Summary of the RealDemo Project 2012-2014

The RealDemo -project was a joint research project focused on enabling the commercialization of the solid oxide fuel cell (SOFC) technology. The project lasted from 2012 to 2014. The project's research partners were VTT, LUT and the Aalto University. The targets of the project were (i) to improve the reliability of SOFC systems, (ii) to simplify the system structure in order to bring down the investment and servicing costs and (iii) to identify the potential applications for the first SOFC system demonstrations. A systematic and formal methodology to extract high-fidelity measurement data for databased model development was investigated with a complete 10 kW SOFC system. By utilizing the obtained experimental data, it was found that the reliability of the system can be improved by utilizing case-specific, data-based approaches for system diagnosis i.e. to identify sensor faults and abnormal operating conditions. Significant reduction of the systems' instrumentation as well as advanced control were also found possible with the data based methods. Several solutions simplifying the system structure were investigated and developed, including novel thermal insulation and supports, fuel recirculation and generation of system safety gases from fuel. Additionally, the results achieved in the power electronics research will lead to more efficient and reliable power conversion equipment for fuel cell systems in particular but also for other applications e.g. solar cells and battery packs. With improved efficiency of the power electronics, the electrical efficiency of the SOFC system can be increased to 54% and beyond. In total, over 10,000 operating hours were accumulated for the 10 kW SOFC demonstration unit by the end of the project.