Hybrid Power Systems Scott L. Swartz, Ph.D. (P.I.) Nexceris LLC - - PowerPoint PPT Presentation

Project Vision

Nexceris will develop a pressure tolerant and ultra high efficiency solid

• xide fuel cell stack that operates via internal reforming of methane

and meets other requirements of hybrid power systems.

Advanced SOFC Stack for Hybrid Power Systems

Scott L. Swartz, Ph.D. (P.I.) Nexceris LLC (Lewis Center, Ohio)

About Nexceris

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Nexceris, LLC

 Founded in 1994 as NexTech Materials, privately held  Technology Developer – advanced ceramics, electrochemical devices  Product Developer – sensors, fuel cells, and catalysts  Manufacturer/Distributor – sensors, fuel cells, and related products  ISO 9001:2015 Certified – covers all products and services

Our Brands

Previous Nexceris Work for ARPA-E

 Subcontractor to DNV on AMPED project (10/2012 through 3/2015)  Developed off-gas monitoring technology for lithium ion battery safety  Working with the Navy to enable safe deployment of lithium ion batteries  Commercializing this technology for Marine and ESS applications

About Nexceris

Nexceris History in SOFC Technology

 1994: Company founded, initiated work on SOFC materials development  2000: Established fuelcellmaterials.com and began selling products  2004: Initiated development of planar cell designs (three patents)  2006: Initiated SOFC stack development, focusing on military applications  2011: Focused efforts on SOFC materials for high performance & durability  2015: Established high power density SOFC stack design (starting point)

About Nexceris

SOFC Materials Planar Cells SOFC Stacks

Project Overview

Federal Funding: $2.15M Project Duration: 24 months SOFC Stack Design and Modeling Advanced Cell Designs Advanced SOFC Materials

Advanced Solid Oxide Fuel Cell Stack

Proprietary Internal Reforming Technology

Innovation: Planar SOFC Cell Designs

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FlexCell

 U.S. Patent No. 8,192,888  Two-layer structure with a perforated mesh layer mechanically supporting a thin electrolyte membrane

Hybrid Cell

 U.S. Patent No. 7,736,787  Identical to FlexCell, except that an anode layer is located between the support and membrane layers

Innovation: High Performance Materials

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By optimizing the processing of ceria barrier layers, adverse reactions between the electrolyte and cathode materials are prevented, which greatly improves SOFC performance.

Innovation: Design for High Efficiency

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Nexceris has process modeling capability and experience in designing SOFC stacks for ultra high efficiency systems.

Thermal Model SOFC Stack Electrochemical Model Reaction Equilibrium Model

SOFC Stack/Hotbox Testing

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Cathode Chimney Stack

12-Cell Stack/Hotbox Anode Heater

Controls Anode Heater Cathode Heater Diagnostics Cavity

SOFC Stack/Hotbox Testing

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Targeted performance achieved during integrated stack/hotbox test.

Project Plan

Objectives: Establish a 10-kW scale SOFC stack design for high pressure operation. Generate detailed specifications and CAD drawings of all stack components.

Task 4. Design of Pressure Tolerant Stack Task 1

Development of Work Plan Objective: Build a comprehensive work plan to enable ARPA-E to track technical progress.

Task 3

Objectives: Establish a CFD model of thermal gradients in an SOFC stack operating via internal methane reforming. Demonstrate approach for reducing thermal gradients. Internal Reforming Process Development

Task 2

Cell Development and Validation Objectives: Establish and scale-up fabrication process, demonstrate target cell performance.

Task 5. Stack Development and Testing

Task 5 Objectives: Advance the SOFC stack design. Demonstrate targeted performance levels under application-specific conditions.

Tech-to-Market

T2M Objectives

 Approach to Market. Nexceris aims to be an SOFC stack manufacturer. We work closely with system integrators to define the requirements and to customize our stack technology to those requirements.  Anticipated First Markets. We anticipate that early adopter markets for the stack technology will come from the military and aerospace sector. We also expect demonstration opportunities in the commercial sector as the stack manufacturing technology is scaled up.  Approach to Manufacture. Managing challenges associated with scale-up

• f SOFC stack manufacturing will be important. Establishing a scale-up and

manufacturing plan will be a critical component of our T2M activities.

Challenges and Potential Partnerships

Anticipated Technical Challenges

 Achieving target stack performance (with a new stack design platform).  Proper stack sealing (since pressurized operation is being targeted).  Achieving long-term stack durability (when operating at high temperature and current density).  Reducing thermal gradients (precise control of the internal methane reforming reaction).

Potential Partnerships

We aim to build relationships with INTEGRATE system development teams, both to obtain guidance on SOFC stack performance targets and (ideally) to establish stack development/supply agreements for Phase II INTEGRATE projects.

Questions?

Nexceris is grateful for the opportunity being provided by ARPA-E, and we look forward to working with all INTEGRATE program participants and stakeholders!