2009 Fuel Cell Seminar

8/3/2019 2009 Fuel Cell Seminar

1/33

Solid Oxide Fuel Cell Developmentfor Transportation and Stationary

Applications:Latest Update on Stack and System

Performance

Steven ShafferDelphi Chief Engineer Fuel Cells

2009 Fuel Cell Seminar

November 17, 2009


2/33

November 17, 2009 2

Delphi Solid Oxide Fuel CellsMarket Opportunities

Clean Coal Power Plant

Advanced Power SystemsMilitary

Auxiliary & Mobile Power Units

Residential Power

Stationary CHP Power Units

Recreational Vehicles

Auxiliary Power Units

Heavy Duty Trucks

Auxiliary Power Units

Delphi Solid Oxide Fuel Cells Provide: Ultra-clean, near zero emissions High-quality, reliable power

High fuel efficiency

Fuel flexibility

Low noise

Commercial Power

Stationary Power Units


3/33

November 17, 2009 3

Delphi SOFC Development Centers

Fenton, Michigan Cell Development

Manufacturing Development

Electrochemical Testing

Material Characterization and Analysis

Rochester, New York Stack Development

System Development

Reformer Development

BOP Development


4/33

November 17, 2009 4

Cell and Stack Development


5/33

November 17, 2009 5

Equipment for Cell Development and Fabrication


6/33

November 17, 2009 6

Typical Gen 3 30-Cell Stack Performance

MG735C676 - 30plus3 Date: 1/29/2009

Fuel: 48.5%H2-48.5%N2-3%H20 Flows: 89.8(A), 151(C)

Stack Voltage and Power Density for Polarization Test

0

5

10

15

20

25

30

35

0 10 20 30 40 50 60 70

Current (Amps)

StackVoltage(V)

0

100

200

300

400

500

600

PowerDensity(mW/cm2)

Stack Voltage (V) Power Density (mW/cm 2) Poly. (Stack Voltage (V)) Poly. (Power Density (mW/cm 2))

Power: 1.53 kW (486 mW/cm2) @ 60A (570 mA per cm2), 25.5 V(0.85V / cell avg), fuel 48.5% H2 ,3% H2O, rest N2, 750 800oC


7/33November 17, 2009 7

Generation 3 30-Cell Stack

Minimal lowering of power density ( 5%) in going from 50% fuel utilization to80% fuel utilization

Stack Voltage and Power Density for Utilization Test

0

50

100

150

200

250

300

350

400

450

500

47 52 57 62 67 72 77 82

Utilization (%)

S

tackPowerDensity


8/33November 17, 2009 8

Cathode Stability (at Carnegie Mellon University)

Powder

5-cell stack (#530) tested 3500+ hrs at 0.8 V/cell

on 28%H2 30%CO 6%H2O 2.5 ppmv S

FabricatedCell

Bulk Cathode Composition via TEM

0

5

10

15

20

25

La Sr La/Sr Fe Co Fe/Co A/B

Atomic%

Powder

Fabricated Cells

530 inlet ROI 1

530 inlet ROI 2530 Outlet ROI 4


9/33November 17, 2009 9

Gen 3 5-Cell Stack Maximum Power

MG735C793 Date: 6/23/2009

Fuel: 48.5%H2-48.5%N2-3%H20

Stack Voltage and Power Density for Polarization Test

0

1

2

3

4

5

6

0 20 40 60 80 100 120

Current (Amps)

StackVoltage(V)

0

100

200

300

400

500

600

700

800

900

PowerD

ensity(mW/cm2)

Produced 500 mW/cm2 @ 60A (570 mA per cm2), 0.87V / cell avg,

fuel 48.5% H2 ,3% H2O, rest N2, 750 800oC Max Power density: 765 mW/cm2 @ 100 Amps (952 mA per cm2),

0.80V / cell avg, fuel 48.5% H2, 3% H2O, rest N2, 750 825oC


10/33November 17, 2009 10

Interconnect Development Materials & Coatings

MG735C624

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

1.2

0.00 500.00 1000.00 1500.00 2000.00 2500.00 3000.00

Time Hrs

Voltage(Volts)

Base material is ferritic stainless steel alloy

Multiple coatings under evaluation Low cost, conventionally processed coating demonstrated good stability in stack test

Graph shows typical repeating unit performance in a stack with coating tested for durability(Fuel = 48.5 % H2, 3% H2O, rest N2, constant current of 570 mA per cm2)

Further development is ongoing


11/33November 17, 2009 11

Gen 3 Stack Durability with Diesel Reformate

MG735C727

Fuel: Reformed Diesel

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

11.1

1.2

0.00 200.00 400.00 600.00 800.00 1000.00 1200.00 1400.00

Time Hrs

A

verageVoltage(V)

10-cell Gen 3 stack on Diesel reformate (24%H2 25% CO 5% CO2 7%H2O Bal N2) at 35 amps and 750C

Initial voltage drop observed in the first 200 hours due to sulfur

Minimal degradation in the last 1300 hours


12/33November 17, 2009 12

Gen 3 30-Cell Stack - Thermal Cycling

0

100

200

300

400

500

600

700

800

0.00 2.00 4.00 6.00 8.00 10.00 12.00

Time Hrs

Temperature(DegC)

Gen 3 30-cell stack being thermal cycled 10 hour cycle from 50oC to operating temperature to 50oC Performance evaluated at each thermal cycle

Constant current load of 30 Amps at operating temperature

Fuel of 48.5% H2, 3% H2O, rest N2


13/33November 17, 2009 13

30-Cell Stack Thermal Cycling Results

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210

Thermal Cycle Number

MeanCellVoltage


14/33November 17, 200914

Red XProblem Solving Tools For Stack Issues

Red X is a registered term of Shainin LLC

Cell Voltage by Stack at 60amps

0.50

0.55

0.60

0.65

0.70

0.75

0.80

0.85

653

657

651

658

659

660

661

665

671

672

662

666

680

681

683

684

690

691

Stack

CellVoltage

Average

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.704/10/2008

4/12/2008

4/14/2008

4/15/2008

4/17/2008

4/24/2008

4/29/2008

5/29/2008

6/6/2008

6/13/2008

6/24/2008

6/26/2008

7/22/2008

7/23/2008

7/24/2008

7/25/2008

7/31/2008

7/31/2008

Build Date

CellVoltage

Range

Average

Range

Did not meetvoltage

range specs

Problem solving tools like Red Xare being utilized in stack manufacturing

Lessons learned are being implemented for Gen 4 stack design andmanufacturing

Example: Find & eliminate the Red Xdriving high cell voltage range


15/33November 17, 2009 15

Stack Other Area

High cellvoltagerange

OtherPerformance

Characteristics

Event Defect

First time qualityissue: IV

performance

Durability issue

Feature

Repeating unit torepeating unit

Other strategies

P = 0.14V M = 0.013V

Components Assembly Process

CassetteCell Cathode

Interconnect

Paste Interconnect Component

CoatingContamination

Other

Red XProblem Definition TreeTM

Problem Definition TreeTM is a registered trademark of Shainin LLC

Red X was identified as contaminationin the interconnect coating from aspecific supplier


16/33November 17, 2009 16

Gen 4 Cell Development for Coal Based Systems


17/33November 17, 2009 17

Gen 4 Stack Design for Coal Based Systems

Gen 3 stack

About 4x active area of Gen3Lower cost interconnects/coatings than Gen3High volume production processes5 kW core building blocks

Gen 4 stack

Delphi is developing its Generation 4 stack as the module formeeting stationary and transportation application requirements

Key stack features are: Laser welded cassette repeating unit configuration

Stamped metallic cassette components

Stamped interconnects Low cost coatings

Low cost, conventionally processed balance of stack components


18/33November 17, 2009 18

Gen 4 Stack Development Status

Laser welding of SOFC parts

Gen 4 stack design is complete

Process development and optimization ongoing to fabricate cells,cassettes, and stacks

First 5-cell stack fabricated and tested


19/33November 17, 2009 19

Gen 4 Stack Performance : 5-cell stack

Achieved power density of 474 mW/cm2

@ 240A (590 mA per cm2

), 0.80V /cell average, fuel 48.5% H2 ,3% H2O, rest N2, 700 800oC

MG735G001-5cell stack Date: 8/26/2009

Fuel: 48.5%H2-48.5%N2-3%H20

0

1

2

3

4

5

6

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

Current (Amps)

StackVoltage(V)

0

50

100

150

200

250

300

350

400

450

500

P

owerDensity(mW/cm2)


20/33

November 17, 2009 20

System Development


21/33


Balance of Plant Components:High Temperature Insulation

InsulationCollars

Old

New


22/33


Balance of Plant Components

Process Air Delivery System Anode Tailgas Recycle Pump


23/33


Diesel Fuel Survey ResultsSummer 2007 Sulfur Levels

0

5

10

15

20

25

30

35

40

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

ppm

frequency

Sulfur ppm

Source: Alliance of Automobile Manufacturers (US andCanada, 160 samples)

Current 2007 ULSD Spec.


24/33


Delphi Solid Oxide Fuel CellsHot Reformate De-Sulfurization

Hot Reformate De-Sulfurization Development

Remove H2S to levels below 10 ppbv (parts per billion volume) from an input of2.5 ppmv (parts per million volume)

Sulfur acts as a poison to SOFC

Maximize operation time between sorbent exchanges

Minimize device volume and operation pressure drop


25/33


Delphi Solid Oxide Fuel CellsHot Reformate De-Sulfurization

A non-regenerating sorbent has been selected that: Meets maximum 10 ppbv output

Meets operating temperature requirements

Capacity is such that a bed operates for at least 6 months prior to requiring bedexchange for the 95th percentile driver

System pressure drop requirements were met at full system reformate flow


26/33


Delphi Solid Oxide Fuel CellDesign of New Diesel APU Platform

Endothermic Diesel Reformer withintegrated burner

Gen 4 SOFC Stack

Highlyintegrated

manifold andheat exchanger

assembly

Fuel and Air SupplySystems

DPS 3000D3 kW net output power

Desulfurizer

Electronics and Controls

Module


27/33

November 17, 2009 2727

Projected Performance Comparison


28/33


DPS3000 D Initial Builds

First design engineeredspecifically as a truck APU

Internal desulfurizer forULSD

ULSD cold-start capable


29/33


Model 386 Peterbilt vehicle received atTCR on 8/28/09

Vehicle provided to Delphi as part of DOEEERE Truck APU Demo project

Vehicle prepped for SOFC APU

Fuel and electrical interface

Mounting Hardware for APUenclosure

AC inverter

Refrigerator

Peterbilt Development Truck


30/33

November 17, 2009 3030

Test to Failure using Step Over Stress strategy to assess stack reliability

Mil Std 810G Method 514.6 Annex C, Truck and Transportation Over US Highways Ambient temperature random vibration in 3 distinct axes

Performance evaluated after each axis of testing

Successfully completed 3.75 million miles equiv. of vibration

Delphi Solid Oxide Fuel CellGen 3 30-Cell Stack Vibration Testing

Vertical


31/33


Systems Vibration Testing

DPS 3000D SOFC System on shaker table


32/33


Delphi SOFC APU Recent Accomplishments

Delphi/Peterbilt Awarded DOE Program for a 1 year vehicledemonstration

Stack durability testing 200 Thermal Cycles

Completed 5 lives accelerated vibration testing

Engineered and Built First Truck APU Designed to operate on Diesel

Integrated Desulfurizer operational

First APU installed on Peterbilt Truck Operational by December 2009


33/33

Acknowledgements
http://www.utcpower.com/http://www.netl.doe.gov/main.htmlhttp://www.ch.doe.gov/insidech/org_offices/fao/doelogo.gif

Documents

2009 Fuel Cell Seminar