Fossil Energy Fuel Cell Program

Wayne Surdoval, SECA CoordinatorJune 3, 2003

National Energy Technology LaboratoryOffice of Fossil Energy

SECA Core Technology

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SECA CORE TECHNOLOGY PROGRAM

W. Nernst“Electrical Glow-Light”

U.S. Patent 623,811April 25, 1899

CC

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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

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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

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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

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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

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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

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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

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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

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SOFC Materials Costs

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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

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SECA Budget ($M)

0

5

10

15

20

25

30

35

2000 2001 2002 2003

Industry TeamsCore Technology Program

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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

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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

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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

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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

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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

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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

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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

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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