Manufacturing cost analysis of 100 and 250 kw fuel cell systems for primary power and combined heat and power applications doe contract no. Validated cell models are applied to 3d stack simulations, where optimization algorithms obtain better designs, faster. The allinone sofc generator prototype will be developed based on the cad, cfd and fea design. Safety precautions are already considered in our product design so the system can handle them automatically.
In addition, the software also performs a bending analysis of the stack to aid with the stack lifting design. Pdf numerical and experimental analysis of a solid oxide. We present computer automated engineering of fuel cell stack design to maximize power production and minimize energy losses. Thermal stress analysis of the planar sofc bonded compliant. Academics tend to see architecture as part of the larger field of software design. Solid oxide fuel cell and power system development at pnnl. This final technical report summarizes the progress made during the project period of 27 months. Modeling and control of fuel cell systems and fuel processors by jay tawee pukrushpan cochairs. Fuel cell, molten carbonate fuel cell and solid oxide fuel cell.
Manufacturing cost analysis of fuel cells for material. Mecastack is a standalone executable program that performs the overall structural analysis of self supported or guy wire supported steel stacks it uses a stiffness matrix to completely model the stack and its loadings, and then applies the appropriate acceptance criteria based upon the user selected design. Development and simulation of an innovative planar stack. The shape of both fuel and air manifolds in the current stack designs are. A single cell consisting of these four layers stacked together is typically only a few millimeters thick.
In case of heater, we do have stack mounted on structure. Third, sofc is a hightemperature technology, thus its exhaust streams will tend to have high temperatures. Automated massmanufacturing and quality assurance of solid oxide fuel cell stacks. Diesel fueled sofc system for class 7class 8 onhighway truck auxiliary power defc3604go14318 dan norrick pi cummins power generation. The fuel cell stack block implements a generic model parameterized to represent most popular types of fuel cell stacks fed with hydrogen and air.
Mecastack can be used to analyze self supported stacks free standing and guyed stacks guy wire supported. Contemporary approaches to planar sofc stack design and. Modeling of sofc stacks and components fraunhofer ikts. Third, sofc is a hightemperature technology, thus its exhaust streams will tend to. The design of the parameters ki1, ki2, and ki3 must satisfy the following constraints. The specific technical objective of this project was to demonstrate, via analyses and testing, progress towards adequate stack life.
The novelty of the project lies in combining state of the art methodologies for costoptimal probabilisticbased design coprd with actual production optimization. Solid oxide fuel cell cell and stack test stations series. Production and reliability oriented sofc cell and stack. They result in a simpler stack design, but they can only be used in a. Innovative, versatile and cost effective solid oxide fuel. Fuelcell and fcview for windows scribner associates. The power levels considered were 1, 5, 10, and 25 kilowatts kw. Planar sofc system modelling and simulation including a 3d. Furthermore, the short conduction path from the anode of one cell to the cathode of the next results in lower ohmic losses and, therefore, higher stack efficiency and lower cost than many of its predecessors. Fuelcell software is designed to control or monitor virtually all of the parameters of an operating pem type fuel cell or stack and perform a wide variety of experiments. In these stack systems, the sofc is attached with auxiliary devices called the balance of plant bop components such as the reformer, burner, heat exchanger, air compressor and fuel processor. The latest study on sofcs is quite interesting for researchers because of its dynamic system and proper operational limitations.
For many businesses, numerical modeling and simulation are valuable tools at various stages of the design workflow, from product development to optimization. Venkat venkataraman brings to bloom energy more than 35 years of experience in process design and optimization. Author provides information on typical length scales in evaluation of power systems with solid oxide fuel cells. The bloom energy server the bloom box is a solid oxide fuel cell sofc power generator made by bloom energy, of sunnyvale, california, that takes a variety of input fuels, including liquid or gaseous hydrocarbons produced from biological sources, to produce. Design and fabricate a well functioning and reliable sofc test stack capable of running a variety of cell types. The sofc program is focused on the design, scaleup, and. Prnewswire the solid oxide fuel cells sofcs global strategic business report report has been added to s offering. Design cell architecture stack design material stability. Considering the dominant role of the cell stack in thermal management, the modeling strategy focused on enabling feedback of heat transport fromto both the bop hardware and the sofc stack.
The x40x60 sofc test station is a standard platform for testing sofc. A solid oxide fuel cell is made up of four layers, three of which are ceramics hence the name. However, no inbuilt sofc module exists within any of the commercial flowsheet simulators. The exergy efficiency of sofc stack wex in ex out in this system is 81%, while 9. The block represents two versions of the stack model. Development and simulation of an innovative planar stack design combining a solid oxide fuel cell sofc with an allothermal steam reformer. Inhouse, adaptable 3d process model for planar sofc stack configurations from different industrial partners process model of tubular sofc cells detailed 2d meamodel for essential mechanisms on structural level for sofc counter flow unit cell. Diesel fueled sofc system for class 7class 8 onhighway truck auxiliary power defc3604go14318 dan norrick pi. The purpose of the tool is to allow sofc manufacturers to numerically test changes in planar stack design to meet doe technical targets. The microtubular sofc stack is designed with cad, cfd and fea software.
Sofc fuel cells, is pleased to announce loi commercialization agreement with magnex co. Production and reliability oriented sofc cell and stack design. Functionality of 0d to 3d models is discussed and selected examples are given. In other words, the distribution of fuelgas with the. Best it company in dhaka is topofstack software ltd. However, the sofc technology still faces many challenges, before it could be commercialized, since cost reduction and an extended lifetime are required. Optimization strategies for solid oxide fuel cell sofc. Minh center for energy research university of california, san diego. Diesel fueled sofc system for class 7class 8 onhighway. Degradation study of pressurized solid oxide fuel cells. Aug 23, 2016 today, guest blogger matteo lualdi of resolvent aps, a comsol certified consultant, discusses the benefits of creating a simulation app to analyze a solid oxide fuel cell stack. Software alg orithms for m eta models th at allow the. Modelling of physical, chemical, and material properties. This presentation contains no proprietary, confidential, or otherwise restricted information 2.
Thermodynamic analysis of solid oxide fuel cell integrated. General description of an sofc stack and flow simulation. Us doe, 2004 office of fossil energy fuel cell program annual report, 2004. Advanced sofc quality control and the role of manufacturing. The sofc stack performance is based on anodesupported planar geometry. Scrutiny of mtsofc stack manifolding design using cfd. Modeling and control of fuel cell systems and fuel processors jay tawee pukrushpan fuel cell stack. August 31, 2017 completion of the new threeyear, eufunded, alleuropean highperformance stack. Emerald control software with automated scripting capability. Sofc mp is a simulation tool developed at pnnl to evaluate the tightly coupled multiphysical phenomena in sofcs. Optimization strategies for solid oxide fuel cell sofc application. Run preliminary tests to identify all polarization processes contributing to the overall polarization using impedance spectroscopy and the calculated distribution of relaxation times drt. The bloom energy server the bloom box is a solid oxide fuel cell sofc power generator made by bloom energy, of sunnyvale, california, that takes a variety of input fuels, including liquid or gaseous hydrocarbons produced from biological sources, to produce electricity at or near the site where it will be used. Today, guest blogger matteo lualdi of resolvent aps, a comsol certified consultant, discusses the benefits of creating a simulation app to analyze a solid oxide fuel cell stack.
Topofstack software limited best mobile app, web design. A solid oxide fuel cell sofc is a promising allsolidstate energy conversion device that produces electricity by electrochemically combining a fuel with an oxidant across an oxide electrolyte. Manufacturing cost analysis of 100 and 250 kw fuel cell. A numerical simulation of the julich f design solid oxide fuel cell stack is conducted by means of an original mathematical model. Sustainability free fulltext development of largescale and. In these stack systems, the sofc is attached with auxiliary devices called the balance of plant bop components such as the reformer, burner, heat exchanger, air. Department of energy doe sponsored project was the development of solid oxide fuel cell sofc technology suitable for ultraefficient central power generation systems utilizing coal and natural gas fuels and featuring greater than 90% carbon dioxide capture. Each cad and any associated text, image or data is in no way sponsored by or affiliated with any company, organization or realworld item, product, or good it may purport to portray. Manufacturing cost analysis of 1, 5, 10 and 25 kw fuel. Building an app to optimize the design of an sofc stack. Nonuniform, multistack solid oxide fuel cell sofc system.
Modelling an entire sofc system can be simplified by employing standard process flowsheeting software. In this work a numerical solid oxide fuel cell model is developed and validated with the experimental data given in the literature. Also developments are in progress such that any abnormalities to the stack during the operation will be notified by the fuel cell system which then could directly be informed our service team, who will be ready and always reachable. Nextech materials bags sofc stack technology contract from the us army fuelcell energy bags contract from the u.
Fabrication and performance evaluation of sixcell two. Steel stack design mecastack software meca enterprises inc. It is technology independent and may also be used with dmfc, pafc, mcfc or sofc type fuel cells. Solid oxide fuel cell interconnect design optimization. Mecastack is a 3d stack design software that is used to design steel stacks, steel chimneys, flares, exhaust stacks, etc. Manufacturing cost analysis of 1 kw and 5 kw solid oxide fuel cell sofc for auxilliary power applications prepared by. The paper presents an innovative development methodology for a production and reliability oriented sofc cell and stack design aiming at improving the stacks robustness, manufacturability, efficiency and cost. Martin norby nielsen for the development of software and elec tronic circuits for. Led by the catalonia institute for energy research irec, the main goal of the cell3ditor project is the development of a 3d printing technology for the industrial production of sofc solid oxide fuel cells stacks by covering research and innovation in all the stages of the industrial value chain. Its open design architecture can include a number of customconfigured options tailored to your exact requirements. Hence, it is going through growing pains right now.
Stationary and emerging market fuel cell system cost. Battelle battelle memorial institute 505 king avenue columbus, oh 43201 prepared for. Details of the developed stack thermal model are presented. Software design has a longer history while the term software architecture is barely 20 years old. Implementing thermal management modeling into sofc. Apr 11, 2018 comminges c, fu qx, zahid m et al 2012 monitoring the degradation of a solid oxide fuel cell stack during 10,000 h via electrochemical impedance spectroscopy.
Deee0005250 battelle january 2016 iii heat exchanger that is overdesigned for the application and is hence probably more expensive than necessary. Numerical simulation as an economic approach to design materials, cell or stack structure was used to develop the sofc technology further. School of science and engineering capstone final report. Jun 30, 2019 this paper investigates the influence of the nonuniform multi stack design on the solid oxide fuel cell system size and performance. The design of the msofc power generator is primarily driven by the.
The practicality and economic viability of using the fuel cell system for a particular application depend to a large degree on the stack s performance, robustness, production cost, as well as on the reproducibility of its characteristics. Technical lead and main contact to develop and execute new fuel cell and electrolysis projects with darpa and boeing phantom works. A single delphi gen 4 sofc stack can provide 9 kw of electrical power and. The model is implemented in the open source toolbox, openfoamr. Ansys mechanical software, modeling of loading within a stack parameters. Sofc test rigs cells, stacks and stack modules demonstration systems competence in system integration independent sofc test laboratory. Cell3ditor project uses ceramics 3d printing to produce.
Custom designed sofc test rigs optional equipment unique walkin frame design allows complete access for test article setup custom furnace integration integrated reformer and desulphurization gas blending, reformate simulation and optional inline gas analysis high temperature, high pressure gas delivery. Scrutiny of mt sofc stack manifolding design using cfd the open fuel cells journal, 2012, 5. Led development of revolutionary solid oxide fuel cell sofc stack design that delivered 10x increase in specific power. Sofc system performance at the design point depends on. For 10 years, ikts has been developing various stack designs, constructed them as prototypes and tested them for their suitability. Dynamic modeling of a parallelconnected solid oxide fuel cell. Sofc test rigs cells, stacks and stack modules demonstration systems competence in system integration independent. Sofc systems with improved reliability and endurance. He leads the development of highly efficient and low cost bloom energy servers.
A solid oxide fuel cell sofc system consists of a fuel cell stack with its auxiliary components. Although there is growing recognition that arch is a field within its own. A computational fluid dynamics and finite element analysis. I want to create sofc stack in aspen plus software, how to create this stack in aspen plus. I want to create sofc stack in aspen plus software, how to create. Sofcs, and the delicate interplay between cell properties, stack design, and operating conditions of the sofc stack. Manufacturing cost analysis of 1 kw and 5 kw solid oxide. Solid oxide fuel cell sofc national energy technology. The planar solid oxide fuel cell sofc stack, in particular, offers easy manufacturing. Department of energy for sofc development dominovas energy signs mou with delphi. The computeraided design cad files and all associated content posted to this website are created, uploaded, managed and. Manufacturing cost analysis of fuel cells for material handling. During his tenure at bloom, he led the company through many technological breakthroughs bringing sofc technology from early stages of development to a very matured state enabling deployment of highly. Implement generic hydrogen fuel cell stack model simulink.
In particular the prosofc project aims at improving the robustness, manufacturability, efficiency and cost of solidpowers stateoftheart sofc stacks so as to reach market entry requirements. The hightemperature fuel cell stack sofc stack is a crucial component within the sofc system. Department of energy doe sponsored project is the development of solid oxide fuel cell sofc cell and stack technology suitable for use in highlyefficient, economicallycompetitive central generation power plant facilities fueled by coal synthesis gas syngas. The computeraided design cad files and all associated content posted to this website are created, uploaded, managed and owned by third party users. In this study, a twodimensional 2d solid oxide fuel cell sofc stack configuration was designed to be operated with six cells. Mecastack is a standalone executable program that performs the overall structural analysis of self supported or guy wire supported steel stacks it uses a stiffness matrix to completely model the stack and its loadings, and then applies the appropriate acceptance criteria based upon the user selected design code. Thermal stress analysis of the planar sofc bonded compliant seal design k. Hundreds of these cells are then connected in series to form what most people refer to as an sofc stack. This paper investigates the influence of the nonuniform multi stack design on the solid oxide fuel cell system size and performance. Within the project an innovative methodology for a production and reliability oriented sofc cell and stack design is developed.
Martin hauth, vincent lawlor, peter cartellieri, christopher x christopher zechmeister, sebastian wolff, christian bucher, jurgen malzbender, jianping wei, andre weber, georgios tsotridis, henrik. I want to create sofc stack in aspen plus software, how to. Due to the limited power of the output, single cell sofc can be arranged into a stack system in series or parallel design. Stack design 4 modules, 66 cellsmodule, series connection. High concentration of nitrogen and steam in the fuel stream cause dilution of fuel, which results in reducing the air requirement for sofc stack cooling in.
Progress posted in european sofc project engineering360. Battelle evaluated lowtemperature polymer electrolyte membrane ltpem and solid oxide fuel cell sofc systems for use as a continuous power supplement primary power and to provide auxiliary heating in combined heat and power chp configurations. With the capabilities of the comsol multiphysics software, it is possible. Pnnl is the leading us doe laboratory for sofc research and development. The practicality and economic viability of using the fuel cell system for a particular application depend to a large degree on the stacks performance, robustness, production cost, as well as on the reproducibility of its characteristics. Aug 31, 2017 progress posted in european sofc project s. Casey brown principal engineer fuelcell energy linkedin. Optimize sofc stack designs quickly and accurately by building a. A new allinone sofc power system for a mini uav is developed.
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