SOFC stack modules for decentralized power generation
Contents
1.
2.
3.
4.
5.
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staxera company presentation
staxera GmbH
Integrated Stack Module (ISM)
Performance
3 kW system demonstrator
Summary
Jeremy Lawrence
staxera GmbH
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staxera company presentation
Jeremy Lawrence
World‘s leading SOFC stack supplier
Defined product
Clear interfaces
Performance guarantee
5.000 hours and 20 thermal cycles
Continuous improvement
Roadmap to higher power
SOFC stacks are ready for system development
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staxera company presentation
Jeremy Lawrence
Security of supply
Active in more than 58 countries
Automobile component supplier
1.6 billion € turnover in 2008
7.5% investment of turnover in R&D
More than 7000 employees
SOFC stacks
100% owned by Webasto AG
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staxera company presentation
Jeremy Lawrence
Core technology - Mk200 stack
75% fuel utilization
High efficiency
Low pressure drop
Low system parasitic losses
Redox stability
Electrolyte supported cells
Mk200 stacks are the heart of each staxera ISM
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staxera company presentation
Jeremy Lawrence
Continuous improvement
Clear roadmap to increased power
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staxera company presentation
Jeremy Lawrence
Industrial customers
www.callux.net
1 kW microCHP
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staxera company presentation
Jeremy Lawrence
3 kW system demonstrator
Research and development customers
Biogas operation
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staxera company presentation
Propane system
Jeremy Lawrence
SOFC research
staxera R&D + production site
Future expansion with an additional 2000m2 factory
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staxera company presentation
Jeremy Lawrence
Manufacturing
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capacity today:
500 ISMs per year
future capacity with 2000m2 hall:
50.000 ISMs per year
staxera company presentation
Jeremy Lawrence
Testing
Four 30-cell stack test stations and six ISM test stations
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staxera company presentation
Jeremy Lawrence
Organization
Dr. Christian Wunderlich
Chief Executive Officer
Susanna Bastian
Corporate Planning
Susanne Kirst
Accounting
Jens Baade
Björn Erik Mai
Mario Heinrich
Jeremy Lawrence
Mario Heinrich
Infrastructure
Testing
R&D (provisional)
Business Development
Production
1x technician
3x engineers
3x scientists
2x engineers
2x technicians
2x engineers
5x technicians
Experienced & established management team
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staxera company presentation
Jeremy Lawrence
Key partners and suppliers
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staxera company presentation
Jeremy Lawrence
Products
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staxera company presentation
Jeremy Lawrence
Products and services
Standardized ISMs (1.1 & 1.4 kW)
Ready for delivery in 8 weeks
Customized ISMs
Tighter system integration
On-site support
Assistance with installation and testing
Fastest path to a SOFC system
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staxera company presentation
Jeremy Lawrence
Systems available from EBZ
3 kW system demonstrator
Available now
Steam reforming, natural gas
High efficiency
Clear path to 20 kW systems
staxera will develop 3 kW and 5 kW ISMs
staxera and EBZ are your partners for SOFC systems
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staxera company presentation
Jeremy Lawrence
ISM and stack performance
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staxera company presentation
Jeremy Lawrence
ISM power
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staxera company presentation
Jeremy Lawrence
Mk200 stack endurance
6.0
5.0
Degradation [%]
4.0
3.0
2.0
Current
Block 1
Block 2
Block 3
Block 4
Block 5
Block 6
Block 7
Block 8
Block 9
Block 10
0.0
-1.0
-2.0
2.4
Block voltage [V]
2.3
26
2.2
24
2.1
22
2.0
20
1.9
18
1.8
16
1.7
14
1.6
0
1000
2000
3000
4000
5000
6000
7000
Operating time [h]
20
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staxera company presentation
Jeremy Lawrence
8000
9000
10000
11000
12
12000
Current [A]
1.0
Mk200 stack thermal cycling
TC5
TC10
TC160
550
800
500
700
450
600
400
500
Stack power
Stack voltage
Core temperature
Current
350
300
Current [A]
400
300
250
200
200
100
...
150
0
40
40
35
35
30
30
25
25
20
20
15
15
10
10
5
0
160
180
200
220
240
260
280
300
320
340
360
380
400
Operating time [h]
21
900
staxera company presentation
Jeremy Lawrence
420
440
...
Temperature [°C]
TC 1
5
3740
3780
3820
0
3860
Stack voltage [V]
Stack power [W]
600
Mk200 stack – no leakage after 150 cycles
DP 1
28.05.2009
3.8
3.7
3.7
3.6
3.6
Spannung [V]
Spannung [V]
3.8
3.5
3.4
3.3
3.2
DP 94
16.08.2009
3.5
3.4
3.3
3.2
3.1
3.1
Beginn DP
3.0
186.2
Ende DP
186.3
186.4
186.5
186.6
Beginn DP
3.0
2112.1
186.7
Ende DP
2112.2
Betriebsdauer [h]
DP 120
21.09.2009
3.8
3.7
3.7
3.6
3.6
3.5
3.4
3.3
3.2
2112.6
DP 160
Block 1
Block 2
Block 3
Block 4
Block 5
Block 6
Block 7
Block 8
Block 9
Block 10
24.10.2009
3.5
3.4
3.3
3.1
Beginn DP
2960.8
Ende DP
2960.9
2961.0
2961.1
2961.2
Betriebsdauer [h]
22
2112.5
3.2
3.1
3.0
2960.7
2112.4
Betriebsdauer [h]
Spannung [V]
Spannung [V]
3.8
2112.3
staxera company presentation
Jeremy Lawrence
Beginn DP
2961.3
3.0
3767.4
3767.5
Ende DP
3767.6
3767.7
3767.8
Betriebsdauer [h]
3767.9
3768.0
ISM start time
1,5 h
585
900
800
45
Core temperature (MEA_1/2)
Temperature Cathode Inlet
Current
Air flow rate
520
40
455
preheater
heat up
temperature control
with air flow
500
25
400
20
time to
full load
325
260
300
15
195
200
10
130
100
5
65
0
0
0.5
1
1.5
Heating time [h]
23
390
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staxera company presentation
Jeremy Lawrence
2
0
2.5
0
Air flow rate [Nl/
l/min]
Temperature [°
°C]
600
35
Current [A]
700
Thermal management
798.7
781.0
770.7
759.1
746.0
808.6
794.1
785.7
776.0
765.6
817.9
807.5
801.8
795.0
788.7
829.1
822.6
819.3
815.2
813.0
833.7
829.4
827.5
825.0
Plane 60
14
I [A]
13
12
826.3
811.2
802.1
791.1
779.8
843.5
834.7
829.4
822.7
817.0
860.8
858.1
856.8
854.2
854.1
848.9
846.9
845.8
844.0
844.9
Plane 45
11
10
9
801.8
785.4
775.8
764.5
751.3
818.8
806.9
799.9
791.3
781.7
834.6
827.0
822.6
816.9
811.0
846.0
842.3
840.3
837.3
835.8
846.1
844.1
843.1
841.2
841.3
20-30 A
Air
Air
Cell group
Plane 31
8
7
6
5
4
840.8
832.2
826.8
819.2
808.5
858.0
855.0
852.9
849.0
844.0
860.0
860.3
860.5
859.5
857.8
860.0
861.6
862.2
865.3
Plane 15
3
2
789.3
780.1
775.2
768.1
760.9
806.8
800.5
797.1
792.6
786.8
822.6
818.9
816.9
813.8
810.2
822.0
820.0
819.0
817.0
815.8
822.1
820.9
820.4
818.8
818.5
1
Plane 1
0.5
0.6
0.7
Voltage [V]
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staxera company presentation
Jeremy Lawrence
0.8
Challenge of thermomechanics
53.7 MPa
Single plane from stack
measured temperature distribution
FEA model
free floating cell
σ1 principal stress
free floating cell
Temperature gradients can lead to cell fracture
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staxera company presentation
Jeremy Lawrence
3 kW system demonstrator
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staxera company presentation
Jeremy Lawrence
3 kW system demonstrator
Cooperation with EBZ
www.ebz-dresden.de
Steam reforming, natural gas
High efficiency (target > 50% at 20 kW)
Stationary electricity generation (or CHP)
Multiple ISMs in one system
Modularity, quality, costs
First step on the path to 20 kW sysems
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staxera company presentation
Jeremy Lawrence
Typical operating point
Total stack power 1900 Wel (two ISMs)
U
40,4 V
Fuel -> Reformer
6,6 l/min
I
23,5 A
Air flow
254 l/min
Fuel -> Afterburner
0,5 l/min
S/C
2,7
Fuel utiliz.
74 %
T Reformer
657 °C
Air utiliz.
18 %
Tmax stack
856 °C
Umin ISM 1
3,20 V (Block 1)
Tmin stack
720 °C
Umin ISM 2
3,28 V (Block 1)
T exhaust
124 °C
Very similar performance from both ISMs
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staxera company presentation
Jeremy Lawrence
Test summary
> 3.000 hours operation
Stable performance
15 thermal cycles
Robust and durable SOFC stacks
Multiple ISMs in one system
Each ISM can be stably controlled
Further information available from www.ebz-dresden.de
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staxera company presentation
Jeremy Lawrence
Product quality, manufacturing cost
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staxera company presentation
Jeremy Lawrence
Stack manufacturing
High yield rate > 90% even with manual assembly processes
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staxera company presentation
Jeremy Lawrence
Cost challenge
500 €/kW can be achieved
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staxera company presentation
Jeremy Lawrence
Summary
staxera is a supplier of SOFC integrated stack modules
Products are focused on industrial customers
Demonstrated continuous improvement since market entry in 2006
Complete 3 kW systems are available from our partner EBZ
Robustness and endurance are key performance differentiators
Thermomechanics is the key design challenge for lightweight stacks
10.000 hours endurance life and 150 cycles demonstrated
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staxera company presentation
Jeremy Lawrence
Thank you for your attention