coal-based igfc project phase i fc26-08nt0003894 · 2013-08-22 · coal-based igfc project phase i...

COAL-BASED IGFC PROJECT

PHASE I FC26-08NT0003894

Praveen Narasimhamurthy – UTC Power

Rick Kerr – Delphi

12th Annual Solid State Energy Conversion Alliance (SECA) Workshop

July 23-25, 2012

Sheraton Station Square Hotel

Pittsburgh, PA

2

OUTLINE

• Summary of stack performance highlights from past year

• Cell and stack fabrication

• Gen 4 stack seal development

• Gen 4 stack voltage variation improvement

• Interconnect and contact material development

• Constant current

• Thermal cycling

3

SUMMARY OF SECA COAL BASED SYSTEM STACK DEVELOPMENT

• Completed scale up of cells from 105 cm2 (active area) cells to 403 cm2 for Gen 4 stacks

• Added additional Gen 4 stack fabrication and testing capabilities

• Fabricated and tested 24 Gen 4 stacks and 55 Gen 3 stacks in past year

• Completed Red X® investigations to improve stack sintering process and decrease stack voltage variation

• Demonstrated 7,000+ hours continuous durability on Gen 3.2 stack; demonstrated 5,000+ hours on Gen 4 stack.

• Completed 70 full thermal cycles on Gen 4 stack, with less than 5% voltage degradation

CELL AND STACK FABRICATION

• Fabricated in past year

– About 2,200 Gen 4-sized

cells

– 24 Gen 4 stacks of varied

configurations (most 30-

cells or greater)

– 55 Gen 3 stacks of varied

configurations (many 30-

cells or greater)

Gen 4 Cell

403cm2

active area

Gen 3 Cell

105cm2

active area

GEN 4 STACK SEAL DEVELOPMENT PROJECT

Inlet Perimeter

CONCENTRATION DIAGRAMS OF POROUS SEAL MICROSTRUCTURES

6

3 0 0 0 2 13

1 25

0 Stack G041 17

0 40-Cell Gen 4 20

1 26

1 35

1 0 0 0 6 34

5 3 5 7 9 12

2 22

0 Stack G035 26

0 40-Cell Gen 4 31

0 33

1 33

1 5 9 11 15 29

STACK SINTERING OPTIMIZATION PROJECT

• Confirmed overheating of the stack seals

– PNNL XRD analyses

– Microstructural analysis

– Coupon confirmation testing at increased sintering

temperatures

• Teardown analyses of previous stacks

• Thermal mapped build stands and stacks during

standard build process

• Developed strategy for investigating build control factors

for improved thermal control during sintering

• Completed stack mapping thermal profiles with varied

build controls

• Confirmation run with new build control parameters

7

8

TEMPERATURE PROFILES PRIOR TO OPTIMIZATION OF SINTERING CYCLE

-200

-150

-100

-50

0

50

100

150

200

10.00 10.50 11.00 11.50 12.00 12.50 13.00 13.50 14.00

Tem

pe

ratu

re D

evia

tio

n f

rom

Sin

teri

ng

Tem

pe

ratu

re, C

els

ius

Time, Hours

Furnace Set Point

Top of Stack

Furnace Air

Stack Internal

TEMPERATURE PROFILES AFTER OPTIMIZATION OF SINTERING CYCLE

9 -100

-80

-60

-40

-20

0

20

40

60

80

100

1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00

Tem

pe

ratu

re D

evia

tio

n f

rom

Sin

teri

ng

Tem

pe

ratu

re, C

els

ius

Time, Hours

Furnace Set Point

Furnace Air

Top of Stack

Stack Internal

SEAL STRUCTURAL IMPROVEMENT FROM SINTERING OPTIMIZATION

10

Inlet Perimeter Inlet Perimeter

Stack Perimeter Seal

Prior to Optimization

of Sintering Cycle

Stack Perimeter Seal

After Optimization of

Sintering Cycle

INITIAL GEN 4, 30-CELL STACK PERFORMANCE USING OPTIMIZED

SINTERING PROFILE

11

0

0.2

0.4

0.6

0.8

1

1.2

0.00 50.00 100.00 150.00 200.00 250.00 300.00

RU

Voltage (

V)

Current(A)

Date: 8/19/2011Fuel: 48.5%H2-48.5%N2-3%H20

RED X® STUDY ON MINIMIZING STACK REPEATING UNIT VOLTAGE VARIATION

• Analyzed numerous Gen 4 stacks

– Cross sections

– Repeating unit teardowns

– X-ray and metallographic analyses of repeating units

– Measurement studies of numerous repeating unit

components

– Optical and SEM inspection of components

• Conducted sintering studies

– Component level

– Full stack level

12

MOST RECENT 38-CELL GEN 4 STACK INITIAL POLARIZATION

PERFORMANCE AFTER RED X ® PROJECT

13

0

50

100

150

200

250

300

350

400

450

500

0

5

10

15

20

25

30

35

40

45

0.00 50.00 100.00 150.00 200.00 250.00 300.00

Po

we

r D

en

sity (

mW

/cm

2)

Sta

ck V

olta

ge

(V

)

Current(A)

Date: 06/27/2012Fuel: 48.5%H2-48.5%N2-3%H20

StackGrossVoltage(V) PowerDensity(mW/cm^2)

MOST RECENT 38-CELL GEN 4 STACK INITIAL POLARIZATION VOLTAGE

SPREAD

14

0

0.2

0.4

0.6

0.8

1

1.2

0.00 50.00 100.00 150.00 200.00 250.00 300.00

RU

Voltage (

V)

Current(A)

Date: 06/27/2012Fuel: 48.5%H2-48.5%N2-3%H20

MOST RECENT 38-CELL GEN 4 STACK INITIAL CONSTANT CURRENT

PERFORMANCE (0.35 A/cm2)

15

0.5

0.6

0.7

0.8

0.9

1

1.1

1.2

0.00 0.20 0.40 0.60 0.80 1.00 1.20

RU

Voltage (

V)

Time(Hrs)

Date: 06/27/2012Fuel: 48.5%H2-48.5%N2-3%H20

GEN 3.2 STACK DURABILITY TESTING (0.57 A/cm2)

0

50

100

150

200

250

300

350

400

450

500

0

5

10

15

20

25

30

0.00 1000.00 2000.00 3000.00 4000.00 5000.00 6000.00 7000.00 8000.00

Pow

er

Density (

mW

/cm

2)

Sta

ck V

oltage (

V)

Time(Hrs)

Dates: 11/23/2010 to 10/17/2011Fuel: 48.5%H2-48.5%N2-3%H20

StackGrossVoltage(V)

PowerDensity(mW/cm^2)

17

GENERATION 3 30-CELL STACK DURABILITY

30-CELL GEN 4 STACK THERMAL CYCLING

18

THERMAL CYCLING CATHODE CONTACT MATERIALS

19

0.5

0.55

0.6

0.65

0.7

0.75

0.8

0.85

0.9

0

100

200

300

400

500

600

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85

Pow

er

Density (

mW

/cm

2)

Cell

Mean V

oltage (

V)

Thermal Cycle Number

Date: 2/9/2012Fuel: 48.5%H2-48.5%N2-3%H20

Power Density (mW/cm2)Mean Voltage (V)Cathode Contact Material A Mean VoltageCathode Contact Material B Mean Voltage

30-CELL GEN 4 STACK CONSTANT CURRENT DURABILITY (0.27 A/cm2)

20

INTERCONNECT MATERIAL PERFORMANCE

21

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0.00 1000.00 2000.00 3000.00 4000.00 5000.00 6000.00

Ce

ll V

olt

age

, Vo

lts

Time, Hours

Mean Cell Voltage

Interconnect Materials 1



22

UTC OBJECTIVES FOR PHASE II

• Design and build 15-25kW SOFC breadboard

• Make modifications to SOFC test stand from Phase I to

test breadboard

• Perform extensive verification of test stand and

breadboard on beater stack prior to start of endurance

testing

• Demonstrate 1500 hours endurance on 4-stack module in

a system construct (breadboard)

• Demonstrate thermally self-sustaining operation

• Demonstrate peak power operation

23

• Demonstrated ~1,250 hours durability on Gen 4 stack module.

• Improved test stand reliability by ~3x to complete Phase I

• Completed conceptual and preliminary design for the 25kW breadboard

• Detailed design and breadboard build is ~80% complete

• Test stand modifications for Phase II are ~80% complete

• Software design and bench verification is 90% complete

• Ex-situ verification of breadboard fuel recycle assembly is underway

– Completed ~100 hours of continuous durability at operating temperatures on

an ex-situ test rig

SUMMARY HIGHLIGHTS - SYSTEM

SOFC

Cell

Delphi

Gen 3

Stack

(30 cells)

Delphi

Gen 4

Stack

(40 cells)

Stack Module

in Test Stand

Conceptual SOFC

Breadboard

Gen 4

Stack

Module

Power Plant

Concept

’08 -’10

’10 - current

6.25kW

’10 - current

25kW

’11 -’12

25kW

’11 -’13

25kW

’14-’16

100-200kW

SOFC

Product

>’17

100-400kW

’11 -’12

5kW

Delphi APU

OVERVIEW – SOFC PRODUCT DEVELOPMENT ROADMAP

Stack Module

TASK 6.3 - STACK MODULE ENDURANCE TESTING

25 Delphi Stack Module in the 50 kW capable

test stand at UTC Power

Cathode

Recuperative

Heat Exchanger

Air Inlet

Heater

Stack Module

Hot Box

Gas Inlet/Exit

Fuel Inlet

Heaters

Hot Box

Safety Sensors

Phase I Stack Performance


26

Endurance Test – System Level Learning


27

Completed fuel contaminant tests

Completed cathode side chromium sampling

Obtained data on stack manifold temperature distribution

Temperature data used to estimate stack heat loss for

Phase II

Obtained data on stack manifold pressure drop

Currently anode over cathode at stack exit; working with

Delphi

Improved test stand reliability

28

TASK 4.1 - BREADBOARD/SYSTEM DESIGN

NPD Gated Process for System Design and Development

Conceptual Design

Requirements Generation

Trade Studies

Conceptual Models

System Matches

Preliminary Physical Layout

Preliminary Design

Component Requirements

Generation

Component Design

Controls Design

FMEA/FA/HA

Detailed Physical Layout

Detailed Design/Test

• Component Tests

• Hardware

Build/Integration

• Test Plan Review

• Breadboard Checkouts

• Endurance Test

Design Review Design Review Test Report

29

Breadboard Schematic


Fuel recycle for maximizing efficiency

HEXs for exhaust heat recovery

Catalytic burner for exhaust management and heat up of cathode inlet air

30

Breadboard Projected Efficiency


Breadboard Projections vs. Ideal

Several BOP (recycle blower) over-sized

Heaters included for contingency on breadboard; not required for a product

Air blower for cathode supply not optimized

31

Control Strategy


Test stand controller

Controls breadboard startup sequence,

transition to load, on-load operation and

breadboard shutdown for product protection

Host PC & Data Acquisition

GUI-based user interface for controlling test

process, monitoring and data collection

Other Controllers

1. Safety Controller

Hard-wired controls for safety and personnel protection

2. Facility Controller

Provides safety shutoff for all reactant supply system

3. After Burner Controller

Controls test stand afterburner

4. Heater controllers

Maintain test stand controller requested heater set point


Breadboard Layout

32

Delphi Stacks

UTCP

Balance of Plant

(BOP)


Breadboard Design

33

Fuel System Components

Air System Components

34

Risk Mitigation: Ex-situ Blower Tests


Test Rig for Blower Performance

and

Endurance Test

Stack

Module

FUTURE WORK

• Continue cost reduction of stack and

power plant components

• Improve stack durability to meet SECA

goals

• Demonstrate breadboard endurance

• Risk reduce for critical components:

blowers, fuel processing components,

catalytic burners

• Collect system level data for scaled-up

power plant/prototype design in future

phases

Beyond Phase II

35

Breadboard

Power

plant

Prototype

36

ACKNOWLEDGEMENTS

Thanks to Joe Stoffa, Briggs White, and Dan Driscoll of the DOE

for their support and technical guidance

http://www.ch.doe.gov/insidech/org_offices/fao/doelogo.gif

http://www.netl.doe.gov/main.html

http://www.utcpower.com/

coal-based igfc project phase i fc26-08nt0003894 · 2013-08-22 · coal-based igfc project phase i...

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