Development Update on Delphi’s Solid Oxide Fuel Cell Systems

Steven ShafferChief Engineer – Fuel Cell Development

San Antonio, TX2007 SECA Annual Review Meeting

2

Fuel Cell Development Team

Acknowledgements

3

Solid Oxide Fuel Cell Market Opportunity

derivatives

US Stationary – APU & CHPNatural Gas, LPG

European micro –CHP& CHCP

Natural Gas

Commercial PowerNatural Gas

FutureGen PowerplantCoal Gas

Recreational VehiclesDiesel, LPG

US MilitaryJP-8

Heavy Duty TruckDiesel

Truck and Trailer Refrigeration

Diesel

4

Truck Cabs are Getting More Advanced

Margaret Sullivan, PACCARTrucks: Truck of the Future2003 Conference ProceedingsFourth Annual SECA Meeting - Seattle, WAApril 15-16, 2003

5

Anti-idling Regulations - State & Local

State-wide idling regulation

Limited to specific areas,

cities or counties

No anti-idling regulation

Source and Details: http://www.atri-online.org/2005.ATRI.IdlingCompendium.pdf

http://www.epa.gov/smartway

In 22 States Anti-Idling laws are adopted(Total Number of States, Counties, Urban areas and

Citieswhich have anti-idling laws in place is 34)

6

Internal Combustion Engine APUs (Diesel)

Margaret Sullivan, PACCARTrucks: Truck of the Future2003 Conference ProceedingsFourth Annual SECA Meeting - Seattle, WAApril 15-16, 2003

SOFC Subsystem DevelopmentStack

8

Generation 3 StackKey Features

Key Stack characteristics– Cassette repeating unit configuration – High volume manufacturable processes (stamping, laser-welding, etc)– Integrated manifold and compact load frame– Low mass and volume

Cassette

Separator plate

Picture frame

Cassette

Separator plate

Picture frame

Generation 3 (30 cell),9 Kg, 2.5 L

9

MG735C584 - 30plus2 Date: 6/22/2007Fuel: 50%H2-50%N2 - Stand #4 Flows: 89.8(A), 148(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)

Stac

k Vo

ltage

(V)

0

50

100

150

200

250

300

350

400

450

500

Pow

er D

ensi

ty (m

W/c

m2)

Stack Voltage (V) Power Density (mW/cm^2)

Generation 3 30-Cell Stack Data

Data below shows a typical 30-cell Generation 3.2 stack tested in the stack laboratory– Produced greater than 450 mW/cm2 at 0.8V per cell with 48.5% H2, 3% H2O, rest N2

10

MG735C584 - 30plus2 Date: 6/22/2007Fuel: 50%H2-50%N2 - Stand #4 Flows: 89.8(A), 148(C)

Stack Cell Voltages for Polarization Test at 60.14 Amps

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30

Cell

Cel

l Vol

tage

(V)

Cassette to Cassette Variation in a 30-Cell StackConsistent performance between cassettes in a Gen 3.2 30-cell stack

– 570 mA/cm2, 48.5% H2, 3% H2O, rest N2– Maximum voltage difference is 0.04 Volts

11

5-cell Stack on Durability Test

MG735C572 - 5plus2 Dates: 5/17/2007 to 7/16/2007Fuel: 50%H2-50%N2 Flows: 8.1(A) 30(C)

Stack Voltage and Power Density for Constant Current Test

0

1

2

3

4

5

6

7

8

9

10

0.00 200.00 400.00 600.00 800.00 1000.00 1200.00 1400.00

Time (Hrs)

Stac

k Vo

ltage

(V)

0

50

100

150

200

250

300

350

400

450

500

Pow

er D

ensi

ty (m

W/c

m2)

Stack Voltage (V) Power Density (mW/cm^2)

Data from 5-cell stack tested for continuous durability– 35% H2, 30% H2O, rest N2, 50% fuel utilization– 570 mA/cm2

– No degradation in 1300 hours – test continuing

12

5-cell Stack on Simulated Diesel Reformate (including 2.5 ppmv H2S) – 3500 Hours

MG735C530 - 5plus2 Dates: 2/6/2007 to 6/29/2007Fuel: DRef+H2S Flows: 3.9(A) 25(C)

Stack Voltage and Power Density for Constant Current Test

-5

-3

-1

1

3

5

7

9

0.00 500.00 1000.00 1500.00 2000.00 2500.00 3000.00 3500.00 4000.00

Time (Hrs)

Stac

k Vo

ltage

(V)

0

100

200

300

400

500

600

700

800

900

1000

Pow

er D

ensi

ty (m

W/c

m2)

Stack Voltage (V) Power Density (mW/cm^2)

H2S introduced

Data from 5-cell stack being tested on simulated diesel reformate at 750oC with 2.5 ppmv H2S

– 28% H2, 30% CO, 6% H2O, 2.5 ppmv H2S – Initial H2S added at constant current density of 570 mA/cm2, 26% drop in performance observed– Current density re-set at 190 mA/cm2 at the nominal operating point– No secondary degradation

13

Increased tape cast width capability of TCF tape casterDeveloped machine specifications for higher volume cell production processingDeveloped timing plan for progression to higher volume cell productionSuccessfully demonstrated capability for fabricating larger footprint bilayers (up to 350 cm2 active area)Added larger screen printer capable of printing very large cells

Key Cell Scale-up Developments

14

Scale-Up of Cell Active Area

SOFC Subsystem DevelopmentReformer

16

Fuel Reformer Development

Delphi is developing reforming technology for Natural Gas, Gasoline and Diesel/JP-8 for SOFC applicationsTwo main designs are being developed:

– CPOx Reformer» Moderate efficiency» Simplicity of design» Not recycle capable

– Recycle Based (Endothermic) Reformer

» High efficiency » Use of water in anode tailgas

to accommodate steam reforming

» Recycle capable

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CPOx Reformer (productive concept)

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Tubular Endothermic Fuel Reformer

Reformate Out

Anode Tailgas Fuel

Cathode Tailgas Air

Recycle

Fuel

Ref A

ir

19

Endothermic Reformer on Test Stand

SOFC Subsystem DevelopmentBalance of Plant

21

Blowers/Pumps

Process Air Module (PAM) Anode Tailgas Recycle Pump

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High Temperature Compact Heat Exchangers

Cathode Air Heat Exchanger

Recycle Cooler

Cathode/Anode Temp. Equalizer

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BOP High Temperature Seal – Thermal cycling• Background :

– High temperature seals between Stack base manifold, Heat exchanger and Reformer to Integrated Component Manifold.

– 50 Thermal Cycles (25C to 900C) – Leak rates < .01 sccm; Helium @ 2psi

Unplated HEX C-Rings(50 Thermal Cycles)

PL316 - C174

0

100

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300

400

500

600

700

800

900

1000

0 5 10 15 20 25 30 35 40 45 50

Cycle Number

Tem

pera

ture

(o C

)

1.00E-10

1.00E-09

1.00E-08

1.00E-07

1.00E-06

1.00E-05

1.00E-04

1.00E-03

1.00E-02

1.00E-01

1.00E+00

Leak

Rat

e (s

ccm

)

Temperature Anode In - Port 1 Cathode In - Port 2 Cathode Out - Port 3 Anode Out - Port 4

Note: All readings taken at 2 psi He

Seal Rings Thermal Cycle test

24

Chromium Vaporization Testing• A test method has been established to measure the rate of

chromium vaporization – Materials are being tested for the rate of chromium vaporization– Coatings for materials and other methods for mitigating chromium vaporization are

being evaluated. – Test methodology also applied to SOFC System and data collected during system

operation

SOFC System Integration

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Delphi Systems Developed During Phase I

2003

Gen 2A0.220 kWgross

2004

Gen 2B/2C0.423 kW, 3.3% efficiency

2005

SPU 1A1.18 kW, 17% efficiency

2006

SPU 1B2.16 kW, 38% efficiencyPhase I Progress

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DC POWER OUTPUT

DESULFURIZED FUEL INPUT

SIGNAL I/O

HOT EXHAUST

AIR INLET

THERMALINSULATION

HOT ZONE MODULE

PLANT SUPPORT MODULE

APPLICATION INTERFACE

MODULE

PROCESS AIR

MODULE

2x30-cell SOFC STACKS

CATHODE AIRHEAT EXCHANGER

CPOX NATURAL GAS REFORMER

SPU 1 SOFC System(NG Stationary & Diesel APU)

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SOFC System Mechanization-CPOx

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SOFC System Mechanization-Anode Tail Gas Recycle

No external water required

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Delphi SOFC System Development Platforms

Set 00 SPU 1 SPU 2

3 kW Development System

3 kW Auxiliary Power Unit

5 kW Stationary Power Unit

NG Q1&Q2 2007 Q1&Q2 2007 Q4 2007*

Diesel Q3 2007 Q3 2007 Q1 2008**Pending

31

SPU 1 System Performance with Improved Stack Temperature Profile

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0 10 20 30 40 50 60 70 80 90 100

Stack Current, Amps

Net

Sys

tem

Effi

cien

cy, %

-1000

-500

0

500

1000

1500

2000

2500

3000

3500

4000

4500

Pow

er, W

Net System EfficiencyStack Gross Power [W]Net System Power [W]

32

Natural Gas (NG) Desulfurization

• Prototype desulfurizers provided by supplier • Successfully demonstrated over 1000 hrs on system test

– Consists of a combo-sorbent bed

Sulfur species present in RGE NG at Delphi SOFC Test Facility

33

Set 00 System Performance 1000 Hour Stability on Natural Gas (CPOx)

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48

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60

0 100 200 300 400 500 600 700 800 900 1000

Time (Hours)

Cur

rent

& V

olta

ge (A

& V

)

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0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

Syst

em P

ower

(KW

)

Stack VoltageNet System Power - 15 Minute AverageLinear (Stack Voltage)

0.84%/500

34

Thermal Cycling of Stacks10-cell stack thermally cycled in a furnace 16 times

– Room temperature to operating temperature in ~90 mins– No loss of power -16 cycles

Thermal Cycles vs Power Density (48.5 % H2, 3% H2O, rest N2 fuel, room temp to 750oC thermal cycles in a furnace)

300

320

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380

400

420

440

460

480

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Thermal Cycles (#)

Pow

er D

ensi

ty @

60

Am

ps

Power Density @ 60 Amps

35

SPU 1 System PerformanceTypical Thermal Cycle

0 10 20 30 40 50 60 700

200

400

600

800

1000

Tem

pera

ture

, deg

C

Delphi SOFC System Thermal Cycling (Set 6-MG736C16601)

Left (553) Cathode InletLeft (553) Anode Outlet

0 10 20 30 40 50 60 700

200

400

600

800

1000

Elapsed Time on Stream (hours)

Tem

pera

ture

, deg

C

CombustorReformer Catalyst

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SPU 1 System Performance45 Thermal Cycles Completed

60

60.5

61

61.5

62

62.5

63

63.5

0.00 200.00 400.00 600.00 800.00 1000.00 1200.00 1400.00

Durability Hour

Ope

n C

ircui

t Vol

tage

, vol

ts

Phase II Next Steps:

38

1.5 kW Diesel APU SPU 1E – 78 L

3 kW Diesel APU – 178 L

Next Steps:Design of New Diesel APU Platform

39

Next Steps:Phase II Performance Testing of SPU 2 System

4x30-cell Gen 3.1 SOFC Stacks in electrical and flow series/parallel configuration

Combustor

Gen 4.2T Natural Gas Reformer

Insulation shell

Recycle cooler heat exchanger

Targets:5 kW Net45% Efficiency

40

System Analysis and Conceptual Stack Design

Provided to Delphi by UTRC

High Efficiency Coal-Based SOFC - Gas Turbine Hybrid System

41

SOFC-Gas Turbine Hybrid Power Plant

System efficiency include CO2 capture and compression to sequestration-ready pipeline conditions

System efficiency approaches 60% without counting CO2 capture and compression

System based on pressurized SOFC integrated with a Twin Pack of UTC Pratt & Whitney’s FT8-3 Gas Turbines

Operate on gasified coal composition as specified by NETL

150 MW system concept reaches efficiencies >53% (HHV) w/ CO2 capture

Modify existing FT8-3 engine is more cost effective than beginning a new engine design program. Design changes can result in 15% reduction in FT8 capital cost

42

SOFC with Bottoming Rankine Cycle Power Plant

System efficiency include CO2 capture and compression to sequestration-ready pipeline conditions

System efficiency approaches 47% without counting CO2 capture and compression

System based on ambientambient SOFC integrated with a bottoming Organic Rankine Cycle

∼35 stacks in the system and ∼ 300 cells per stack

1 MW demo system concept reaches efficiency >43% (HHV) w/ CO2 capture

Required cell power density in the range of 0.27 -0.3 W/cm2

43

SOFC Stack Module Concept

Annular stack module design

10 MW module array with single supply / exhaust lines

Module power 1MW

Module diameter ∼250 cm

Stack power 50 kW

Cell active area 360 cm2

Power density 0.45 W/cm2

∼280 cells per stack

1 MW module

44

SOFC Stack Module ConceptLinear stack module design

2.5 MW module array with single supply / exhaust lines

Stack power 500 kW

Cell active area 360 cm2

Power density 0.45 W/cm2

∼2800 cells per stack

45

Summary of Phase II Progress:

Set 000.84%1.0%%/500 hrsDegradation Rate

Set 0010001500*hrsOperation Life

Completed SPU 13650cyclesCycle Durability

Projected SPU 2$670 $600 $/kWCost

SPU 138%40%%Fuel to Electric Efficiency (Peak)

SPU 13.43-10kWNet Rated Power

Nat GasNat GasFuel

3Q 20074Q 2008Target Date

Current Status

DOE/SECA Ph II

(CONTRACT)Target Metric

7/24/2007 0:00