APC 400kW1MW User Manual

APPLYING FUEL CELLS TO DATA CENTERS FOR POWER AND COGENERATION by AMY L CARLSON B.S., Kansas State University, 2009 A REPORT submitted i

1 CHAPTER 1 - Introduction Data centers have become ever-present in the economy as information management evolves from paper to digita

2 CHAPTER 2 - Background Information The background information of fuel cells is important to understand before discussing their useful

3 The improvements to the PEMFCs included the fuel cell being more “powerful, lighter, safer, simpler to operate, and more reliable” [8, p

4 Figure 2-1 Fuel Cell System Components [A] The fuel cell stack requires hydrogen in order to produce electricity. Hydrocarbon fuels are conver

5 Figure 2-2 Fuel Cell Diagram [A] The result of a fuel cell’s chemical process is water, as stated in the above net reaction equation, and heat

6 Figure 2-3 UTC Power's PureCell Model 400 Fuel Cell Module [B] There are eight different types of fuel cells, and they are classified in

7 sulfur must still be removed from the fuel. The operating temperature also allows for the use of moderately priced high-temperature materials [17

8 2.2.2 Molten Carbonate Fuel Cell A molten carbonate fuel cell contains an electrolyte made of lithium-potassium carbonate salts. These salts

9 Figure 2-4 MCFC Dual Fuel Operation [C] Because MCFCs have minimal moving parts to cause wear and a moderate operating temperature, few system

10 This type of fuel cell operates at relatively low temperatures, 140°F to 194°F (60°C to 90°C), resulting in a quick start up time [11, p. 45; 10

Copyright AMY L CARLSON 2009

11 they are not poisoned by trace levels of carbon monoxide. Like other fuel cells, the anodes in SOFCs are poisoned by sulfur [17, p. 50; 25, p. 1

12 Table 2-1 Fuel Cell Types Comparison [D] PAFC MCFC PEMFC SOFC Electrolyte Liquid phosphoric acid Molten carbonate salt Polymer exchange mem

13 CHAPTER 3 - Data Center Power The required quality of a data center’s power is essential due to society’s high reliance on the services that

14 p. 172]. The large amount of downtime due to an outage is just the reason why no data center connects to the electric grid without some sort of

15 electrical system for short-term power outages and during the startup time required for diesel generators for long-term outages. The UP

16 reliability requested for office equipment and the budget. Figure 3-2 shows another one-line diagram without the offices on emergenc

17 3.3.1 Fuel Cells as Primary Power Data centers have a near constant power demand and require a high degree of reliability, making

18 Figure 3-3 One Line Diagram: Fuel Cell Providing Primary Power Where local utilities allow, a surplus of power produced by a fuel cell is able

19 3.3.2 Fuel Cells as Secondary Power Because of the disadvantages associated with diesel generators, some data center owners are consi

20 Figure 3-4 Hydrogen Storage Tanks Located Outdoors [E] High temperature fuel cells (>390°F or 200°C) are advantageous for CHP applications.

Abstract Data center space and power densities are increasing as today’s society becomes more dependent on computer systems for processing and s

21 Figure 3-5 Three APC Fuel Cells Installed in a Server Rack [F] APC’s InfraStruXureTM with Integrated Fuel Cells system is aimed at pr

22 Ideal applications for the APC fuel cell are small to medium data centers. These fuel cells are best suited for facilities that are restricte

23 Rack mounted fuel cells can also provide secondary power to a fuel cell system providing primary power. A one line diagram of this

24 CHAPTER 4 - Fuel Cell Combined Heat and Power Systems Combined heat and power systems use similar configurations as typical HVAC systems. Howeve

25 4.1 Typical HVAC Systems in Data Centers Cooling for data center facilities is typically provided by CRAC units supplied with chilled water from

26 raised floor. Cold air is distributed to the IT equipment below the raised floor and through perforated floor tiles [1, p. 19].

27 4.2 Fuel Cell Combined Heat and Power System Applications The byproducts of a fuel cell’s electrochemical reaction are heat and water. The water

28 From the heat exchangers, excess waste heat is delivered to the fuel cell system’s cooling module, where the heat is rejected. For

29 Figure 4-4 Single-Effect Absorption Chiller Cooling Process [I] Absorption chillers are classified by the number of generators they h

30 produce 250ºF hot water to be used with a single-effect absorption chiller. PEMFCs do not produce waste heat with high enough tem

iv Table of Contents List of Figures ...

31 If boilers are used to supply supplementary heat to the absorption chillers, they will cycle on and off as the cooling load varies. When opera

32 single and double-effect chillers, first costs are usually the highest with the double-effect type. However, double-effect chillers are more ene

33 4.2.2 Domestic Water Heating in a Fuel Cell CHP System The low grade heat exchanger within a fuel cell system is able to provide pre-heating for

34 CHAPTER 5 - Advantages of Fuel Cells used in Data Centers Fuel cells offer several advantages for data centers in comparison to receiv

35 Low noise levels offer flexibility in data center siting. Because they are so quiet, fuel cells are able to be placed within clo

36 Table 5-1 was taken from the “Report to Congress on Server and Data Center Energy Efficiency Public Law 109-431” and compares the emission

37 7080901001/2 Hour 8 Hours 24 HoursMission LengthReliability Figure 5-2 Reliability of a Well-Maintained Diesel Generator [L] Proper maintenance

38 90% with a MCFC CHP system. In addition, the efficiencies of fuel cells remain high even when the loads vary from design loads [64, para 5; 10,

39 5.5 Minimal Maintenance Due to their few moving parts, fuel cell systems require minimal maintenance. This has been demonstrated in multiple

40 their power from renewable energy resources. Rebates are offered for several types of renewable energy technologies, including

v 5.3 Increased Reliability ...36 5.3 High Effici

41  Energy & Atmosphere Credit 1: Optimize Energy Performance This credit is intended to increase levels of the building’s energy p

42 However, retaining walls may not be necessary with the low noise levels of fuel cell systems. In fact, the EPC recommends fuel cells f

43 The EPC Guide for Data Centers draft also includes the Energy & Atmosphere prerequisite for fundamental refrigerant managemen

44 CHAPTER 6 - Disadvantages of Fuel Cells used in Data Centers There are several disadvantages associated with installing a fuel cell sys

45 UTC Power, FuelCell Energy, and CFC Solutions report their fuel cell stack life anywhere from 3 to 10 years. UTC Power’s PureCell Mo

46 CHAPTER 7 - Future Predictions for Fuel Cells As shown in Chapter 6, there are several obstacles for fuel cell manufacturers to ove

47 Figure 7-1 FuelCell Energy Cost Reductions [N] As mentioned previously, in order for fuel cell prices to continue to decrease, hig

48 cell market will grow and subsequently support the development of stationary fuel cells [12, p. 20 -21]. Currently, the hydrogen infrastructur

49 or to be easily and cheaply replaced. They also state that fuel cells would be more competitive in the automotive industry if they had a longer

50 The goal of NREL and Xcel Energy’s project is to improve the efficiency of producing hydrogen from a renewable resource. NREL

vi List of Figures Figure 2-1 Fuel Cell System Components... 4 Figure

51 CHAPTER 8 - Conclusions Fuel cells are an exciting technology that many design engineers are just now learning about. To end the report, recomme

52 electrical system’s overall reliability. There are other aspects gained from this fuel cell’s history that would give more insight to the design

53 Before going any further into the procedure, the electrical loads of the facility need to be calculated. Knowing the electrical demands of

54 cells. There may be a local fuel cell technician available. If not, employees of the data center will need to take on the responsibility.

55 References Cited [1] “Report to Congress on Server and Data Center Energy Efficiency Public Law 109-431,” U.S. Environmental Protection Agency,

56 [10] M. Ellis, M. Von Spakovsky, and D. Nelson, “Fuel Cell Systems: Efficient, Flexible Energy Conversion for the 21st Century,” IEEE Journal ,

57 [20] Cooling, Heating, and Power for Buildings (CHP-B) Instruction Module. Mississippi State, Department of Mechanical Engineering, 2004. [21]

58 [29] W. Allen, D. Fletcher, and K. Fellhoelter, “Securing Critical Information and Communication Infrastructures Through Electric Power Grid Ind

59 [38] “New OK Fuel Cell APC Solution OK-ISX-FCXR10-30”, http://www.oksolar.com/0_n_cart/htm/724930.htm Accessed Jan. 17, 2009. [39] G. Whitmor

60 [48] B.F. Kolanowski, Small-Scale Cogeneration Handbook. Lilburn, Georgia: The Fairmont Press, Inc., 2008. [49] “Thermally Activated Technolog

vii List of Tables Table 2-1 Fuel Cell Types Comparison ...12 Table

61 [57] “DFC 300 Product Brochure,” http://www.fuelcellenergy.com/files/FCE%20DFC300_Product_Sheet_032508.pdf Accessed February 9, 2009. [58] “P

62 [66] “Installation Profile Verizon,” http://www.energyreinvented.com/phpworx/index.php?cmd=controller&action=download_section&usr=f17dc4

63 [75] R. Tierney, “Fuel Cells: Cost-Effective, Reliable, and Ready Now,” http://www.govenergy.com/2008/pdfs/technology/TierneyTech6.pdf Accessed

64 [85] M. Antich, “Obama’s Stimulus Package Offers Funds for Fleet,” http://www.businessfleet.com/Blog/Market-Trends/Story/2009/02/Obama-s-Stimulu

65 [96] “PureCell Model 400 System Guide Specification,” http://energyreinvented.com/phpworx/index.php?cmd=controller&action=download_section&

66 Graphics References [A] M. Ellis, M.B. Gunes, “Status of Fuel Cell Systems for Combined Heat and Power Applications in Buildings,” ASHRAE, vol.

67 [K] “Report to Congress on Server and Data Center Energy Efficiency Public Law 109-431,” U.S. Environmental Protection Agency, Energy Star Progr

68 Appendix A - Relevant Codes and Standards “Hydrogen is no more or less dangerous than other flammable fuels, including gasoline and natural ga

69 12. IEEE 1547.1 – 2005 – Standard Conformance Test Procedures for Equipment Interconnecting Distributed Resources with Electric Power S

70 Appendix B - Data Sheets for Stationary Fuel Cells DFC300 Data Sheet [57]

viii Acknowledgements I would like to thank my supervisory committee, Fred Hasler, Ray Yunk, and Chuck Burton, for the guidance and

71

72 PureCell Model 400 System [56]

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74 InfraStruXure Data Sheet [36]

75

76 Appendix C - Fuel Cell Items in the American Recovery and Reinvestment Act [86]

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ix Dedication I would like to dedicate this report to my loving and supportive husband and family. Thank you for your continuous