Manufacturing Cost Analyses Of Fuel Cell Systems For .
BattelleVince ContiniFritz EubanksMike HeinrichsManoj ValluriMike JansenPaul GeorgeMahan MansouriManufacturing Cost Analyses of Fuel Cell Systems forPrimary Power and Combined Heat and Power Applications3/31/20171
Outline ApproachDesign BasisRepresentative SystemsPEM System Costs BOP Stack Total SOFC System Costs BOP Stack Total Sensitivity Analysis Summary/Conclusions2
Approach – Manufacturing Cost Analysis MethodologyMarketAssessment Characterization ofpotential markets Identification ofoperational andperformancerequirements Evaluation of fuel celltechnologies relativeto requirements Selection of specificsystems for costmodeling3System DesignCost Modeling Conduct literaturesearch Develop systemdesign Gather industry input Size components Gather stakeholderinput Refine design Develop bill ofmaterials (BOM) Definemanufacturingprocesses Estimate equipmentrequirements Gather vendorquotes Define material costs Estimate capitalexpenditures Determineoutsourcedcomponent costs Estimate systemassembly Develop preliminarycosts Gather stakeholderinput Refine models andupdate costsSensitivity & LifeCycle CostAnalysis Sensitivity analysisof individual costcontributors Life cycle costanalysis to estimatetotal cost ofownership
Primary Power/CHP Nominal Design BasisMetric/FeatureInput, FuelInput, AirInput, OtherOutputNet Power OutputSystem Efficiency (electrical)LTPEMSOFCSystem Efficiency OverallLTPEMSOFCSystem LifeSystem Maintenance Interval(filter change: sulfur trap, air filter, fuel filter)Grid ConnectionOperate off-gridStart off-gridObjectiveUtility Natural Gas or Propane( 30 psig preferred)Ambient air (-20 to 50 C)N/A120/240 VAC480 VAC 3-phase optional1, 5, 10, 25, 100, 250 kW30%40%80%90%50,000 hours1 yearYes, local and/or utilityYes, critical load back-upNoMaterial presented here will concentrate on 25 and 250 kW systems4
Representative LTPEM CHP systemComplexsystem due toneed for fuelprocessing withH2 cleanup –requiringmultiple heatexchangers5
Representative SOFC CHP systemSOFC system isless complexthan the PEMsystem due tosimpler fuelprocessor andless neededheatexchangers6
25-kW CHP PEM BOP Cost25 kWBoP Components100 Units( /each)1000 Units( /each)10,000 Units( /each)50,000 Units( /each)Fuel Supply 1,782 646 553 508Water Supply 2,267 2,083 1,495 1,164Fuel Processing 19,140 14,355 11,813 10,537Air Supply (Combustion) 1,311 1,550 4,198 11,150 10,638 1,198 1,270 3,109 10,321 7,900 1,106 1,098 2,715 9,555 7,283 1,069 1,045 2,545 8,899 6,970Instrumentation and Control 3,068 2,762 2,495 2,357Assembly Components 2,019 1,836 1,652 1,485Additional Work Estimate 4,300 3,400 2,900 2,700BOP Total 61,423 48,879 42,665 39,279Air Supply (Cathode)Heat RecoveryAC PowerDC Power7BOP hasseveralsignificantcontributors,particularly forthe PEMsystems – mostnotably, the fuelprocessing andAC & DC Power
25-kW CHP PEM BOP Cost DistributionBOP has several significant contributors, particularly for the PEM systems– most notably, the fuel processing and AC & DC Power – a hybrid 3-portDC/AC inverter has potential to lower cost of power equipment8
250-kW CHP PEM BOP Cost250 kWBOP Components100 Units( /each)1,000 Units( /each)10,000 Units( /each)50,000 Units( /each)Fuel Supply 14,879 12,452 11,166 10,358Water Supply 3,340 3,144 3,023 2,915Fuel Processing 94,462 79,221 70,458 66,491Air Supply 17,254 15,851 14,473 13,607Heat Recovery 56,215 51,218 46,680 44,665Power Electronics 114,436 91,898 72,617 59,454Instrumentation and Control 2,622 2,340 2,108 2,055Assembly Components 22,540 20,490 18,440 16,600Additional Work Estimate 24,300 22,100 19,900 17,900 350,048 298,714 258,865 234,045BOP TotalBOP has several significant contributors– most notably, AC & DCPower – fuel processing is less significant than for PEM systems9
250-kW CHP PEM BOP Cost DistributionBOP has several significant contributors, particularly for the PEM systems– most notably, the fuel processing and AC & DC Power – a hybrid 3-portDC/AC inverter has potential to lower cost of power equipment10
25-kW CHP PEM Stack Manufacturing Cost25 kW SystemStack Components100Units 10,2881,000Units 5,26610,000Units 3,62450,000Units 3,515 508 304 240 238Cathode GasketAnode Bipolar Plate 179 1,986 81 1,229 65 1,065 65 1,064Cathode Bipolar Plate 1,905 1,148 983 983 111 94 158 58 88 126 53 82 123 35 78 123Test and conditioning 1,445 227 120 116TotalCost per kWnet 16,674 667 8,527 341 6,354 254 6,217 249MEAAnode / Cooling GasketEnd platesAssembly hardwareAssembly laborThe catalyst, membrane and gas diffusion layer (GDL) all contribute to makethe membrane electrode assembly (MEA) the largest contributor to stack cost11
25-kW CHP PEM Fuel Cell Stack Volume Trend 18,000 16,000 14,000 12,000 10,000 8,000 6,000 4,000 2,000 025 kW System PEM Stack Cost1001,00010,000Stacks per yearMaterialLaborMachineScrapTooling50,000Material cost is the highest contributor at all production levels12
25-kW CHP PEM Fuel Cell System Cost Summary100Units1,000Units10,000Units50,000Units 16,674 8,527 6,354 6,217 567 101 65 64CHP Hardware 22,817 18,890 17,356 16,329FC BOP Hardware 38,606 29,990 25,309 22,950DescriptionTotal stack manufacturing cost, with scrapStack manufacturing capital costSystem assembly, test, and conditioningTotal system cost, pre-markup 1,558 365 293 293 80,221 57,873 49,378 45,852System cost per net KW, pre-markup 3,209 2,315 1,975 1,83450%50%50%50% 120,332 86,809 74,067 68,779 4,813 3,472 2,963 2,751Sales markupTotal system cost, with markupSystem cost per net KW, with markupBOP dominates system cost for all capacities and volumesexamined13
25-kW PEM System Cost - Volume Trend 57,873 49,37814BOPcontribution tocost is evenmore substantialas productionvolumeincreases
250-kW CHP PEM Fuel Cell System Cost 000UnitsTotal stack manufacturing cost, with scrapFuel, Water, and Air Supply Components 70,197 52,589 50,432 50,009 35,472 31,447 28,662 26,881Fuel Processor Components 94,462 79,221 70,458 66,491Heat Recovery Components 56,215 51,218 46,680 44,665Power Electronic, Control, and Instrumentation Components 117,058 94,238 74,725 61,509Assembly Components and Additional Work Estimate 46,840 42,590 38,340 34,500 420,245 351,303 309,297 284,054 1,681 1,405 1,237 1,13650%50%50%50% 630,367 526,954 463,945 426,081 2,521 2,108 1,856 1,704Total system cost, pre-markupSystem cost per net KW, pre-markupSales markupTotal system cost, with markupSystem cost per net KW, with markupBOP dominates system cost for all capacities and volumesexamined15
250-kW CHP PEM Fuel Cell System CostDistribution (1,000 units per year)AssemblyComponents andAdditional WorkEstimate12.1%250 kW PEM Systems1,000 Units/YearTotal StackManufacturing15.0%Fuel, Water, andAir SupplyComponents9.0%Power Electronic,Control, andInstrumentationComponents26.8%Heat RecoveryComponents14.6%16Fuel ProcessorComponents22.6%
Representative SOFC CHP systemSOFC system isless complexthan the PEMsystem due tosimpler fuelprocessor andless neededheatexchangers17
25-kW CHP SOFC BoP Cost25 kWBoP Components100 Units( /each)1000 Units( /each)10,000 Units( /each)50,000 Units( /each)Fuel Supply 1,782 646 553 508Fuel Processing 3,686 2,531 1,933 1,847Start-up Air Supply(CPOX) 1,094 1,004 931 899 816 735 661 641Heat Recovery 2,376 1,881 1,618 1,532AC Power 11,150 10,321 9,555 8,898DC Power 10,638 7,900 7,283 6,970Instrumentation andControl 2,993 2,346 2,123 2,006Assembly Components 1,047 951 854 770Additional Work Estimate 2,100 1,700 1,500 1,400BOP Total 37,682 30,014 27,011 25,471Cathode Air18BOP has severalsignificantcontributors–most notably, AC& DC Power –fuel processingis lesssignificant thanfor PEM systems
25-kW SOFC BOP Cost DistributionAC & DC Power contribute even more significantly than for the PEM systemas other costs are lower – a hybrid 3-port DC/AC inverter has potential tolower cost of power equipment19
250-kW CHP SOFC BOP Cost250 kWBOP Components100 Units( /each)1,000 Units( /each)10,000 Units( /each)50,000 Units( /each)Fuel Supply 7,953 6,093 5,372 4,815Fuel Processing 14,347 9,797 8,604 8,253Air Supply 10,345 9,607 8,937 8,741Heat Recovery 33,857 31,718 29,718 28,470Power Electronics 114,436 91,898 72,617 59,454Instrumentation andControl 3,526 3,152 2,836 2,763Assembly Components 7,710 7,010 6,310 5,680Additional Work Estimate 11,400 10,400 9,400 8,500 203,575 169,675 143,793 126,677BOP Total20BOP has severalsignificantcontributors–most notably, AC& DC Power –fuel processingis lesssignificant thanfor PEM systems
250-kW SOFC BOP Cost DistributionBOP has several significant contributors, particularly for the PEM systems– most notably AC & DC Power and heat recovery – the hybrid 3-portDC/AC inverter lowers cost of power equipment, but it is still significant21
SOFC Stack Manufacturing Cost – 25kW System25 kW SystemStack Components100 Units ( /each)1,000 Units ( /each)10,000 Units ( /each)50,000 Units ( /each) 4,828 1,109 434 365 180 380 212 1,444 3,890 822 229 266 98 2,589 16,848 674 3,395 870 370 275 121 286 135 168 655 720 214 212 81 856 8,358 334 2,766 495 363 191 115 199 128 112 401 644 200 207 67 668 6,555 262 2,650 444 357 189 111 196 123 112 373 643 191 206 50 656 6,302 252Ceramic CellsInterconnectsAnode FrameAnode MeshCathode FrameCathode MeshPicture FrameLaser WeldGlass Ceramic SealingEnd PlatesAssembly HardwareAssembly LaborStack BrazingTest and ConditioningTotal CostCost per kWnetAll costs include manufacturing scrap22Machineutilization leadsto significantcost reductionsfor processingsteps such aslaser weld andsealing whileceramic cellsremain high dueto machine time(kiln firingprocess andscreen printing)
SOFC Fuel Cell Stack Volume Trend 18,000 16,000 14,000 12,000 10,000 8,000 6,000 4,000 2,000 025 kW SOFC Stack 50,000Stacks per yearCosts more evenly spread for SOFC Stacks between material, labor andmachine costs –with machine cost dominating at low volume23
25 kW CHP SOFC Fuel Cell System Cost Summary100 Units( /each)1000 Units( /each)10,000 Units( /each)50,000 Units( /each)Total stack manufacturing cost,with scrap 16,848 8,358 6,555 6,302Stack manufacturing capital cost 748 209 135 126CHP Hardware 23,134 19,433 17,939 16,939FC BOP Hardware 14,548 10,581 9,073 8,532System assembly, test, andconditioning 1,428 399 330 330Total system cost, pre-markupSystem cost per KWnet, premarkupSales Markup 56,706 38,980 34,032 32,229 2,268 1,559 1,361 1,28950%50%50%50%Total system price, with markupSystem price per KWnet, withmarkup 85,059 58,470 51,048 48,344 3,402 2,339 2,042 1,934BOP ComponentsBOP dominates system cost for all capacities and volumesexamined24
25 kW SOFC CHP System Cost - Volume Trend 39,980 34,03225BOPcontribution tocost is evenmore substantialas productionvolumeincreases
250-kW CHP SOFC Fuel Cell System Cost al stack manufacturing cost, with scrapFuel, Water, and Air Supply Components 87,497 70,430 66,665 66,327 18,298 15,700 14,309 13,556Fuel Processor Components 14,347 9,797 8,604 8,253Heat Recovery Components 33,857 31,718 29,718 28,470Power Electronic, Control, and Instrumentation Components 117,962 95,050 75,453 62,217Assembly Components and Additional Work Estimate 19,110 17,410 15,710 14,180 291,072 240,105 210,458 193,004 1,164 960 842 77250%50%50%50% 436,608 360,157 315,686 289,505 1,746 1,441 1,263 1,158DescriptionTotal system cost, pre-markupSystem cost per net KW, pre-markupSales markupTotal system cost, with markupSystem cost per net KW, with markupBOP dominates system cost for all capacities and volumes examined26
CHP Fuel Cell System Cost ComparisonFor both technologies, BOP (including CHP hardware)dominates – more significant for the PEM systems27
250-kW PEM and SOFC system costs at 1,000units per year28
Sensitivity Analysis: 100-kW PEM Systems29
Sensitivity Analysis: 100-kW SOFC Systems30
Summary BOP dominates system cost Within BOP, hardware directly related to connecting to the grid representsmajor portion of cost for both PEM and SOFC systems Recently developed hybrid inverters eliminate need for separate DC/DCConverter – though power electronics still represent the highest cost systemcomponent Heat exchangers, particularly high temperature, also represent a major portionof the BOP Attractive value proposition shown for locations where electricity prices are highand natural gas prices low For greater detail on these studies, please refer to the reports posted on theDOE EREE website.31
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Backup Slides33
Seven-tube 250-kW reformer configuration andthree-tube 100-kW reformer configurationØ102mm34Ø318mm
CHP PEM Fuel Cell System Cost ComparisonPEM System Cost per kWnet 25,000System Cost /kW net 20,000100 Units/Year1,000 Units/year10,000 Units/Year50,000 Units/Year 15,000 10,000 5,000 01 kW PEM System 5 kW PEM System 10 kW PEM System25 kW PEM System35
CHP SOFC Fuel Cell System Cost ComparisonSOFC System Cost per kWnetSystem Cost /kWnet 25,000100 ts/Year 20,000 15,000 10,000 5,000 01kW SOFCSystem365kW SOFCSystem10kW SOFC 25kW SOFCSystemSystem
PEM Fuel Cell Design ParametersParameterPower Density (W/cm2)Current Density (A/cm2)Cell Voltage (VDC)Active Area Per Cell (cm2)Net Power (kW)Gross Power (kW)Number of Cells (#)Full Load Stack Voltage (VDC)Membrane Base MaterialCatalyst LoadingCatalyst Application5 kW10 kW25 kW0.270.40.68200151.26221101575PFSA, 0.2mm thick, PTFE reinforced0.4 mg Pt/cm2 (total)4001012110752530276188Cathode is 2:1 relative to AnodeCatalyst ink prepared, slot die coating deposition, heatdried, decal transferGas diffusion layer (GDL) BaseMaterialCarbon paper 0.2 mm thickGDL ConstructionCarbon paper dip-coated with PTFE for watermanagementMembrane electrode assembly (MEA)ConstructionSealsStack AssemblyBipolar PlatesEnd Plates371 kWHot press and die cut1 mm silicone, infection moldedHand assembled, tie rodsGraphite composite, compression moldedDie cast and machined A356 aluminum
SOFC Fuel Cell Design ParametersParameterCell Power Density (W/cm2)Cell Current Density (A/cm2)Cell Voltage (VDC)Active Area Per Cell (cm2)Rated Net Power (kW, continuous)Rated Gross Power (kW, continuous)Number of Cells (#)Open Circuit Voltage (VDC)Full Load Stack Voltage (VDC)Cell DesignAnode MaterialAnode ApplicationAnode Active Layer MaterialAnode Active Layer ApplicationAnode Contact Layer MaterialAnode Contact Layer ApplicationElectrolyte MaterialElectrolyte Application381 kW5 kW10 575Planar, Anode supportedNi-8YSZ, 250 µm thickTape cast, kiln fireNI-YSZ, 15 µm thickScreen Print, kiln fireNI-YSZ, 10 µm thickScreen Print, kiln fire8YSZ, 8 µm thickScreen print, kiln fire25kW4002530268295188
SOFC Fuel Cell Design ParametersParameterCathode Active Layer MaterialCathode Active Layer ApplicationCathode MaterialCathode ApplicationCathode Contact Layer MaterialCathode Contact Layer ApplicationSealsStack AssemblyInterconnectsEnd Plates39YSZ/LSM, 5µm thickScreen Print, kiln fireLSCF, 30 µm thickScreen Print, kiln fireLSM/YSZ, 10 µm thickScreen Print, kiln fireWet application bonded glass/ceramicHand Assembled, tie rods, furnace brazedFerritic Stainless Steel (SS-441) withPerovskite coating, 2-3 µm thickDie Cast and Machined A560 Steel
Primary Power/CHP Electrical System SchematicSystem Control and InterlocksNatural/PropaneGas ReformerDC24 or 48 VDCACDCBatteryManagementBatteries24 or 48 VDCnominal40DCDC BOP loads(if used)AC BOP loads(if used)MainDisconnect/lockout120 VAC, 240 VAC240/480 VAC 3-phasedepending onapplicationFuel CellStackVoltageOn-site AC LoadGrid Interconnectionand Transfer Switch
Life Cycle Cost Analysis Assumptions – Restaurant in Southern California41
Life Cycle Cost Analysis – 25kW SystemSignificantannual savingson utilities forSan Diegorestaurant dueto highelectricity costs42
Life Cycle Cost Analysis – 25kW SystemEven with highcost of naturalgas in Hawaii,still significantsavingsresulting fromCHP system isheat load issubstantial43
Life Cycle Cost Analysis – 25kW SystemPEM systemsbenefit evenmore fromshutting downwhen therestaurant is notopen forbusiness44
Life Cycle Cost AnalysisPEM – 1,000 units/yearCost of SystemInstallation CostAnnual Cost of Capital(10%)Annual ConsumablesAnnual O & M CostsAnnual ElectricityUtility CostAnnual Gas Utility CostAnnual TotalAnnual SavingsPEM – 10,000 units/yearCost of SystemInstallation CostAnnual Cost of Capital(10%)Annual ConsumablesAnnual O & M CostsAnnual ElectricityUtility CostAnnual Gas Utility CostAnnual TotalAnnual SavingsFuel Cell 86,809 10,000 24,683 1,252 750 96,028 32,373 155,087Utilities OnlyN/AN/AN/AN/AN/A 143,226 22,184 165,410Utilities OnlyN/AN/A 21,434N/A791.15 750N/AN/AInstallation CostAnnual Cost of Capital(10%)Annual ConsumablesAnnual O & M CostsAnnual Electricity UtilityCostAnnual Gas Utility CostAnnual TotalSOFC – 10,000 units/yearCost of SystemInstallation CostFuel Cell 58,470 10,000 32,373 151,377 22,184 165,410Annual ElectricityUtility CostAnnual Gas Utility CostAnnual Total 17,457N/A 521 750N/AN/A 135,427 31,663 146,420 18,990 26,290 161,717Fuel Cell 51,048 10,000Annual O & M Costs 143,226Utilities OnlyN/AN/A 96,028Annual Cost of Capital(10%)Annual Consumables 96,028 14,033Cost of SystemAnnual Savings 10,323Fuel Cell 74,067 10,000SOFC – 1,000 units/yearUtilities OnlyN/AN/A 15,586N/A 460 750N/AN/A 96,028 135,427 31,663 144,487 26,290 161,717Annual Savings 20,922Annual savings after all costs are taken into consideration*Annual cost comparison when using CHP system in San Diego Restaurantwith a Production Volume of 1,000 or 10,000 Units per Year45
Life Cycle Cost AnalysisFavorable payback period and return on investment –but does require significant production volumes*Cumulative cash flows for PEM and SOFC systems with productionvolumes of 1,000 and 10,000 units/year in the San Diego store46
Cycle Cost Analysis Sensitivity analysis of individual cost contributors Life cycle cost analysis to estimate total cost of ownership 3 . Primary Power/CHP Nominal Design Basis . 227 . 120 . 116 . Total. 16,674 . 8,527 . 6,354 . 6,217 . Cost per kW. net. 667 . 341 . 254 . 249 . 11 .
Fuel transfer pump (35) is mounted on the back of unit injector hydraulic pump (1). The fuel transfer pump pushes pressurized fuel out of the outlet port and the fuel transfer pump draws new fuel into the inlet port. Fuel is drawn from fuel tank (12) and flows through two micron fuel filter (11) . Fuel flows from fuel filter (11) to the inlet .
5-6 FUEL SYSTEM AND THROTTLE BODY FUEL TANK LIFT-UP Remove the front seat. ( 7-4) Remove the fuel tank mounting bolts. Lift and support the fuel tank with its prop stay. FUEL TANK REMOVAL Lift and support the fuel tank with its prop stay. (L7above) Disconnect the fuel pump lead wire coupler 10. Pla
Fuel Pressure: Fuel Pressure Regulator and System Pressure. Fuel System: Pumps, Relays . significant volume of fuel may come out. Be ready to catch all the gas in the filter . The 3 main things to check in the fuel circuit are the fuel pump relay, and the 2 fuel pumps. 1. Fuel Injection Relay Test
ATJ/F-24 fuel blend appears to result in accelerated wear in fuel-lubricated rotary fuel injection pumps. At various fuel inlet temperatures, the use of maximum concentration CI/LI in a 30% ATJ/F-24 fuel blend appears to retard the accelerated wear observed in prior fuel -lubricated rotary fuel injection pump studies.
replacement cost after 25/30/35 kh LH 2 storage system cost propulsion system cost FCS cost TCO dominated by fuel cost: LNG option slightly cheaper than diesel and much cheaper than LH 2 LH 2 break-even cost at 57% efficiency: 2030 /ton LNG fuel cost factors per MMBTU basis: 4 NG, 5 liquefaction, 4 transport and bunkering LSMGO LNG LH 2-FC
fuel pressure to the fuel injection pump. The pressure regulator regulates the fuel at an absolute pressure of 150 kPa (22 psi) when the engine is at idle speed. The fuel injection pump increases the fuel to a maximum pressure of 200 MPa (2900 psi). The fuel injection pump delivers the fuel to the high-pressure manifold (Rail). The fuel .
The main difference between Carburetor and Fuel injection system {CarburetorzFuel is atomized by processes relying on the air speed greater than fuel speed at the fuel nozzle, zThe amount of fuel drawn into the engine depends upon the air velocity in the venturi {Fuel Injection SystemzThe fuel speed at the point of delivery is greater than the air speed to atomize the fuel.File Size: 2MB
the fuel pressure regulator, not the pump itself, to control pressure in the fuel rail. Any fuel not required by engine demand is diverted back to the fuel tank via the pressure regulator. Therefore, it’s impor-tant to remember that fuel pumps them-selves only supply fuel volume; they do not create pressure in the fuel lines.
