Based on the technology trifecta—power, hydrogen, and water—the name “Altered Carbon Portal” perfectly describes Fuel Cell Energy’s innovative Tri-gen plant. Located at Toyota’s terminal in the Port of Long Beach, this cutting-edge facility houses a 2.8MW Molten Carbonate Fuel Cell (MCFC). This MCFC converts natural gas into syngas (a mix of hydrogen, carbon dioxide and water) via internal steam reforming. The process produces electricity from 70% of the hydrogen, while the remaining 30% undergoes multi-stage Pressure Swing Absorption for purification, yielding up to 1,200 kg/day of fuel-grade hydrogen. Additionally, water condensed from the exhaust is used to wash cars at Toyota’s terminal before shipment to dealerships.
Two Hydrogen Stations
Adjacent to the plant, Shell designed and built two hydrogen refueling stations: one for heavy-duty port trucks and another for passenger cars. The hydrogen-powered Toyota Mirais are refueled here for deliveries. The hydrogen from the Tri-gen plant is stored in a 1,600 kg 44-tank system, which supplies both hydrogen stations. Notably, Shell maintains and operates both stations.
Renewable Biogas
Toyota envisioned the project in 2016 to increase the sustainability of its port operations. At this time, Fuel Cell Energy had experience operating a similar pilot project at the Fountain Valley water treatment plant, which opened in 2011 and which I attended. The Fountain Valley plant was smaller, operating at just one-tenth the size of the Tri-gen plant but tested the same concepts. It used digester gas from special bacteria processing solid waste into fertilizer and biogas. This digester gas was captured and fed into the MCFC as fuel. 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, converting it into renewable natural gas. This gas is injected into a Southwest Gas pipeline as biomethane for distribution. Fuel Cell Energy pays for this renewably sourced biomethane at the source but uses the gas available at the port, thus validating the green hydrogen and power claim. Given the terminal’s smaller energy needs 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 poured in December 2021. Site engineering, procurement, and construction were completed by Fastech, a company well-versed in building hydrogen infrastructure. The first power was produced in October 2023 and connected to Edison in November. Shell began refueling operations in December, initially fueling a Mirai, followed by the first heavy-duty truck fueling in January 2024.
History of Fuel Cell Energy Projects
Fuel Cell Energy’s main product is the Molten Carbonate Fuel Cell. My first experience with this fuel cell was at the Michigan Alternative and Renewable Energy Center in Muskegon, which opened in 2004. The center, affiliated with Grand Valley State University where I worked 2002-2007, housed a 200 kW unit that I regularly studied. Interestingly, Fuel Cell Energy stepped in at short notice 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, capturing 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, located in Seoul, South Korea, produces 56 MW from 21 units of 2.8 MW plants. The company continually improves its product line, increasing stack durability from 3 to 7 years before replacement is needed. Each stack produces about 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.
Molten Carbonate Fuel Cell
The operation of the Molten Carbonate Fuel Cell is a marvel of engineering, combining chemistry, electrochemistry, and mechanical principles. It deserves a separate article altogether, but here’s a short explanation for the “altered carbon” claim in the title. The heart of this fuel cell is its molten carbonate electrolyte, a mix 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 mix feeds into the fuel cell, hydrogen is consumed, continuously driving the reaction. The fuel cell uses about 70% of the hydrogen available, with the leftover hydrogen either oxidized for more heat or purified for refueling. There are more technical details, but let’s stop here.
Since its launch in late 2023, the Tri-gen plant has become a showcase of sustainability and hydrogen innovation at the Port of Long Beach. Fuel Cell Energy is proud of its engineering marvel and welcomes showcasing its technology to prospective customers, industry, and communities.