Fuel Cell R&D at VTT Technical Research Centre of Finland

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1 Fuel Cell R&D at VTT Technical Research Centre of Finland

2 VTT Fuel Cells Fuel cells can be applied anywhere where electricity is needed. Typical applications are replacement of batteries in the W-power range, back-up power in the 1 kw 100 kw range, power for transport and speciality vehicles, and power production, from 1 kw residential to the stationary power of several MW. It is therefore expected that a major new industrial sector will emerge in the coming decades around fuel cells and their application. The technology is nevertheless complex, and requires both research and development work in order to reach maturity with regard to durability and cost. fuel cell research supports VTTthe industry s product development by maintaining a development platform comprising a large pool of know-how, a broad selection of research facilities and a range of advanced modelling tools. The work is encompassing a variety of technologies throughout the business chain. Networking with industry is performed through contract work involving consultation and technology development. We also undertake research projects, in which industrial enterprises are encouraged to participate. These research projects are mostly co-funded by the Finnish Funding Agency for Technology and Innovation, the European research programmes, industry and VTT. At present more than 30 different companies are involved in the various projects. VTT participates actively in European projects and European and international networks. Thus a large network involving universities, research organisations and industry within Finland and Europe can be utilised to convene research groups of high competence to solve different problems. The main research areas today are SOFC system research SOFC stack development PEMFC and hydrogen quality PEM materials and components Enzyme catalysed & printed fuel cells 2 Jari Kiviaho Chief Research Scientist Tel jari.kiviaho@vtt.fi

3 SOFC system research The purpose of SOFC system research at VTT is to provide novel technological solutions, tools and know-how for industrial companies in support of the development and application of products based on SOFC technology. The activities include research, development, experimental evaluation and modelling of SOFC stacks and cells, balance-ofplant (BoP) components and complete proof-of-concept SOFC systems. Modelling know-how and tools enables steady-state and dynamic system modelling and simulation at both component and system level. Modelling is applied to process design and optimisation, control system design and testing, failure analysis, and state estimation. The reliability of the modelling is verifi ed by comparing the results to other, more detailed models, and particularly to the experimental data obtained from in-house experimental facilities. The large-scale dynamic system models prepared at VTT can be operated in real-time or faster using standard PCs. This enables, for example, the screening of the behaviour of the studied processes and real-time based control hardware testing. SOFC cell and stack research is focused on understanding the limiting conditions in system operation with respect to lifetime and reliability. VTT is capable of conducting long-term testing under well defi ned gas atmospheres, including controlled addition of fuel and oxidant impurities. Measurement facilities enable both in-situ degradation and contamination assessment, as well as post mortal cell analysis. VTT can provide reliable and neutral performance data for cell and stack developers. VTT has the capability and facilities to conduct in-house development, prototyping and evaluation of BoP components for SOFC systems. Additionally, components from partners or third parties can be evaluated experimentally to assess their applicability for SOFC system use. Endurance testing and performance characterisation of the components is possible in automated test stands that can simulate SOFC system relevant operating conditions. VTT has the required know-how and research infrastructure to design, simulate, assemble and test complete proof-ofconcept SOFC systems. Research is conducted to investigate the performance, durability and reliability of the SOFC stack and BoP components in a real system environment. VTT can provide reliable services and partnership for stack and BoP component developers and SOFC system integrators. SOFC Demonstration Unit Research Facilities at VTT Matias Halinen Senior Scientist Tel matias.halinen@vtt.fi 3

4 Fuel Cell R&D at VTT SOFC stack development SOFC stack development at VTT started in Since 2010 stack development has been carried out as contract research, where the aim is to develop a stack structure suitable for different power ranges and for mass production. Stack development is based on the project partner s high performance cells and VTT s innovations on fl ow geometry, protective coatings and sealings. Global comparison reveals the electrical performance of VTT s current stack design to be comparable or superior to state-ofthe-art SOFC stacks. VTT is focusing on stack design, modelling, characterisation, and post-analysis. Cells, coatings and sealings are developed together with strategic partners. All manufacturing methods and materials are chosen for their suitability for up-scaling with a view to mass-production. Stack design is strongly supported by CFD, mechanical, and thermal modelling to optimise stack structure. Performance and life-time tests are conducted under realistic operating conditions. Stack characterisation is combined with electrochemical impedance spectroscopy and microscopy post-analysis to obtain detailed information on degradation mechanisms. Stack design is strongly supported by modeling modelled temperature profi les with different fl ow confi gurations Average cell voltage at 650 ºC, measured with synthetic steam reformate Stacks installed in a test bench Assembled short stack Olli Himanen Senior Scientist Tel olli.himanen@vtt.fi 4

5 Fuel Cell R&D at VTT PEMFC and hydrogen quality The polymer electrolyte membrane (PEM) fuel cell research at VTT is conducted in close collaboration with partners from universities and industry. The PEMFC group at VTT is researching both PEMFC and high temperature PEMFC (HT- PEM or PBIFC). The main focus in PEM research is on system development, and in PBIFC on material and stack development. The main goal of our work is to support industry in applying fuel cell technology in their products and to help develop systems, components and software solutions in this fi eld. In the long term VTT intends to become the expert organisation in Finland for offering engineering and research services to both domestic and international partners. The main domestic areas of focus has been identifi ed as the application of fuel cell technology in industrial working machines, such as material-handling vehicles. Another emerging market is the utilisation of by-product hydrogen from industry. Present research activities at VTT can be divided into three main categories: 1) development of PEMFC power sources for systems research purposes, supported by laboratory testing facilities, 2) development of materials and components for fuel cells and stacks and 3) organisation of technology demonstrations in various suitable application areas. Competences in fuel cell and hydrogen safety and reliability have been accumulated. The future goal is to develop new knowledge on fuel cell and hydrogen safety and reliability in order to be the main independent provider for fuel cell system safety and reliability analysis in Finland. The aim of research activity into LT-PEM (low temperature) systems has been to increase the expertise in power source design, construction and hybridisation. PEMFC systems up to 16kWe scale have been constructed as part of a hybrid system fi eld demonstration and research platform on forklift application. Integrated research platforms, laboratory testing facilities and tools to aid system design and optimisation are developed according to customer needs. VTT offers world class experimental facilities for experimental studies of PEM fuel cells from cell level to large scale stacks and from BoP components to fuel cell hybrid systems. Our knowledge and experience in system design, optimization and control is considerable and our mission is to ensure success to domestic and global industries aiming to commercialize fuel cell technology. A 8kW PEMFC system based on commercial stack Test driving Kalmar ECF-55 forklift with in-house developed 16 kw PEMFC hybrid system Jari Ihonen Tel jari.ihonen@vtt.fi 5

6 Fuel Cell R&D at VTT PEM materials and components In addition to stack and system design VTT has development programmes for all major PEMFC stack components except the membrane, i.e. catalysts, gas diffusion layers, bipolar plates, end plates and current collectors. The main drivers behind these developments are the improvement of durability and the decrease in cost of PEMFC stacks. The work has recently been extended to PEM water electrolysis cells. The key competencies applied in the development work are molecular modelling of catalyst structures, production of metallic and oxide nanoparticles, development of polymer fi llers and compounding processes, and surface treatment and corrosion protection of different metals and alloys. As PEMFC catalyst supports, carbon nanotubes and nanofi bers have recently been shown to have superior stability over traditional carbon blacks. Graphite composite bipolar plates have been developed for high temperature operation at 200 C, and CrN coated stainless steel plates for low temperature operation at 80 C. Advanced ex-situ and in-situ characterisation methods including the multisinglecell are used to verify material properties and the electrochemical performance. The multisingle setup for in-situ evaluation of PEMFC materials Graphite composite plates for HT-PEM Coated stainless steel inserts for the multisingle cell Pertti Kauranen Tel

7 Fuel Cell R&D at VTT Enzyme catalysed & printed fuel cells Printed electronics with an integrated power source has remarkable market potential in several mass-marketed consumer products, e.g. as package-integrated functionalities. There is also an emerging market in more specifi c disposable, electronics-equipped applications, such as smart patches and drug delivery systems in medicine, advanced inventory and luggage tracking, active brochures, and other information carrying materials. The power supply development also aims to meet the demands of active RFID tags. For many applications the power source should be biodegradable or made suitable for incineration along with normal household waste. The production costs should also be reasonable. As an alternative power source, the miniaturised biological fuel cell has the potential for development to meet these demands. We have developed a printable, fully enzymatic biofuel cell (BioBattery) based on the use of enzymes as a catalyst on both cathode and anode electrodes. The low peak current capacity of an enzymatic fuel cell can be improved by integrating the cell with a printed supercapacitor. The structure of the printed supercapacitor is designed for easy manufacture on the same printing substrate as the enzymatic fuel cell. The environmental requirements of the power source are also taken into account in the supercapacitor materials choice. The development of printed biofuel cells is studied in the Tekes-funded project Printed Enzymatic Power Supply with Embedded Capacitor on Next-generation Devices being carried out by VTT in collaboration with Aalto University, Tampere University of Technology and Åbo Akademi, the latter acting as coordinator. This project aims at further improvement in the performance of the BioBattery developed earlier, and at demonstrating its feasibility, both from an application and commercial viewpoint, by optimising the power supply for use in selected applications with varying demands for power and operation time. This BioBattery can be stored prior to use in dry state even for weeks or months, while in use it is able to generate power for several days. We have demonstrated the R2R processability (including drying) of the biologically active materials and the manufacturing of anodic and cathodic layers by rotary screen printing using VTTs ROKO pilot scale printing line. VTTs ROKO pilot scale printing line Printed enzyme catalysed fuel cell powering a digital thermometer Maria Smolander, Team Leader Tel maria.smolander@vt.fi 7

8 FINLAND Additional Information VTT Fuel Cells Jari Kiviaho Chief Research Scientist Tel Biologinkuja 5, Espoo P.O. Box 1000 FI VTT, Finland SOFC System Research Matias Halinen Senior Scientist Tel PEM Materials and Components Pertti Kauranen Tel Enzyme Catalysed & Printed Fuel Cells Maria Smolander Tel SOFC Stack Development Olli Himanen Senior Scientist Tel PEMFC and Hydrogen Quality Jari Ihonen Tel Espoo VTT TECHNICAL RESEARCH CENTRE OF FINLAND Technology and market foresight Strategic research Product and service development IPR and licensing Assessments, testing, inspection, certification Technology and innovation management Technology partnership