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Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU för tunga fordons applikationer) Claudia Göbel, Jan Froitzheim and Jan-Erik Svensson Energy and Materials Chemistry and Chemical Engineering Chalmers University of Technology

Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

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Page 1: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Improving Lifetime Performance of SOFC for Truck APUs

(Förbättringar av livslängden av fastoxidbränsleceller-APUför tunga fordons applikationer)

Claudia Göbel, Jan Froitzheim and Jan-Erik SvenssonEnergy and Materials

Chemistry and Chemical EngineeringChalmers University of Technology

Page 2: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

United States

Claudia Göbel

Page 3: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Outline

Part I: Overview SOFC for Mobile Applications

Part II: Final results from the FFI project

3

Page 4: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

The electrolyte is an oxygen ion conducting material (600-900 ºC)

Advantages• High electrical efficiency

• O2- conductive electrolyte Fuel flexibility (H2, natural gas,

biogas.. diesel)• High operating temperature

No need for expensive catalysts such as Pt

4

Solid Oxide Fuel Cell (SOFC)

Electrolyte CathodeAir side

AnodeFuel side

e-e-

Oxygen Ions

Oxygen ions

Page 5: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Electrolyte supported Anode supported

>800 °C 800-650 °C

Metal supported

700-500 °C

There is a general trend towards lower operating temperatures.

⇒ Possibility to use less expensive materials⇒ Higher efficiency possible⇒ Longer lifetimes⇒ Faster heating/cooling

5

Solid Oxide Fuel Cell (SOFC)

Page 6: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

SOFC for Mobile Applications

• APU units for trucks (eg. Delphi; EU-projects: DESTA, SAFARI, SAPIENS; National projects: Mestrex (AT), FFI project (SE))

• Range extenders for EV vehicles (eg. Nissan, Honda; new EU project: COMPASS)

• Special applications such as drones, robots, unmanned water vehicles…etc. (eg. Adelan R&D, NEXceris, US military, NASA)

6

Page 7: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

APU units for trucks

www.eberspaecher.com 7

Page 8: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Range extenders for EV vehicles

https://newsroom.nissan-global.com/releases/160614-01-e 8

How the e-Bio Fuel Cell system works• Fueled by liquid fuel: easy to handle, can use conventional fuel tank• Hydrogen generated through reformation of 100% ethanol or ethanol-blended water• Power generated by SOFC stack from reformate hydrogen and air• Generated electricity charges battery and powers drive motor

Page 9: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Nissan collaborates with Ceres, Plansee and AVL for range extenders

[1] http://insideevs.com/nissan-unveils-worlds-first-solid-oxide-fuel-cell-vehicle-e-nv200-sofc/[2] http://media.nissan.eu/content/dam/services/SE/brochure/Nissan_e-NV200_BtoC_SE.pdf 9

• An electric vehicle with a 5 kW SOFC system and a 30 liter tank for bio-ethanol.[1]

• Range: 600 km[1] (compared to ~150 km[2] without the SOFC range extender)

Page 10: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Companies focusing on SOFC for mobile applications

10

UK-based SOFC manufacturer

Austrian-based automotive consulting firm as well as an independent research institute.

Finnish/Estonian-based SOFC manufacturer

Page 11: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Electrolyte supported Anode supported

>800 °C 800-650 °C

Metal supported

700-500 °C

11

Solid Oxide Fuel Cell (SOFC)

Page 12: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

AVL List GmbH

V. Lawlor, M. Reissig, J. Makinson, J. Rechberger ECS Transactions. 78 (2017) 191. 12

Mestrex Project:Development of a highly fuel efficient range extender system based on a high-temperature fuel cell (SOFC), which can be operated with CO2-neutral, ethanol-based fuels.

Mestrex Objective: AVL Eventual Target:

System performance (net)

3kW - 5kW 20 kW - 30 kW

Electrical efficiency >50% 55% - 60%

Noise level <60 dB <40 dB

Start time <30min <5 min

Weight/power <20 kg/kW 3-4 kg/kW

Volume/power <25l/kW 4-5l/kW

Lifetime >500h 5000h

Cost/kW <10,000€/kW €250/kW (Funded by the Austrian Ministry for Transport, Innovation and Technology (BMVIT) in the program

“Mobility of the Future”)

Page 13: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Electrolyte supported Anode supported

>800 °C 800-650 °C

Metal supported

700-500 °C

13

Solid Oxide Fuel Cell (SOFC)

Page 14: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Elcogen

http://www.elcogen.com/technology/ 14

Operating temperature

650°C

Operating temperature

650°C

Elcogen stacks have achieved a WORLD

RECORD in primary energy conversion efficiency to

electricity of 74 %

Page 15: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Elcogen

High efficiency, high power density and fuel flexibility offered by Elcogen is prerequisite for automotive industry. Battery electric vehicle range extender

utilizing biofuels discards the plug-in charging need and onboard power production in long haul trucks decreases significantly diesel fuel emissions.

Industrial CHPResidential & mCHP Automotive Electrolyzers for energy storage and power to fuelIndustrial CHP

http://www.elcogen.com/technology/ 15

Automotive

Page 16: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Electrolyte supported Anode supported

>800 °C 800-650 °C

Metal supported

700-500 °C

16

Solid Oxide Fuel Cell (SOFC)

Page 17: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Ceres Power – Metal supported SOFC

R.T. Leah, A. Bone, E. Hammer, A. Selcuk, M. Rahman, A. Clare, S. Mukerjee, M. Selby ECS Transactions. 78 (2017) 87.

17

Page 18: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Ceres Power – Metal supported SOFC

18

[1] http://www.cerespower.com/work-with-our-steelcell/applications-for-our-steelcell/[2] http://www.cerespower.com/news/latest-news/new-joint-development-agreement-with-honda/[3] https://www.businessgreen.com/bg/news/2463114/ceres-power-teams-up-with-nissan-to-develop-range-extending-fuel-cell-for-evshttps://www.businessgreen.com/bg/news/2463114/ceres-power-teams-up-with-nissan-to-develop-range-extending-fuel-cell-for-evs

Page 19: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Ceres Power – Metal supported SOFC

19

[1] http://www.cerespower.com/work-with-our-steelcell/applications-for-our-steelcell/[2] http://www.cerespower.com/news/latest-news/new-joint-development-agreement-with-honda/[3] https://www.businessgreen.com/bg/news/2463114/ceres-power-teams-up-with-nissan-to-develop-range-extending-fuel-cell-for-evshttps://www.businessgreen.com/bg/news/2463114/ceres-power-teams-up-with-nissan-to-develop-range-extending-fuel-cell-for-evs

[2]

[3]

Page 20: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Ceres Power – Metal supported SOFC

R.T. Leah, A. Bone, E. Hammer, A. Selcuk, M. Rahman, A. Clare, S. Mukerjee, M. Selby ECS Transactions. 78 (2017) 87.

20

Only 9 min until operation (15 min to full power)

Page 21: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Ceres Power – Metal supported SOFC

R.T. Leah, A. Bone, E. Hammer, A. Selcuk, M. Rahman, A. Clare, S. Mukerjee, M. Selby ECS Transactions. 78 (2017) 87.

21

Up to 3000 cycles were presented at the conference

Page 22: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Other projects/companies focusing on SOFC for mobile applications

22

• COMPASS (Current EU project H2020): Collaborative effort of AVL, Plansee, Nissan and Research Center Jülich to develop advanced SOFC APU systems for range extender applications in passenger cars.

• SAFARI project: SOFC APU For Auxiliary Road-truck Installations running on LNG (End December 31, 2016).

• SAPIENS: SOFC Auxiliary Power using Liquid petroleum gas (LPG) as fuel (End October 31, 2015).

• Delphi Automotive LLP: Has developed and demonstrated a practical, operational SOFC auxiliary power unit (APU) for heavy duty commercial trucks that operate with many types of fuels including natural gas, diesel, bio-diesel, propane, gasoline, coal-derived fuel and military logistics fuel.

• Eberspächer: APU running on Diesel (Partner in the DESTA project)• Adelan R&D: Projects include unmanned aerial vehicles (UAVs), road

vehicles, recreational vehicles, portable power and micro combined heat and power (mCHP) applications.

Page 23: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Outline

Part I: Overview SOFC for Mobile Applications

Part II: Final results from the FFI project

23

Page 24: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

The FFI project

24

Förbättringar av livslängden av fastoxidbränsleceller-APU för tunga fordonsapplikationer

Page 25: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Single cells 1 kW stack 3 kW stack

Our project partner is ElcogenElcogen is a Finnish/Estonian SOFC developer selling cells and stacks

http://www.elcogen.com/technology/ 25

Page 26: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Elcogen

http://www.elcogen.com/technology/ 26

Operating temperature

650°C

“Elcogen’s industry leading SOFC technology is positioned to achieve market-enabling targets in the 3 most critical fuel cell performance parameters: efficiency,

lifetime and cost”

Page 27: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Solid Oxide Fuel Cell (SOFC)

27

Electrolyte CathodeAir side

AnodeFuel side

e-e-

Oxygen Ions

Oxygen ions

U < 1 V

Page 28: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Solid Oxide Fuel Cell Stack

28

e-

O2-

O2-

O2-

O2-

e-

O2-

O2-

InterconnectFerritic Stainless Steel

• Similar thermal expansion as the ceramics used in SOFC

• Good electrical conductivity• Formability• Cheap to produce

Page 29: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Cost analysis 1 kW Stack50 000 Units

30%

35%

16%

19%

Cells InterconnectsSealing, End plate etc Assembly Hardware

Manufacturing cost analysis of 1 kW and 5kW solid oxide fuel cell (SOFC) for auxillary power applications. 2014, Battelle.

29

Page 30: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Improve oxidation resistance at the cathode and the anode side

Reduce chromium evaporation

Reduce electrical resistance

Improving Lifetime and Performance of SOFC for Truck APUs- In a cost efficient way

30

Objectives

Page 31: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Problems at Interconnect levelCorrosion

• Chromium evaporation

• Growing Cr2O3 layer→ Chromium consumption→ Increase in electrical resistance

31

Cr2O3(s) + 2 H2O(g) + 1.5 O2(g) 2 CrO2(OH)2(g)

poisoning thecathode!

O2 +H2O(g)

FeCr FeCrCr2O3

CrO2(OH)2(g)

Page 32: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Possible ways to overcome Cr-evaporation

FeCrMn FeCrMnCr2O3

(Cr,Mn)3O4

FeCrMn

Co (640nm)

Change substrate composition:

CrO2(OH)2 (g)

Apply Co coatings:

Decreases Cr-evaporation, however, still too high!

Minimize Cr evaporation by presence of (Co,Mn)3O4

Cr2O3

(Co,Mn)3O4CrO2(OH)2 (g)

FeCrMn

32

Page 33: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Could the mechanical deformation process cause increased Cr vaporization?

The pre-coated concept

33

SteelCo coating Stamping

Page 34: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Uncoated and undeformed

No signs of increased Cr vaporization after mechanical deformation/stamping!

Crofer 22 APU, 850 ˚C, Air-3% H2O, 6 sL min-1

Co Co

Coated (post-coated and pre-coated)

The pre-coated conceptCr-evaporation

H. Falk-Windisch, M. Sattari, J.-E. Svensson, J. Froitzheim J. Power Sources.297 (2015) 217.

34

0 hPre-coated

336 hPre-coated

Page 35: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Possible ways to decrease oxide scale growth rate

Ce (10nm)Co (640nm)

FeCrMn

Apply Ce coating:

Ce (10nm)

Apply Co coatings:

Minimize Cr evaporation by presence of (Co,Mn)3O4

FeCrMn

FeCrMn

Co (640nm)Cr2O3

(Co,Mn)3O4CrO2(OH)2 (g)

FeCrMn

Decreases oxide scale growth35

Page 36: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Mass gain

36

Co+Ce has lower mass gain than Co

Sanergy HT, 850°C, 6000ml/min

Page 37: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Co+Ce coating performs as good as Co coating with regard to Cr-evaporation

Cr Evaporation1000 hours exposure

37Sanergy HT, 850°C, 6000ml/min

Page 38: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Cr Evaporation

38

Co/Ce coated FSS

Uncoated FSS (1000 h measurement) Average rate: 1.85 * 10-4 mg cm-2 h-1

FSS, 800°C, 6000ml/min air

Page 39: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Area Specific Resistance

39Ce/Co coated FSS, 800°C

Page 40: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

Summary

• Co coating greatly decreases Cr-evaporation.

• Self-healing effect of Co allows for pre-coating.

• Ce coating decreases growth of Cr2O3 layer.

• Longterm stability of Ce/Co coating up to 37 000 h with regard to Cr-evaporation and ASR.

• Stack data with Elcogen shows good performance of Ce/Co coating.

40

Page 41: Improving Lifetime Performance of SOFC for Truck APUs · 2017-12-07 · Improving Lifetime Performance of SOFC for Truck APUs (Förbättringar av livslängden av fastoxidbränsleceller-APU

The FFI project

41

Förbättringar av livslängden av fastoxidbränsleceller-APU för tunga fordonsapplikationer

Kostnadseffektiva IT-SOFC Bränsleceller för mobilaapplikation