Fossil Energy Fuel Cell Program
Wayne Surdoval, SECA CoordinatorJune 3, 2003
National Energy Technology LaboratoryOffice of Fossil Energy
SECA Core Technology
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SECA CORE TECHNOLOGY PROGRAM
W. Nernst“Electrical Glow-Light”
U.S. Patent 623,811April 25, 1899
CC
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SECA SECA Program Structure
Program Management
ResearchTopicsNeeds
Industry Integration TeamsTechnology
Transfer
Small BusinessUniversity National
LabIndustry
PowerElectronicsModeling &Simulation
Materials
Controls &Diagnostics
FuelProcessing
FuelProcessing
Manufacturing
Modeling &Simulation
PowerElectronics
Controls &Diagnostics
Manufacturing
Materials
Core Technology Program
Fuel CellCore
Technology
Project Management
Industry Input
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Core Technology Program Powering All Ships
SiemensWestinghouse
SiemensWestinghouse
DelphiDelphiGeneralElectricGeneralElectric
FuelCellEnergy
FuelCellEnergy
AcumentricsAcumentrics
Cummins PowerGeneration
Cummins PowerGeneration
• Materials• Modeling and simulation• Fuel processing
• Power electronics• Controls and diagnostics• Manufacturing
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Intellectual PropertyIntellectual PropertyCornerstone of the AllianceCornerstone of the Alliance
• Non-Exclusive License
- Open for 1 year after issue of a U.S. patent
- Ready market of potential licensees
- Best designs vs. highest bidder
- Dispute Resolution Mechanism
• Promotes Collaboration - Limits Duplication• Pilot program; reevaluate after 2 years
CTP Industry Teams
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Solid Oxide Fuel Cell
OxidantFlow
FuelFlow
OxidantFlow
End Plate
CathodeElectrolyte Matrix
Anode
BipolarPlate
CathodeElectrolyte Matrix
Anode
End Plate
FuelFlow
Current Flow
Fuel Flow
Anode
Interconnection
Electrolyte
Cathode
Air flow
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The Vision: Fuel Cells in 2010
Cost
Volume
Low Cost/High VolumeLow Cost/High Volume$400/kW > 50,000 units/yr$400/kW > 50,000 units/yr
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Different Approaches!
• Stack extrusion• Plasma spray
• Cathode supported• 800 C• Redesigned tubular• Seal-less stack
SiemensWestinghouse
• Tape calendering• 2–stage sintering
• Anode supported • 750 C• Hybrid compatible• Internal reforming
General Electric Company
• Tape casting• Screen printing• 2–stage sintering
• Anode supported • 750 C • Ultra compact• Rapid transient capability
Delphi-Battelle
• Tape casting • Screen printing• Co-sintering
• Electrolyte supported• 850 C• Thermally matched materials• Seal-less stack
Cummins-SOFCo
ManufacturingDesignTeam
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Two New Different Approaches!
• Tape casting• Screen printing• Co-sintering• Electrostatic
deposition
• Anode supported • < 700 C • Low cost metals
FuelCellEnergy, Inc.
• Extrusion• Dip processing• Spray deposition
• Anode supported microtube• 750 C• Thermally matched materials• Robust & rapid start-up
AcumentricsCorporation
ManufacturingDesignTeam
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SOFC Materials Costs
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Current Priorities: Core Technology Program
• Lower cost precursor processing • Cost model methodology
Material cost4
• Direct DC to AC conversion• DC to DC design for fuel cells
Powerelectronics
3
• Metal oxides with interface modification• Catalyst surface modification• Characterize thermodynamics/kinetics
Anode/fuel processing
2
• Micro structure optimization• Mixed conduction• Interface modification
Cathodeperformance
2
• Models with electrochemistry• Structural characterization
Modeling2
• Modifying components in alloys• Coatings
Interconnect1• Glass and compressive seals Gas seals1
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SECA Budget ($M)
0
5
10
15
20
25
30
35
2000 2001 2002 2003
Industry TeamsCore Technology Program
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Core Technology Program FY 2003
$4,648,150
$2,399,963
$533,987
$150,000
$2,467,900
$500,000
Materials
Fuel Processing
Manufacturing
Sensors andDiagnosticsModeling andSimulationPowerElectronics
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Stack Technology – Seals & Cross CuttingPNNL – Seals, Modeling and Analysis, Cathodes, Anodes, Interconnects, Fuel Processing
LBNL – Metallic supported cell structure, Cathode interface modification
ANL – Metallic supported cell structure, Interconnects, Fuel Processing
OxidantFlow
FuelFlow
OxidantFlow
End PlateCathodeElectrolyte MatrAnode
BipolarPlate
CathodeElectrolyteAnodeEnd Plate
FuelFlow
Current Flow
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Materials - Interconnects
Develop low temperature interconnect suitable for SOFC
• U. of Pittsburgh• Ceramatec• Southwest Research Institute• PNNL• ANL
Thin foil Interconnect
SealCell
Spacer
Images courtesy of Delphi
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Modeling and Simulation
Structural, performance, and optimization design tools• PNNL• NETL• ORNL• U. of Florida • Georgia Tech• TIAX
Image courtesy of PNNL
Image courtesy of Delphi
Image courtesy of Delphi
Image courtesy of NETL
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Materials - CathodesCathode performance – 2x improvement
• U. of Washington • U. of Missouri Rolla • U. of Utah• Functional Coating, LLC • Georgia Tech• PNNL
Images courtesy of NexTech
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Fuel Processing and Anode Tolerance
Tubular cPox Reformer
Carbon and sulfur resistant anodes
• Northwestern • GTI
Carbon and sulfur resistant reforming catalysts
• LANL • ANL• NETL
Image courtesy of Delphi
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Power Electronics / Controls & Diagnostics Interaction between fuel cell, power conditioning system and application loads
• U. of Illinois
DC-DC / DC-AC converters• Texas A&M • Virginia Polytechnic Institute
High Temperature Sensors• NexTech Materials
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Manufacturing
Low cost and consistent precursor materials
• NexTech Materials • U. of Utah
Supportelectrode
Supportelectrode
Bilayer
Thin electrolyte onsupport electrode
layerElectrolyte
TAPE FORMING ROLLINGROLLINGImage courtesy of HoneywellTAPE CALENDERING