© Fraunhofer IKTS

Materials and Manufacturing Technologies for Electrochemical Converters and Storage Devices

M. Kusnezoff, R. Weidl, C. Wunderlich, A. Michaelis

© Fraunhofer IKTS

Fraunhofer IKTS Figures

Dresden Gruna branch

Hermsdorf branch

Dresden Klotzsche branch

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Fraunhofer Center for Energy InnovationUCONN – IKTS Center in Advanced Energy Systems

Electrochemical Storage

Distributed Generation

Micro-grid

Conversion

Discovery Device Demonstration Deployment

Batteries and Energy Storage

Fuel Cells and Electrolyzers

Microgrid Engineering

Envrionmental Technologies

Novel functional materials for innovative

energy storage systems

Integration in renewable and grid support systems

Advanced electrochemical energy conversion systems

Enhanced electrical efficiancy

Minimal environmental impact

Cost effectivenes and suitability for global adoption

Fuel Cells

New materials for gas/ liquid separation membranes,

filtration and catalytic conversion

Manufacturing-Procedures for membranes and

catalysts

Process integration, chemical processing and

production of biofuels

Integration and validation of components and

subsystems in flexible microgrid architectures

Development of scalable and reliable electrical power

distribution and management

Dr. Prabhakar Singh

© Fraunhofer IKTS

MATERIALS ANDPROCESSES

MECHANICAL ANDAUTOMOTIVE ENGINEERING

ELECTRONICS ANDMICROSYSTEMS

ENERGYMATERIAL DIAGNOSTICS

SYSTEMS EXPERTISE

TECHNOLOGY EXPERTISE

MATERIALS EXPERTISE

MATERIAL AND PROCESSDIAGNOSTICS

ENVIRONMENTAL ANDPROCESS ENGINEERING

MEDICAL TECHNOLOGY

OPTICS

Fraunhofer IKTSBusiness Segments

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Fraunhofer IKTSEnergy and Environmental Technologies

Thermoelectric materialsEnergy harvesting (piezo ceramic)

Small low temperature fuel cells (PEFC)

High temperaturefuel cells

Lithium & Sodium batteries Photovoltaics

High temperature batteries

Metal air batteries

Gas reforming

Gas purification

Supercaps Bioenergy

© Fraunhofer IKTS

Fraunhofer IKTSElectrochemical Conversion and Storage Devices

Thermoelectric materialsEnergy harvesting (piezo ceramic)

Small low temperature fuel cells (PEFC)

High temperaturefuel cells

Lithium & Sodium batteries Photovoltaics

High temperature batteries

Metal air batteries

Gas reforming

Gas purification

Supercaps Bioenergy

© Fraunhofer IKTS

Electrochemical Conversion and Storage DevicesManufacturing Synergies

Material Synthesis and Processing

Coating of Electrodes Battery Cells AssemblingInitialization and Test of

Battery CellsSystem Integration, Power Management

Materials Synthesis andProcessing

Coating of CeramicElectrolyte

Assembling of StacksSealing ofSOFC Stacks

SOFC System integration, System Operation

Material Synthesis andProcessing

Manufacturing of Half Cells

Lamination of Electrodeswith Matrix

Initialization of MCFC Stacks

MCFC System Integration. System Operation

Batteries

SOFC Systems

MCFC Systems

IKTScore field

In development

Material Synthesis andProcessing

Coating of Electrodes Assembling of Supercaps Test of Supercaps System Integration

Supercaps

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Distributed Power Generation and Storage

Impact on Energy Infrastructure

High Temperature Fuel Cell Technology

Batteries

Summary

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ENERGYImpact on Energy InfrastructureFuel Cell: Direct and Reversed Conversion

© Fraunhofer IKTS

ENERGYImpact on Energy InfrastructureBattery: Energy Feed Optimizer

Home Users

~ 10 kWh

Energy feedoptimization

„Own electricity“

Always parallel to grid

D: ~ 5 GWh*

* 1.5 Mio PV-stations

Buffer (PV, Industry)

~ 100 … 500 kWh

Load balancing

Energy feed optimization

Local grid

Grid balancing, Wind

> 1 MWh

Peakshaving (rapid)

Load balancing

Blackout / Brownout

cosf-Compensation

D: ~ 35 GWh*

* 44 GW, 10% for 8 h duration

© Fraunhofer IKTS

ENERGYFuel cellsMarkets and Advantages

Applicationefficiencyfuel

CO2 reduction potentials

microCHP1-3 kW

ηel = 35…55%

natural gas grid Biogas in natural gas grid „Power-to-Gas“ strategy Highest efficiency technology

Remote power supply0.1-20 kW

ηel = 25…40%

LPG Bioethanol

100% Bioethanol in selected applications and markets

reduced fuel and fuel logistic cost

Industrial CHP20-2000 kW

ηel = 45…65%

Natural gas grid Biogas

Distributed generation On-site gasification from

biogeneous waste „Power-to-Gas“ strategy

High temperature fuel cells offer:

Significant reduction of energy cost by highest efficiencies

potentials for a CO2-neutral on site electricity generation

© Fraunhofer IKTS

DFC®

TechnologyIntegrated

Stack ModulePlanar

Mini-StackBundled

MicrotubesCeramic

Multilayer

Biogas

SOFC

Natural Gas

SOFC

LPG

SOFC

Butane

SOFC

Hydrogen

PEFC

eneramicby Fraunhofer

â

NG / Biogas

MCFC

CFY StackTechnology

10 kW1 kW100 W10 W1 W 1 MW

hand-held portable stationary

ENERGYFuel cellsApplication Examples

© Fraunhofer IKTS

Fuel cellsFrom Powder to Power

Production Planning, Pilot Manufacturing

• Design to Cost• Production Planning• Pilot Manufacturing

System Engineering and Demonstration

• Proof-of-Concept• System Prototypes• Safety Concept, CE

Customized Test-Rigsand Validation

• Customized Test-Rigs• Assembly, Commissio-

ning and Operation

CAD and Simulation

• System Concepts• 3-D CAD Drafting• Process Models • Component Models

Reactors and System Components

• Reformer, Burner, HEX• Membrane Reactors• Sensors

SOFC and SOECStacks

• CFY Mk35x, 10-40E• HotBox-Integration• Test & Characterization

Cell and Stack Components

• Electrodes, MEAs• Contact Layers• Glas Sealings

Materials andProcesses

• Powders, Pastes, Foils• Protective Coatings• Characterization

ENERGY

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Application-dependentinstallation

Scope of IKTSdevelopment

Fuel Cellsh2e: SOFC/Battery-Hybrid System for Indian Market

=

=

=

≠ =

~

SOFC

Stack

Ambient Air

Fuel

Desulf Reformer Burner

BoPDC/DC

Converter

Heat

Exchangers

Exhaust

Hot Water

Tank

Inverter

Charge

ControllerBattery

Public

Grid

Usable Heat

Electricity

End-User

Demand

1.0 .. 1.3 kWel

1.0 .. 1.6 kWth

SOFC-Gen I / h2e Power Generator

0.3 .. 3 kWel

20 .. 30 kWh / day

500 l / day

60 .. 80 °C

80 .. 125 MJ / day

(23 .. 35 kWh / day)

© Fraunhofer IKTS

G1 Prototype Testing and Process Optimization,Nov./Dec. 2014

G1 Prototype Commissioning in Pune, India,Dec. 2014

Controls Development and System Design Iteration,Jan. – Sept. 2015

G2 Prototype Commissioning at IKTS,Oct. 2015

h2e® G2 Prototype Demonstration in India,starting Dec. 2015

Fuel Cellsh2e Outline

© Fraunhofer IKTS

Batteries - Energy Storage DevicesIKTS portfolio

High-temperaturebatteries

Metal-air batteriesLi-Ion batteries

ENERGY

© Fraunhofer IKTS

Batteries - Energy Storage DevicesIKTS portfolio

High-temperaturebatteries

Metal-air batteriesLi-Ion batteries

ENERGY

© Fraunhofer IKTS

BatteriesNa-based High Temperature Battery

Outdated and congested energy grids

Demand for decentralized energy storage solutions

Accessibility of strategic resources

Growing share of renewable energies

Strong cyclical fluctuations

Cushion of load peaks

Cost reduction

Via optimized cell design andeconomical manufacturing methods

Development objectives

Performance

With new electrode material andsynthesis routes

Independance

From restricted raw materials

ENERGY

© Fraunhofer IKTS

BatteriesNa-ß-Al2O3 Manufacturing

Isostatic pressingcups

Dry compactionpellets

Extrusiontubes

e.g. 20 mm, wall thickness 1.5 mm,

height 25 mm

20 to30 mm,thickness 0.5 to 2 mm

20 to 60 mm, wall thickness 1.5 mm, length up

to 600 mm

Sintered dry compacted ß“ aluminate pellet of 1 mm in thickness

Sintered ß“ ceramics of different geometries

Extrusion of ß“ aluminate tubes

ENERGY

© Fraunhofer IKTS

BatteriesCell Manufacturing

Material synthesisand processing

Manufacturing

Characterization

Cell design

ENERGY

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SummaryR&D Service & Technology Transfer for SME & Industry

High temperature electrolysis and stationary fuel cells will play a keyrole in the transistion to renewable energy infrastructure and IKTS is a key partner understanding the technology from material to system

SOFC and MCFC fuel cell technology allows highest efficiency and is in transition to commercial products in three key markets

microCHP

off-grid power

CHP & distributed generation

Batteries are essential for hybridization of power generation units tooptimize the energy feed and stabilize the grid

Hight temperature sodium battery is a mature technology (alreadyused at nuclear power plants) and offers greatest potential for low coststationary storage systems

Cost is still a challenge…

© Fraunhofer IKTS

Commercial Business

Research

Product development

Production

Pro

du

ct

ide

as

SoP

Fraunhofer

Partner

Advance development

Technology development i.t.n.s.

Process development

Product & Business Definition, Marketing

SoP = start of production = interactions

Business Development

SummaryR&D Service & Technology Transfer for SME & Industry

Source: G. Schuh, S. Klappert (Hrsg.), Technologiemanagement, Springer 2011

Service partner in technology development

You can buy: Any part as needed The whole process Risk sharing model

© Fraunhofer IKTS

Vielen Dank für Ihre Aufmerksamkeit