Sintered Ceramics & Metals

SOFC | Scaling from batch to continuous mass production

Challenges, solutions & how to bridge the gap with ONEJOONS development process

How Solid Oxide Fuel Cell producers can increase efficiency and throughput with two verified kiln concepts and reach seamless integration with a proven development process

Upscaling SOFC production discussed in 4 aspects

This page focuses on imminent challenges of SOFC producers, ONEJOONS solutions and the process we deploy to move you from Batch to Mass production.

You would like to learn more about our
solutions for SOFC producers?

We would be pleased to show you in a personal
appointment what we can do for you.

Yes, I would like to receive more information about upscaling SOFC production
1. Challenges for SOFC producers

Imminent demand increase but limited scalability of
current supply solutions

The current equipment has limitations that won´t meet the needs of increased efficiency and
capacity just by multiplying (more batch kilns) or scaling (bigger batch kilns)

Current equipment limitations and challenges:
Most SOECs are debindered / sintered in batch kilns with:

  • Limited throughput
  • Long processing times cold-to-cold
  • Poor binder / gas removal
  • Limited explosion limit control
  • High energy consumption in relation to throughput

 

So why not just get a bigger batch kiln?

  • Disproportionate relation between firing time and size leads to
    longer cycle cold-to-cold times
  • Decreasing temperature uniformity within the batch
  • Even worse binder / gas removal

Batch Furnaces

Upscaling Firing Times

  • Upscaling the furnace volume 1:1 with the stack geometry increases the temperature differences within the batch
  • In order to maintain the quality of the final product, the process time has to be increased

Continuous Furnaces

Further process improvements

  • Downscaling the volume of each batch decreases the total furnace time in the opposite way that upscaling it does
  • Utilizing this principle should shorten the firing cycle
  • A shorter cycle time leads to a shorter furnace and/or a higher throughput.

2. Our Solutions: Two SOFC Kiln Concepts

Two continuous kiln concepts, optimized for mass production

The concepts meet the needs of upscaling companies, first by leveraging proven and reliable technology as foundation to reduce risk, and second by complementing them with advanced solutions for uniform and reproducible heat treatment

  • Faster more uniform heat-up: Product is conveyed through an evenly heated and fully soaked furnace zone resulting in better heat transfer and temperature uniformity within each furnace charge
     
  • Risk reduction: Concepts are hybrids with long history at Onejoon
    By leveraging proven technology as foundation, we significantly reduce the risk of failure and can support you with years of design and operational experience
     
  • Better debinding for increased product quality:
    Forced convection ensures proper binder and gas removal from cells, preventing cells from curving and forming carbon deposits  
     
  • Increased process control: Smaller control zones allow for better process parameter adjustability and monitorability
     
  • Safer production: Full explosion limit control via adjustable exhaust and air intakes within each zone
     
  • High energy efficiency: Less energy to maintain temperature, reduced wall losses, optimized cross section and air recirculation
     
  • Rapid deployment: Modularized design allows for fast project execution and short lead times

Find the best SOFC kiln for you

Two continuous kiln concepts, optimized for mass production

Summary

Furnace/Kiln type:

SOFC - FLEX

SOFC - VOLUME

Concept Complexity:

- High

- Medium

Gas Tightness:

- Possible

- Very good

Temperature Profile:

- Very high flexibility- Flexible

Atmosphere Profile:

- High flexibility- Flexible

Reaction Control:

- Depends on carrier / saggar- Depends on carrier / saggar

Max Temperature:

- Limited by roller material

- High

Energy Efficiency:

- Low- Medium

Throughput:

- Medium- High

SOFC FLEX

No restrictions. Stay flexible and change processes, products and throughput.

  • Debinding with forced convection up to 600 °C 
  • Sintering up to the max. operating temperature 1.400 °C
  • Atmosphere separation through sluices 
  • Available in various sizes: 4 meter lab to 50 meter mass production furnace
  • Single and multi lane designs available for increased throughput 

SOFC VOLUME

No compromises, only throughput. Exceptional process stability and equipment availability.

  • Debinding with forced convection up to 600 °C 
  • Sintering up to the max. operating temperature 1.450 °C (higher on request)
  • High energy efficiency
  • Modularized design allows for fast lead times
  • Single and multi pusher lane designs available for increased throughput

3. Lab2Scale - Development process

Seamless. We bridge the gap together with you utilizing out End 2 End development process.

You come with your process as is and leave with a running production, trained operators and global service support.

ONEJOON is an Experienced Global Supplier of High Temperature Continuous Furnace Technology, with a reputation of Quality and Service, ONEJOON works with their customers from concept design through implementation to tailor the furnace solutions that produce the highest level of quality and repeatability for optimal Fuel Cell performance.

Labtoscale ONEJOONS proven development process from laboratory to production furnace
4. ONEJOONS Service Range/Offer

ONEJOON as a Turnkey Supplier

Furnaces, cell handling and material flow automation.

Seamless integration: To reach your production line’s full potential

  • Single point of contact for the entire project
  • Faster lead times
  • Less interfaces between suppliers
  • Common control scheme

We’ll provide the Turn-Key solution that meets your requirements!

ONEJOON Turn-Key solutions

Individual furnace systems for your SOFC production

Just because every customer has special requirements

Together with you, we will work out the optimal solution for your SOFC production. Worldwide.

  • selection of the suitable plant concept and furnace type
  • definition of the scope of delivery
  • design of the system based on your specification
  • configuration of the system from standardised components as well as customer-specific adaptations
  • presentation of the plant concept and preparation of the offer
  • design and project management by our specialists
  • worldwide shipping
  • assembly, commissioning and acceptance of the plant at your location
  • management and supervision of the installation by German, American or Korean specialists
  • commissioning and process adjustment by our engineers for process engineering
  • preparation of the operating and maintenance instructions and the CE declaration of conformity
  • production support, if desired
  • services: plant maintenance, spare parts, repairs

We are looking forward to your request, contact us today!

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You would like to learn more about our
solutions for SOFC producers?

We would be pleased to show you in a personal
appointment what we can do for you.

Yes, I would like to receive more information about upscaling SOFC production
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