Brennstoffzellen-Systeme von der Forschung zur Kommerzialisierung: Integration Simulation Testen

Brennstoffzellen-Systeme von der Forschung zur Kommerzialisierung: Integration Simulation Testen IEA Workshop Brennstoffzellen: Markteinführung, Markthemmnisse und F&E-Schwerpunkte 27. Februar 2014, Graz Peter Prenninger AVL List GmbH AVL Central Research Coordination, Peter Prenninger 1

Efficiency 30 % 50 % 70 % SOFC TECHNOLOGY EFFICIENCY ENABLER SOFC Technology ICE Technology SOFC & GT Technology High efficient fuel gas generation from NG, methanol, Diesel and all Biofuels (80-99%) High efficient energy conversion in SOFC (>50%) 5-10 kw 100-500 kw 1-5 MW Power Range Best suited for combined SOFC-GT cycles AVL Central Research Coordination, Peter Prenninger 2

Challenges in: Systems Engineering Virtual System Development Component Analysis and Optimization System Integration Validation and Commercialization AVL Central Research Coordination, Peter Prenninger 3

PRODUCT REQUIREMENTS Portable power out of diesel fuel without noise and emissions! Other markets: Military Anode blower Air blower APU Stack Module Design Targets: 3kW electrical power 10kW thermal power el. efficiency ~35% Marine Fuel: road diesel (< 15 ppm S) 80L, 75kg ~ 55dB(A) noise Fuel pumps Valves Gas processing unit Incl. reformer, start-burner, off-gas cleaning, heat exchange, manifolding 8000h lifetime 300/3000 cold/warm cycles Camping AVL Central Research Coordination, Peter Prenninger 4

PRODUCT REQUIREMENTS SIMULATION SUPPORT AVL Central Research Coordination, Peter Prenninger 5

CUSTOMER AND MARKET ASPECTS Idling Time per Week: 30, 40, 50 & 57.83 h Diesel price: 3.9 5.0 $/gal (3.9 $/ga l= 0.79 /l) Fuel Consumption (Idling): o Truck: 0.75 gal/h (2.84 l/h) o ICE APU: measured, improved map o SOFC APU: expected efficiency 2016 Sales price SOFC APU 12.000 $ (9.230 ) Sales price ICE APU 10.000 $ (7.700 ) AVL Central Research Coordination, Peter Prenninger 6

FULFILMENT OF CUSTOMER EXPECATIONS Comparison Truck Idling vs. SOFC APU Pay back period 3,9 $: 1,62 years 4,25 $: 1,50 years 4,5 $: 1,41 years 5 $: 1,27 years Years 1,8 1,6 1,4 1,2 1 0,8 0,6 0,4 0,2 0 3.9 $ 4.25 $ 4.5 $ 5 $ Diesel price AVL Central Research Coordination, Peter Prenninger 7

Challenges in: Systems Engineering Very mature rivals (costs, reliability ) Extremely high customer expectations Fairly unknow load cycles no field experience AVL Central Research Coordination, Peter Prenninger 8

Challenges in: Systems Engineering Virtual System Development Component Analysis and Optimization System Integration Validation and Commercialization AVL Central Research Coordination, Peter Prenninger 9

VIRTUAL SYSTEM LAYOUT Burning Chamber Reformer Isolation Exhaust Fuel POX-Air Bypass-Air Air Plate Heat Exchanger Pipe Heat Exchanger Oxidation Catalyst Fuel Cell Stack AVL Central Research Coordination, Peter Prenninger 10

VIRTUAL SYSTEM LAYOUT Air conditioning circuit Air supply and filter Vehicle cooling circuit ICE exhaust from TC Power electronics, Batteries ICE Internal Combustion Engine TC Turbocharger AVL Central Research Coordination, Peter Prenninger 11

VIRTUAL SYSTEM LAYOUT Specifications: 3kW electrical power 10kW thermal power el. efficiency >35% Fuel: road Diesel (max 15ppm sulfur) 80L/70kg < 55dB(A) noise 650mm Technology: Solid Oxide Fuel Cell metal-supported stacks anode recirculation auto thermal reforming highly efficient radialblowers for media supply system internal regeneration approaches AVL Central Research Coordination, Peter Prenninger 12

Challenges in: Virtual System Development Systems engineering approach needed System integration aspects Model development based on unknows AVL Central Research Coordination, Peter Prenninger 13

Challenges in: Systems Engineering Virtual System Development Component Analysis and Optimization System Integration Validation and Commercialization AVL Central Research Coordination, Peter Prenninger 14

COMPONENTS & SUB-SYSTEMS Detailed investigation of performance of critical components by means of numerical simulation boundary condition for linked components (e.g. insulation, air management, control functions ) AVL Central Research Coordination, Peter Prenninger 15

COMPONENTS & SUB-SYSTEMS Example 3D+ CFD simulation of cells and stacks Solid oxide fuel cell domains with transport across domain interfaces and reactions 1/ 2O 2 2 2e O 2 H2 O 2 C n H m O p 2 H O 2e CO H O CO n p H O n CO n p m / 2 2 2 H 2 H 2 Requested results: Electronic (e - ) potential in electrodes and interconnect Ionic (O 2- ) potential in electrolyte Electrochemical reaction rates at TPB, chemical reaction rates in anode domain Velocity, pressure and species mass fractions in channels and electrodes Temperature in all domains AVL Central Research Coordination, Peter Prenninger 16

COMPONENTS & SUB-SYSTEMS Model validation Comparison to experimental results CFD mesh: 1.3 mio. cells Active area: 127 cm 2 Interconnect Channels Nickel mesh Glass sealing Electrodes, electrolyte AVL Central Research Coordination, Peter Prenninger 17

COMPONENTS & SUB-SYSTEMS Model validation Test cell: voltage and power density vs. current density, fitted result [1] Kim J.W., Virkar A.V., Fung K.Z., Mehta K., Singhal S.C., Polarization Effects in Intermediate Temperature, Anode- Supported Solid Oxide Fuel Cells, Journal of The Electrochemical Society 146, 69-78, 1999. AVL Central Research Coordination, Peter Prenninger 18

COMPONENTS & SUB-SYSTEMS Model validation Temperature (K) of cathode interconnect Var.2 ( = 1.25) Ref. ( = 1.333) Var.1 ( = 1.667) AVL Central Research Coordination, Peter Prenninger 19

COMPONENTS & SUB-SYSTEMS Very focused development of particular key enabling technologies & components Air and Gas Management AVL Schrick FC Blowers AVL Central Research Coordination, Peter Prenninger 20

COMPONENTS & SUB-SYSTEMS power demand (load cycle) p1/p2 m_dot,air T1 Vstack V_low_limit cell diagnosis current demand air utilisation stack temperature demand temperature feedback loop power controller + compressor demand current + model + PID & + f(i, ) PID thermal management controller max min min max max min SP = set point cathode HEX temperature SP current SP m_dot,air SP 1 kw SOFC APU Proof-of-concept SOFC stack from research partner High dynamics in self-sustained mode Control concept for transient mode incl. AVL stack-monitoring technique AVL-THDA System efficiency > 35% Successful full hot box system integration AVL Central Research Coordination, Peter Prenninger 21

Challenges in: Component Analysis and Optimization Availability of high quality tools Non-existing development environment Very little know how on supplier level Premature components & subsystems AVL Central Research Coordination, Peter Prenninger 22

Challenges in: Systems Engineering Virtual System Development Component Analysis and Optimization System Integration Validation and Commercialization AVL Central Research Coordination, Peter Prenninger 23

TEST ENVIRONMENT FOR SYSTEM INTEGRATION AVL Central Research Coordination, Peter Prenninger 24

TEST ENVIRONMENT FOR SYSTEM INTEGRATION Test of single components, subsystems, stacks at operating temperature and complete systems on 1D & 2D vibration test rigs Random noise tests Frequency sweep tests Test of bad-road truck vibration profiles Christoph Kügele, Tomas Dehne 25

SYSTEM TESTING Experimental results 1 stack systems: ~2.2kW gross power output ~1.8kW net power output 29% electrical efficiency start up time ~1h operation completely without lab infrastructure (inert gas, ) very reasonable degradation ~2000h of operation with Gen 0 (stopped) and with Gen I 50 cold starts / 100 warm starts <55dB(A) noise level AVL Central Research Coordination, Peter Prenninger 26

CONTINUOUS SYSTEM IMPROVEMENT AVL APU Generations nominated for Austrian national prize 2013 Gen. 1.0 Sep. 2011 first AVL System with full functionality Gen. 1.1 Oct. 2012 first vehicle integration Gen. 2 May 2013 2 stack design -25% in size AVL Central Research Coordination, Peter Prenninger 27

Challenges in: System Integration Simultaneous establishment of test infrastructure Parallel basic research and contiuous improvement System development based on premature components AVL Central Research Coordination, Peter Prenninger 28

Challenges in: Systems Engineering Virtual System Development Component Analysis and Optimization System Integration Validation and Commercialization AVL Central Research Coordination, Peter Prenninger 29

1930 ADDITIONAL MARKET OPPORTUNITIES Synergies SOFC CHP System (Components, Control ) Front Rear Hotbox BoP 900 AVL Central Research Coordination, Peter Prenninger 30

SUPPORT OF COMMERCIALIZATION Assumptions for System OEM/Tier 1 Invest: Series development, validation, certification 15.6 Mio $ Build up manufacturing line 2.6 Mio $ Sales Price: 12.000 $ Sales Volume (3 Scenarios): Year Cons. Balanc. Aggr. 1 3.000 5.000 8.000 2 3.500 7.000 15.000 3 4.500 11.000 20.000 4 6.500 16.000 22.000 5 8.500 19.000 22.000 6 10.000 20.000 22.000 Lot size Year AVL Central Research Coordination, Peter Prenninger 31

SUPPORT OF COMMERCIALIZATION Assumptions Production Cost incl. licence fee, sales & admin. overhead 3 Scenarios: Year Low Average High 1 8.190$ 9.100$ 10.010$ 2 7.605$ 8.450$ 9.295$ 3 7.020$ 7.800$ 8.580$ 4 6.727$ 7.475$ 8.223$ 5 6.482$ 7.202$ 7.922$ 12000 $ 10000 8000 6000 4000 2000 6 6.482$ 7.202$ 7.922$ 0 0 1 2 3 4 5 6 Year AVL Central Research Coordination, Peter Prenninger 32

Breal Even [years] SUPPORT OF COMMERCIALIZATION OEM/Tier 1 Scenarios Break Even vs. Production cost / Sales scenarios 2,5 2 1,5 1 Low Prod. Cost Avg. Prod. Cost High Prod. Cost 0,5 0 Agressive Balanced Conservative AVL Central Research Coordination, Peter Prenninger 33

Challenges in: Validation and Commercialization High market inertia low early market volume High dependence on outer boundary conditions (legislation, energy prize, ) OEM expectation: mature prototypes RoI as conventional products AVL Central Research Coordination, Peter Prenninger 34

Brennstoffzellen-Systeme von der Forschung zur Kommerzialisierung: Integration Simulation Testen IEA Workshop Brennstoffzellen: Markteinführung, Markthemmnisse und F&E-Schwerpunkte 27. Februar 2014, Graz Peter Prenninger AVL List GmbH Acknowledgement: The results presented are based on research projects funded by the Austrian Ministry of Transport, Innovation and Technology (a3/a3plus-projects SOFC APU I & II and ASys1) as well as the European Union FP7 (DESTA). AVL Central Research Coordination, Peter Prenninger 35