Periodic Reporting for period 2 - SO-FREE (Solid oxide fuel cell combined heat and power: Future-ready Energy)
Période du rapport: 2022-07-01 au 2023-12-31
Considering the prospected evolution of the gas network in Europe, and the fuel alternatives for residential-commercial-scale SOFC-CHP, likely fuel compositions for the midterm future can be rationally defined. Current gas grid infrastructure regulation relies a lot on safeguarding down-stream appliances (often combustion-based) in terms of the Wobbe Index and other parameters. Large-scale field demonstration projects have shown, however, that up to 20% H2 by volume will not impair most appliances currently connected to the gas grid. Above this limit, all down-stream appliances would have to be changed, therefore one may go directly to 100% H2. 20% H2 by volume is however a very small contribution in terms of energy and will not achieve significant CO2 reduction for equivalent energy transfer. It is important to evaluate which NG-H2 compositions can be viable all things considered, and in the meantime appliances that are fully fuel-flexible will guarantee a smooth transition to any finally to be established range of energy carriers.
The overall objective of SO-FREE is the development of a fully future-ready solid oxide fuel cell based system for combined heat and power generation. This means a versatile system concept for efficient, near-zeroemission, fuel-flexible and truly modular power and heat supply to end users in the residential, commercial, municipal and agricultural sectors.
Beyond the primary objective required by the call topic – i.e. the delivery of a pre-certified SOFC-CHP system allowing an operation window from zero to 100% H2 in natural gas and with additions of purified biogas – the project will endeavour the realization of a standardized stack-system interface, allowing full interchangeability of SOFC stack types within a given SOFC-CHP system. This interface design will be taken to the International Electrotechnical Commission as a New Work Item Proposal for international standardization. In such a way all commercial barriers to full and free competition between SOFC stack suppliers and system integrators aim to be levelled.
Furthermore, this interoperability will be proved by doubling the required demonstration period: two systems will be run for 9 months each, each operating, alternately, two different stacks, which will be exchanged between the two systems. One system will be operated to assess compliance with all applicable certification requirements of a TRL 6 prototype, defining the outstanding pathway to full product certification; the other system will run at TRL7 (demonstration in operational environment) providing combined heat and power with natural gas with injections of H2.
As a final proof of robustness and flexibility, the two stacks integrated in each of the two systems (differing in terms of component selection but based on a single optimised design, fruit of dialectic development between AVL and ICI) will be characteristic of the extreme ends of the spectrum of SOFC operating temperatures: 650°C (Elcogen) and 850°C (IKTS).
The overall objective of SO-FREE is the development of a fully future-ready solid oxide fuel cell based system for combined heat and power generation. This means a versatile system concept for efficient, near-zeroemission, fuel-flexible and truly modular power and heat supply to end users in the residential, commercial, municipal and agricultural sectors.
Beyond the primary objective required by the call topic – i.e. the delivery of a pre-certified SOFC-CHP system allowing an operation window from zero to 100% H2 in natural gas and with additions of purified biogas – the project will endeavour the realization of a standardized stack-system interface, allowing full interchangeability of SOFC stack types within a given SOFC-CHP system. This interface design will be taken to the International Electrotechnical Commission as a New Work Item Proposal for international standardization. In such a way all commercial barriers to full and free competition between SOFC stack suppliers and system integrators aim to be levelled.
Furthermore, this interoperability will be proved by doubling the required demonstration period: two systems will be run for 9 months each, each operating, alternately, two different stacks, which will be exchanged between the two systems. One system will be operated to assess compliance with all applicable certification requirements of a TRL 6 prototype, defining the outstanding pathway to full product certification; the other system will run at TRL7 (demonstration in operational environment) providing combined heat and power with natural gas with injections of H2.
As a final proof of robustness and flexibility, the two stacks integrated in each of the two systems (differing in terms of component selection but based on a single optimised design, fruit of dialectic development between AVL and ICI) will be characteristic of the extreme ends of the spectrum of SOFC operating temperatures: 650°C (Elcogen) and 850°C (IKTS).
In the first RP the basis of the design of the final systems is defined. This has comprised:
- an experimental campaign for performance characterisation of the 2 stack modules to be integrated in the system: the campaign is ongoing with a slight delay but seems to be confirming preliminary performance maps provided by stack suppliers
- first definition of a common stack module-system interface: in D2.3 a full description of the current interface is provided
- preliminary design of the first reference system in iterative loop with the activities of stack characterisation and stack module-system interface standardization: the design has been completed at P&ID level
- pre-assessment of the regulatory framework and of applicable directives and standards for certification of the SO-FREE system: D4.1 provides a first complete outline of relevant legal requirements and the application to the system components.
Furthermore, the visual identity and communication profile of SO-FREE has been professionally set up, with preparation of dissemination and communication materials. Also the Data management plan has been elaborated and is being compiled with inputs from the Partners as relevant data start to be generated.
- an experimental campaign for performance characterisation of the 2 stack modules to be integrated in the system: the campaign is ongoing with a slight delay but seems to be confirming preliminary performance maps provided by stack suppliers
- first definition of a common stack module-system interface: in D2.3 a full description of the current interface is provided
- preliminary design of the first reference system in iterative loop with the activities of stack characterisation and stack module-system interface standardization: the design has been completed at P&ID level
- pre-assessment of the regulatory framework and of applicable directives and standards for certification of the SO-FREE system: D4.1 provides a first complete outline of relevant legal requirements and the application to the system components.
Furthermore, the visual identity and communication profile of SO-FREE has been professionally set up, with preparation of dissemination and communication materials. Also the Data management plan has been elaborated and is being compiled with inputs from the Partners as relevant data start to be generated.
This project will bring forth a fuel cell system that is uniquely flexible in terms of fuel feed, maintaining the high electrical and overall efficiency of a SOFC-type solution. System design will be completely innovative, focusing on flexibility also in terms of the stack module that can be incorporated within it. These targeted advancements beyond the state-of-the-art are further backed by the objective of a complete pre-certification of the system, defining the path to market introduction, and the aim to enter the SO-FREE stack module-system interface into a procedure for international standardization.
Until the end of the project it is aimed to freeze the system design for the manufacture of 2 systems that will be shipped to 2 different locations for 2 different demonstration campaigns, also proving the feasibility of exchanging two stack types - of very different operating characteristics - between the 2 systems halway through the demonstration campaign.
Impacts:
Impact 1: Plug-and-play residential CHP systems adapted to the full range of SOFC stack technologies, leading to volume increase and cost reductions across the supply chain
Impact 2: Demonstration of long-term operation (>6000 h) at stack level with degradation rate below 1%/1000h in the operation window 0 to 20% and >67% H2 in natural gas, clean biogas and 100% H2, thus proving the tolerance of the SOFC systems to this range of fuels
Impact 3: Confirmation that flexi-fuel operation mode allows the lifetime and efficiencies targeted by the 2024 MAWP values to be reached, thus demonstrating that SOFC systems are fully H2 ready
Impact 4: Demonstrate that BoP components are compatible for this wide range of gas composition, by qualifying them for the 0 to 20% and >67% H2 in natural gas, clean biogas and 100% H2 fuel range and by integrating them in SOFC systems, maintaining CAPEX targeted by the 2024 MAWP values
Impact 5: Demonstrate the operation at system level in relevant environment, with an electrical efficiency >48% LHV for the defined operation window from 0 to 100% H2 in natural gas and clean biogas, a behaviour and a degradation rate similar to natural gas-fed SOFC systems, and with availability >90% over the operating duration (9 months minimum)
Impact 6: Decrease of CO2 emissions of SOFC by at least 40% during operation as compared to a standard natural gas fuel cell fed system and demonstrate that the primary energy reduction through cogeneration is available also to pure H2 networks
Impact 7: Strengthen the competitiveness of European fuel cell industry
Impact 8: Consolidation of background research results into competitive products
Impact 9: Recommendations for international standardisation of a stack module-system interface through a New Working Item Proposal and update of current standards
Impact 10: Making SOFC-CHP systems ready for increased H2 concentration in NG contributes to increase reliability and to provide flexibility to the energy system, allowing easier penetration of further RES power capacity.
Impact 11: Thanks to the standardised stack module-system interface European SOC industries could upscale manufacturing thus investing more in high-level job creation and market cultivation.
Until the end of the project it is aimed to freeze the system design for the manufacture of 2 systems that will be shipped to 2 different locations for 2 different demonstration campaigns, also proving the feasibility of exchanging two stack types - of very different operating characteristics - between the 2 systems halway through the demonstration campaign.
Impacts:
Impact 1: Plug-and-play residential CHP systems adapted to the full range of SOFC stack technologies, leading to volume increase and cost reductions across the supply chain
Impact 2: Demonstration of long-term operation (>6000 h) at stack level with degradation rate below 1%/1000h in the operation window 0 to 20% and >67% H2 in natural gas, clean biogas and 100% H2, thus proving the tolerance of the SOFC systems to this range of fuels
Impact 3: Confirmation that flexi-fuel operation mode allows the lifetime and efficiencies targeted by the 2024 MAWP values to be reached, thus demonstrating that SOFC systems are fully H2 ready
Impact 4: Demonstrate that BoP components are compatible for this wide range of gas composition, by qualifying them for the 0 to 20% and >67% H2 in natural gas, clean biogas and 100% H2 fuel range and by integrating them in SOFC systems, maintaining CAPEX targeted by the 2024 MAWP values
Impact 5: Demonstrate the operation at system level in relevant environment, with an electrical efficiency >48% LHV for the defined operation window from 0 to 100% H2 in natural gas and clean biogas, a behaviour and a degradation rate similar to natural gas-fed SOFC systems, and with availability >90% over the operating duration (9 months minimum)
Impact 6: Decrease of CO2 emissions of SOFC by at least 40% during operation as compared to a standard natural gas fuel cell fed system and demonstrate that the primary energy reduction through cogeneration is available also to pure H2 networks
Impact 7: Strengthen the competitiveness of European fuel cell industry
Impact 8: Consolidation of background research results into competitive products
Impact 9: Recommendations for international standardisation of a stack module-system interface through a New Working Item Proposal and update of current standards
Impact 10: Making SOFC-CHP systems ready for increased H2 concentration in NG contributes to increase reliability and to provide flexibility to the energy system, allowing easier penetration of further RES power capacity.
Impact 11: Thanks to the standardised stack module-system interface European SOC industries could upscale manufacturing thus investing more in high-level job creation and market cultivation.