1. Zaff Hi-Tech MoU ; FC Technology for KSA
Use of Flare Gases To
Generate Electricity
from
Solid Oxide Fuel Cells
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2. Flare Gases & Reduction Milestones
Over 150 billion m³ of gas are being flared & vented annually
The gas flared annually equals 30 % of the European Union’s gas consumption, or 75 % of Russia’s gas exports
KSA Flares 2 billion m³/year equivelant to 16 Giga Kw using Fuel Cells
World Bank will ask Oil Cos. to Stop Flaring Gas by 2030
World Bank is leading 33 Nations & Cos. in Global Gas Flare Reduction Partnership to shrink Flaring by 30 % by 2017
Source : World Bank Data
Source : World Bank : Eduard Gismatullin  Jun 18, 2014
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3. Extracts from IPCC Report
2. Future Climate Changes, Risks and Impacts
Continued emission of greenhouse gases will cause further warming and long- lasting changes in all components of the climate system, increasing the likelihood of severe, pervasive and irreversible impacts for people and ecosystems.
Limiting climate change would require substantial and sustained reductions in greenhouse gas emissions which, together with adaptation, can limit climate change.
2.1 Key drivers of future climate
Cumulative emissions of CO2 largely determine global mean surface warming by the late 21st century and beyond. Projections of greenhouse gas emissions vary over a wide range, depending on both socioeconomic development and climate policy.
Source : IPCC :
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4. Zaff Hi-Tech MoU ; FC Technology for KSA
Why Fuel Cells and not e.g. Steam Turbines?
High Electrical Efficiency > 60% (20-38% for Steam Turbines)
Stable Efficiency under Partial-Load Operation
Low CO2-emmissions ( Measured as x/KwHr of Electricty Produced )
No Moving Parts (Low Maintenance) which is important for remote installations
Low Noise Emmission ( < 60 db. )
Modular Assembly Enabling Upscaling from KW to MW-units
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5. Why SOFC for flare gas electrification?
SOFC is the most efficient technology available to convert methane rich gases into electricity
the long term cost potential of the technology is below 1500€/kW and hence competitive to conventioal solutions (gas engines & turbines)
Due to the biogas boom in Europe low cost gas cleaning technology is available and could be easily adapted to flare gases
SOFC should be more tolerant to heating value fluctuations than engines or turbines, as no combustion takes place and oxygen and fuel are always physically seperated
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6. Zaff Hi-Tech MoU ; FC Technology for KSA
What is C©HP
Onsite & decentral generation of electrical and heat and/or cooling
Waste-heat recovery for heating, cooling, dehumidification, or process applications.
Seamless system integration for a variety of technologies, thermal applications, and fuel types into existing infrastructure.
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7. Zaff Hi-Tech MoU ; FC Technology for KSA
Benefits of CHP
Efficiency Benefits
CHP requires less fuel to produce a given energy output, and avoids transmission and distribution losses that occur when electricity travels over power lines.
Reliability Benefits
CHP can be designed to provide high-quality electricity and thermal energy to a site regardless of what might occur on the power grid, decreasing the impact of outages and improving power quality for sensitive equipment.
Environmental Benefits
Because less fuel is burned to produce each unit of energy output, CHP reduces air pollution and greenhouse gas emissions.
Economic Benefits
CHP can save facilities considerable money on their energy bills due to its high efficiency and can provide a hedge against unstable energy costs.
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8. Zaff Hi-Tech MoU ; FC Technology for KSA
Benchmark Bloom Energy
Bloom Energy product: Bloom Box 2.0
200kW, 60% electr. efficiency,
Sales price <3000US$/kW for 10 year carefree
about 100MW installed capacity
Bloom Electrons, electr. lower price than grid (in selected locations)
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9. Zaff Hi-Tech MoU ; FC Technology for KSA
How does it work ?
Burner
HEX
Reformer
Compressor NG
Air
Anode
K ode a t h
Desulf.
Heat
Cooling
Electricity
up to 60% electrical efficiency
~90% total efficiency
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10. Zaff Hi-Tech MoU ; FC Technology for KSA
Components required for a SOFC system
Start-up burner
(for combustion with preheated air)
Air NG
Exhaust
Steam Reformer
Disulphuriser
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11. Zaff Hi-Tech MoU ; FC Technology for KSA
SOFC Stack Module
Module 3
Module 4
Module 5
integration of single stacks to achieve desired output power
Key challenges: thermal integration & gas distribution
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12. Zaff Hi-Tech MoU ; FC Technology for KSA
5-10kW System Demonstrator
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13. Zaff Hi-Tech MoU ; FC Technology for KSA
Operating Results of System Demonstrator
dedicated 500hr test showed no degradation
>50% electrical efficiency achieved
electrical output power from 1kW to 6.5kW (sizeable)
in total: around 3.500hr test experience
Gen II tested (>55% efficiency)
Gen III under development (included absorbtion chiller for cooling)
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14. Case Study SOFC Distributed Power Generation
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15. Zaff Hi-Tech MoU ; FC Technology for KSA
Study Outline
Based on existing 10 Kw CHP, the study will concentrate on;
Flare Gase Chemical composition
Gas Cleaning process
Pre-reforming
Adaptation to Local Environment
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16. Bar Chart Representation
Adapting Existing Kw CHP Module Q1 Q2 Q3 Q4
Partner & Business Model Development
Partner Defintion
Business Plan
Financing Plan
Product Defintion
Product Identification
Product Specification Development
CHP Platform
Flare gas Adaptation Studies
CHP Demoproject
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17. Roadmap for large-scale SOFC Products
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18. Development Phases of Large SOFC Generators
Detailed Product
Specs
Application
Development
Production
Planning
Field Tests
Supply Chain
Development
Product
Certification
Stack Assembly
Line Build-up
System Assembly
Line Build-up
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19. Bar Chart for Development – 100 Kw CHPQ1 Q2 Q3 Q4
CHP 100 kW Product
Detailed Product Specifications
Upscale Development
Field Tests
Production Planning
Supply Chain Development
Product Certification
Stack Assembly Line Build-up
System Assembly Line Build-up
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20. Zaff Hi-Tech MoU ; FC Technology for KSA
The consortia offers
Access (Know-How and IPR) to advanced SOFC power generation technology from powder to turn-key systems
openess for technology transfer to Saudi Arabia
flexibility in business models for local Saudi value creation (e.g. local license manufacturing of end-products)
>20 years of experience
>100 specific SOFC projects with leading international energy solution providers
local representation by Zaff Hi-Tech
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21. Zaff Hi-Tech MoU ; FC Technology for KSA
Thank You for Attending Zaff Hi-Tech MoU ; FC Technology for KSA AVL / Graz Austria Plansee / Ruette Austria Fraunhofer Research Institute / Dresden Germany ATNS / Roma Italy
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22. Zaff Hi-Tech MoU ; FC Technology for KSA
AVL
AVL is the world's largest independent company for development, simulation and testing technology of powertrains (hybrid, combustion engines, transmission, electric drive, batteries, fuel cells and software) for passenger cars, trucks and stationary power generation. AVL has 7200 employees worldwide and a turnover of Mio€ (2012).
Fraunhofer
Fraunhofer Society ; Largest Applied Research Centre in Germany; Staff ; Budget 2 Billion€
Plansee
Established 1921 & still privately owned; in 2012/2013, 1.2 Billion € Sales ; 29 Mn € R&D; 5700 Employees, . The Plansee Group aims to be the world’s leading and preferred supplier of high-technology materials. Since 20 Yrs active in SOFC Technology; World Leader in Powder Metallurgical components & technologies Solid Oxide Fuel Cells
ATNS Consultants
Senior Consultants Network operating in Telecoms & Advanced Technology Fields
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23. Zaff Hi-Tech MoU ; FC Technology for KSA
Annex
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24. Zaff Hi-Tech MoU ; FC Technology for KSA
Flared Gas World Wide
• Over 150 billion cubic meters (or 5,3 trillion cubic feet) of natural gas are being flared and vented annually. • The gas flared annually is equivalent to 25 per cent of the United States’ gas consumption, 30 per cent of the European Union’s gas consumption, or 75 per cent of Russia’s gas exports. The gas flared yearly also represents more than the combined gas consumption of Central and South America. • The annual 35 bcm (or 1,2 trillion cubic feet) of gas flared in Africa alone is equivalent to half of that continent’s power consumption. • Flaring gas has a global impact on climate change by adding about 400 million tons of CO2 in annual emissions. • Fewer than 20 countries account for more than 70 percent of gas flaring and venting. And just four countries together flare about 70 billion cubic meters of associated gas.
Source : World Bank :
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25. Zaff Hi-Tech MoU ; FC Technology for KSA
The Kingdome Flares +/- 2 Billion Nm³ / Year Equaling MW / Year Using Fuel Cells
Source : World Bank Data
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26. Flaring Reduction Mile Stones 2017 & 2030
World Bank Will Ask Oil Companies to Stop Flaring Gas by 2030
The World Bank will urge producers of oil to stop flaring natural gas by 2030, saying the amount of fuel wasted in the practice would generate enough power to meet all of Africa’s demand for electricity
The World Bank is leading 33 companies and nations in the Global Gas Flaring Reduction partnership that seeks to shrink the industry custom by 30 % in the five years to 2017
Halting the burning of about 140 billion cubic meters of gas globally every year would reduce carbon-dioxide emissions equivalent to taking about 70 million cars off the roads
Source : World Bank : Eduard Gismatullin  Jun 18, 2014
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27. IPCC Report
AR5 SYR SPM

28. Agriculture, forests and other land uses
IPCC Report
Sources of emissions
Energy production remains the primary driver of GHG emissions
6.4%
24%
21%
14%
35%
Building Sector
Agriculture, forests and other land uses
Transport
Industry
Energy Sector
2010 GHG emissions
AR5 WGIII SPM 28

29. The window for action is rapidly closing
IPCC Report
The window for action is rapidly closing
65% of our carbon budget compatible with a 2°C goal already used
Amount
Remaining:
Total Carbon
Budget:
275 GtC
Amount Used :
790 GtC
515
GtC
AR5 WGI SPM 29

30. Limiting Temperature Increase to 2˚C
IPCC Report
Limiting Temperature Increase to 2˚C
Measures exist to achieve the substantial emissions reductions required to limit likely warming to 2°C
A combination of adaptation and substantial, sustained reductions in greenhouse gas emissions can limit climate change risks
Implementing reductions in greenhouse gas emissions poses substantial technological, economic, social, and institutional challenges
But delaying mitigation will substantially increase the challenges associated with limiting warming to 2°C
AR5 WGI SPM, AR5 WGII SPM,AR5 WGIII SPM 30

31. IPCC Report Mitigation Measures More efficient use of energy
Greater use of low-carbon and no-carbon energy • Many of these technologies exist today
Improved carbon sinks • Reduced deforestation and improved forest management and planting of new forests • Bio-energy with carbon capture and storage
Lifestyle and behavioural changes
AR5 WGIII SPM 31

32. Extracts from IPCC Report
2. Future Climate Changes, Risks and Impacts
Continued emission of greenhouse gases will cause further warming and long- lasting changes in all components of the climate system, increasing the likelihood of severe, pervasive and irreversible impacts for people and ecosystems.
Limiting climate change would require substantial and sustained reductions in greenhouse gas emissions which, together with adaptation, can limit climate change.
2.1 Key drivers of future climate
Cumulative emissions of CO2 largely determine global mean surface warming by the late 21st century and beyond. Projections of greenhouse gas emissions vary over a wide range, depending on both socioeconomic development and climate policy.
Source : IPCC :
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33. Extracts from IPCC Report Cont. 2
3. Future Pathways for Adaptation, Mitigation and Sustainable Development
Adaptation and mitigation are complementary strategies for reducing and managing the risks of climate change. Substantial emissions reductions over the next few decades can reduce climate risks in the 21st century and beyond, increase prospects for effective adaptation, reduce the costs and challenges of mitigation in the longer term, and contribute to climate-resilient pathways for sustainable development.
3.2 Climate change risks reduced by mitigation and adaptation
Without additional mitigation efforts beyond those in place today, and even with adaptation, warming by the end of the 21st century will lead to high to very high risk of severe, widespread, and irreversible impacts globally (high confidence). Mitigation involves some level of co-benefits and of risks due to adverse side-effects, but these risks do not involve the same possibility of severe, widespread, and irreversible impacts as risks from climate change, increasing the benefits from near-term mitigation efforts.
Source : IPCC :
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34. Proton Exchange Membrane PEM FC
Basic Cell Reaction
2H2 + O2  2H2O + 2e-
Types of fuel cells; design[edit]
Fuel cells come in many varieties; however, they all work in the same general manner. They are made up of three adjacent segments: the anode, the electrolyte, and thecathode. Two chemical reactions occur at the interfaces of the three different segments. The net result of the two reactions is that fuel is consumed, water or carbon dioxide is created, and an electric current is created, which can be used to power electrical devices, normally referred to as the load.
At the anode a catalyst oxidizes the fuel, usually hydrogen, turning the fuel into a positively charged ion and a negatively charged electron. The electrolyte is a substance specifically designed so ions can pass through it, but the electrons cannot. The freed electrons travel through a wire creating the electric current. The ions travel through the electrolyte to the cathode. Once reaching the cathode, the ions are reunited with the electrons and the two react with a third chemical, usually oxygen, to create water or carbon dioxide.
A block diagram of a fuel cell
The most important design features in a fuel cell are[citation needed]:
The electrolyte substance. The electrolyte substance usually defines the type of fuel cell.
The fuel that is used. The most common fuel is hydrogen.
The anode catalyst breaks down the fuel into electrons and ions. The anode catalyst is usually made up of very fine platinum powder.
The cathode catalyst turns the ions into the waste chemicals like water or carbon dioxide. The cathode catalyst is often made up of nickel but it can also be a nanomaterial-based catalyst.
A typical fuel cell produces a voltage from 0.6 V to 0.7 V at full rated load. Voltage decreases as current increases, due to several factors:
Activation loss
Ohmic loss (voltage drop due to resistance of the cell components and interconnections)
Mass transport loss (depletion of reactants at catalyst sites under high loads, causing rapid loss of voltage).[14]
To deliver the desired amount of energy, the fuel cells can be combined in series to yield highervoltage, and in parallel to allow a higher current to be supplied. Such a design is called a fuel cell stack. The cell surface area can also be increased, to allow higher current from each cell. Within the stack, reactant gases must be distributed uniformly over each of the cells to maximize the power output.[15][16][17]
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35. PEM Fuel Cell Stack Structure
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36. Solid Oxide Fuel Cell Principle Gas Suited Fuel Cell « SOFC »
Reforming:
CH4 + H20 à CO + 3H2
CO + H2O à CO2 + H2
Anode Reaction:
H2 + O2- à H20 + 2e-
CO + O2- à CO2 + 2e-
Cathode Reaction:
O2 + 4e- à 2 O2-
5.5 Kw Hr / Nm3 50% efficiency
5 KwHr / Litre Diesel @ 50% efficiency
H2 + CO + CO2
CO2 + H2
CH4 + H2O
CO  + H2O
Reforming
2H2 + O2     2H2O + 2e-
2CO + O2     2CO2 + 2e-
Basic Cell Reaction
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37. Zaff Hi-Tech MoU ; FC Technology for KSA
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38. Well_Head Gas Composition
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39. FC Impurities Tolerance – ref. data
Fuel Impurity Tolerance of Solid Oxide Fuel Cells
Kazunari Sasaki, S. Adachi, K. Haga, M. Uchikawa, J. Yamamoto, A. Iyoshi, J.-T. Chou, Y. Shiratori & K. Itoh
Sulfur Poisoning of SOFCs: Voltage Oscillation and Ni Oxidation
T. Yoshizumi, S. Taniguchi, Y. Shiratori K. Sasaki
Phosphorus Poisoning of Ni-Cermet Anodes in Solid Oxide Fuel Cells
K. Haga, Y. Shiratori, Y. Nojiri, K. Ito, & K. Sasak
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40. Varied FC Plates Profiles
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