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Cummins Power Generation SECA Phase 1 ReviewDan Norrick Manager Advanced DevelopmentCummins Power Generation
August 7, 2007San Antonio, TX
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Agenda
IntroductionSECA Phase 1 ResultsPhase 1 Development ProgressApplication of 6S Design Tools to fuel
reforming strategySome Remaining ChallengesAcknowledgements
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Agenda
IntroductionSECA Phase 1 ResultsPhase 1 Development ProgressApplication of 6S Design Tools to fuel
reforming strategySome Remaining ChallengesAcknowledgements
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The Engine Business:
The Components Business:
The Power Generation Business:
Power of One
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160 Countries33,500 EmployeesUS$ 11.4 Billion in SalesUS$ 278 Million in R&D
Parts Distribution Centers (15)
Factories (26)
Technical Centers (16)
Distributors (550)
Sales and Service (5,587)
Global Operations - 2007
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Cummins - Revenues$11.4 Billion in 2006
Engine Business
Power Generation Business $2.2B (20%)
Filtration & Other Business
International Distributor Business
4 kW to 2.5 MW gensets
Engine Business
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Commercial
Consumer
Energy Solutions
Alternators
G-Drive Engines
PowerElectronics
Cummins Power Generation Revenue by Business Group
Rental
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Typical Applications
Diesel Commercial Standby & Prime
Marine
3- 20 kW
3 – 95kW
3 – 15 kW
Commercial Mobile
Residential Standby
12 – 45 kW
8 kW – 2.7 MW
Recreational Vehicle
Rental
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Versa Power Systems (VPS)
Focused on SOFC commercializationDemonstrated cost-effective SOFC ceramic cell
manufacturing technologyDeveloped a highly competitive state-of-the-art SOFC
stack technology Built and operated multiple generations of complete,
integrated SOFC systems
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Agenda
IntroductionSECA Phase 1 ResultsPhase 1 Development ProgressApplication of 6S Design Tools to fuel
reforming strategySome Remaining ChallengesAcknowledgements
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CPG-VPS SECA Team
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Cummins Power GenerationVersa Power Systems Teaming Plan
Reformer developmentElectronic controlsPower electronics Fuel systemsAir handling systemsNoise and vibrationPower system integrationManufacturingMarketing, sales,
distribution
High performance planar cell & metallic interconnect technologyPlanar SOFC stacksHigh temperature thermal
integrationExperienced SOFC system
integrators
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CPG-VPS Team Phase 1 Accomplishments Overview
Successfully delivered 3kWe nominal fully-integrated, automatically-controlled SOFC system called Mission 1 (or M1) system meeting SECA Phase 1 metrics.
Developed a system concept & development plan for a Mission 2 (M2), mobile APU system.
Developed, engineered, and prototyped a Mission 2 (M2) stack and hot module.
Advanced core SOFC materials technology towards CPG’s Value Package Introduction (VPI) goals in the area of sulfur tolerance and alignment to ultra-low sulfur diesel (ULSD).
Identified low-cost BOP components applicable to SOFC and implemented in demonstration air supply system.
Initiated application of 6S design tools to system optimization.
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CPG – VPS SECA Phase 1 Test Unit in Cell 137 at CPG
Unit startupOct 2, 2006
SECA Test StartOct 15, 2006319 hours
SECA Test CompletedJan 4, 20072250 hours
Unit shut downJan 23, 20072700 hours99% Availability
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CPG – VPS SECA Phase 1 Test Results
Commercial Pipeline (local utility) NG
Commercial Commodity
Fuel Type
kW4.6Peak Power (Net DC)%99> 80 %Availability
% (Full system)% (Stacks)
6.35.7
7 %Total Degradation - ref(1500h + Tran.)
% / 10 (Full system)% / 10 (Stacks)
1.10.5
1% / 10 Transient Degradation
% / 500 hrs1.72% / 500 hrsSteady State Degradation
% (4pt. Ave.)37.1%25Efficiency Mobile (Net DC/LHV)
kW (4pt. Ave.)3.2kW3 – 10Power Rating (Net DC@ NOC)
ActualTARGETREQUIREMENTRESULTS AGAINST PHASE 1 METRICS
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Gas Composition @ Desulfurizer Outlet
Carbon Dioxide0.81%
Oxygen0.07%
Hydrogen0.10%
Nitrogen2.10%
Other0.01%
n-pantane0.01%
i-pantane0.01%
Butane0.02%
Isobutane0.02%
Propane0.17%
Ethane1.89%
Methane94.78%
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System Parameters @ NOC & Peak Power
26%37%%Net DC Efficiency
56.9%57.6%%Fuel Utilization
64.186.7VVoltage
8542ACurrent
402268mW/cm2Power Density
Peak PowerNOCUnit
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Sankey Diagram
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Phase 1 Test Plan
System Heat Up and Load Ramp Up
up to 300 hr Stabilization
Period
1000 hr Steady State Constant Current
SECA Deg. target <2%/500 hrs
10 Transient Cycles: 9 power cycles to system Net Zero condition
1 deep thermal cycle to Stack temp <50C SECA deg. target <1%/after 10 cycles
100 hr Stabilization
Period
500 hr Steady State Constant Current
SECA Deg. target <2%/500 hrs
Potential System preparation +
Maximum power test
Cooldown
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Stack Current & Voltage
0
20
40
60
80
100
120
140
160
-320 -120 80 280 480 680 880 1080 1280 1480 1680 1880 2080
Time (hours )
Stac
k Vo
ltage
( V)
0
20
40
60
80
100
Stac
k C
urre
nt ( A
)
EE590IT580
1000 hours NOC 500 hours NOCTran
sien
t tes
t
Pea
k po
wer
test
Unintentional trip Unintentional tripUnintentional
tripUnintentional
trip
A
V
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Stack Voltage, Current & Gross DC Power at the 10 transient cycle period
0
20
40
60
80
100
120
1000 1020 1040 1060 1080 1100 1120 1140 1160 1180
Time (hours )
Stac
k Vo
ltage
( V)
Stac
k C
urre
nt (A
)
0
1000
2000
3000
4000
5000
6000
Gro
ss D
C P
ower
( W)
EE590IT580Gross DC Power
A
W
V
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Phase 1 ASR Progress
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
2003 Q1 2004 Q3 2004 Q1 2005 Q2 2005 Q4 2005 Phase 1Test
AS
R R
ange
(Ohm
-cm
2 )
Phase 1 Target(Internal Goal)
Typical range 0-1000 hours
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SECA Phase 1 Cost Targets Audited Cost Comparison
$0$100$200$300$400$500$600$700$800$900
Target Audited
$/kW
Stack & Reformer C&PE BOP Assembly
Proposal Model
Phase 1 Audited
$742
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Agenda
IntroductionSECA Phase 1 ResultsPhase 1 Development ProgressApplication of 6S Design Tools to fuel
reforming strategySome Remaining ChallengesAcknowledgements
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VPS Technical Advances
Reduced Direct Internal ReformingProvides flexibility to operate with a wide variety of fuels, reforming technologies and operating conditionsShifts stack heat rejection to other cooling meansReduced DIR capability integrated into Phase 1 stack technologySystem reformer modifications completed to increase natural gas conversion to H2 and CO; increased heat transfer in the afterburner / reformer design
Internal CompressionBetter suited to mobile applications with shock and vibration environmentReplaces cold external system components with integrated in-stack (hot) clampingReduces system volume and weightReduces system part count and complexity
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VPS Internal Compression Thermal Cycling Performance
Test Results (121 cm2 active area):
6-cell GT055296-0020 (PCI2) TC ComparisonMarch 20-April 10, 2006, Stand 20, 725degC furnace temp
0.6
0.7
0.8
0.9
1.0
1.1
TC0TC1TC2TC3TC4TC5TC6TC7TC8TC9TC10TC11TC12TC13TC14TC15TC16TC17
Thermal Cycle
Ave
rage
Cel
l Vol
tage
(V)
60A Avg V70/35 Avg V
60A, 27%Uf, 36%Ua3%H2O humidified fuel725degC furnace
47A, 70%Uf, 35%Ua3%H2O humidified fuel725degC furnace
External Compression Internal Compression
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VPS M2 APU Stack: Highlights
VPS developed the Mission 2 (M2) stack in response to CPG’s mobile APU system / stack Requirements
M2 APU-stack development objectives:Preparation for SECA Phase 2Advancement towards commercialization program goals at CPGForm factorDiesel reformateAccelerated start protocol
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VPS M2 APU Stack
Baseline layout
112 cells - 200cm2
4 stacks6.5kWe gross (NOC)11kWe gross (Peak)12” x 12” x 12” overallClose-coupled central
cathode preheatNo internal reformingExternal manifold
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M2 APU Stack: Status
M2 stack progressed from requirements and idea stage through engineering/testing of two stack iterations.
Demonstrated: Cell Manufacturing scaleup, and stable manufacturing development
The M2 stack is a technical fit for CPG’s future APU development
custom-engineered to meet mobile APU product requirements.
17 x 28 cell stacks were built and tested9 stacks of REV008 stacks of REV01
A compact air heat exchanger was taken from concept through completion of proof of concept component testing for integration into the APU hot module
M2: REV00
M2: REV01
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VPS M2 Stack REV00: Performance at 0.4 A/cm2
GT056763-0006 (M2 Stack)
65% Fuel Utilization, 30% Air Utilization, 78 A, Tfurnace 655 CAverage Cell Voltage
0.700
0.720
0.740
0.760
0.780
0.800
0.820
0.840
0 100 200 300 400 500 600 700 800 900 1000
Time [hrs]
Volta
ge [V
]
Average Cell Degradation 22 mV/1000hrs or 2.7%/1000hrs
Average Cell Degradation22mV/1000h, or 2.7%/1000h
0. 4A/cm2: passed at 85% UtF
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M2 Stack REV00: Power CurveGT056763-0003 TC0 - Power Curve
21-Nov-06, Stand 23
0.5
0.6
0.7
0.8
0.9
1
1.1
0.00 1.00 2.00 3.00 4.00 5.00 6.00
Elapsed Time (hrs)
Cel
l Vol
tage
(V)
-5%
5%
15%
25%
35%
45%
55%
65%
75%
85%
95%
Util
izat
ions
Cell 1Cell 2Cell 3Cell 4Cell 5Cell 6Cell 7Cell 8Cell 9Cell 10Cell 11Cell 12Cell 13Cell 14Cell 15Cell 16Cell 17Cell 18Cell 19Cell 20Cell 21Cell 22Cell 23Cell 24Cell 25Cell 28ufua
Stable at 0.5A/cm2425 mW/cm2
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6-cell thin cell stack operated for more than 5,000 hours at 0.49 W/cm² (80 Amps) and 70% fuel utilization.
- Degradation rate 0.74% per 1000 hours (<6 mV per 1,000 hours per cell) -
G T 0 5 5 1 5 7 -0 0 0 3 C S - P C S P la tfo rm C e ll V o lta g e s (0 .6 m m c e lls )7 0 /3 5 , 8 0 A m p F u rn a c e T e m p 7 0 0 C , S ta n d 2 ; 1 1 -D e c -0 3 to 1 2 -J u l-0 4
0
0 .2
0 .4
0 .6
0 .8
1
0 1 0 0 0 2 0 0 0 3 0 0 0 4 0 0 0 5 0 0 0D u ra t io n (h rs )
Volta
ge (V
)
C e ll 1C e ll 2C e ll 3C e ll 4C e ll 5C e ll 6
Cost Reduction: Thin Cell Development
6 Cell Stack; 121 cm², 0.6 mm thick cells700°C, 660 mA/cm2
70% Uf: 5.16 slpm H2, 4.69 slpm N2, 3% H2O 35% Ua: 24.55 slpm air
Cell ThicknessMaterial Cost
Reduction1 mm --
0.6 mm 29%0.3 mm 51%
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Agenda
IntroductionSECA Phase 1 ResultsPhase 1 Development ProgressApplication of 6S Design Tools to fuel
reforming strategySome Remaining ChallengesAcknowledgements
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Diesel Diesel Reforming 6S Technology Evaluation
SR with WCR – Steam Reforming (SR) with Water Condensation Recycle (WCR)
SR with WMR – SR with Water Membrane Recycle (WMR)ATR with HAGR – AutoThermal Reforming (ATR) with Hot Anode
Gas Recycle (HAGR)ATR with WAGR – ATR with Warm Anode Gas Recycle (WAGR)ATR with WCRATR with WMR ATR with supplemental waterCPOX – Catalytic Partial OXidation (CPOX) CPOX with downstream WCR injectionCPOX with downstream storage water injection (with water tank)
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Auto-thermal Reformer (ATR)
Reformer
Atomizer
Pump
ULSD
Air Mixer
Reformate
CO, H2, CO2, H2O, etc.
Lower carbon formation riskHigher reformation efficiency
Water steamSteam generator
Liquid water
{ From anode gas recycle
From water membrane recycle
Steam
{From anode gas condensationFrom water storage
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Catalytic Partial Oxidation (CPOX) Reformer
Reformer
Atomizer
Pump
ULSD
Air Mixer
Reformate
CO, H2, CO2, H2O, etc.
High carbon formation riskLow reformation efficiency
Steam to prevent carbon formation
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SR vs. ATR vs. CPOX (3 kW net DC)
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00.310.67Water Requirement (GPH)0.310.260.20Diesel Consumption (GPH)
25.5%30.5%39.0%Overall System Efficiency70%85%110%Reformer Efficiency95%95%95%DC Boost Efficiency
43.5%43.5%43.5%Stack Efficiency 0.400.450.50Parasitic Power (kW)
01.13.0S/CCPOXATRSR
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Ranking of Reformation Technologies
ATR with WMR
ATR with supplemental water
CPOX with downstream storage water injection
CPOX with downstream WCR injection
ATR with WCR
SR with WMR
SR with WCR
ATR with WAGR
ATR with HAGR
CPOX
C&E Matrix
CPOX with downstream WCR injection8
6
ATR with WMRATR with WCR
5
CPOX1
SR with WCR10
SR with WMR9
CPOX with downstream storage water injection
7
ATR with supplemental water4
ATR with WAGR3
ATR with HAGR2
Pugh MatrixRanking
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Common Electronics Architecture
Cummins Onan Hybrid QD™
Fuel Cell DC Bus
120Vac 60 Hz
Batteries
Fuel Cell
HQD HMI Interface
HQD Inverter
VoltageBoost (new)
System Control (new)
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Agenda
IntroductionSECA Phase 1 ResultsPhase 1 Development ProgressApplication of 6S Design Tools to fuel
reforming strategySome Remaining ChallengesAcknowledgements
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Challenges remain…
SOFC stack evolutionZero net water diesel fuel reformingSulfur (ULSD)Transient operations
Start-stop without purge gasesLoad pickup / variable load operations Hibernation
DegradationSteady state (life) degradationTransient degradation
Mechanical robustnessControls
Autonomous control of all transient operationsDynamic load sharing with stored energy (hybrid mode) – recalibration to fuel cell time constants
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VPS M2 Mobile APU Stack
Stabilize the platformAttain statistical
confidence to integrate into mobile APU systems with full product capability
Characterization over full operating range M2: REV01
New form factor, HX arrangementAdditional M2 stack development is needed to:
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Fuel / Reforming
FuelCPG’s SECA work to date based on LPG and Natural Gas
On-highway ULSD (< 15 ppmw sulfur) is critical to successful commercialization of CPG Target Markets
ULSD transition underway in supply system
ReformingExploring zero net water alternatives for commercialization
Examining water management strategies (recovery vs. recycle)
Strategic partner for co-development
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Sulfur Tolerance
CPG expects 15ppm by weight sulfur in ULSD to result in ~ 3-5ppm by volume in reformate (ATR or CPOX)
Two pronged approach:
Identification and development of sulfur tolerant anode materials (preferred approach, cell and stack selection factor)
• Cost, size, weight, maintenance of desulfurizers
• Anticipate need for recovery from temporary sulfur spikes
Incorporate de-sulfurization (backup plan)• Liquid phase
• Gas phase
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Sulfur Tolerance
Novel anode material systemImproved performance and stable operation to at
least 1000 hours compared to VPS standard TSC2 cell
Tested H2S concentrations of 1-5 ppm in humidified H2 fuel
Next stage of development will move to single cell and extended stack durability testing
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VPS APU Advanced Anode Enhances Sulfur Tolerance
G L O B 1 0 1 4 9 1 : 1 p p m H 2 S P o is o n in g C e ll w ith S ilve r P a s te C o m p a ris o n W ith G L O B 1 0 1 2 6 5 , S ta n d a rd T S C -2 C e ll
0 .7
0 .75
0 .8
0 .85
0 .9
0 :00 :00 12 :00 :00 24 :00 :00 36 :00 :00 48 :00 :00 60 :00 :00 72 :00 :00 84 :00 :00 96 :00 :00
E lap sed T im e
Cel
l Vol
tage
(V)
G LO B 101491 G LO B 101265
1ppm H 2S in jec ted
T = 750°CU f = 50%U a = 25%I = 0 .5 A /cm 2
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VPS APU Advanced Anode Enhances Sulfur Tolerance
Degradation CurveGlob 101490; (Sulfur Poisoning: 1-5 ppm, Ag Catalyst)
Oven #18, March 28 to April 4, 2006
0.700
0.720
0.740
0.760
0.780
0.800
0 24 48 72 96 120 144Elapsed Time, h
Volta
ge, V
H2 CO 1ppm H2S in H2
1 ppm H2S injection
5ppm H2S in H2 H2
5 ppm H2S injection
)
Target range for ULSD reformate
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Transient Response
Stack transient response robustness will be a selection factor for non-base load applications like APU’s
System effects of slow response areIncreased energy storage requirements
Higher system losses with energy transport into/out of storage
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Example: Influence of transient response on energy storage requirements for RV’s
0123456789
10
2 5 10 20 50Fuel Cell Stack Power Ramp Rate (W/s )
Num
ber o
f Bat
terie
s R
equi
red
Typical RV’s
~ 1% / sec~ 0.1% / sec
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Real World DurabilityTransient
Ability to sustain start / stop cycles without excessive degradationAbility to enter and recover from state of “hibernation” without degradationAbility to start consistent with loads and manageable energy storage requirements
Operational life timeInterrelated with start time, transient degradationVaries by market but expected to be substantially greater than current technology (gensets)
Low Start Time
Low Cycle Degradation
Extended Start Time
Hi Cycle Degradation
Low Operating Hours High Operating Hours
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Thermal CyclingCell Level
250 thermal cycles and 4500 hours proven at the single cell levelDegradation corresponds to 0.05%/Thermal CycleNo sealing loss as shown at 85% Ut
Test 101406: Steady-State Cell Voltage Degradation Over 250 Thermal Cycles
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time at Current (h)
Cel
l Vol
tage
(V)
TC 5
TC 1
00
TC 7
5
TC 5
0
TC 1
7
TC 7
TC 6
TC 1
50
TC 1
25
Cell Dimensions 10 x 10 cm²T = 750°CI = 0.500 A/cm²Ua = 25%Uf = 50%Fuel = 50:50 H2:N2 Mix / 3% Water
TC 2
00
TC 1
75
TC 2
25
TC 2
50
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GT055526-0037 - 21 Cell PCI - High Power Test20-May-05, TC6
10.0
12.0
14.0
16.0
18.0
20.0
22.0
24.0
0 20 40 60 80 100 120 140Current
Volta
ge
0
300
600
900
1200
1500
1800
2100
Stac
k Po
wer
(W)
Stack VoltageStack Power
21 Cell Stack @ 121 cm2 active area46% Uf, 36% Ua, 0.966 A/cm240 slpm H2, 120 slpm Air675 Furnace Temperature
1900 W0.75 W/cm2
0.78V/cell
Thermal Cycling
Stack Level40 thermal cycles on 21 cell stack segmentFollowing 3000 hours & 6 thermal cycles in-system, this stack segment was operated at 0.966 A/cm2Produced >1900W, at 0.75 W/cm2Average cell voltage ~0.78 V
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Shock & Vibration
Much speculated, some modeling, little dataLimited, anecdotal experience is positiveEngineering issuesPlanar SOFC stacks require controlled clamping load to maintain seals, electrical contactCoefficient of Thermal Expansion mismatch and creep must be controlled
Two pronged approach to evaluation and design:Modeling (ALD)Sub-system testing
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Shock and vibration
Shock & Vibration: As part of a separate, Imperial College, automotive engine effort
The Advanced Battery Solid Oxide Linked Unit to maximize Efficiency (ABSOLUTE) Hybrid, VPS supplied 300 W stack for testingVPS stack was pre-conditioned and performance documented at VPS prior to shipment to EnglandDuring shipment from Versa Power to London, the stack experienced shocks as high as 14.4 G Post-shipment testing at Imperial College indicated no apparent degradation / damage from shipping shocks (stack operated within 1% of rated power)
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Cummins Power GenerationTeaming for Commercialization
Electronic controlsPower electronics Fuel systemsAir handling
systemsNoise and vibrationPower system
integrationManufacturingMarketing, sales,
distribution
High performance SOFC stacks and manifolds
Application engineering expertise and data to support integration of stacks
Reformer development
High temperature thermal integration
Specialized SOFC components (e.g. HT blowers, HT HX)
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Acknowledgements
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Dave BerryDon CollinsHeather QuedenfeldCrystal SharpTravis ShultzWayne Surdoval
Xin LiJie LuoDennis OtrembaBrad PalmerJamal ThompsonCharles Vesely
US DOE SECA DE-FC26-01NT41244
Sofiane BenhaddadBrian Borglum Casey BrownJake KelsallMichael PastulaRandy Petri Mark RichardsEric TangTony Wood
SECA ProgramCummins Power GenerationSECA Phase 1 Review San Antonio, TXAugust 7, 2007
This presentation was prepared with the support of the U.S. Department of Energy, under Award no. DE-FC26-01NT41244. However, any opinions, findings, conclusions, or recommendations expressed herein are those of the author(s) and do not necessarily reflect the views of the DOE.