Setember 2010

At the end of this month the project was duly closed. Wärtsilä has continued the development of a 50kW planar SOFC system beyond this project. During 2010, a second generation 50kW unit has been developed. The unit is based on an entirely new platform which is designed for lower cost and even better serviceability. It will have the capability to run on either natural gas or biogas.


For Topsoe Fuel Cell, the pre-commercial facility will be the venue for a further development of cost effective methods for the production of SOFC. Based on the gained knowledge and experience a plan for a commercial manufacturing facility with a capacity of 100MW or even larger and a further cost reduction by a factor of 5 to 10 is in the making.


Together, Wärtsilä and Topsoe Fuel Cell have set up a joint development and marketing plan targeting a demonstration market of 50kW SOFC-based power systems starting 2012.



May 2010

The Demo SOFC program has reached a significant milestone with the delivery of the demonstration unit to the Wärtsilä laboratory.
The factory approval of the unit took place in April at the main assembly plant and the unit was successfully delivered to the test site later that same month.
The unit is being commissioned and prepared for the start of the test program. Once operational, 50 kW of electrical power will be delivered from the unit.








April 2009


The Topsoe Fuel Cell manufacturing facility is officially inaugurated by the Danish Minister of the Economy Lene Espersen. Dr. Haldor Topsøe (left), founder of the company, and Claus Olsen(right), Managing Director, watch as the red ribbon is being cut.











February 2009


The installation of the equipment in Building 64 which houses the cell manufacturing has been completed in December 2008. Now, the manufacturing engineering team is in the middle of commissioning of the machinery and getting all processes fully up and running.

The tape caster is one of the highlights of the new facility at Lyngby. At well above 30 m length it is definitely the largest piece of equipment. It was custom-made according to Topsoe Fuel Cell specifications and offers a wide range of interesting features for the manufacturing the SOFC cell support:

  • Continuous oven with controlled temperature and airflow

  • On-line measurement of the thickness

  • Automatic material handling


Much emphasis was put on finding the right balance between automation and manual processes in this pilot facility. A good example is the material handling of the cell during manufacture. The cells are automatically loaded on trays which are inserted into carts. Unloading from the trays is automated as well. Shuttling the carts from one operation to the next is still a manual process.

The manufacturing facility is laid out for a maximum annual capacity of 5 Megawatt. So batch ovens were the smart choice for sintering of the cells in order to optimize investment and complexity. In a future mass production facility a continuous oven may be employed instead.

Topsoe Fuel Cell plans to considerably reduce production cost once the new facility is fully up and running. The modular will allow to introduce new processes or improved equipment as these become available in the future. All in all the new manufacturing facility is a major advancement towards the commercialization of SOFC.













The tapecaster. The continuous process allows to produce a batch of SOFC which combined reach a length of about 1 kilometer.



 Spraying machine with automated loading station for cells.


  Batch ovens for sintering of the cells.




September 2008

The Haldor Topsoe photographer used a clear day in September to get a nice shot of the new manufacturing facility from the air. 












The new manufacturing facility at Lyngby, Denmark. From the right: Building 64 (cell manufacturing), Building 62 (stack assembly). Topsoe Fuel Cell headquarters on the left 




August 2008 

One of the first batches of stacks was assembled in Building 62 (stack assembly) of the new facility. The cells were still produced at an external facility while the installation of the equipment in Building 64 (cell manufacturing) has started.












The Topsoe Fuel Cell team of operators happily presents 24 brand new SOFC stacks. 



June 2008 

The Spanish Prime Minister José Luis Rodríguez Zapatero and the Danish Prime Minister Anders Fogh Rasmussen visited Topsoe Fuel Cell on 30 June 2008.
The prime ministers were received by Dr. Haldor Topsøe, chairman of the board of Haldor Topsøe A/S, and Claus Olsen, managing director of Topsoe Fuel Cell. The visit focused on Topsoe Fuel Cell’s contribution to solving some of the global climate and energy challenges.
After Dr. Haldor Topsøe had presented and introduced the company, managing director Claus Olsen guided prime ministers Zapatero

and Rasmussen through the development of fuel cells and their role in the global energy supply.
Managing director Claus Olsen talked about the perspective for the use of fuel cells in trucks, containers and ships, and the prime ministers saw how fuel cells may be used as power units in emergency hospitals.
”We had an interesting dialogue with Prime Minister Zapatero and Prime Minister Rasmussen. They were very interested in both the technology and its applications – and of course in when we expect fuel cells to be available on the commercial market,” said Claus Olsen, who appreciates that fuel cells have been on the prime ministers’ agenda.















José Luis Rodriguez Zapatero, Prime Minister of Spain; Anders Fogh Rasmussen, Prime Minister of Denmark;

Pernille Noyé, Topsoe Fuel Cell (from left)


The ministerial motorcade in front of the new production facility at Lyngby.


May 2008


Construction of the buildings and technical installations for the new cell and stack manufacturing plant is finalised. The building for stack production, which was taken over at the end of December 2007, is now fully commissioned. Remaining to be installed and commissioned is only the equipment for stack conditioning and hot testing. In the beginning of May 2008, the building - which will house the cell production - was officially “handed over” to Topsoe Fuel Cell by the construction company. Installation of equipment is the next step, and all major equipment has been ordered and will be delivered and installed over the next five months.

When designing the building, emphasis was put on the natural work flow in the cell preparation in order to minimise handling, and thus costs. Also the working environment for the production staff has been given high priority, for instance are roof top windows installed through-out the building, and glass doors and walls are used to let in as much daylight as possible. Ventilation is designed to meet all emission and work regulations, and rooms with noisy equipment are equipped with the best possible sound insulation,

The plant is scheduled to start up in the last quarter of 2008, and is expected to meet the initial capacity in all production steps before the end of 2008. To allow for easy adaptations and optimisations of the individual production steps, the production will not be fully automated from the start. This also has the advantage that each production module can be commissioned and trimmed independently. In addition, the manufacturing unit features are dedicated to trials and running-in of new production equipment. This is a vital element for stable expansion of production capacity.

The combined production area also includes laboratories for quality control and assurance, together with areas dedicated to technology development. The closeness of research, development and production is considered very important for synergies, and moreover facilitates transfer of technology steps.








Interior Building 64, North part for spraying,

printing,QC&A, handling. June 2008



Exterior of Building 62 (left, 3 windows) and Building 64

with the technical installations on top in a semi-open structure.

Terrain-work in progress, June 2008


October 2007

Topping-out ceremony at Denmark’s first fuel cell production plant


Topsoe Fuel Cell has celebrated the topping-out of Denmark’s first fuel cell production plant. In recognition of the importance of the important role fuel cells will play in the future energy policies, The topping out ceremony was attended by Minister for the Environment Ms. Connie Hedegaard.

”Today’s topping-out ceremony marks an important milestone in Danish fuel cell development, Topsoe Fuel Cell’s new production plant represents a significant change of gear in the Danish-European efforts towards the development and commercialisation of fuel cells,” managing director Claus Olsen said in his speech.

Minister Connie Hedegaard emphasised the technology’s perspective: ”If your efforts are successful, they will benefit the environment and at the same time create a unique export opportunity for Denmark. Congratulations to Topsoe Fuel Cell, congratulations to those of you who will work with this challenging technology and congratulations to the environment.”

Guests from collaborating institutions and partners attended the ceremony including partners from the Danish Research Institute Risø, the EU and the Danish Energy Authority. Also Dr. Haldor Topsøe, owner of Topsoe Fuel Cell, took part in the ceremony.

The buildings will be finished in May, after which production equipment will be installed and tested over the summer of 2008. Production is expected to commence in Autumn 2008. In the first phase, fuel cells will be produced for demonstration projects, which can support the further development of the technology.






June 2007
The construction of buildings, installations and equipment supported by the EU LIFE Environment Programme is well in progress. The building, which will house stack production and stocks, is being refurbished. Specifications of the technical installations are being finalised, and the final legislative approvals from the authorities are moving forward. It is estimated that the entrepreneur will officially handover the building during late autumn 2007.

The necessary permits for the building, which will house the upscaled cell production, have been obtained and it is expected that the first turf will be cut during summer 2007. Specifications of the technical installations are still open and the legislative process is advancing. The handover from the entrepreneur is estimated to be during the second quarter of 2008.

Custom production equipment with long lead times is under design. In order to reduce the start-up time of the final production facilities, part of the production equipment has been established in temporary facilities, and optimisation of the equipment is already in progress. Ordering of all major equipment is expected to take place during the second half of 2007.



September 2006
Topsoe Fuel Cell and Wärtsilä Corporation are selected for a EUR 4.8 million grant from the EU LIFE Environment programme  
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