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Fossil Energy Fuel Cell Program Wayne Surdoval, SECA Coordinator June 3, 2003 National Energy Technology Laboratory Office of Fossil Energy SECA Core Technology
Fossil Energy Fuel Cell Program
Wayne Surdoval, SECA CoordinatorJune 3, 2003
National Energy Technology LaboratoryOffice of Fossil Energy
SECA Core Technology
IAPG, GPPD-DWC 4/30/03
SECA CORE TECHNOLOGY PROGRAM
W. Nernst“Electrical Glow-Light”
U.S. Patent 623,811April 25, 1899
CC
IAPG, GPPD-DWC 4/30/03
SECA SECA Program Structure
Program Management
ResearchTopicsNeeds
Industry Integration TeamsTechnology
Transfer
Small BusinessUniversity National
LabIndustry
PowerElectronicsModeling &Simulation
Materials
Controls &Diagnostics
FuelProcessing
FuelProcessing
Manufacturing
Modeling &Simulation
PowerElectronics
Controls &Diagnostics
Manufacturing
Materials
Core Technology Program
Fuel CellCore
Technology
Project Management
Industry Input
IAPG, GPPD-DWC 4/30/03
Core Technology Program Powering All Ships
SiemensWestinghouse
SiemensWestinghouse
DelphiDelphiGeneralElectricGeneralElectric
FuelCellEnergy
FuelCellEnergy
AcumentricsAcumentrics
Cummins PowerGeneration
Cummins PowerGeneration
• Materials• Modeling and simulation• Fuel processing
• Power electronics• Controls and diagnostics• Manufacturing
IAPG, GPPD-DWC 4/30/03
Intellectual PropertyIntellectual PropertyCornerstone of the AllianceCornerstone of the Alliance
• Non-Exclusive License
- Open for 1 year after issue of a U.S. patent
- Ready market of potential licensees
- Best designs vs. highest bidder
- Dispute Resolution Mechanism
• Promotes Collaboration - Limits Duplication• Pilot program; reevaluate after 2 years
CTP Industry Teams
IAPG, GPPD-DWC 4/30/03
Solid Oxide Fuel Cell
OxidantFlow
FuelFlow
OxidantFlow
End Plate
CathodeElectrolyte Matrix
Anode
BipolarPlate
CathodeElectrolyte Matrix
Anode
End Plate
FuelFlow
Current Flow
Fuel Flow
Anode
Interconnection
Electrolyte
Cathode
Air flow
IAPG, GPPD-DWC 4/30/03
The Vision: Fuel Cells in 2010
Cost
Volume
Low Cost/High VolumeLow Cost/High Volume$400/kW > 50,000 units/yr$400/kW > 50,000 units/yr
IAPG, GPPD-DWC 4/30/03
Different Approaches!
• Stack extrusion• Plasma spray
• Cathode supported• 800 C• Redesigned tubular• Seal-less stack
SiemensWestinghouse
• Tape calendering• 2–stage sintering
• Anode supported • 750 C• Hybrid compatible• Internal reforming
General Electric Company
• Tape casting• Screen printing• 2–stage sintering
• Anode supported • 750 C • Ultra compact• Rapid transient capability
Delphi-Battelle
• Tape casting • Screen printing• Co-sintering
• Electrolyte supported• 850 C• Thermally matched materials• Seal-less stack
Cummins-SOFCo
ManufacturingDesignTeam
IAPG, GPPD-DWC 4/30/03
Two New Different Approaches!
• Tape casting• Screen printing• Co-sintering• Electrostatic
deposition
• Anode supported • < 700 C • Low cost metals
FuelCellEnergy, Inc.
• Extrusion• Dip processing• Spray deposition
• Anode supported microtube• 750 C• Thermally matched materials• Robust & rapid start-up
AcumentricsCorporation
ManufacturingDesignTeam
IAPG, GPPD-DWC 4/30/03
SOFC Materials Costs
IAPG, GPPD-DWC 4/30/03
Current Priorities: Core Technology Program
• Lower cost precursor processing • Cost model methodology
Material cost4
• Direct DC to AC conversion• DC to DC design for fuel cells
Powerelectronics
3
• Metal oxides with interface modification• Catalyst surface modification• Characterize thermodynamics/kinetics
Anode/fuel processing
2
• Micro structure optimization• Mixed conduction• Interface modification
Cathodeperformance
2
• Models with electrochemistry• Structural characterization
Modeling2
• Modifying components in alloys• Coatings
Interconnect1• Glass and compressive seals Gas seals1
IAPG, GPPD-DWC 4/30/03
SECA Budget ($M)
0
5
10
15
20
25
30
35
2000 2001 2002 2003
Industry TeamsCore Technology Program
IAPG, GPPD-DWC 4/30/03
Core Technology Program FY 2003
$4,648,150
$2,399,963
$533,987
$150,000
$2,467,900
$500,000
Materials
Fuel Processing
Manufacturing
Sensors andDiagnosticsModeling andSimulationPowerElectronics
IAPG, GPPD-DWC 4/30/03
Stack Technology – Seals & Cross CuttingPNNL – Seals, Modeling and Analysis, Cathodes, Anodes, Interconnects, Fuel Processing
LBNL – Metallic supported cell structure, Cathode interface modification
ANL – Metallic supported cell structure, Interconnects, Fuel Processing
OxidantFlow
FuelFlow
OxidantFlow
End PlateCathodeElectrolyte MatrAnode
BipolarPlate
CathodeElectrolyteAnodeEnd Plate
FuelFlow
Current Flow
IAPG, GPPD-DWC 4/30/03
Materials - Interconnects
Develop low temperature interconnect suitable for SOFC
• U. of Pittsburgh• Ceramatec• Southwest Research Institute• PNNL• ANL
Thin foil Interconnect
SealCell
Spacer
Images courtesy of Delphi
IAPG, GPPD-DWC 4/30/03
Modeling and Simulation
Structural, performance, and optimization design tools• PNNL• NETL• ORNL• U. of Florida • Georgia Tech• TIAX
Image courtesy of PNNL
Image courtesy of Delphi
Image courtesy of Delphi
Image courtesy of NETL
IAPG, GPPD-DWC 4/30/03
Materials - CathodesCathode performance – 2x improvement
• U. of Washington • U. of Missouri Rolla • U. of Utah• Functional Coating, LLC • Georgia Tech• PNNL
Images courtesy of NexTech
IAPG, GPPD-DWC 4/30/03
Fuel Processing and Anode Tolerance
Tubular cPox Reformer
Carbon and sulfur resistant anodes
• Northwestern • GTI
Carbon and sulfur resistant reforming catalysts
• LANL • ANL• NETL
Image courtesy of Delphi
IAPG, GPPD-DWC 4/30/03
Power Electronics / Controls & Diagnostics Interaction between fuel cell, power conditioning system and application loads
• U. of Illinois
DC-DC / DC-AC converters• Texas A&M • Virginia Polytechnic Institute
High Temperature Sensors• NexTech Materials
IAPG, GPPD-DWC 4/30/03
Manufacturing
Low cost and consistent precursor materials
• NexTech Materials • U. of Utah
Supportelectrode
Supportelectrode
Bilayer
Thin electrolyte onsupport electrode
layerElectrolyte
TAPE FORMING ROLLINGROLLINGImage courtesy of HoneywellTAPE CALENDERING
