automated testing of sofc stack hotboxes · welcome to our presentation at the hannovermesse 2010....
TRANSCRIPT
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EBZ GmbH
Automated testing of SOFC stack hotboxes
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
WELCOME to our presentation at the Hannovermesse 2010
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EBZ GmbH
Who will guide you through the next 20 minutes:
Falk Schröter
Project Manager in EBZ GmbH
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
� Hardware design
� Software design
� Testing
� Commissioning
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EBZ GmbH
Abstract
� Company profile
� Introduction to EBZ ProControl
� 3 kW Demonstrator for staxera ISM box
� Automated start sequence – requirements and solution
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
� Automated start sequence – requirements and solution
� Discussion & questions
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EBZ GmbH
� SOFC system development since 2002
� 15 engineers and technicians
� 4 generations of SOFC systems
� Part of SOFC cluster Dresden:
staxera, Fraunhofer IKTS, EBZ
Company Profile
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
staxera, Fraunhofer IKTS, EBZ
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EBZ GmbH
EBZ GmbH
Fuel Cells & Process Technology
Dresden
� SOFC Test rigs � Heat exchangers
Company Profile
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
cells, stacks and
stack modules
� Demonstration
systems
� Competence in
system integration
� Independent
SOFC test laboratory
Test environments for staxera‘s
Integrated Stack Modules (ISM):
� Preheating Modules
� Steam Reforming Modules
� 1-3 kWel demonstration systems
� Heat exchangers
� Evaporators
� El. gas heaters
� Desulphurizers
� Reforming units
� Burners
� Measurement and
controls
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EBZ GmbH
staxera (Germany)
� 5 Hotbox test stands delivered
� 0.5 to 1.5 kWel stacks
� Long-term tests and thermal
cycling experiments possible
References: Stack test rig
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
cycling experiments possible
� Evaporator, air and gas heaters
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EBZ GmbH
3 kW Demonstrator 20 kW System
Motivation
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
2x Mk200 ISMsEfficiency 35-40%
5x Mk2xx ISMsEfficiency 60%
Demonstrate the potential of SOFC technology
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EBZ GmbH
staxera experience Focus of cooperation with EBZ
Extensive stack testing mainly with
CPOX based reformates
Performance of stacks
under internal reforming
conditions
Background & objectives
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
Stack testing in laboratory
environments
Proof of stack performance and stability in
real system
Single stack module operation
for 1 – 1.2 kWel
Demonstration of scalability of staxera
stack technology
� multiple ISMs in one system
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EBZ GmbH
� Operation of 2 parallel ISM 3.0
� Gross stack power 2x 1.1 kWel
� in future 2x 1.5 kW ISMs
� Desulphurizer and steam pre-reformer
for pipeline natural gas
� Two-zone porous media burner for fast
3 kWel Research & Demonstration system
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
� Two-zone porous media burner for fast
system start-up and anode off-gas
burning
� Stack efficiency 50 %el, system
efficiency about 35 %el
� System in operation since 09/2009
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EBZ GmbH
software solution with pre-defined programs for testing single cells and SOFC stacks, e.g. the measurement of IV-characteristic curves
� not as flexible as necessary
GUI of test rig with pre-defined procedures
Reasons for EBZ ProControl
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
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EBZ GmbH
� Comfortable graphical programming
� No script language or a special programming language
� Simulates a virtual user who is able to monitor and influence variables
� Syntax checking for fail-safe operation
� Time-controlled, event-controlled or mixed code execution
Advantages for test rig controls
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
� Time-controlled, event-controlled or mixed code execution
� Test rig control via network possible
� Sequences can be saved, loaded and append
� Including an overriding event management for parallel supervising of variables independent from Safety-PLC
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EBZ GmbH
� Threshold monitoring, e.g. temperatures
� Special steps and combinations of process engineering, e.g. leakage tests and cell reduction
� Recording of characteristic curves, e.g. IV-curves
� Connectable to various OPC servers, e.g. M1-OPC Standardserver
Advantages for test rig controls
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
� Connectable to various OPC servers, e.g. M1-OPC Standardserver from Bachmann electronic GmbH
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EBZ GmbH
Process
Variable 1
Variable 2
Variable 3
...
PLC (Compact FieldPoint)
GUI
Test rigComputer
Hardware outputs
Hardware outputsHardware inputs
Published data
Commun. ports
Data flow in a test rig
EBZ ProControl
Test rig's or remote PC
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
Variable n
...
Database
externaldevices
sensors actuators
externalcontoller
safety system
communication via LANserial communication (RS-232, RS-485) or ethernethard wired communication via current loop or voltage signalsdata flow via software protocoldigital voltage signals (0...24 V)
Commun. ports
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EBZ GmbH 3 kWel Research & Demonstration system
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
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EBZ GmbH Automated warm start
Steps for the automated start:
1. Set stack air to control mode "Temperature"
2. Set burner air to control mode "Flow"
3. Set control thermocouple
4. Set control range of stack air blower between 25…100 %
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
4. Set control range of stack air blower between 25…100 %
5. Set control temperature of stack
6. Set burner air flow and gradient
7. Set default values for burner natural gas
8. Start ignition sequence
9. If ignition succeeded, switch to control by temperature
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EBZ GmbH Automated start
10. Adapt control temperature and natural gas flow
11. Monitor the outlet temperature of evaporator and change gradient, if 200 °C is reached
12. Change flow rate of DI-water to 300 g/h
13. Start reforming mode, if reformer temperature is high enough
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
13. Start reforming mode, if reformer temperature is high enough
14. Set operation point values
15. Set low limit monitoring for DI-water flow
16. Set operation mode, gradient and setpoint for the DC-load
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EBZ GmbH Step 1: Overview
Following step
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
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EBZ GmbH Step 1: Detail Action 1
Enable or dis-able this action
Process name and URL
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
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EBZ GmbH Step 1: Detail Action 2
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
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EBZ GmbH Step 9: Detail Event
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
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EBZ GmbH Step 9: Detail Go on condition
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
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EBZ GmbH Step 15: Overview
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
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EBZ GmbH Step 15: Detail Go on condition
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
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EBZ GmbH Results from this script
Step 25 finished
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
Step 9
Step 12 Step 15
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EBZ GmbH
Thank you for your attention and visit us here on the Hannovermesse 2010, booth J47
Contact
Contact Us
EBZ GmbH Fuel CellsPhone: +49(0)351/47939-0 Postal: Marschnerstrasse 26, 01307 Dresden, Germany
Fax: +49(0)351/47939-18 Visitors: Seifhennersdorfer Straße 16, 01099 Dresden, Germany
Email: [email protected] Web: www.ebz-fc.de
EBZ Entwicklungs- und Vertriebsgesellschaft Brennstoffzelle GmbH
Marschnerstr. 26
01307 Dresden
Tel. +49 (0) 351 47939-0
Fax +49 (0) 351 47939-18
E-mail [email protected]