OVERVIEW
CONSULTING
PROJECTS
- Manufacturing Cost Modeling
- Product Development
- LabVIEW

CASE STUDIES

- Energy Storage
- Electric Vehicle
- Electrolyzer & Fuel Cell
- SOFC
- Hydrogen Storage
- Photovoltaic
- Appliance
- Stirling Engine
- Medical Device
 
 

Involved Presentations & Reports:

2015:

For an intermediate temperature SOFC stack developer, conducted manufacturing cost scenario analysis. The bottom-up manufacturing  cost model illustrated  the major cost drivers of the existing SOFC stack design. Value mapping visualized  all the hidden costs in the fabrication processes. The stack and system BOP components cost models were developed. The work was highly appreciated by the researchers.

2012:

For a novel thin film SOFC stack developer, conducted manufacturing cost scenario analysis. The bottom-up manufacturing  cost model illustrated  the major cost drivers of the existing SOFC stack design. Value mapping visualized  all the hidden costs in the fabrication processes. The lowest cost fabrication processes were developed. The work was highly appreciated by the researchers.

2011:

For Harvard University, developed a low temperature thin film SOFC stack manufacturing cost model. The cost analysis activity clearly showed the major cost drivers and cost reduction potentials of the existing SOFC stack design by value mapping the fabrication processes. The work was highly appreciated by the researchers.

2008:

For a commercial client, developed a SOFC metal interconnect manufacturing cost model. The analysis included the base metal and ceramic coating cost analysis. Cost comparison with other competing technologies showed the cost advantage of this metal interconnect. The cost analysis identified the major cost drivers of the technology and pointed out the potential cost reduction areas as well.

2005~2006:

For a NIST metal matrix composite interconnect development project, developed a multiple scenarios manufacturing cost model. The analysis helped the client select the low cost development pathway. The final cost analysis report also helped client to attract potential commercialization investment partners. The work was highly appreciated by the researchers.

2004:

Cost Model of SOFC Technology, 2004 (PDF)

Connecticut Global Fuel Cell Center, First International Conference on Fuel Cell Development and Deployment, 2004, Storrs, Connecticut

Solid Oxide Fuel Cell Manufacturing Cost Model: Simulating Relationships between Performance, Manufacturing, and Cost of Production, 2004  (PDF)

DOE Cooperative Agreement Number DE-FC26-02NT41568

Abstract: The successful commercialization of fuel cells will depend on the achievement of competitive system costs and efficiencies. System cost directly impacts the capital equipment component of cost of electricity (COE) and is a major contributor to the O&M component. The replacement costs for equipment (also heavily influenced by stack life) is generally a major contributor to O&M costs.  

In this project, we worked with the SECA industrial teams to estimate the impact of general manufacturing issues of interest using an activities-based cost model for anode-supported planar SOFC stacks with metallic interconnects.  An earlier model developed for NETL for anode supported planar SOFCs was enhanced by linkage to a performance/thermal/mechanical model, by addition of Quality Control steps to the process flow with specific characterization methods, and by assessment of economies of scale.  The 3-dimensional adiabatic performance model was used to calculate the average power density for the assumed geometry and operating conditions (i.e., inlet and exhaust temperatures, utilization, and fuel composition) based on publicly available polarization curves.

The SECA teams provided guidance on what manufacturing and design issues should be assessed in this Phase I demonstration of cost modeling capabilities. We considered the impact of the following parameters on yield of cost: layer thickness (i.e., anode, electrolyte, and cathode) on cost and stress levels, statistical nature of ceramic material failure on yield, and Quality Control steps and strategies.

In this demonstration of the capabilities of the linked model, only the active stack (i.e., anode, electrolyte, and cathode) and interconnect materials were included in the analysis. Factory costs are presented on an area and kilowatt basis to allow developers to extrapolate to their level of performance, stack design, materials, seal and system configurations, and internal corporate overheads and margin goals.

2003:

Manufacturing Model: Simulating Relationships Between Performance, Manufacturing, and Cost of Production, 2003 (PDF)

SECA Core Technology Program Workshop, Sacramento, California

Useful Links:

Solid State Energy Conversion Alliance (SECA)

http://www.netl.doe.gov/technologies/coalpower/fuelcells/seca/

Acumentrics

http://www.acumentrics.com/products-power-generators.htm

Cummins Power Generation

http://www.cumminspower.com/emea/about/environmental/fuelcells/

Delphi Automotive Systems

http://delphi.com/manufacturers/auto/fuelcells/

FuelCell Energy

http://www.fuelcellenergy.com/

General Electric Global Research

http://www.gepower.com/research/seca/sofc_research.htm

Siemens Power Generation

http://www.powergeneration.siemens.com/products-solutions-services/products-packages/fuel-cells/

Versa Power Systems

http://www.versa-power.com/company.htm

 

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