Development of Fuel Cells at Topsoe Fuel Cell A/S From Science to Industrial Technology Niels Christiansen

Transcription

1 Development of Fuel Cells at Topsoe Fuel Cell A/S From Science to Industrial Technology Niels Christiansen Topsoe Fuel Cell A/S Nymøllevej Lyngby, Denmark

2 Haldor Topsøe A/S has been comitted to catalytic process technology for more than 70 years Since 1940, all technologies have been anchored in fundamental research The company is represented throughout the world Head-quarter in Denmark Alberta Los Angeles Houston Copenhagen Moscow Bahrain New Delhi Beijing Tokyo Engineering offices in Denmark, India, Russia and USA Catalyst Manufacture in Denmark and USA Rio de Janeiro Buenos Aires Kuala Lumpur

3 Business Areas Fertilizer industry Basic chemicals The refining industry The environmental and power sector Automotive industry (emerging) Process licenses Catalysts Engineering services Site supervision Start-up & test run

4 Topsøe s business model harvests from specialized and customized research Topsøe delivers highly customized solutions via dialogue with clients Topsøe s solutions bridge fundamental understanding and industrial experience. Catalysts Research and Development Technology licensing Engineering Client

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6 From sub-nano scale to micro and meso scale Catalyst Hydrogen synthesis Fuel Processing Catalysis to macro scale Fuel Cells SOFC

7 Power Generation - Why Fuel Cells? Small units Decentralized power generation High efficiency Efficient at part load Fast response Muliti-fuel capabilities Fuel Cell Efficiency: η = ΔG/ΔH 32 Carnot limit: η c = 1 T l /T h

8 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 H 2 + CO + O 2 SOFC SOEC H 2 O + CO 2 + electric energy ( G) + heat (T S)

9 Types of Fuel Cells SOFC MCFC PAFC PEMFC AFC Electrolyte YSZ ScSZ Li 2 CO 3 H 3 PO 4 K 2 CO 3 Perfluoro sulfonic acid KOH Cathode LSM LSCF Li/NiO Pt/C Pt/C Pt/Au Anode Ni/YSZ Ni Pt/C Pt/C Pt/Pd Temperature o C 650 o C 200 o C o C 100 o C Fuel H 2, CO, CH 4, Biogas, NH 4 H 2, CO, (CH 4 ) H 2 H 2 H 2 8

10 Collaboration on SOFC in Denmark HTAS Collaboration with Risø on SOFC since W stack: 1996 TOFC RISØ TOFC Topsoe and Risoe Pilot Production: (5 MW/year capacity) Cells Stacks Modules (sub-system)

11 From Material to System From Science to Technology Know how Integrated Product Development Worldwide SOFC designs

12 From Science to Technology Cost R&D Processing Design Engineering Technology Reliability Materials Performance Maturing: An integrated innovation approach Evolution stages: Development Dominant Mature

13 Bring knowledge-holders together within the organisation and beyond R&D and Technology transfer network Major challenges Chal. Knowledge partners (transmitters) Geographically distance DTU IC Cultural distance Different value network TOFC (receptor) FZJ Vertical or horisontal collaboration Active communication links VTT EIFER KIT Y USTAN X Integration into receptors process and strategies GTec Seek and manage tensions between established practices and ideas from outsiders

14 Open innovation s dilemma Dependant on: Organizational membrane Passage of knowledge from one partner to the other Receptivity of each organisation (capability to learn from others and to adopt new ideas) Degree of overlap (buffer) from one organizations skills into the other. Difference in pressure (commitment and competencies) between to two organisations

15 Balanced Innovation Strategies Internal network Radical External network Local Open Individual I Collaborative Closed Incremental Global

16 Technology Evolution Different value networks Gap Radical innovation Core technology

17 SOFC Generations and Metal-Supported Cells Radical Innovation Development 1G 2G 2.5G Improved reliability Reduced material cost LSM+YSZ YSZ Ni+YSZ LSM+YSZ YSZ Ni+YSZ LSCF/LSC CGO YSZ Ni+YSZ 3G based on ceramics Metallic support operating temperature O C

18 Advice to Leaders of Open Innovation 1. Define the knowledge needed through open innovation 2. Bring knowledge-holders together within the organisation and beyond 3. Seek and manage tensions between established practices and ideas from outsiders 4. Accept the challenge of simultaneously addressing multiple tasks 5. Consider successful practices developed in other organisations 6. Work with partners to co-create new ideas and products 7. Use established platforms to simplify and speed collaboration A. Sigismund Huff et al., MIT Press, 2013

19 The Target Markets Auxiliary Power Unit APU Transport Power 3 5 kw e Micro-Combined Heat and Power Distributed Generation Large stationary DG CHP Stacks Modules Powercore m-chp Residential Power 1 kw e kw e

20 Micro-CHP Efficient, clean and silent cogeneration in private homes Electricity Electrical power Heat Fuel options Natural gas network Biogas network Steam and CO 2 Air Natural Gas Heat Fuel Cell System LPG Advantages High energy efficiency compared to the power grid Reduced emissions of NO X and CO 2 Reduces load on central power plant

21 Demonstration of CHP-Application Bio gas New Energy plant with SOFC unit Landfill gas Local heat network Geothermal heatpumps New Energy plant, Vaasa, Finland 20kW Combined Heat and Power Start of demonstration October 2009 Electrical efficiency approx. 46% (with methane content of 35 47%)

22 Demonstration of Marine SOFC APU with Wärtsilä Methanol on board as fuel Flue gas MeOH Methanator HTAS catalyst Ejector MeOH SOFC Depleted Air Catalytic Burner Anode Cathode Air 20 kw Marine APU Demonstrator 24 TOFC 12x 12 cm 2 stacks

23 From Aerospace to Ground Transportation Truck APU Light weight stack aerospace APU stack Transportation Truck idling in USA : 4.5 billion liters of diesel fuel contributing to air pollution and CO 2 emission. Design issues: Robust cast casing. Easy installation. 10g vibration h operation. Low pressure drop. 2-5 kw EU DESTA project

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25 Energy Storage Hydrogen production by water electrolysis SOFC H 2 H 2 O H 2 O H 2 H 2 + O 2- H 2 O + 2e - Reversible Ofuel 2- cell SOEC ½O 2 + 2e - O 2- SOEC H 2 O + 2e - H 2 + O 2- O 2- O 2-2e - +½O 2 ½O 2 ½O 2

26 Electrolysis

27 Electrolysis

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29 Diversity of Energy Sources Energy Carriers, SOFC & SOEC 1. SOFC: Distributed Power, CHP (smart grids) 2. SOEC: Energy storage and CO 2 conversion 3. Catalysis: Synthetic fuel from renewables Biomass Liquid Fuel Coal Syngas Natural gas Renewables Nuclear Electricity SOFC SOEC Electricity Hydrogen Hydrogen Methanol SNG DME Gasoline Diesel CO 2 recycling CO 2 + H 2 O Syngas (CO +H 2 )

30 Accept the challenge of simultaneously addressing multiple tasks Search information Materials Design R&D Processing Lifetime Reliability & Performance Real world practice concept Share information Cost Search solutions J. Collins and J. I. Porras, Harper Collins Publ., 1994