The D2Service project helped to significantly improve the current and the next fuel cell-based micro-CHP and back-up power systems of two major European manufacturers. Progress was made on several aspects of the systems beyond the state of the art: The layout of the micro-CHP system was redesigned with focus on easy access and exchange of all components, resulting in a significantly decreased service effort in terms of service time, system down time, costs, required training and error-proneness. Some tasks like exchanging the air filter have become so simple that they can be performed by the customers themselves after receiving a replacement filter by mail. Some more complex maintenance tasks can be performed by local, non-specialised technicians with the help of easily understandable manuals and simple service procedures. For this, guidelines to design easily understandable service manuals have been developed, which can serve as concept and inspiration for installation and service manuals for both micro-CHP and similar appliances that are not necessarily fuel cell-based.
The durability of some key components has been improved, thereby reducing service frequency and replacement costs. By a special coating, chromium evaporation of the cathode-side heat exchanger and a subsequent stack poisoning is prevented. For the desulphurisation of the natural gas, a catalyst material has been identified with a potential life time 60,000 hours, thus eliminating the need of exchanging the component altogether.
Remote control and monitoring is a powerful technology to reduce the service costs further by avoiding costly on-site service. For both micro-CHP and back-up power systems, remote monitoring systems have been improved within the project, allowing for remote failure detection and mitigation. For the back-up power systems improved in the project, specialised algorithms allow for the estimation of the remaining-of-life of the stack and life prolongation by remotely controlled air starvation.
Overall, the project developments significantly decrease operating costs and thereby help to spread the distribution of efficient fuel cell technology in and beyond Europe. Manufacturers, service providers and customers are all expected to benefit from this alternative for low-emission, efficient and decentralized energy production being more widely available and significantly easier and more inexpensive to install service and maintain.
