METAL-SUPPORTED CERIA ELECTROLYTE-BASED SOFC STACK … Library/Events/2017/sofc proceedings... ·...
Transcript of METAL-SUPPORTED CERIA ELECTROLYTE-BASED SOFC STACK … Library/Events/2017/sofc proceedings... ·...
METAL-SUPPORTED CERIA ELECTROLYTE-BASED SOFC STACK FOR SCALABLE, LOW COST, HIGH EFFICIENCY AND ROBUST STATIONARY POWER SYSTEMS
Charles Vesely – Cummins IncBal Dosanjh – Ceres Power Ltd
12-June-2017
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Agenda
Cummins’ emerging strategy Building a strong foundation with Ceres Power Ceres SOFC pedigree & sample data FE27844 Objectives 5kW building block fundamentals Acknowledgements
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Cummins Inc Business Units
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Distribution Business18%
Power Generation Business14%
Components Business20%
Engine Business48%
Cummins’ Market Segments aligned to Fuel Cells
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Marine DefenseMining Oil & Gas Rail
ComponentsMission Critical Prime PowerCommercial & IndustrialUnlimited Rights Data
Corporate Expansion into New Technologies
Tom LinebargerCEO
HR CAO CFO COO Corp Strategy
Exec Director Electrification
Business Development
Initiative
Direct report into CEO first line Responsible for electrification technologies
– Energy storage systems– Power electronics– Electric machines– Fuel Cells (multiple applications)
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Cummins Fuel Cell Capabilities Cummins’ Core competency in SOFC Balance of Plant and System
Integration building on existing ICE capability Systems Engineering Computational Fluid Dynamics Heat Transfer Catalytic Processes
Advanced Controls capabilities Power Electronics design and manufacture DC-DC DC-AC Inverters
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Cummins building strong foundations with Ceres Power
Relationship commenced in 2013 Mutual, long term goals centered on product excellence Complementary market focus
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Data Centers Line of sight to first large scale application of
fuel cells Cummins to lead system integration Builds on Cummins’ existing customer base and
relationships
Cummins building strong foundations with Ceres Power
Relationship commenced in 2013 Mutual, long term goals centered on product excellence Complementary market focus and long term growth prospects
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Data Centers
Range ExtendersAPU
Residential
Commercial & Industrial
Ceres Power Ltd. © 2017
Commercial Progress
APPLICATION
REGION
>10 GWRESIDENTIAL
> 5 GWDATA CENTRE
/ BACK UP
>10 GWCOMMERCIAL
>10 GW APU
JAPAN
KOREA
EUROPE
USA & RoW * Customers* includes DoE CCS and Power System applications
INCREASING APPLICATIONS
INCREASIN
G TERRITORIES
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Ceres Power Ltd. © 2017
Volumetric Power Density Progress
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3
4
5
6
Stac
k Vo
lum
e Po
tent
ial
Litre
s/kW
M3 /M
W
1kWStack
5kW DemoPenta-01Complete July 2016
MechanicalIntegration of cells AND manifolds5kW2017
PerformanceDevelopment 950W@>60%LHV Gross EfficiencyComplete (STK0215)May 2016
Future
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FurtherPlanned R&D
Complete
On-going
Future
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Ceres Power Ltd. © 2017
0 2 4 6 8 10 120.6
0.7
0.8
0.9
1M
ean
Cel
l Vol
tage
(V)
Time (kh)
Steady state degradation <0.3% Stack, FCM and Complete Fuel Cell Power System
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Grid lines show 0.3%/kh
V3.0-3.2 Stack Level (Reformate)
Fuel Cell SystemV4.0 Stack Level (Reformate)
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Ceres Power Ltd. © 2017
2015 2016 2017 2018 2019
Deg
rada
tion
Rat
e
Year
Released to
Target
Degradation Rate Improvement Through R&D
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R&D Cell*
V3
V4
@ 20% higher current density & 15% higher fuel utilisation
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Ceres Power Ltd. © 2017
SteelCell Stacks Show World Class Robustness to On-Off Cycles
0 500 1000 1500 2000 2500 30000
0.2
0.4
0.6
0.8
1
Thermal Cycles
Mea
n C
ell V
olta
ge (V
)
Fuel: SimRef
Test Ongoing
Fuel: H2/N2dT = 350oC
>2500 thermal cycles
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Ceres Power Ltd. © 2017
0 10 20 30 40 50 6050
60
70
80
90
100
E-Stop Cycles
Cel
l Pow
er (%
)
Robustness to Redox cycles and E-stops allows for new applications
10 years life
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FE27844 Objectives Development of:
Complete internal fuel reforming capability Larger active cell area to achieve integrated, compact, low cost 5kW stack Integrated 5 kW modular stack platform scalable from 5 – 100kW 5 kW FCPS demonstrator utilizing integrated 5 kW modular stack platform
Demonstration of: 5kW FCPS performance through minimum of 1,000 hours of real-time testing:
Galvanostatic Degradation: <0.5%/1000hrs Robustness: >10 on/off cycles; >5 emergency stops (e-stops)
Cost modelling to show system cost of $1,500/kW (2011 currency basis) achievable at production volumes
Predictive modelling using demonstration test results to show system lifetime robustness capability of:
Galvanostatic Degradation: <0.1%/1,000hrs Robustness: >2,000 on/off cycles ; >60 e-stops
Partnership with PNNL for anode poison sensitivity Partnership with UConn for cathode poison robustness
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Move to Greater Internal Reforming
Simulated low temperature reformate showing stable performance -tests continuing
Testing commenced on methane and natural gas feedstocks
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< 0.2% /khrsdegradation
Demonstration system will utilise internal reforming for system performance benefit
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Larger Cell Area Roadmap Ceres plans a step by step approach to achieve large area cells
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520
Today’sBaselineV4.0 cell
Optimised V4.0 cell
‘Large Area’ Cell
2 x 1 Stack with ‘Large Area’
Cell225
375
2 x 1 Stack withOptimised V4.0
cell
Active Area [cm2]
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Next steps & commercialisation
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5kW system building blocks
Proven 1kW technology scaled to 5kW stacks– Increase in cell area and cell count per stack
DoE funded system to include 2 x 5kW stacks Design approach taken is scalable to 100-500kW
– Flexibility designed-in to suit multiple fields and applications
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1160
mm
5kW system modelling
Building on the 1kW SteelGentechnology, the target is for the power system design to produce electricity at >60%ɳ net
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Matlab physical system simulation model used to conduct trade off analyses & optimise system design principles
Focus on ability to further integrate BoPcomponents to yield further minor improvements and lower cost
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Progress & Accomplishments
VoC work successfully completed Good team working dynamic System modelling supports 5kW, 60%ɳ & durability targets can be achieved Architecture design review of modular 5kW / 10kW system complete Sub-system component selection in progress Large area cell trials in progress – target for first demonstration Sep 2017 Poison work progressing to plan with UConn & PNNL
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Next Steps
Continue to detailed design release Commence bench testing of sub-system BoP components Continue cathode & anode poison work Continue to develop pipeline of activities beyond end of DoE project
– Create a springboard to next stage product development / field trials
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Acknowledgements
The work summarized in this paper was funded by the U.S. Department of Energy’s Solid Oxide Fuel Cell Program.
NETL: Patcharin Burke, Angela Bosley, Shailesh Vora, Joseph Stoffa, PNNL: Jeffry Stevenson University of Connecticut: Prabhakar Singh
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