Solid Oxide Fuel Cell Development at Topsoe Fuel Cell A/S

Transcription

1 Solid Oxide Fuel Cell Development at Topsoe Fuel Cell A/S

2 Briefly on Topsoe Fuel Cell Development, marketing and sales of SOFC technology Founded in 2004 Subsidiary of Haldor Topsøe A/S (wholly owned) SOFC research & development since 1989 Full time employees: 30 (January 2007) 50 (June 2007) Strategic R&D partner: Risø National Laboratory (50 empl. engaged in SOFC) TOFC s Position in the Value Chain System Integrator Fuel Materials & components Fuel cell stack Fuel cell device End use Service/ maintenance

3 SOFC Principles H 2 + O 2- H 2 O + 2e - Anode - O 2- Electrolyte O 2- Catode ½O 2 + 2e - O 2-

4 Power Generation

5 Generic SOFC unit Control DC/AC converter AC electricity Air Natural gas Filter/ blower Preheat Preheat Desulfurization Prereformer Fuel cell stack CO 2 Water

6 SOFC Development at Topsoe/Risø : Electrolyte-supported cells Operation temperature: 1000 C Ceramic interconnect 500 W HTAS/Risø stack (>500 h in 1996) : Anode-supported cells Operation temperature: C Metallic interconnect 100 W HTAS stack (>12000 h in 2004) 1 kw+ HTAS stack (in 2003) 2003 and future: Metal-supported cells Operation temperature: C

7 Anode supported planar Cells Thin Planar Cells 375 m Cell voltage [V] Single Cell Performance C 750 C 650 C > 1,5 W/cm Power density [W/cm 2 ] Current density [A/cm 2] Wide temperature operation window

8 Manufacture of Anode-supported Cells High Tech - Industrially Relevant - Low cost

9 Anode supported Cells 22x50 cm2 24x24 cm2 21 cm 12x12 cm2 Our largest cell to day: 22 x 50 cm2

10 The Topsoe Stack Concept Compact Multilayer Design 75-Cell Stack ( oc) 1 mm per repeatable unit 2.4 kw/liter at 0,38 A/cm2 0,25 kw/ kg 60 V at 20A Five cell stack 75 mm hours + 9 full thermal cykles 5 4,5 4 3,5 Volt 3 2, mm 1, mm 0, x12 cm Hours

11 Larger Cells: 18 x 18 cm2 75 cells 12x12 cm2 Stack Voltage [V] Degradation at high power density Stack W/cm2 durability 0,7 A/cm Stack Voltage Voltage at 75% F.U. 3 Stack Power 300 Power at 75% F.U Current [A] 60 cells 18x18 cm2 Co-flow 160 Stack Power [W] Cost / performance optimization

12 Flow geometry Modelling and Experimental Cross flow Co flow Counter flow Flow design Counterflow Crossflow Coflow Temp. gradient ( C/m) Temp. average ( C) Power density (W/cm 2 ) U (V) Counter-flow I (Amp) 75-Cell Stack Natural Gas FU: 65% 1.8 kw

13 Stack Modelling Cross-flow, 18x18 cm 2 foot print Finite elemente Modelling Large temperature gradient

14 Cell development - Generations Reduced cost Improved reliability ceramic support metallic support 1000 o C 850 o C 700 o C 600 o C

15 SOFC System Development

16 Product Requirements Comparison (2) CHP APU S.U. time, min. 480 <20 Lifetime, hours Efficiency (el),% >45 >35 Maintenance, h Cycles Cost $/kw <1000 <300

17 SOFC System Modelling kw Base Case Natural Gas Flue Gas E 5 Natural gas E1 Desulphurisation Prereformer Water for start up Flue Gas E7 E 6 Catalytic Burner Anode recycle E 2 SOFC Anode Cathode E 3 Air Blower Air Case Base Case NG Prereform Stationary Methanol APU application DME APU application Diesel CPO (O2/C = 0.35) El Eff. % Cogen Eff % Energy Flows (kj/s)

18 Transient Part Load Cycle HIL Test System 1 kw stack P_demand P_gross P_net 600 System efficiency Electric power [W] Efficiency [-] Time [s] Max. el. eff.: 55% Total load cycle el. eff.: 37 %

19 Flow sheet of AVL Test Stand

20 Integrated Hot Box

21 TOFC Lightweight Hot Box 1.8 kw el Project for US Air Force 2 x 40 cells (12x12 cm 2 ) Projected Weight stack + manifold 5,7 kg Volume stack + manifold 2 liters Operate on de-sulphurized JP-8/synthetic diesel 1.5 kw nominal power over 500 hours 10 start up/shut down cycles Fuel utilization > 80% (nominal power) System efficiency > 30%

22 SOFC Projects supported by Danish Utilities I) Stack hot box for micro CHP II) 10 kw test and demo facility H. C. Ørsted Power Plant / Copenhagen Flue Gas E 5 Natural gas E1 Desulphurisation Prereformer Water for start up E 6 E 2 SOFC Flue Gas E7 Catalytic Anode recycle Anode Cathode Burner E 3 Air Blower Air

23 Carbon Formation - Graphite Data Deg. c Carbon Formation Region No Carbon O/C ratio

24 Methanation of MeOH for SOFC Electrical net efficiency = 53 % Co-gen efficiency = 82 %

25 Carbon Formation nm Ni Crystals Haldor Topsøe catalyst Carbon whisker Ni crystal 700 Deg. C Carbon Formation Region No Carbon Formation O/C ratio

26 TOFC / Wärtsilä Collaboration Wärtsilä 5 kw test system with 4 TOFC stacks Wärtsilä 25 kw -prototype with 24 TOFC Stacks Voltage [V] and Current [A] ,0 550,0 1050,0 1550,0 2050,0 2550,0 3050,0 Running Hours Average Stack Voltage Average Stack Current Average Current Density Current Density [ma/cm 2 ] kwe-prototype kwe, NG, methanol, bio gas

27 24 Stacks for the 20 kw Prototype

28 Secure Channels to Market Diversification & Consolidation!"## $%

29 Conclusion New, up-scaled cell and stack manufacturing plant Start-up 2008 Capacity: 150, ,000 cells 3,800 standard stacks > 4 MW Supported by EU with 4.8 m EUR Standard production of 12x12 cm 2 stacks 18x18 cm 2 co-flow stacks tested Next generation cells and stacks on track