Senior Flexonics have developed a production-ready CAPH using AluChrom 318, which gives robustness, cost effectiveness and industry leading low levels of Cr leakage. Senior Flexonics have also invested in equipment and tooling for process efficiency – manufacturing of the CAPH using new processes proves that the cycle time is reduced by over two thirds. Senior Flexonics overcame manufacturing challenges presented by using AluChrom, including significantly modifying the form of the gas plate and improving laser welding consistency and quality. The new production equipment has been transferred, installed and recommissioned at their manufacturing facility in Czechia, with trials completed, ready for low-volume production.
Sunfire have proven printed glass seals as the best-value method for industrial production of fuel cell stacks, developed production processes and achieved process automation levels supported by a cost-benefit analysis. Sunfire have also undertaken intensive testing, including full units that integrate the new CAPH and optimised fuel cell stack, with performance tests showing these technologies are ready for use in series production.
UBHAM designed and used a Denuder technique to quantitatively analyse the chromium vaporisation from Inconel 625 and AluChrom 318. Cr evaporation rate for AluChrom 318 is approx. one order of magnitude lower than for Inconel 625. Their extensive materials research generated a number of key results, including: (i) low cost, low Cr evaporation and excellent high temperature corrosion resistance make AluChrom 318 highly suitable for CAPH application, (ii) AluChrom has improved Cr leakage rates when compared to all other materials after just 150 hours, (ii) AluChrom surface reduces Cr oxide content and increases Alumina thus offering a more robust surface material. UBHAM also investigated pre-heat treatment for material optimisation and found the best corrosion resistance was for samples pre-treated at 1100°C for 1 hour.
ICI Caldaie integrated the heat exchanger prototypes into their test rig and adapted it to test in the widest range of conditions possible and improve the quality of data collected. ICI Caldaie’s testing proves the Senior Flexonics CAPH performance levels and demonstrates their potential for other (larger) domestic/commercial CHP applications.
Field testing undertaken by Vaillant also generated positive results for HEATSTACK in terms of system performance and lifespan.
The exploitation of project outputs is supported by a techno-economic assessment including life cycle analysis, full business plan and exploitation strategy. Dissemination of project results includes featuring at the 2019 Bruges Workshop Series on Fuel Cell Systems, promotion at the Hannover Messe exhibition (2019, 2018), presentation at Fuel Cell and Hydrogen Joint Undertaking’s flagship event in 2018, and sponsoring the Joint European Summer School Fuel Cell, Electrolyser, and Battery Technologies. External publications include a blogpost and webinar, as well as via the project’s own website, social media and brochures.
