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SOFC Seals: SECA CTP Seal Meeting OverviewSOFC Seals: SECA CTP Seal Meeting Overview(Meeting held at Sandia National Laboratory, July 8-9, 2003)
NETL PNNLWayne Surdoval Prabhakar SinghDon Collins Jeff StevensonLane Wilson Moe Khaleel
Presented at SECA Core Technology Meeting, Albany, NYSept 30-Oct.1, 2003
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Acknowledgements
•We thank Sandia National Laboratory, specially Drs. Ron Loehman and Bill Hammeter for hosting the SECA-CTP seal meeting. We also thank other staff at Sandia for sharing information about their capabilities with meeting participants.
• We thank Kevin Moore for facilitation at the meeting.
•We thank Sandia National Laboratory, specially Drs. Ron Loehman and Bill Hammeter for hosting the SECA-CTP seal meeting. We also thank other staff at Sandia for sharing information about their capabilities with meeting participants.
• We thank Kevin Moore for facilitation at the meeting.
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Industries Universities Govt.Agencies National Labs
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Industries Universities Govt.Agencies National Labs
Participants
NAME AFFILIATION PHONE EMAIL ADDRESSBill Hammetter Sandia Nat'l Labs 505) 272-7603 [email protected] Surdoval DOE/NETL (412) 386-6002 [email protected] Singh PNNL (509) 375-5945 [email protected] Moore DOE/NETL (304) 594-1450 [email protected] Qu Georgia Tech (404) 894-5687 [email protected] Seabaugh NexTech Materials (614) 842-6606 [email protected] Singer DOE/Science (202) 586-4336 [email protected] Veyo Siemens Westinghouse (412) 256-1901 [email protected] Singh Univ. of Cincinnati (513) 556-5172 [email protected] Minh GE Power Systems (310) 538-7250 [email protected] Steinetz NASA Glenn (216) 433-3302 [email protected] Krumpelt Argonne Nat'l Lab (630) 252-8520 [email protected] Loehman Sandia Nat'l Labs (505) 272-7601 [email protected]. Elangovan Ceramatec, Inc. (801) 978-2162 [email protected] Lewinsohn Ceramatec. Inc. (801) 956-1001 [email protected] Stevenson PNNL (509) 372-4697 [email protected] Brow Univ. Missouri-Rolla (573) 341-6812 [email protected] A. Khaleel PNNL (509) 375-2438 [email protected] V. Virkar MSRS/Univ. of Utah (801) 581-5396 [email protected] P. Bansal NASA Glenn Res. Ctr. (216) 433-3855 [email protected] C. Williams NETL – DOE (304) 285-4747 [email protected] Collins NETL - DOE (304) 285-4156 [email protected] Santella Oak Ridge Nat'l Lab (865) 574-4805 [email protected] Patel Fuel Cell Energy (203) 825-6072 [email protected] Wilson NETL - DOE (304) 285-1336 [email protected] Lashway Ceramatec (801) 978-2154 [email protected] Dunning DOE/Albany Res. Ctr. (541) 967-5876 [email protected] Glass Sandia Nat'l Labs (505) 845-8050 [email protected] Burchett Sandia Nat'l Labs (505) 844-6446 [email protected]
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Outline
! SECA CTP Priorities ! Seal Meeting Objectives! Accomplishments! Workshop Presentations! Group Discussions and Story Board! Path Forward
! SECA CTP Priorities ! Seal Meeting Objectives! Accomplishments! Workshop Presentations! Group Discussions and Story Board! Path Forward
SECA 4/15/03
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
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• Metal oxides with interface modification• Catalyst surface modification• Characterize thermodynamics/kinetics
Anode/fuel processing
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• Micro structure optimization• Mixed conduction• Interface modification
Cathodeperformance
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• Models with electrochemistry• Structural characterization
Modeling2
• Modifying components in alloys• Coatings
Interconnect1• Glass and compressive seals Gas seals1
HowWhat
" Rita Bajura, SECA Annual Meeting, Seattle 2003
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Objective" Review SOFC sealing issues and requirements" Present current status of SOFC sealing technology
"Seal materials"Materials interactions "Failure processes
" Identify "Advance concepts"Designs and development approaches
"" Review SOFC sealing issues and requirementsReview SOFC sealing issues and requirements"" Present current status of SOFC sealing technologyPresent current status of SOFC sealing technology
"Seal materials"Materials interactions "Failure processes
" Identify Identify "Advance concepts"Designs and development approaches
Develop group consensus on promising R&D concepts / directionsDevelop group consensus on promising R&D concepts / directions
Utilize information for scoping and coordination of SECA-SOFC sealing activities
Utilize information for scoping and coordination of SECA-SOFC sealing activities
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Meeting results"Obtained input from participants on new seal concepts including materials design and fabrication processes
" Established consensus (via facilitated break-out sessions) on promising concepts and future R&D directions
" Published results from the meeting regarding new sealing technologies
" SECA CTP meeting results are available on:
http://www.seca.doe.gov
"Obtained input from participants on new seal concepts including materials design and fabrication processes
" Established consensus (via facilitated break-out sessions) on promising concepts and future R&D directions
" Published results from the meeting regarding new sealing technologies
" SECA CTP meeting results are available on:
http://www.seca.doe.gov
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SOFC Seal functions
SOFC seals:" Prevent mixing of fuel and oxidant within a cell stack
" Prevent leaking of fuel and oxidant from stack
" Electrically isolate cells in stack
" May provide mechanical bonding of cell components
SOFC seals:" Prevent mixing of fuel and oxidant within a cell stack
" Prevent leaking of fuel and oxidant from stack
" Electrically isolate cells in stack
" May provide mechanical bonding of cell components
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Seal Requirements
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Technology Status
" Rigid seals – most mature, easy to fabricate but require CTE match, chemical stability
" Compressive seals – promising with respect to CTE but limited development, requires external load frame
"Cross cutting tools –
"Computational tools – available to study various failure modes during steady state and thermal cyclic conditions
" Other experimental tools - characterization, mechanical and chemical behavior
" Rigid seals – most mature, easy to fabricate but require CTE match, chemical stability
" Compressive seals – promising with respect to CTE but limited development, requires external load frame
"Cross cutting tools –
"Computational tools – available to study various failure modes during steady state and thermal cyclic conditions
" Other experimental tools - characterization, mechanical and chemical behavior
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Rigid glass seals
• Al-Si-X( Alkaline) system
• CTE tailored
• Al-Si-X( Alkaline) system
• CTE tailored
• Porosity formation
• Interaction with scales
• Porosity formation
• Interaction with scales
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Brazed metal seals
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Compressive seals
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Seal designs
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Design Parameters
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SBIR Seal Development Activities
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Technical approach
Three approaches considered:
• Rigid chemical
• Sliding mechanical
• Compliant wet
Analyze:
• Pros
• Cons
Analyze:
• Pros
• Cons
Three approaches considered:Three approaches considered:
•• Rigid chemicalRigid chemical
•• Sliding mechanicalSliding mechanical
•• Compliant wetCompliant wet
Identify development needs:
• Fundamental gaps
• Engineering needs
Identify development needs:Identify development needs:
•• Fundamental gapsFundamental gaps
•• Engineering needsEngineering needs
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Technical Challenges
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Technical Challenges
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Next generation concepts• Self healing
• Functionally graded
• Compliant wet seal
• High temperature spring
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Compliant Molten Seals
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Technical Challenges
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Summary
Based on the findings from the CTP seal meeting, we initiated:
• Seal development program at Sandia National Laboratory
• Collaboration with NASA
• More emphasis on seal development activities within PNNL-Core Technology Program
Based on the findings from the CTP seal meeting, we initiated:
• Seal development program at Sandia National Laboratory
• Collaboration with NASA
• More emphasis on seal development activities within PNNL-Core Technology Program
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Summary
"Based on the availability of funds , we plan to initiate seal development projects through solicitations .
"We seek specific ideas and white papers on broad areas identified in workshop report.
"We encourage you to review results from the web site
"Based on the availability of funds , we plan to initiate seal development projects through solicitations .
"We seek specific ideas and white papers on broad areas identified in workshop report.
"We encourage you to review results from the web site
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Compressive seals
Fuel//AirFuel//Air Air//AirAir//Air
Silver metal shows porosity formation and cracking under seal exposure conditions
Silver metal shows porosity formation and cracking under seal exposure conditions
fuel
air
O-ring GasketO-ring Gasket
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Seal Development Approach
Select a cell and stack design
Select Cell and Stack component materials
Develop and validate failure & reliability
models under nominal operating conditions
Optimize design and materials to meet
operational boundaries; Identify limitations
Transfer design, design tools & materials information
to Industry teams
Alternate seal conceptsAlternate seal concepts
Conduct parametric tests
Experimental Validation of Design
Experimental Validation of Design
Design/ Materials selection
Design/ Materials selection
Design/ Materials Optimization
Design/ Materials Optimization
