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Development Update on Delphi’s Solid Oxide Fuel Cell System Steven Shaffer Chief Engineer, Fuel Cells Pacific Grove, CA 2005 SECA Review Meeting
Development Update on Delphi’s Solid Oxide Fuel Cell System
Steven ShafferChief Engineer, Fuel Cells
Pacific Grove, CA2005 SECA Review Meeting
April 20, 2005 2
Solid Oxide Fuel Cell Potential Markets
Automotive APU
Heavy Duty Truck APU to eliminate long term idling or
EPU as part of Electric Truck Architecture
Military uses are similar to that in mobile applications with
modifications for High Sulfur fuels: JP8
Commercial Power Units
Residential Power Units with Combined Heat and Power.
April 20, 2005 3
Market Overview
STATIONARY SYSTEMS
Efficiency
Continuous operation/long life
Fuels: Natural gas, Coal based syngas
TRANSPORTATION SYSTEMS
Compact size and low mass
On-Off Cycling
Fast start-up time
Fuels : Gasoline, Diesel, JP-8
Market Drivers
April 20, 2005 4
Project Overview
Program: Solid Oxide Fuel Cell (SOFC) for Auxiliary Power in Heavy Duty Vehicle Applications
– Program Objective: To demonstrate, in a laboratory environment, a SOFC APU capable of operating on low sulfur diesel fuel, for the Commercial Trucking Industry
Sponsor: U.S. DOE – Hydrogen, Fuel Cells and Infrastructure Technologies
Project Duration: 48 months
Leverage Delphi’s technology development and investment in SOFC technologies to meet APU commercial trucking application requirements
April 20, 2005 5
DOE-Delphi APU Industry Collaboration
Delphi has teamed with 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. Delphi has enlisted Electricore to provide administrative assistance.
PACCAR, Mt. Vernon, WAVolvo Trucks North America (VTNA),
Greensboro, NC
April 20, 2005 6
Project Overview
Bradley
Stryker
Abrams
Program: Fuel Cell Based Ground Vehicle APU’s Sponsor: TACOMTechnology program to support development of SOFC APU’s for military vehicle usage in “Silent Watch” modeFocus of the program is development and laboratory demonstration of a reformer operation on JP-8 world-wide logistic fuelTACOM/TARDEC’s primary interest is in three Military Ground Vehicles: – Bradley – Stryker – Abrams
April 20, 2005 7
Delphi SOFC APU Development Progression
APU development progression from the Proof Of Concept unit to a Generation 3 APU design that will be the building block for the transportation markets
Generation 3SOFC APU
Generation 1 SOFC APU
Generation 2SOFC APU
63 Liters70 kg155 Liters
204 kg70 Liters
70 kg
20052000 2002-2004
April 20, 2005 8
Outline
IntroductionStack DevelopmentFuel Reformer DevelopmentBalance of Plant DevelopmentElectronics and Controls DevelopmentSystem Integration and TestingSummary and Conclusion
April 20, 2005 9
Stack IntroductionDelphi is developing SOFC stack technology for transportation and stationary marketsDelphi is working with Battelle- Pacific Northwest National Laboratory (PNNL) for the development of the SOFC technology under DOE’s SECA programThe development history from Delphi’s Generation 2 stacks to the current Generation 3.1 stack sub-system is shown below
Generation 2 (2x15-cell), >20 Kg, 6 L2002 - 2003
Generation 3 (30-cell),13 Kg, 3.5 L
2004
Generation 3.1 (30 cell),9 Kg, 2.5 L
2005
April 20, 2005 10
Generation 3.1 Stack Cell Characteristics
Delphi is developing and fabricating its own SOFC cell with the characteristic electrode-electrolyte layers shown below Cell fabrication includes tape-casting, screen-printing and sintering processesCurrent focus is on process development and capital investment for increasing the volumes of cell manufacturing to pilot line levels
LSCF Cathode
Doped Ceria
YSZelectrolyte
Ni-YSZAnode
April 20, 2005 11
Button cell testing demonstrated the effect of Cr (in vapor phase) in degradation of cathodeImproved interconnects are being developed to overcome this degradation in the stack
Generation 3.1 Stack Cell Characteristics
200
300
400
500
600
700
800
0 10 20 30 40 50 60 70 80 90 100
Time (Hours)
Spec
ific
Pow
er (m
W/c
m2 )
Cr containing alloy
Baseline Cr-free Test
Improved IC #3
Improved IC # 1Improved IC # 2
April 20, 2005 12
Button cell testing of current cell configuration demonstrated no degradation for greater than 2000 hours (48.5% H2, 3% H2O, rest N2, 750oC)
Generation 3.1 Stack Cell Characteristics
700
800
900
0
100
200
300
400
500
600
0 200 400 600 800 1000 1200 1400 1600 1800 2000Time (Hours)
Spec
ific
Pow
er (m
W/c
m^2
)
ButtonCell
April 20, 2005 13
Generation 3.1 StackKey Design Features
The new Generation 3.1 stack has evolutionary improvements over Delphi’s Generation 3.0 stack design Key Generation 3.1 stack characteristics– Co-flow cassette configuration– Integrated manifold– Compact load frame– Improved interconnect – Low mass– Low volume – Improved manufacturability of stack sub-system
Picture frame
Separatorplate
April 20, 2005 14
Generation 3.1 Stack 30-Cell Stack
Generation 3.1 30-cell stack (2.5 liter, 9 Kg)
30-cell stacks of Generation 3.1 design have been successfully fabricated and tested30-cell modules are the building blocks for Delphi’s power systemsCurrently being tested in the system
April 20, 2005 15
Generation 3.1 Stack 30-Cell Stack Data
Power – Data below shows a 30-cell Generation 3.1 stack producing 1821 Watts at 21 Volts
(0.7 Volts/cell) with 48.5% H2, 3% H2O, rest N2 simulated reformate (power density of 578 mW/cm2, 42% fuel utilization)
0
5
10
15
20
25
30
35
0 20 40 60 80 100Current (Amps)
Volta
ge (V
olts
)
0
200
400
600
800
1000
1200
1400
1600
1800
2000
Pow
er (W
atts
)
April 20, 2005 16
Generation 3.1 StackThermal Cycling
0
100
200
300
400
500
600
700
0 1 2 3 4 5 6Thermal Cycle #
Pow
er D
ensi
ty (m
W/c
m^2
)
Power Density (mW/cm2) @ 0.7Volts/cell , 48.5% H2, 3% H2O, restN2
Thermal Cycling– Data below shows a 10-cell Gen 3.1 stack showing no degradation in power after 5
thermal cycles» 90 minute heat-up in a furnace (limited by fastest possible heat-up rate of the
furnace)
April 20, 2005 17
Generation 3.1 Stack Continuous Durability
Continuous Durability– Data below shows a 5-cell stack showing <10% degradation in 2400 hours (constant
current of 32 Amperes) – test stopped intentionally due to facilities shutdown» Minimal degradation in the last 1000 hours (~1%)
0.00
50.00
100.00
150.00
200.00
250.00
300.00
0 500 1000 1500 2000 2500Time (Hours)
Pow
er D
ensi
ty (m
W/c
m2)
2400 hours
April 20, 2005 18
Generation 3.1 Stack Fuel Utilization
Fuel Utilization– Data below shows a utilization curve of a Generation 3 single cell on 48.5% H2, 3% H2O,
and balance N2
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00%
Fuel Utilization (%)
Pow
er D
ensi
ty (W
/cm
²)
April 20, 2005 19
Stack SummaryKey progress has been made in stack technology to meet SECA and eventually production targets
Stack Metrics
Performance Demonstrated
(March 05)
Power*
1800 Watts (580 mW/cm2)
Mass (30-cell stack)
9 Kg (including load frame & base
manifold)
Volume (30-cell stack)
2.5 liters (including load frame & base
manifold)
Continuous Durability
> 2400 hours
Thermal Cycles > 5 cycles (furnace)
Start-up time 75 minutes (system) *, 48.5% H2, 3% H2O, rest N2 @ 0.7 V/cell, @ 42% FU
April 20, 2005 20
Outline
IntroductionStack DevelopmentFuel Reformer DevelopmentBalance of Plant DevelopmentElectronics and Controls DevelopmentSystem Integration and TestingSummary and Conclusion
April 20, 2005 21
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» No recycle
– Endothermic Reformer» High efficiency» Use of water for endothermic
reaction» Efficient thermal management» Recycle capable
April 20, 2005 22
Gasoline CPOx ReformerDevelopment Status
Reformer Efficiency– No short term issues
(>78% efficiency)Reformate Quality
– Meeting requirementsCarbon Avoidance
– Several refinements in design and controls
Durability– Demonstrated to 100 hrs
Start Time– <3 min start demonstrated
Gasoline CPOx Reformer Assembly
April 20, 2005 23
Natural Gas CPOx ReformerDevelopment Status
Reformer Efficiency– POx mode > 84%
Reformate Quality– Meeting requirements
Carbon Avoidance– under study
Durability– Demonstrated to 310 hrs
Start Time– < 3 min start demonstrated
Natural Gas CPOx Reformer Assembly
April 20, 2005 24
Natural Gas CPOxComposition over Turndown on Methane
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0% 20% 40% 60% 80% 100% 120% 140% 160% 180% 200%Percentage of Rated Power
Mol
e Pe
rcen
t (CH
4, C
O2,
H2O
)
0
5
10
15
20
25
30
35
40
Mol
e Pe
rcen
t (CO
, H2)
CH4 TestCO2 TestH2O TestCO TestH2 Test
Idle Max Power
Operating Range
April 20, 2005 25
Natural Gas CPOx ReformerDurability on Methane
Durability test on reformer showing encouraging results– 300 hours test data shown below
April 20, 2005 26
Endothermic ReformerDevelopment Status
Gains in reformer efficiency over CPOx achieved
– Gross Reforming efficiency > 120 % (accounting for LHV of liquid fuel only in the input in an anoderecycle mechanism for endothermic reforming)
Consistent reformate quality demonstrated
– Methane less than 1%– Higher hydrocarbons less than 0.1%
Improved thermal management features incorporated
– Lower mass design– New combustor design– Reduced package size
Endothermic Planar Reformer
April 20, 2005 27
CPOx / Endothermic ReformingTest Results - Summary
Units NGCPOx Reformer
NGEndothermic
ReactorSingle Planar
GasolineCPOx Reformer
GasolineEndothermic
Reformer
Fuel - Methane Methane CARBPh2Gasoline
CARBPh2Gasoline
H2 mol % 32.7 33.0 21.0 29.9
CO mol % 15.5 17.3 22.2 27.2
CH4 mol % 0.32 0.59 0.58 0.53
HC's > C2 mol % 0.02 un-detectable 0.06 0.08
Gross Reforming Efficiency
w/ CH4
% 85 137 80 122
April 20, 2005 28
Outline
IntroductionStack DevelopmentFuel Reformer DevelopmentBalance of Plant DevelopmentElectronics and Controls Development System Integration and TestingSummary and Conclusion
April 20, 2005 29
Balance of Plant DevelopmentDevelopment of all required Balance of Plant components based on system requirementsSOFC Balance of Plant components based on automotive industry components and automotive industry manufacturing include:
– Fuel injection system (fuel fittings, fuel injector, fuel line)
– Air meters– Flow control valves– Electronic Control Unit– Heat exchangers– Air filtration– Cathode tubes
Air Meters
Heat Exchangers
Fuel Metering
Cathode Air Tubes
April 20, 2005 30
Balance of Plant Development
Custom developed hardware
Air Delivery System
Anode Recycle Pump
Integrated Component Manifold
Hot Zone Insulation
April 20, 2005 31
Outline
IntroductionStack DevelopmentFuel Reformer DevelopmentBalance of Plant DevelopmentElectronics and Controls DevelopmentSystem Integration and TestingSummary and Conclusion
April 20, 2005 32
Electronics and Controls Development
Electrical Architectures– Transportation Auxiliary Power Unit– Stationary Power Unit
Power Electronics– Auxiliary Power Unit (APU)
» DCDC Converters– Stationary Power Unit (SPU)
» DCAC Inverter» DCDC Converters
– 3000 kVA AC Load Bank
Power and Signal Distribution– Bussed Electrical Center (BEC)– System wiring harness
» Power harness» Signal harness
Control– Hardware Design Update – Rapid Algorithm Development– Flexible System Control Algorithm/Software
April 20, 2005 33
State-of-the-Art Development
– Entire model is auto-coded– Two OSEK-compliant operating
systems– CAN Communication– Flash over CAN capable
Size and Complexity– Large/Complex algorithm set– High input/output count– 436K Code, 125K Calibration
Savings – MicroAutoBox– Signal conditioning– $20k savings per system– No software engineer
Development Speed– Algorithm modifications to code
and test(< 30 minutes)
AutocodeGeneration
Compile and loadInto Delphi Controller
Subsystem Verification, Validation, Integration and System Test
SOFC APU SystemSOFC HardwareEmulation Test Bench
Control Algorithms& Plant Model
(Simulink)
Virtually Test & Tune Algorithm
SOFC Hardware Simulator or OPAL RT Testdrive HIL System
Real-Time “C” Code
(Embedded Coder)
SOFC System Control Development: Rapid Algorithm Development Process
April 20, 2005 34
Outline
IntroductionStack DevelopmentFuel Reformer DevelopmentBalance of Plant DevelopmentElectronics and Controls DevelopmentSystem Integration and TestingSummary and Conclusion
April 20, 2005 35
Generation 3 System SECA Test Profile Targets
SPU 1B Off-Peak System Characteristics
41.3%
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
35.0%
40.0%
45.0%
0% 20%
40%
50%
60%
80%
100%
% of Maximum Electrical Load
Fuel
-to-N
et-E
lect
ric E
ffici
ency
0.00
0.05
0.10
0.15
0.20
0.250.0 0.6 1.2 1.5 1.8 2.4 3.0
System Net Power, kW
Fuel
Con
sum
ptio
n, g
/sec A : Rated Power, 3
kW Minimum
B : Nominal Operating Condition (NOC):Peak System Efficiency: Min 35%
A
B
Delphi’s Generation 3 System will be operated at the rated conditions shown below to meet SECA’s Phase 1 targets
April 20, 2005 36
Generation 3 SOFC System
Hot ExhaustAir Inlet
DC Power Output
Generation 3 System63 Liters, 70 Kg
April 20, 2005 37
Generation 3 SOFC System
Hot Zone Module
Application Interface Module
Plant Support
Module
April 20, 2005 38
Generation 3 SOFC System
2x30-cell SOFC Stacks
CPOx Natural
Gas Reformer
Cathode Air
Heat Exchanger
April 20, 2005 39
Generation 3 SOFC System TestFrom Methane to Electric PowerFrom Methane to Electric Power
First test of Generation 3 First test of Generation 3 System completed System completed
–– Methane fuel Methane fuel –– 2x30 cell Gen 3.1 stacks2x30 cell Gen 3.1 stacks–– CPOxCPOx reformerreformer
Test demonstratedTest demonstrated–– Automated StartAutomated Start--upup–– Good quality Good quality CPOxCPOx reformate reformate –– 1500 Watts net power (1931 1500 Watts net power (1931
Watts stack gross power)Watts stack gross power)–– 3 Thermal Cycles3 Thermal Cycles
Next StepsNext Steps–– Durability testing and Durability testing and
validation per SECA profilevalidation per SECA profile
April 20, 2005 40
Summary and Conclusions
A “Generation 3 SOFC System” has been demonstrated and is currently being tested with methane fuelKey sub-systems have been developed and successfully integrated into the Generation 3 system
– Generation 3.1 stack sub-system with 30-cell stacks – Natural Gas CPOx reformer– Balance of Plant and Power Electronics
Current focus is to demonstrate the Generation 3 system to SECA targetsFurther advanced development is focused on improving performanceand reducing life cycle cost:
– Continuous durability, improved efficiency, thermal cycling – Fast start-up (for transportation applications)
Delphi is committed to working with DOE and its partners to bring this novel technology to market
April 20, 2005 41
Acknowledgements
Fuel Cell Tech Team
