Periodic Reporting for period 4 - RoRePower (Robust and Remote Power Supply)
Reporting period: 2022-10-01 to 2023-12-31
Fuel cells can play a major role in the energy market as a clean, highly efficient way to produce energy in decentralized power generation. Reliable fuel cell systems for continuous, off-grid energy supply open very promising export markets for the European fuel cell industry. The applications for this kind of fuel cell technology are characterized by key requirements such as low maintenance, long service life of components, capability of remote monitoring and reliable operation in critical applications like oil, gas, or safety infrastructure. In addition, they are able to cope with harsh climate conditions both in cold and hot regions. The overall objective of this project is to further develop and demonstrate solid oxide fuel cell (SOFC) systems for off-grid power generation in markets, such as the gas and oil infrastructure in remote regions with harsh climate conditions (from -40 to +50°C), and the power supply of telecommunication towers especially in emerging countries (e.g. telecom base stations or microwave transceivers). In addition, one objective was also to demonstrate 47 SOFC units in remote sites.
The project will develop and demonstrate the reliable operation of two different off-grid, remote power systems from three different manufacturers. The requirements of the generators are:
• Start-up and operation at -40°C to +50°C ambient temperature for natural gas
• High electrical efficiency (> 35%)
• Long term validation and demonstration in relevant environment to gain reliable data from field (> 24 months)
• High availability (98.5 %)
• Service and maintenance concept defined (Maintenance frequency 15 months)
• Meet the regionally different normative requirements with a modular design
• Increase the reproducibility of production stages of fuel cell systems in large quantities (> 90%)
• Training course for less educative personnel (two courses from each manufacturer)
• Service contract concept created for end-customer (one concept per manufacturer)
The project will develop and demonstrate the reliable operation of two different off-grid, remote power systems from three different manufacturers. The requirements of the generators are:
• Start-up and operation at -40°C to +50°C ambient temperature for natural gas
• High electrical efficiency (> 35%)
• Long term validation and demonstration in relevant environment to gain reliable data from field (> 24 months)
• High availability (98.5 %)
• Service and maintenance concept defined (Maintenance frequency 15 months)
• Meet the regionally different normative requirements with a modular design
• Increase the reproducibility of production stages of fuel cell systems in large quantities (> 90%)
• Training course for less educative personnel (two courses from each manufacturer)
• Service contract concept created for end-customer (one concept per manufacturer)
The RoRePower project aims at strengthening the European SOFC industry’s world-leading position for SOFC technology and exploit it in the robust remote power segment. 50 RoRePower units have been installed in relevant customer environment during the RoRePower project. Project fulfilled project target well in the case of in the number of installed units, but demonstration times were too short in many cases. Main reasons for delays were Ukraine war and COVID-19 because many already agreed installations could not make in time. In addition, original plan was that data will be received for project used from all the demo units to analyze the performance of the demo units and the technology in general level. However, data was reported only from 16 demo units. From rest of the units there was no possibility to get the data mainly due to confidentiality restrictions from the customers. However, it seems that high power supply security have been reached. In addition following progress have been achieved during the project:
• For strengthening the European value chain, industrial partners agreed on shared BOP components and performed an intensive market research for specific parts as well as shared BoP components for the extended climate requirements.
• To introduce SOFC technology to niche market, industrial partners have focused on the intensification of contacts with existing customers and the acquisition of new end users and use cases.
• For increasing trust of new customer by demonstrating technology in relevant field environment, RoRePower project has installed many Sunfire Fuel Cells Remote units a telecom application in USA.
• Providing improved energy efficient product compared to the incumbent technologies, the Sunfire-Remote 900 prototype could demonstrate an electrical efficiency of > 35 % and the smaller Sunfire-Remote 400 of more than 33 %.
• For strengthening the European value chain, industrial partners agreed on shared BOP components and performed an intensive market research for specific parts as well as shared BoP components for the extended climate requirements.
• To introduce SOFC technology to niche market, industrial partners have focused on the intensification of contacts with existing customers and the acquisition of new end users and use cases.
• For increasing trust of new customer by demonstrating technology in relevant field environment, RoRePower project has installed many Sunfire Fuel Cells Remote units a telecom application in USA.
• Providing improved energy efficient product compared to the incumbent technologies, the Sunfire-Remote 900 prototype could demonstrate an electrical efficiency of > 35 % and the smaller Sunfire-Remote 400 of more than 33 %.
50 SOFC remote units have been installed and demonstrated in end-customer sites and those units have been achieved almost all project targets, which indicates that progress in project has been good. In comparison with the state-of-the-art level 1) a significant reduction of TCO have been achieved by cost reduction of BOP component, stack, and its periphery. Also the common supply chain and joint procurement for system manufacturer in the case of generic component and spare parts have decreased the TCO remarkable amount, 2) harmful emissions (CO2, SOx, NOx, particulate matter), noise, vibrations, and the risk of soil contamination by liquid fuels have been reduced and 3) higher power supply security have been reached.
The expectation of the RoRePower consortium is a potential market of several hundred units per year in the oil and gas market and several thousand in the telecom sector. There are approximately 30 000 off-grid telecom towers worldwide and most of them are powered with diesel generators, which have to be replaced every 4 to 7 years. During the RoRePower project SOFC systems will be delivered to both the oil/gas and telecommunication sectors. The fuel cells provide increased electrical efficiency in those markets compared to the incumbent technologies. Fuel cells with higher electrical efficiency also offer reduced maintenance requirements. The overall total cost of electricity will be decreased with the RoRePower products already at relatively modest product volumes. In addition, with respect to the thermoelectric generators, an 80% CO2 emission decrease is expected. With respect to Diesel combustion engines, the change from Diesel to natural gas or LPG on its own provides a CO2 reduction 70% in the power range of the project (2 kWe). Compared to conventional diesel generators, the fuel cell systems have much less NOx, CO, and particle emissions, which increases the wellbeing of e.g. people working around them.
The expectation of the RoRePower consortium is a potential market of several hundred units per year in the oil and gas market and several thousand in the telecom sector. There are approximately 30 000 off-grid telecom towers worldwide and most of them are powered with diesel generators, which have to be replaced every 4 to 7 years. During the RoRePower project SOFC systems will be delivered to both the oil/gas and telecommunication sectors. The fuel cells provide increased electrical efficiency in those markets compared to the incumbent technologies. Fuel cells with higher electrical efficiency also offer reduced maintenance requirements. The overall total cost of electricity will be decreased with the RoRePower products already at relatively modest product volumes. In addition, with respect to the thermoelectric generators, an 80% CO2 emission decrease is expected. With respect to Diesel combustion engines, the change from Diesel to natural gas or LPG on its own provides a CO2 reduction 70% in the power range of the project (2 kWe). Compared to conventional diesel generators, the fuel cell systems have much less NOx, CO, and particle emissions, which increases the wellbeing of e.g. people working around them.