Solid Oxide Fuel Cell Development for Transportation and Stationary Applications: Latest Update on Stack and System

Performance Steven Shaffer Delphi Chief Engineer Fuel Cells 2009 Fuel Cell Seminar November 17, 2009

Delphi Solid Oxide Fuel Cells Market Opportunities

Delphi Solid Oxide Fuel Cells Provide:

Ultra-clean, near zero emissions High-quality, reliable power High fuel efficiency Fuel flexibility Low noise
Residential Power Stationary CHP Power Units

Commercial Power Stationary Power Units

Heavy Duty Trucks Auxiliary Power Units

Military Auxiliary & Mobile Power Units Recreational Vehicles Auxiliary Power Units
November 17, 2009

Clean Coal Power Plant Advanced Power Systems

Delphi SOFC Development Centers

Fenton, Michigan

Rochester, New York

Cell Development Manufacturing Development Electrochemical Testing Material Characterization and Analysis

Stack Development System Development Reformer Development BOP Development

November 17, 2009

Cell and Stack Development

November 17, 2009

Equipment for Cell Development and Fabrication

November 17, 2009

Typical Gen 3 30-Cell Stack Performance

Power: 1.53 kW (486 mW/cm2) @ 60A (570 mA per cm2), 25.5 V (0.85V / cell avg), fuel 48.5% H2 ,3% H2O, rest N2, 750 800oC
MG735C676 - 30plus3 Date: 1/29/2009 Fuel: 48.5%H2-48.5%N2-3%H20 Flows: 89.8(A), 151(C) Stack Voltage and Power Density for Polarization Test

35

600

30

500

Stack Voltage (V)

400 20 300 15 200 10 100

0 0 10 20 30 40 50 60 70 Current (Amps)
Stack Voltage (V) Power Density (mW/cm^2) Poly. (Stack Voltage (V)) Poly. (Power Density (mW/cm^2))

Power Density (mW/cm2)

25

November 17, 2009

Generation 3 30-Cell Stack

Minimal lowering of power density ( 5%) in going from 50% fuel utilization to 80% fuel utilization

Stack Voltage and Power Density for Utilization Test

500 450 400 350

Stack Power Density

300 250 200 150 100 50 0

47

52

57

62

67

72

77

82

Utilization (%)
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Cathode Stability (at Carnegie Mellon University)

Powder
25 Powder Fabricated Cells 530 inlet ROI 1 530 inlet ROI 2 530 Outlet ROI 4

Bulk Cathode Composition via TEM

20

Atomic %

Fabricated Cell

15

10

0 La Sr La/Sr Fe Co Fe/Co A/B

5-cell stack (#530) tested 3500+ hrs at 0.8 V/cell on 28%H2 30%CO 6%H2O 2.5 ppmv S
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Gen 3 5-Cell Stack Maximum Power

Produced 500 mW/cm2 @ 60A (570 mA per cm2), 0.87V / cell avg, fuel 48.5% H2 ,3% H2O, rest N2, 750 800oC Max Power density: 765 mW/cm2 @ 100 Amps (952 mA per cm2), 0.80V / cell avg, fuel 48.5% H2, 3% H2O, rest N2, 750 825oC
MG735C793 Date: 6/23/2009 Fuel: 48.5%H2-48.5%N2-3%H20 Stack Voltage and Power Density for Polarization Test

900 800

5 700

Stack Voltage (V)

600 500

3 400 2 300 200 1 100 0 0

20

40

60
Current (Amps)
November 17, 2009

80

100

120

Power Density (mW/cm2)

Interconnect Development Materials & Coatings

Base material is ferritic stainless steel alloy Multiple coatings under evaluation
Low cost, conventionally processed coating demonstrated good stability in stack test Graph shows typical repeating unit performance in a stack with coating tested for durability (Fuel = 48.5 % H2, 3% H2O, rest N2, constant current of 570 mA per cm2) Further development is ongoing

1.2 1.1 1 0.9 0.8

Voltage (Volts)

MG735C624

0.7 0.6 0.5 0.4 0.3 0.2 0.1 0

0.00 500.00 1000.00 1500.00 Time Hrs 2000.00 2500.00 3000.00

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10

Gen 3 Stack Durability with Diesel Reformate

10-cell Gen 3 stack on Diesel reformate (24%H2 25% CO 5% CO2 7% H2O Bal N2) at 35 amps and 750C Initial voltage drop observed in the first 200 hours due to sulfur Minimal degradation in the last 1300 hours
MG735C727 Fuel: Reformed Diesel

1.2 1.1 1 0.9

Average Voltage (V)

0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0.00

200.00

400.00

600.00

800.00 Time Hrs

1000.00

1200.00

1400.00

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11

Gen 3 30-Cell Stack - Thermal Cycling

Gen 3 30-cell stack being thermal cycled

800

10 hour cycle from 50oC to operating temperature to 50oC Performance evaluated at each thermal cycle Constant current load of 30 Amps at operating temperature Fuel of 48.5% H2, 3% H2O, rest N2

700

600

Temperature (Deg C)

500

400

300

200

100

0 0.00

2.00

4.00

6.00 Time Hrs

8.00

10.00

12.00

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30-Cell Stack Thermal Cycling Results

0.9

0.8

0.7

Mean Cell Voltage

0.6

0.5

0.4

0.3

0.2

0.1

0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210

Thermal Cycle Number

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13

Red X Problem Solving Tools For Stack Issues

Problem solving tools like Red X are being utilized in stack manufacturing Lessons learned are being implemented for Gen 4 stack design and manufacturing Example: Find & eliminate the Red X driving high cell voltage range

Cell Voltage by Stack at 60amps

Average Range

Build Date
4/10/2008 4/12/2008 4/14/2008 4/15/2008 4/17/2008 4/24/2008 4/29/2008 5/29/2008 6/13/2008 6/24/2008 6/26/2008 7/22/2008 7/23/2008 7/24/2008 7/25/2008 7/31/2008 7/31/2008
0.70 0.85 0.60 0.80 0.50

6/6/2008

Cell Voltage Average

0.70

0.40

0.65

0.30

0.60

0.20

0.55

0.10

0.50

0.00

653

657

651

658

659

660

661

665

671

672

662

666

680

681

683

684

690

Stack

Red X is a registered term of Shainin LLC

691

Cell Voltage Range

0.75

Did not meet voltage range specs

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14

Red X Problem Definition TreeTM

Stack Other Area

High cell voltage range

Other Performance Characteristics P = 0.14V M = 0.013V

Event

Defect

Feature Components Assembly Process

First time quality issue: IV performance Repeating unit to repeating unit

Durability issue Cassette Other strategies Paste Interconnect Component Cell Cathode Interconnect

Coating Contamination

Other

Red X was identified as contamination in the interconnect coating from a specific supplier
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Problem Definition TreeTM is a registered trademark of Shainin LLC

Gen 4 Cell Development for Coal Based Systems

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Gen 4 Stack Design for Coal Based Systems

Delphi is developing its Generation 4 stack as the module for meeting stationary and transportation application requirements Key stack features are:

Laser welded cassette repeating unit configuration Stamped metallic cassette components Stamped interconnects Low cost coatings Low cost, conventionally processed balance of stack components

About 4x active area of Gen3 Lower cost interconnects/coatings than Gen3 High volume production processes 5 kW core building blocks Gen 4 stack
Gen 3 stack
November 17, 2009 17

Gen 4 Stack Development Status

Gen 4 stack design is complete Process development and optimization ongoing to fabricate cells, cassettes, and stacks First 5-cell stack fabricated and tested

Laser welding of SOFC parts

November 17, 2009 18

Gen 4 Stack Performance : 5-cell stack

Achieved power density of 474 mW/cm2 @ 240A (590 mA per cm2), 0.80V / cell average, fuel 48.5% H2 ,3% H2O, rest N2, 700 800oC
MG735G001-5cell stack Date: 8/26/2009 Fuel: 48.5%H2-48.5%N2-3%H20

500 450

5 400
Power Density (mW/cm2)

350 4
Stack Voltage (V)

300 3 250 200 2 150 100 1 50 0 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 Current (Amps)

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System Development

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20

Balance of Plant Components: High Temperature Insulation

Old

New

Insulation Collars

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21

Balance of Plant Components

Process Air Delivery System

Anode Tailgas Recycle Pump

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22

Diesel Fuel Survey Results Summer 2007 Sulfur Levels

40 35 30 25
frequency

Current 2007 ULSD Spec.

20 15 10 5 0 1 2 3 4 5 6 7 8 9 ppm 10 11 12 13 14 15 16 17

Sulfur ppm

Source: Alliance of Automobile Manufacturers (US and Canada, 160 samples)

November 17, 2009 23

Delphi Solid Oxide Fuel Cells Hot Reformate De-Sulfurization

Hot Reformate De-Sulfurization Development

Remove H2S to levels below 10 ppbv (parts per billion volume) from an input of 2.5 ppmv (parts per million volume) Sulfur acts as a poison to SOFC Maximize operation time between sorbent exchanges Minimize device volume and operation pressure drop

Fuel

<15 ppmw Sulfur

Reformer

<2.5 ppmv Sulfur

Reformate Desulfurizer

<10 ppbv Sulfur

SOFC Stack

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24

Delphi Solid Oxide Fuel Cells Hot Reformate De-Sulfurization

A non-regenerating sorbent has been selected that:

Meets maximum 10 ppbv output Meets operating temperature requirements Capacity is such that a bed operates for at least 6 months prior to requiring bed exchange for the 95th percentile driver System pressure drop requirements were met at full system reformate flow

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Delphi Solid Oxide Fuel Cell Design of New Diesel APU Platform
Gen 4 SOFC Stack Endothermic Diesel Reformer with integrated burner

Desulfurizer

Highly integrated manifold and heat exchanger assembly

DPS 3000D 3 kW net output power

Electronics and Controls Module

Fuel and Air Supply Systems

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Projected Performance Comparison

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27

27

DPS3000 D Initial Builds

First design engineered specifically as a truck APU Internal desulfurizer for ULSD ULSD cold-start capable

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28

Peterbilt Development Truck

Model 386 Peterbilt vehicle received at TCR on 8/28/09 Vehicle provided to Delphi as part of DOE EERE Truck APU Demo project Vehicle prepped for SOFC APU

Fuel and electrical interface

Mounting Hardware for APU enclosure

AC inverter
Refrigerator

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Delphi Solid Oxide Fuel Cell Gen 3 30-Cell Stack Vibration Testing

Test to Failure using Step Over Stress strategy to assess stack reliability Mil Std 810G Method 514.6 Annex C, Truck and Transportation Over US Highways Ambient temperature random vibration in 3 distinct axes Performance evaluated after each axis of testing Successfully completed 3.75 million miles equiv. of vibration

Vertical

Lateral
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30

30

Systems Vibration Testing

DPS 3000D SOFC System on shaker table

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31

Delphi SOFC APU Recent Accomplishments

Delphi/Peterbilt Awarded DOE Program for a 1 year vehicle demonstration Stack durability testing

200 Thermal Cycles Completed 5 lives accelerated vibration testing

Engineered and Built First Truck APU

Designed to operate on Diesel Integrated Desulfurizer operational

First APU installed on Peterbilt Truck

Operational by December 2009

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Acknowledgements

November 17, 2009

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