Fuel Cell Research and Development
Development and Commercialization of 10 kW Solid Oxide Fuel Cell (SOFC) Power Systems
As a world leader in the design and manufacture of power generation equipment and technology, Cummins Power Generation is working today to develop fuel cell technology for tomorrow.
In the fall of 2001, the DOE awarded Cummins Power Generation a cost sharing contract to develop and commercialize a 10 kW Solid Oxide Fuel Cell system for a wide range of commercial applications.
Total DOE funding over the entire ten–year program will be $71 million. Versa Power Systems, Inc. will provide the core fuel cell stack and certain key high temperature components for the program. The cost share contribution from Cummins and our development partners will total up to $54 million over the life of the contract.
Cummins Power Generation was selected for the contract based on its market share leadership in power generation in Recreational Vehicles (RV’s), Commercial Mobile (e.g. utility boom trucks, fire trucks), and Telecom (remote or emergency power) markets, and its ability to bring the technology to the consumer.
The solid oxide fuel cell (SOFC) power system will provide virtually silent power with significantly lower fuel consumption and exhaust emission than existing generator sets. Additional benefits will include higher reliability and lower maintenance than required by today’s systems.
The program is working towards a clear goal of commercialization of SOFC technology, and the vision of a new family of power generation products demonstrating superior value for our customers. An engineering mock–up of the SOFC power system illustrates the team’s vision in the form of a new RV power plant.
Design work to date indicates the feasibility of packaging the SOFC power system on a platform consistent with our most advanced existing Diesel RV gensets, with the SOFC hot section occupying a space envelope comparable to the existing engine, generator, cooling system, muffler and noise reduction packaging.
The major subsections are packaged to provide effective thermal management. Controls and power electronics, including the 120VAC output inverter, are integrated consistent with our extensive experience in RV products. Balance of plant components – blower, fuel controls, fluid connections, are between the electronics and the hot box housing the stacks, reformer, recuperator, manifolding, and thermal insulation.
The result is a packaged SOFC power system configured to directly replace its Diesel powered predecessor. In fact, recent developments in advanced RV power systems resulting in the new Onan Hybrid Quiet Diesel™ have paved the way for a seamless transition to fuel cell generation.
Cost reduction is major emphasis
A key objective of the program is to reduce the manufacturing costs associated with SOFC in order to price fuel cells near the costs of current premium diesel, generator sets. The target is to build a 10 kW system with a factory cost of $400/kW, which is competitive with current reciprocating engine systems of this size. Cummins expects that demand will increase for this cost–effective technology, and thereby significantly replace reciprocating engine technology.
Key to the SOFC power system will be Versa Power System’s high performance planar SOFC stacks. This technology combines state–of–the–art SOFC materials with cost effective ceramic fabrication techniques used in the microelectronics industry. The cells are produced using traditional tape casting, sizing, screen printing, and co–firing operations. Interconnects are low–cost metallic components. The cell and stack design includes advanced proprietary VPS technology which has demonstrated excellent stability and resistance to degradation. The benefit of this approach will be the development of high–volume, low–cost manufacturing of standardized high–performance SOFC stacks.
SOFC technology is environmentally friendly and highly social
A major advantage of SOFC technology is that it facilitates the clean and environmentally friendly use of fossil fuels such as natural gas, LP, gasoline and diesel fuel to develop power efficiently and with extremely low emissions. Fuel cells produce electrical power by oxidizing reformed fuel within a special ceramic substrate to produce direct–current electricity. The only waste products are water vapor and a small amount of carbon dioxide.
Even the best engine driven generator sets produce a characteristic sound that’s unwelcome in many noise sensitive areas, such as campgrounds and residential neighborhoods. SOFC power systems demonstrate the potential for affordably generating highly sociable power that’s clean, but not heard.
Three–phase SECA Program
Phase 1 (2001–2006)
- – First generation system design and engineering
- – Key component design and development
- – SOFC materials and stack development
Prototype system meeting Phase I objectives demonstrated
Testing of the Phase I prototype is nearing completion in Cummins’ Fridley, Minnesota Technical Center. The unit has completed over 1500 hours of testing, producing 3 kilowatts of electrical power while operating on commercial pipeline natural gas. Performance has met expectations and the system reliability has been exceptional. Upon completion of the Phase I test, marked by the peak power test in early January 2007, Cummins and Versa Power expect to transition into Phase II.
Phase II (2007–2008)
- – Second generation system design and engineering
- – Development of diesel fuel processing
- – Improved materials performance and stack optimization
- – Prototype system meeting Phase II objectives demonstrated
Advanced engineering work at Cummins leading to Phase II has been ramping up. Key elements of the Phase II work will be addressing the challenges of reforming commercial diesel fuel, controlling the system through transients, including start–up and shut down, characterizing and engineering mechanical robustness for the mobile environment, and continued focus on cost reduction. Versa Power Systems will focus their efforts on continuing improvements in stack performance, sulfur tolerance, degradation reduction, and tolerance to start–stop cycles.
Phase III (2009–2011)
- – SOFC power system performance and cost developed to full commercial levels
- – Resolution of key technical challenges to market introduction
- – Commercial product ready for introduction to target markets
The SOFC power system development is supported through a contract (DE–FC26–01NT41244) with the United States Department of Energy (DOE) and the National Energy Technology Laboratory, a section of the DOE (www.seca.doe.gov). Project team members include Cummins Power Generation, and Versa Power Systems, Inc.
In addition to our SECA SOFC program, Cummins Power Generation has been awarded a contract under the auspices of the DOE’s Energy Efficiency and Renewable Energy (EERE) office to develop a solid oxide fuel cell (SOFC) auxiliary power system for heavy–duty trucks. This new application of fuel cell technology has the potential to sharply reduce engine idling time for America’s 458,000 long–haul trucks, shrinking the trucking industry’s fuel consumption while creating virtually no pollutants.
Trucking industry sources estimate that heavy (Class 7 and Class 8) trucks spend an average of six hours per day idling, primarily to keep engines warm and truck cabs warm or cool for driver comfort. These idling engines consume 840 million gallons of diesel fuel annually, creating an enormous opportunity for fuel savings.
Cummins and Cummins Power Generation are dedicated to supporting the needs of the trucking industry for clean, efficient, reliable power. Cummins Power Generation has a long history of producing mobile power units, including auxiliary power units (apu’s) for on–highway trucks. The announced introduction of the ComfortGuard™ diesel engine powered apu is the latest in this line products. As SOFC technology matures, CPG looks forward to bringing the advantages of the SOFC technology to bear in this application.
The SOFC–based auxiliary power units planned for development by Cummins Power Generation will operate on the new, ultra–low–sulfur diesel fuel (ULSD) currently being phased into the fuel supply system. ULSD will provide a better, cleaner alternative to today’s higher–emissions diesel fuels.
The Cooperative Development Agreement was placed through the DOE Golden, CO field office and provides Federal funding of $3.2 million. Cummins Power Generation and their development partners contribute $1.6 million cost share for a total program of $4.8 million.
Cummins Power Generation’s OEM partner is International Truck & Engine, a leading manufacturer of heavy–duty trucks.
