, bine (1.33) [9], implying that the profitability of the MCFC-
more electric power will be required. These states will be based systems is also low. Although low profitability is a
possible under the following conditions: disadvantage of the MCFC-based systems, the CAPEX will
likely be substantially lowered shortly after the fuel cell
 The MCFC operates at 773 K (500  C) in the extreme low- market expands.
current-density-region: 13e38 mA/cm2.
 The TIT should be 1000  C for the gas turbine and 400  C for Energy efficiency design index
the steam turbine in the bottoming cycle.
The EEDI value depends on the hydrocarbon fuel consumption
in a propulsion system. Fig. 6 depicts the reference lines and
Economic evaluation the attained EEDI values of the various propulsion systems for
the LH2 tanker [9]. The MCFC-based propulsion systems have
The LCC, NPV, and B/C ratio are evaluated to compare the relatively lower EEDI values than the other systems.
MCFC-GT and MCFC-ST systems, as shown in Table 6. The The reference value of Phase 2 is 14.45 g-CO2/ton-NM and
CAPEX of the stand-alone 28 MW MCFC is 265 MUS$. The will apply to ships built from 2020 to 2024. Because the specific
CAPEX of the MCFC-GT system is 247 MUS$, and that of the fuel consumptions of LNG are almost identical, both hybrid

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i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 8 ) 1 e1 3 9

Table 5 e Performance of hybrid MCFC based propulsion


systems.
Item Unit MCFC-GT MCFC-ST
2
Total active area m 18,500 20,700
Fuel utilization factor e 0.75 0.75
Steam-to-carbon ratio e 3 3
Specific fuel consumption, LNG g/kWh 126 124
Specific fuel consumption, H2 g/kWh 19 17
Fuel consumption rate, LNG ton/hr 2.93 3.23
Fuel consumption rate, H2 ton/hr 0.44 0.44
Steam reforming heat duty kW 10,210 11,231
Steam reforming efficiency % 70.13 69.68
MCFC efficiency % 52.74 52.72
MCFC stack power output kW 23,173 25,918
Power consumption for BOPs
- LNG compressor kW 84 92
- H2 compressor kW 37 37
- Air compressor kW e 1900
- Water pump kW 0.70 0.77
Secondary machinery Gas Steam
turbine turbine
Power output, recovery kW 5,017 4,111
TIT K 1423 788
Pressure bar 6 60
Isentropic efficiency e 0.8 0.9
In-flow rate kg/sec 26.54 4.68
Net power output kW 28,068 27,999
Electrical efficiency, LHV % 53.87 50.11

Table 6 e LCC, NPV, and B/C ratio of MCFC-based


propulsion systems.
Item Unit Stand-alone MCFC MCFC-GT MCFC-ST
LCC US$ 850,672,897 813,880,104 822,810,122
NPV US$ 43,186,473 79,979,266 71,049,248
Fig. 5 e MCFC performance curves: (A) current density and B/C ratio e 1.05 1.10 1.09

cell voltage curve and (B) current density and power


density curve.

systems have similar EEDI values: 13.28 (MCFC-GT) and 13.20


(MCFC-ST) g-CO2/ton-NM. The lowest EEDI value for the
stand-alone MCFC is 10.04 g-CO2/ton-NM.
The reference value of Phase 3 is 12.64 g-CO2/ton-NM after
2025. If the MCFC-GT and MCFC-ST systems are equipped in
new propulsion systems, they will violate the Phase 3
requirement. This means that the LNG consumption should
be considerably reduced.
In the recent MEPC 71st session, an accelerated imple-
mentation period of Phase 3 or the introduction of Phase 4 as a
new strict reference was proposed [67]. The reference value of
Phase 4 will be 11.38 g-CO2/ton-NM. If Phase 4 is implemented,
the stand-alone MCFC will become the unique propulsion
system for the LH2 tanker. Fig. 6 e EEDI results for various propulsion systems for LH2
tanker.
NOX emission

The Tier III limits of a ship propulsion system are 1.62 g kWh1, and the MCFC-ST system emits 1.14 g kWh1;
2.0e3.4 g kWh1 in the ECAs [5]. The most stringent limit is thus, both hybrid systems satisfy the Tier III requirement.
2.0 g kWh1 for operation above 2000 rpm. Both hybrid sys- Several countries around the ECAs have adopted NOX
tems must satisfy this limit. The MCFC-GT system emits reduction policies [68]. Beginning in 2007, the Norwegian

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government began taxing merchant ships equipped with pri- Hanbat National University in Daejeon, Republic of Korea for
mary machinery with an output greater than 750 kW. Sweden his advice, suggestions, and discussions related to this
and Finland have implemented NOX regulations by port. The research.
USCG assesses a penalty of 25,000 US$ for a Tier III violation.
Because these are more stringent regulations than CO2
reduction, they will affect the propulsion system of LH2 Nomenclature
tankers in the future.
Acell Total active area, cm2
An Anode stream
Conclusions Bt Benefit, US$
Ca Cathode stream
This research proposed MCFC-based hybrid propulsion sys- CC Catalytic combustion stream
tems for a 140K LH2 tanker. The systems integrated the MCFC CF Non-dimensional conversion factor of CO2
with the Brayton cycle or Rankine cycle as the bottoming Ct Cost, US$
cycle. The MCFC, which is operated at atmospheric pressure, E0 Reversible potential at standard conditions, V
is the primary machinery, and the gas turbine and steam Ex Exhaust stream
turbine are the secondary machinery. The energy efficiency F Faraday constant, 96,485 C/mol
and economic and environmental aspects were considered in Feed Feed stream
a comparison of the MCFC-GT and MCFC-ST systems. Dg Gibbs free energy, J/mol
The MCFC-GT system was found to have higher electrical h Specific enthalpy, J/mol
efficiency than the MCFC-ST system; the MCFC-GT system Dh Activation energy, J/mol
was found to be suitable for the LH2 tanker, where the MCFC j Current density, mA/cm2
generates 23.5 MW and the gas turbine generates 4.6 MW. The M Molar mass, g/mol
total system efficiency depends on the power consumption of m_ Molar flow rate, mol/sec
the BOPs. Because the air compressor is the greatest power N Number of cells
consumer, it must be part of the gas turbine. NG Natural gas stream
The NPV and B/C ratio were evaluated on the basis of the n Molecular number
LCC. The MCFC-GT system had an NPV that was 1.18 times P Partial pressure, bar
and 1.13 times higher than that of the stand-alone MCFC and PME 75% of the MCR
the MCFC-ST system, respectively. Because both hybrid sys- Q_ Heat quantity, W
tems showed higher B/C ratios than 1.0, they were economi- R Rankine cycle stream
cally feasible. Even though the MCFC-based systems were Ran Anode activation loss, U-cm2
relatively less economically feasible than the DFDE system, Rca Cathode activation loss, U-cm2
they could be an alternative to satisfy the enforced environ- Rohm Ohmic loss, U-cm2
mental regulations. R Molar gas constant, J/mol-K
The EEDI and NOX limits were set as part of the environ- r Social discount rate
mental measures for ship propulsion systems. Both hybrid T Temperature, K
systems were in compliance with the EEDI Phase 2 and Tier III Vcell Cell voltage, V
requirements. LH2 tankers after 2025 must follow the EEDI VRef Service speed, knot
Phase 3 regulations. If the Phase 4 regulations are introduced, _
W Power, W
then the propulsion systems should be improved beyond their
Z Component cost, US$
present state. In addition, the EEDI calculation method for LH2
hNernst Nernst loss, V
tankers must be introduced in the future.
x Efficiency
A LH2 tanker is an eco-friendly ship that transports clean
fuel. During ship hoteling, the ship can be utilized for Abbreviations
distributed generation; i.e., the ship becomes a temporary B/C Benefit-cost
power plant and supplies surplus electricity produced by the BOG Boil-off gas
MCFC-based hybrid system to the onshore power grid. Thus, a CAPEX Capital expenditure
ship-to-shore power supply method should be developed. DFDE Dual-fuel diesel engine
DWT Deadweight
ECA Emission control area
Funding EEDI Energy efficiency design index
IMO International Maritime Organization
This paper was supported by BK21 Plus Program. LCC Life-cycle cost
LHV Low heating value
LNG Liquefied natural gas
Acknowledgements MCFC Molten carbonate fuel cell
MCFC-GT MCFC-gas turbine
The authors gratefully acknowledge Prof. Choong-Gon Lee at MCFC-ST MCFC-steam turbine
the Department of Chemical and Biological Engineering, MCR Maximum continuous rating

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