WP6 - Functional Demonstrator

The main objective of this work package is the design and construction of a modularized functional demonstrator. The demonstrator will have a total power of > 60 kWe derived from batteries and fuel cells; of which 60 kWe will be from fuel cell unit and the battery will have 20 kW power output. The second aim is to connect the developed genset demonstrator to the low voltage electrical grid (400VAC) and operate it for 3 months, while the emissions will be measured under different load scenarios.

6.1 WP Leader

MAN Energy Solutions (MAN)

6.2 Tasks and Outputs

Process, mechanical and electrical design + component procurement

Figure 1: Battery system, power electronics units (two middle photos), EMS and the control cabinet incorporating the Human Machine Interface (HMI) of the MAN ES battery container (from left to right)

  • SolydEra SPA (SE_SPA) already delivered the fuel cell system to DLR Stuttgart. The SOFC system consisting of the 40x 1,5 kW SOFC stacks and the required balances of plant (BOPs) (including the gas compressor) and providing the associated process, mechanical and electrical design of the fuel cell unit. Read more here
  • Lloyd’s Register EMEA (LR) supports the process by providing safety regulations in the maritime field that can be applied to the design concept.
  • Deliverable D6.2 - Drawings and layout for Design on Battery Container – completed
  • Deliverable D6.3 - Drawings and layout for the design of FC Cabinet – completed
Battery container manufacturing, assembly and software programming
  • The manufacturing, assembly and software programming of the battery container was carried out by MAN Energy Solutions (MAN) in cooperation with subcontractors. This task includes the set-up of control cabinets, power electronics and programming of the control system based on MAN Energy Solutions (MAN)
  • The battery container is further interconnected with the fuel cell cabinet via a common 600V DC busbar system.
  • Moreover, the battery container includes an energy management system unit (EMS), which is responsible for power distribution calculation between the available hybrid power sources.

Figure 2: Battery and main controller container

Demonstrator site preparation
  • For the installation and operation of the modularized battery and fuel cell functional demonstrator at DLR premises a location was prepared with all interfaces and connections. Read more here

Figure 3: Demonstration site at DLR Stuttgart (June 2024)

Figure 4 : Test site plan

Installation and operation of demonstrator

Figure 5: SOFC unit for the demonstrator located at DLR Stuttgart

Figure 6: Demonstration site (October 2024)

Fuel cell testing on inclination pod
  • Testing of a 1.5 kWe solid-oxide fuel cell unit on an inclination pod was implemented by Technische Universiteit Delft (TUD) in close cooperation with SolydEra SPA (SE_SPA) and Lloyd’s Register EMEA (LR) in order to identify potential influences and effects of the exposure of the fuel cell unit to marine conditions: inclinations, ship motions and vibrations were examined.
  • The concept design of the experiment is shown below in Figure 7 and Figure 8.

Figure 1 Concept design of the inclination experiment

Figure 7: Concept design of the inclination experiment

Real testing at SolydEra premises in Italy

Figure 8: Real testing at SolydEra premises in Italy

Watch the video

  • Deliverable D6.1 - Safety report on the tests of fuel cell unit on the inclination pod – completed

6.3 Duration and Status

  • Months 7 - 54
  • Status – in progress
  • MS11 – List of specifications – completed
  • MS12 – Technical drawings – completed

6.4 WP6 Highlights

  • Design, construction, installation, and operation of a modularized functional demonstrator consisting of a Solid Oxide Fuel Cell-Unit and a Battery container (including a battery rack system, power electronics units, a main controller and an energy management system (EMS), in other words the real-time PC).
  • Connection of the modularized functional demonstrator to the local low voltage 400VAC electrical grid (at DLR site) and its operation for 3 months.
  • Testing of a fuel cell unit on an inclination pod (simulating the behaviour of a SOFC unit under rough sea conditions).
  • Battery Container: all required parts (container, battery system, power electronics, etc.) were procured, the internal software was programmed. The Battery Container was physically assembled in March 2024 and will be transported to the Deutsches Zentrum für Luft – und Raumfahrt (DLR) premises in August 2024.
  • SOFC-Unit: tests with the reduced-power SOFC Unit were successfully completed, the 60kW SOFC Stack Unit system was completed and delivered in June 
  • Demonstrator Site Preparation: the test site on Deutsches Zentrum für Luft – und Raumfahrt (DLR) premises was finalized and ensure alignment with all necessary connections, interfaces, and safety regulations for both SOFC and Battery Container

6.5 Next Steps

  • Installation and Operation: The installation completed by the end of August 2024. Currently, the operation of the demonstrator is scheduled with a detailed execution plan. Furthermore, a test protocol has been drafted regarding the power profiles to be tested, including edge cases, normal operation modes, stepwise power load variations, and dynamic tests.
  • Emission measurements are planned for one month of testing operations. The required results will then be analysed by the expert team at Lund University. Read more under WP7 description.

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 Last updated: October 24th, 2024