Project Overview. by Dimosthenis Trimis / TU Bergakademie Freiberg Technical Co-ordinator on behalf of the FlameSOFC consortium

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1 Contract No (SES6) Co-ordinator: Jürgen Valldorf / VDI/VDE-IT Fuel Flexible, -regulated, Modular, Electrically Integrated SOFC-System Project Overview by Dimosthenis Trimis / TU Bergakademie Freiberg Technical Co-ordinator on behalf of the FlameSOFC consortium HarmonHy Final Conference, 04/10/2006, Brussels

2 Main Project Objectives Overall target: development of a robust stationary NG, LPG, IGO, or FAME fired SOFC based micro-chp system. Power target: 2 kw el net output (expected future mainstream high volume mass market for micro-chps) Power modulation target: > 1:4 Efficiency targets: > 35% net electrical, > 90 % total CHP efficiency Durability target: > h (no catalytic components; limitations mainly at the SOFC stack level) Cost targets (for series production > pieces per year): < 1950 for the complete micro-chp < 400 /kw el concerning the stack components < 100 /kw el concerning the inverter power electronics Start-up time: significantly less than 60 minutes Main target application: domestic micro-chp for single or twofamily homes with electrical grid connection (further potential as backup power unit, up-scaling) HarmonHy Final Conference, 04/10/2006, Brussels 2

3 Market situation / MTS study 2 kw el case; enduser price and market volume Enduser price target for SOFC and PEM CHP units at 5 years payback SOFC micro-chp demand curve for single/two-family homes (natural gas) HarmonHy Final Conference, 04/10/2006, Brussels 3

4 Market situation / MTS study Optimal size analysis single family homes DE, 5 years payback, 4% interest η El (LHV) Enduser price ( ) Condition: 8 cents/kwh back to grid *) SOFC 45% 30% 15% 9% η CHP (LHV) = 90% Condition: 0 cents/kwh back to grid kwel *) German law for microchp assures a buy back price for electricity back to the grid of about 8 cents/kwh (ca. the half of the electricity price); DIRECTIVE 2004/8/EC on the promotion of cogeneration (27)... Especially for small scale and micro-cogeneration units access to the grid system of electricity produced from high-efficiency cogeneration may be facilitated subject to notification to the Commission. HarmonHy Final Conference, 04/10/2006, Brussels 4

5 Exhaust gas Proposed technological solution IGO / FAME and blends Warm Unit for liquid fuels (Liquid) Cold Heat Recovery Evaporator (Liquid mode, Elec. Heated at Start) Feed Preheater SOFC Recuperator Soot Trap feed Off Gas Por. Burner Unit for gaseous fuels Mix Prep. DC / AC Converter Electrical Power NG / LPG Fuel Processor SOFC & power electronics BoP (Gas) Network Integration Unit The overall proposed technological solution is significantly simpler and innovative in comparison to existing practice: No sensitive catalysts are used for the fuel processing, enabling a long durability No de-ionized water management is needed The large operational windows of the individual components and the additional operational safety given by the soot trap yield a robust nonsensitive design Multi-fuel feedstock is enabled Up-scalable and potentially lowcost SOFC technology is applied HarmonHy Final Conference, 04/10/2006, Brussels 5

6 Partnership Partner number Partner short name Name Type County 1 VDI/VDE-IT VDI/VDE Innovation + Technik GmbH SME DE 3 MTS MTS GROUP (Merloni TermoSanitari SpA) IND IT 4 FED Fagor Electrodomesticos S. Coop IND ES 5 EBZ Entwicklungs- und Vertriebsgesellschaft Brennstoffzelle mbh SME DE 6 HTc HTceramix SA SME CH 7 PROMEOS PMC Porous Media Combustion GmbH SME DE 8 STC Stobbe Tech Ceramics A/S SME DK 9 IKERLAN Ikerlan S. Coop. RI ES 10 ECN Energy research center of the Netherlands RI NL 11 OWI Oel-Wärme-Institut ggmbh RI DE 12 UERLN Friedrich-Alexander-Universität Erlangen-Nürnberg UNI DE 13 EPFL Ecole Polytechnique Fédérale de Lausanne UNI CH 14 POLITO Politecnico di Torino UNI IT 15 NTUA National Technical University of Athens UNI GR 16 IST Instituto Superior Tecnico UNI PT 17 IMPERIAL Imperial college of science technology and medicine UNI UK 18 BUTE Budapest University of Technology and Economics UNI HU 19 IEO EC BREC Instytut Energetyki Odnawialnej RI PL 21 TU-BAF Technische Universität Bergakademie Freiberg UNI DE 22 ELCO ELCO Shared Services GmbH, MTS-Group IND DE HarmonHy Final Conference, 04/10/2006, Brussels 6

7 Workplan (PERT) FlameSOFC started Oct.2005 current state Three major milestones: Operation of combined basic components including first phase SOFC stack (M18) Operation of final prototype of FlameSOFC unit with all components as for the targeted final evaluation (M36) Certification of evaluation units (M38) HarmonHy Final Conference, 04/10/2006, Brussels 7

8 Current project state Overview The project started since 12 months First versions of all basic components are already available The detailed simulation tools for the component development and optimization are available or in the validation phase Process flow scheme, P&IDs etc. frozen for 1st phase unit (lab unit; short stack with full scale periphery) Integration of first phase unit starts in January 2007 System control, selection of BoP components etc. as well as the sustainability activities (LCA, market studies etc.) are proceeding well HarmonHy Final Conference, 04/10/2006, Brussels 8

9 Current project state Expected net efficiency Nett SOFC efficiency (LHV) at 80% utilisation η (%) Natural gas LPG Heating oil FAME % 20% 40% 60% 80% 100% 120% Load The process simulation (AspenOne Ver.12), considering all peripheral components and the currently available characteristics, indicates that the FlameSOFC unit will reach a net el. efficiency of ca. 30% at full load (up to 37 % at min power and NG fuel) HarmonHy Final Conference, 04/10/2006, Brussels 9

10 Current project state Development state of selected components IGO / FAME and blends Unit for liquid fuels Unit for gaseous fuels NG / LPG (Liquid) Evaporator Mix Prep. (Gas) Sampling position 250 mm (Liquid mode, Elec. Heated at Start) Recuperator Fuel Processor Reformate outlet Soot Trap Exhaust gas Cold Heat Recovery Warm Feed Preheater SOFC Off Gas Por. Burner feed SOFC & power electronics DC / AC Converter Electrical Power BoP Network Integration Unit Selected porous structure for T-POX reactor: SiC foam Thermocouple connection At current state soot limit at λ c = 0.42 air ratio, target λ c = 0.4 for NG fuel HarmonHy Final Conference, 04/10/2006, Brussels 10

11 Current project state Development state of selected components IGO / FAME and blends Unit for liquid fuels Unit for gaseous fuels NG / LPG (Liquid) Evaporator Mix Prep. (Gas) (Liquid mode, Elec. Heated at Start) Recuperator Fuel Processor Soot Trap Exhaust gas Cold Heat Recovery Feed Preheater SOFC feed Off Gas Por. Burner SOFC & power electronics DC / AC Converter Electrical Power BoP Network Integration Unit Full size lab samples Ø144xL102 mm 150 cpsi Pressure drop 2 mbar (unloaded) up to 10 mbar (loaded) Warm HarmonHy Final Conference, 04/10/2006, Brussels 11

12 Current project state Development state of selected components IGO / FAME and blends Unit for liquid fuels Unit for gaseous fuels NG / LPG 1st phase short stack (0,5 1 kw) (Liquid) Evaporator Mix Prep. (Gas) (Liquid mode, Elec. Heated at Start) Recuperator Fuel Processor Soot Trap Exhaust gas Cold Heat Recovery Feed Preheater SOFC feed Off Gas Por. Burner SOFC & power electronics DC / AC Converter Electrical Power BoP Network Integration Unit Several stacks tested (5 to 24-cells stacks) 500W-class stack operated in HTc HoTBox Power densities of > 400mW/cm 2 Warm HarmonHy Final Conference, 04/10/2006, Brussels 12

13 Current project state Development state of selected components IGO / FAME and blends Unit for liquid fuels (Liquid) Evaporator Unit for gaseous fuels Mix Prep. NG / LPG (Gas) Stack components development for 2nd phase full scale stack 1st phase cell (Liquid mode, Elec. Heated at Start) Recuperator Fuel Processor 2nd phase cells Soot Trap Exhaust gas Cold Heat Recovery Feed Preheater SOFC feed Off Gas Por. Burner SOFC & power electronics DC / AC Converter Electrical Power BoP Network Integration Unit 139 x 231 mm plain cells Optical QC New fully automatic screen printer installed for cathode deposition First manufacturing trials for other large area components (SOFConnex ) Production and QC control procedures optimization on-going Warm HarmonHy Final Conference, 04/10/2006, Brussels 13

14 Current project state Development state of selected components IGO / FAME and blends Unit for liquid fuels Unit for gaseous fuels NG / LPG Development of 2nd phase stack (Liquid) Evaporator Mix Prep. (Gas) (Liquid mode, Elec. Heated at Start) Recuperator Fuel Processor Soot Trap Exhaust gas Cold Heat Recovery Warm Feed Preheater SOFC Off Gas Por. Burner feed SOFC & power electronics DC / AC Converter Electrical Power BoP Network Integration Unit Specifications: Stack Power: 2.3kW el 0.5kW el Power density: 1kW el /l Specific Power: 0.3W/cm 2 Active Area: 200cm 2 Nominal Pressure Drops: - side: 16 mbar - Fuel side: 10 mbar HarmonHy Final Conference, 04/10/2006, Brussels 14

15 Current project state Development state of selected components IGO / FAME and blends Unit for liquid fuels Unit for gaseous fuels NG / LPG (Liquid) Evaporator Mix Prep. (Gas) SiC-foam Exhaust gas Cold Heat Recovery Warm (Liquid mode, Elec. Heated at Start) Feed Preheater Recuperator Soot Trap SOFC Off Gas Por. Burner feed Fuel Processor SOFC & power electronics DC / AC Converter Electrical Power BoP Network Integration Unit Mixing chamber Insulation Burner in operation with reformate gas The burner can operate with reformate gas (cold/hot, start-up/load rejection) and anode (low heating value) Dimensions: ø 130 mm housing diameter ø 80 mm x 125 mm porous body 10 mm wall insulation HarmonHy Final Conference, 04/10/2006, Brussels 15

16 Current project state Development state of selected components IGO / FAME and blends Unit for liquid fuels (Liquid) Evaporator Unit for gaseous fuels Mix Prep. NG / LPG (Gas) Preliminary prototype (Liquid mode, Elec. Heated at Start) Recuperator Fuel Processor Feed Soot Trap SOFC feed SOFC & power electronics DC / AC Converter Network Integration Unit Plate type heat exchanger from high temperature alloy Preliminary prototype almost fulfills specification from process scheme Exhaust gas Cold Heat Recovery Preheater Off Gas Por. Burner Electrical Power BoP Optimized prototype (genetic algorithm optimization with modefrontier) under construction Warm HarmonHy Final Conference, 04/10/2006, Brussels 16

17 Final remarks The close collaboration between industry, SMEs, industrial and scientific research centres representing a wide variety of technological and socioeconomic expertises assure the practical realisation of the FlameSOFC micro-chp system and indicate the pathway for a market introduction in the mid term. The vertical development activities on the component level (SP2000) are effectively integrated through horizontal continuously monitoring actions (SP1000) harmonizing the individual development efforts for the sake of the overall system performance optimization. The horizontal sustainability activities (SP3000) will elaborate the relevant socioeconomic information and indicate the necessary strategies for a wide societal acceptance of the advanced technology. A final concept evaluation through certified FlameSOFC micro-chp systems in two demonstration sites will enable an overall assessment of the developed technologies and their practical performance (WP1400). The project started smoothly; The current development state is on track Results of the first integrated unit are expected in the second quarter of 2007 HarmonHy Final Conference, 04/10/2006, Brussels 17

18 Thank you for your attention! HarmonHy Final Conference, 04/10/2006, Brussels 18