DOE OSTI2012
A one year project to examine the processes employed in the manufacture of combined heat and power stationary fuel cells operating in the 100-400kWe range was commissioned in June 2010. The results of this project would be used to inform decision makers in charge of allocating R&D resources by highlighting the most expensive steps in the manufacturing process where processing alternatives might have the greatest potential for high impact cost reduction. Three fuel cell technologies were examined: phosphoric acid (PAFC), molten carbonate (MCFC), and solid oxide (SOFC) fuel cells. Two fuel cell technologies, PAFC and MCFC, are represented by commercially available products within the study boundaries. United Technologies Corporation (UTC) offers the PureCell 400 ® , a 400 kWe combined heat and power PAFC system. FuelCell Energy (FCE) offers the DFC-300 ® , a 375 kWe combined heat and power MCFC. A combined heat and power SOFC within the study boundaries is not available in the marketplace at the time of this study. Process based cost models using 2010 dollars were developed for each fuel cell technology. For all three technologies, model boundaries encompassed all direct and indirect materials; direct and indirect labor; capital, maintenance, tooling, floor space, and energy costs associated with the manufacturing process. Cost estimates were developed with academic and patent literature, industry partners, supplier quotations, Monte Carlo simulation software, and DFMA software. Life cycle and non-manufacturing costs such as sales, administration, R&D, office floor space, and profit were not quantified. Results presented are for assumed annual production volumes of 5, 20, 50, and 500 MWe/yr, and expressed in terms of dollars per kilowatt of electrical energy. A model baseline production volume of 20 MWe/yr (similar to recent production volumes experienced by UTC and FCE) was assumed for all three technologies.