Portable LPG-Fueled Microtubular Fuel Cell Dr. Sascha Kühn Hannover Messe 2013, Technical Forum, Hannover 10th of April 2013 Funded by the European Union and the Free State of Saxony
eZelleron GmbH - Copying prohibited!
Markets
Comparison
Portable and Mobile Applications
weight per time
Leistungsanforderung
25.03.2013
www.eZelleron.de
25.03.2013
www.eZelleron.de
APU range extender UAV
1000 W
LTEFunk
LEV Scooter
500 W
Emergency Power
Boats Cargobike
E-Bikes GSMFunk
Emergency -Kit
Camping Leisure
semistationär eZelleron GmbH - Copying prohibited!
mobil
portabel 25.03.2013
Mobilitätsgrad
www.eZelleron.de
eZelleron GmbH - Copying prohibited!
1
Energy storage
Mobile Markets 2017
Comparison
Power density, robustness, quick-start
Power Density (W/kg)
50 W, soldier power
Values based on: Pike Research Study, 2012
go::batt 375
attractivity
500 W, UAV go::batt 5000
200 W, millitary power
200 W, emergency power
go::batt 125
1 W, models
go::batt 5
Energy Density (Wh/kg)
50 W, emergency power
3.000 W, emergency power
500 W, emergency power
1 W, personal power
risc eZelleron GmbH - Copying prohibited!
www.eZelleron.de
25.03.2013
USPs
eZelleron GmbH - Copying prohibited!
www.eZelleron.de
25.03.2013
eZelleron GmbH The Company
- We can use available fuels (LPG) not only hydrogen - quick-startable for mobile applications - Extremely light-weight due to high power density - Cost efficient (materials choice, mass manufacturing methods)
Founded 12/2007, 22 Employees Strategic Partners: Upper Austria University (2 Project Staff) Fraunhofer IKTS (22 Project Staff) IP Big Portfolio of 13 worldwide Patent Familys (USA, Japan, Europe) Several receips, strategic documents and publications
Hall 27 B50
Pre-Seed-Capital: > 10 Mio. EUR Seed-Capital: 3,1 Mio. EUR Funded Project Volume: 7,5 Mio. EUR
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
eZelleron GmbH - Copying prohibited!
25.03.2013
Fraunhofer Campus, Dresden www.eZelleron.de
2
Outline
Fuel Cell – Technological Issues Power Density, Robustness, Quick-startability O2-
Cermet Anode Substrate Why Powder Injection Moulding? Mass-Manufacturing of Substrates Proprietary Binder System
eO2
Thin film technology for the Electrolyte Layer Electrophoretic Deposition (EPD) Stacking System
www.eZelleron.de
Ceramic Processing Methods
O2H+
ee-
O2-H
O2-
e-
Cathode polarisation resistance (ohmic, concentration) activation energy reaction area
O2
Electrolyte
H2
oxygen vacancy formation enthalpy
25.03.2013
Rough summary
ionic cond. metallic cond.
materials, temperature microstructure (TPB, percolation) internal ionic resistance
System development Stacking Hotbox System eZelleron GmbH - Copying prohibited!
ionic cond. mixed cond.
eZelleron GmbH - Copying prohibited!
+
H++ eeH
H2
Anode polarisation resistance (ohmic, concentration) activation energy reaction area electric conductivity materials, temperature particle size distr. microstructure (TPB, percolation)
25.03.2013
www.eZelleron.de
Binder system & Feedstock high requirements on accuracy
Material preparation/ Compounding
Complexity of the workpiece
Identification of suitable combinations of organic Adjuvants -
Uniaxial pressing
Hot Moulding
Wetting agents Disperser Plastisicer Binder Release agents Defoamer
Cold isostatic pressing
Mechanic, chemical und thermomechanic process engineering
Number of Units eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
3
Debindering Technologies Thermal
Solvent (eZelleron)
• quick • very quick • nearly no emissions • no emissions • binder recycling • lowest cost
Advantages Disadvantages
Katalytic
Bindersystem & Feedstock
• long process times • impossible for complex geometries • high poluting emissions
• dangerous reactants
eZelleron GmbH - Copying prohibited!
Material
Parameters
Density Binder
~0,9 g/cm3
Density Feedstock
~3 g/cm3
Powder Content
~80 gew-%
Processing Temperature
130-145 °C (SG)
Tool Temperture
~50 °C
Processing of Feedstocks
Debindering
Injection Pressure about 200 bar
Solution Debindering
Relative high Viskosity
Temperature: 60°C
High Green Density Good Demoulding Capacities
www.eZelleron.de
25.03.2013
eZelleron GmbH - Copying prohibited!
Cycle Times: 4 – 6 h Backbone Debindering at 1000°C
25.03.2013
www.eZelleron.de
Powder Injection Moulding
Scheer Extruder
Parameters
• • • •
Gap width Temperatures Roller speed Feeding speed • • • • • • •
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
viscosity speed temperatures (Tool, nozzle, cooling) pressure, after pressure geometries (nozzle, screw) clamping force materials (abrasion resistance)
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
4
Injection Moulding
Injection Moulding
Computertomography
Influence of CIM-Parameters
eZelleron GmbH - Copying prohibited!
www.eZelleron.de
25.03.2013
Gasdiffusion
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
Outline
Mercury-Porosimetry of Ni-Samples
4,0 3,0 2,0 1,0
50 47 % useable Porevolume
40 30 20
Cumulated specific Porevolume (%TD)
medium free waylenght H2, 700 °C
Relative Porevolume (%)
5,0
Cermet Anode Substrate Why Powder Injection Moulding? Mass-Manufacturing of Substrates Proprietary Binder System Thin film technology for the Electrolyte Layer Electrophoretic Deposition (EPD) Stacking System
10
0,0
System development Stacking Hotbox System
0 1
10
100
1000
10000
Pore Diameter (nm) eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
5
Fuel Cell – Technological Issues
How to reach the Goal?
Power Density, Robustness, Quick-startability
O2
eee-
O2
Electrolyte
H2
materials, temperature microstructure (TPB, percolation) internal ionic resistance oxygen vacancy formation enthalpy eZelleron GmbH - Copying prohibited!
O2H+ + O2-H
O2-
Cathode polarisation resistance (ohmic, concentration) activation energy reaction area
process development for the electrolyte
ionic cond. metallic cond.
H++ H
ee-
H2
Requirements
Goal
Power Density Robustness Quick-startability
Materials, temperature Thermomech. Stability High ionic conductivity
Anode polarisation resistance (ohmic, concentration) activation energy reaction area electric conductivity
Thin layer (no weibull behaviour, low resistance) Low grain size (mechanical stability, conductivity) Good adhesion (thermomechanical) Nanopowders Low sintering temperatures (high green densitys) Impregnation
materials, temperature particle size distr. microstructure (TPB, percolation)
Electrophoretic Impregnation Electrophoretic Deposition
www.eZelleron.de
25.03.2013
eZelleron GmbH - Copying prohibited!
Crystallite Size 27 nm
Electric current (A)
40 nm
www.eZelleron.de
25.03.2013
Correlation of Layer Thickness
YSZ: Habitus of the powder
Particle Size
Issues internal ionic resistance oxygen vacancy formation enthalpy
0,8
80
0,7
70
0,6
60
0,5
50
0,4
40
0,3
30
0,2
20
0,1
0,1 µm.
10
1150 °C, Basis, 24 V
0 0
20
40
60
80
100
Layer Thickness (µm)
O2e-
ionic cond. mixed cond.
0 120
Time (s) eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
6
Impregnated membrane 0 µm
70 µm
1 µm.
Green layer 100 µm
1 µm.
180 µm
1 µm.
1 µm.
5 µm.
30 µm.
eZelleron GmbH - Copying prohibited!
10 µm. www.eZelleron.de
25.03.2013
eZelleron GmbH - Copying prohibited!
25.03.2013
Resulting microstructure
Advanced Microstructure
EPD, sintered at 1250 °C
SEM
www.eZelleron.de
1 µm.
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
7
Microtubular Fuel Cells
Aufbau der eZelleron SOFC
Sintering – Mass-production
Prozessschritte
eZelleron GmbH - Copying prohibited!
www.eZelleron.de
25.03.2013
25.03.2013
Advantage: High Power-Density
Long term test
2008 Cell Generation (LSCF-Cathode)
750 h Test
• high power-densities • no up-scaling just numbering up • quick development cycles
1600 1400
www.eZelleron.de
active area: 3,7 cm² Fuel: 98 % H2, 2 % H2O, FU: 60 % Oxidant: Air, AU: 15 %
1200
P (mW/cm²)
eZelleron GmbH - Copying prohibited!
1000
P (mW/cm²) @ 0,7 V
800 600
active area: 3,7 cm² Fuel: 98 % H2, 2 % H2O, FU: 60 % Oxidant: Air, AU: 15 % Voltage: 0,7 V
400 200
One tube has 3,7 cm², that means > 5 W @ 850 °C
0 600
650
700
750
T (°C) eZelleron GmbH - Copying prohibited!
25.03.2013
800
850
900
www.eZelleron.de
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
8
Massproduction of Microtubues
Outline
Any quantity available.
• • • • •
Cermet Anode Substrate Why Powder Injection Moulding? Mass-Manufacturing of Substrates Proprietary Binder System
cheap compact (47 x 3 mm / 1,7 g) robust und quick-startable Very good cycleable Fueled by LPG (Propane/ Butane)
Thin film technology for the Electrolyte Layer Electrophoretic Deposition (EPD) Stacking System
System development Stacking Hotbox System 25.03.2013
www.eZelleron.de
eZelleron GmbH - Copying prohibited!
www.eZelleron.de
25.03.2013
Stack
Cell in Stack Environment
go::batt 125
Power losses 1,2
1,0
Voltage (V)
2,0
850 °C 800 °C 750 °C
1,8 1,6 1,4
0,8
1,2
0,6
1,0 0,8
0,4
0,6
0,2
0,4
active area: 3,7 cm² Fuel: 98 % H2, 2 % H2O, FU: 60 % Oxidant: Air, AU: 15 %
0,2
0,0
0,0 0,00
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
electrical power(W)
eZelleron GmbH - Copying prohibited!
0,50
1,00
1,50
2,00
Current (A) eZelleron GmbH - Copying prohibited!
25.03.2013
2,50
3,00 www.eZelleron.de
9
Cell in Stack Environment
Cell in Stack Environment
Fuel Utilisation 3,50
Thermocycling Capability
2,50
electrical power(mW/cm²)
3,00
Current (A)
600
0,6 V 0,7 V 0,8 V
2,00 1,50 1,00 0,50 0,00 0%
20%
40%
60%
80%
25.03.2013
400 300 200 100 0
100%
0
Fuel Utilisation FU eZelleron GmbH - Copying prohibited!
500
200
400
600
800
1000
cycle Nr. www.eZelleron.de
eZelleron GmbH - Copying prohibited!
25.03.2013
Stack
Stack
250 h -Test
Fully Automated Thermal Cycling
www.eZelleron.de
14 12 10
P (W)
8 6 4
Temp.: 850 °C Fuel: synth. Reformat Oxidant: Air, AU: 15 % Voltage: 0,7 V
2 0
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
10
Hotbox
Gasbattery
Fully integrated system
go::batt 125
eZelleron GmbH 25.03.2013
www.eZelleron.de
Gasbatteries
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
25.03.2013
www.eZelleron.de
Come to our Booth
eZell2
LPG - worldwide available! No precious metals! Up to 20 times lighter than Li-Ion-Batteries.
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
eZelleron GmbH - Copying prohibited!
11
Stack
Lightweight design 850 W, 1,7 kg 360 tubes, 2 g per tube 240,0
850 °C 800 °C 750 °C
20,0
200,0
12,0
120,0
8,0
80,0
4,0
40,0
Voltage (V)
160,0
0,0 0,00
5,00
10,00
15,00
70 mm
16,0
electrical power(W)
24,0
0,0 20,00
Current (A) eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
AR-200 AirCell
eZelleron GmbH - Copying prohibited!
www.eZelleron.de
25.03.2013
Comparison PEM, SOFC, eZelleron Feature
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
PEM
SOFC eZell
Efficiency above 50 % possible
Operates on Hydrocarbons (LPG,…)
No Water Management needed (OT > 100 °C)
No Outside and Storage Temp. Limitation
Easy Fuel Processing
Easy System Architecture
Useable Waste Heat Temp.
No Noble Metalls needed (Price)
Power density above 0,3 kW/kg
Very good ruggedness (vibrations, …)
Start-up time below 1 Minute
More than 100 Cycles
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
12
eZelleron
Cooperate with us!
Conclusion
• • • • • •
Feedstocks (mass production) Cells (mass Production) Stacks (small series production, customer made solutions) Hotbox (customer made solutions in the end of 2013) Gasbatteries (available in 2014 + customer made solutions) Individual hybrid systems (customer made solutions) Dr.-Ing. Sascha Kühn Managing Director / CTO
eZelleron GmbH Winterbergstr. 28 01277 Dresden · Germany tel.: +49 351 250 88 78 - 0 mob.: +49 176 13 93 55 - 10 fax: +49 351 250 88 78 - 9
[email protected] eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
eZelleron GmbH - Copying prohibited!
Funded by the European Union and the Free State of Saxony
25.03.2013
www.eZelleron.de
Copyright 2008-2011 eZelleron GmbH Alle Rechte vorbehalten
•
• • • •
•
Weitergabe und Vervielfältigung dieser Publikation oder von Teilen daraus sind, zu welchem Zweck und in welcher Form auch immer, ohne die ausdrückliche schriftliche Genehmigung durch die eZelleron GmbH nicht gestattet. In dieser Publikation enthaltene Informationen können ohne vorherige Ankündigung geändert werden. Die von der eZelleron GmbH oder deren Vertriebsfirmen angebotenen Produkte können Komponenten anderer Hersteller enthalten. iPhone und iPad sind Marken der Apple Inc. (Cupertino, Kalifornien, USA) SEGWAY ist eine Marke der Segway Inc. (Bedford, New Hampshire, USA) eZelleron, go::batt 5, go::batt 125, go::batt 375 und weitere im Text erwähnte eZelleron-Produkte und -Dienstleistungen sowie die entsprechenden Logos sind Marken oder eingetragene Marken der eZelleron GmbH in Deutschland und anderen Ländern weltweit. Alle anderen Namen von Produkten und Dienstleistungen sind Marken der jeweiligen Firmen
eZelleron GmbH - Copying prohibited!
25.03.2013
www.eZelleron.de
13
