Siemens SECA Pgh 2010 07 27.ppt [Read-Only]...SFC Technology has demonstrated Best-in-Class performance Nuon Westervort NetherlandsNuon, Westervort ,Netherlands-Ontario Power - 250

Siemens Energy

11th Annual SECA WorkshopPittsburgh, PAJuly 27, 2010

Joseph PierreSiemens EnergyFossil Power Generation

Schutzvermerk / Copyright-VermerkCopyright © Siemens Energy Inc. 2010. All Rights Reserved

Stationary Fuel Cells

The world is changing –Siemens has answers to these burning questionsSiemens has answers to these burning questions

Population growth

Industry

We solve the challenges of a booming population

Increasing life expectancy

growth

CO2

°C)

CO2emissions

HealthcareD

iffer

ence

from

185

0–18

99 (

1850 1900 1950 2000

-0.5

0.0

0.5

0.7 + 0,76 °C

Energy

We supply better and affordable healthcare

We lower CO2emissions with our

Rising temperatures

GDP increase in

Energy

Copyright © Siemens Energy Inc. 2010. All Rights Reserved

Source: Siemens

energy solutions GDP increase indeveloping countries

Answers provided by 15 Divisions in three Sectorsin three Sectors

Sectors Divisions Former Groups■ Automation and Drives (A&D)■ Industrial Solutions and

Services (I&S)■ Siemens Building

Technologies (SBT)

■ Industry Automation■ Drive Technologies■ Building Technologiesus

try

■ Osram■ Industry Solutions■ Mobility

■ Osram■ Transportation Systems (TS)

■ Power Generation (PG)■ Power Transmission and

Distribution (PTD)

■ Oil & Gas■ Fossil Power

Indu

■ Energy Service■ Power Transmission Distribution (PTD)

■ Industrial Solutions and Services (I&S OGM)

■ Fossil PowerGeneration

■ Renewable Energy

Ener

gy

■ Power Transmission■ Power Distribution

■ Medical Solutions (Med)■ Imaging & IT■ Workflow & Solutions■ Diagnostics

alth

care


Hea

Siemens Energy Sector –Answers for energy supplyAnswers for energy supply

Energy products and solutions – in 6 Divisions

Power Distribution

Power Transmission

Oil & Gas Fossil PowerGeneration

RenewableEnergy

Energy Service


Fossil Power Generation Division –Organizational structureOrganizational structure

DivisionFossil Power Generation

BusinessUnits

Products(E F PR)

CEO Dr. Michael Suess

Energy Solutions(E F ES)

Instrumentation &Electrical (E F IE)

Business Segment( )

■ Steam Turbines■ Generators■ Gas Turbines

■ Northern Europe, CIS, Germany

■ Southern Europe

■ Power Plant Solutions, Europe, CIS

■ Power Plant Solutions

Segments

( ) ( )

New Technologies(E F NT)■ Fuel Gasification■ Gas Turbines

■ Sales■ System Integration■ Feeder Plants

■ Southern Europe, Africa, Middle East,West Asia

■ Region Americas, Asia-Pacific, Australia, Spain, Portugal

■ Power Plant Solutions, Near Middle East, Africa, Asia-Pacific

■ Power Plant Solutions Americas

■ Steam Power Plant

■ Fuel Gasification■ Stationary Fuel Cells■ Carbon Capture

and Storage

p g■ Intergroup Business

and Operational I&C NPPs

■ Product Management

Solutions■ Project Site Execution■ Module &

Project Engineering

Nuclear Power,Conventional Island(E F NP)


Nr. 2 Nr. 2 Nr. 1 Marketposition

New Technologies Business Segment (E F NT)New Technologies Business Segment (E F NT)

Portfolio Strategy

■ Fuel gasification– Gasifier– Technology licenses– Gasifier island solutions for IGCC,

■ Expansion of the gasifier component business■ Development and marketing of other CCS

components (C b C t d St )Gasifier island solutions for IGCC,

production of chemical products from coal („Coal-to-Chemicals“)

■ Stationary fuel cells■ New technologies for carbon capture

(Carbon Capture and Storage)■ Development of IGCC-integrated concept

solutions

g p


Welcome to SFC HeadquartersWelcome to SFC Headquarters

Bldg. 304 High Pressure Test Lab

Bldg. 801 Engineering and AdministrationBldg. 601 Manufacturing and Development


George Westinghouse Science and Technology Park

SFC Technology has demonstrated Best-in-Class performance

Nuon Westervort Netherlands - Ontario Power - 250 kW CHPNuon, Westervort ,Netherlands100 kW CHP RWE, Essen, Germany – 100 kW CHP

Ontario Power - 250 kW CHP

GTT Torino, Italy - 100 kW CHPPhase I Stack Test

, y

SCE, Irvine, CA - 220 kW Pressurized Hybrid SFC 5 kWe Stadtwerke Hannover, Germany

SFC 200 CHP

SECA HPD5 kW


Developed over 25 fully integrated SOFC power generating systems, including the world’s first pressurized hybrid demonstration unit

AcknowledgementAcknowledgement

This material is based upon work supported by the Department of Energyunder Award Numbers DE-FC26-05NT42613


DOE SECA Coal-based System Program

Program ObjectivesPhase I Conceptual design and feasibility analysis of baseline design and Proof-of-Concept (POC) system 3Q2008

DOE SECA Coal based System Program

Verify Delta-8 performance via cell and stack tests 3Q2008 Initiate and complete 5,000 hrs Delta8 R0 stack test 1Q2009

Phase II

Detailed design performance and cost anal sis of baseline design 3Q2010 Detailed design, performance, and cost analysis of baseline design 3Q2010 Initiate and complete 1,500 hrs of operation Delta8 R1 Stack Test 3Q2010

Phase III Initiate and complete 5,000 hrs operation of Delta8 “MWe-class” module 3Q2012 Initiate and complete 25,000 hrs operation of MWe-scale POC System 3Q2015

A Multi-Year, Multi-Phase DOE Program Phase I – 3 years: $26M Phase II – 2 years: $17M

Phase III 5 ears $33M

Initiate and complete 25,000 hrs operation of MWe scale POC System 3Q2015 Corroborate performance and cost of 100 MWe baseline design 3Q2015

Phase III – 5 years: $33M

The ultimate goal of DOE program beyond Phase III: Coal syngas fueled >100 MWe class fuel cell


The ultimate goal of DOE program beyond Phase III: Coal syngas fueled, >100 MWe class fuel cell central station efficiency >50%, with 90% CO2 isolation at $400/kWe (excluding CO2

sequestration and gasification systems)

DOE SECA Coal-based System ProgramPhase II Key Activities

Baseline Systems Analysis

Phase II Key Activities

Cell and Module Development

POCD8R1 Stack Test


Significant ResultsSignificant Results

• Identified an alternate high(er) efficiency cycle conceptIdentified an alternate high(er) efficiency cycle concept

• Increased power density between 800-1000C on cylindrical cells through material and process improvements

• Showed voltage stability of the power-enhanced cells at 900o and 1000oC

• Demonstrated stability of the power-enhanced cells through 10 thermal cycles

• Transfer power enhancement technology to Delta8 cells

• Initiated testing of a power-enhanced Delta8 cell

• Continued HPD test with an excellent voltage stability

• Completed construction and initiated validation of Pressurized Test Facility


Facility

• Initiated POCD8R1 Stack Test

Baseline System Analysis

GoalsMust Operate on Coal Synthesis GasM t U F l C ll

Baseline System Analysis

Technical ChallengesCell performance confirmationEffi i t tMust Use a Fuel Cell

CO2 Capture ≥ 90%Efficiency ≥50% (Net AC/Coal HHV)Power System Capacity >100 MWe

Efficiency targetsHandling inerts in the alternate high

efficiency cycle conceptWater management

Cost ≤ $600/Max kWe (End Phase 1 Concept Design)

Objectives

AccomplishmentsContinued evaluation of alternate higher

efficiency conceptBaseline System Performance and Cost Estimate

UpdatesBaseline System Performance AnalysisConfirm the Proffered Baseline System Concept

y pValidated performance and cost of the

Baseline System

Confirm the Proffered Baseline System ConceptBaseline System(s) Definition and Analysis Baseline System Cost AnalysisFactory Cost Report


Pressurized Cell Testing

Goals:Validate the existing test facility against existing

i d ll t t d t

Pressurized Cell Testing

Technical Challenges:Fuel distribution within the test article

pressurized cell test data. Obtain performance data on the Delta8 cell

configuration under pressurized conditions

High temperature leak rateFuel bypass

Objectives:Design improved Delta8 pressurized test

Activities: Assembly of tubular cell test article

articlesProcure and assemble tubular test articles to

validate test rigUpgrade existing test facility

completedInstallation of tubular test article into test

facility completedFacility modifications and shakedown

Conduct testing and obtain performance data at elevated pressures

Conduct post test analysis

underway


Pressurized Cell & Stack TestTubular Cell Test 1213 Heater AssemblyTubular Cell Test 1213 – Heater Assembly

T t ti l 1 ½ clam shell All (4) clam shell

Clam-Shell heaters


Test article 1 ½ clam shell heaters installed

All (4) clam shell heaters installed

Pressurized Cell & Stack TestT b lar Cell Test 1213 Ins lation WrapTubular Cell Test 1213 – Insulation Wrap

Insulation wrap


Before final insulation

Insulation complete Covered with Aluminum sheeting

Pressurized Cell & Stack TestT b lar Cell Test 1213 Installation in Test RigTubular Cell Test 1213 – Installation in Test Rig

Article installed in pressureArticle installed in pressure vessel with final insulation wraps

Pressure vessel


Article lowered into the pressure vessel

Cell DevelopmentCell Development

Technical Challenges• Dimensional control (side bow and taper) of Delta8

cell

Goals• Achieve cost and performance requirements

tili i HPD D lt 8 l l l ll cell• Elimination of air electrode flaws• Elimination of closed end cracks• Ability to achieve high yield with Delta8 cell• Ability to spray electrolyte at high feed rates in

utilizing HPD Delta8 seal-less planar cell design

• Manufacture Cells and Bundles for Proof-of Concept tests

Ability to spray electrolyte at high feed rates in carousel design

• Demonstrate ability to implement additive into a manufacturing friendly process

Objectives• Develop process conditions for the

manufacturing of the air electrodes for the D lt 8 t ti l th ll hi h Activities/AccomplishmentsDelta8 one meter active length cells which improve quality and lower cost

• Develop process conditions for the application of electrolyte, fuel electrode, and interconnection utilizing PS which improve

Activities/Accomplishments• Dimensional control of air electrode• Reduction of Air Electrode Flaws• Elimination of closed end cracks

interconnection utilizing PS which improve quality and lower cost

• Develop high quality, low cost process for the bundling of Delta8 cells

• Development lower operating temperature

• Application of electrolyte at commercially viable conditions

• Cell and Bundle Development and Manufacturing• Demonstrate stable high performance of power-

h d ll


Development lower operating temperature cell enhanced cells

• Evaluation and definition of manufacturing process for power enhanced cells

Performance of Power Enhanced Cylindrical CellPerformance of Power Enhanced Cylindrical Cell

0.875900°C D t

0.750

0.775

0.800

0.825

0.850 900° C Data940° C Data800° C Data1000° C Data

0.625

0.650

0.675

0.700

0.725

Cel

l Vo

ltage

(V)

0 500

0.525

0.550

0.575

0.600

0.50050 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475

Current Density (mA/cm 2)


Enhanced power at all temperatures

Voltage Stability of Power Enhanced Cylindrical CellVoltage Stability of Power Enhanced Cylindrical Cell

1.100 1100

0.800

0.900

1.000

age

(V)

800

900

1000

0 400

0.500

0.600

0.700

Den

sity

(A/c

m2 )

- V

olta

400

500

600

700

ell

Tem

pera

ture

(°C

)

Cell Vo ltageCurrent DensityAverage Temperature

0.100

0.200

0.300

0.400

Cur

rent

D

100

200

300

400 Ce

J = 200 mA/cm2

………. Test Continues0.000

0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 12,000 13,000

Elapsed Time on Test (hours)

0


Excellent Voltage Stability … Test continues…

Cell Thermal Stability – Cylindrical CellsCell Thermal Stability Cylindrical Cells

1.100 1100Cell Voltage

0.800

0.900

1.000

olta

ge (V

)

800

900

1000Current DensityAverage Temperature

900° C

1000°

0 400

0.500

0.600

0.700

ensi

ty (A

/cm

2 ) -

Vo

400

500

600

700

Tem

pera

ture

(°C

)

10 Thermal Cycles Stand tripped.

0.100

0.200

0.300

0.400

Cur

rent

D

100

200

300

400

0.0000 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400

Elapsed Time on Test in Hours

0


Cell went through 10 thermal cycles without losing voltage and was very stable at 1000C. Test continues…

Delta8 Cell AssemblyDelta8 Cell Assembly


Delta8 Cell Performance Curve-Voltage vs. Current DensityDensity

0 800

0 725

0.750

0.775

0.800

0 650

0.675

0.700

0.725

Volta

ge (V

)

D elta 8 @ 900°C

0 575

0.600

0.625

0.650D elta 8 @ 800°C

0.550

0.575

0 50 100 150 200 250 300 350 400

Current Density (mA/cm2)


Cell assembly process needs to be improved to lower fuel by pass

Delta8 Cell Life Time PlotDelta8 Cell Life Time Plot

0 800

0.900

1.000

1.100

800

900

1000

1100

C)800°C

900°C

0 500

0.600

0.700

0.800

olta

ges

(V)

500

600

700

800

& T

empe

ratu

re (

°C

0.200

0.300

0.400

0.500

Cel

l Vo

200

300

400

500

Cur

rent

(Am

pere

s

J = 250 mA/cm2

(485 Amperes)

0.000

0.100

0.200

0 100 200 300 400 500 600 700 800 900 1000


0

100

200Closed End VoltageCurrent (amps)Average Temperature



HPD Voltage StabilityHPD Voltage Stability

0 80

0.90

1.00

1.10

(A/c

m2 ) Average Temperature: 900ºC

Fuel Utilization: 80%Fuel: Humidified Hydrogen

UpgradedTesting

Instrumentation

Stand Maintenance an

Calibration

0.50

0.60

0.70

0.80

rren

t Den

sity

(

Cell Voltage (V)

0.20

0.30

0.40

0.50

olta

ge (V

), C

ur Current Density (A/cm2)

0.00

0.10

0 2,500 5,000 7,500 10,000 12,500 15,000 17,500 20,000 22,500 25,000 27,500 30,000 32,500

Test Duration (Hours)

Cel

l Vo


Test Duration (Hours)

POCD8R1 Stack TestPOCD8R1 Stack Test

Technical Challenges (D&B)• Cell Production / Bundle Assembly

– Cell production yield

Goals• Deliver a ≥ 25 kWe SOFC stack

i ti D lt 8 ll Cell production yield – Cell/bundle dimensional tolerances– Bundle assembly and sintering

• Back-up for critical contractor • Delta8 cell and bundle integrity

incorporating Delta8 cells• Initiate End-of-Phase II Stack Test• Achieve 1,500 hrs operating time prior to

End-of-Phase II• Satisfy performance requirements as

specified in the Minimum Requirements Document

Objectives (D&B) (FY)• Complete R1 module design 3Q09 • Complete R1 module assembly 2Q10• Cells and bundle manufacturing 4Q09

Activities/Accomplishments• Integrating BOP with test article• Validating control system software• Assembling external recirculation loop

Id tif d lif b k hi i t tCells and bundle manufacturing 4Q09• Complete R1 BOP design 3Q09• Complete R1 BOP assembly 4Q09• Complete R1 test article 2Q10

bl d i t ll ti

• Identify and qualify backup machining contractor


assembly and installation• Initiate stack test 2Q10

POCD8R1 Stack TestPOCD8R1 Stack Test

Technical Challenges• Fuel side heating

Goals• Initiate End-of-Phase II SECA Stack Test

• Anode stream recirculator• New stack architecture (IBA)• One meter Delta8 cells

• Achieve 1,500 hrs operating time prior to End-of-Phase II

• Satisfy performance requirements as specified in the Minimum Requirements

Objectives

Document

Activities/AccomplishmentsObjectives• System startup 03/01 • Begin Load to NOC 03/07• Initiate cell conditioning 03/21

Activities/Accomplishments• Initiated stack test • Heatup completed• Introduction of NHmix and Hydrogen

• Peak power test 04/06• VJ curves at NOC 04/25• Initiate Stability Test 04/25• Initiate system shutdown 06/25

• Achieved current loading >300 amps• Disassembly/Root Cause Investigation completed


y• Stack test completed 06/27• Complete Root Cause

Investigation 06/15

POCD8R1 Stack Test SummaryPOCD8R1 Stack Test Summary

• Second generator to test Delta 8 cells First, POCD8R0, operated for 5300 hours with max DC power of 9.8 kW Stack was damaged due to failure of the control system hard drive

• Began operation in March 2010 Operated for 400 hours

C Loaded to 11.1 kW stack DC power• Design successfully demonstrated many advanced features:

Integral Bundle Assembly (IBA)Cast ceramic components Cast ceramic components

Fuel side heating Fuel recirculator

• Several cells failed during an air transient at 400 hoursSeveral cells failed during an air transient at 400 hours Stack failed during loading (311 amps at failure vs 818 amps at NOC) Stack was damaged early in heatup by intermittent electrical shorts caused

by carbon formation


y Stack contained more organic binders than previous generators

Delta 8 CellDelta 8 Cell

Plating Electrolyte Interconnection

C th dA d CathodeCathode(Air electrode)

Anode (Fuel electrode)

Cathode –Electrolyte

Component MaterialCathode (Air Electrode) Doped lanthanum manganiteElectrolyte Scandia stabilized zirconium oxide

Delta 8 Cell Materials

Electrolyte Scandia stabilized zirconium oxideInterconnection Doped lanthanum chromiteAnode (Fuel Electrode) Nickel – zirconium oxide cermetPlating Nickel


POCD8R1 Stack Test – Delta8 Bundle (8 cell)POCD8R1 Stack Test Delta8 Bundle (8 cell)


POCD8R1 Stack Test - IBA & Bundle Row AssemblyPOCD8R1 Stack Test IBA & Bundle Row Assembly


Up-righting finished IBA Row AssemblyUp-righted IBA

POCD8R1 Stack Test - Bundle RowsPOCD8R1 Stack Test Bundle Rows

Copyright © Siemens Energy Inc. 2010. All Rights ReservedBundle rows installed in the stack assembly fixture

POCD8R1 Stack TestStack AssemblyStack Assembly

Copyright © Siemens Energy Inc. 2010. All Rights ReservedStack being installed into container

POCD8R1 Generator and Recirculation LoopPOCD8R1 Generator and Recirculation Loop

Advanced features:• Integral Bundle g

Assembly (IBA)• Cast ceramic

components • Fuel side heating• Fuel side heating• Fuel circulator

Prereformer

Circulator


Fuel Heater

POCD8R1 Test FacilityPOCD8R1 Test Facility


POCD8R1 Instrumentation and ControlPOCD8R1 Instrumentation and Control


POCD8R1 OperationPOCD8R1 Operation


POCD8R1 Stack Test Root Cause AnalysisRoot Cause Analysis

Power Lead Root Cause Analysis Process

Recirculation Outlet

Fuel Plenum

• Review stack voltage data• Review stack temperature data• Review fuel cell manufacturing

Cell StackRecirculation

Inlet

Recirculation Plenum

history• Review operating procedure• Review thermal stress models

Outer Container

Fuel Barrier• Carefully examine disassembly of test article

• Perform fractography analysis on Process Air

Exhaust

Outer Containerbroken fuel cell• 58 observations• 12 failure mechanisms


• 31 recommendations• Path forward defined

In-stack CarbonIn stack Carbon

Carbon on Saffil FeltCarbon on Saffil Felt


Damaged Bundle Row

POCD8R1 Stack Test Root Cause InvestigationPOCD8R1 Stack Test Root Cause InvestigationBundle 5 Shorting During Heat Up

800

1000

7.7

7.9

T05T

600

empe

ratu

re (C

)

7.5

Volta

ge (V

)

T05MV_B5

V_B2

V_B1V B3

200

400Te

7.1

7.3V_B3V_B4

V_B6

Bundle 5 voltage experienced t h t d i h t

03/4/2010

0:003/4/2010

4:483/4/2010

9:363/4/2010

14:243/4/2010

19:123/5/2010

0:003/5/2010

4:483/5/2010

9:363/5/2010

14:243/5/2010

19:123/6/2010

0:00

Time

6.9

two shorts during heat up


Bundle 5 shorting at low temperature may have led to tight closed end fuel cell cracks

Time

AcknowledgementsAcknowledgements

Special thanks go to:

• Joe Stoffa, Program Manager• Heather Quendenfeld, Director, Power Systems Division

Wayne Surdoval• Wayne Surdoval• Travis Shultz


AcknowledgementsAcknowledgements

A sincere debt of gratitude to the more than 250


dedicated employees – past and present - of the Siemens Stationary Fuel Cell Division

Documents

Siemens SECA Pgh 2010 07 27.ppt [Read-Only]...SFC Technology has demonstrated Best-in-Class performance Nuon Westervort NetherlandsNuon, Westervort ,Netherlands-Ontario Power - 250