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technical hub for the multi-level approach. It provides inputs on the required flow rates and heat duties in the system. Sizing information, together with information from the thermodynamic model, then flows to the conceptual design. SOFC Cost Structure The main difference in SOFC stack cost compared to PEFC cost relates to the simpler system configuration of the SOFC system. This is mainly due to the fact that SOFC stacks do not contain the high-cost precious metals that PEFCs contain. This is off-set in part by the relatively complex manufacturing process required for the SOFC electrode/electrolyte plates and by the somewhat lower power density in SOFC systems. Low-temperature operation (enabled with electrode-supported planar configuration) enables the use of low-cost metallic interconnects that can be manufactured with conventional metal forming operations. The balance of plant contains all the direct stack support systems, reformer, compressors, pumps, and recuperating heat exchangers. Its cost is low by comparison to the PEFC because of the simplicity of the reformer. However, the cost of the recuperating heat exchangers partially offsets that. To provide some perspective on the viability of SOFCs in APU applications from a cost perspective, NETL sponsored a cost estimate of a small-scale (5 kW), simple-cycle SOFC anode-supported system, operated on gasoline. The estimated manufacturing cost (see Figure 1- 14) could well be close to that estimated for comparable PEFC systems, while providing somewhat higher system efficiency. While the stack, insulation, and stack balance in this simple-cycle system is a key component; the balance of plant is also an important factor. The stack cost mainly depends on the achievable power density. Small systems like these will likely not be operated under high pressure. While this simplifies the design and reduces cost for compressors and expanders (which are not readily available at low cost for this size range in any case), it might also negatively affect the power density achievable. A key challenge with small-scale SOFC systems is to overcome heat loss. The higher the heat loss the more recuperation is required to maintain the fuel cell within an acceptable temperature range, and hence to ensure good performance. The large fraction of cost related to balance of plant issues is mainly due to the very small scale of this system, which results in a significant reverse economy of scale. While design work is still ongoing, it is anticipated that the cost structure of this system will reduce the cost of balance of plant further, and further improve the competitiveness of these systems. 1-31PDF Image | Fuel Cell Handbook (Seventh Edition)
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