A Performance Based, Multi-Process Cost Model for Solid Oxide Fuel Cells
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A Performance Based, Multi-Process Cost Model for Solid Oxide Fuel Cells Heather Benson-Woodward, Mark Koslowske, Randolph Kirchain1, and Isa Bar-On. Mechanical Engineering Department, Worcester Polytechnic Institute Worcester, MA 01609, USA. 1 Department of Materials Science and Engineering and Engineering Systems Division, Massachusetts Institute of Technology, Cambridge, MA 02139, USA. ABSTRACT Cost effective high volume manufacture (HVM) is a major challenge to the success of solid oxide fuel cells (SOFCs). More than fifteen processing methods have been reported in the literature many of which could be used in various combinations to create the desired product characteristics. Modeling tools are needed to aid in the selection of the appropriate process combination prior to making expensive investment decisions. This paper describes the development of a multi-process cost model that permits the comparison of manufacturing cost for different processing combinations and various materials. Two specific processing methods are discussed, tape casting and screen printing. The results are compared with data and experience from the fuel cell and electronic packaging industries. Initial comparisons show good agreement with this experience base. Sensitivity of manufacturing costs to SOFC performance requirements such as maximum power density and operation temperature is investigated. INTRODUCTION The success of SOFC technology depends on producing a cost competitive product within performance specifications. Several materials/process technologies have been proposed for the electrolyte in SOFCs [1,2]. The designer will need an analytical tool to select between technology routes to meet the performance and cost goals for these devices. This project describes a multi-process cost model that takes required performance data (maximum power density, Pmax, and operating temperature) and maps it to cost regimes for HVM conditions. The model consists of three parts: i) a device performance model that calculates the required electrolyte thickness based on materials properties; ii) process tolerance models deriving from processing experience, and iii) a process based cost model that uses results from i and ii as inputs In the absence of HVM data for SOFCs the cost model is validated in two ways. First, the model predictions are compared with SOFC cost model data from the literature. Second, the cost model is used to estimate the cost of commercially available alumina layers. Finally, the sensitivity of the cost results to variations in some of the model parameters is presented. This paper reports only a preliminary effort in this direction. It is expected that the model will be refined with the availability of further data.
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BACKGROUND Two planar SOFC architectures are currently being investigated: anode supported and electrolyte supported stack geometries. In the anode supported architecture the 0.5 to 1 mm thick anode is tape-cast from a Nickel Cermet material. The electrolyte layer made of Yttria Stabilized Zir
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