SOFC Micro-CHP Developing Products Today

Transcription

1 SOFC Micro-CHP Developing Products Today Presented to 8 th European Fuel Cell Forum Lucerne Dr Karl Föger Chief Technology Officer Ceramic Fuel Cells Limited 1 July

2 Disclaimer This Presentation has been prepared by, and is proprietary to, Ceramic Fuel Cells Limited ( CFCL ). This Presentation does not constitute or form part of an offer for sale or subscription or an invitation or solicitation of an offer to subscribe for or purchase any securities and neither this document nor anything contained herein shall form the basis of any contract or commitment whatsoever. No representation or warranty, express or implied, is given by CFCL, its Directors, employees or professional advisors as to the accuracy, fairness, sufficiency or completeness of the information, opinions or beliefs contained in this document. Except in the case of fraud, no liability is accepted for any loss, cost or damage suffered or incurred as a result of the reliance on such information, opinions or beliefs. The information in this Presentation reflects prevailing conditions and the views of CFCL as of this date, which are subject to change. CFCL

3 Overview Introduction to Ceramic Fuel Cells Micro-CHP product requirements CFCL Technology Partners Product Development Fuel Cell Commercialisation Volume Manufacturing Learning Curves Supply Chain Finally 3

4 Ceramic Fuel Cells Limited Formed in staff Powder to System developer with extensive IP portfolio Melbourne HQ, UK and German offices ASX and AIM dual listed 4

5 Micro-CHP Product CFCL develops fuel cell modules to generate electricity inside home heating systems Product optimised for high electric (>50%) and total efficiency (>80%), much higher than current energy supply (electricity grid + boiler) Recent studies endorse CFCL approach - Marcogaz Workshop, Paris May UK BERR Microgeneration Report, June 2008 Can create significant value for Utility, Appliance maker and Homeowner 5

6 Home Heating Requirements Germany Heating Energy kwh/m 2 year Subsidies Average housing stock: 220 kwh/m 2 per year New building: kwh/m 2 per year Low energy house: < 60 kwh/m 2 per year Passive house: < 15 kwh/m2 per year Current Average New Building Data: Deutsche Energie Agentur Attached Terrace House Low Energy Building Passive House Houses are becoming much more efficient they need less heat 6

7 Micro-CHP Commercial Value Daten von Jungbluth: Thesis RWTH Aachen 2006 Building efficiency kwh/m 2 pa Above 1kW th hours Above 2 kw th hours Energy for heating 100m 2 heated area Heating system shut-down during 3 months When a product is shut down for months, it is not creating value Maximise commercial value by maximising operating hours Focus on high electrical efficiency and low heat to power ratio 7

8 High Performance Anode Supported Cell under real operating conditions CFCL s Technology Voltage, V T OP = 750 o C Fuel = Prereformed (380 o C) NG S/C = 2 U F = 65%; U AIR = 58% Power Density, mw/cm Current Density, ma/cm 2 Thin and flexible (250μm) High Output: (>600mW/cm 2 ) 8

9 CFCL s Technology Fuel Cell Stack 2x2 Array Stack FSS Interconnector 50 Layers = 2kW NET 200 * 170 * 140 mm Co-flow Design η STACK = >60% Details: Poster B0609 J Love et al Thursday, July 3, :00 h 9

10 Stack Hot BoP Insulation Design Specifications Maximum Output Fuel Air Electric efficiency Total efficiency Heat to power ratio Inputs 2 kw e Desulf. NG 2 stoich AC > 50% >80% < 0.5 NG, Air, water CE approved pre-commercial system 10

11 4th Generation BoP Compact, Highly efficient Low thermal & parasitic losses Significant cost reduction Fuel Delivery Gas pump Not required Fuel Control Valves Solved Fuel Isolating Valve Solved Air Delivery and Air Pre-Heat Hot Balance of Plant (BoP) Fuel Processing De-sulphuriser Solved Reformer Solved Stack after-burner Solved Fuel pre-heater Solved Steam generator Solved Fuel / steam mixer Solved Exhaust mixer Not required Air blower Air pre-heater Auxiliary Burner Air pre-heater bypass valve Solved Solved Not required Solved Control & Electronics Temperature recorders Temp recorder & control Pressure recorders Solved Solved Solved Heat Recovery Heat recovery heat exchanger Cooling water pump Development Not required Water Delivery Steam generator water feed pump Solved Differential pressure recorders Controller & power electronics Solved Solved 11

12 Commercialisation through Partners Utility Partners with >20 million customers Appliance Partners: Leading boiler makers Supply Companies CFCL engineers embedded with appliance partners 12

13 Developing Products CFCL Field trial units CFCL & Appliance partner Semi-integrated units CFCL & Appliance partner Fully-integrated units Commercial Production Complete Four units, Aust, NZ, Germany Installed units in: Germany, France, UK. Holland & Japan, mid Integration underway Component Supply Chain, Cost-down Volume orders Utilities and appliance partners 13

14 Field tests, from

15 Costs Simple design Volume production Supply Chain partners Reliability Simple, robust design Component selection Lifetime Identify and eliminate degradation mechanisms Clear end of life commercial value model Fuel Cell Commercialisation 15

16 Make Reliable products, at Low Cost Need to scale up to volume manufacturing: Capacity to fulfil orders Moving to volume is critical to get products into the market Reduce Costs But also make consistent and reliable products Fuel Cell Commercialisation Commercial Reliability needs a manufactured product QA/QC Systems Automation versus hand built : Robotic yields vs Manual yields Fuel Cell is serial device need very consistent components and assembly Start the Volume learning curve Other suppliers need to see a commitment to volume manufacture 16

17 Lifetime Fuel Cell Commercialisation Targets Industry consensus target (and CFCL target) of hours for fuel cell products But - no consensus on what end of life means Different applications will have different targets SOFCs are different to other fuel cells 1-2kW mchp home products are different to MW power stations Lifetime is important because it affects customer value End of life is a commercial (not technical) decision Accelerated testing We cannot test one stack for 5 years and then start developing products! Predictive models, working with FZ Jülich and other partners 17

18 CFCL 'lifetime value' model As a fuel cell degrades, the outputs & efficiency changes The outputs and efficiency affect the value for the customer Once the product stops creating value, it should be replaced CFCL model connects technical performance with customer value Key Drivers How the customer uses the mchp product - Output of Power vs Heat - Running Hours Costs - Unit capital cost - Gas input costs vs Power price Maintenance - How often? - Replacement stack cost Lifetime Model 18

19 Building a plant in Heinsberg, Germany Volume Manufacturing Commercial production of CFCL fuel cell modules Initial capacity 10,000 units per year Existing leased building Total project cost 12.4m Completion June 2009 Future expansion options Up to 160,000 units per year in the same building Option to buy Greenfield site Long term cell supply partnerships Leading advanced ceramics manufacturers Supply anode supported cells to CFCL specification Technical Co-operation 19

20 Higher Volumes = Lower Unit Costs Learning Curves Volume Cost of unit 2n = (Cost of unit n) x (Slope of learning curve) Learning rates (% cost reduction for double output) are higher when the product starts with high complexity and low automation Activity % Aerospace 15 Shipbuilding Complex machine tools for new models Repetitive electronics manufacturing 5-10 Repetitive machine or Punch-press operations 5-10 Repetitive welding operations 10 Raw Materials 4-7 Purchased parts Source: NASA System Price /Euro/kWp Solar PV System Learning Curve System Price 9000 Installed capacity Annual Increase Example Solar PV Modules: 20% Systems: 17% Inverter: 8-10% Cumulative installed Capacity /MWp 20

21 Steeper Learning Curve = Quicker cost reductions Learning Curves Number of Units Produced Total Production Cost 85% Slope 87% Slope % Unit Cost Decrease , , , % learning: reduction by factor 15 cumulative 13% learning: reduction by factor 10 cumulative We are at the start of the Learning Curve for Fuel Cells Similar learning curves to other energy technologies? 21

22 Supply Chain Secure supply of low cost, commercially available components GENNEX TM Fuel Cell Module Cells: CeramTec, HC Starck Metal Stack components: Large EU suppliers Hot Balance of Plant Components: Heat exchanger, pre-reformer, catalysts, burner, steam delivery Transition pieces: Manifold, castings Insulation Micro-CHP Appliance Cold Balance of Plant: Inverter, Control system, Blower, Water treatment and delivery, Safety System Waste heat recovery and auxiliary boiler Suppliers are committed when volume orders are in sight 22

23 Commercial BoP Components Many components already developed and optimised Examples of dramatic cost reductions from commercial suppliers: Blower 95% cheaper Heat Exchanger 60% lighter 60% smaller 95% cheaper Gas System 85% cheaper 23

24 Finally Encouraging Future Leaders! CFCL annual prize to German students Encourage and reward outstanding fuel cell research Cash + Trip to CFCL in Melbourne Prize awarded at Hannover, April 2008, to Mr Helmut Kronemayer PhD work on using lasers to measure high temperatures in combustion systems Details at cfcl.com.au 24