Modular SOEC System for Efficient H2 Production at High Current Density

PI Hossein Ghezel-Ayagh

June 8 2017

2017 DOE Hydrogen and Fuel Cells Project ID TV041 Program Review

This presentation does not contain any proprietary confidential or otherwise restricted information

Timeline bull Project Start Date 10012016 bull Project End Date 09302019

Budget bull Total Project Budget $375000000 bull Total Recipient Share $75000000 bull Total Federal Share $300000000

bull Total DOE Funds Spent $7703900 Estimated as of 33117

Overview

Barrier bull Key barriers addressed in the project

are ndash F Capital Cost ndash G System Efficiency and

Electricity Cost ndash J Renewable Electricity

Generation Integration

Partner bull Versa Power Systems (VPS) bull DOEFE National Energy

Technology Laboratory (NETL)

2

Timeline bull Project Start Date 10012016 bull Project End Date 09302019

Budget bull Total Project Budget $375000000 bull Total Recipient Share $75000000 bull Total Federal Share $300000000

bull Total DOE Funds Spent $7703900 Estimated as of 33117

Overview

Barrier bull Key barriers addressed in the project

are ndash F Capital Cost ndash G System Efficiency and

Electricity Cost ndash J Renewable Electricity

Generation Integration

Partner bull Versa Power Systems (VPS) bull DOEFE National Energy

Technology Laboratory (NETL)

2

Relevance

Objective

bull Demonstrate the potential of Solid Oxide Electrolysis Cell (SOEC) systems to produce hydrogen at a cost of lt$2 kg H2 exclusive of delivery compression storage and dispensing

Project Goals bull Improve SOEC performance to achieve gt95 stack electrical efficiency

based on LHV of H2 (gt90 system electrical efficiency) resulting in significant reduction in cost of electricity usage for electrolysis

bull Enhance SOEC stack endurance by reducing SOEC degradation rate ndash Single cell degradation rate of le11000 hours ndash Stack degradation rate of le21000 hours

bull Develop SOEC system design configuration to achieve gt75 overall (thermal + electric) efficiency

bull Impart subsystem robustness for operation on load profiles compatible with intermittent renewable energy sources

3

4

ApproachCell Technology Improvement

bull Top-down approach to explore the effects of system and stack operating conditions on performance and durability

bull Perform single cell tests to establish desirable stack and system operating conditions and reduce performance degradation rate ndash Operating voltagecurrent densityndash Hydrogensteam recyclingndash Operating pressurendash Operating temperaturendash Steam utilization

bull Conduct post-test microstructural analysis to understand and improve cell and interconnect materials stability

2H2O+4e-2H2 +2O=

ElectrolyteO= O=

Cathode

Anode2O= O2 +4e-

+

_

e-

H2

O2

e-

e-

H2O

Anode-Supported Solid Oxide Electrolysis Cell

5

ApproachStack Technology Development

bull Develop components for scale up of the existing baseline SOEC stack design using Compact SOFC Architecture (CSA) stack platform to meet the project goals for performance and endurance

‒ Full size CSA stack (350 cells) has a capacity of 38 kg H2day at a current density of 15 Acm2

bull Design build and test subscale technology stacks in 2 to 5 kg H2day size range to verify functionalities of stack components

bull Demonstrate 4kg H2day production in a stack with electric efficiency better than 95 and degradation of less than 2khr1000 hr test

Baseline 20 cell stackDemonstrated stable electrolysis

operation at 2 Acm2

Full size CSA stack 38 kg H2day

10 liter stack volume

44cm

(17

3in

ch)

Approach Breadboard System Demonstration

bull Develop bases of design and operation for a breadboard demonstration prototype ndash gt4 kg H2day capacity ndash Operating current density 1 to 2 Acm2

ndash Thermal integration to quantify system heat input needsby either heat recovery from effluent streams or using a steam generator

bull Develop design of the breadboard system ndash Process design (eg PampIDs equipment specs HAZOP

safety analysis and controls) ndash Mechanical design (eg thermally self-sustained stack

module equipment integration and solid modelling) ndash Electrical design (eg power supply instrumentation and

control hardware) bull Demonstrate targeted metrics

ndash gt1000 hours steady state operation ndash gt75 overall (electrical + thermal) system efficiency ndash gt90 system electrical efficiency ndash Ability to operate intermittently

Example of a thermally self-sustained stack module design

6

Approach Techno-Economic Analysis

bull Leverage FCErsquos SOFC baseline celland stack technology as well as system design and scale-up in development of electrolysis systems

bull Develop basis of design for a commercial forecourt 1500 kg H2day commercial system

ndash Utilize CSA stack design architecture bull Develop flow sheet alternatives to

optimize system performance and cost

bull Perform simulation studies using firstprinciple conservation laws

bull Develop Balance-of-Plant (BoP) Equipment specifications and cost

bull Investigate economic impact of ndash Electricity Cost ndash Capital Cost ndash System resiliency and dynamic

response bull Employ H2A analysis model

Electrolysis Process Flow Sheet

200 kW SOFC System BOP 7

8

ApproachMilestones FY2017 and FY2018

TaskSubtaskTitle

MilestoneDescription(GoNo-GoDecisionCriteria)

CompletionDate

Status(Percent

Completed)

EnduranceImprovement

Complete1000hr testofsinglecellwithvoltagedegradationratele41000hrs 12312016 100

Complete1000hr testofsinglecellwithvoltagedegradationrateofle21000hrs 12312017

TechnologyStackTests

Completegt500hourstestingofastackacrossamatrixofge5operatingpointstoidentifydesignimprovements 6302017 25

Stacktesting(ge1000hours)withelectricalefficiencyge95(LHVbased)atge1Acm2 ampdegradationrate le41000hrsGo-No-GoDecisionSuccesscriteriaforcontinuationtoBP2

3312018

Completepost-testanalysisof themetricstacktobeutilizedinfurtherreductionofthestackdegradationrate 6302018

SystemConfigurationand

ParametricAnalysis

Developelectrolysisperformancecharacteristicmapsofsystemoperatingparametersto beusedforoptimization 3312017 100

Develop systemconfiguration andoperationalparametersforachievinggt75overallsystemefficiency 9302017 5

Createconceptualdesignofagt4kgH2 daySOECdemonstrationsystemwithestimatedoverallefficiencygt75Go-No-GoDecisionSuccesscriteriaforcontinuationtoBP2

3312018

DetailedSystemDesign

Completedetailedsystemdesignforgt4kgH2daydemonstration 9302018

Accomplishments and Progress Cell Degradation Test at 1 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 1 Acm2

Stabilization Period

T = 750⁰C I = 16 A (1 Acm2) Cathode Flow = 0136 SLPM H2 78 humidity Anode Flow ndash 0467 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt15 mV1000h or 13 1000h over the last 2300 hours after initial stabilization

9

Accomplishments and Progress Cell Degradation Test at 2 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 2 Acm2

Stabilization Period T = 750⁰C I = 32 A (2 Acm2) Cathode Flow = 0272 SLPM H2 78 humidity Anode Flow ndash 0934 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt44 mV1000h or 351000h over the last 2400 hours after initial stabilization

10

11

Accomplishments and ProgressOperation Window Exploration

OperatingParameter Range SystemImpactsatHigher EndofRange

Current 1-2 Acm2

(Target11-132Vcell)1- ReducedStackCost2- HigherStackExitTemperatureforHeatRecovery3- LowerStackEfficiency4- LifeImpact

SteamUtilization(Stack) 50-95 1- Simpler H2 Purification2- LowerStackEfficiency

SteamInletConcentration

40-100 1- HigherStack Efficiency2- LessRecycle(ReducedBoP Cost)3- HarderH2 Purification4- PotentialLifeImpact

CellPressure 1-10 bara 1- HigherStackEfficiency (First~4bar)2- Simpler H2 Purification3- LowerStackEfficiency(Above~5bar)4- PotentialLifeImpact

AnodeO2Concentration(outlet)

40-100 1- LessAirFlowtoAnode(LessBoP Cost)2- SimplerforPressurizedOperation(LessBoP Cost)3- HigherVoltage(LessEfficient)

OperatingTemperature 650degCto800degC 1- Higher StackEfficiency2- PotentialLifeImpact

bull Large number of experiments across the above ranges were completed (gt 500 test conditions) bull Degradation testing at select points planned

Accomplishments and Progress Temperature Effect on Performance

Temperature Variation - Constant flow Curves

09

1

11

12

13

14

15

16

17

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

75 Us 2 Acm2 ndash 80 Inlet Steam ndash 5 Bara

All Curves ndash Air Flush

650degC

800degC

750degC

700degC

ge95 Stack Electric Efficiency

Current Density [Acm^2] 12

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara

10 Bara

1 Bara

All Curves ndash Air Flush

ge95 Stack Electric Efficiency

Accomplishments and Progress Pressure Effect on Performance

Pressure ndash Constant Flow Curves 75 Us 2 Acm2 ndash 80 Inlet Steamndash 750degC

Current Density [Acm^2] 13

14

Accomplishments and ProgressInlet Conc Effect on Performance

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge[V

]

CurrentDensity[Acm^2]

50SteamUtilizationUs (1and2Acm2) ConstantFlowCurves5Barandash 750degC

ge95StackElectricEfficiency

40Inlet

80Inlet

60Inlet

AllCurvesndash AirFlush

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

4

ApproachCell Technology Improvement

bull Top-down approach to explore the effects of system and stack operating conditions on performance and durability

bull Perform single cell tests to establish desirable stack and system operating conditions and reduce performance degradation rate ndash Operating voltagecurrent densityndash Hydrogensteam recyclingndash Operating pressurendash Operating temperaturendash Steam utilization

bull Conduct post-test microstructural analysis to understand and improve cell and interconnect materials stability

2H2O+4e-2H2 +2O=

ElectrolyteO= O=

Cathode

Anode2O= O2 +4e-

+

_

e-

H2

O2

e-

e-

H2O

Anode-Supported Solid Oxide Electrolysis Cell

5

ApproachStack Technology Development

bull Develop components for scale up of the existing baseline SOEC stack design using Compact SOFC Architecture (CSA) stack platform to meet the project goals for performance and endurance

‒ Full size CSA stack (350 cells) has a capacity of 38 kg H2day at a current density of 15 Acm2

bull Design build and test subscale technology stacks in 2 to 5 kg H2day size range to verify functionalities of stack components

bull Demonstrate 4kg H2day production in a stack with electric efficiency better than 95 and degradation of less than 2khr1000 hr test

Baseline 20 cell stackDemonstrated stable electrolysis

operation at 2 Acm2

Full size CSA stack 38 kg H2day

10 liter stack volume

44cm

(17

3in

ch)

Approach Breadboard System Demonstration

bull Develop bases of design and operation for a breadboard demonstration prototype ndash gt4 kg H2day capacity ndash Operating current density 1 to 2 Acm2

ndash Thermal integration to quantify system heat input needsby either heat recovery from effluent streams or using a steam generator

bull Develop design of the breadboard system ndash Process design (eg PampIDs equipment specs HAZOP

safety analysis and controls) ndash Mechanical design (eg thermally self-sustained stack

module equipment integration and solid modelling) ndash Electrical design (eg power supply instrumentation and

control hardware) bull Demonstrate targeted metrics

ndash gt1000 hours steady state operation ndash gt75 overall (electrical + thermal) system efficiency ndash gt90 system electrical efficiency ndash Ability to operate intermittently

Example of a thermally self-sustained stack module design

6

Approach Techno-Economic Analysis

bull Leverage FCErsquos SOFC baseline celland stack technology as well as system design and scale-up in development of electrolysis systems

bull Develop basis of design for a commercial forecourt 1500 kg H2day commercial system

ndash Utilize CSA stack design architecture bull Develop flow sheet alternatives to

optimize system performance and cost

bull Perform simulation studies using firstprinciple conservation laws

bull Develop Balance-of-Plant (BoP) Equipment specifications and cost

bull Investigate economic impact of ndash Electricity Cost ndash Capital Cost ndash System resiliency and dynamic

response bull Employ H2A analysis model

Electrolysis Process Flow Sheet

200 kW SOFC System BOP 7

8

ApproachMilestones FY2017 and FY2018

TaskSubtaskTitle

MilestoneDescription(GoNo-GoDecisionCriteria)

CompletionDate

Status(Percent

Completed)

EnduranceImprovement

Complete1000hr testofsinglecellwithvoltagedegradationratele41000hrs 12312016 100

Complete1000hr testofsinglecellwithvoltagedegradationrateofle21000hrs 12312017

TechnologyStackTests

Completegt500hourstestingofastackacrossamatrixofge5operatingpointstoidentifydesignimprovements 6302017 25

Stacktesting(ge1000hours)withelectricalefficiencyge95(LHVbased)atge1Acm2 ampdegradationrate le41000hrsGo-No-GoDecisionSuccesscriteriaforcontinuationtoBP2

3312018

Completepost-testanalysisof themetricstacktobeutilizedinfurtherreductionofthestackdegradationrate 6302018

SystemConfigurationand

ParametricAnalysis

Developelectrolysisperformancecharacteristicmapsofsystemoperatingparametersto beusedforoptimization 3312017 100

Develop systemconfiguration andoperationalparametersforachievinggt75overallsystemefficiency 9302017 5

Createconceptualdesignofagt4kgH2 daySOECdemonstrationsystemwithestimatedoverallefficiencygt75Go-No-GoDecisionSuccesscriteriaforcontinuationtoBP2

3312018

DetailedSystemDesign

Completedetailedsystemdesignforgt4kgH2daydemonstration 9302018

Accomplishments and Progress Cell Degradation Test at 1 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 1 Acm2

Stabilization Period

T = 750⁰C I = 16 A (1 Acm2) Cathode Flow = 0136 SLPM H2 78 humidity Anode Flow ndash 0467 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt15 mV1000h or 13 1000h over the last 2300 hours after initial stabilization

9

Accomplishments and Progress Cell Degradation Test at 2 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 2 Acm2

Stabilization Period T = 750⁰C I = 32 A (2 Acm2) Cathode Flow = 0272 SLPM H2 78 humidity Anode Flow ndash 0934 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt44 mV1000h or 351000h over the last 2400 hours after initial stabilization

10

11

Accomplishments and ProgressOperation Window Exploration

OperatingParameter Range SystemImpactsatHigher EndofRange

Current 1-2 Acm2

(Target11-132Vcell)1- ReducedStackCost2- HigherStackExitTemperatureforHeatRecovery3- LowerStackEfficiency4- LifeImpact

SteamUtilization(Stack) 50-95 1- Simpler H2 Purification2- LowerStackEfficiency

SteamInletConcentration

40-100 1- HigherStack Efficiency2- LessRecycle(ReducedBoP Cost)3- HarderH2 Purification4- PotentialLifeImpact

CellPressure 1-10 bara 1- HigherStackEfficiency (First~4bar)2- Simpler H2 Purification3- LowerStackEfficiency(Above~5bar)4- PotentialLifeImpact

AnodeO2Concentration(outlet)

40-100 1- LessAirFlowtoAnode(LessBoP Cost)2- SimplerforPressurizedOperation(LessBoP Cost)3- HigherVoltage(LessEfficient)

OperatingTemperature 650degCto800degC 1- Higher StackEfficiency2- PotentialLifeImpact

bull Large number of experiments across the above ranges were completed (gt 500 test conditions) bull Degradation testing at select points planned

Accomplishments and Progress Temperature Effect on Performance

Temperature Variation - Constant flow Curves

09

1

11

12

13

14

15

16

17

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

75 Us 2 Acm2 ndash 80 Inlet Steam ndash 5 Bara

All Curves ndash Air Flush

650degC

800degC

750degC

700degC

ge95 Stack Electric Efficiency

Current Density [Acm^2] 12

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara

10 Bara

1 Bara

All Curves ndash Air Flush

ge95 Stack Electric Efficiency

Accomplishments and Progress Pressure Effect on Performance

Pressure ndash Constant Flow Curves 75 Us 2 Acm2 ndash 80 Inlet Steamndash 750degC

Current Density [Acm^2] 13

14

Accomplishments and ProgressInlet Conc Effect on Performance

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge[V

]

CurrentDensity[Acm^2]

50SteamUtilizationUs (1and2Acm2) ConstantFlowCurves5Barandash 750degC

ge95StackElectricEfficiency

40Inlet

80Inlet

60Inlet

AllCurvesndash AirFlush

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

5

ApproachStack Technology Development

bull Develop components for scale up of the existing baseline SOEC stack design using Compact SOFC Architecture (CSA) stack platform to meet the project goals for performance and endurance

‒ Full size CSA stack (350 cells) has a capacity of 38 kg H2day at a current density of 15 Acm2

bull Design build and test subscale technology stacks in 2 to 5 kg H2day size range to verify functionalities of stack components

bull Demonstrate 4kg H2day production in a stack with electric efficiency better than 95 and degradation of less than 2khr1000 hr test

Baseline 20 cell stackDemonstrated stable electrolysis

operation at 2 Acm2

Full size CSA stack 38 kg H2day

10 liter stack volume

44cm

(17

3in

ch)

Approach Breadboard System Demonstration

bull Develop bases of design and operation for a breadboard demonstration prototype ndash gt4 kg H2day capacity ndash Operating current density 1 to 2 Acm2

ndash Thermal integration to quantify system heat input needsby either heat recovery from effluent streams or using a steam generator

bull Develop design of the breadboard system ndash Process design (eg PampIDs equipment specs HAZOP

safety analysis and controls) ndash Mechanical design (eg thermally self-sustained stack

module equipment integration and solid modelling) ndash Electrical design (eg power supply instrumentation and

control hardware) bull Demonstrate targeted metrics

ndash gt1000 hours steady state operation ndash gt75 overall (electrical + thermal) system efficiency ndash gt90 system electrical efficiency ndash Ability to operate intermittently

Example of a thermally self-sustained stack module design

6

Approach Techno-Economic Analysis

bull Leverage FCErsquos SOFC baseline celland stack technology as well as system design and scale-up in development of electrolysis systems

bull Develop basis of design for a commercial forecourt 1500 kg H2day commercial system

ndash Utilize CSA stack design architecture bull Develop flow sheet alternatives to

optimize system performance and cost

bull Perform simulation studies using firstprinciple conservation laws

bull Develop Balance-of-Plant (BoP) Equipment specifications and cost

bull Investigate economic impact of ndash Electricity Cost ndash Capital Cost ndash System resiliency and dynamic

response bull Employ H2A analysis model

Electrolysis Process Flow Sheet

200 kW SOFC System BOP 7

8

ApproachMilestones FY2017 and FY2018

TaskSubtaskTitle

MilestoneDescription(GoNo-GoDecisionCriteria)

CompletionDate

Status(Percent

Completed)

EnduranceImprovement

Complete1000hr testofsinglecellwithvoltagedegradationratele41000hrs 12312016 100

Complete1000hr testofsinglecellwithvoltagedegradationrateofle21000hrs 12312017

TechnologyStackTests

Completegt500hourstestingofastackacrossamatrixofge5operatingpointstoidentifydesignimprovements 6302017 25

Stacktesting(ge1000hours)withelectricalefficiencyge95(LHVbased)atge1Acm2 ampdegradationrate le41000hrsGo-No-GoDecisionSuccesscriteriaforcontinuationtoBP2

3312018

Completepost-testanalysisof themetricstacktobeutilizedinfurtherreductionofthestackdegradationrate 6302018

SystemConfigurationand

ParametricAnalysis

Developelectrolysisperformancecharacteristicmapsofsystemoperatingparametersto beusedforoptimization 3312017 100

Develop systemconfiguration andoperationalparametersforachievinggt75overallsystemefficiency 9302017 5

Createconceptualdesignofagt4kgH2 daySOECdemonstrationsystemwithestimatedoverallefficiencygt75Go-No-GoDecisionSuccesscriteriaforcontinuationtoBP2

3312018

DetailedSystemDesign

Completedetailedsystemdesignforgt4kgH2daydemonstration 9302018

Accomplishments and Progress Cell Degradation Test at 1 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 1 Acm2

Stabilization Period

T = 750⁰C I = 16 A (1 Acm2) Cathode Flow = 0136 SLPM H2 78 humidity Anode Flow ndash 0467 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt15 mV1000h or 13 1000h over the last 2300 hours after initial stabilization

9

Accomplishments and Progress Cell Degradation Test at 2 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 2 Acm2

Stabilization Period T = 750⁰C I = 32 A (2 Acm2) Cathode Flow = 0272 SLPM H2 78 humidity Anode Flow ndash 0934 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt44 mV1000h or 351000h over the last 2400 hours after initial stabilization

10

11

Accomplishments and ProgressOperation Window Exploration

OperatingParameter Range SystemImpactsatHigher EndofRange

Current 1-2 Acm2

(Target11-132Vcell)1- ReducedStackCost2- HigherStackExitTemperatureforHeatRecovery3- LowerStackEfficiency4- LifeImpact

SteamUtilization(Stack) 50-95 1- Simpler H2 Purification2- LowerStackEfficiency

SteamInletConcentration

40-100 1- HigherStack Efficiency2- LessRecycle(ReducedBoP Cost)3- HarderH2 Purification4- PotentialLifeImpact

CellPressure 1-10 bara 1- HigherStackEfficiency (First~4bar)2- Simpler H2 Purification3- LowerStackEfficiency(Above~5bar)4- PotentialLifeImpact

AnodeO2Concentration(outlet)

40-100 1- LessAirFlowtoAnode(LessBoP Cost)2- SimplerforPressurizedOperation(LessBoP Cost)3- HigherVoltage(LessEfficient)

OperatingTemperature 650degCto800degC 1- Higher StackEfficiency2- PotentialLifeImpact

bull Large number of experiments across the above ranges were completed (gt 500 test conditions) bull Degradation testing at select points planned

Accomplishments and Progress Temperature Effect on Performance

Temperature Variation - Constant flow Curves

09

1

11

12

13

14

15

16

17

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

75 Us 2 Acm2 ndash 80 Inlet Steam ndash 5 Bara

All Curves ndash Air Flush

650degC

800degC

750degC

700degC

ge95 Stack Electric Efficiency

Current Density [Acm^2] 12

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara

10 Bara

1 Bara

All Curves ndash Air Flush

ge95 Stack Electric Efficiency

Accomplishments and Progress Pressure Effect on Performance

Pressure ndash Constant Flow Curves 75 Us 2 Acm2 ndash 80 Inlet Steamndash 750degC

Current Density [Acm^2] 13

14

Accomplishments and ProgressInlet Conc Effect on Performance

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge[V

]

CurrentDensity[Acm^2]

50SteamUtilizationUs (1and2Acm2) ConstantFlowCurves5Barandash 750degC

ge95StackElectricEfficiency

40Inlet

80Inlet

60Inlet

AllCurvesndash AirFlush

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

Approach Breadboard System Demonstration

bull Develop bases of design and operation for a breadboard demonstration prototype ndash gt4 kg H2day capacity ndash Operating current density 1 to 2 Acm2

ndash Thermal integration to quantify system heat input needsby either heat recovery from effluent streams or using a steam generator

bull Develop design of the breadboard system ndash Process design (eg PampIDs equipment specs HAZOP

safety analysis and controls) ndash Mechanical design (eg thermally self-sustained stack

module equipment integration and solid modelling) ndash Electrical design (eg power supply instrumentation and

control hardware) bull Demonstrate targeted metrics

ndash gt1000 hours steady state operation ndash gt75 overall (electrical + thermal) system efficiency ndash gt90 system electrical efficiency ndash Ability to operate intermittently

Example of a thermally self-sustained stack module design

6

Approach Techno-Economic Analysis

bull Leverage FCErsquos SOFC baseline celland stack technology as well as system design and scale-up in development of electrolysis systems

bull Develop basis of design for a commercial forecourt 1500 kg H2day commercial system

ndash Utilize CSA stack design architecture bull Develop flow sheet alternatives to

optimize system performance and cost

bull Perform simulation studies using firstprinciple conservation laws

bull Develop Balance-of-Plant (BoP) Equipment specifications and cost

bull Investigate economic impact of ndash Electricity Cost ndash Capital Cost ndash System resiliency and dynamic

response bull Employ H2A analysis model

Electrolysis Process Flow Sheet

200 kW SOFC System BOP 7

8

ApproachMilestones FY2017 and FY2018

TaskSubtaskTitle

MilestoneDescription(GoNo-GoDecisionCriteria)

CompletionDate

Status(Percent

Completed)

EnduranceImprovement

Complete1000hr testofsinglecellwithvoltagedegradationratele41000hrs 12312016 100

Complete1000hr testofsinglecellwithvoltagedegradationrateofle21000hrs 12312017

TechnologyStackTests

Completegt500hourstestingofastackacrossamatrixofge5operatingpointstoidentifydesignimprovements 6302017 25

Stacktesting(ge1000hours)withelectricalefficiencyge95(LHVbased)atge1Acm2 ampdegradationrate le41000hrsGo-No-GoDecisionSuccesscriteriaforcontinuationtoBP2

3312018

Completepost-testanalysisof themetricstacktobeutilizedinfurtherreductionofthestackdegradationrate 6302018

SystemConfigurationand

ParametricAnalysis

Developelectrolysisperformancecharacteristicmapsofsystemoperatingparametersto beusedforoptimization 3312017 100

Develop systemconfiguration andoperationalparametersforachievinggt75overallsystemefficiency 9302017 5

Createconceptualdesignofagt4kgH2 daySOECdemonstrationsystemwithestimatedoverallefficiencygt75Go-No-GoDecisionSuccesscriteriaforcontinuationtoBP2

3312018

DetailedSystemDesign

Completedetailedsystemdesignforgt4kgH2daydemonstration 9302018

Accomplishments and Progress Cell Degradation Test at 1 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 1 Acm2

Stabilization Period

T = 750⁰C I = 16 A (1 Acm2) Cathode Flow = 0136 SLPM H2 78 humidity Anode Flow ndash 0467 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt15 mV1000h or 13 1000h over the last 2300 hours after initial stabilization

9

Accomplishments and Progress Cell Degradation Test at 2 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 2 Acm2

Stabilization Period T = 750⁰C I = 32 A (2 Acm2) Cathode Flow = 0272 SLPM H2 78 humidity Anode Flow ndash 0934 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt44 mV1000h or 351000h over the last 2400 hours after initial stabilization

10

11

Accomplishments and ProgressOperation Window Exploration

OperatingParameter Range SystemImpactsatHigher EndofRange

Current 1-2 Acm2

(Target11-132Vcell)1- ReducedStackCost2- HigherStackExitTemperatureforHeatRecovery3- LowerStackEfficiency4- LifeImpact

SteamUtilization(Stack) 50-95 1- Simpler H2 Purification2- LowerStackEfficiency

SteamInletConcentration

40-100 1- HigherStack Efficiency2- LessRecycle(ReducedBoP Cost)3- HarderH2 Purification4- PotentialLifeImpact

CellPressure 1-10 bara 1- HigherStackEfficiency (First~4bar)2- Simpler H2 Purification3- LowerStackEfficiency(Above~5bar)4- PotentialLifeImpact

AnodeO2Concentration(outlet)

40-100 1- LessAirFlowtoAnode(LessBoP Cost)2- SimplerforPressurizedOperation(LessBoP Cost)3- HigherVoltage(LessEfficient)

OperatingTemperature 650degCto800degC 1- Higher StackEfficiency2- PotentialLifeImpact

bull Large number of experiments across the above ranges were completed (gt 500 test conditions) bull Degradation testing at select points planned

Accomplishments and Progress Temperature Effect on Performance

Temperature Variation - Constant flow Curves

09

1

11

12

13

14

15

16

17

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

75 Us 2 Acm2 ndash 80 Inlet Steam ndash 5 Bara

All Curves ndash Air Flush

650degC

800degC

750degC

700degC

ge95 Stack Electric Efficiency

Current Density [Acm^2] 12

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara

10 Bara

1 Bara

All Curves ndash Air Flush

ge95 Stack Electric Efficiency

Accomplishments and Progress Pressure Effect on Performance

Pressure ndash Constant Flow Curves 75 Us 2 Acm2 ndash 80 Inlet Steamndash 750degC

Current Density [Acm^2] 13

14

Accomplishments and ProgressInlet Conc Effect on Performance

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge[V

]

CurrentDensity[Acm^2]

50SteamUtilizationUs (1and2Acm2) ConstantFlowCurves5Barandash 750degC

ge95StackElectricEfficiency

40Inlet

80Inlet

60Inlet

AllCurvesndash AirFlush

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

Approach Techno-Economic Analysis

bull Leverage FCErsquos SOFC baseline celland stack technology as well as system design and scale-up in development of electrolysis systems

bull Develop basis of design for a commercial forecourt 1500 kg H2day commercial system

ndash Utilize CSA stack design architecture bull Develop flow sheet alternatives to

optimize system performance and cost

bull Perform simulation studies using firstprinciple conservation laws

bull Develop Balance-of-Plant (BoP) Equipment specifications and cost

bull Investigate economic impact of ndash Electricity Cost ndash Capital Cost ndash System resiliency and dynamic

response bull Employ H2A analysis model

Electrolysis Process Flow Sheet

200 kW SOFC System BOP 7

8

ApproachMilestones FY2017 and FY2018

TaskSubtaskTitle

MilestoneDescription(GoNo-GoDecisionCriteria)

CompletionDate

Status(Percent

Completed)

EnduranceImprovement

Complete1000hr testofsinglecellwithvoltagedegradationratele41000hrs 12312016 100

Complete1000hr testofsinglecellwithvoltagedegradationrateofle21000hrs 12312017

TechnologyStackTests

Completegt500hourstestingofastackacrossamatrixofge5operatingpointstoidentifydesignimprovements 6302017 25

Stacktesting(ge1000hours)withelectricalefficiencyge95(LHVbased)atge1Acm2 ampdegradationrate le41000hrsGo-No-GoDecisionSuccesscriteriaforcontinuationtoBP2

3312018

Completepost-testanalysisof themetricstacktobeutilizedinfurtherreductionofthestackdegradationrate 6302018

SystemConfigurationand

ParametricAnalysis

Developelectrolysisperformancecharacteristicmapsofsystemoperatingparametersto beusedforoptimization 3312017 100

Develop systemconfiguration andoperationalparametersforachievinggt75overallsystemefficiency 9302017 5

Createconceptualdesignofagt4kgH2 daySOECdemonstrationsystemwithestimatedoverallefficiencygt75Go-No-GoDecisionSuccesscriteriaforcontinuationtoBP2

3312018

DetailedSystemDesign

Completedetailedsystemdesignforgt4kgH2daydemonstration 9302018

Accomplishments and Progress Cell Degradation Test at 1 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 1 Acm2

Stabilization Period

T = 750⁰C I = 16 A (1 Acm2) Cathode Flow = 0136 SLPM H2 78 humidity Anode Flow ndash 0467 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt15 mV1000h or 13 1000h over the last 2300 hours after initial stabilization

9

Accomplishments and Progress Cell Degradation Test at 2 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 2 Acm2

Stabilization Period T = 750⁰C I = 32 A (2 Acm2) Cathode Flow = 0272 SLPM H2 78 humidity Anode Flow ndash 0934 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt44 mV1000h or 351000h over the last 2400 hours after initial stabilization

10

11

Accomplishments and ProgressOperation Window Exploration

OperatingParameter Range SystemImpactsatHigher EndofRange

Current 1-2 Acm2

(Target11-132Vcell)1- ReducedStackCost2- HigherStackExitTemperatureforHeatRecovery3- LowerStackEfficiency4- LifeImpact

SteamUtilization(Stack) 50-95 1- Simpler H2 Purification2- LowerStackEfficiency

SteamInletConcentration

40-100 1- HigherStack Efficiency2- LessRecycle(ReducedBoP Cost)3- HarderH2 Purification4- PotentialLifeImpact

CellPressure 1-10 bara 1- HigherStackEfficiency (First~4bar)2- Simpler H2 Purification3- LowerStackEfficiency(Above~5bar)4- PotentialLifeImpact

AnodeO2Concentration(outlet)

40-100 1- LessAirFlowtoAnode(LessBoP Cost)2- SimplerforPressurizedOperation(LessBoP Cost)3- HigherVoltage(LessEfficient)

OperatingTemperature 650degCto800degC 1- Higher StackEfficiency2- PotentialLifeImpact

bull Large number of experiments across the above ranges were completed (gt 500 test conditions) bull Degradation testing at select points planned

Accomplishments and Progress Temperature Effect on Performance

Temperature Variation - Constant flow Curves

09

1

11

12

13

14

15

16

17

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

75 Us 2 Acm2 ndash 80 Inlet Steam ndash 5 Bara

All Curves ndash Air Flush

650degC

800degC

750degC

700degC

ge95 Stack Electric Efficiency

Current Density [Acm^2] 12

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara

10 Bara

1 Bara

All Curves ndash Air Flush

ge95 Stack Electric Efficiency

Accomplishments and Progress Pressure Effect on Performance

Pressure ndash Constant Flow Curves 75 Us 2 Acm2 ndash 80 Inlet Steamndash 750degC

Current Density [Acm^2] 13

14

Accomplishments and ProgressInlet Conc Effect on Performance

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge[V

]

CurrentDensity[Acm^2]

50SteamUtilizationUs (1and2Acm2) ConstantFlowCurves5Barandash 750degC

ge95StackElectricEfficiency

40Inlet

80Inlet

60Inlet

AllCurvesndash AirFlush

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

8

ApproachMilestones FY2017 and FY2018

TaskSubtaskTitle

MilestoneDescription(GoNo-GoDecisionCriteria)

CompletionDate

Status(Percent

Completed)

EnduranceImprovement

Complete1000hr testofsinglecellwithvoltagedegradationratele41000hrs 12312016 100

Complete1000hr testofsinglecellwithvoltagedegradationrateofle21000hrs 12312017

TechnologyStackTests

Completegt500hourstestingofastackacrossamatrixofge5operatingpointstoidentifydesignimprovements 6302017 25

Stacktesting(ge1000hours)withelectricalefficiencyge95(LHVbased)atge1Acm2 ampdegradationrate le41000hrsGo-No-GoDecisionSuccesscriteriaforcontinuationtoBP2

3312018

Completepost-testanalysisof themetricstacktobeutilizedinfurtherreductionofthestackdegradationrate 6302018

SystemConfigurationand

ParametricAnalysis

Developelectrolysisperformancecharacteristicmapsofsystemoperatingparametersto beusedforoptimization 3312017 100

Develop systemconfiguration andoperationalparametersforachievinggt75overallsystemefficiency 9302017 5

Createconceptualdesignofagt4kgH2 daySOECdemonstrationsystemwithestimatedoverallefficiencygt75Go-No-GoDecisionSuccesscriteriaforcontinuationtoBP2

3312018

DetailedSystemDesign

Completedetailedsystemdesignforgt4kgH2daydemonstration 9302018

Accomplishments and Progress Cell Degradation Test at 1 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 1 Acm2

Stabilization Period

T = 750⁰C I = 16 A (1 Acm2) Cathode Flow = 0136 SLPM H2 78 humidity Anode Flow ndash 0467 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt15 mV1000h or 13 1000h over the last 2300 hours after initial stabilization

9

Accomplishments and Progress Cell Degradation Test at 2 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 2 Acm2

Stabilization Period T = 750⁰C I = 32 A (2 Acm2) Cathode Flow = 0272 SLPM H2 78 humidity Anode Flow ndash 0934 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt44 mV1000h or 351000h over the last 2400 hours after initial stabilization

10

11

Accomplishments and ProgressOperation Window Exploration

OperatingParameter Range SystemImpactsatHigher EndofRange

Current 1-2 Acm2

(Target11-132Vcell)1- ReducedStackCost2- HigherStackExitTemperatureforHeatRecovery3- LowerStackEfficiency4- LifeImpact

SteamUtilization(Stack) 50-95 1- Simpler H2 Purification2- LowerStackEfficiency

SteamInletConcentration

40-100 1- HigherStack Efficiency2- LessRecycle(ReducedBoP Cost)3- HarderH2 Purification4- PotentialLifeImpact

CellPressure 1-10 bara 1- HigherStackEfficiency (First~4bar)2- Simpler H2 Purification3- LowerStackEfficiency(Above~5bar)4- PotentialLifeImpact

AnodeO2Concentration(outlet)

40-100 1- LessAirFlowtoAnode(LessBoP Cost)2- SimplerforPressurizedOperation(LessBoP Cost)3- HigherVoltage(LessEfficient)

OperatingTemperature 650degCto800degC 1- Higher StackEfficiency2- PotentialLifeImpact

bull Large number of experiments across the above ranges were completed (gt 500 test conditions) bull Degradation testing at select points planned

Accomplishments and Progress Temperature Effect on Performance

Temperature Variation - Constant flow Curves

09

1

11

12

13

14

15

16

17

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

75 Us 2 Acm2 ndash 80 Inlet Steam ndash 5 Bara

All Curves ndash Air Flush

650degC

800degC

750degC

700degC

ge95 Stack Electric Efficiency

Current Density [Acm^2] 12

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara

10 Bara

1 Bara

All Curves ndash Air Flush

ge95 Stack Electric Efficiency

Accomplishments and Progress Pressure Effect on Performance

Pressure ndash Constant Flow Curves 75 Us 2 Acm2 ndash 80 Inlet Steamndash 750degC

Current Density [Acm^2] 13

14

Accomplishments and ProgressInlet Conc Effect on Performance

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge[V

]

CurrentDensity[Acm^2]

50SteamUtilizationUs (1and2Acm2) ConstantFlowCurves5Barandash 750degC

ge95StackElectricEfficiency

40Inlet

80Inlet

60Inlet

AllCurvesndash AirFlush

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

Accomplishments and Progress Cell Degradation Test at 1 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 1 Acm2

Stabilization Period

T = 750⁰C I = 16 A (1 Acm2) Cathode Flow = 0136 SLPM H2 78 humidity Anode Flow ndash 0467 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt15 mV1000h or 13 1000h over the last 2300 hours after initial stabilization

9

Accomplishments and Progress Cell Degradation Test at 2 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 2 Acm2

Stabilization Period T = 750⁰C I = 32 A (2 Acm2) Cathode Flow = 0272 SLPM H2 78 humidity Anode Flow ndash 0934 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt44 mV1000h or 351000h over the last 2400 hours after initial stabilization

10

11

Accomplishments and ProgressOperation Window Exploration

OperatingParameter Range SystemImpactsatHigher EndofRange

Current 1-2 Acm2

(Target11-132Vcell)1- ReducedStackCost2- HigherStackExitTemperatureforHeatRecovery3- LowerStackEfficiency4- LifeImpact

SteamUtilization(Stack) 50-95 1- Simpler H2 Purification2- LowerStackEfficiency

SteamInletConcentration

40-100 1- HigherStack Efficiency2- LessRecycle(ReducedBoP Cost)3- HarderH2 Purification4- PotentialLifeImpact

CellPressure 1-10 bara 1- HigherStackEfficiency (First~4bar)2- Simpler H2 Purification3- LowerStackEfficiency(Above~5bar)4- PotentialLifeImpact

AnodeO2Concentration(outlet)

40-100 1- LessAirFlowtoAnode(LessBoP Cost)2- SimplerforPressurizedOperation(LessBoP Cost)3- HigherVoltage(LessEfficient)

OperatingTemperature 650degCto800degC 1- Higher StackEfficiency2- PotentialLifeImpact

bull Large number of experiments across the above ranges were completed (gt 500 test conditions) bull Degradation testing at select points planned

Accomplishments and Progress Temperature Effect on Performance

Temperature Variation - Constant flow Curves

09

1

11

12

13

14

15

16

17

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

75 Us 2 Acm2 ndash 80 Inlet Steam ndash 5 Bara

All Curves ndash Air Flush

650degC

800degC

750degC

700degC

ge95 Stack Electric Efficiency

Current Density [Acm^2] 12

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara

10 Bara

1 Bara

All Curves ndash Air Flush

ge95 Stack Electric Efficiency

Accomplishments and Progress Pressure Effect on Performance

Pressure ndash Constant Flow Curves 75 Us 2 Acm2 ndash 80 Inlet Steamndash 750degC

Current Density [Acm^2] 13

14

Accomplishments and ProgressInlet Conc Effect on Performance

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge[V

]

CurrentDensity[Acm^2]

50SteamUtilizationUs (1and2Acm2) ConstantFlowCurves5Barandash 750degC

ge95StackElectricEfficiency

40Inlet

80Inlet

60Inlet

AllCurvesndash AirFlush

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

Accomplishments and Progress Cell Degradation Test at 2 Acm2

Test of HiPoD (High Power Density) cell (5 cm x 5 cm x 003 cm) at 2 Acm2

Stabilization Period T = 750⁰C I = 32 A (2 Acm2) Cathode Flow = 0272 SLPM H2 78 humidity Anode Flow ndash 0934 SLPM Air Flush

bull Demonstrated voltage degradation rate of lt44 mV1000h or 351000h over the last 2400 hours after initial stabilization

10

11

Accomplishments and ProgressOperation Window Exploration

OperatingParameter Range SystemImpactsatHigher EndofRange

Current 1-2 Acm2

(Target11-132Vcell)1- ReducedStackCost2- HigherStackExitTemperatureforHeatRecovery3- LowerStackEfficiency4- LifeImpact

SteamUtilization(Stack) 50-95 1- Simpler H2 Purification2- LowerStackEfficiency

SteamInletConcentration

40-100 1- HigherStack Efficiency2- LessRecycle(ReducedBoP Cost)3- HarderH2 Purification4- PotentialLifeImpact

CellPressure 1-10 bara 1- HigherStackEfficiency (First~4bar)2- Simpler H2 Purification3- LowerStackEfficiency(Above~5bar)4- PotentialLifeImpact

AnodeO2Concentration(outlet)

40-100 1- LessAirFlowtoAnode(LessBoP Cost)2- SimplerforPressurizedOperation(LessBoP Cost)3- HigherVoltage(LessEfficient)

OperatingTemperature 650degCto800degC 1- Higher StackEfficiency2- PotentialLifeImpact

bull Large number of experiments across the above ranges were completed (gt 500 test conditions) bull Degradation testing at select points planned

Accomplishments and Progress Temperature Effect on Performance

Temperature Variation - Constant flow Curves

09

1

11

12

13

14

15

16

17

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

75 Us 2 Acm2 ndash 80 Inlet Steam ndash 5 Bara

All Curves ndash Air Flush

650degC

800degC

750degC

700degC

ge95 Stack Electric Efficiency

Current Density [Acm^2] 12

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara

10 Bara

1 Bara

All Curves ndash Air Flush

ge95 Stack Electric Efficiency

Accomplishments and Progress Pressure Effect on Performance

Pressure ndash Constant Flow Curves 75 Us 2 Acm2 ndash 80 Inlet Steamndash 750degC

Current Density [Acm^2] 13

14

Accomplishments and ProgressInlet Conc Effect on Performance

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge[V

]

CurrentDensity[Acm^2]

50SteamUtilizationUs (1and2Acm2) ConstantFlowCurves5Barandash 750degC

ge95StackElectricEfficiency

40Inlet

80Inlet

60Inlet

AllCurvesndash AirFlush

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

11

Accomplishments and ProgressOperation Window Exploration

OperatingParameter Range SystemImpactsatHigher EndofRange

Current 1-2 Acm2

(Target11-132Vcell)1- ReducedStackCost2- HigherStackExitTemperatureforHeatRecovery3- LowerStackEfficiency4- LifeImpact

SteamUtilization(Stack) 50-95 1- Simpler H2 Purification2- LowerStackEfficiency

SteamInletConcentration

40-100 1- HigherStack Efficiency2- LessRecycle(ReducedBoP Cost)3- HarderH2 Purification4- PotentialLifeImpact

CellPressure 1-10 bara 1- HigherStackEfficiency (First~4bar)2- Simpler H2 Purification3- LowerStackEfficiency(Above~5bar)4- PotentialLifeImpact

AnodeO2Concentration(outlet)

40-100 1- LessAirFlowtoAnode(LessBoP Cost)2- SimplerforPressurizedOperation(LessBoP Cost)3- HigherVoltage(LessEfficient)

OperatingTemperature 650degCto800degC 1- Higher StackEfficiency2- PotentialLifeImpact

bull Large number of experiments across the above ranges were completed (gt 500 test conditions) bull Degradation testing at select points planned

Accomplishments and Progress Temperature Effect on Performance

Temperature Variation - Constant flow Curves

09

1

11

12

13

14

15

16

17

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

75 Us 2 Acm2 ndash 80 Inlet Steam ndash 5 Bara

All Curves ndash Air Flush

650degC

800degC

750degC

700degC

ge95 Stack Electric Efficiency

Current Density [Acm^2] 12

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara

10 Bara

1 Bara

All Curves ndash Air Flush

ge95 Stack Electric Efficiency

Accomplishments and Progress Pressure Effect on Performance

Pressure ndash Constant Flow Curves 75 Us 2 Acm2 ndash 80 Inlet Steamndash 750degC

Current Density [Acm^2] 13

14

Accomplishments and ProgressInlet Conc Effect on Performance

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge[V

]

CurrentDensity[Acm^2]

50SteamUtilizationUs (1and2Acm2) ConstantFlowCurves5Barandash 750degC

ge95StackElectricEfficiency

40Inlet

80Inlet

60Inlet

AllCurvesndash AirFlush

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

Accomplishments and Progress Temperature Effect on Performance

Temperature Variation - Constant flow Curves

09

1

11

12

13

14

15

16

17

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

75 Us 2 Acm2 ndash 80 Inlet Steam ndash 5 Bara

All Curves ndash Air Flush

650degC

800degC

750degC

700degC

ge95 Stack Electric Efficiency

Current Density [Acm^2] 12

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara

10 Bara

1 Bara

All Curves ndash Air Flush

ge95 Stack Electric Efficiency

Accomplishments and Progress Pressure Effect on Performance

Pressure ndash Constant Flow Curves 75 Us 2 Acm2 ndash 80 Inlet Steamndash 750degC

Current Density [Acm^2] 13

14

Accomplishments and ProgressInlet Conc Effect on Performance

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge[V

]

CurrentDensity[Acm^2]

50SteamUtilizationUs (1and2Acm2) ConstantFlowCurves5Barandash 750degC

ge95StackElectricEfficiency

40Inlet

80Inlet

60Inlet

AllCurvesndash AirFlush

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara

10 Bara

1 Bara

All Curves ndash Air Flush

ge95 Stack Electric Efficiency

Accomplishments and Progress Pressure Effect on Performance

Pressure ndash Constant Flow Curves 75 Us 2 Acm2 ndash 80 Inlet Steamndash 750degC

Current Density [Acm^2] 13

14

Accomplishments and ProgressInlet Conc Effect on Performance

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge[V

]

CurrentDensity[Acm^2]

50SteamUtilizationUs (1and2Acm2) ConstantFlowCurves5Barandash 750degC

ge95StackElectricEfficiency

40Inlet

80Inlet

60Inlet

AllCurvesndash AirFlush

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

14

Accomplishments and ProgressInlet Conc Effect on Performance

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge[V

]

CurrentDensity[Acm^2]

50SteamUtilizationUs (1and2Acm2) ConstantFlowCurves5Barandash 750degC

ge95StackElectricEfficiency

40Inlet

80Inlet

60Inlet

AllCurvesndash AirFlush

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

Accomplishments and Progress AirO2 Effect on Performance

AirO2 Flush Effects - Constant Flow Curve

09

1

11

12

13

14

15

-22 -17 -12 -07 -02

Cell

Volta

ge [V

]

5 Bara - 750degC - 80 Steam Inlet - 75 US at Maximum Current

Air Flush

Oxygen Flush

ge95 Stack Electric Efficiency

- Air Flush

- Air Flush - O2 Flush

- O2 Flush

Current Density [Acm^2] 15

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

Cell

Volta

ge [V

]

Accomplishments and Progress Steam Utilization Effects on Performance Steam Utilization Effects - Constant Flow Curve

09

1

11

12

13

14

15

16 5 Bara - 750degC - 60 Steam Inlet ndash Air Flush

33 US

50 US

67 US

83 US

92 US

ge95 Stack Electric Efficiency

-22 -17 -12 -07 -02 Current Density [Acm^2] 16

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

bull Versa Power Systems (VPS) ndash Provides expertise in bull SOFC materials amp components

RampD bull Stack design bull Cellstack pilot manufacturing

and QC

bull DOENETL ndash Supports development of

SOFC technology for power generation focused on bull Increased SOFC endurance bull Stacksystem scale-up and cost

reduction bull Power system integration and

demonstration

Collaborations

Cell Pilot Manufacturing Processes at VPS (Tape Casting Screen Printing and Co-sintering)

50 kW System Natural Gas Fuel

(8rsquox20rsquox8rsquo6rdquo)

16 kWe Stack 120-cells

(550 cm2 Active Area per Cell) 17

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

Remaining Challenges and Barriers

bull Cell and Stack ndash Degradation reduction at high current

density

ndash Determination of operating parameters impacts on cell endurance

ndash Scale up of stack architecture and manufacturing process

bull System and Demonstration ndash System efficiency target of 75 (LHV

of H2) ndash High pressure solid oxide system

design and demonstration

ndash Development of cost optimized system to meet $2kg H2 target 45-Cell stack (gt4 kg H2 day)

for demonstration tests 18

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

Proposed Future Work

bull Cell and Stack ndash Degradation characterization ndash Cell and stack fabrication for testing and

demonstration of milestone targets ndash Cell performance model development ndash Development of system flowsheet and

model in Chemcad simulation platform bull System and Demonstration

ndash Tradeoff analysis considering wide ranges of operating parameters

ndash Detailed system design and performance optimization

ndash Demonstration of highly efficient and power dense SOEC in a breadboard system

ndash H2A Analysis

Any proposed future work is subject to change based on funding levels 19

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

Technology Transfer Activities

Reversible SOFC (RSOFC) System for Energy Storage

bull In addition to the opportunities for low-cost H2 production SOEC technology is an enabler for development of RSOFC for electric energy storage

bull Advantage over conventional storage ndash Long duration achieved by adding

hydrogen storage without adding stacks

bull Advantage over other Hydrogen based storage ndash Efficiency advantage- due to higher

efficiency of SOFC in fuel cell and electrolysis modes of operation

6 MWh RSOFC System

Water Stora

ge

1MW x 6 h SOFC Power Delivery

20

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

Summary

bull Met Q1 and Q2 Milestone targets as planned ndash Long term cell performance degradation rate of le41000 was

demonstrated at 1 amp 2 Acm2

ndash Cell operating parameter investigation was completed to determine stack operational windows to be used in system design bull gt500 test conditions evaluated

bull Initiated gt500hr test of a 20 HiPoD cell stack to establish design improvements

bull Initiated preliminary system flowsheet design ndash Develop alternative configurations for heat recovery ndash Perform mass and energy balances at the operating parameters

selected in Q2 milestone for optimum system performance

21

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

TECHNICAL BACK-UP SLIDES

22

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

10 microm

HiPoD Cell Technology

Component Materials Thickness Porosity Process

Anode NiYSZ 03 mm ~ 40 Tape casting

Electrolyte YSZ 5 - 10 microm lt 5 Screen printing

Cathode Conducting ceramic 10 - 50 microm ~ 30 Screen printing 23

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

24

HiPoD Electrolysis Performance

bull Lowering fuel electrode porosity by modifying microstructure and increasing nickel oxide content of the as-prepared substrate have proved successful in recent SOFC development

bull The increased nickel oxide content cell can be fired to the same density as regular cell but after reduction to nickel metal it will be more porous due to the volume change as greater amount of nickel oxide is reduced to nickel metal

bull A SOEC (HiPod) cell with this modified fuel electrode delivered a performance of over 6 Acm2 in a single cell test at 78 (LHV) efficiency

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

HiPoD Fuel Cell Performance

bull Baseline HiPoD Cell Performance Characteristics in Fuel Cell Mode

25

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

26

SOEC Compared to PEM

bull To reach the DOE 2020 water electrolysis efficiency (LHV) target of 78 an upper limit for the electrolysis operating voltage is 16 V (see Figure) This voltage will deliver a 78 LHV efficiency in hydrogen production At this upper limit voltage FCErsquos RSOF7 cell operating in regenerative mode has shown the potential for achieving a current density greater than 3 Acm2

bull In comparison a PEM-based regenerative cell will have a much lower current density of less than 05 Acm2 at 16 V

bull Capital cost reduction can be strongly driven by improvements in stack current density in most systems Improvements in stack current density result in a reduction of cell active area and a corresponding decrease in material cost

26

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

27

0400

0600

0800

1000

1200

1400

1600

0 480 960 1440 1920 2400 2880

Volta

ge V

Elapsed Time h

Total 6080 cycles003 mVcycle degradation

20mincycles(5900)

4hour cycles(180)

Equivalentdailycycles 1year 5years 10years 15years

Accelerated Cycling (6080 Cycles)

2012 DOE Hydrogen and Fuel Cell Program Annual Merit Review 27

1 Cell Stack - 81 cm2 Active AreaFurnace Temperature 800degCFuel H2 + 50 H2O UfUH2O = 30Oxidant Air Ua = 30Current plusmn 243 A (03 Acm2)

CellmaterialsetRSOFC-7

SOFC16hoursSOEC16hoursTransition08hours

SOFC8minSOEC8minTransition4min

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28

Publications and Presentations

1 A Wood H He T Joia M Krivy D Steedman ldquoCommunicationmdashElectrolysis at High Efficiency with Remarkable Hydrogen Production Ratesrdquo Journal of Electrochemical Society 2016 volume 163 issue 5 F327-F329

2 Eric Tang Tony Wood Sofiane Benhaddad Casey Brown Hongpeng HeJeff Nelson Oliver Grande Ben Nuttall Mark Richards Randy PetrildquoAdvanced Materials for RSOFC Dual Operation with Low DegradationrdquoFinal Report httpswwwostigovscitechservletspurl1058912

3 Eric Tang Tony Wood Casey Brown Micah Casteel Michael Pastula MarkRichards and Randy Petri ldquoSolid Oxide Based Electrolysis and StackTechnology with Ultra-High Electrolysis Current Density (gt3Acm2) and Efficiencyrdquo 2016 DOE Hydrogen and Fuel Cell Program Review June 82016 Washington DC httpswwwhydrogenenergygovpdfsreview16pd124_petri_2016_opdf

4 H Ghezel-Ayagh ldquoAdvances in SOFC Power System Developmentrdquo 17th Annual Solid Oxide Fuel Cell (SOFC) Project Review Meeting PittsburghPA July 19-21 2016 httpswwwnetldoegovFile20LibraryEvents2016sofcGhezel-Ayaghpdf

28