High Efficiency, Low Cost & Robust Hybrid SOFC/IC Engine Power - - PowerPoint PPT Presentation

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High Efficiency, Low Cost & Robust Hybrid SOFC/IC Engine Power - - PowerPoint PPT Presentation

Dec 10, 2023 331 likes •422 views

High Efficiency, Low Cost & Robust Hybrid SOFC/IC Engine Power Generator Rob Braun, Colorado School of Mines Project Vision Demonstrate a hybrid fuel cell system that can drive both radically lower cost (<850 $/kW) and ultra-high

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SLIDE 1

High Efficiency, Low Cost & Robust Hybrid SOFC/IC Engine Power Generator

Rob Braun, Colorado School of Mines Project Vision

  • Demonstrate a hybrid fuel cell system that can drive both radically lower

cost (<850 $/kW) and ultra-high efficiency (>71%) for 125 kW class distributed power generation applications.

  • Integrates lower-temperature, pressurized metal-supported SOFC

technology (¼ scale) with full-scale IC engine, positive displacement BOP, and novel power-conditioning technology.

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SLIDE 2

Project Overview

Context/History of project Mines: >20-yr experience on fuel cell systems and SOFC technology. : REBELS and REFUEL projects CSU : ARID project; long history in alt. fuels and stationary engines Kohler: Commercial/Industrial engine power systems from 20 kW to 40 MW Air Squared: World leader in scroll tech, >50 govt projects, GENSETS

  • Key aspects: we started early, met continuously ahead of FOA, and

leveraged existing relationships.

  • Fed. funding:

$3.1M Length 24 mo.

Team member Location Role in project Mines Golden, CO Lead, Systems/Control, SOFC stack, TEA, T2M CSU

  • Ft. Collins, CO

Tail-gas engine, Integration test facility Kohler Power Systems Kohler, WI Engine, Alternator, High efficiency/Low-cost inverter, T2M, Commercialization partner Air Squared Broomfield, CO Scroll Compressor/Expander

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SLIDE 3

Innovation - Integrate robust, pressurized metal-supported SOFC with high h engine, inverter and rotating equipment

Features:

  • Low cell temp, thermal management  reduce air preheater duty by >60%
  • Pressurization  increases power density, lowers both costs and BOP duty
  • Gasified diesel engine converts residual fuel gas to drive auxiliaries (BOP)
  • Simple after-treatment enables low engine emissions (NOx, CO)

h = 35% 12-16 kW h = 98% Low cost

600°C >350 mW/cm2

>71% efficiency <850 $/kW

125 kW

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SLIDE 4

Technical Objectives & Organization

Task 1: System Modeling for Integration and Control (CSM) Task 2: Pressurized Stack Module Development (CSM) Task 3: IC Engine & Alternator Development (CSU/Kohler) Task 4: Development of Compressor/Expander (Air-Squared) Task 5: Inverter Design and Fabrication (Kohler) Task 6: Fuel Cell Simulator & Integrated System Testing (CSU/CSM/Kohler) Task 7: Techno Economic Analysis and T2M (Tech to Market) - (CSM/Kohler)

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SLIDE 5

Technology-to-Market

Anticipated First Markets

  • Critical loads
  • Commercial
  • Industrial CHP (eventually)

Critical Loads Commercial Buildings Industrial CHP Data Centers

SOFC Hybrid

Markets

Approach to Market

  • Analysis needed
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SLIDE 6

Technology-to-Market

SEGMENTATION

  • Determination of key segment

variables

  • Spark Spread
  • Rate Structure
  • Self Generation Incentives
  • Load Profile, Peak Load
  • Corporate Sustainability Targets
  • Definition and segment of market
  • Clear and defined segment

profiles

TARGETING POSITIONING

  • Attractiveness analysis of

each segment

  • Selection of target

markets

  • Design positioning concepts
  • Selection of position

concept and communication

  • Leverage Kohler’s ability

to scale

Analysis Approach has 3 primary steps: Key Elements for Product Development & Success:

  • Kohler’s ability to scale, systems integrator, and existing customer base to help

define requirements

  • Partnership with and access to pilot scale stacks from Ceres Power
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SLIDE 7

Challenges and Potential Partnerships

SYSTEM-LEVEL

  • Control:
  • over dynamic operating range
  • through mode transitions
  • Water/thermal management (esp. startup)
  • Engine/FC interactions, Maintaining system pressure
  • Heat exchangers

COMPONENTS SOFC Stack

  • Performance (>350 mW/cm2)
  • Pressurization (3-5 bar)
  • Durability (degradation, X-press D’s, coking…)
  • Cost trajectory

Engine

  • Durability/service intervals for target life cycle (20,000-h)
  • Combustion control with low-Btu/high moisture content fuel
  • 35%-LHV engine efficiency target

Compressor/Expander

  • Compressor efficiency/Scaling
  • Expander inlet temperature

limit and maintaining efficiency Inverter

  • 98% efficiency
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SLIDE 8

The Team

Rob Braun, Mechanical Engineering Neal Sullivan, Mechanical Engineering Tyrone Vincent, Electrical Engineering Rob Danforth, Director – Engineering Labs Isaac Frampton, Staff Engineer Todd Bandhauer, Mechanical Engineering Dan Olsen, Mechanical Engineering Brett Windom, Mechanical Engineering Bryce Shaffer