Manufacturing Model: Simulating SECA Core Technology TIAX LLC Acorn Park Program Workshop Relationships Between Cambridge, Massachusetts 02140-2390 Performance, Manufacturing, and Sacramento Cost of Production Reference: February 19-20, 2003 TIAX LLC -80034 DE-FC26-02NT41568
1 Technical Issues 2 R&D Objectives and Approach 3 Activities for Phase I 1
Technical Issues For commercial success, SOFC technologies must ultimately be manufacturable and cost competitive. A number of factors contribute to uncertainty at this time. � Cell design, stack designs, and production processes are still in early stages of development � SOFC stacks are radically different in structure from any currently mass- produced ceramic products � Relationships between cell and stack design, design tolerances, and stack performance are not very well established 2
Technical Issues Proposed manufacturing processes may be amenable to high-volume production, however, specific processes and sequences must be selected. Potential Process Flow for Planar Anode-Supported SOFC Multi- -Fired Process Flow Fired Process Flow Multi Process Flow Process Flow Multi-Fired Process Flow Process Flow Assumptions Assumptions Assumptions Interconnect Multi-Fired Progressive Paint Braze Shear � Electrical layer Rolling of onto Braze Process Interconnect � Electrical layer Interconnect Interconnect powders are made Illustrative powders are made by ball milling and by ball milling and calcining. calcining. Anode Electrolyte Cathode � Interconnects are � Interconnects are Electrolyte Cathode Anode made by metal Small Powder Small Powder made by metal Powder Prep Prep Prep forming forming Fabrication techniques. techniques. Vacuum � Automated Blanking / Sinter in Air QC Leak Screen Tape Cast Plasma Sinter in Air Finish Edges � Automated Slicing 1400C Check Print inspection of the Spray inspection of the electrical layers electrical layers occurs after occurs after Vacuum Screen sintering. Slip Cast Plasma sintering. Print Spray Slurry Slurry Spray Spray Stack Assembly Note: Alternative production processes appear in gray to the bottom of actual production processes assumed 3
Technical Issues Relationships between cell and stack design, design tolerances, stack performance, and process yields are not very well established. � Properties of individual layers, e.g., physical attributes, conductivity (electrical or ionic), polarization, transport, mechanical, are not well defined as a function of temperature � Manufacturing Options � Individual process steps � Sequence of steps � Impact on � Process yield, tolerances, and reproducibility � Performance � Thermal cycling and Life � Cost 4
Technical Issues Challenges A state-of-the-art SOFC manufacturing model will allow developers and NETL to minimize the uncertainties inherently associated with commercialization of a new technology. The model must be able to: � Handle all key SOFC stack components, including ceramic cells and interconnects � Relate manufactured cost to product quality and likely performance, taking into account � manufacturing tolerances � product yield � line speed � Address a range of manufacturing volumes, ranging from tens of MW to hundreds of MW per year � Adapt to individual production processes under development by SECA industrial teams 5
1 Technical Issues 2 R&D Objectives and Approach 3 Activities for Phase I 6
R&D Objectives and Approach Objectives The Manufacturing Model Project will develop a tool to provide guidance to the DOE and SECA development teams on system design and manufacturing processes selection. Phase I Phase 2 SOFC Manufacturing Model SOFC Manufacturing Framework and Model Expansion Demonstration and Use � Develop model � Expand Phase I model framework framework to other SOFC Objectives system designs, � Demonstrate benefit of alternative materials, and model for system manufacturing processes development trade-off analyses � Incorporate findings and research of SECA teams � Develop Phase 2 plan Deliverables � Model framework � Workshop with SECA stakeholders � Demonstration of model capabilities The primary output of the model will be an activity based manufacturing cost for various SOFC system scenarios. 7
Activities for Phase I Tasks Phase I will be conducted in three tasks. Task 1 Task 2 Task 3 Model Framework Model Reporting Development Demonstration � Develop architecture of � Revise existing model � Report project progress manufacturing model architecture based on � Prepare Phase I report Objectives Task 1 workshop � Review architecture that summarizes critical with SECA � Demonstrate manufacturing steps and stakeholders manufacturing model with performance parameters baseline SOFC system � Define Phase II development effort � Workshop with SECA � Workshop with SECA � Monthly updates stakeholders stakeholders � Phase I final report � Definition of model Deliverables framework, user interface with model, and critical issues to be assessed, model assumptions 8
Activities for Phase I Deliverables We anticipate that we will provide DOE and industrial teams with some key conclusions and recommendations: � Identification of critical manufacturing steps and performance parameters � if considerable uncertainty exists about these steps, specific additional SECA R&D objectives may be developed � Refinement of SECA technology cost and performance estimates � Definition of desirable next steps 9
Model Architecture Modeling Approach Link to Performance/Structural Module The cost model will be augmented with a SOFC performance model to help relate manufacturing quality to performance. User Interface SOFC Scenario Compiler Module Activity-Based Cost Performance Model Structural Module Databases 10
Model Architecture Modeling Approach Cost Model The model uses a set of databases to calculate cost for defined production (process flow) scenarios and performance assumptions. Inputs Outputs (Results) • Design • Tables • Performance • Graphs Parameters Calculation Engine (Activity-Based) • Crystal Ball • Manufacture – sensitivity • Process flow Processes and Flow – “frequency • Equipment options • Production Scenarios distribution” Material Material Capital Manufacturing Purchased Formulation Process Cost Properties Equipment Costs Components Database Database Database Database Database • Labor • Vendors • Density • Cost vs. • Anode • Equipment • Cost vs. • Real estate • Cost vs. • Particle size volume • Cathode process data product • Overhead volume distribution • Specifica- • Electrolyte • Throughput volume . . • Surface area tions • Interconnects • Size limit . . . . • Automation . . . . • Scrap . . • Yield The model description provides a unified framework for discussion of input parameters of interest to the Team members. 11
Model Architecture Performance/Structural Module Capabilities The module also accounts for all the relevant thermo-electrochemical phenomena which influence cell performance and, ultimately, cost. Interconnect • Heat conduction • Current conduction Flow passages Anode and cathode reaction zones • Heat convection • Electrochemical reactions • Plug flow of gas • Heat generation Anode and cathode porous electrodes Electrolyte • Heat conduction • Ion conduction • Current conduction • Heat conduction • Species diffusion • Internal reforming on anode 12
Model Architecture Performance/Structural Module Interface with Cost Model The performance/structural module is used to predict power density, thermal stresses, and other performance factors that influence cost. Performance/Structural Module Framework Electrochemical Chemical reactions reactions* Current Heat Heat Heat Boundary generation generation conduction convection conditions Stack/cell Temperature Compressive load geometry gradients on the cell # Stress Defects distribution Power Material density yield * Internal reforming reactions # Compressive load needed for establishing contact between different stack layers 13
1 Technical Issues 2 R&D Objectives and Approach 3 Activities for Phase I 14
Manufacturing Model Technical Issues We met with the SECA technical teams to discuss what relationships among cell and stack design, design tolerances, stack performance, and process yields should be considered in Phase 1? � Properties of individual layers � Thickness and other physical attributes � Polarization and conductivity (electrical or ionic) � Transport � Mechanical � Manufacturing Options � Individual process steps � Sequence of steps � Impact on � Process yield, tolerances, and reproducibility � Performance � Thermal cycling and life � Cost 15
Manufacturing Model Stack Design We discussed selection of a stack design for demonstration of the model capabilities and an initial assessment of the impact of selected manufacturing/design factors. � What planar stack configuration should be modeled in Phase I? � Rectangular or circular � Co-, counter-, or cross-flow � What design details (e.g., seals, manifolds, insulation) should be included in the Phase I modeling effort? � What size (kW) stack should we consider? 16
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