Rolls-Royce Fuel Cell Systems (RRFCS) is developing a 1MW fuel cell hybrid system package, supported by a prototype demonstration of a 250kW generator module in 2006. The ongoing design process has been focused from the early stages towards simplicity as a key to achieve the demanding cost targets for an effective market entry. This paper describes how the specifically designed components are being integrated as a system. A description of the progress against the demonstration plan is provided. The baseline plant is expected to provide excellent part-load performance in an extensive range of operating conditions, while a modular architecture guarantees availability and reliability. Finally, opportunities for further increases in efficiency and power density are discussed, as the technology evolves towards a next generation product.

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The nature of the flow field in a three stage axial flow compressor, including a detailed survey at the exit of an embedded stator as well as the overall performance of the compressor is presented and interpreted in this paper. The measurements include area traverse of a miniature five hole probe (1.07 mm dia) downstream of stator 2, radial traverses of a miniature five hole probe at the inlet, downstream of stator 3 and at the exit of the compressor at various circumferential locations, area traverse of a low response thermocouple probe downstream of stator 2, radial traverses of a single sensor hot-wire probe at the inlet, and casing static pressure measurements at various circumferential and axial locations across the compressor at the peak efficiency operating point. Spectral analysis of the hot-wire data reveal the existence of several harmonics of all three rotor blade passing frequencies at the inlet of the compressor. Mean velocity, pressure and total temperature contours as well as secondary flow contours at the exit of the stator 2 are reported and interpreted. Hub clearance flow is shown to eliminate the suction surface corner separation. Secondary flow contours show the migration of fluid particles toward the core of the low pressure regions located near the suction side casing endwall corner. The RMS value of the spatial fluctuations in mean velocity downstream of the second stator (which appear as temporal variations to the subsequent rotor) have been derived and shown to be significant.

The nature of the flow field in a three stage axial flow compressor, including a detailed survey at the exit of an embedded stator as well as the overall performance of the compressor is presented and interpreted in this paper. The measurements include area traverse of a miniature five hole probe (1.07 mm dia) downstream of stator 2, radial traverses of a miniature five hole probe at the inlet, downstream of stator 3 and at the exit of the compressor at various circumferential locations, area traverse of a low response thermocouple probe downstream of stator 2, radial traverses of a single sensor hot-wire probe at the inlet, and casing static pressure measurements at various circumferential and axial locations across the compressor at the peak efficiency operating point. Mean velocity, pressure and total temperature contours as well as secondary flow contours at the exit of the stator 2 are reported and interpreted. Secondary flow contours show the migration of fluid particles toward the core of the low pressure regions located near the suction side casing endwall corner.

Rolls-Royce Fuel Cell Systems (RRFCS) is developing a low cost 1MW fuel cell hybrid system package, supported by a prototype demonstration of a 250kW module in 2006. This paper describes the detailed design process that has been carried out to produce the fuel cell stack, tailored turbo-machinery and other plant components for this hybrid. Progress in demonstrating components is described. Component interfacing, operability and control challenges have been assessed prior to assembly of the complete system and are reviewed. The baseline plant will be highly efficient compared to incumbent power generation technologies but is primarily optimised around cost-reduction. Evolution of the product will include opportunities for further increases in efficiency and power density. Opportunities for improvement are discussed.