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Proceedings of the 2002 U.S. DOE Hydrogen Program Review Life Cycle Maintenance Cost Maintenance requirements assume scheduled replacement of electrochemical stacks and wear parts on rotating equipment. Over time, the mean time between major service is expected to increase while the cost for replacement parts is expected to decrease. A small percentage of modules will suffer breakdowns (leading to automatic shutdown of that module but not affecting the others). Both scheduled and remedial maintenance are accomplished by field exchange (”hot swap”) of a replacement module and returning the removed unit to the factory for refurbishment or repair. The estimated average annual maintenance costs (including labor) for these modules are $85. per kW per year. Natural Gas Cost An example commercial natural gas cost of $5.00 per mcf was used, with 926 BTU/scf lower heating value. Actual natural gas costs vary widely within the U.S. and with time. Input Electric Power Cost DC power from on-site renewable generation (wind, photovoltaic, or small hydroelectric) can vary widely in cost depending on accounting assumptions. The total cost per kWh will depend on installed equipment cost, annual capital charge percentages, maintenance costs, tax credits (if any), and annual capacity factor (ratio of average annual power to rated power: typically a low percentage for renewable systems). Where equipment cost is treated as “sunk”, the annual capital charge percentage is zero, leading to very low power cost. In some cases, low cost off- peak power may be available from a utility. The example below uses an input power cost of 2.0 cents per kWh, which could equal the maintenance cost of a renewable system. Grid Power Buy/Sell Prices Utility cooperation and buy/sell prices for distributed generation sites vary widely with individual utilities. It is assumed many users will choose to operate independent of the grid to minimize installed costs, maximize safety, and avoid grid disturbances from compromising premium power quality. In some cases, utility purchase prices are so low they would not cover the incremental cost of natural gas fuel to generate export power. Where net metering provisions exist, monthly or annual electric energy imports and exports are offset against each other, with the difference being billed or paid. Conversely, a utility interconnection would permit a smaller capacity to be installed, provide enhanced peak power, and produce incremental revenues where utility buy prices are favorable. The extremely high 65-72% natural gas to AC efficiencies of the systems leads to low marginal generation costs, especially when fuel costs are moderate. Inputs Systems are expected to be capable of operation on natural gas (or propane) and electric power inputs in any proportions. Efficiency from propane is the same as natural gas on an LHV basis. The calculations below were performed for 100% natural gas and 100% electric power. When both are used, costs are in proportion. Outputs The three economically valued outputs are AC power, hydrogen, and hot water. Hot water is produced by the system only when natural gas or propane is being used. AC power and hydrogen may be simultaneously produced in any desired proportion. The average annual load factors (percentage of maximum capacity actually used) depend greatly upon the nature of the business (or residence) where the equipment is used and whether grid connection is used. In the example below, 99% primary output load factor is used: NREL/CP-610-32405 10PDF Image | Nafion Resins: Novel Device Applications
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