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Solid Oxide Fuel Cell Developmentfor Transportation and Stationary
Applications:Latest Update on Stack and System
Performance
Steven ShafferDelphi Chief Engineer Fuel Cells
2009 Fuel Cell Seminar
November 17, 2009
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November 17, 2009 2
Delphi Solid Oxide Fuel CellsMarket Opportunities
Clean Coal Power Plant
Advanced Power SystemsMilitary
Auxiliary & Mobile Power Units
Residential Power
Stationary CHP Power Units
Recreational Vehicles
Auxiliary Power Units
Heavy Duty Trucks
Auxiliary Power Units
Delphi Solid Oxide Fuel Cells Provide: Ultra-clean, near zero emissions High-quality, reliable power
High fuel efficiency
Fuel flexibility
Low noise
Commercial Power
Stationary Power Units
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November 17, 2009 3
Delphi SOFC Development Centers
Fenton, Michigan Cell Development
Manufacturing Development
Electrochemical Testing
Material Characterization and Analysis
Rochester, New York Stack Development
System Development
Reformer Development
BOP Development
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Cell and Stack Development
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Equipment for Cell Development and Fabrication
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Typical Gen 3 30-Cell Stack Performance
MG735C676 - 30plus3 Date: 1/29/2009
Fuel: 48.5%H2-48.5%N2-3%H20 Flows: 89.8(A), 151(C)
Stack Voltage and Power Density for Polarization Test
0
5
10
15
20
25
30
35
0 10 20 30 40 50 60 70
Current (Amps)
StackVoltage(V)
0
100
200
300
400
500
600
PowerDensity(mW/cm2)
Stack Voltage (V) Power Density (mW/cm 2) Poly. (Stack Voltage (V)) Poly. (Power Density (mW/cm 2))
Power: 1.53 kW (486 mW/cm2) @ 60A (570 mA per cm2), 25.5 V(0.85V / cell avg), fuel 48.5% H2 ,3% H2O, rest N2, 750 800oC
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Generation 3 30-Cell Stack
Minimal lowering of power density ( 5%) in going from 50% fuel utilization to80% fuel utilization
Stack Voltage and Power Density for Utilization Test
0
50
100
150
200
250
300
350
400
450
500
47 52 57 62 67 72 77 82
Utilization (%)
S
tackPowerDensity
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Cathode Stability (at Carnegie Mellon University)
Powder
5-cell stack (#530) tested 3500+ hrs at 0.8 V/cell
on 28%H2 30%CO 6%H2O 2.5 ppmv S
FabricatedCell
Bulk Cathode Composition via TEM
0
5
10
15
20
25
La Sr La/Sr Fe Co Fe/Co A/B
Atomic%
Powder
Fabricated Cells
530 inlet ROI 1
530 inlet ROI 2530 Outlet ROI 4
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Gen 3 5-Cell Stack Maximum Power
MG735C793 Date: 6/23/2009
Fuel: 48.5%H2-48.5%N2-3%H20
Stack Voltage and Power Density for Polarization Test
0
1
2
3
4
5
6
0 20 40 60 80 100 120
Current (Amps)
StackVoltage(V)
0
100
200
300
400
500
600
700
800
900
PowerD
ensity(mW/cm2)
Produced 500 mW/cm2 @ 60A (570 mA per cm2), 0.87V / cell avg,
fuel 48.5% H2 ,3% H2O, rest N2, 750 800oC Max Power density: 765 mW/cm2 @ 100 Amps (952 mA per cm2),
0.80V / cell avg, fuel 48.5% H2, 3% H2O, rest N2, 750 825oC
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Interconnect Development Materials & Coatings
MG735C624
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
0.00 500.00 1000.00 1500.00 2000.00 2500.00 3000.00
Time Hrs
Voltage(Volts)
Base material is ferritic stainless steel alloy
Multiple coatings under evaluation Low cost, conventionally processed coating demonstrated good stability in stack test
Graph shows typical repeating unit performance in a stack with coating tested for durability(Fuel = 48.5 % H2, 3% H2O, rest N2, constant current of 570 mA per cm2)
Further development is ongoing
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Gen 3 Stack Durability with Diesel Reformate
MG735C727
Fuel: Reformed Diesel
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
11.1
1.2
0.00 200.00 400.00 600.00 800.00 1000.00 1200.00 1400.00
Time Hrs
A
verageVoltage(V)
10-cell Gen 3 stack on Diesel reformate (24%H2 25% CO 5% CO2 7%H2O Bal N2) at 35 amps and 750C
Initial voltage drop observed in the first 200 hours due to sulfur
Minimal degradation in the last 1300 hours
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Gen 3 30-Cell Stack - Thermal Cycling
0
100
200
300
400
500
600
700
800
0.00 2.00 4.00 6.00 8.00 10.00 12.00
Time Hrs
Temperature(DegC)
Gen 3 30-cell stack being thermal cycled 10 hour cycle from 50oC to operating temperature to 50oC Performance evaluated at each thermal cycle
Constant current load of 30 Amps at operating temperature
Fuel of 48.5% H2, 3% H2O, rest N2
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30-Cell Stack Thermal Cycling Results
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210
Thermal Cycle Number
MeanCellVoltage
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Red XProblem Solving Tools For Stack Issues
Red X is a registered term of Shainin LLC
Cell Voltage by Stack at 60amps
0.50
0.55
0.60
0.65
0.70
0.75
0.80
0.85
653
657
651
658
659
660
661
665
671
672
662
666
680
681
683
684
690
691
Stack
CellVoltage
Average
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.704/10/2008
4/12/2008
4/14/2008
4/15/2008
4/17/2008
4/24/2008
4/29/2008
5/29/2008
6/6/2008
6/13/2008
6/24/2008
6/26/2008
7/22/2008
7/23/2008
7/24/2008
7/25/2008
7/31/2008
7/31/2008
Build Date
CellVoltage
Range
Average
Range
Did not meetvoltage
range specs
Problem solving tools like Red Xare being utilized in stack manufacturing
Lessons learned are being implemented for Gen 4 stack design andmanufacturing
Example: Find & eliminate the Red Xdriving high cell voltage range
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Stack Other Area
High cellvoltagerange
OtherPerformance
Characteristics
Event Defect
First time qualityissue: IV
performance
Durability issue
Feature
Repeating unit torepeating unit
Other strategies
P = 0.14V M = 0.013V
Components Assembly Process
CassetteCell Cathode
Interconnect
Paste Interconnect Component
CoatingContamination
Other
Red XProblem Definition TreeTM
Problem Definition TreeTM is a registered trademark of Shainin LLC
Red X was identified as contaminationin the interconnect coating from aspecific supplier
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Gen 4 Cell Development for Coal Based Systems
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Gen 4 Stack Design for Coal Based Systems
Gen 3 stack
About 4x active area of Gen3Lower cost interconnects/coatings than Gen3High volume production processes5 kW core building blocks
Gen 4 stack
Delphi is developing its Generation 4 stack as the module formeeting stationary and transportation application requirements
Key stack features are: Laser welded cassette repeating unit configuration
Stamped metallic cassette components
Stamped interconnects Low cost coatings
Low cost, conventionally processed balance of stack components
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Gen 4 Stack Development Status
Laser welding of SOFC parts
Gen 4 stack design is complete
Process development and optimization ongoing to fabricate cells,cassettes, and stacks
First 5-cell stack fabricated and tested
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Gen 4 Stack Performance : 5-cell stack
Achieved power density of 474 mW/cm2
@ 240A (590 mA per cm2
), 0.80V /cell average, fuel 48.5% H2 ,3% H2O, rest N2, 700 800oC
MG735G001-5cell stack Date: 8/26/2009
Fuel: 48.5%H2-48.5%N2-3%H20
0
1
2
3
4
5
6
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Current (Amps)
StackVoltage(V)
0
50
100
150
200
250
300
350
400
450
500
P
owerDensity(mW/cm2)
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System Development
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Balance of Plant Components:High Temperature Insulation
InsulationCollars
Old
New
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Balance of Plant Components
Process Air Delivery System Anode Tailgas Recycle Pump
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Diesel Fuel Survey ResultsSummer 2007 Sulfur Levels
0
5
10
15
20
25
30
35
40
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
ppm
frequency
Sulfur ppm
Source: Alliance of Automobile Manufacturers (US andCanada, 160 samples)
Current 2007 ULSD Spec.
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Delphi Solid Oxide Fuel CellsHot Reformate De-Sulfurization
Hot Reformate De-Sulfurization Development
Remove H2S to levels below 10 ppbv (parts per billion volume) from an input of2.5 ppmv (parts per million volume)
Sulfur acts as a poison to SOFC
Maximize operation time between sorbent exchanges
Minimize device volume and operation pressure drop
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Delphi Solid Oxide Fuel CellsHot Reformate De-Sulfurization
A non-regenerating sorbent has been selected that: Meets maximum 10 ppbv output
Meets operating temperature requirements
Capacity is such that a bed operates for at least 6 months prior to requiring bedexchange for the 95th percentile driver
System pressure drop requirements were met at full system reformate flow
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Delphi Solid Oxide Fuel CellDesign of New Diesel APU Platform
Endothermic Diesel Reformer withintegrated burner
Gen 4 SOFC Stack
Highlyintegrated
manifold andheat exchanger
assembly
Fuel and Air SupplySystems
DPS 3000D3 kW net output power
Desulfurizer
Electronics and Controls
Module
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Projected Performance Comparison
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DPS3000 D Initial Builds
First design engineeredspecifically as a truck APU
Internal desulfurizer forULSD
ULSD cold-start capable
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Model 386 Peterbilt vehicle received atTCR on 8/28/09
Vehicle provided to Delphi as part of DOEEERE Truck APU Demo project
Vehicle prepped for SOFC APU
Fuel and electrical interface
Mounting Hardware for APUenclosure
AC inverter
Refrigerator
Peterbilt Development Truck
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Test to Failure using Step Over Stress strategy to assess stack reliability
Mil Std 810G Method 514.6 Annex C, Truck and Transportation Over US Highways Ambient temperature random vibration in 3 distinct axes
Performance evaluated after each axis of testing
Successfully completed 3.75 million miles equiv. of vibration
Delphi Solid Oxide Fuel CellGen 3 30-Cell Stack Vibration Testing
Vertical
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Systems Vibration Testing
DPS 3000D SOFC System on shaker table
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Delphi SOFC APU Recent Accomplishments
Delphi/Peterbilt Awarded DOE Program for a 1 year vehicledemonstration
Stack durability testing 200 Thermal Cycles
Completed 5 lives accelerated vibration testing
Engineered and Built First Truck APU Designed to operate on Diesel
Integrated Desulfurizer operational
First APU installed on Peterbilt Truck Operational by December 2009
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Acknowledgements
http://www.utcpower.com/http://www.netl.doe.gov/main.htmlhttp://www.ch.doe.gov/insidech/org_offices/fao/doelogo.gif