Delphi SOFC Development Update

Steven ShafferChief Engineer – Fuel Cell Development

Pittsburgh, PA2008 SECA Annual Review Meeting

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OutlineCell and Stack DevelopmentReformer DevelopmentBalance of Plant DevelopmentSystems Development Programs Leveraging SECA Activities

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SOFC Subsystem DevelopmentCells and Stacks

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Electrolyte: 8 mol. YSZ (~10 µm)

Active Anode: NiO – YSZ (~10 µm)

Bulk Anode: NiO – YSZ (~500 µm)

Interlayer: Ceria Based Layer (~4 µm)

Cathode: LSCF (~30 µm)

Anode Supported Cell MicrostructureDelphi is fabricating anode supported cells with LSCF cathodeCurrent footprint is 140mm x 98mm (active area 105 sq cm)A typical microstructure is shown below

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Manufacturing System Development

Process Flow Diagram (PFD)

Product Definition:

Process Definition:

Failure Mode Analysis:PFMEA

Control Strategy:Process Control Plan,Error proofing

Technical Requirements:

Manufacturing:Process Monitoring,Standard Cell & EOP, Layered Audit

Process Flow DiagramPrioritized RPN PFMEAProcess Control PlanWork InstructionsProcess Monitoring FormBuild DatabaseStandard Cell DocumentationGate Charts

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Large Footprint Cell Fabrication

350 cm2 active area

105 cm2 active area

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Generation 3 StackKey Features

Key Stack characteristics– Cassette repeating unit configuration – High volume manufacturable processes (stamping, laser-welding, etc)– Integrated manifold and compact load frame– Low mass and volume

Cassette

Separator plate

Picture frame

Cassette

Separator plate

Picture frame

Generation 3 (30 cell),9 Kg, 2.5 L

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Cassette Variation in a 30-Cell StackConsistent performance between cassettes in a 30-cell stack

Voltage difference between best and worst cassette is 0.05V or lessAchieved by application of high volume manufacturing process control methods

Polarization Test Stack Cell Voltages

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Polarization Test Stack Cell Voltages at 60 Amps

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Generation 3 30-Cell Stack Data

Stack Voltage and Power Density for Polarization Test

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Data shows a typical 30-cell Gen 3 stack tested in the stack laboratory furnace

Power: 1.44 kW (450 mW/cm2) @ 60A (570 mA per cm2), 24.6 V (0.82V / cell avg), fuel 48.5% H2 (3% H2O, rest N2), 750oC

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Generation 3 Stack Recent Improvements

Stack Voltage and Power Density for Polarization Test

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Interconnect developmentData for a 30-cell Generation 3 stack tested in a stack laboratory furnaceDemonstrated 1.8kW (570 mW/cm2) @ 75A (0.71 mA/cm2), 24.5V (0.82 V / cell), fuel 48.5% H2 (3% H2O, rest N2), 750oC (800oC avg stack internal temp)Demonstrated comparable thermal cycling capability and stability

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Generation 3 Stack Recent ImprovementsImprovements to cathode material

Data for a 5-cell Generation 3 stack tested in a stack laboratory furnaceDemonstrated 725 mW/cm2 @ 0.80V / cell (48.5% H2, 3% H2O, rest N2), 750oCCurrently evaluating thermal cycling capability and stability – results to date comparable to current cathode material set

Stack Voltage and Power Density for Polarization Test

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Thermal Cycling of Stacks

Stable thermal cycling performance demonstratedData shown for 30-cell stack, 2 hour heat-upRobust interconnect system and cellsMechanical integrity with improved seal technology

Thermal Cycling of 30-cell Stack

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TC10, 0%H2O

TC4 @ 51Amps

all other cycles, 3%H2O

Anode Cathode CrossoverInitial 47.0 27.0 0.0

TC5 40.0 36.0 0.0

TC10 26.0 13.0 0.0

TC15 39.0 26.0 0.0

TC20 52.0 32.0 0.0

TC25 48.0 40.0 0.0

Thermal Cycle Leak Data Leak (SCCM)Cycle

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Next Generation Single Cell Repeating Unit

Gen3.2 Next Generation Cassette

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SOFC Subsystem DevelopmentReformer

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Fuel Reformer DevelopmentDelphi is developing reforming technology for Natural Gas, Gasoline and Diesel/JP-8 for SOFC applicationsTwo main designs are being developed:

– CPOx Reformer» Moderate efficiency» Simplicity of design» Not recycle capable

– Recycle Based (Endothermic) Reformer

» High efficiency » Use of water in anode tailgas

to accommodate steam reforming

» Recycle capable

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Reformer Recycle Flow

Vaporizer

GPC(startup)

Stack

REF

COMB

GPC - (run combustor)

Tailgas

Air

Elec. pwr Hot air

Tailgas (ATG)Recycle

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Tubular Endothermic Fuel Reformer

Reformate Out

Anode Tailgas Fuel

Cathode Tailgas Air

Recycle

Fuel

Ref A

ir

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Concept A1 Concept B1

Concept C1 Concept D1

Reactor Modeling -Temperature

Lower delP

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SOFC Subsystem DevelopmentBalance of Plant

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Process Air• Current Blower and

Manifold Asm. • New Process Air Blower

by R & D Dynamics

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Anode Tail Gas Recycle Pump• Current Recycle Pump • New Recycle Pump by

R & D Dynamics

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High Temperature Insulation• Thermal Insulation

– Currently using micro-porous insulation – Insulation is metal wrapped using standard manufacturing process

Integrated Component Manifold

Insulation Shell

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Diesel Fuel Survey ResultsSummer 2007 – Sulfur Levels

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Source: Alliance of Automobile Manufacturers (US and Canada, 160 samples)

Current 2007 ULSD Spec.

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Delphi Solid Oxide Fuel CellsHot Reformate De-Sulfurization

• Hot Reformate De-Sulfurization Development– Remove H2S to levels below 10 ppbv (parts per billion volume) from an

input of 2.5 ppmv (parts per million volume)» Sulfur acts as a poison to SOFC

– Operate from ambient start up conditions to 800ºC– Maximize operation time between sorbent exchanges– Minimize device volume and operation pressure drop

<2.5 ppmv Sulfur

ReformerReformate

Desulfurizer SOFC Stack

Fuel<15 ppmw

Sulfur<10 ppbv

Sulfur

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Delphi Solid Oxide Fuel CellsHot Reformate De-Sulfurization

• A non-regenerating sorbent has been selected that:

– Meets maximum 10 ppbv output– Meets operating temperature

requirements– Capacity is such that a bed

operates for at least 6 months prior to requiring bed exchange

– System pressure drop requirements were met at full system reformate flow

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SOFC Power System Development

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Delphi Solid Oxide Fuel Cells Diesel SOFC Powerplant

2 x 30 Gen 3.1 SOFC Stacks

System Exhaust

CPOx Diesel Reformer

Insulation ShellRecycle Pump

Diesel Fuel Injectors

Process Air Module (PAM)

Reformer air metering system

Cathode Air Heat Exchanger (CHEX)

Fuel Input

Application Interface Module (AIM)

Air Inlet

Outer Enclosure

• Additions to Natural Gas System for Diesel Capability (no sulfur):

• Diesel fuel vaporizer• Electric start vaporizer• Carrier air pump• Carrier air control manifold• Injection air controller• Check valve assembly• Fuel pump and filter asm

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Diesel SOFC Powerplant

SPU 1E Diesel SOFC Powerplant

Diesel Fuel Tanks

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Delphi Solid Oxide Fuel Cells Truck Technology Demo Enhancements

SPU 1E Powerplant (79 Liters)Q4-2007

31 in long x 15.8 in wide x 9.8 in tall

Demonstrator Chassis (362 Liters)Q1-2008

1.25 kW / 16% Efficiency (No Sulfur Diesel)39 in long x 21 in wide x 27 in tall

• Additions for Truck Demonstrator:

• Truck output power converter• Truck input power converter• AC input power converter• Power interface controller• Truck mounting frame and

enclosure with vibration isolators

• Electronics housing with vibration isolators

• Reducing gas supply asm and controller

• User interface panel• Remote user interface head• Wireless remote PC

monitoring system

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Class 8 Truck Diesel System Demonstrator

Electronics Tray

SPU 1E Powerplant

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APU Load Profile Implementation

• Simulates Morning, Afternoon, and Evening loads

– Food & Entertainment– HVAC system– MISC AC power loads

• Utilizes battery for load spikes, while subsequently charging

• Approximate sharing rate 50W/s with room for improvement

• Electronics & Software developed internally with off-the-shelf hardware

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Delphi Diesel SOFC Systems

SPU 1E Powerplant (79 Liters)Q4-2007

1.25 kW / 14% Efficiency (No Sulfur Diesel)790 mm long x 400 mm wide x 250 mm tall

31 in long x 15.8 in wide x 9.8 in tall

Demonstrator Chassis (362 Liters)Q1-2008

1.25 kW / 14% Efficiency (No Sulfur Diesel)991 mm long x 533 mm wide x 686 mm tall

39 in long x 21 in wide x 27 in tall

DPS3000-D (244 Liters)Q1-2009

3.5 kW / 25% Efficiency (US07 Diesel)626 mm long x 549 mm wide x 676 mm tall

25 in long x 22 in wide x 27 in tall

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Diesel SOFC APU Conceptual Design

DPS3000-D626 mm long x 549 mm wide x 676 mm tall (244 Liters)

150 Kg

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Projected Performance Comparison

Revised based onPower density and single large active area stack

Diesel IC Gen Set

Diesel IC Gen Set vs. Delphi Diesel SOFC APU

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Programs Leveraging SECA Activities

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Government Programs Leveraging SECAHeavy Duty Truck Fuel Cell APU

Delphi has teamed with DOE EERE and OEM’s PACCAR Incorporated and Volvo Trucks North America (VTNA) to define system level requirements for a Fuel Cell (SOFC) based Auxiliary Power Unit (APU) for the commercial trucking industry operating on diesel fuel.

Volvo Trucks North America (VTNA), Greensboro, NC PACCAR, Mt. Vernon, WA

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Delphi Diesel SOFC APU Demonstrator Chassis

Accomplishments:•First operation of Delphi SOFC outside of a laboratory•First complete start-up on truck generator power•Automatic transition of truck loads to fuel cell system (truck engine off)•SOFC Fuel Cell System support of truck loads (860Wnet):

•HVAC Blower•Radio•Interior lights and dashboard lights•Headlamps & running lights•Windshield wipers•Battery charging•Fuel pump•12V cooler accessory

April 25th, 2008

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Delphi Diesel SOFC APU Peterbilt Demonstration

• 06/03/08: System start-up on truck power. 10 hour operation running approximately 800 W net (HVAC blower, radio, CB, dome light, battery pack).

• Specifications:– Fuel: “Zero Sulfur” diesel (1.2

ppmw S max)– Peak power 1300 W– Conditioned 12 Volt output– 39 in long x 21 in wide x 27 in tall– 600 lbs, – Start time: 3 hours

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Diesel SOFC System Operation on Class 8 Truck

Warm-up(Truck Running)

Cool-down(Truck Running)SOFC System Run (Truck Engine Off)

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Stack Testing at NUWC

Ref: Solid Oxide Fuel Cells for Undersea Naval Applications

10th Electrochemical Power Sources R&D Symposium

Alan Burke, Ph.D.; Louis G. Alan Burke, Ph.D.; Louis G. CarreiroCarreiro, Ph.D., Ph.D.

Naval Undersea Warfare Center (NUWC), Division NewportNaval Undersea Warfare Center (NUWC), Division Newport

Delphi, SECA (Dept. of Energy) and the Navy are collaborating for Solid Oxide Fuel Cell technology development for Undersea Naval applicationsA Delphi 10-cell stack developed under the SECA program was tested at the Naval Undersea Warfare Center (NUWC) under simulated conditions specific for this applicationStack produced very encouraging performance

Demonstrated excellent reproducibility during the offsite testDemonstrated and met power density requirement that was set for this specific application test (see next slide)Testing included performance evaluation with pure oxygen on the cathode side and actual reformate on the anode side

Next step is to test a stack at higher power levels

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SOFC Stack Performance Under Simulated UUV Operating Conditions (1 atm, 725º C)

Ref: Solid Oxide Fuel Cells for Undersea Naval Applications

10th Electrochemical Power Sources R&D Symposium

Alan Burke, Ph.D.; Louis G. Alan Burke, Ph.D.; Louis G. CarreiroCarreiro, Ph.D., Ph.D.

Naval Undersea Warfare Center (NUWC), Division NewportNaval Undersea Warfare Center (NUWC), Division Newport

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Model, VDelphi, VModel,PDelphi, P

Targeted Steady State operating point: 0.8 V/cell at 0.3 A/cm2

Model does not consider methane reformation at the cell surface, localized cooling from methane reforming could explain higher OCV & lower voltage at low current density

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Acknowledgements