manufacturing fuel cell manhattan project...manhattan manufacturing fuel cell project •mfcmp phase...
TRANSCRIPT
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Presented by
Carmine Meola
Rebecca Morris
Manufacturing Fuel Cell Manhattan Project
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Example Special Projects within the B2PCOE
• Energy Usage – Ship Yard Cost Reduction
• Lead Free – Manhattan Project (DOD Leverage)
• Best Practices for Assurance of Skilled Workers
• Best Practices in Ship System Integration
• Advanced Shipbuilding Affordability Technologies
• Manufacturing Fuel Cell Manhattan Project
MFCMP Project Sponsors
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Manhattan Manufacturing Fuel Cell Project
• MFCMP Phase 2
• Location: Butte, MT
• Dates
– Polymer and BOP Session: March 15 – 20, 2011
– Ceramic Fuel Cell Session: March 17 – 22, 2011
– Joint Session Days: March 17 – 20, 2011
– Leadership Wrap Up: March 23, 2011
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Manufacturing Fuel Cell Project
Program Leaders
• Rebecca Clayton – ONR
• Carmine Meola – ACI
• Rebecca Morris – ACI
• Mark Shinners – ACI
• Randy Hiebert – MTT
• Robert Hyatt – MTT
• Jay McCloskey – MTT
• Brian Park – MTT
• Ray Rogers - MTT
Technical Leaders
• Mark Cervi – NSWC Philadelphia
• John Christensen – Consultant
• Marc Gietter – CERDEC
• Leo Grassilli – ONR
• Shailesh Shah – CERDEC
• Mike Ulsh – NREL / DOE
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Participants • Joe Bonadies – Delphi Corp.
• David Carter – Argonne
• Mark Cervi – GDIT / NSWC
• Paul Chalmers – Hydrogenics
• John Christensen - Consultant
• Aaron Crumm – AMI
• William Ernst – Consultant
• Matt Fay – General Motors
• Marc Gietter – CERDEC
• Leo Grassilli – ONR
• Pat Hearn - Ballard
• Dennis Kountz – DuPont
• Rebecca Morris – ACI
• Randy Petri – Versa
• Joe Poshusta – Protonex
• Jolyon Rawson - Acumentrics
• Steve Rock – RPI
• Kathryn Rutter - Ballard
• Shailesh Shah – CERDEC
• Duarte Sousa – Ballard
• Eric Stanfield – NIST
• Matt Steinbroner – Consultant
• Scott Swartz – NexTech
• John Trocciola – Consultant
• Mike Ulsh – NREL / DOE
• Doug Wheeler – DJW Tech
Manufacturing Fuel Cell Project
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Objectives , Benefits, and Applications
Manufacturing Fuel Cell Project
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• Objectives Phase 1 – October 2010
√ Identify manufacturing cost drivers to achieve
affordability
√ Identify best practices in fuel cell manufacturing
technology
√ Identify manufacturing technology gaps
Objectives Completed
B2PCOE
Montana Tech
SME’s
Industry Academia Government FC Consortiums
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Manufacturing Fuel Cell Project
Manufacturing Roadmap
• Projects to resolve the gaps
• Schedule a strategy for effective investment
- Sequence Projects
- Prioritize Projects
- Projects that can benefit all
• Manufacturing Fuel Cell Publication: Oct. 2011
Deliverables Phase 2 – March 2011
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Navy Benefits
Why the Navy Cares • Reduce logistics and financial footprints for
delivering energy
• Increase fuel efficiencies
• Modularity for distributed power systems
• Supplemental Power
• Reduce ship signatures
– Lower thermal signatures
– Lower audible noise
• Low maintenance when compared to diesel generators
• Lower hydrocarbon emissions
• Lower SO2 and NO2 emissions
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Fuel Cells
Polymer Ceramic
MEA BOS Planar Tubular
Ionomer &
Membrane
Gas Diffusion
Layer
Ink Mixing &
Delivery
Catalyst Coated
Membrane
MEA Low Temp
PEM
MEA High Temp
PEM
PEM
Bi-Polar Plate
Stack Assem
Comm & Testing
Stack Separator
Plate
Inspection
Seals
Cells
Current
Collector
Insulation
BOP
Reactant Mngt
Power Mngt
Controls &
Software
Mech & Package
Ruggedization
Thermal Mngt
Inspection
Manufacturing Fuel Cell Project Taxonomy
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DOD Applications That May Benefit
Manufacturing Fuel Cell Project
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Soldier Power
Unmanned UAV
Emergency Power
Tactical APUs
Aircraft APUs
Shipboard APUs
Material Handling
Distributed Stationary Power
1 10 100 1000 10000 100000 1000000
System Power in Watts
Target Applications
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Manufacturing Fuel Cell Project
Cost Drivers
For Polymer Fuel Cells (MEA, BP, BOP)
Courtesy of
Ballard
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Polymer Membrane Fuel Cell Session
Key Cost Drivers For
Membrane Electrode
Assembly (MEA)
• Electrode
• Pt group catalyst
• Membrane
• GDL / Seals
• Assembly
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Polymer Membrane Fuel Cell Session
• Bipolar Plate
• Labor
• End Plate
• Stack Sealing
• Hardware
• Packaging
Key Cost Drivers For PEM Bipolar Plates
Low Temp BP Manufacturing Process
High Temp BP Manufacturing Process
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BOP for Polymer & Ceramic Fuel Cell Session
Key Cost Drivers BOP
• Stack
• ATR / Reactant Management
• Mechanicals Packaging
• Controls
• Thermal Management
• Power Conditioning /
Management
• Balance of Hot Zone
Example of SOFC Heat Removal
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Manufacturing Fuel Cell Project
Cost Drivers For Ceramic Fuel Cells (Planar, Tubular)
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Repeat Unit Exploded View
Cell-frame
assembly
Spacer
Interconnect
Separator plate
RU Seal
Interconnect
Repeat Unit
Repeat Unit
Contact Paste
Ceramic Membrane Fuel Cell Session
Key Cost Drivers For Planar Designs
• Planar Cells
• Separator Plates
• Seals
• Manifolds
• Compression Means
• Contact Layers
• Terminal Conductor Plates
Internal Manifold of Planar SOFC
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Anode
Electrolyte
Ceramic Membrane Fuel Cell Session
Tubular SOFC
Coil Winding
for Current
Collection
• Recuperator
• Current Collection
• Cell
• Insulation
• Burner
• Reforming
• Seals
• Mechanical Enclosure
• Manifold
Key Cost Drivers For Tubular Designs
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Manufacturing Fuel Cell Project
Path Forward
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Manufacturing Technology Gap Categories
• Production Automation
• Production Material
• QC during Manufacturing
• QC for Product
• BOP Hardware
• BOP Performance
• Materials
• Design Performance
• Design Controls
Manufacturing areas where projects have been
Identified to resolve gaps
Total of 70 Gaps Identified
About 32 Projects
recommended to Address
Cost Savings
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Polymer Projects
• Manufacturing cost trade-off analysis
on raw material
• Reduce PT loading to 0.15 g/m2
• Develop patch coating
• Direct coated layers on membranes
• Develop paper GDL for HTPEM
• Develop continuous mixing process
• Improve ink mixing process
• Direct coating layers on GDL
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Polymer Projects Continued
• Process development for mitigation from
discrete to continuous
• Develop X-Y gradients H2 rich inlets to H2
depleted outlets
• Reduce critical design requirements and
defect rejection criteria
• Development of a low cost resin for HTPEM bipolar plates
• Measurement of vapor pressure of phosphoric acid over HTPEM
• Utilize metallic bipolar plates for LTPEM
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Ceramic Projects
• Protective coatings for metallic stack
components
• Defect free electrolyte layer
• Manufacturing of low-cost , high-efficiency
insulation packages
• Solid oxide fuel cells stack manufacturing ,commission
and testing
• Net shape manufacturing of stack methods
• Solid oxide fuel cell automated assembly
• Automation of current collection application for tubular
SOFC
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BOP Projects
• Manufacturing of low-cost, high-efficiency
heat exchangers
• Liquid metering pumps for sub kilowatt
reformed based FC systems
• Best practices for manufacturing anode gas movement devices
• Manufacturing improvements for fuel cell humidification systems
• Specification analysis for fuel cell power systems
• Liquid flow meter for sub-kilowatt reformer based FC systems
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Fuel Processing Projects
• Improve Sulfur Sensor for logistics fuels
• Improve desulfurization of JP-8, JP-5, F76
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FC Area vs Costs by Projects
$-
$5,000,000
$10,000,000
$15,000,000
$20,000,000
$25,000,000
$30,000,000
0
2
4
6
8
10
12
14
Cost $26,276,694 $23,456,956 $13,821,200 $5,375,185
Projects 12 10 7 3
Polymer Ceramic BOP FP
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Recommendations
• Implement discrete projects that will have
an immediate benefit to reducing fuel cell cost
• Establish CALCE or SAMETAC type consortium
for fuel cells
• Recommend consortium specific projects
• Establish manufacturing working group
• Propose a phase III power management and
integration session
• Propose a plan to the ONR for an alternative energy
COE for Naval Platforms
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Discrete Fuel Cell Projects
• Application specific - will have cost benefit to
Navy and other DOD programs
• Immediate benefits < 3 yrs
• Unique to manufacturer – proprietary to a
degree - will result in cost reduction of fuel
cell systems
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• Addressing (DoD) specification “Feature Creep”
• Cross-cutting development of automation capabilities for
cells and stacks
• Understanding critical-to-quality parameters for ceramic
powder specification and enhancing supply chain leverage
• Developing transfer functions for the linkages between
manufacturing variability and cell performance/durability
• Developing solutions for the transition from solvent- to
aqueous- based processing
• Developing methods (protocols and transfer functions) and
support equipment to enable accelerated lifetime testing for
SOFC cells and stacks
Consortium Projects
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• Establish government-industry consortia to address over-
arching issues
• Not cost effective for individual companies to address
themselves
• Work would benefit all industry
• Supports the competitiveness of the North American fuel cell
manufacturing base
• Benefit from capabilities across federal agency labs and
academia
• Would incorporate non-disclosure agreements where
necessary
Consortium Benefits
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Manufacturing Working Group
• Continue collaboration and „esprit de corps‟
developed in the MFCMP
• Forum for labs / academia to report on new
developments related to manufacturing
• Capture manufacturing needs and issues for DoD and
DOE consumption and action
• Group to be informed on DoD application requirements and
developments by DoD fuel cell TWG
• Group possibly hosted by FCHEA or NDIA Manufacturing Division
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Power Management and Integration
• FC power management issues were
discussed in Phase I but not addressed fully
• Integration of FC power management into DoD
deployed systems needs to be developed (e.g.,
integration with other renewables, and hybrid
systems)
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Path Forward
• ONR has begun funding efforts
of MFCMP recommendations
• MFCMP team will brief ONR and other
DoD PMs on the findings and potential cost savings to secure additional funding
• Propose a development of an alternative energy center of excellence
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Q&A
Carmine Meola
610 362 1200 x 235
Rebecca Morris
610 362 1200 x 102
http://www.aciusa.org
http://www.navyb2pcoe.org
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Back Up Slides
Manufacturing Fuel Cell Manhattan Project
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MFCMP Scope:
Power ranges
• <0.5 kW (man portable / man wearable)
• 0.5 kW< Power range < 10kW (mobile power)
Fuels: Hydrogen and reformed hydro-carbons
•Packaged Fuels < 0.5 kW
• Near term solution
• Move through the supply chain like batteries
• Examples: methanol, ethanol, propane, butane, chemical
hydrides, hydrogen
•Logistics Fuels > 0.5 kW (long term solution)
• Long Term Solution
• Examples: JP-8, diesel
Fuel Cell Project Scope
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Applications
Navy Applications • Unmanned Vehicles (Unmanned undersea vehicles, UAV, UGV)
• Submarine Emergency Power
• Ship Service (0.5-2.0 MW)
• CHP base housing / apartments
• CHP PX, Fire Station
• Material Handling/Fork Lifts (DLA)
• Automotive (Camp Pendleton, 6 ea GM vehicles planned)
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ARMY Applications • Soldier Portable Power
• Battery Charging
• Power Source (hybrid configurations)
• Remote Sensors
• UAVs / UGVs
• Vehicle Auxiliary Power
• Base Camp Power
Applications
USMC Applications • Man-portable Charger, CERDEC, 250 W
• Portable Power, TARDEC
• Tactical Wheeled Vehicle Onboard Power, CAASCOM, 5-10 kW
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Polymer Membrane Fuel Cell Session
Major Key Manufacturing Needs Identified for MEA
• Ink mixing to coating operation - minimize time
• Ink processing through continuous methods
• Correlating QC measurements to requirements
– What tests are necessary?
• Need on-line /real time QC testing techniques
• Raw material traceability
• Relate existing metrics and to downstream product
requirements
• Maximum utilization of catalyst
• High production volumes will need quick turnaround
testing of subsystems
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Key Manufacturing Needs Identified for Bi-Polar Plates
• For LTPEM the bipolar plates need the use of alternate graphite
resin compositions to facilitate easier molding
• Testing and evaluating critical design parameters of bipolar plates
(BP)
• A low cost metallic plate would use more conventional
manufacturing process- thus lowering cost
• For HTPEM it is critical to reduce multiple heat treatments for cost
reduction
• For HTPEM find a method to employ air cooling process to replace
high water pressure /steam mixture
Polymer Membrane Fuel Cell Session
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Key BOP Manufacturing Needs Identified
• Autothermal Reformers (ATR) need to operate at
temperatures near or below 800°C to eliminate the use of
high cost metal alloys; the latest ATR designs & catalyst
appear to have resolved this issue
• Catalytic Partial Oxidation Reformers susceptible to coking
issues- requiring insulative housing and filter systems
• The CO2 and CO removal process are not designed to suit
small scale reformate clean-up
• Water management systems need to utilize more efficient
designs to reduce weight and cost over the present
membrane modules
BOP for Polymer & Ceramic Fuel Cell Session
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Balance of Plant - cont
• Commercial fuel and oxidant delivery as well as air
supply components generally do not satisfy the
specifications for the critical parameters for fuel cell
applications
• Heat exchangers also fall into this category
• When feasible, safety and control systems should
transition to software based systems
• Alternate plate fin exchangers may provide a more cost
effective solution, providing low material and
manufacturing costs
BOP for Polymer & Ceramic Fuel Cell Session
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Key Planar Manufacturing Needs Identified • Assurance of stack quality is labor intensive requiring a more
mechanized approach to assure consistency at higher volumes
• Optimization by the means of decoupling QC process would increase
throughput and reduce cycle time
• There is little industry standardization for stacks. The Capital equipment
to produce larger volumes is a significant cost
• An accelerated testing strategy needs to be developed for stacking as
well as BOP. i.e. thermal cycling, load cycling, etc for lifetime prediction
• Optimization of coating and material selection for end plates, bipolar
plates and flow field is needed.
• There is a lot of material waste in seals. A dispensing or molding
process for forming seals would reduce cost
Ceramic Membrane Fuel Cell Session
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Ceramic Fuel Cell Session
Key Manufacturing Needs Identified • Dimensional tolerances of tubes difficult with high aspect ratio
tube with thin walls
• The application of a uniform electrolyte layer on the tube is
challenging and is prone to yield loss
• Current collector process needs to be automated with high rate
wire winding and tie off
• Current QC test for both planar and tubular FCs require in-process
testing prior to stack assembly to reduce cost. This includes
analysis of powders batches, slurries, tape cast, green tape,
electrolytes, etc.
• The relevant tests must be identified that will affect the quality of
the overall stack
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Manufacturing Technology Gap Categories
• Production Automation
• Production Material
• QC during Manufacturing
• QC for Product
• BOP Hardware
• BOP Performance
• Materials
• Design Performance
• Design Controls
0
2
4
6
8
10
12
14
Am
ou
nt
of
Po
ten
tial
Pro
jects
Manufacturing Areas
Fuel Cell Gaps - Identified
Series1 6 13 8 7 6 8 10 9 3
Production
Automation
Production
Material
QC
Manufact.
QC Final
Products
Hardware
(BOP)
Availability
Hardware
(BOP)
Performanc
Materials
(Improved)
Design
Perform
Specs
Design;
Controls
Manufacturing
areas where
projects have
been Identified
To resolve gaps
Total of 70 Gaps Identified
30 Projects to Address Cost Savings
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Ceramic Projects
4,398,636.90
4,313,655.60
2,926,421.15
2,864,947.44
2,672,534.00
2,353,766.00
2,147,817.30
894,468.00
567,264.00
317,445.23
Coatings
Increased Stack Throughout
Automated Assembly
Ceramic Installation (2)
Endplates EES/QC Modifed
Endplates
Current Collection
Defect Free Electrolytes
Electrolyte MU
Automation
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Compression
Means, 7%
Planar Cells, 40%
Separator Plates,
23%
Terminal Conductor
Plates, 3%
Contact Layers, 5%
Seals, 15%
Manifolds, 7%
Ceramic Planar Costs
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Burner
9%
Mechanical/Enclosure
0%
Recuperator
26%
Reforming
3%
Insulation
9%
Cell
27%
Current Collection
16%
Seals
3%Manifold
7%
Ceramic Tubular Costs
Less than 500 watt systems
Greater than 500 watt systems