thermal management of fuel cell systems using metal ... · case studies of additive manufacturing...

© HiETA Technologies Ltd 2018 - The information in this presentation contains confidential and/or privileged material. You are hereby notified that any disclosure, copying, distribution or use of the information contained herein or in any attachment is strictly prohibited.

Thermal management of fuel cell systems using metal additive manufacturing

13th March 2018

The 14th International Hydrogen and Fuel Cell Conference

NEC, Birmingham

Desi Bacheva

[email protected]

© HiETA Technologies Ltd 2016

Content

Introduction to HiETA

Technology introduction

Case studies of Additive Manufacturing Phase-change heat exchanger for PEM fuel cells

Conclusions


HiETA Technologies

Specialists in thermal management and lightweighting solutions enabled by Additive Manufacturing (AM)

Established 6 years with approximately 40 staff

Running 9 Powder Bed AM Machines

Based in Bristol and Bath Science Park


Myriad technologies

“joining of materials, usually by layers, to create products from 3D model data”

Our focus is metal powder-bed processes

Key inputs:Laser Power

Powder

Data

Argon flow

Many other considerations….

Metal Additive Manufacturing

© HiETA Technologies Ltd 2016© HiETA Technologies Ltd 2018 - The information in this presentation contains confidential and/or privileged material. You are hereby notified that any disclosure, copying, distribution or use of the information contained herein or in any attachment is strictly prohibited.

Rapid Product Development

Benefits of AM

Micro Gas Turbine Range Extender

Recuperator

Inverted Brayton cycle exhaust heat

recovery system

Lightweight/

Lightweight and cooled turbine

wheel for turbocharger

Thermal Efficiency/ Energy

Recovery

Customisation/High Value Low Volume Parts

Package Space Reductions

Heat exchanger formed around turbo machinery

for reduced package spacing

3 months from requirements to

demonstrator

2kW of energy recovery from exhaust

heat

Approx. 25% reduction in mass

40% reduction in product volume


HiETA Products

COMPONENTS

Low temp heat

exchanger

High efficiency integrated micro

gas turbine

Inverted Brayton Cycle waste heat

recovery

Modular heat exchanger

High temp heat

exchanger

Turbo machinery

Fuel & combustion

Multi-functional & Lightweight

Design EngineeringServices

Additive ManufacturingServices

TestingServices

1D AnalysisCFD, FEA & Topology OptimisationConceptual & detailed design

Renishaw AM250 & Ren AM500M machinesAlSi10Mg, Ti6Al4VInc625, Inc718, CM247LC

Heat transfer surface characterisationLow temperature heat exchangersPhase change heat exchangersNDI/NDT services

Water cooled charge air coolers

Phase-change condensers

Annular recuperators

Cuboid recuperators

Solid turbine wheels

Cooled turbine wheels

Cooled compressors

Fuel cooling injectorsClassification Unclassified TECHNICAL

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HiETA Technologies Ltd. This document and associated information is confidential and privileged material. You are hereby notified that any disclosure,

copying, distribution without explicit written permission from HiETA Technologies Ltd is strictly prohibited.

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Porous injectors & filters

Integrated combustors

Combined structural & cooling

Penetrating & double lap joining

Hybrid truss & mass customisation

SYSTEMS


Additive Manufacturing Value Chain

Maximum performance

Least weight design

Minimum cost

Quality

© HiETA Technologies Ltd 2016© HiETA Technologies Ltd 2018 - The information in this presentation contains confidential and/or privileged material. You are hereby notified that any disclosure, copying, distribution or use of the information contained herein or in any attachment is strictly prohibited.

What is the cost?


Conventional geometries

HiETA proprietary geometries, fabricated via additive manufacturing, have a “volume goodness factor” up to 5 x greater than conventional geometries, meaning HiETA heat exchangers can be up to 5 x smaller.

4L vs 15LCharge air cooler

8L vs 54L2kWe CHP

4L vs 51L30kW Range Extender

70kg vs 1.5T!400 kW CHP

Optimised HX Design


Case Study


Additive Manufacture for Automotive Fuel CellSystem (AMAFS)


Introduction

Problem statement: Fuel Cell Electric Vehicles have a significant potential to reduce CO2 emissions in the future car fleet. In PEM fuel cell systems, the requisite heat exchanger and auxiliary elements represent a major element of the cost and performance as well as driving the output power density of the system.

Project Objective: To utilise metal additive manufacturing to progressively develop and demonstrate an innovative phase-change heat exchanger for an automotive Fuel Cell system.


HX Design: Considerations

Inlet Duct

Pre-separation

Post-separation

Core

Outlet Duct

Material: Stainless steel 316L

Design driven by:

- Performance requirements: Thermal duty 34.5 KW

- Physical requirements: weight, volume, footprint

- Manufacturing requirements: Design for AM

- CAD file size and build file processing


HX Design: Development Cycle

Test rig design, experimental evaluation

and validation of CFD model

1-D sizing and Concept Generation

Single tube isothermal CFD and shape

optimization for max heat transfer and min

pressure drop

Test blocks design and manufacture


HX Design: Considerations

▪ Parametric model of creating original hot- and cold-fluid geometry to produce better quality surfaces that have more efficient packing.

▪ Reduced hot – to – cold separation

▪ Better nesting of hot and cold fluids resulting in increased compactness

▪ Cold-fluid bridging to reduce mass

▪ Multiple coolant headers to improve coolant distribution

Half HX core


Summary

This project has been successful in demonstrating the potential of AM to significantlyimprove the output power density of automotive fuel cell systems. This is achievedthrough increased performance of its thermal management system, reducedpackaging and component intergration.

Benefits powder-bed metal AM can be realised if:

Choose the “right” part/system

Design team willing/empowered to innovate, specifically design for process and function

Ability to integrate can unlock many benefits – overcome short term cost challenges

Optimise both process and post-processing stages

Hardware is progressing and build times are reducing

Technology is no longer simply “Emerging”

High-value low-volume applications & full supply chain volume production is achievable

The key is maximising the value at a system level


Thank you for your attention

Desi Bacheva

Customer Validation Lead

HiETA Technologies Ltd

[email protected]

thermal management of fuel cell systems using metal ... · case studies of additive manufacturing...

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