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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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