brennstoffzellen-systeme von der forschung zur ... · avl central research coordination, peter...
TRANSCRIPT
AVL Central Research Coordination, Peter Prenninger 1
Brennstoffzellen-Systeme – von der Forschung zur Kommerzialisierung: Integration – Simulation – Testen IEA Workshop Brennstoffzellen: Markteinführung, Markthemmnisse und F&E-Schwerpunkte 27. Februar 2014, Graz
Peter Prenninger
AVL List GmbH
AVL Central Research Coordination, Peter Prenninger 2 2
SOFC TECHNOLOGY – EFFICIENCY ENABLER
5-10 kW 100-500 kW 1-5 MW
Power Range
E
ffic
iency
30 %
50 %
7
0 %
ICE Technology
SOFC Technology High efficient fuel gas generation from NG, methanol, Diesel and all Biofuels (80-99%)
High efficient energy conversion in SOFC (>50%)
Best suited for combined SOFC-GT cycles
SOFC & GT Technology
AVL Central Research Coordination, Peter Prenninger 3
Challenges in:
• Systems Engineering
• Virtual System Development
• Component Analysis and Optimization
• System Integration
• Validation and Commercialization
AVL Central Research Coordination, Peter Prenninger 4 4
Portable power out of diesel fuel without noise and emissions! Other markets:
Camping
Marine
Military
Anode blower
APU Stack Module
Air blower
Gas processing unit
Incl. reformer, start-burner, off-gas cleaning, heatexchange, manifolding
Valves
Fuel pumps
Design Targets:
3kW electrical power
10kW thermal power
el. efficiency ~35%
Fuel: road diesel (< 15 ppm S)
80L, 75kg
~ 55dB(A) noise
8000h lifetime
300/3000 cold/warm cycles
PRODUCT REQUIREMENTS
AVL Central Research Coordination, Peter Prenninger 6
• Idling Time per Week: 30, 40, 50 & 57.83 h
• Diesel price: 3.9 – 5.0 $/gal (3.9 $/ga l= 0.79 €/l)
• Fuel Consumption (Idling):
o Truck: 0.75 gal/h (2.84 l/h)
o ICE APU: measured, improved map
o SOFC APU: expected efficiency 2016
• Sales price SOFC APU 12.000 $ (9.230 €)
• Sales price ICE APU 10.000 $ (7.700 €)
CUSTOMER AND MARKET ASPECTS
AVL Central Research Coordination, Peter Prenninger 7
Comparison Truck Idling vs. SOFC APU
0
0,2
0,4
0,6
0,8
1
1,2
1,4
1,6
1,8
3.9 $ 4.25 $ 4.5 $ 5 $
Years
Diesel price
Pay back period
• 3,9 $: 1,62 years
• 4,25 $: 1,50 years
• 4,5 $: 1,41 years
• 5 $: 1,27 years
FULFILMENT OF CUSTOMER EXPECATIONS
AVL Central Research Coordination, Peter Prenninger 8
Challenges in:
• Systems Engineering
Very mature rivals (costs, reliability…)
Extremely high customer expectations
Fairly unknow load cycles – no field experience
AVL Central Research Coordination, Peter Prenninger 9
Challenges in:
• Systems Engineering
• Virtual System Development
• Component Analysis and Optimization
• System Integration
• Validation and Commercialization
AVL Central Research Coordination, Peter Prenninger 10
VIRTUAL SYSTEM LAYOUT
Air
POX-Air
Fuel
Bypass-Air
Exhaust
Fuel Cell StackOxidation Catalyst
Reformer
Pipe Heat ExchangerPlate Heat Exchanger
Burning Chamber Isolation
AVL Central Research Coordination, Peter Prenninger 11 11
Vehicle cooling circuit
Air supply and filter
ICE exhaust from TC
Power electronics, Batteries
Air conditioning circuit
ICE…Internal Combustion Engine
TC…Turbocharger
VIRTUAL SYSTEM LAYOUT
AVL Central Research Coordination, Peter Prenninger 12
650mm
Specifications:
• 3kW electrical power
• 10kW thermal power
• el. efficiency >35%
• Fuel: road Diesel (max 15ppm sulfur)
• 80L/70kg
• < 55dB(A) noise
Technology:
• Solid Oxide Fuel Cell
• metal-supported stacks
• anode recirculation
• auto thermal reforming
• highly efficient radial-blowers for media supply
• system internal regeneration approaches
VIRTUAL SYSTEM LAYOUT
AVL Central Research Coordination, Peter Prenninger 13
Challenges in:
• Virtual System Development
Systems engineering approach needed
System integration aspects
Model development based on „unknows“
AVL Central Research Coordination, Peter Prenninger 14
Challenges in:
• Systems Engineering
• Virtual System Development
• Component Analysis and Optimization
• System Integration
• Validation and Commercialization
AVL Central Research Coordination, Peter Prenninger 15 15
Detailed investigation of performance of critical components by means of numerical
simulation – boundary condition for linked components (e.g. insulation, air
management, control functions …)
COMPONENTS & SUB-SYSTEMS
AVL Central Research Coordination, Peter Prenninger 16 16
Solid oxide fuel cell domains with transport across domain interfaces and reactions
Requested results:
Electronic (e-) potential in electrodes and interconnect
Ionic (O2-) potential in electrolyte
Electrochemical reaction rates at TPB, chemical reaction rates in anode domain
Velocity, pressure and species mass fractions in channels and electrodes
Temperature in all domains
Example 3D+ CFD simulation of cells and stacks
2
2 Oe2O2/1
e2OHOH 2
2
2
222
22pmn
HCOOHCO
H2/mpnCOnOHpnOHC
COMPONENTS & SUB-SYSTEMS
AVL Central Research Coordination, Peter Prenninger 17 17
Interconnect
Channels
Nickel mesh
Glass sealing
Electrodes, electrolyte
Model validation
Comparison to experimental results
CFD mesh: 1.3 mio. cells
Active area: 127 cm2
COMPONENTS & SUB-SYSTEMS
AVL Central Research Coordination, Peter Prenninger 18 18
Test cell: voltage and power density vs. current density, fitted result
[1] Kim J.W., Virkar A.V., Fung K.Z., Mehta K., Singhal S.C., Polarization Effects in Intermediate Temperature, Anode-
Supported Solid Oxide Fuel Cells, Journal of The Electrochemical Society 146, 69-78, 1999.
Model validation
COMPONENTS & SUB-SYSTEMS
AVL Central Research Coordination, Peter Prenninger 19 19
Temperature (K) of cathode interconnect
Var.2 ( = 1.25) Ref. ( = 1.333) Var.1 ( = 1.667)
Model validation
COMPONENTS & SUB-SYSTEMS
AVL Central Research Coordination, Peter Prenninger 20 20
AVL Schrick FC Blowers
COMPONENTS & SUB-SYSTEMS
Very focused development of
particular „key enabling“
technologies & components
Air and Gas Management
AVL Central Research Coordination, Peter Prenninger 21
• 1 kW SOFC APU Proof-of-concept
• SOFC stack from research partner
• High dynamics in „self-sustained“ mode
• Control concept for transient mode incl. AVL
stack-monitoring technique „AVL-THDA“
• System efficiency > 35%
• Successful full hot box system integration
current SP
cathode HEX
temperature SP
power demand
(load cycle)
p1/p2
m_dot,air
T1
Vstack
V_low_limit
demand current
+
+compressor
model
min
min
max
&
cell diagnosis
power controller
PID
+
+
m_dot,air
SPair utilisation
stack temperature
demand temperature min
max
maxPID
f(I,)
current demand
thermal management controller SP = set point
feedback loop
current SP
cathode HEX
temperature SP
power demand
(load cycle)
p1/p2
m_dot,air
T1
Vstack
V_low_limit
demand current
+
+compressor
model
min
min
max
&
cell diagnosis
power controller
PID
+
+
m_dot,air
SPair utilisation
stack temperature
demand temperature min
max
maxPID
f(I,)
current demand
thermal management controller SP = set point
current SP
cathode HEX
temperature SP
power demand
(load cycle)
p1/p2
m_dot,air
T1
Vstack
V_low_limit
demand current
+
+compressor
model
min
min
max
&
cell diagnosis
power controller
PID
+
+
m_dot,air
SPair utilisation
stack temperature
demand temperature min
max
maxPID
f(I,)
current demand
thermal management controller SP = set point
feedback loop
COMPONENTS & SUB-SYSTEMS
AVL Central Research Coordination, Peter Prenninger 22
Challenges in:
• Component Analysis and Optimization
Availability of high quality tools
Non-existing development environment
Very little know how on supplier level
Premature components & subsystems
AVL Central Research Coordination, Peter Prenninger 23
Challenges in:
• Systems Engineering
• Virtual System Development
• Component Analysis and Optimization
• System Integration
• Validation and Commercialization
Christoph Kügele, Tomas Dehne
25
Test of single components, subsystems,
stacks at operating temperature and complete
systems on 1D & 2D vibration test rigs
Random noise tests
Frequency sweep tests
Test of bad-road truck vibration profiles
TEST ENVIRONMENT FOR SYSTEM INTEGRATION
AVL Central Research Coordination, Peter Prenninger 26 26
Experimental results 1 stack systems:
~2.2kW gross power output
~1.8kW net power output
29% electrical efficiency
start up time ~1h
operation completely without lab
infrastructure (inert gas,…)
very reasonable degradation
~2000h of operation with Gen 0
(stopped) and with Gen I
50 cold starts / 100 warm starts
<55dB(A) noise level
SYSTEM TESTING
AVL Central Research Coordination, Peter Prenninger 27 27
AVL APU Generations
Sep. 2011
Gen. 1.0
first AVL System with full
functionality
Oct. 2012
Gen. 1.1
first vehicle integration
May 2013
Gen. 2
2 stack design -25% in size
nominated for Austrian national prize 2013
CONTINUOUS SYSTEM IMPROVEMENT
AVL Central Research Coordination, Peter Prenninger 28
Challenges in:
• System Integration
Simultaneous establishment of test infrastructure
Parallel basic research and contiuous improvement
System development based on premature components
AVL Central Research Coordination, Peter Prenninger 29
Challenges in:
• Systems Engineering
• Virtual System Development
• Component Analysis and Optimization
• System Integration
• Validation and Commercialization
AVL Central Research Coordination, Peter Prenninger 30 30
Synergies SOFC CHP System (Components, Control …)
Front
19
30
900
Rear
Hotbox
BoP
ADDITIONAL MARKET OPPORTUNITIES
AVL Central Research Coordination, Peter Prenninger 31
Invest:
Assumptions for System OEM/Tier 1
• Series development, validation, certification 15.6 Mio $
• Build up manufacturing line 2.6 Mio $
• Sales Price: 12.000 $
• Sales Volume (3 Scenarios):
Lot size
Year
Year Cons. Balanc. Aggr.
1 3.000 5.000 8.000
2 3.500 7.000 15.000
3 4.500 11.000 20.000
4 6.500 16.000 22.000
5 8.500 19.000 22.000
6 10.000 20.000 22.000
SUPPORT OF COMMERCIALIZATION
AVL Central Research Coordination, Peter Prenninger 32
Production Cost incl. licence fee, sales & admin. overhead
Assumptions
Year Low Average High
1 8.190$ 9.100$ 10.010$
2 7.605$ 8.450$ 9.295$
3 7.020$ 7.800$ 8.580$
4 6.727$ 7.475$ 8.223$
5 6.482$ 7.202$ 7.922$
6 6.482$ 7.202$ 7.922$ 0
2000
4000
6000
8000
10000
12000
0 1 2 3 4 5 6
$
Year
3 Scenarios:
SUPPORT OF COMMERCIALIZATION
AVL Central Research Coordination, Peter Prenninger 33
Break Even vs. Production cost / Sales scenarios
OEM/Tier 1 Scenarios
0
0,5
1
1,5
2
2,5
Agressive Balanced Conservative
Bre
al
Ev
en
[years
]
Low Prod. Cost
Avg. Prod. Cost
High Prod. Cost
SUPPORT OF COMMERCIALIZATION
AVL Central Research Coordination, Peter Prenninger 34
Challenges in:
• Validation and Commercialization
High market inertia – low early market volume
High dependence on „outer boundary conditions“ (legislation, energy prize, …)
OEM expectation: „mature“ prototypes – RoI as „conventional“ products
AVL Central Research Coordination, Peter Prenninger 35
Brennstoffzellen-Systeme – von der Forschung zur Kommerzialisierung: Integration – Simulation – Testen IEA Workshop Brennstoffzellen: Markteinführung, Markthemmnisse und F&E-Schwerpunkte 27. Februar 2014, Graz
Peter Prenninger
AVL List GmbH
Acknowledgement:
The results presented are based on research
projects funded by
the Austrian Ministry of Transport, Innovation
and Technology (a3/a3plus-Projects SOFC
APU I & II and ASys1)
as well as the European Union FP7 (DESTA).