SAGE Enterprises Fuel Cell Challenge V Presentation
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Fuel FlexiblePortable Reformer for LPG Fuel
Cells
University of South CarolinaSmartstate Center for Strategic Approaches to the Generation of Electricity
May 2013
M. Kai Mayeda, Sungtak Kim, Erdem Sasmaz, Jochen Lauterbach
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Team
• 20+ years catalysis research• High throughput catalyst
exploration, discovery, and design• System optimization and prototype
development• Production scale up
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UAV Market
$9B/yr spent on battery-powered drones in the
USTeal Group Corporation, 2012http://www.marketresearchmedia.com/
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Fuel Cell Power
Stalker Payload: 3 lb Flight Time: 2+ hrs Altitude: up to 15,000 ft Propulsion: electric/battery
Stalker eXtended Endurance (Stalker XE) Payload: 2 lb Flight Time: 8+ hrs Altitude: up to 15,000 ft Propulsion: electric/fuel cell
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What is the problem?
• No LPG supply chain
• JP-8 is the NATO fuel of choice
• Reformer cannot use water, hydrogen, electricity, or
any additional chemicals
• Compact (dorm-room sized refrigerator)
• No desulfurization (up to 3000 ppm)
• 5 wt% minimum conversion
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Core technology: The Catalyst
• Capable of converting (JP-8) and diesel
• Resists coking & easy to regenerate
• > 40 wt% JP-8 conversion
• Sulfur tolerant
Patent App.: US 2013/0041198 A1
PropaneButaneEthyleneEthanePropylene1-butene
0 1 2 3 4 5 6 70%
5%
10%
15%
20%
Regeneration Count
LP
G Y
ield
70 hrs
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Pre-Fuel Cell Challenge
Carrier gas
Gas product 0.3 gLPG/hr
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Space Velocity testing
0 1 2 3 4 5 6 7 8 9 100%
5%
10%
15%
20%
25%
WHSV=10
WHSV=20
WHSV=40
WHSV=80
Time on Stream (hr)
kg C
2-C4
out
/ k
g JP
-8 in
(%)
Product yield increased and catalyst deactivation rate decreased with decreasing WHSV
WHSV (h-1) 10 20 40 80
Catalyst – JP8 flow 1.5g – 0.31ml/min 0.75g – 0.31ml/min 0.37g – 0.31ml/min 0.185g – 0.31mi/min
• Reaction T: 450oC• Catalyst: Pt-Gd/ZSM-5• No Carrier gas
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0 1 2 3 4 5 6 7 8 9 100%
5%
10%
15%
Time on Stream (hr)
kg C
2-C
4 o
ut
/ kg J
P-8
in
Simplify and Recycle
0 1 2 3 4 5 6 70%
5%
10%
15%
20%
Time on Stream (hr)
kg
C2-C
4 o
ut
/ kg
JP
-8 in Average LPG
yield for 7h
Average LPG production rate (g/hr)
JP-8recycling
34.5% (±1.7) 2.4
JP-8 14.2% (±0.7) 2.0
recycle
single pass
Minimal carrier gas influencew/helium
w/o helium
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Post-Fuel Cell Challenge
Carrier gas
JP-8 recycle
Peltier cooler
Gas product, 18 gLPG/hr
60x increase!
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Portable Reformer
Buy SmartDraw!- purchased copies print this document without a watermark .
Visit www.smartdraw.com or call 1-800-768-3729.
0.3 gLPG/hr
18 gLPG/hr
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Dieselor
Kerosene • Silent power generation
• High fuel efficiency• 1 kW ~ 0.3
gal/hr
• Fuel flexibility
Expanding our Market
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Visit www.smartdraw.com or call 1-800-768-3729.
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Business Plan: Near Term
TM
sageenergy.biz
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Business Plan: Long term
• Defense contractors as collaborators/partners
• Full demonstrations for 3rd party investment• Customer-driven prototype design• Additional funding and guidance
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Milestones
System Design• Catalyst screening• Process optimization• Scale-up
Alpha Prototype• Construction and
testing• Define customer
needs
Funding• SBIR/STTR• Venture capitalist• SC Launch
Marketing• Meet with
Customers• Define the exit
strategy
Production
0.3 to 18 gLPG/hr Simplify system design 15% to 40% conversion Alpha prototype construction
Peltier cooler Stepper motors Tube furnace No carrier gas
Established LLC Written business plan Developed website Identified potential investors
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Acknowledgements
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END
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Supporting Slides
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Potential Market
• $2.1B/yr spent on power sources (mainly batteries)1
• $9B/yr spent on battery-powered drones in the US2
• 2005-2010: US approved $380M of drone exports• Canada & Australia to spend $1B and $3B per annum3
• Sulfurized fuel for cooking• Military: expensive to make specialized jet fuel burners
SBIR solicitation A13-045, February 20134
• Developing countries use dirty fuels for cooking:5
703 TWh of energy used from oil75% of non-OECD residents burn dirty biowaste or charcoal
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Market Strategy: Sales
Projected revenue• Unit sales
• Production - $10,000/unitSale - $40,000/unit
• Estimated to sell hundreds of units per year
• Annual service contracts• Technical servicing• Catalyst replacement
• Profits in excess of $5M
FY 2013 FY 2014 FY 2015$ 0
$ 2 M
$ 4 M
$ 6 M
$ 8 M
$ 10 M
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Market Pains
• What’s wrong with batteries?• 0.1-0.3 kJ/cm3 energy density
(LPG = 26 kJ/cm3)• 1-5 hrs recharge
• Sulfurized fuel cooking consequences• respiratory problems and asthma• acidification of local environments
• Absent infrastructure• costly or inconsistent supply• enormous capital costs to build
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Representative competitor
Precision Combustion, Inc. Autothermal reforming Partial oxidation Catalytic cracking All require additional chemical inputs All produce H2 (0.008 kJ/cm3, 1 atm)
Industrial refinery and LPG extractionCheap and efficient, but immobile
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LiquidFuel
LPG
Large market size:• Military operations
• Small drones• Cooking Appliances• Portable energy
• Portable power• Sea expeditions• RVs
LPG SOFC Stalker XE
M1 tanks
Cougar
Humvee
Applications
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