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Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9 th Annual SECA Workshop Pittsburgh, PA August 5-7, 2008 Hossein Ghezel-Ayagh

Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

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Page 1: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Solid Oxide Fuel Cell Program at

FuelCell Energy Inc.

9th Annual SECA WorkshopPittsburgh, PA

August 5-7, 2008

Hossein Ghezel-Ayagh

Page 2: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Introduction:FCE SECA program team membersSOFC cell and stack technology overview

SECA Coal-Based SOFC Program OutlineTechnical Approach and Status:

Cell development (performance, endurance, area scale-up)Stack development (performance, endurance, stack height scale-up)MW module development

System and Cost Analyses:Integrated Gasification Fuel Cell (IGFC) System ConfigurationStack Cost EstimateBaseline (400MW) Power Plant Cost Estimate

10 kW Stack Metric TestConclusions

Presentation Outline

Page 3: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

R & D MANUFACTURING

Torrington, CTDanbury, CTFCE is a high temperature fuel cell company that has been involved in development of fuel cells for stationary power applications for over 30 years. Much of this development work has been supportedby DOE programs.

FuelCell Energy (FCE)

Page 4: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

SECA COST REDUCTION PROGRAM FuelCell Energy, Inc (FCE) has been

engaged in a DOE managed, SECA program to develop a 3-10kW SOFC power plant system since April, 2003. Phase I of this program ended in Sept 2006, surpassing all DOE specified metrics for performance, endurance and cost.

SECA COAL BASED PROGRAMIn September 2006, the FCE team

initiated work on a multi-phase SECA program to develop an affordable, multi-MW size SOFC power plant system to operate on coal syngas fuel, with near zero emissions.

SOFC MW Module

FCE SECA SOFC Programs

Page 5: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

FuelCell Energy Inc. (FCE), Danbury, CTManufacturing and commercialization of fuel cell power plant

systems in sizes ranging from 300kW to Multi-MW.

The FCE team is comprised of diverse organizations with expertise in key functional areas:

Versa Power Systems Inc. (VPS), Littleton, COSolid Oxide Fuel Cell (SOFC) development and manufacturing

technologies.

Gas Technology Institute (GTI), Des Plaines, ILGasification and fuel Processing Technologies. SOFC contaminant studies.

WorleyParsons Inc. (WP), Reading, PAPower generation experience, including turbine and gas clean-up

technologies.

Nexant Inc. San Francisco, CAEnergy consulting and technology services.

SatCon Power Systems Inc. Burlington, ON, Canada.Power control and conditioning systems.

Pacific Northwest National Laboratory (PNNL), Richland, WASOFC cell and stack computational modeling.

FCE SECA Coal-Based SOFC Team

Page 6: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Anode

Cathode

Electrolyte

ANODE SUPPORTED PLANAR CELL DESIGN:• Anode – nickel-zirconia cermet (~1mm thick)• Electrolyte – yttria-stabilized zirconia (YSZ) (~10μm thick)• Cathode – conducting ceramic (~ 50µm thick)

FCE utilizes the cell and stack design of its technology team partner, Versa Power Systems Inc. (VPS) for all its SOFC programs.

VPS Cell Technology

Page 7: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

The “TSC” process for SOFC component fabrication has proven to be cost effective with high yields and excellent quality.

Tape Casting “T”

Screen Printing“S”

Co-Sintering“C”

VPS has been developing cost effective SOFC manufacturing procedures since 1998 and has well established processes, quality procedures and equipment for the manufacture of fuel cells and stacks.

VPS SOFC Manufacturing

Page 8: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

The FCE team employs a building block approach to its power plant development. This enables simplified, low cost manufacturing processes with high production yields.

Anode Supported, Planar Cell Design

Internally Manifolded Stack Building Block Design

Stack Building Blocks Assembled Into Stack Tower

Cell and Stack Technology

Page 9: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Introduction:FCE SECA program team membersSOFC cell and stack technology overview

SECA Coal-Based SOFC Program OutlineTechnical Approach and Status:

Cell development (performance, endurance, area scale-up)Stack development (performance, endurance, stack height scale-up)MW module development

System and Cost Analyses:Integrated Gasification Fuel Cell (IGFC) System ConfigurationStack Cost EstimateBaseline (400MW) Power Plant Cost Estimate

10 kW Stack Metric TestConclusions

Presentation Outline

Page 10: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

The FCE team will utilize the SOFC cell and stack technology successfully demonstrated in the SECA Cost Reduction Program as the basis for scale-up and further development in the Multi-MW Coal-Based SECA Program

Program Objectives:Development of large scale (>100 MWe) coal-based SOFC systems with:

At least 50% overall efficiency from coal (higher heating value) Performance to meet DOE specified metrics for power output,

degradation, availability, reliability, etc.Factory cost <$400/kW >90% of carbon capture from coal syngas for sequestration

Coal-Based SOFC Power Plant Development Program

Page 11: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Design

5 MW Proof of Concept

2008 2010 2012 2015

≥ 250 kWModule Demonstration Unit

Phase IIIPhase IIPhase I

Multi-Stack Tower

10 kW Stack

SECA Coal Based Multi-Phase Program Plan

Page 12: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

MULTI-MW SOFC POWER BLOCK CONCEPTUAL

DESIGN

Coal-Based SOFC power plant development benefits from other successfully demonstrated DOE supported programs.

FCE High Efficiency Hybrid Fuel Cell–Turbine Product Development

DOE Vision 21 (2000 - 2008)

FCE MW Class Fuel Cell Product DevelopmentDOE PDI (1994 - 2005)

3-10kW SOFC Development(Versa Power Systems)

DOE SECA (2003 - 2006)

20kW DFC Operating on Destec Coal Syngas (4,000 hours)

DOE-EPRI (1990 - 1992)

SECA Coal-Based Multi-MW SOFC Power Plant Development

Page 13: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

SECA Coal-Based Program Work Breakdown Structure

Task 1.SOFC Cell

Development

1.1 Design, Development and

Optimization

1.2 Manufacturing Process

Development and Fabrication

1.3 Testing and Validation

Task 3 Baseline Power Plant

Development

3.1 Conceptual System Analysis and Down Select

3.2 Baseline System Definition

3.3 System Analysis

3.4 Cost Analysis

Task 2 SOFC Stack

Development

2.1 Stack Design

2.2 Stack Components Development

2.3 Fabrication and Testing

2.4 Module Concept

Development

Task 5 Management

and Reporting

5.1 Technical Briefings, Kick-off

5.2 Reporting and Deliverables

5.3 Prepare Phase II Renewal

Application

5.4 Final Report Preparation

Task 4 Proof of Concept

Development

4.1 Basic Engineering

Design

4.2 System Analysis

4.3 Cost Analysis

Task 6 Manufacturing Capacity Dev.

6.1 Manufacturing Equip Dev. &

Commissioning

The work breakdown structure is designed to ensure success in achieving the program objectives with minimal risk.

VPS Technical LeadEric Tang

FCE Technical LeadJim Walzak

FCE: Hossein Ghezel-AyaghVPS: Randy Petri

VPS Technical LeadEric Tang

Page 14: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Introduction:FCE SECA program team membersSOFC cell and stack technology overview

SECA Coal-Based SOFC Program OutlineTechnical Approach and Status:

Cell development (performance, endurance, area scale-up)Stack development (performance, endurance, stack height scale-up)MW module development

System and Cost Analyses:Integrated Gasification Fuel Cell (IGFC) System ConfigurationStack Cost EstimateBaseline (400MW) Power Plant Cost Estimate

10 kW Stack Metric TestConclusions

Presentation Outline

Page 15: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

SOFC Key Technical Improvements

Cell Target

Performance

Reliability

Cost Size

Manufacturing process Stack designReliability

Mechanical and thermal mechanical strength for fabrication and operation

MaterialsManufacturabilityStack designPower density

Power densityFuel utilizationEndurance: transient and steady state

There has been significant accomplishments in key areas including: performance, cost, size, and reliability.

Page 16: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Single cell testing of high performance components shows a potential performance gain of 4-17% and a significant increase in endurance (decreased degradation of 50%).

5000 hrs0.7%6 4%847 mV9%794 mVNew Cell #4

4300 hrs1.5%13 9%885 mV17%852 mVNew Cell #3

7100 hrs1.6%14 6%864 mV7%783 mVNew Cell #2

8600 hrs1.5%13 5%854 mV8%788 mVNew Cell #1

6500 hrs1.7%14 Baseline812 mVBaseline730 mVBaseline

%mVGainPeak VGainPeak V

Testing Duration

Degradation Per

1000 hrs

Performance at 750°C, 0.74 A/cm2

Performance at 700°C, 0.74 A/cm2

Cell Type

Performance and Endurance Enhancement

Page 17: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Performance Curve ComparisonHPC Cell with Stardard TSC-2 Cell

0.6

0.7

0.8

0.9

1

1.1

0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80

Current Density, A/cm2

Volta

ge, V

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

Pow

er D

ensi

ty, W

/cm

2

New Cell 750 - V New Cell 700 - V TSC-2 750 - V TSC-2 700 - VNew cell 750 - P New cell 700 - P TSC-2 750 - P TSC-2 700 - P

Cell active area = 81cm2Fuel = hydrogen (2L/min)Fuel humidity = 3% Oxidant = air (2L/min)

9% Performance enhancement

at 750°C

17% Performance enhancement

at 700°C

New high performance components show significant performance (voltage) improvement as compared to baseline component cells.

Cell Performance Enhancement

Page 18: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

0.000

0.200

0.400

0.600

0.800

1.000

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5001Elapsed Time, hrs

Volta

ge, V Steady state degradation rate of 6 mV/1000 hrs (less than 0.7%/1000

hrs) has been demonstrated over 5,000 hrs

Significant improvement in endurance (decreased degradation rate) has been shown in single cell testing with improved cell components.

Cell Area = 81 cm2

T=750°CI = 40.5 A (0.5 A/cm2)Cathode flow = 2.9 SLPM air (25% air utilization)Fuel Flow = 0.608 SLPM H2, 0.608 SLPM N2, (50% fuel utilization)

Long Term Steady State Test of an LTS-3 Cell

Cell Endurance Enhancement

Page 19: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Cell Scale-Up Development• Cell Scale-Up Process Development:> Cells up to 33 x 33 cm2

were produced with baseline TSC II process to evaluate process capability

• Manufacturing, Tooling and Facility Development:

> All major manufacturing process equipment have been established for both size and volume scale-up

> Key equipment has been commissioned to handle cell production volume of 1 MW/year

Page 20: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Cell Scale-Up Development25 x 25 cm2 cells with 550 cm2 active area were selected for the 10 kW stack

block. More than 1000 cells (25 x 25 cm2) have been produced with a high level of

process control. Production yields over 95% have been demonstrated.

Page 21: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Scaled-Up Cell Area:Performance Validation

Stainless Steel Current Collectors, Cross-Flow Gas Delivery

0.400

0.500

0.600

0.700

0.800

0.900

1.000

1.100

0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90

Current Density (A/cm2)

Volta

ge (V

)

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

Pow

er D

ensi

ty (W

/cm

2 )

Test 101524 (10 x 10 cm2) - V

Test 20003 (20 x 20 cm2) - V

Test 25002 (25 x 25 cm2) - V

Test 101524 (10 x 10 cm2) - P

Test 20003 (20 x 20 cm2) - P

Test 25002 (25 x 25 cm2) - P

Temperature: 750°CFuel: H2 + 3% H2OOxidant: Air

Single cell testing of large area components showed no significant performance difference as compared to the baseline size cells.

Page 22: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Scaled-Up Cell Area:Reliability (Thermal Cycle) Validation

Stainless Steel Current Collectors, Cross-Flow Gas Delivery

0.400

0.500

0.600

0.700

0.800

0.900

1.000

1.100

0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80

Current Density, A/cm2

Volta

ge, V

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

Pow

er D

ensi

ty, W

/cm

2

750 - V

750 Post 11TC - V

750 - P

750 Post 11TC - P

Test 25004 Cell Size: 25 x 25 cm2

Temperature: 750°CFuel: H2 + 3% H2OOxidant: Air

Large area cell components showed good thermal cyclability.

Page 23: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Degradation Curve, G lob 25008; (GDC10 with BSCF/LCN 70/30), Oven #7, June 25, 2008

0.0

0.2

0.4

0.6

0.8

1.0

0 400 800 1200 1600 2000

Elapsed Tim e (hours)

Cel

l Vol

tage

(V)

600

650

700

750

800

850

Tem

pera

ture

, °C

550 cm2 Active Area Single Cell Furnace Temperature: 750°CFuel: 55 H2:45 N2 + 3% H2O, Uf = 50%Oxidant: Air, Ua = 25%Current Density: 500 mA/cm2

Large area cell components showed good steady-state endurance of 0.6% loss per 1000 hours

Scaled-Up Cell Area:Long-Term Testing

Page 24: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Stack Design Approach• Model-driven design approach is utilized for specific

challenges • Modeling has provided guidance to engineering

design and component development using both CFD and FEA

• Progressively increased from single cell, 6-cell, 16-cell, 64-cell stack to tower modeling

• Validated through component and stack testing

°C

Fi

Ai

Page 25: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Stack Modeling

PNNL ModelingGeneric 64-cell Stack CFD Modeling using PNNL super computerLargest SOFC model available with >5 million computational cellsUsed for Short and Tall Stack Structural Analysis

VPS/FCE In house ModelingDetailed Stack Mechanical ModelingFuel Cell Stack Flow Modeling Module ConfigurationReliability Studies

Page 26: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Stack Test Facility & Infrastructure

Modification of existing VPS single cell test stands to accommodate tests of scaled-up cells of up to 25X25 cm (550 cm2 active area)Modification of two existing VPS stack test stands to accommodate short full-area stack testing of up to 2.5 kWAcquisition of 2 single cell test stands to accommodate tests of cell sizes up to 38X38 cm at VPSAcquisition of 3 large-area stack test stands to accommodate stack scale-up development of 10 –25 kW at VPSConstruction of a 10-30 kW test facility to accommodate SOFC stack tower testing at FCE

Page 27: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

0.16 kW1-cell

1 kW6-cell

2.5 kW16-cell

10 kW64-cell

10

2.5

1

Power (kW/stack)

45

6

18

21

Quantity

6064 cells

4516 cells

216 cells

Total

StackDesign

126

Total Power (kW)

Large-Area Stack Tests

Page 28: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Excellent performance and transient characteristics achieved.

Large-Area 6-Cell Stack Performance

Scale Up 6-cell Stack (GT057192-0007) Average Cell Voltages At Various Operating Conditions Before and After Thermal Cycle

0.700

0.750

0.800

0.850

0.900

0.950

1.000

1.050

1.100

0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00

Elapsed Time

Volta

ge

0

50

100

150

200

250

300

Cur

rent

(A)

80% Uf

50% Uf

Load Transient

Average Voltage TC #0Average Voltage TC #1

Current Temperature = 725oC

500mA/cm2~415mW/cm2

388mA/cm2

, hr

Page 29: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Excellent performance observed in short 16-cell stack testing of scaled-up area (550 cm2 active area) cells.

GT057235-0003 TC1 Average Cell Voltage16 cell PCI3 Coal based

21-Feb-08; Stand 24

0.5

0.6

0.7

0.8

0.9

1

1.1

0 5 10 15 20 25 30

Elapsed Time (hours)

Volta

ge (V

)

0

50

100

150

200

250

300

Cur

rent

(A)

27% uf, 18% ua, 213A (0.388 A/cm^2)

Uf/Ua

75% Uf

CurrentVoltage

Large-Area 16-Cell (2.5 kW) Stack Performance

Page 30: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Large-Area 16-cell Stack (2.5 kW) Long-Term Testing

GT057235-0016 TC0 Cell Voltages at 213 A

Test Stand 23

0.0

0.2

0.4

0.6

0.8

1.0

1.2

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400Elapsed Time (h)

Vol

tage

(V)

12 mV / 1000 h or 1.5% / 1000 h

Cell 1

Ce ll 2

Ce ll 3

Ce ll 4

Ce ll 5

Ce ll 6

Ce ll 7

Ce ll 8

Ce ll 9

Ce ll 10

Ce ll 11

Ce ll 12

Ce ll 13

Ce ll 14

Ce ll 15

Ce ll 16

16 Cell Stack - 550 cm2 Active AreaFurnace Temperature: 710°C NOCFuel: 58% H2, 17%N2, 5% natural gas,

20% H2O, Uf = 61.5%Oxidant: Air, Ua = 13.5%Current Density: 0.388 A/cm2

Long-term tests of the large-area 16-cell stack showed stable and uniform cell-to-cell performance.

Page 31: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

10-kW Stack Fabrication

V1-001 stack at FCE V2-002 stack at VPS GT057382-0002 GT057259-0001

V2-001 stack installed at FCE after tests at

VPS

GT057382-0001

To date, six 10-kW stacks were fabricated for testing at VPS and FCE.

Page 32: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Peak Power Test Results of 10 kW Stacks

Version 2 stacks generate excellent repeatability at 213 A condition.

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

GT057382-0001 GT057382-0002 GT057382-0003

10 kW Stacks (v2)

Pea

k P

ower

at B

OL

(kW

)

Page 33: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

GT057382-0001 Average Cell Votage and Stack Power

Test Stand #27

0.0

0.2

0.4

0.6

0.8

1.0

1.2

24 30 36 42 48 54

Elapsed Time (h)

Ave

rage

Cel

l Vol

tage

(V)

0

2000

4000

6000

8000

10000

12000

Sta

ck P

ower

(W)

Peak Power 11.0 kW at 213 A

loss ofdata

10 kW Stack (V2-001) Testing

Shipped to FCE for further testing

V2-001 stack exhibited stable performance at VPS facilities prior to shipment to FCE.

T furnace = 710 CUf = 61.5% with

5.0 % NG, 60.5% H2, 17.1% N2, 17.4% H2OUa = 17.5%

Page 34: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

10-kW Stack (V2-003) Test at VPS

GT057382-0003Average Cell Votage and Stack Power

0.0

0.2

0.4

0.6

0.8

1.0

1.2

26 32 38 44 50 56 62 68 74

Elapsed Time (h)

Ave

rage

Cel

l Vol

tage

(V)

0

2000

4000

6000

8000

10000

12000

Sta

ck P

ower

(W)

peak power 11.0 kW at 213 ANOC power 10.4 kW at 200 A

T furnace = 695C peak, 700C NOCUf = 61.5% with 5.0 % NG, 60.5% H2,

17.1% N2, 17.4% H2OUa = 13.5% peak, 13.1% NOC

Continued tests at VPS

V2-003 stack shows stable performance at VPS facilities.

Page 35: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Building Block Approach

Building block for stack towers 10- 50 kW Building block for

stack modules of ≥ 250 kW

10 kW Stack Stack Tower Stack Module

Building Block for a ≥100MWe Integrated Gasification Fuel Cell (IGFC) system

Page 36: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Design Parameters:20 stack towers per moduleFive stacks per tower64 cells per stack550cm2 active area per cell>300mW/cm2 power density

The SOFC MW module is built off lessons learned from FCE’scommercial MW-scale products

MW-Scale SOFC Stack Module

Page 37: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Introduction:FCE SECA program team membersSOFC cell and stack technology overview

SECA Coal-Based SOFC Program OutlineTechnical Approach and Status:

Cell development (performance, endurance, area scale-up)Stack development (performance, endurance, stack height scale-up)MW module development

System and Cost Analyses:Integrated Gasification Fuel Cell (IGFC) System ConfigurationStack Cost EstimateBaseline (400MW) Power Plant Cost Estimate

10 kW Stack Metric TestConclusions

Presentation Outline

Page 38: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Integrated Gasification Fuel Cell System (IGFC)

System analysis has indicated that SOFC offers great potential for generation of highly efficient power with >90% carbon capture from coal using conventional gasification technologies.

Page 39: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Advanced Coal-Based SOFC Systems

Combined with high methane producing gasification, coal based SOFC systems are capable of achieving >50% efficiency

Net Output Excluding CO2 CompressionTotal Auxiliary Loads @ 20 kV -36,211

Net Power Output at 20 kV 544,809MainStep-Up Transformer 20 kV/230 kV -981

Net Power Output at 230 kV 543,828

Net Efficiency Excluding CO2 Compression As Fed Coal feed, lb/h 291,667Coal HHV (AF), Btu/lb 11,872Thermal Input, kWth 1,014,809Net Plant Efficiency (HHV) 53.59%

Page 40: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Baseline Power Plant Cost

Baseline System

Cost

Fuel Cell Stack Cost Balance-of-plant Equipment and Site work Cost

DC-to-ACInverter Cost

Module Enclosure/ Assembly Cost

Page 41: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Preliminary Stack Cost by Category

The majority of stack cost is driven by the cost of materials.The relatively low labor cost is attributed to the many years of cell

and stack process development at VPS.Stack cost estimates are planned to be audited by an independent

auditor.

Materials$173/kW85%

Labor$11/kW5%

Other$21/kW

10%

Page 42: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

System Cost Estimation Methodology

• WorleyParsons’ in-house cost database and conceptual estimating tools based on:> Past projects> Recent quotes> In-house parametric factoring methodology

• WorleyParsons’ cost model uses bottoms-up reference estimates for key components that can be easily adjusted for system alternatives based on data provided by heat and mass balance calculations

• Costs are referenced to year 2002 USD• Cost is based on a power plant size of 400MW and factory output

capacity of 800MW/year.

This methodology provides a sound basis for the comparison of BOP and system design options.

Page 43: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Preliminary Baseline System Cost

Cost estimation based on 5 x 400 MW manufacturing production has established that system equipment factory cost of < $600/kW is achievable.

Net power rating (kW) does not include CO2 compression

Total Factory Equipment Cost (2002 USD) = 589$/kW

Fuel Cell Module224 $/kW

38%

Balance of Plant365 $/kW

62%

Total BOP Cost (2002 USD) =

HRSG31 $/kW

9%

Expanders27 $/kW

7%

Blowers 34 $/kW

9%

Other Equipment3 $/kW

1%

Steam Turbine12 $/kW

3%

Cooling Water2 $/kW

0%

Instrumentation & Control7 $/kW

2%

Electric Accessories9 $/kW

2%

Inverter113 $/kW

31%

Heaters & Coolers126 $/kW

36%

365 $/kW

Page 44: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Introduction:FCE SECA program team membersSOFC cell and stack technology overview

SECA Coal-Based SOFC Program OutlineTechnical Approach and Status:

Cell development (performance, endurance, area scale-up)Stack development (performance, endurance, stack height scale-up)MW module development

System and Cost Analyses:Integrated Gasification Fuel Cell (IGFC) System ConfigurationStack Cost EstimateBaseline (400MW) Power Plant Cost Estimate

10 kW Stack Metric TestConclusions

Presentation Outline

Page 45: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

10-kW Metric Test

PHASE I Metric Test SECA Coal-Based Systems

DELIVERABLE POWER RATING ≥10kW

5000 hours STEADY STATE TEST (Normal Operating Conditions) Δ Power < 4.0% degradation/1000 hours

TEST SEQUENCE

1) Start-up 2) Peak Power Test 3) Steady State Test 4) Shut-down

FUEL TYPE Simulated (subject to DOE concurrence, up to 25% CH4, dry basis)

MAINTENANCE INTERVALS Design aspects should not require maintenance at intervals more frequent than annually.

Page 46: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

10-kW Stack Metric Test at VPSPerformance

GT057382-0002 Average Cell Voltage and Stack Power

Test Stand #27

0.0

0.2

0.4

0.6

0.8

1.0

1.2

34 40 46 52 58 64 70 76 82 88 94 100 106 112 118 124 130

Elapsed Time (h)

Ave

rage

Cel

l Vol

tage

(V)

0

2000

4000

6000

8000

10000

12000

Sta

ck P

ower

(W)

peak power 11.0 kW at 213 ANOC 10.5 kW at 200 A

64-cell Stack with 550 cm2 cellsUf = 61.5% with 5.0 % NG, 60.5% H2, 17.1% N2, 17.4% H2OUa = 15.5% peak, 15.3% NOC

Continued operation of the 10 kW stack is planned to meet the 5000 hours of metric test requirements.

Page 47: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

10-kW Stack Metric Test at VPSOperational Data

GT057382-0002 Individual Cell & Stack Voltages

Test Stand #27

0.0

0.2

0.4

0.6

0.8

1.0

1.2

34 40 46 52 58 64 70 76 82 88 94 100 106 112 118 124 130Elapsed Time (h)

Cel

l Vol

tage

(V)

0

5

10

15

20

25

30

35

40

45

50

55

60

Sta

ck V

olta

ge (V

)

peak power 11.0 kW at 213 A

Stack Zone at 705 C

NOC 10.5 kW at 200 A

Stack Zone at 700 C

64-cell Stack with 550 cm2 cellsUf = 61.5% with 5.0 % NG, 60.5% H2, 17.1% N2, 17.4% H2OUa = 15.5% peak, 15.3% NOC

64-cell stack has shown excellent cell-to-cell voltage uniformity.

Page 48: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Introduction:FCE SECA program team membersSOFC cell and stack technology overview

SECA Coal-Based SOFC Program OutlineTechnical Approach and Status:

Cell development (performance, endurance, area scale-up)Stack development (performance, endurance, stack height scale-up)MW module development

System and Cost Analyses:Integrated Gasification Fuel Cell (IGFC) System ConfigurationStack Cost EstimateBaseline (400MW) Power Plant Cost Estimate

10 kW Stack Metric TestConclusions

Presentation Outline

Page 49: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Stack Technology Progression

220Gross Power (W)

16Number of Cells

81Cell Active Area (cm2)

11,000Gross Power (W)

64Number of Cells

550Cell Active Area (cm2)

1,152Gross Power (W)

28Number of Cells

121Cell Active Area (cm2)

Page 50: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Multi-dimensional Gap:

Size, Cost, Performance, Endurance

Year2015201020082006

1 kW

1 MW

100 kW

10 kW

10 MW

3kW 121cm2 Active Area

28 cells/stack4 Stacks/Tower >250 kW

Power Module

Phase IIPhase II Phase IIIPhase III

Determine optimum cell/stack/ module size and design

Stack Tower/Module Demonstration

Phase IPhase I

2012

5 MW Proof-of-Concept

(POC)

Multi-Stack Tower

SOFC Stack Module Development Path

Phase I Metric Test

10kW Stack550cm2 Active Area

64 cells/stack

Page 51: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

Several significant technical milestones in cell and stack development have been achieved:

SOFC manufacturing scale-up from the baseline size of 156cm2 to greater than 1000cm2 has been successfully demonstrated. Production capacity for scaled-up 625cm2 (550cm2 active area) components has been successfully validated. Efforts are well underway to enhance stack manufacturing capacity to 500kW/year and cell manufacturing capacity to 1,000kW/year by the end of the Phase I program (October 2008). Single cell testing of advanced cell components has demonstrated ~8-10% performance improvement over baseline cell components. Advanced cell components also have shown significant improvement in endurance (decreased decay rate) over the baseline cells. Stability and uniformity in operation of the scaled-up cells have been successfully demonstrated in several 10-kW stacks of 64 cells.

Preliminary cost analysis of the SOFC Multi-MW Baseline Power Plant System shows a clear path to achieving the SECA cost goals. Technical advances indicate that SOFC offers a viable option for clean, reliable, highly efficient and cost effective power generation from coal based fuel sources.

Conclusions

Page 52: Solid Oxide Fuel Cell Program at FuelCell Energy Inc. library/events/2008/seca... · Solid Oxide Fuel Cell Program at FuelCell Energy Inc. 9th Annual SECA Workshop ... Introduction:

The support provided by NETL is acknowledged and gratefully appreciated by the FCE team.

Many thanks to Wayne Surdoval, Travis Shultz, and Heather Quedenfeld for their project and technical guidance.

Acknowledgements