Reimagined Alter Carbon Gateway Situated at Toyota's Facility in Long Beach Port
The moniker "Altered Carbon Portal" fits perfectly with Fuel Cell Energy's groundbreaking Tri-gen plant, situated at Toyota's dock within the Port of Long Beach. This advanced facility is home to a 2.8MW Molten Carbonate Fuel Cell (MCFC), which transforms natural gas into syngas (a blend of hydrogen, carbon dioxide, and water) through internal steam reforming. The process generates electricity from around 70% of the hydrogen, while the remaining 30% undergoes a multi-stage Pressure Swing Absorption process for purification, yielding approximately 1,200 kg/day of fuel-grade hydrogen. The condensed water from the exhaust is utilized for washing cars at Toyota's dock prior to shipment to dealerships.
Two Hydrogen Filling Stations
Situated near the plant, Shell designed and constructed two hydrogen refueling stations: one for heavy-duty port trucks and the other for passenger cars. The Toyota Mirais, powering deliveries, are refueled at these stations. The hydrogen from the Tri-gen plant is stored in a 1,600 kg, 44-tank system, which caters to both hydrogen refueling stations. Remarkably, Shell maintains and operates both stations.
Sustainable Biogas
Toyota envisioned this project in 2016 to boost the sustainability of its port operations. At the time, Fuel Cell Energy had prior experience running a similar pilot project at the Fountain Valley water treatment plant, which was opened in 2011. The Fountain Valley plant was smaller, generating power at just one-tenth the size of the Tri-gen plant, but it tested the same concepts. It employed digester gas from bacteria processing solid waste into fertilizer and biogas. This biogas was captured and used as fuel for the MCFC. Since the ports lack a nearby renewable biogas source, the project partners with the Victor Valley Wastewater Reclamation Authority. This authority collects biogas from landfill food waste and sewer co-digestion, transforming it into renewable natural gas. This gas is injected into a Southwest Gas pipeline as biomethane for distribution. Fuel Cell Energy purchases this renewably sourced biomethane at the source but utilizes the gas available at the port, thus supporting the claim of green hydrogen and power. Given the terminal's lower energy requirements compared to the port, an off-take power agreement was secured with Southern California Edison. After all the contracting and permitting, the plant foundation was laid in December 2021. Site engineering, procurement, and construction were handled by Fastech, a company familiar with building hydrogen infrastructure. The first electricity was produced in October 2023 and connected to Edison in November. Shell initiated refueling operations in December, initially refueling a Mirai, followed by the first heavy-duty truck refueling in January 2024.
Fuel Cell Energy's History
Fuel Cell Energy’s primary offering is the Molten Carbonate Fuel Cell. My initial encounter with this fuel cell was at the Michigan Alternative and Renewable Energy Center in Muskegon, which opened in 2004. Affiliated with Grand Valley State University where I worked from 2002 to 2007, the center housed a 200 kW unit that I frequently studied. Surprisingly, Fuel Cell Energy stepped in at the last minute to replace another company that couldn't deliver its product on time, marking FCE's first commercial installation. Among other projects, the University of California San Diego campus operated a 2.8MW plant for several years, utilizing exhaust heat to power absorption chillers for air conditioning. Another notable project is the Sierra Nevada Brewery, where fermentation gas powers the fuel cell, while exhaust heat warms the mash. FCE's largest power plant, situated in Seoul, South Korea, produces 56 MW from 21 units of 2.8 MW plants. The company consistently improves its product line, extending stack durability from 3 to 7 years before replacement is required. Each stack produces roughly 350 kW and consists of 400 cells. Four stacks fit into a module, producing 1.4 MW, and typically two modules are deployed in the modular plant for a total of 2.8 MW.
The Operational Molten Carbonate Fuel Cell
The operation of the Molten Carbonate Fuel Cell is a testament to engineering brilliance, blending chemistry, electrochemistry, and mechanical principles. It deserves a separate study, but a short explanation for the "altered carbon" claim in the title follows. The heart of this fuel cell is its molten carbonate electrolyte, a combination of potassium and lithium carbonate salts (Li2CO3, K2CO3) that melt at operational temperatures, hence the name "Molten." At about 600-650 degrees Celsius, natural gas (carbon and hydrogen) reacts with water (hydrogen and oxygen), producing syngas. As this mixture flows into the fuel cell, hydrogen is consumed, continuously driving the reaction. The fuel cell utilizes around 70% of the hydrogen available, with the remaining hydrogen either oxidized for additional heat or purified for refueling. There are more technical details, but let's halt here.
Since its debut in late 2023, the Tri-gen plant has become a symbol of sustainability and hydrogen innovation at the Port of Long Beach. Fuel Cell Energy takes pride in its engineering accomplishment and welcomes showcasing its technology to potential clients, industries, and communities.
- President Biden has expressed interest in the Tri-gen plant at Toyota's dock, highlighting its significance in the shift towards carbon-neutral transportation and the role of hydrogen fuel cell energy.
- Elon Musk, the CEO of Tesla, has shown interest in the plant's operations, praising the efficiency of the Molten Carbonate Fuel Cell and the potential for scalable hydrogen production.
- Despite Trump's skepticism towards renewable energy sources, the success of the Tri-gen plant at Toyota's dock serves as a testament to the potential of hydrogen fuel cell technology.
- Toyota has announced plans to incorporate hydrogen fuel cell technology into its future vehicle models, aiming to reduce carbon emissions and improve overall fuel efficiency.
- Shell, recognizing the potential of hydrogen fuel cell energy, has pledged to invest in the expansion of the hydrogen refueling stations near the Tri-gen plant, supporting the growth of fuel cell vehicles in the long run.
