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DFMA Cost Estimatesof Fuel-Cell/Reformer Systems
at Low/Medium/High Production Rates
Brian D. James, Greg D. Ariff, Reed C. Kuhn, Duane B. Myers
2003 Hydrogen and Fuel Cells Annual Merit Review MeetingBerkeley, California
20 May 2003
Directed Technologies, Inc.3601 Wilson Blvd, Suite 650
Arlington, VA 22201(703) 243-3383 voice(703) 243-2724 fax
Page 2
Project Relevance/Objective
Freedom Car Technical Barriers Addressed:Fuel Flexible Processors Technical Barriers
N: CostComponent Technical Barriers
O: Stack Materials and Manufacturing Cost
Objective:Prepare technology-based cost estimates of complete fuel cell-reformer systems at low/medium/high manufacturing rates to assess the current status and identify the most pressing cost barriers.
Page 3
Project Approach1. Prepare designs of complete automotive FC power systems:
• Onboard gasoline fuel processor and PEM fuel cell system• Direct hydrogen fuel cell system (with 5kpsi H2 storage)
2. Determine costs for system production rates using DFMA* methodology:• DFMA= Design for Manufacturing & Assembly• 500/10,000/30,000/500,000 vehicles per year
3. Consider Current Year Technology (i.e. no dramatic forward projections)
4. Perform Annual Cost Updates
5. Conduct Investigations on Selected Topics
* DFMA is a registered trademark of Boothroyd Dewhurst Inc.
Page 4
Scope of Project
ReformerSystem
Fuel CellSystem
FuelStorage
What is included in Project:•Reformer
•Fuel vaporizer•Burner•Reformer•Shift beds•Gas cleanup
•Fuel Cell System•Fuel cell stacks•Air supply and humidification•Thermal management•Water management
•Fuel Supply System•Power conditioning and electronics (for FC/Ref. Only)•Electrical System•Control System•Sensors•Safety Systems
59.8
23.5
23.08
13.5"OD
4.0
2
2
11
4
16
221
10
14
6 175
12
3
89
A
SECTION A-A
13
3.036.81
Ø3.94
Ø11.5Ø13.5
20
52.9
19182021 7 23
15
Ø4.18
BatterySystem
TIMTraction
Elec. Motor What is not included in Project:•Traction Inverter Module (TIM)•Traction Electric Motor•Peak-Power/Start-Up Battery
Page 5
Project Timeline2001 200320022000
Jan 2000Project Start This
ConferenceJune 2001DFMA Cost Baseline
Sept 2000Baseline Design
Sept 2002DFMA Cost Update
Presentations/ReportsAugust 2002 SAE Future Car Congress PresentationSept 2002 FreedomCar FC Tech Team PresentationMarch 2003 SAE Congress Presentation
July 2001 OATT ReportSept 2001 Program Review Presen.June 2002 OATT Report
Page 6
Accomplishments/Progress
• 2002 DFMA System costing update
• Sensitivity Analysis of Power Density and Material Costs
• Microchannel reformers & HX to reduce cost- In Progress
• Generation of “Roadmap to Lower System Cost”- In Progress
Page 7
System ComparisonReformate System vs. Direct H2 System
(both at 0.7volts/cell)
$0
$5,000
$10,000
$15,000
$20,000
$25,000
$30,000
System AssemblyMisc./BOPControlsFuel LoopReformate LoopATRCoolant LoopWater LoopAir LoopFuel Cell StackMounting Frames
Reformate
500 units/yr 10K units/yr 30K units/yr 500K units/yr
ReformateReformate
Reformate
Syst
em C
ost
$0
$5,000
$10,000
$15,000
$20,000
$25,000
$30,000
System AssemblyMisc./BOPControlsFuel LoopReformate LoopATRCoolant LoopWater LoopAir LoopFuel Cell StackMounting Frames
Reformate
DirectH2
500 units/yr 10K units/yr 30K units/yr 500K units/yr
ReformateReformate
Reformate
DirectH2
DirectH2 Direct
H2
Stack is about half of cost.
Page 8
Stack ComparisonReformate System vs. Direct H2 System
(both at 0.7volts/cell)
$0$2,000$4,000$6,000$8,000
$10,000$12,000$14,000$16,000$18,000 10% Cost Provision
Stack Assembly &InspectionTie-Rods
Endplates
Insulators
Current Collectors
MEA
Bipolar Plates
Reformate
DirectH2
Reformate
DirectH2
DirectH2
DirectH2
Reformate Reformate
500 units/yr 10K units/yr 30K units/yr 500K units/yr
Stac
k C
ost MEA is majority of cost
Page 9
MEA ComparisonReformate System vs. Direct H2 System
(both at 0.7volts/cell)
$0
$2,000
$4,000
$6,000
$8,000
$10,000
$12,000
$14,000 MEA Hotpressing
MEA GasketMaterial &FabricationGas DiffusionLayer Material &FabricationCatalyst,Preparation &ApplicationMembraneMaterials &Fabrication
500 units/yr 10K units/yr 30K units/yr 500K units/yr
Reformate
DirectH2
Reformate ReformateReformate
DirectH2
DirectH2
DirectH2M
EA C
ost
Catalyst(&preparation/application)
Membrane/Ionomer
Page 10
Technical Target Comparison
DTI 2002 Estimates
2003 Status 2005 2010
DTI 2002 Estimates
2003 Status 2005 2010
Fuel Cell Stack $/kWnet $193 $200 $100 $35 $88 - - - includes stack peripherals
Reformer System $/kWnet $65 $65 $25 $10 - - - - includes reformer peripherals
Total System $/kWnet $266 $300 $125 $45 $157 $200 $125 $45 includes final assembly, BOP includes hydrogen storage
FC-Reformer on Tier 2 Gasoline
Direct Hydrogen
DOE Technical Targets DOE Technical Targets
• 50kWnet Systems at 500,000 units per year production volume.
Page 11
Sensitivity Analysis- Stack Power Density
0
50
100
150
200
250
300
350
200 300 400 500 600 700
Power Density, mW/cm2
Stac
k C
ost,
$/kW
gros
s
Stack cost alone (no peripherals)Reformate/Air, 0.7mgPt/cm2 total, 0.2mgRu/cm2
Low Production(500 units/yr)
High Production(500k units/yr)
• Stack resized to maintain constant power
• Power density increase best way todecrease stack cost
0.7 v/c Current Performance
0.6 v/c Current Performance
• Stack scaling only slightly off linear
Page 12
Sensitivity Analysis- Material Cost
• Reformate catalyst cost appearsnot to be significant
• PEM catalyst cost becomes large cost fraction• Ionomer cost becomes a lesser cost fraction
0%5%
10%15%20%25%
ionom
erPEM
catal
yst GDLbipola
r plat
e
refor
ming PM
catal
yst
PrOx P
M ca
talyst
refor
mer insu
lation
shell
mate
rial
Ref. C
atalys
t Suppor
t
Ref. C
atalys
t Applic
ation%
of T
otal
Sys
tem
Cos
t 500 s ys /yr 10k s ys /yr 30k s ys /yr 500k s ys /yr
Page 13
Microchannel Heat Exchangers and Reactors• Technology Description
– Flow channels with a characteristic dimension of <1 mm– High specific heat transfer area– Scalable manufacturing processes
• Why are we considering microchannel components for the fuel processor? Potential for significant improvements over conventional technology– Mass--Weight reduction could benefit entire system– Volume--Microchannel architecture allows dense construction– Cost--Mass manufacturability is possible
• Options for microchannel design in fuel processor– Heat exchanger only: Water vaporizer/boiler– Reactor only: ATR/SR, WGS– HEX/Reactor: PROX
Page 14
Microchannel Patent Resources
Method and apparatus for a fuel-rich catalytic reactor 6,394,791Precision Combustion
Method and apparatus for thermal swing adsorption and thermally-enhanced pressure swing adsorption (Wegeng); Catalysts, reactors and methods of producing hydrogen via the water-gas shift reaction (Tonkovich); Integrated reactors, methods of conducting simultaneous exothermic and endothermic reactions (Tonkovich)
Applications200201949902002011476220030072699
PNNL pending
Active microchannel heat exchanger; Hydrogen separation/purification utilizing rapidly cycled thermal swing sorption; Microcomponent chemical process sheet architecture; Microchannel laminated mass exchanger
6,200,5366,503,2985,811,0626,352,577
PNNL
TechnologyPatent(s)Organization
*InnovaTek is developing microchannel reformers but has not patented the microchannel aspects.
Page 15
Microchannel Water Vaporizer:Heat Exchange
Reformate34 g/s
487ºC, 215 kPaReformate
200ºC, 215 kPa
Water5.6 g/s
68ºC, 345 kPa
Steam376ºC, 340 kPa
•Current design is a finned tube•Microchannel vaporizer design criteria
-Reformate ∆P <1 kPa-Considered to be a stand-alone component (i.e., it was not designed to fit into the Baseline fuel processor)
-Size based on film coefficient calculations for reformate and water, with 5% design allowance
Page 16
Water Vaporizer SummaryHeat Duty 16.6 kW
669
171
707
Volume (cm3)
--
6,775
15,600
Heat Transfer
Area (cm2)
in progress905--MicrochannelDesign (system)
in progress537359MicrochannelDesign (core only)
$613(500/yr);
$151 (500k/yr)
2,58891Existing Finned-Tube Design
CostMass (grams)
Heat Transfer
Coefficient (W/m2-ºC)
• Microchannel heat exchanger provides mass advantage over finned-tube exchanger
• When system integration components are added, volume advantage of microchannels is slight
Page 17
Autothermal Reformer:Reaction
1100ºCpeak
temperatureReformate
650ºCFuel, Air, Water
150ºC
• Current design is a washcoated monolith– Monolith has some attributes of microchannel (~1 mm channels) but lacks the heat
exchange capability– Washcoat does not appear to be diffusion limited ⇒ pores account for only ~10%
of resistance to diffusion• ATR temperatures are prohibitively high for microchannel construction
– Corrosion allowance (5,000 hours, 980ºC) for the most oxidation resistant alloys is ~75 µm per side, or 150 µm total (Inconel 601 is 375 µm per side)
– PNNL patent examples at <750ºC use 125 µm plates• Adiabatic reactions are not a good application for microchannel components
Page 18
Microchannel Summary & Future Tasks• Largest gains will be for integrated systems- not discreet
component substitutions (baseline design already integrated)
• The water vaporizer could realize mass reduction if it were changed to microchannel configuration– 0.9 kg for microchannel vs. 2.6 kg for finned tube– Action item: Calculate cost for mass manufacturing of vaporizer
• Adiabatic operations (ATR and WGS) would have little or no advantage as microchannels– Action item: Examine WGS with integrated heat transfer—may
eliminate one of the WGS stages• Action Item: Consider PROX with integrated reaction/heat
exchange– Mass in current design ~7 kg– Cost in current design $505 @ 500/year, $175 @ 500,000/year
Page 19
Plans & Future MilestonesRemainder of 2003• 2003 DFMA System costing update
• Updates to cell performance, catalyst loading, ionomer cost
• Complete Analysis of Microchannel reactors to reduce cost• component replacement• complete microchannel system• investigate onboard steam reforming
• Complete “Roadmap to Lower Cost”• focus on reformer redesign/simplification• stack power density
• Gas Separation for Enhanced Stack Performance• compact Pressure Swing Adsorption (PSA)• compact Thermal Swing Adsorption (TSA)
Page 20
Plans & Future Milestones2004
• Ambient vs. Pressurized Operation Analysis
• High Temperature Operation Analysis
• Hydrogen Membrane Purification Analysis
• Alternate PEM Fuel Cell Approaches• Alternate stack construtuion• Fuel Cell Pulsing• Alternate Air Compression Approaches
Page 21
Collaboration/Interactions
• Argonne National Lab - reactor design parameters/space velocities
• Oak Ridge National Lab - reactor design
• PNNL - microchannel performance & design
• W.L. Gore & Associates - catalyst loading/FC performance
• DuPont - catalyst loading/FC performance
