Niels Christiansen

Solid oxide fuel cell development at Topsoe Fuel Cell and Risø

The consortium of Topsoe Fuel Cell A/S and Riso National Laboratory has scaled up its production capacity of anode-supported cells to about 1100 per week. The consortium has an extended program to develop the SOFC technology all the way to a marketable product. Standard stacks have been tested for more than 13 000 h. Post-mortem analysis has revealed the dominating degradation mechanisms. Recently, the degradation rate has been reduced to below 0.5% per 1000 h by introduction of improved stack component materials, including improved metallic interconnects. Several 50- or 75-cell stacks in the 1 kWe and above power range have been tested successfully on methane-rich reformate gas at a fuel utilization up to 92%. Stack and system modeling – including cost optimization analysis – is used to develop 5–25 kWe stack modules for operation in the 700–850°C temperature range. A special effort is focused on manufacturing and testing of larger anode-supported cells and stacks with a footprint of 18 × 18 cm 2 . The SOFC program comprises the development of next-generation cells with metallic supports for operation at lower temperature with increased durability, lower cost, and high mechanical robustness. A range of fuels have been studied including natural gas, LPG, methanol, DME, diesel and ammonia. A multi-stack design study for a 24-stack module prototype has been finalized, and stack construction is under way for a 20 kWe prototype running on natural gas. The studies predict system electrical efficiencies from 50% to 56% (AC out/LHV fuel in) depending on the fuel used and the size of the system.

Solid oxide fuel cell development at Topsoe Fuel Cell A/S and Risø National Laboratory

The consortium of Topsoe Fuel Cell A/S and Risoe National Laboratory has up-scaled its production capacity. Stacks are based on a compact thin plate multilayer design with metallic interconnects and 12x12 cm{sup 2} or 18x18 cm{sup 2} foot print. Larger (500 cm{sup 2}) cells are currently under evaluation. Stacks have been tested successfully for more than 13000 hours. Several 50 or 75 cell stacks in the 1+ kW power range have been tested successfully at a fuel utilisation of up to 92%. Multi stack modules consisting of four 75 cell stacks have been tested for more than 4000 hours with pre-reformed natural gas and modules consisting of twelve stacks are under development. Our SOFC program comprises development of next generation cells with porous ferritic steel is used as a cheap, ductile, robust cell support and the electrolyte is based on scandia-doped zirconia with improved durability. In collaboration with Waertsilae, a 24-stack prototype based on natural gas is being tested. The range of fuels have further been extended to include ethanol and coal syn-gas by development of a new coke resistant catalyst suitable for future SOFC technology.

Solid Oxide Fuel Cell (SOFC) Development in Denmark

The SOFC technology under development at Risø National Laboratory (RISØ) and Topsoe Fuel Cell A/S (TOFC) is based on an integrated approach ranging from basic materials research on single component level over development of cell and stack manufacturing technology to system studies and modelling. The effort also comprises an extensive cell and stack testing program. Systems design, development and test is pursued by TOFC in collaboration with various partners. The standard cells are thin and robust with dimensions of 12 x 12 cm2 and cell stacks are based on internal manifolding. Production of cells is being up-scaled continuously. The durability of the standard stack design with standard cells has been tested for more than 13000 hours including nine full thermal cycles with an overall voltage degradation rate of about 1% per 1000 hours. Recently, the degradation rate has been significantly reduced by introduction of improved stack component materials. 75-cell stacks in the 1+ kW power range have been tested successfully. Stacks have been delivered in a pre-reduced state to partners and tested successfully in test systems with natural gas as fuel. The consortium of TOFC and RISØ has an extended program to develop the SOFC technology all the way to a marketable product. Stack and system modelling including cost optimisation analysis is used to develop multi kW stack modules for operation in the temperature range 700-850oC. To ensure the emergence of cost-competitive solutions, a special effort is focused on larger anode-supported cells as well as a new generation of SOFCs based on porous metal supports and new electrode and electrolyte materials. The SOFC program comprises development of next generation of cells and multi stack modules for operation at lower temperature with increased durability and mechanical robustness in order to ensure long-term competitiveness.

Status of Development and Manufacture of Solid Oxide Fuel Cell at Topsoe Fuel Cell A/S and Riso̸/DTU

and Risø/DTU DTU Orbit (01/04/2019) Status of Development and Manufacture of Solid Oxide Fuel Cell at Topsoe Fuel Cell A/S and Risø/DTU Fuel Cell (TOFC) provides the SOFC technology platform: Cells, stacks, and integrated stack module for different applications and collaborates with integrator partners to develop, test and demonstrate SOFC applications. The technology development is based on a R&D consortium with Risø National Laboratory (Risø/DTU) which includes material synthesis and cost effective ceramic manufacturing methods for anode and metal supported flat planar cells in addition to multilayer assembling for compact stacks with metallic interconnects. The development is focussing on high electrochemical performance and durability as well as maximal robustness. In 2008 TOFC has constructed a 5 MW/year cell and stack production facility in Denmark featuring all the necessary unit operations from ceramic powder, continuous tape casting, screen printing, spray painting and sintering to complete stack modules. TOFCs engagement in SOFC technology includes system development in collaboration with system partners and development and manufacturing of integrated stack assemblies called PowerCore. ©2009 COPYRIGHT ECS The Electrochemical Society

Solid Oxide Fuel Cells, Marketing Issues

Clean and sufficient energy is an important precondition for the continued growth in global wealth. Solutions must be found to utilize the remaining fossil fuels more efficiently and also to ensure that new environmentally friendly fuels can secure power production in the post-fossil fuel era. This is the essence of the global energy challenge.