Automated testing of SOFC stack hotboxes · WELCOME to our presentation at the Hannovermesse 2010....

EBZ GmbH

Automated testing of SOFC stack hotboxes

EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany

Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany

Email: [email protected] Web: www.ebz-fc.de

WELCOME to our presentation at the Hannovermesse 2010

EBZ GmbH

Who will guide you through the next 20 minutes:

Falk Schröter

Project Manager in EBZ GmbH




� Hardware design

� Software design

� Testing

� Commissioning

EBZ GmbH

Abstract

� Company profile

� Introduction to EBZ ProControl

� 3 kW Demonstrator for staxera ISM box

� Automated start sequence – requirements and solution




� Automated start sequence – requirements and solution

� Discussion & questions

EBZ GmbH

� SOFC system development since 2002

� 15 engineers and technicians

� 4 generations of SOFC systems

� Part of SOFC cluster Dresden:

staxera, Fraunhofer IKTS, EBZ

Company Profile




staxera, Fraunhofer IKTS, EBZ

EBZ GmbH

EBZ GmbH

Fuel Cells & Process Technology

Dresden

� SOFC Test rigs � Heat exchangers

Company Profile




cells, stacks and

stack modules

� Demonstration

systems

� Competence in

system integration

� Independent

SOFC test laboratory

Test environments for staxera‘s

Integrated Stack Modules (ISM):

� Preheating Modules

� Steam Reforming Modules

� 1-3 kWel demonstration systems

� Heat exchangers

� Evaporators

� El. gas heaters

� Desulphurizers

� Reforming units

� Burners

� Measurement and

controls

EBZ GmbH

staxera (Germany)

� 5 Hotbox test stands delivered

� 0.5 to 1.5 kWel stacks

� Long-term tests and thermal

cycling experiments possible

References: Stack test rig




cycling experiments possible

� Evaporator, air and gas heaters

EBZ GmbH

3 kW Demonstrator 20 kW System

Motivation




2x Mk200 ISMsEfficiency 35-40%

5x Mk2xx ISMsEfficiency 60%

Demonstrate the potential of SOFC technology

EBZ GmbH

staxera experience Focus of cooperation with EBZ

Extensive stack testing mainly with

CPOX based reformates

Performance of stacks

under internal reforming

conditions

Background & objectives




Stack testing in laboratory

environments

Proof of stack performance and stability in

real system

Single stack module operation

for 1 – 1.2 kWel

Demonstration of scalability of staxera

stack technology

� multiple ISMs in one system

EBZ GmbH

� Operation of 2 parallel ISM 3.0

� Gross stack power 2x 1.1 kWel

� in future 2x 1.5 kW ISMs

� Desulphurizer and steam pre-reformer

for pipeline natural gas

� Two-zone porous media burner for fast

3 kWel Research & Demonstration system




� Two-zone porous media burner for fast

system start-up and anode off-gas

burning

� Stack efficiency 50 %el, system

efficiency about 35 %el

� System in operation since 09/2009

EBZ GmbH

software solution with pre-defined programs for testing single cells and SOFC stacks, e.g. the measurement of IV-characteristic curves

� not as flexible as necessary

GUI of test rig with pre-defined procedures

Reasons for EBZ ProControl




EBZ GmbH

� Comfortable graphical programming

� No script language or a special programming language

� Simulates a virtual user who is able to monitor and influence variables

� Syntax checking for fail-safe operation

� Time-controlled, event-controlled or mixed code execution

Advantages for test rig controls




� Time-controlled, event-controlled or mixed code execution

� Test rig control via network possible

� Sequences can be saved, loaded and append

� Including an overriding event management for parallel supervising of variables independent from Safety-PLC

EBZ GmbH

� Threshold monitoring, e.g. temperatures

� Special steps and combinations of process engineering, e.g. leakage tests and cell reduction

� Recording of characteristic curves, e.g. IV-curves

� Connectable to various OPC servers, e.g. M1-OPC Standardserver

Advantages for test rig controls




� Connectable to various OPC servers, e.g. M1-OPC Standardserver from Bachmann electronic GmbH

EBZ GmbH

Process

Variable 1

Variable 2

Variable 3

...

PLC (Compact FieldPoint)

GUI

Test rigComputer

Hardware outputs

Hardware outputsHardware inputs

Published data

Commun. ports

Data flow in a test rig

EBZ ProControl

Test rig's or remote PC




Variable n

...

Database

externaldevices

sensors actuators

externalcontoller

safety system

communication via LANserial communication (RS-232, RS-485) or ethernethard wired communication via current loop or voltage signalsdata flow via software protocoldigital voltage signals (0...24 V)

Commun. ports

EBZ GmbH 3 kWel Research & Demonstration system




EBZ GmbH Automated warm start

Steps for the automated start:

1. Set stack air to control mode "Temperature"

2. Set burner air to control mode "Flow"

3. Set control thermocouple

4. Set control range of stack air blower between 25…100 %




4. Set control range of stack air blower between 25…100 %

5. Set control temperature of stack

6. Set burner air flow and gradient

7. Set default values for burner natural gas

8. Start ignition sequence

9. If ignition succeeded, switch to control by temperature

EBZ GmbH Automated start

10. Adapt control temperature and natural gas flow

11. Monitor the outlet temperature of evaporator and change gradient, if 200 °C is reached

12. Change flow rate of DI-water to 300 g/h

13. Start reforming mode, if reformer temperature is high enough




13. Start reforming mode, if reformer temperature is high enough

14. Set operation point values

15. Set low limit monitoring for DI-water flow

16. Set operation mode, gradient and setpoint for the DC-load

EBZ GmbH Step 1: Overview

Following step




EBZ GmbH Step 1: Detail Action 1

Enable or dis-able this action

Process name and URL




EBZ GmbH Step 1: Detail Action 2




EBZ GmbH Step 9: Detail Event




EBZ GmbH Step 9: Detail Go on condition




EBZ GmbH Step 15: Overview




EBZ GmbH Step 15: Detail Go on condition




EBZ GmbH Results from this script

Step 25 finished




Step 9

Step 12 Step 15

EBZ GmbH

Thank you for your attention and visit us here on the Hannovermesse 2010, booth J47

Contact

Contact Us




EBZ Entwicklungs- und Vertriebsgesellschaft Brennstoffzelle GmbH

Marschnerstr. 26

01307 Dresden

Tel. +49 (0) 351 47939-0

Fax +49 (0) 351 47939-18

E-mail [email protected]

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Automated testing of SOFC stack hotboxes · WELCOME to our presentation at the Hannovermesse 2010....

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