manufacturing analysis of sofc interconnect coating processes · • coating processes are scaled...
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Manufacturing Analysis of SOFC Interconnect Coating Processes
M. Seabaugh*, M. Beachy, S. Ibanez, R. Kimbrell, M. Day, L. Thrun and S. Swartz
11th Annual SECA Workshop, Pittsburgh, PA July 28, 2010
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Cost-Effective IC Coating Process Development
• Objectives: To Determine--
– Manufacturing cost for 400MW/year interconnect coatings. ($5-7 each at 400 MW)
– What manufacturing route(s) present the most cost-effective and technically feasible IC coating.
– Whether MCO, MCO-REE or other coatings present the best opportunities for commercialization.
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Conclusions
• Aerosol is cost effective versus other approaches.– At High Production Volume, $1.65 per 625 cm2 plate
– Low Capital Investment Compared to Competing Methods
• Opportunities for cost reduction with lower cost materials and simplified processes. – Coating Thickness Can Be Further Reduced
– Alternative Materials Can Cut High Volume Costs
• MCO and Perovskite aerosol coatings stable and high performance– Lifetimes >1500 hours demonstrated in Phase I
– ASR values < 0.05 ohm-cm2 for coated IC Components after 1000 hour tests w/ thermal cycing
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Commercialization
• Coating processes are scaled to large component sizes• Up to 1200 cm2 Area Components
• Masking, Dual Coatings, High Relief Surfaces Demonstrated
• Aerosol production capacity (# of parts) easily scaled• Spray Coating Times are Short
• Furnace Requirements Easily Met by Conventional Equipment
• Immediate and Future Products• Value-added paints, inks and spray suspensions• Interconnect coating services• Interconnect manufacturing services
• Intellectual Property Protection and Access
• Filed Provisional Patents on Perovskite Coatings
• Licensing Strategy in Place to Provide Clients Freedom to Operate
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Technology Developer –advanced ceramics, electrochemical devices
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Service Provider—Materials and Processes Tailored for Client
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Commercial Service Examples
Tape Casting
Tailored Properties
Electrolyte Powders
Electrode Powders
Tailored Current Collect
Custom Cell Solution
IC Protective Powder
Custom Spray Process
Tailored Interconnects
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Summary of Coating Cost Analyses
Comparison of Prevalent IC Coating Technologies
(Estimated at 400 MW/year production)
Metric/Technique Plasma IBED Electroplating EPD ASD
Coating Density Intermed. Excel. High Intermed. Intermed.
Coating Thickness
(µm)> 20 < 5 1-10 5-20 5-20
Composition
FlexibilityGood Low Limited Excellent Excellent
Capital Cost ($) 3.1M 3.7M 2.5M 2.2M 1.5M
Operating Cost ($) 1.1M 1.2M 1.6M 1.5M 1.5M
Coating Cost per
interconnect ($/part) $2.61 $2.03 $1.95 $1.93 $1.65
Coating Cost per
Kilowatt ($/kW) $10.44 $8.12 $7.80 $7.72 $6.60
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Breakdown of Coated IC Costs
$0.00
$1.00
$2.00
$3.00
$4.00
$5.00
$6.00
$7.00
$8.00
Utilities,Supplies, etc.
Operating Labor
Depreciation
Raw Materials
Costs Modeled for
400MW Production
625 cm2 Interconnect Area
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Breakdown of Coated IC Cost: Aerosol Deposition
IC Raw Materials
56%
IC Depreciation2%
IC Operating Labor
3%
IC Operating Costs11%
Raw Materials7%
Depreciation2%
Operating Labor13%
Operating Costs6%
• Costs Modeled for 400MW
Production
• 625 cm2 IC Area
• Stamped 0.5 mm thick IC
• $8.80/kg Steel Cost
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MCO Materials Synthesis
Material Mn1.5Co1.5O4-d MnCo2O4-d
CTE (RT-1000°C)
11.4 ppm/°C* 13.5 ppm/°C**
BulkConductivity
~60 S/cm, 800°C† 36 S/cm, 800°C††
Surface Area 8-14 m2/g 8-14 m2/g
XRD Mixed (Cub +Tet) Spinel Cubic Spinel
20 25 30 35 40 45 50 55 60
degrees 2q
*
*
**
* **
**
▼
* 18-0408 MnCo2O4
▼▼
▼
▼▼
▼ 23-1237 MnCo2O4
20 25 30 35 40 45 50 55 60
Inte
nsity
Degrees Two Theta
* Yang et al, Electrochem. and Sol. State Lett. 8 A168-A170 (2005)** Kiefer et al, 26th Riso Int. Symposium on Mat. Sci., Solid State Electrochemistry p 261-266†Chen et al, Solid State Ionics, 176 (5-6) 425-33 (2005)††Yang et al, Int. J. of Hydrogen Energy, 32 (2007), 3648-3654
Synthesizing 25-100 kg lotsScaling Production to 500kg
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Examples of Coated Components
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Extension to Cathode Current Collection
MCO Coating
Fired, 10 microns thick
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Microstructure of Mn1.5Co1.5O4-d Coatings
20 mm20 mm
MCO
AL441HP
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Initial Performance MCO v. Uncoated
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Thermal Cycling MCO v. Uncoated
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Lifetime Stability MCO v. Uncoated
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SEM Cross Sections
MCO
MCOSS441
SS441
LSM
LSM
0 4 8 12 16
Sig
nal
Str
en
gth
Distance (microns)
Cr
Mn
Fe
Co
MCO
Coating
Stainless
Steel
Substrate
0 10 20 30 40 50
Sig
nal
Str
en
gth
Distance (microns)
Cr
Mn
Fe
Co
MCO
Coating
Stainless Steel
Substrate
6 μm
12 μm
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Impact of Coating Thickness Performance
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Impact of Coating Thickness Manufacturing Cost
$0
$1,000
$2,000
$3,000
$4,000
$5,000
0 400,000 800,000 1,200,000 1,600,000
Yearl
y P
rod
ucti
on
Co
st
($0
00
)
Production Volume (Parts/Year)
5 μm
10 μm
20 μm
40 μm
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Perovskite Coating
Epoxy
Perovskite
AL441-HP
20 mm20 mm
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Initial Performance Perovskite v. MCO & Uncoated
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Thermal Cycling Perovskite v. MCO & Uncoated
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Lifetime StabilityPerovskite v. MCO & Uncoated
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EDAX of Perovskite Tested for 1000h, 800°C, 0.5A/cm2
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Impact on Materials Selection Manufacturing Cost
$1.50
$1.55
$1.60
$1.65
$1.70
MCO LNC LNF
Co
ati
ng
Co
st
($
/p
art
)
Coating Composition
Perovskite 1 Perovskite 2
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Future Work
• Commercialization with Clients
– Coating Services
– Coating Value Added Materials
• Reducing Process Costs
– Integration of Process into IC Manufacturing Cycles
– Simplifying Process Cycles
– Reducing Process Cycle Times
• Validating Materials Cost Reduction Strategies
– Long Term Testing
– Short Stack Validation
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Acknowledgements
• Clients, Colleagues and Collaborators
• U.S. Department of Energy
– DE-PS02-08ER08-34, • Briggs White, Project Manager
• State of Ohio Third Frontier Program
For More Information:Matthew Seabaugh(614) 842-6606 extension [email protected]