“Fuel Cells for the Future”

“Fuel Cells for the Future”
Niels Christiansen
Topsoe Fuel Cell A/S
Nymøllevej 55
2800 Lyngby

Topsoe and Risø
500 W stack: 1996
TOPSOE FUEL CELL A/S
• Development, marketing and sales of SOFC technology
• Founded in 2004
• Subsidiary of Haldor Topsøe A/S
• Full time employees:
- March 2007: 40
- October 2008: 100
• Strategic R&D partner: Risø National Laboratory
Topsoe/Risø started
SOFC in 1989

New TOFC Manufacturing Facility
Cell manufacture
Stack assembly
Start up: Q4, 2008
5 MW annually
~ 250.000 cells
4 July 2008

Up-scaled Cell Manufacture in New Facility
Ceramic processing – Cost efficient – Industrial up-scaleable

Power Generation
Why Fuel Cells?
Future SOFC
High efficiency
Efficient at part load
Fast response
FuelCellEfficiency:
η = ΔG/ΔH
Carnot limit:
η c
= 1 – T l /T h

Types of Fuel Cels
H 2
, CO
CH 4
, NH 3

SOFC system
• Fuel flexibility (No demand for pure hydrogen)
• Cheap materials (no noble metals)
• No liquid electrolytes
• High electrical efficiency
• High value waste heat (high temperature)
• System integrateability (simple system lay out)
Control
DC/AC
converter
El
Air
Fuel
gas
Filter/
blower
Preheat
Preheat
Desulfurization
Prereformer
Fuel
cell
stack
H 2 O
CO 2
Heat

Fuel Cell and Electrolyser
SOFC
SOEC
H 2
H 2
O
H 2
O
H 2
H 2
+ O 2- → H 2
O + 2e -
O 2-
½O 2
+ 2e - → O 2-
H 2
O + 2e - → H 2
+ O 2-
O 2-
O 2- → 2e - +½O 2
½O 2
½O 2

Practical Fuel Cell Voltage
E 0 = - ΔG 0 /nF
ΔG 0 = ΔH 0 –TΔS 0
Cell Voltage (V)
Total loss

Single Cell Performance
”Standard” TOFC cells
Cell voltage [V]
1.2
1.1
1.0
0.9
0.8
0.7 0.4
0.6
850°C
750°C
650°C
> 1,5
W/cm 2
1.6
1.2
0.8
0.0
Power density [W/cm 2 ]
Thin Planar Cells
375 μm
0.50
0.0 0.5 1.0 1.5 2.0 2.5
Current density [A/cm 2]
Wide temperature operation window
22x50 cm 2

Internal Electrical Loss as Function of Temperature
Resistance R i
( Ω*cm 2 )
1.1
1
0.9
0.8
Total cell loss: R i
0.7
0.6
0.5
Cathode loss
0.4
0.3
Anode loss
0.2
0.1
0
690 710 730 750 770 790 810 830 850
Temperature in o C
Electrical power
P = U I – R i I 2
ASR Rtot_imp Rcathode Ranode Rconc Relec

Perovskite Structure ABO 3
Electrical conductivity of La 1-a
Sr a
MnO 3-d
Conductivity (at 1000 C)
350
300
250
200
150
100
50
0
σ (Ω -1 cm -1 )
0 0,1 0,2 0,3 0,4 0,5 0,6
a

Topsoe Stack Concept
Compact Multilayer design
75-Cell Stack (750-800 o C)
75 mm
• 1 mm per repeatable unit
• 2.4 kW/liter at 0,38 A/cm 2
• 0,25 kW/ kg
• 60 V at 20A
120 mm
120 mm
12x12 cm2

TOFC State of The Art Stacks
● Compact multilayer design
● Cost / performance
optimization
● Stable performance
0.5
75 cells
12x12 cm 2 0.0
Temperature 764 – 770 o C; Fuel utilization 70 – 77%; CH4 with s/c = 1.5
Stack power (kW)
3.5
3.0
2.5
2.0
1.5
1.0
Stack durability
55 62 67 40
Current (A)
60 cells
18x18 cm 2
Co-flow

Development of Metallic Interconnects with Ceramic
Coatings
Poisoning of the cathode by Cr-species
Volt
5
4,5
4
3,5
3
2,5
2
1,5
1
0,5
0
0 2000 4000 6000 8000 10000 12000 14000
Hours
13000 hours
stack test
5
4,8
New Alloy
New Coating
ASR 0,5 ohmcm2
4,6
Volt
4,4
4,2
4
3,8
Old Alloy (Fe22Cr high Si)
Old Coating
ASR 1,0 ohmcm2
3,6
0 100 200 300 400 500 600
Hours

Cell development – Generations
An engineering focus on:
• Manufacturability
• Reliability
• Cost reduction
1G
2G
3G
LSCF
CGO
YSZ or SSZ
FeCr
metallic support
EU project: “METSOFC”
reduced cost
reliability
LSM
YSZ
Ni/YSZ
LSM
YSZ
Ni/YSZ
LSCF
CGO
YSZ or SSZ
Ni/YSZ
durability
ceramic support
1000 o C
850 o C 750 o C 600 o C

Next Generation Cells – Metal Supported
Metal supported cell - Cross section
15μm

Thin Film SOFC
Future generations ?
Atomic Layer Deposition
650 mW/cm 2
at 400 o C
Potential for transportation segment

Cathode Infiltration with
Ceria Nano Particles
ceria-infiltrated
LSM/YSZ-electrode
mindre modstand
R p at 600 o C
LSM/YSZ: 1.96
LSM/YSZ/CeO 2 : 0.64
M. Søgård, T. Sholklapper, M. Wandel, M. Mogensen, Infiltration of Cathodes, Europ. SOFC Forum, Lucerne 2008

Improved Sulfur Tolerance of Ni/YSZ Anodes
CeO 2
nano-paticles
coated on Ni particles

Ceramic Composite Anode with Sulfur Tolerance
Anode
material
R p
at 650 o C
(Ωcm 2 )
STN/CGO 0.44
Ni/YSZ 0.81

System devlopment

SOFC System – 250 kW el Base Case with NG Fuel
Reforming: CH 4
+ 2H 2
O → CO 2
+ 4H 2
(-ΔH 0 923
= - 189.2 kJ/mole)
Reverse Shift: H 2
+ CO 2
→ H 2
O + CO (-ΔH 0 923 = - 35.5kJ/mole)
Electrochemical oxidation: H 2
+ ½O 2
→ H 2
O (-ΔH 0 = 247.4 kJ/mole)
Flue Gas
E 5
Natural gas
E1
Desulphurisation
Prereformer
Natural Gas
Water for start
up
E 6
E 2
SOFC
Flue Gas
E7
Catalytic
Anode
recycle
Anode
Cathode
Burner
E 3
Air Blower
Air

System Efficiency with different Fuels
Energy Flows (kJ/s)
Fuel
Electric eff.
% LHV, net
Total eff. %
(90° C)
Natural gas 55 84
Biogas with 50 % CO2 54 80
Methanol 53 85
DME 53 83
Ammonia 55 84
Diesel CPO (5 kW) 41 85

Carbon Formation - Graphite Data
900
800
Deg. c
700
600
500
Carbon Formation Region
No Carbon
400
300
200
1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00
O/C ratio

Methanation of MeOH for SOFC
Electrical net efficiency = 53 %
Co-gen efficiency = 82 %

Carbon Formation - 250 nm Ni Crystals
Haldor Topsøe catalyst
Carbon whisker
900
800
Ni crystal
700
Deg. C
600
500
Carbon Formation Region
No Carbon
400
300
200
0.5 0.75 1 1.25 1.5 1.75 2
O/C ratio

Methanation of Coal Gas
E 5
Flue gas
P 1
E 1
X 1
Methanator
Haldor Topsøe catalyst
R 1
Methanol/DME
SOFC
Carbon whisker
E 7
Catalytic
Burner
E 3
K1
Ni crystal
Depleted Air
Air
Coal gasification

Technology Partners
TOFC / Wärtsilä Collaboration
Wärtsilä 5 kW
test system
with 4 TOFC stacks
Wärtsilä 20 kW α-prototype
with 24 TOFC Stacks
Voltage [V] and Current [A]
90
80
70
60
50
40
30
20
10
300
250
200
150
100
50
Current Density [mA/cm 2 ]
0
50,0 550,0 1050,0 1550,0 2050,0 2550,0 3050,0
Running Hours
Average Stack Voltage Average Stack Current Average Current Density
0

Demonstration Project – METHAPU
• Demonstrator unit for a Marine-APU with a power of 20 kWe
• METHAPU-Project
• On-board the Swedish cargo vessel “Wallenius Wilhelmsen”
• Methanol as fuel
• Start of demonstration Q1/2009
Supported by funding under the
Sixth Research Framework Programme
of the European Union

New SOFC Test and Demo Facilities in Denmark
5 kW test unit
with MeOH reformer
10 kW test and demo facility
with NG pre-reformer
Power Core units
H. C. Ørsted Power Plant
Copenhagen

Power and Heat for Single/Multi Family Homes
Synergistic Integration of SOFC and Hot BOP components
Integrated μ-CHP Power Core
> 50% Eff el (AC), 0.7kW
demonstrated in Japan
1 – 2 kW el
Electricity
Steam
and CO 2
Air
Natural Gas
Heat
Fuel Cell System

NH 3 as SOFC Fuel
Amminex Ammonia Storage and TOFC SOFC
TOFC 30 Cell Stack fuel with ammonia

Diversity of Energy Sources, Carriers and SOFC
Power Systems CO 2 Conversion by SOEC Electrolysis
Biomass
Liquid Fuel
Coal
Syngas
Natural gas
SOFC
Electricity
Renewables
Electricity
SOEC
Hydrogen
Nuclear
CO 2
Syngas

Thank you for your attention