LARGE-SOFC. Publishable Executive Summary: M13-M24

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1 Project no LARGE-SOFC Towards a Large SOFC Power Plant Instrument: Thematic Priority: Integrated Project 6.1 Sustainable Energy Systems Publishable Executive Summary: M13-M24 Period covered: from to Date of preparation: Start date of project: Project coordinator name: Organisation name of lead contractor for this deliverable: Duration: 36 months Mr. Rolf Rosenberg VTT Technical Research Centre of Finland Revision 1 Publishable Executive Summary M13-M24 Page 1 (6)

2 Publishable Executive Summary The Large-SOFC European consortium is developing the technologies necessary for Large Solid Oxide Fuel Cell-based (SOFC) power plants. The project Towards a Large SOFC Power Plant has a three year life, and started on January 1, The total project budget is 11 Million Euros. The research consortium coordinated by VTT Technical Research Centre of Finland comprises collaborators from several European countries: Wärtsilä Finland Oy (Finland), Rolls-Royce Fuel Cell Systems Ltd (UK), Topsoe Fuel Cell A/S (Denmark), Forschungszentrum Jülich GmbH (Germany), Dipartimento di Ingegneria Chimica e di Processo "G.B. Bonino" - Università di Genova (Italy), BOSAL RESEARCH nv (Belgium), The Switch (former Verteco Oy) (Finland) and Inmatec Technologies GmbH (Germany). Objectives The objective is to develop concepts for components and sub-systems and verify their suitability for use in both pressurized and atmospheric SOFC units for large-scale power plants for the medium to long term. The focus is on technologies for SOFC units with the potential for hundreds kw to several MW, with a capital cost of Euro1000/kW or less at production scale, having 50,000 hours durability and efficiencies of 60% plus in power generation mode and 80% for CHP. The project's primary aim is to address the basic problems of moving from existing kw size SOFC units to units of several hundred kw to MW size SOFC power plants. The work is divided into two parts: The first and largest part of the project targets the systems, components and sub-system challenges of large scale SOFC units in the following work packages: System analysis, Balance of Plant (BoP) modelling and validation System layout and integration Components and sub-systems Development of industrial scale stack Verification of the systems and sub-systems This is supported by a second part, which is a package of work examining the required infrastructure and socio economic issues that will affect installation and operation of SOFC systems. Thus the package involves: Fuels Connection to grid Safety and Life Cycle Assessment (LCA) Training and dissemination of information The project is expected to provide a clear picture of how MW size power plants should be planned, developed, manufactured and brought into use. Publishable Executive Summary M13-M24 Page 2 (6)

3 Contractors involved, coordinator contact details Participant Participant Country short name VTT Technical Research Centre of Finland VTT FI Wärtsilä Finland* ) Wärtsilä FI Rolls-Royce Fuel Cell Systems Ltd RRFCS UK Topsoe Fuel Cell A/S TOFC DK Forschungszentrum Jülich GmbH FZJ DE Dipartimento di Ingegneria Chimica e di UNIGE IT Processo "G.B. Bonino" - Università di Genova BOSAL RESEARCH nv Bosal BE The Switch **) Switch FI Inmatec Technologies GmbH Inmatec DE *) Former Wärtsilä Corporation **) Former Verteco Oy Coordinator contact information: VTT Technical Research Centre of Finland Rolf Rosenberg, Chief Research Scientist Tel rolf.rosenberg@vtt.fi Work performed The 1-D SOFC model developed in the project has been further optimized and additional features for start-up were implemented. The component models for heat exchangers and reformers available in Apros and in the FZJ-Simulink model were validated using measurement data. The Apros model is now ready for simulation of the 50 kw unit. Steady state calculations wer used to further investigate and develop the 50 kw concept developed during the first project year. The elementary balance and system parameters were calculated. During the first year different concepts for the 50 kw unit were analysed and one chosen for further development. The final detailed design of the 50 kw fuel cell unit has now been done. The different integrated sub-systems and solutions have been chosen and validated. The manufacturing methods and development of modular design has been a major effort. The Hybrid System simulation tools at UNIGE has been developed and a thermo economic comparison of different plant designs has been performed. Wärtsilä and Rolls-Royce Fuel Cell Systems LTD supplied economic data to University of Genoa for this modelling work. Different designs for a hybrid system have been analysed in order to find the highest possible electrical efficiency. BoP components are an integral part of designing a high efficiency and competitive cost SOFC system. The components studied in the project are: Publishable Executive Summary M13-M24 Page 3 (6)

4 Turbomachinery, gas and air recirculation Heat exchanges and recuperators Fuel processing equipment Power electronics and control systems Insulation The turbomachinery and recirculation devices for hybrid systems were studied by modelling. The gas recirculation performance of ejector was compared to a system with blower. For nonpressurised systems air and anode gas recirculation blowers were designed and tested. A centrifugal blower with magnetic bearings was designed and manufactured. Another commercially available one was acquired and tested. A test stand to test blowers was constructed and used for anode recycle blower characterisation. An experimental campaign was carried out to produce data for recuperator design and theoretical model validation. New test rigs were developed and constructed for testing of creep and chemical stability of materials for heat exchangers. A number of tests have been carried out looking at manufacturing aspects of SOFC heat exchangers. Commercial heat exchangers have been characterised under both stationary and dynamic conditions. Power electronics and controls have been developed for 1 MW pressurised SOFC system. Hardware and software architectures were developed. The converter conceptual design for the 50 kw verification unit was completed, components were selected and the first prototype constructed and tested. Advanced software controls were also developed. Insulation solutions both for pressurised and non-pressurised SOFC units have been studied. Special attention was paid to shrinkage, compatibility, assembly and handling. Different materials were characterised. In January 2008 a unit consisting of two 2.5 kw stacks divided by a flow distribution manifold was tested under various operating conditions relevant for the upcoming 50 kw demonstration unit. Production of stacks with the design used in the 50 kw demonstration unit was initiated. An analysis of selected key mechanical and electrical quality assurance parameters was carried out in the initial production phase to ensure optimum quality of the stacks throughout the later production phase. A wide range of ceramic raw materials for RRFC stacks have been evaluated. The work proved the need and benefit of a calcinations step during manufacturing. As a result a calcination schedule with a peak temperature of 1100ºC and 8 hrs dwell time has been adopted as standard. The construction of the test site for the 50 kw SOFC unit is almost finished. Identifying and procurement of suitable measurement instruments for the verification has also been started but is waiting for final specifications for the 50 kw unit. Modifications to the pressurised system test rig were conducted by RRFCS, including updating the electricity supply and pre-heater transformer unit together with improvements to Publishable Executive Summary M13-M24 Page 4 (6)

5 the controls system. The nitrogen supply was upgraded in order to provide an increased flow and to meet the set target. A test rig for evaporator and anode gas recycling blower has been constructed and taken into use. Another test rig for pre-reformer validations has also been constructed and taken into use. Heat exchanger testing has been progressing. The part load testing has been done successfully and the unit seems to be able to achieve the pressure loss level specified in the requirement specifications. A report on availability and production of biofuels for SOFC has been finalised. The report also contains a section on purity requirements for SOFC use. Influence of toluene and HCN on cell behaviour has been studied experimentally. In normal concentrations the results show that they have no influence. Grid connection rules and standards have been analysed in order to take these in consideration when constructing SOFC power plants A safety documentation package was compiled in order to ensure safe installation of the 50 kw verification unit. LCA will evaluate the environmental impact of operating a SOFC power plant. The result will be compared with conventional power plants. Different fuels will be considered. The project is now starting data collection from RRFCS and Wärtsilä. One public work shop and five internal workshops were organised as well as one summer school. Results achieved The Dynamic Apros model with validated component models is now ready for simulation of the 50 kw SOFC concept verification unit. The final detailed design of the 50 kw fuel cell unit has now been done. Different designs for a hybrid system has been analysed in order to find the highest possible electrical efficiency. A centrifugal blower with magnetic bearings was designed and manufactured. New test rigs were developed and constructed for testing of creep and chemical stability of materials for heat exchangers. New power electronic concepts have been manufactured and tested. The 2.5 kw stacks were tested and approved for use in the 50 kw unit. Stack manufacturing has started. A number of ceramic materials for RRFCS stacks have been analysed. A calcination step necessary for the manufacturing has been developed. Test rigs for pre-reformer and evaporator as well as anode re-circulation equipment have been manufactured. Expected end results The project is expected to produce know-how and technology which enables the participating companies to produce large fuel cell power plants from 2009 onwards. It will also produce information about alternative fuels which will be helpful in the production of power and heat Publishable Executive Summary M13-M24 Page 5 (6)

6 with lower CO 2 emissions than current levels. Information about grid connection, safety and Life Cycle Assessment, (LCA) of fuel cell power systems will also be produced. The project will organise training through summer schools and disseminate information through technical workshops. Intentions for use and impact No publishable results at this stage. European Commission 6 th Framework Programme Project no Towards a Large SOFC Power Plant Abbreviation: LARGE-SOFC Publishable Executive Summary M13-M24 Page 6 (6)