Deliverable 19: Cost analysis and benchmarking of EVOLVE stack WP 6

Transcription

1 Deliverable 19: Cost analysis and benchmarking of EVOLVE stack WP 6 Authors Dr. Henrik Hedlund & Dr. Saema Ansar Expected delivery time: 31/01/2017 Delivery time: 31/01/2017 Project acronym: EVOLVE Project full title: Evolved materials and innovative design for highperformance, durable and reliable SOFC cell and stack Grant agreement n

2 Outlines Outlines... 2 List of Figures... 3 List of Tables Cost analysis of EVOLVE cell Background Approach Cost analysis... 5 Conclusion

3 List of Figures Figure 1 Different layers and components in the fuel cell stack.... Fehler! Textmarke nicht definiert. Figure 2 BOM costs per cell as a function of volume (# units = SOFC cells).... Fehler! Textmarke nicht definiert. Figure 3 Costs of other resources per cell as a function of volume (# units = SOFC cells).... Fehler! Textmarke nicht definiert. Figure 4 Total costs per cell as a function of volume (# units = SOFC cells).... Fehler! Textmarke nicht definiert. List of Tables Table 1 List of different layers... 5 Table 2 other design considerations for the cell... 5 Table 3 Cost analysis for S 1 Lab-scale scenario Table 4 Cost analysis for S 2 Small pilot-scale scenario... 7 Table 5 Cost analysis for S 3 Extended pilot-scale scenario... 8 Table 6 Cost analysis for S 4 Volume scale scenario Table 7 indicative cost per unit for EVOLVE cell Table 8 Estimated cost per kw fort he EVOLVE cell Actual and future

4 1. Cost analysis of EVOLVE cell 1.1. Background This cost analysis is part of the deliverables within the EVOLVE project and serve a number of purposes, including being an essential part of a competitive analysis and benchmarking to peer technologies, providing quantitative measures of some supply scenarios for EVOLVE fuel cell applications, and providing sourcing options and alternatives for different levels of power production and supply 1.2. Approach In order to collect necessary information for the analysis, a document was compiled with instructions how to fill in a survey with quantitative cost figures for different supply scenarios, complemented with a quotation request to suppliers and developers of different components and treatments to be provided for the EVOLVE fuel cell (see Appendix 1 Saan Energi Quotations & Survey, September 2016 ). Representative pricing of feedstock materials were collected based on communication with different potential supplier and are listed in Appendix 2. Fig 1 below gives the schematic of the EVOLVE cell and table 1 enlist different parts with actual known processing method and supplier/developer. When necessary (for example for cathode layer), additional communication with additional potential suppliers was held to attain values representative of larger production scenarios. The cost analysis here given was remained focus on the EVOVLE cell. It was considered that the other parts of serial repeat unit (SRU), including bi-polar plates, protective coatings, sealing and joining would be of similar cost range as calculated by earlier studies on SOFC cost analysis given in [1, 2] Figure 1 Different layers and components in the fuel cell stack. [1] Manufacturing cost analysis of 1 kw and 5 kw solid oxide fuel cell (SOFC) for auxiliary power applications. Battelle. US Department of Energy [2] Cost study for manufacturing of solid oxide fuel cell systems. PNNL US Department of Energy

5 Table 1 List of different layers No Component description Material(s) Process(es) Supplier/Developer 1 Metal foam NiCrAl 01 - Alantum 2 Impregnated coating LST + NiO Dip coating LST - Cerpotech Process - Saan Energi 3 Roughness adjustment layer LST + NiO Tape casting LST Cerpotech Process Saan Energi 4 Anode function layer LST / GDC + NiO Screen printing LST Cerpotech Process Saan Energi 5 Layer 1 of bi-layer electrolyte Nano-8YSZ Tangential dip coating Layer 1 - DLR 6 Layer 2 of bi-layer electrolyte GDC EPVD Layer 2 - Ceraco 7 Cathode LSCF + GDC Screen printing Cathode CNR Table 2 other design considerations for the cell 1 Cell type Planar 2 Area of substrate, anode and electrolytes 90 x 100 mm² 3 Area of cathode 82 x 92 mm² 1.3. Cost analysis The cost analysis is structured around four different supply scenarios for fuel cell, i. e. A lab-scale scenario (S 1 ) - manufacturing of components and layers (1-7) of a limited number of fuel cells for lab-scale production. The number was selected to be 3 pieces / day, which was selected based on yield by actual PVD coating process as this corresponds to the longest processing time. A small pilot-scale scenario (S 2 ) - manufacturing of components and layers (1-7) for a number of fuel cells for small pilot-scale with yield of 100 pieces / day, An extended pilot-scale scenario (S 3 ) - manufacturing of components and layers (1-7) of a number of fuel cells for extended pilot-scale with yield of pieces / day, and 5

6 A volume scale scenario (S 4 ) - manufacturing of components and layers (1-7) of a number of fuel cells for volume scale production with yield of pieces/day. The cost analysis is further structured into costs related to material (BOM, bill-of-material) and costs related to usage of other resources, such as process, equipments, staff and overhead. In this analysis within the EVOLVE project, the costs are aggregated into BOM and summarized costs for other resources (process, equipment, staff & overhead). For some instances, there are some more details of specific costs. Finally, the analysis will also show a division of costs for different components and layers. For calculation details, please refer to the excel-sheet in appendix 2 EVOLVE project Cost analysis of innovative fuel cell platform and specific figures collected from surveys and quotations submitted by the different suppliers in the project (Alantum, Cerpotech, DLR, Ceraco, CNR and Saan Energi). S 1 Lab-scale scenario The cost analysis for a lab-scale scenario with a manufacturing yield limited to 3 cells / day (# units) is summarized below. Costs of material (BOM - ) No Component description # Units Low unit cost High unit cost Low target High target 1 Metal foam * 6 3,60 1 3, Impregnated coating 3 4,02 2 4, Roughness adjustment layer 3 4 Anode function layer 3 5 Layer 1 of bi-layer electrolyte 3 40, , Layer 2 of bi-layer electrolyte ** 3 105, , Cathode *** 3 144, , Total BOM ( ) 3 296,62 312, Costs of other resources (process, equipment, staff & overhead - ) No Component description # Units Low unit cost High unit cost Low target High target 1 Metal foam 6 * These costs are included in the BOM for layer 1 2 Impregnated coating 3 6,32 2 8, Roughness adjustment layer 3 4 Anode function layer 3 5 Layer 1 of bi-layer electrolyte 3 160, , Layer 2 of bi-layer electrolyte 3 ** These costs are included in the BOM for layer 6 7 Cathode 3 *** These costs are included in the BOM for layer 7 Total costs of other resources ( ) 3 166,32 168, Total costs (S 1, ) 3 466,54 484, Costs substrate (1-4, ) 3 17,54 20, Costs functional layer (5-7, ) 3 449,00 464, Cost figures for lab-scale scenario (S 1) provided by Alantum. 2 Cost figures for lab-scale scenario (S 1) provided by Saan Energi. 3 Cost figures for lab-scale scenario (S 1) provided by DLR. 4 Cost figures for lab-scale scenario (S 1) were estimated based on cost figures provided by Ceraco for scenario S3 and then statistical tools were employed from table 5-10 in ref [1]. 5 Cost figures for lab-scale scenario (S 1) provided by CNR. 6 pieces for metal foam are considered since in actual design 2 foams are pressed together for each cell. 6

7 [1] Manufacturing cost analysis of 1 kw and 5 kw solid oxide fuel cell (SOFC) for auxilliary power applications. Battelle. US Department of Energy Table 3 Cost analysis for S 1 Lab-scale scenario. Median cost of 1 x EVOLVE Cell in lab scale scenario 456,50 S 2 Small pilot-scale scenario The cost analysis for a small pilot-scale scenario with manufacturing of up to 100 pieces of fuel cells (# units) / day is summarized below. Costs of material (BOM - ) No Component description # Units Low unit cost High unit cost Low target High target 1 Metal foam * 200 3,60 1 3, Impregnated coating 100 4,02 2 4, Roughness adjustment layer Anode function layer Layer 1 of bi-layer electrolyte , , Layer 2 of bi-layer electrolyte ** , , Cathode *** , , Total BOM ( ) ,62 219, Costs of other resources (process, equipment, staff & overhead - ) No Component description # Units Low unit cost High unit cost Low target High target 1 Metal foam 200 * These costs are included in the BOM for layer 1 2 Impregnated coating 100 6,32 2 8, Roughness adjustment layer Anode function layer Layer 1 of bi-layer electrolyte , , Layer 2 of bi-layer electrolyte 100 ** These costs are included in the BOM for layer 6 7 Cathode 100 *** These costs are included in the BOM for layer 7 Total costs of other resources ( ) ,32 168, Total costs (S 2, ) ,54 391, Costs substrate (1-4, ) ,54 20, Costs functional layer (5-7, ) ,00 371, Cost figures for small pilot-scale scenario (S 2) provided by Alantum. 2 Cost figures for small pilot-scale scenario (S 2) provided by Saan Energi. 3 Cost figures for small pilot-scale scenario (S 2) provided by DLR. 4 Cost figures for small pilot-scale scenario (S 2) estimated based on cost statistics for SOFC from table 5-10 in [1] and S 3 figures from Ceraco. 5 Cost figures for small pilot-scale scenario (S 2) provided by Heraeus Group (as a complement to CNR s lab-scale estimates). [1] Manufacturing cost analysis of 1 kw and 5 kw solid oxide fuel cell (SOFC) for auxilliary power applications. Battelle. US Department of Energy Table 4 Cost analysis for S 2 Small pilot-scale scenario Median cost of 1 x EVOLVE Cell in small pilot scale scenario 363,50 7

8 S 3 Extended pilot-scale scenario The cost analysis for an extended pilot-scale scenario with manufacturing of pieces of fuel cells (# units) / day is summarized in table 3 below. Costs of material (BOM - ) No Component description # Units Low unit cost High unit cost Low target High target 1 Metal foam * ,40 1 2, Impregnated coating ,68 2 3, Roughness adjustment layer Anode function layer Layer 1 of bi-layer electrolyte ,00 3 8, Layer 2 of bi-layer electrolyte ** , , Cathode *** , , Total BOM ( ) ,28 106, Costs of other resources (process, equipment, staff & overhead - ) No Component description # Units Low unit cost High unit cost Low target High target 1 Metal foam * These costs are included in the BOM for layer 1 2 Impregnated coating ,68 2 6, Roughness adjustment layer Anode function layer Layer 1 of bi-layer electrolyte , , Layer 2 of bi-layer electrolyte ** These costs are included in the BOM for layer 6 7 Cathode *** These costs are included in the BOM for layer 7 Total costs of other resources ( ) ,68 22, Total costs (S 3, ) ,36 131, Costs substrate (1-4, ) ,16 14, Costs functional layer (5-7, ) ,20 117, Cost figures for extended pilot-scale scenario (S 3) estimated based on cost statistics for SOFC from table 5-10 in [1] and S 1-S 2 figures from Alantum. 2 Cost figures for extended pilot-scale scenario (S 3) estimated based on cost statistics for SOFC from table 5-10 in [1] and S 1-S 2 figures from Saan Energi. 3 Cost figures for extended pilot-scale scenario (S 3) provided by DLR. 4 Cost figures for extended pilot-scale scenario (S 3) provided by Ceraco. 5 Cost figures for extended pilot-scale scenario (S 3) provided by Heraeus Group (as a complement to CNR s lab-scale estimates). [1] Manufacturing cost analysis of 1 kw and 5 kw solid oxide fuel cell (SOFC) for auxilliary power applications. Battelle. US Department of Energy Table 5 Cost analysis for S 3 Extended pilot-scale scenario Median cost of 1 x EVOLVE Cell in extended pilot scale scenario 112,20 S 4 Volume scale scenario The cost analysis for a volume scale scenario with manufacturing of pieces of fuel cells (# units) / day is summarized in table 4 below. Costs of material (BOM - ) No Component description # Units Low unit cost High unit cost Low target High target 8

9 1 Metal foam * ,44 1 1, Impregnated coating ,61 2 1, Roughness adjustment layer Anode function layer Layer 1 of bi-layer electrolyte ,00 3 2, Layer 2 of bi-layer electrolyte ** , , Cathode *** ,40 5 5, Total BOM ( ) ,45 22, Costs of other resources (process, equipment, staff & overhead - ) No Component description # Units Low unit cost High unit cost Low target High target 1 Metal foam * These costs are included in the BOM for layer 1 2 Impregnated coating ,39 2 5, Roughness adjustment layer Anode function layer Layer 1 of bi-layer electrolyte ,00 3 4, Layer 2 of bi-layer electrolyte ** These costs are included in the BOM for layer 6 7 Cathode *** These costs are included in the BOM for layer 7 Total costs of other resources ( ) ,39 9, Total costs (S 4, ) ,28 33, Costs substrate (1-4, ) ,88 10, Costs functional layer (5-7, ) ,40 23, Cost figures for volume scale scenario (S 4) estimated based on cost statistics for SOFC from table 5-10 in [1] and S 1-S 2 figures from Alantum. 2 Cost figures for volume scale scenario (S 4) estimated based on cost statistics for SOFC from table 5-10 in [1] and S 1-S 2 figures from Saan Energi. 3 Cost figures for volume scale scenario (S 4) provided by DLR. 4 Cost figures for volume scale scenario (S 4) provided by Ceraco. 5 Cost figures for volume scale scenario (S 4) provided by Heraeus Group (as a complement to CNR s lab-scale estimates). [1] Manufacturing cost analysis of 1 kw and 5 kw solid oxide fuel cell (SOFC) for auxilliary power applications. Battelle. US Department of Energy Table 6 Cost analysis for S 4 Volume scale scenario. Median cost of 1 x EVOLVE Cell in volume scale scenario 22,40 BOM costs The change of BOM costs per piece of fuel cell (unit) with volume (# units) is shown in diagram 1 below. 9

10 Figure 2 BOM costs per cell as a function of volume (# units = SOFC cells). Costs of other resources The change of costs of other resources per piece of fuel cell (unit) with volume (# units) is shown in diagram 2 below. Figure 3 Costs of other resources per cell as a function of volume (# units = SOFC cells). 10

11 Total costs The total cost per piece of fuel cell (unit) with volume (# units) is shown in diagram 3 below. Figure 4 Total costs per cell as a function of volume (# units = SOFC cells). Conclusion Base on available data and best estimates, following indicative cost per unit for EVOLVE cell can be considered for different production scenarios (Table 7) Table 7 indicative cost per unit for EVOLVE cell Median cost of 1 x EVOLVE Cell in lab scale scenario (3 cells /day) 456,50 Median cost of 1 x EVOLVE Cell in small pilot scale scenario (100 cells /day) 363,50 Median cost of 1 x EVOLVE Cell in extended pilot scale scenario (1000 cells / day) 112,20 Median cost of 1 x EVOLVE Cell in volume scale scenario (10000 cells /day) 22,40 Considering volume scale scenario and taking costs of other parts and processes of SRU and stack assembling from ref 1 and 2, the cost of stack based on EVOLVE cell can be estimated with actual performance of 166 mw/ cm² and also with incorporating expected improvements. These improvements can be expected as the technology matures. The improvements will mainly stem from reaching higher OCV, lowering the thickness of electrolyte from 2 µm to 1 µm (which will improve performance and reduce costs), and improving the performance of electrodes mainly on air side. With these aspects considered, the EU target value of 1000 /kw can be realistically achieved. 11

12 Table 8 Estimated cost per kw for the EVOLVE cell Actual and future Actual Project scenario with improved performance and lower cost coming from thinner electrolyte, higher OCV and lower losses from cathode Power density per SRU W/cm² Effective area per SRU cm² Power per SRU W No of SRU needed for 1 kw Estimated cost per SRU Includes cost for Evolve cell from this study and takes other SRU costs and stack assembling cost from ref 1 and 2 Cost of 1 kw

13 Appendix 1: Survey and questionnaire for EVOVE cell cost analysis Below is the survey sent out to collect information for the cost analysis. Cost analysis Quotations & Survey This request focuses on collecting information from suppliers and component producers in order to perform an analysis of different costs related to the technology platform developed in the consortium of EVOLVE. The collection of information may be undertaken via a quotation or by answering questions in a survey. The main reasoning behind the request is to retrieve better and more accurate information regarding cost figures, to improve the quality of a cost analysis. This analysis will serve different purposes, including 1. cost breakdown of components of a fuel cell developed in the EVOLVE project, 2. cost benchmarking of EVOLVE cells vis-à-vis existing technologies and to use these cost figures for performance benchmarking later on, 3. quantitative input for potential business development activities, e g competitive analysis (SWOT), 4. quantitative input for different project- and business targets. For each supplier and component producer, these costs figures may constitute estimates for different production volumes, in which the estimates are indicated as a cost range (see below in the survey tables). We would prefer that industrial partners (Alantum, Cerpotech, and Ceraco) provide us with a quotation with information about different scenarios, volumes, cost figures, etc, in accordance with the information requested below. For other suppliers or component producers, we appreciate if you can provide us with such a quotation in case you are able to. Otherwise, please help us by filling in the survey. 13

14 Design, Components, Materials and Processes No Component description Material(s) Process(es) Supplier/Developer 1 Metal foam NiCrAl 01 - Alantum 2 Impregnated coating LST + NiO Dip coating LST - Cerpotech Process - Saan Energi 3 Roughness adjustment layer LST + NiO Tape casting LST Cerpotech Process Saan Energi 4 Anode function layer LST / GDC + NiO Screen printing? LST Cerpotech Process DLR 5 Layer 1 of bi-layer electrolyte Nano-8YSZ? Tangential dip coating? Layer 1 - DLR 6 Layer 2 of bi-layer electrolyte GDC EPVD Layer 2 - Ceraco 7 Cathode LSCF + GDC Screen printing Cathode - CNR Quotations For component 1: Metal foam - Alantum Please quote pricing for a foam production of 54 cm²/day Please quote pricing for a foam production of cm²/day Please quote pricing for a foam production of cm²/day 14

15 Please quote pricing for a foam production of cm²/day For component 2, 3 and 4: LST Cerpotech For impregnated coating, roughness adjustment layer and anode function layer, respectively 1. Please quote pricing for batches of 5 kg, 20 kg, 100 kg and 1000 kg for coarse LST 2. Please quote pricing for batches of 5 kg, 20 kg, 100 kg and 1000 kg for fine LST For component 6: Layer 2 of bi-layer electrolyte - Ceraco Please quote pricing for 3 pieces of 90 cm²/day Please quote pricing for 100 pieces of 90 cm²/day Please quote pricing for pieces of 90 cm²/day Please quote pricing for pieces of 90 cm²/day 15

16 Survey The survey shall cover four scenarios of production: 1. Cost figures related to present lab-scale production 3 pieces of 90x100 cm² per day production is considered. 3 pieces per day are selected because in an earlier conversation with Ceraco, it was told that a deposition rate of a 90x100 mm² or 90 cm² piece is about 3 hours. Hence with 9 hours of EPVD operation this member was opted. In case the number need to be revised, please state it. 2. Cost figures related to a scaling up of production (three scale scenarios). 100 pieces per day pieces per day pieces per day Information is requested for For component 4 and 5: DLR Please provide a quotation if you can or otherwise fill in the survey For component 7: CNR Please provide a quotation if you can or otherwise fill in the survey For each production scenario, please answer the questions below regarding costs for BOM (1a, 1b, etc) and processing cost (2a, 2b, etc). Processing cost is further divided into equipment-, staff and other operational costs. 16

17 A. Lab-scale production (3 pieces per day) 1 Bill of Materials (BOM) What are the BOM costs for different layers and/or components? # Material type Description Commercial source available with known cost Yes / No Cost range ($ or euro per unit) Low target High target Amount needed for one cell (90 cm²) Net Gross (Net + losses) Ref 1a Material a example : NiO 1b Material b example : Ethanol 1c 1d Material c Material d 2 Processing Cost What are the processes and equipment involved in the processing of different layers and/or components and what are related costs? Equipment Needed # Processes Involved Equipment name Capital investment needed for equipment ($ or euro) Yield of equipment (units per hour of production) Staff Needs Other operational costs ($ or euro) 2a Process a (example: ink making) Equipment a1 Type of staff required (Please indicate one of these: non-skilled staff, skilled technician, engineer, scientist) Please provide an aggregated cost figure including cost for electricity, water, gases and other consumables for the process Equipment a2 2b Process b Equipment b1 17

18 Equipment b1 Please indicate how much of the produced product after a specific process is needed for a cell (90 cm²) 18

19 B. Scale-up production (100 pieces per day) 1 Bill of Materials (BOM) What are the BOM costs for different layers and/or components? # Material type Description Commercial source available with known cost Yes / No Cost range ($ or euro per unit) Low target High target Amount needed for one cell (90 cm²) Net Gross (Net + losses) Ref 1a Material a example : NiO 1b Material b example : Ethanol 1c 1d Material c Material d 2 Processing Cost What are the processes and equipment involved in the processing of different layers and/or components and what are related costs? Equipment Needed # Processes Involved Equipment name Capital investment needed for equipment ($ or euro) Yield of equipment (units per hour of production) Staff Needs Other operational costs ($ or euro) 2a Process a (example: ink making) Equipment a1 Type of staff required (Please indicate one of these: non-skilled staff, skilled technician, engineer, scientist) Please provide an aggregated cost figure including cost for electricity, water, gases and other consumables for the process Equipment a2 2b Process b Equipment b1 19

20 Equipment b1 Please indicate how much of the produced product after a specific process is needed for a cell (90 cm²) 20

21 C. Scale-up production (1 000 pieces per day) 1 Bill of Materials (BOM) What are the BOM costs for different layers and/or components? # Material type Description Commercial source available with known cost Yes / No Cost range ($ or euro per unit) Low target High target Amount needed for one cell (90 cm²) Net Gross (Net + losses) Ref 1a Material a example : NiO 1b Material b example : Ethanol 1c 1d Material c Material d 2 Processing Cost What are the processes and equipment involved in the processing of different layers and/or components and what are related costs? Equipment Needed # Processes Involved Equipment name Capital investment needed for equipment ($ or euro) Yield of equipment (units per hour of production) Staff Needs Other operational costs ($ or euro) 2a Process a (example: ink making) Equipment a1 Type of staff required (Please indicate one of these: non-skilled staff, skilled technician, engineer, scientist) Please provide an aggregated cost figure including cost for electricity, water, gases and other consumables for the process Equipment a2 2b Process b Equipment b1 21

22 Equipment b1 Please indicate how much of the produced product after a specific process is needed for a cell (90 cm²) 22

23 D. Scale-up production ( pieces per day) 1 Bill of Materials (BOM) What are the BOM costs for different layers and/or components? # Material type Description Commercial source available with known cost Yes / No Cost range ($ or euro per unit) Low target High target Amount needed for one cell (90 cm²) Net Gross (Net + losses) Ref 1a Material a example : NiO 1b Material b example : Ethanol 1c 1d Material c Material d 2 Processing Cost What are the processes and equipment involved in the processing of different layers and/or components and what are related costs? Equipment Needed # Processes Involved Equipment name Capital investment needed for equipment ($ or euro) Yield of equipment (units per hour of production) Staff Needs Other operational costs ($ or euro) 2a Process a (example: ink making) Equipment a1 Type of staff required (Please indicate one of these: non-skilled staff, skilled technician, engineer, scientist) Please provide an aggregated cost figure including cost for electricity, water, gases and other consumables for the process Equipment a2 2b Process b Equipment b1 23

24 Equipment b1 Please indicate how much of the produced product after a specific process is needed for a cell (90 cm²) Appendix 2: Representative pricing of feedstock materials Material Cost Cost Cost Cost S1 S2 S3 S4 NiO 140 /kg 110 /kg 81 /kg 56 /kg LST 670 /kg 440 /kg 220 /kg 188 /kg LSCF 740 /kg 520 /kg 230 /kg 192 /kg 10-GDC 320 /kg 240 /kg 180 /kg 134 /kg Ethanol 2.95 /kg 1.6 /kg 0.85 /kg 0.85 /kg Distilled water 0.71 /kg 0.55 /kg 0.15 /kg 0.11 /kg Other additives 250 /L 250 /L 200 /L 200 /L (simplified cost) All costs are based on communication with different potential powder suppliers. However no supplier has any legal basis or commitment of supply with these prices. 24