SECA Program Review · 2014. 7. 29. · The electrical performance of Siemens cathodeThe electrical...
Transcript of SECA Program Review · 2014. 7. 29. · The electrical performance of Siemens cathodeThe electrical...
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SECA Program Review
Presented at the 10th Annual SECA WorkshoppPittsburgh, PAJuly 15, 2009
Shailesh D. VoraSiemens EnergyFossil Power Generation Stationary Fuel Cells
Schutzvermerk / Copyright-VermerkCopyright © Siemens Energy Inc. 2009. All Rights Reserved
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Significant ResultsSignificant Results
Demonstrated significantly higher power density and higher power per cell relative to cylindrical cells through materials and cell design i timprovements
Demonstrated voltage stability of next generation cells - Delta8
Completed Phase 1 stack testCompleted Phase 1 stack test
Met all Phase 1 milestones
Developed lower cost and scalable processes for cell manufacturingDeveloped lower cost and scalable processes for cell manufacturing
Developed materials and processes to further increase cell power by 50%
Increased Delta8 cell length to 100 cm from 75 cm– new cell active area 2570 cm2
Completed stack design for Phase II stack test
Slide 2 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
p g
Initiated assembly of Phase II stack
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Siemens Tubular GeometrySeal-Less Solid Oxide Fuel CellSeal Less Solid Oxide Fuel Cell
C th d InterconnectionCathode Supported
D = 22 mm
Interconnection
Fuel flow
L = 1500 mm
A = 850 cm2
Electrolyte
Air electrode
T = 1000oC
Fuel electrodeAi fl
Air Flow
Air flow
Air feed tube (AFT)
Slide 3 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
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Siemens Solid Oxide Fuel CellMaterials and ProcessingMaterials and Processing
Component Material Present Fabrication ProcessAir ElectrodeElectrolyteInterconnectionF l El t d
Doped LaMnO3
ZrO2(Sc2O3)Doped LaCrO3
Ni Z O (Y O )
Extrusion-SinteredAtmospheric Plasma SprayingAtmospheric Plasma SprayingAt h i Pl S iFuel Electrode Ni-ZrO2 (Y2O3) Atmospheric Plasma Spraying
Slide 4 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
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Base-line Cell PerformanceBase line Cell Performance
Single Cell PerformanceSingle Cell Performance
DC Power: 110 W/cell @ 0.70 VFuel: HydrogenTemperature: 1000oCTemperature: 1000 CFuel Utilization: 80%
In-System Performance
Net AC Power: 100 W/cellFuel: Reformed natural gasTemperature: 940oC averageNet electrical efficiency: 46% (atmospheric pressure)
Slide 5 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Net electrical efficiency: 46% (atmospheric pressure)
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Cell Voltage StabilityCell Voltage Stability
1.10
0.80
0.90
1.00
sity
(A/c
m2 )
Temperature: 1000 C Fuel Utilization: 85%
Changed Test Stand
0.50
0.60
0.70
V), C
urre
nt D
ens
Cell Voltage (V)Changed Test Stand
0.20
0.30
0.40
Cel
l Vol
tage
(V
Current Density (A/cm2)
0.00
0.10
0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000
Test Duration (Hours)
Slide 6 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
∼ 0.1% per 1000 hours voltage degradation
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Transition from Tubular to High Power Density (HPD) Cell
Interconnection
Electrolyte
Interconnection
ElectrolyteInterconnectionInterconnection
a s t o o ubu a to g o e e s ty ( ) Ce
Air Electrode
Electrolyte
Air Electrode
Electrolyte
Fuel ElectrodeAir Flow Fuel Electrode
Air ElectrodeElectrolyte
Fuel Electrode
Air Flow Air Electrode
ElectrolyteFuel Electrode
Air Flow
Air Flow
Tubular HPD
Closed end enables seal-less design
Red ction in ohmic resistance
Advantages
Reduction in ohmic resistance
Increase in cell power density
More compact stack
Slide 7 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Same cell materials and manufacturing processes – Different design
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First Generation HPD Cellsst Ge e at o Ce s
Active Length: 75 cmg
Active area: ~900 cm2
Slide 8 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Developed HPD5 (five channels) and demonstrated benefits relative to tubular cells
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HPD Voltage StabilityHPD Voltage Stability
0.90
1.00
1.10
m2 )
Average Temperature: 900ºCFuel Utilization: 80%Fuel: Humidified Hydrogen
UpgradedTesting
Instrumentation
Cooled for Stand Maintenance and
Calibration
0 50
0.60
0.70
0.80
ent D
ensi
ty (A
/cm
Cell Voltage (V)
0.20
0.30
0.40
0.50
Volta
ge (V
), C
urre
Current Density (A/cm2)
0.00
0.10
0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000 24,000 26,000 28,000 30,000
Test Duration (Hours)
Cel
l V
Slide 9 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Test Duration (Hours)
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Accomplishments and Next StepsAccomplishments and Next Steps
Demonstrated thermal cyclic stability - can withstand multiple y y pthermal cycles
Demonstrated voltage stability - voltage decline of ∼ 0.1% /1000 h
Cost reduction measures in progress
– Increase cell power density
– Lower parts count
– Reduce assembly cost
– Simplify balance-of-plant
Slide 10 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
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Next Generation Cell Concept – Delta8…Next Generation Cell Concept Delta8…
Closed end - maintains seal-less design Shorter current path - reduction in ohmic resistance Increase cell power densityIncrease volumetric power density of stackIncrease cell active area (higher power per cell)
Slide 11 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
…leading to cost reduction in the cell area
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Delta8 Cell Performance –Voltage vs. Current DensityVoltage vs. Current Density
0.78
0.79
0.80
0.25
0.30
Power Density
Tavg = 975 ºCFuel Utilization = 80%Fuel = Humidified Hydrogen
0.75
0.76
0.77
age
(V)
0.15
0.20
sity
(Wat
ts/c
m2 )
yFuel = Humidified HydrogenCell Length = 75 cmCell Width = 15 cmCell Area = 1950 cm2
0 72
0.73
0.74 Vol
ta
0.10
Pow
er D
ensVoltage
10% higher power density compared to last year through processing improvements
0.70
0.71
0.72
150 175 200 225 250 275 300 325 350 3750.00
0.05year through processing improvements
550 watts per cell @ 0.7 V (extrapolated)
Slide 12 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Current Density (mA/cm2)
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Cell Performance ComparisonCell Performance Comparison
2250
2500
CylindricalDelta8
1950
1750
2000
(Wat
ts)
e a8T = 1000 C
Fuel Utilization = 80% Fuel = Hydrogen Cell Voltage = 0.7 V
1000
1250
1500
(cm
2 ) Cel
l Pow
er
850
550500
750
1000
Cel
l Are
a (
110
0
250
Cell Area Cell Power
Slide 13 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Delta8 cell area increased by ∼ 2X vs. cylindrical cell… cell power increased by ~ 5X
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Delta8 Cell Voltage Stability (2-cell test)Delta8 Cell Voltage Stability (2 cell test)
2.20
1.60
1.80
2.00
2.20
(A/c
m2 )
Average Temperature = 950ºCFuel Utilization = 80 %Fuel = Humidified Hydrogen
1.00
1.20
1.40
Cur
rent
Des
nity
(
Voltage (V)
0 20
0.40
0.60
0.80
Volta
ge (V
), C
Current Density (A/cm2)
0.00
0.20
0 125 250 375 500 625 750 875 1000 1125 1250 1375 1500 1625 1750 1875 2000
Test Duration (Hours)
Slide 14 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Excellent voltage stability
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Cell and Bundle ComparisonCell and Bundle Comparison
24 cylindrical cellsT = 1000 CFuel Utilization = 80%F l H d
DC power: 2.6 kWeWeight: 34 kg
550 W1950 cm2
CylindricalDelta8
Fuel = HydrogenCell Voltage = 0.7 V
2x2x
850 cm2
5x5x
6 Delta8 cellsDC power: 3.3 kWeWeight: 20 kg
110 W
Reduced weight by 40%, increased power by 25%
Area Power
Slide 15 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
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Phase I Stack TestPhase I Stack Test
24 Delta8 cells (75 cm long)
4 bundles (six cells each)
Internal recuperator
Cast ceramic open end holder
Operation on simulated coal gas
Thermally self sustaining
Modified existing balance of plant for stack test
Slide 16 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
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Phase I Integrated SystemPhase I Integrated System
Cell Stack Complete System
Slide 17 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Cell Stack Complete System
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Phase I Stack Test ResultsPhase I Stack Test Results
Phase I Minimum Requirements
Siemens System Test
ResultsResults
DELIVERABLE POWER RATING ≥ 10 kW 10 kW
5000 hours 5300 hours STEADY STATE TEST (Normal Operating Conditions) Δ Power < 4.0% degradation/1000 hours No detectable degradation
1) Start up and conditioning
TEST SEQUENCE
1) Start-up and conditioning2) Peak Power Test (after ~300 hours) 3) VJ curve 3) Steady State Test (balance of 5000 hours) 4) Shut-down
In accordance with DOE approved Test Plan
FUEL TYPE Simulated (subject to DOE concurrence, up to 25% CH4, dry basis)
Hydrogen and simulated coal gas
Availability factor of 85% at
Slide 18 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
AVAILABILITY Report availability 50% power or greater
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Cell Development . . .Cell Development . . .
Cell Fabrication
– Seamless closed end
– One-Step sintering of cathode
Mass production concepts for plasma spray– Mass production concepts for plasma spray
Cell Power Enhancement
. . . Results in cost reduction, scale-up and manufacturability
Slide 19 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
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Present Process To Attach Closed EndPresent Process To Attach Closed End
Closed end cap is attached to the cell in the green stage and the assembly is sintered
Slide 20 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
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Seamless Closed EndSeamless Closed End
Slide 21 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Closed end cap is extruded with the cell … resulting in reduced labor
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Horizontal (One-Step) Sintering of CathodeHorizontal (One Step) Sintering of Cathode
Old process – Two- step sintering– Horizontal sintering (∼ 1200 ºC) followed by vertical sintering at ∼1500 ºC
New process– Developed non-reactive substrate to sinter cathodes in one step up to ∼1500 ºC
Slide 22 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
… resulting in reduced labor, uniform porosity, and uniform dimensions
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Plasma Spraying
Present Process
Plasma Spraying
Single part per event
One gun system
Each surface is individuallyEach surface is individually coated
Significant part handling
Not scale-up friendly
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Plasma SprayingConcept for Mass Production
Manufacturing Carousel Design
Concept for Mass Production
Multiple cells processed in one event
Plasma guns travel verticallyPlasma guns travel vertically while carousel rotates
Multiple plasma guns
R b t t di i l tRobust to dimensional part variation
All surfaces coated i lt lsimultaneously
Significant reduction in spray time
Slide 24 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
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Cell Power EnhancementCell Power Enhancement
The electrical performance of Siemens cathodeThe electrical performance of Siemens cathode supported cells is primarily influenced by the cathode–electrolyte interface due to high polarization
cathode+EL21.0%
950oC
Ohmic33.6%cathode-p
58.1%
anode-p7.5%
anode10.3% IC
3.2%
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Cell Power EnhancementCell Power Enhancement
Lowered electrolyte densification temperature by ∼300 ºCLowered electrolyte densification temperature by ∼300 C through materials and processing improvements
Maintain active cathode layer porosity– Maintain active cathode layer porosity– Prevent formation of insulating phases at the cathode-
electrolyte interface
Reduced electrolyte thickness by 50%
Materials and process development work done on cylindrical cells
Readily transferrable to Delta8 cells
Slide 26 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Readily transferrable to Delta8 cells
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Electrolyte MicrostructuresElectrolyte Microstructures
Anode
80umElectrolyte
Present electrolyte
Cathode
½ Thickness electrolyte
20um
¼ Thickness electrolyte
40um
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Cell Performance – Cylindrical CellsCell Performance Cylindrical Cells
0.850
0.750
0.775
0.800
0.825
0.850
New cell materials and
0 625
0.650
0.675
0.700
0.725
Vol
tage
(V)
materials and processing
50%
0.525
0.550
0.575
0.600
0.625
Present cell materials and processing
Temperature = 900 CFuel Utilization = 80%Fuel = Humidified hydrogen
0.50050 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475
Current Density (mA/cm2)
Slide 28 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
50% higher power density at 0.70 V
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Voltage Stability of Power Enhanced Cylindrical CellVoltage Stability of Power Enhanced Cylindrical Cell
1.1 1100
0.7
0.8
0.9
1.0
Vol
tage
(V)
700
800
900
1000
°C)
Cell Voltage
0.4
0.5
0.6
0.7
Dens
ity (A
/cm
2 ) -
V
400
500
600
700
Tem
pera
ture
(°Cell Voltage
Current DensityC.E. TemperatureMid Temperature
0.0
0.1
0.2
0.3
Cur
rent
0
100
200
300
0 500 1000 1500 2000 2500 3000 3500
Test Duration (Hours)
0
Excellent Voltage Stability …
………. Test Continues
Slide 29 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Excellent Voltage Stability … Next step: Adapt Process and Materials to Delta8 cells
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Delta8 Cells – Increased Cell Length and AreaDelta8 Cells Increased Cell Length and Area
1 M active length cell L = 100 cmW = 15 cm
This Year
A = 2570 cm2
L = 75 cmW = 15 cm
Last Year
W = 15 cmA = 1950 cm2
Slide 30 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
1 M active length cell selected for Phase II stack test
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1x8 Delta8 Bundle (1 M active length cells)1x8 Delta8 Bundle (1 M active length cells)
Slide 31 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
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Performance Projection - 1 M Delta8 Cells and BundlesPerformance Projection 1 M Delta8 Cells and Bundles
725 W
CylindricalDelta8
Temperature: 1,000 ºCFuel Utilization: 80%Fuel: Humidified HydrogenCell Voltage: 0.70 V *
6.5x6.5x2570 cm2
850 cm2
3x3x6.5x6.5x
110 W
Area Power
* Projection based on data for 75
Delta8 area increased by ∼3X vs. cylindrical, however power increased by ∼6.5X
24 cylindrical cellsDC power: 2.6 kWeWeight: 34 kg
8 Delta8 cellsDC power: 5.8 kWe*Weight: 32 kg
Area Powerdata o 5cm active length cells
Slide 32 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Reduced weight by 5% and increased power by 120%, resulting in lower cost and smaller footprint
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Basic Building Block for Larger UnitsBasic Building Block for Larger Units
Eight 1 M Delta8 cells
Fully integrated bundle assembly contains fuel plenum, cell bundle, open end seal, recuperator, exhaust plenum, intake air plenum and electrical connectors
Cast ceramic components
Provides fuel, air, exhaust and electrical interfaces for the fuel cells
Compact recuperator preheats incoming air and eliminates external hot pipingCompact recuperator preheats incoming air and eliminates external hot piping
Six basic building blocks will be tested in Phase II stack test
Slide 33 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
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Phase II StackPhase II Stack
Recirc PlenumStack Liner
Recirc PlenumGuard Heaters
Dielectric Boards
DielectricDielectric Boards
Cell Bundles
Slide 34 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
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Delta8 Cell Module - Power System Building BlockDelta8 Cell Module Power System Building Block
480 Delta8 cells
Natural gas fuel
Nominal Power ~ 250 kW (atm. pressure)(atm. pressure)
Module Dimensions:
Height – 3.4 m
Exhaust
Width – 3.7 m
Depth – 1.9 mAirAir
Slide 35 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Larger fuel cell power systems are effectively assembled by aggregating modules
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SummarySummary
Met all Phase I milestones
E t bli h d D lt 8 ll i t d f b i t d b th 75 dEstablished Delta8 cell processing parameters and fabricated both 75 cm and 100 cm active length cells and bundles with these cells
Demonstrated seamless closed end extrusion for Delta8 cells
Showed significant progress in developing mass production concept of plasma spray process
Improved power density of Delta8 cells by approximately 10% over first generation cellsgeneration cells
Demonstrated voltage stability of Delta8 cells
Showed 50% power enhancement in tubular cells by lowering the electrolyte d ifi ti t t d d i th l t l t thi k i h lfdensification temperature and reducing the electrolyte thickness in half –Reduction of electrolyte thickness to ¼ of present value is feasible
Completed design of Phase II stack test
Slide 36 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved
Initiated assembly of Phase II stack test
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AcknowledgementsAcknowledgements
DOE NETL C t t N DE FC26 05NT42613DOE-NETL. Contact No.DE-FC26-05NT42613
Wayne Surdoval, Travis Shultz, Heather Quedenfeld - NETL
Siemens Stationary Fuel Cells TeamSiemens Stationary Fuel Cells Team
Slide 37 July 2009 E F NT SFC10th Annual SECA WorkshopCopyright © Siemens Energy Inc. 2009. All Rights Reserved