Progress Report on Performance and Reliability ...
Transcript of Progress Report on Performance and Reliability ...
![Page 1: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/1.jpg)
Progress Report on Performance and Reliability Advancements in a Durable Low Temperature Tubular SOFC
14th June 2018Praveen Cheekatamarla
![Page 2: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/2.jpg)
Agenda About Atrex Energy, Inc.
Applications of remote power generators
Technical progress Cell technology improvements 5kWEL stack Manufacturing automation
Further work
Acknowledgements
![Page 3: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/3.jpg)
About Atrex Energy “Powder to Power”
Commercially developed tubular Solid Oxide Fuel Cell (SOFC) technology and systems with ~ 600 stacks shipped – NG, Biogas & Propane, accumulating >6 Million hours of run time Fielded units include configurations up to 1.5kW but
demonstrated up to 10kW prototypes Customers include oil and gas, telecommunications, rail,
environmental monitoring, mining, construction, maritime and US Coast Guard
Units running in remote environments for >35,000hrs FC1 certification from the Canadian Standards Association
Military Technology Product Development – Fuel Flexible Solutions using JP8, DF2, F24, S8, GTL – 2nd generation technology with >40% net DC efficiency
Hybrid Energy Storage Module – Intelligent power management with ability to connect 6 different power sources for optimal fuel efficiency
Atrex Energy continues to transition its commercially available SOFC technologies for advanced power applications with fuel flexible solutions
![Page 4: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/4.jpg)
Remote NG and Propane Applications
LPG, Alaska
NG, TX LPG, Wyoming
NG, PALPG, Alaska
![Page 5: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/5.jpg)
3+ yr operation on well head natural gas (Texas) C
urr
en
t/A
or
Vo
lta
ge
/V
![Page 6: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/6.jpg)
Technical Progress: Performance and Durability
Enhancements
![Page 7: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/7.jpg)
SOFC Improvements
Sub-stoichiometric O/C (POX) for fuel efficiency and cell performance improvement
Integral/internal reforming catalyst – high carbon tolerance
Tailored catalyst to enhance oxidation reactions and suppress fuel decomposition
Fuel LHV-to-electricity efficiency of >55%
Intermediate operating temperature for cost reduction and stack longevity
Enabled by enhanced electrode performance
Cathode infiltration for improved ORR
Anode infiltration for improved kinetics and conductivity
Internal solid fuel element for durability enhancement
Resilient against high fuel utilization operation
![Page 8: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/8.jpg)
Low Temperature, O/C< Substoich. – Cell Performance Improvement
O/C = 1.2 O/C = 0.6
Major improvement by combining electrode infiltration and low O/C fuel processing Electrode infiltration
Cell performance improvement at lower temperature Lower impact of thermal gradients across the stack
Lower O/C fuel processing Further improvement in cell performance at all temperatures with bigger
boost at lower temperatures
9% in
crea
se
![Page 9: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/9.jpg)
Sub-stoich. O/C Operation at Low Temperature
48 cell stack Stack temperature: 730-760 deg C Partial Oxidation of Natural gas at
O/C < stoichiometry (0.5-0.6) No degradation over the course of
the test - >5000 hours
20 cell stack Stack temperature: 680 deg C Partial Oxidation of Natural gas at
O/C < stoichiometry (0.5-0.6) 1800+ hours of operation without
carbon fouling or degradation
0
0.2
0.4
0.6
0.8
1
0
10
20
30
40
50
60
10/17/2017 12/6/2017 1/25/2018 3/16/2018 5/5/2018 6/24/2018
O/C
Mol
ar R
atio
Stac
k Vo
ltage
and
Cur
rent
Stack Voltage
Stack Current
O/C Ratio
![Page 10: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/10.jpg)
Integrated Solid Fuel Element
Anode protection: Redox chemistry supplements the fuel requirement under high Ufconditions
Peak shaving: The response time of the solid fuel has been demonstrated to be less than 1 sec. The solid fuel element can actively respond during sudden load changes
Flow fixed / flow dropped
Load increased / load fixed
Load
injector
Fe (Redox)
![Page 11: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/11.jpg)
Combined Impact of SOFC Improvements (Stack) – High Uf, Low O/C
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0
20
40
60
80
100
120
2530 2550 2570 2590
Aver
age
Cell
Volta
ge
Stk
V/Cu
rren
t/T,
Uf (
%)
Time, Minutes
Fuel Utilization
Average Cell Volt
Stack Amps
Stack Voltage
Average Stk Temp (C)/10
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0
20
40
60
80
100
120
140
2875 2880 2885 2890 2895 2900
Aver
age
Cell
Volta
ge, O
/C M
olar
Rat
io
Stk
V/Cu
rren
t/T,
Uf (
%)
Time, Minutes
Fuel Utilization
Average Cell Volt
Stack Amps
Stack Voltage
Average Stk Temp (C)/10
O/C
Stack: 20 cells O/C: 1.2 Uf: 45-100% T: 700-750 C Avg Cell V: 0.86 –
0.8V
Stack: 20 cells O/C: 0.8 Uf: 70-100% T: 700-750 C Avg Cell V: 0.84 – 0.81V (30mV drop) Sustainability: >12 minutes @ 100% Uf
![Page 12: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/12.jpg)
Combined Impact of SOFC Improvements (Stack) – Low Temp., High Uf, Low O/C
Stack: 20 cells O/C: 0.7 - 0.8 Uf: 70-120% T: 700-725 C Avg Cell V: 0.80 – 0.77V (30mV drop) Sustainability: >5 minutes @ 120% Uf
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0
20
40
60
80
100
120
140
4110 4115 4120 4125 4130 4135 4140
Aver
age
Cell
Volta
ge
Stk
V/Cu
rren
t/T,
Uf (
%)
Time, Minutes
Fuel Utilization
Average Cell Volt
Stack Amps
Stack Voltage
Average Stk Temp (C)/10
Stack: 20 cells O/C: 0.5-0.6 Uf: 90 - 100% T: 630-680 C Avg Cell V: 0.80 – 0.77V (30mV
drop) Sustainability: >5 minutes @
100% Uf0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0
10
20
30
40
50
60
70
80
90
100
110
120
4150 4155 4160 4165 4170 4175 4180 4185
Aver
age
Cell
Volta
ge
Stk
V/Cu
rren
t/T,
Uf (
%)
Time, Minutes
Fuel Utilization
Average Cell Volt
Stack Amps
Stack Voltage
Average Stk Temp (C)/10
![Page 13: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/13.jpg)
5KW Natural Gas SOFC Generator
Fuel Inlet
Stacks
Exhaust 2.5kW sub-module tests complete Developed an 85% effective heat
exchanger Balance of plant design complete Design based on the commercial
platform Spatial thermal gradient <50deg C ~ 30” * 50” * 37”
![Page 14: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/14.jpg)
5KW Natural Gas SOFC Generator Baseline tests complete Construction of enhanced stacks underway
500
750
1000
1250
1500
1750
2000
2250
2500
2750
3000
0
20
40
60
80
100
120
3 5 7 9 11 13 15 17 19 21
Pow
er, W
; Tem
pera
ture
, C
Volts
, V; A
mps
, A
Time, Hours
Power, kW
Stack Current
Stack Voltage
Average Stk Temp
![Page 15: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/15.jpg)
Process Modification – Automation & Cost Reduction
Cell fab. process modification for automation and cost reduction Thinner anode wall
Simplified functional layer deposition
Process Automation Tasks Improved anode powder filling
Cathode and anode infiltration
Fuel processor tube fabrication
![Page 16: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/16.jpg)
Thinner Anode Cell Performance
Thinner anode cell showed moderate improvement in performance
600+ hours of operation at O/C of 0.5, Temperature of 700 deg C, and with infiltrated Cathode showed stable performance
Manufacturing yield is comparable to the current standard process
![Page 17: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/17.jpg)
Cost Reduction via Process Improvements Cell fabrication process modification for cost savings
Printed barrier, cathode and current collection layers 48% cost reduction 4500+ hours of continuous operation under aggressive operating conditions shows
stable performance 825 deg C, thermal cycling, load cycling
![Page 18: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/18.jpg)
Semi-Automatic Anode Infiltration
Features: Automatic solution
dispense with precise quantity control
Manual cell handling
Optional automatic cell handler for higher capacities
fixture
Solution dispensing system
![Page 19: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/19.jpg)
Powder Filling - Process Automation
Features: Completely automated
process for dispensing, packing the high durometer bag
Improved quality control
High throughput processing
Bag
Plug
![Page 20: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/20.jpg)
Automatic Cathode Infiltration
Features: Automatic slurry spray Automatic or manual cell loading Automatic purge for the slurry delivery line
![Page 21: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/21.jpg)
Verified to be compatible with NETL’s process/materials
Improved SOFC performance at lower temperatures
Stability tests in progress, >2000 hours
Automatic Cathode Infiltration
![Page 22: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/22.jpg)
Major Forward Activities
Integration and evaluation of enhancements in a 0.5 kWeSOFC system Evaluate thin wall anode cell with enhanced electrode (infiltration)
for low temperature and high efficiency (low O/C)
5kW System Development Integrate and evaluate low temperature, sub-stoichiometric O/C
operation
Finalize 5KW system packaging
Demonstration
Manufacturing Automation Fuel processing tube fabrication automation
Stack assembly
![Page 23: Progress Report on Performance and Reliability ...](https://reader030.fdocuments.in/reader030/viewer/2022012104/616a14a011a7b741a34e984a/html5/thumbnails/23.jpg)
Acknowledgement DOE Project management: Steven Markovich, Shailesh Vora
Collaborators
University of South Carolina: Prof. Kevin Huang and his team
NETL Team: Dr. Hackett, Dr. Shiwoo Funding Support from SECA through contract number DE-
FE0028063 2.5kW/5kW product dev.
Durable, Efficient SOFC
Increased presence of SOFCs in the US Natural Gas and Telecom markets