WP3 - Genset System Engineering & Proof of Concept

This work package involves the system engineering of the hybrid SOFC-Battery genset, the optimization of the sizing of the SOFC fuel cell and the battery unit, as well as design validation of the SOFC-Battery hybrid genset in an experimental proof-of-concept. Finally, the aim of this work package is the development of virtual genset simulator and an engineering proposal for a multi-MW genset that which integration will be further planned in WP4.

3.1 WP Leader

Deutsches Zentrum für Luft – und Raumfahrt/German Aerospace Center (DLR)

3.2 Tasks and Outputs

Genset process system engineering and validation

  • The overall objective of this subtask is to engineer a 5 to 60 MWe SOFC-Battery hybrid genset concept based on KPI’s defined in WP2. The task focuses on the development of first Process Flow Diagrams (PFD) by comparing different process flow concepts. An optimization of the heat exchanger network and the development of a piping and instrumentation diagram (P&ID) is performed. This development process is done iteratively based on the input of the experimental results and analysis of the proof-of-concept and the demonstrator in WP6. At this stage of the project the first PFD, optimization and a Process and Instrumentation Diagam (PnID) development took already place and will be refined after the results of the upcoming experiments.
  • In addition, transient models were developed that will be validated during the experimental campaign alongside the application and parameterisation of an energy management system. The final outcome of this task will be a complete P&ID and engineering design of the hybrid genset capable to satisfy the requirements defined in WP2 and safety related requirements.
  • Deliverable D3.1 – Report on safety and regulatory requirements for large-scale integration of scalable modular genset on-board cruise ships – completed.

Hybrid genset sizing and design

  • The key objective of this task is a development of guidelines and a pathway towards the scale up of the underlying technology via a modular genset approach to reach multi- MW scales that meet the safety requirements and integration. For that, the targeted power output of 5 to 60 MW will be realized by modular genset units of 100 to 250 kWe.
  • Deliverable D3.2 – Steady state and dynamic operation of the hybrid genset system with unitized control algorithm – pending.

Fuel cell module assembling and operation

  • Within this subtask a large stack module (LSM) with 30 kWe has been assembled, and will be operated in close collaboration between tested SP_SA and DLR.
  • Deliverable D3.3 – Report on sizing of modular genset and scalability to multi-MW scale – pending.

Hybrid fuel cell + battery PoC build-up and operation

  • The main objective of this task is to build up the proof-of-concept (PoC), consisting of the large stack module (LSM) and the battery together with the adaptation of the control. Currently the focus is on the preparation of the test rig at DLR and the design of the electric part needed for the PoC for the hybridization via a battery.
  • Deliverable D3.4 – Report of the 30 kWe PoC operation for different energy profiles– pending.

Virtual genset simulator

  • The purpose of this subtask is to compile the results of work done in several different tasks to build a so-called Virtual Genset Simulator (VGS) that can be integrated to ship energy system simulators used by CdA and MW. For that the technical and functional requirements have already been defined.
  • Deliverable D3.5 – Virtual genset simulator tool – pending.

3.3 Duration and Status

  • Months 1 - 36
  • Status – in progress.
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