After long and successful development history of Solid Oxide Cells (SOC) continuous improvement in performance, longevity, manufacturing, and system integration it is necessary to bring this highly efficient technology to the market. The activities on material development and optimization at IKTS are focused mainly on enhancement of durability for SOFC, SOEC, and rSOC operation and on boosting the power density. During recent years considerable efforts on simplification and automation of cell and stack manufacturing processes have been addressed. The processes for electrode manufacturing have been adjusted for high yield automated printing on thin electrolytes with integrated quality control measures. Efficient ways for reduction of time and energy consumption for sealing process of SOC stacks have been found and demonstrated in pilot production as well as automated assembling of components to stacks was shown. The increasing interest in “green hydrogen” created multiple opportunities for SOEC technology to be considered as inherent part of industrial and chemical processes. IKTS pioneering work on coupled operation of SOEC module with Fischer-Tropsch reactor provided first demonstration of feasibility of this approach for wax production. However, high power electrolysis applications (>10 MW) will need new approaches for stack design and put higher requirements on durability.
The rapid development of additive manufacturing (AM) technologies enables a radical paradigm shift in the construction of heat exchangers. In place of a layout limited to the use of planar or tubular starting materials, heat exchangers can now be optimized, reflecting their function and application in a particular environment. The complexity of form is no longer a restriction but a quality. Instead of brazing elements, resulting in rather inflexible standard components prone to leakages, with AM, we finally can create seamless integrated and custom solutions from monolithic material. To address AM for heat exchangers we both focus on the processes, materials, and connections as well as on the construction abilities within certain modeling and simulation tools. AM is not the total loss of restrictions. Depending on the processes used, delicate constraints have to be considered. But on the other hand, we can access materials, which can operate in a much wider heat range. It is evident that conventional modeling techniques cannot match the requirements of a flexible and adaptive form finding. Instead, we exploit biomimetic and mathematical approaches with parametric modeling. This results in unseen configurations and pushes the limits of how we should think about heat exchangers today.
Despite long and successful development history of Solid Oxide Cells (SOC) continuous improvement in performance, longevity, manufacturing and system integration is necessary to bring this highly efficient technology to the market. The activities on material development and optimization at IKTS are focused mainly on enhancement of durability in SOFC, SOEC and rSOC operation and on boosting the power density for electrolysis operation. The recent results show considerable enhancement in cell longevity and power density. The SOC priorities in applied research are moving from materials to industrialization and Fraunhofer as applied R&D service provider is following this trend. During recent years considerable efforts on simplification and automation of cell and stack manufacturing processes has been addressed at IKTS. The manufacturing processes for electrode manufacturing have been adjusted for high yield automated printing on thin electrolytes with integrated quality control measures. The efficient ways for reduction of time and energy consumption for sealing process of SOC stacks have been found and shown in pilot production as well as automated assembling of components to stacks demonstrated. Furthermore the stack integration into modules utilizing stacks of different providers has been addressed during last years and reliable solutions for building of compact stack modules of higher power (2 to 10 kW) has been developed and tested with industrial partners. The increasing interest in “green hydrogen” generated multiple opportunities for SOEC technology to be considered as inherent part of industrial and chemical processes. IKTS pioneering work on coupled operation of SOEC module with Fischer-Tropsch reactor provided first demonstration of feasibility of this approach for waxes production. The process design and analysis of steel, using SOEC technology, has been performed and resulted in multiple demonstration activities in last four years. Recently novel approaches for ammonia production are addressed at IKTS showing opportunity for transportable chemicals/fuel production without need of CO2 source. High power electrolysis applications (>10 MW) will need new approaches for stack design and put higher requirements on durability. High power electrolysis applications will also open a new window of opportunities for industrial SOFC power plants. This vision is considered as outline for our future research.
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