Cold start dynamics and temperature sliding observer design of an automotive SOFC APU

This paper presents a dynamic model for studying the cold start dynamics and observer design of an auxiliary power unit (APU) for automotive applications. The APU is embedded with a solid oxide fuel cell (SOFC) stack which is a quiet and pollutant-free electric generator; however, it suffers from slow start problem from ambient conditions. The SOFC APU system equips with an after-burner to accelerate the start-up transient in this research. The combustion chamber burns the residual fuel (and air) left from the SOFC to raise the exhaust temperature to preheat the SOFC stack through an energy recovery unit. Since thermal effect is the dominant factor that influences the SOFC transient and steady performance, a nonlinear real-time sliding observer for stack temperature was implemented into the system dynamics to monitor the temperature variation for future controller design. The simulation results show that a 100 W APU system in this research takes about 2 min (in theory) for start-up without considering the thermal limitation of the cell fracture.     

3D multiphysics modeling aided APU development for vehicle applications: A thermo-structural investigation

Solid oxide fuel cells (SOFC) are suitable for on-board electricity generation as Auxiliary Power Unit (APU) to support the electric power supply in heavy-duty vehicles. In order to satisfy the requirements of a lightweight fuel cell stack for mobile applications, thin-walled components must be used for the stack structure. This necessity is associated with material, process and design difficulties that must be solved in order to achieve a successful utilization. In this work a novel lightweight SOFC stack design with metal-supported cell was studied both numerically and experimentally. The metallic components are made from the Intermediate Temperature Metal (ITM), a high performance, high chromium ferritic stainless steels alloy. The multiphysics modeling approach (fluid dynamics, heat transfer, structural mechanics) was utilized in this work to predict the temperature distribution and the thermo-structural behavior of the new developed design. Geometric details of the fuel cell stack components as well as appropriate nonlinear, temperature and time-dependent constitutive models were developed to describe the material behavior. Experimental data were used to determine the material model parameters and validated the simulation results. The three-dimensional stress and deformation distributions in the individual stack components were evaluated and their maximum values for elements at risk were identified. Thus, the developed model enables the investigation of sustainability and serviceability of the structural elements to ensure a reliable operation of the stack. The developed computational model can be used as a design tool for parametric studies and optimization analysis to investigate the effects of process boundary conditions, material properties as well as geometrical design parameters and their variation on the induced thermal stresses.     

Fuel cell system modeling for solid oxide fuel cell/gas turbine hybrid power plants, Part I: Modeling and simulation framework

A sustainable future power supply requires high fuel-to-electricity conversion efficiencies even in small-scale power plants. A promising technology to reach this goal is a hybrid power plant in which a gas turbine (GT) is coupled with a solid oxide fuel cell (SOFC). This paper presents a dynamic model of a pressurized SOFC system consisting of the fuel cell stack with combustion zone and balance-of-plant components such as desulphurization, humidification, reformer, ejector and heat exchangers. The model includes thermal coupling between the different components. A number of control loops for fuel and air flows as well as power management are integrated in order to keep the system within the desired operation window. Models and controls are implemented in a MATLAB/SIMULINK environment. Different hybrid cycles proposed earlier are discussed and a preferred cycle is developed. Simulation results show the prospects of the developed modeling and control system.     

Modeling and control of a SOFC-GT-based autonomous power system

In this article, a dynamic, lumped model of a solid oxide fuel cell (SOFC) is described, as a step towards developing control relevant models for a SOFC combined with a gas turbine (GT) in an autonomous power system. The model is evaluated against a distributed dynamic tubular SOFC model. The simulation results confirm that the simple model is able to capture the important dynamics of the SOFC and hence it is concluded that the simple model can be used for control and operability studies of the hybrid system. Several such lumped models can be aggregated to approximate the distributed nature of important variables of the SOFC. Further, models of all other components of a SOFC-GT-based autonomous power system are developed and a control structure for the total system is developed. The controller provides satisfactory performance for load changes at the cost of efficiency.     

A computational fluid dynamics and finite element analysis design of a microtubular solid oxide fuel cell stack for fixed wing mini unmanned aerial vehicles

Computational fluid dynamics (CFD) and finite element analysis (FEA) are important modelling and simulation techniques to design and develop fuel cell stacks and their balance of plant (BoP) systems.The aim of this work is to design a microtubular solid oxide fuel cell (SOFC) stack by coupling CFD and FEA models to capture the multiphysics nature of the system. The focus is to study the distribution of fluids inside the fuel cell stack, the dissipation of heat from the fuel cell bundle, and any deformation of the fuel cells and the stack canister due to thermal stresses, which is important to address during the design process. The stack is part of an innovative all-in-one SOFC generator with an integrated BoP system to power a fixed wing mini unmanned aerial vehicle. Including the computational optimisation at an early stage of the development process is hence a prerequisite in developing a reliable and robust all-in-one SOFC generator system. The presented computational model considers the bundle of fuel cells as the heat source. This could be improved in the future by replacing the heat source with electrochemical reactions to accurately predict the influence of heat on the stack design.     

A review of solid oxide fuel cell component fabrication methods toward lowering temperature

The solid oxide fuel cells (SOFCs) emerge as an alternative power generation system for high-scale stationary application and power plant station. The SOFC consumption leads to the high-efficiency energy production that forms variety of fuels up to 60% energy conversion; the operation system does not involve the burning process and minimizes the air pollution. Also, the aptitude to provide the cogenerative energy production from the heat waste during the operation process serve SOFC as an attractive green technology and environmentally friendly. However, the SOFC consumption remains limited for transportation and portable applications because the simple design of power source compartment is still the major hurdle in each SOFC component development and commercialization. Therefore, the appropriate fabrication method of each SOFC component is important to achieve the reliability of the SOFC application for the small-scale power generation design. In this paper, an overview of the design types and SOFC components and properties following electrode, electrolyte, interconnect and sealant are discussed and summarized. As the third-generation fuel cells, which entice the commercialization stage, this paper concentrates more on the fabrication method of each SOFC components that were explored including the working principle, advantage, disadvantage and several previous works on each fabrication method, which are described to finding the appropriate fabrication method toward lowering the operating temperature and develop the simple design of SOFC power sources system for the transportation and portable application. The targeted market power production of SOFC system for transportation application is about 5 kW and 250 W for portable application.     

High-fidelity stack and system modeling for tubular solid oxide fuel cell system design and thermal management

Effective thermal integration of system components is critical to the performance of small-scale (<10 kW) solid oxide fuel cell systems. This paper presents a steady-state design and simulation tool for a highly-integrated tubular SOFC system. The SOFC is modeled using a high fidelity, one-dimensional tube model coupled to a three-dimensional computational fluid dynamics (CFD) model. Recuperative heat exchange between SOFC tail-gas and inlet cathode air and reformer air/fuel preheat processes are captured within the CFD model. Quasi one-dimensional thermal resistance models of the tail-gas combustor (TGC) and catalytic partial oxidation (CPOx) complete the balance of plant (BoP) and SOFC coupling. The simulation tool is demonstrated on a prototype 66-tube SOFC system with 650 W of nominal gross power. Stack cooling predominately occurs at the external surface of the tubes where radiation accounts for 66-92% of heat transfer. A strong relationship develops between the power output of a tube and its view factor to the relatively cold cylinder wall surrounding the bundle. The bundle geometry yields seven view factor groupings which correspond to seven power groupings with tube powers ranging from 7.6-10.8 W. Furthermore, the low effectiveness of the co-flow recuperator contributes to lower tube powers at the bundle outer periphery.     

Investigation on performance of an integrated solid oxide fuel cell and absorption chiller tri-generation system

An integrated tri-generation system incorporating a solid oxide fuel cell (SOFC) and a double-effect water/Lithium Bromide absorption chiller is presented in this paper. The proposed tri-generation system can provide power, cooling or heating simultaneously with a typical gas produced from a gasication process. The system conguration and design are discussed, and the energy and mass balances are obtained through the matrix representation method and integrated into a simulation program by MATLAB soft package. The developed model comprises of three modules: SOFC module, exhaust combusting and HRSG module, and the absorption chiller module. Validation of the SOFC model is performed by comparison with a single tubular cell of Siemens-Westinghouse, and a specific case study of the system is presented. For parametric analysis, the fuel utilization ratio, fuel flow ratio and air inlet temperature are investigated and the results are discussed in detail.     

Fuzzy neural control of a hybrid fuel cell/battery distributed power generation system

An innovative control strategy is proposed of hybrid distributed generation (HDG) systems, including solid oxide fuel cell (SOFC) as the main energy source and battery energy storage as the auxiliary power source. The overall configuration of the HDG system is given, and dynamic models for the SOFC power plant, battery bank and its power electronic interfacing are briefly described, and controller design methodologies for the power conditioning units and fuel cell to control the power flow from the hybrid power plant to the utility grid are presented. To distribute the power between power sources, the fuzzy switching controller has been developed. Then, a Lyapunov based-neuro fuzzy algorithm is presented for designing the controllers of fuel cell power plant, DC/DC and DC/AC converters; to regulate the input fuel flow and meet a desirable output power demand. Simulation results are given to show the overall system performance including load-following and power management of the system.     

Improving the load-following capability of a solid oxide fuel cell system through the use of time delay control

As a new energy technology with distributed generation prospects, the load-following capability of solid oxide fuel cell (SOFC) systems is one of the main obstacles for commercial operation. This paper introduces a time delay control with an observer (TDO) in the fuel supply system to enhance the load-following capability to realize rapid load-following without fuel starvation. A dynamic model reflecting a 5-kW SOFC system with components such as a cell stack, combustor, heat exchanger and gas supply is developed in MATLAB/Simulink to implement time delay control. TDO is improved to TDOF (time delay control with an observer and filter) to avoid the undesirable impact of external disturbances (such as fuel disturbances) on the stability of the SOFC system. The fuel supply system can be driven by the TDOF controller to closely follow the reference trajectory based on the past responses and the input variables of the system during load-following operation. Simulation results reveal that the SOFC system is able to meet the requirement of load-following due to the satisfactory dynamic performance when the TDOF controller is applied in the fuel supply system. The system is appropriate for complicated power environments.     

Dynamic modeling of electrical characteristics of solid oxide fuel cells using fractional derivatives

An efficient controller is greatly important for the quick load-following response of solid oxide fuel cell (SOFC) power systems, which is vital for the fuel utilization and the life of the stack. To design such a controller, an accurate dynamic model of SOFC electrical characteristics is critical. Here an integer order dynamic model is established by a transient equivalent circuit, and then a fractional order dynamic model is done in the perspective of the fractional derivatives theory. The parameters of the dynamic models then are optimized via genetic algorithms according to electrochemical impedance spectroscopy (EIS) experimental data. Finally, the dynamic response experiments from the models are studied. The results show that the fractional order dynamic model has higher accuracy for representing the dynamics of the SOFC electrical characteristics, which lays a solid foundation for the controller based on the accurate model.     

Full load synthesis/design optimization of a hybrid SOFC–GT power plant

In this paper, the optimization of a hybrid solid oxide fuel cell–gas turbine (SOFC–GT) power plant is presented. The plant layout is based on an internal reforming SOFC stack; it also consists of a radial gas turbine, centrifugal compressors and plate-fin heat exchangers. In the first part of the paper, the bulk-flow model used to simulate the plant is presented. In the second part, a thermoeconomic model is developed by introducing capital cost functions. The whole plant is first simulated for a fixed configuration of the most important synthesis/design (S/D) parameters in order to establish a reference design configuration. Next a S/D optimization of the plant is carried out using a traditional single-level approach, based on a genetic algorithm. The optimization determined a set of S/D decision variable values with a capital cost significantly lower than that of the reference design, even though the net electrical efficiency for the optimal configuration was very close to that of the initial one. Furthermore, the optimization procedure dramatically reduced the SOFC active area and the compact heat exchanger areas.     

A performance analysis of integrated solid oxide fuel cell and heat recovery steam generator for IGFC system

Solid oxide fuel cell (SOFC) is a promising technology for electricity generation. Sulfur-free syngas from a gas-cleaning unit serves as fuel for SOFC in integrated gasification fuel cell (IGFC) power plants. It converts the chemical energy of fuel gas directly into electric energy, thus high efficiencies can be achieved. The outputs from SOFC can be utilized by heat recovery steam generator (HRSG), which drives the steam turbine for electricity production. The SOFC stack model was developed using the process flow sheet simulator Aspen Plus, which is of the equilibrium type. Various ranges of syngas properties gathered from different literature were used for the simulation. The results indicate a trade-off efficiency and power with respect to a variety of SOFC inputs. The HRSG located after SOFC was included in the current simulation study with various operating parameters. This paper describes IGFC power plants, particularly the optimization of HRSG to improve the efficiency of the heat recovery from the SOFC exhaust gas and to maximize the power production in the steam cycle in the IGFC system. HRSG output from different pressure levels varies depending on the SOFC output. The steam turbine efficiency was calculated for measuring the total power plant output. The aim of this paper is to provide a simulation model for the optimal selection of the operative parameters of HRSG and SOFC for the IGFC system by comparing it with other models. The simulation model should be flexible enough for use in future development and capable of predicting system performance under various operating conditions.     

Control of a solid oxide fuel cell stack based on unmodeled dynamic compensations

To guarantee solid oxide fuel cell (SOFC) safe operation, plenty control strategies have been developed to control stack temperature and voltage within a reasonable range. However, these control approaches ignore unmodeled dynamics of the SOFC system, which may lead to unsatisfactory control results, sometimes even make the system unstable. To overcome this challenge, a unique control strategy which considers unmodeled dynamic compensations of the SOFC system is proposed in this paper. A model of the SOFC system is firstly built, which includes a known linear model and an unmodeled nonlinear dynamic estimation. A nonlinear controller based on the unmodeled dynamic compensation is then developed to force the SOFC to track desired stack temperature and voltage. To evaluate the control performance, the proposed control method is compared with a traditional sliding mode controller. The simulation results show if the unmodeled dynamics have a small effect on the SOFC, both the sliding mode controller and the proposed controller can achieve a precise tracking. If the unmodeled dynamics have a great impact on the SOFC, the temperature and voltage can be well controlled with the proposed control strategy. However, in the sliding mode controller, the temperature and voltage trajectories deviate largely from the reference values.     

A performance analysis of integrated solid oxide fuel cell and heat recovery steam generator for IGFC system

Solid oxide fuel cell (SOFC) is a promising technology for electricity generation. Sulfur-free syngas from a gas-cleaning unit serves as fuel for SOFC in integrated gasification fuel cell (IGFC) power plants. It converts the chemical energy of fuel gas directly into electric energy, thus high efficiencies can be achieved. The outputs from SOFC can be utilized by heat recovery steam generator (HRSG), which drives the steam turbine for electricity production. The SOFC stack model was developed using the process flow sheet simulator Aspen Plus, which is of the equilibrium type. Various ranges of syngas properties gathered from different literature were used for the simulation. The results indicate a trade-off efficiency and power with respect to a variety of SOFC inputs. The HRSG located after SOFC was included in the current simulation study with various operating parameters. This paper describes IGFC power plants, particularly the optimization of HRSG to improve the efficiency of the heat recovery from the SOFC exhaust gas and to maximize the power production in the steam cycle in the IGFC system. HRSG output from different pressure levels varies depending on the SOFC output. The steam turbine efficiency was calculated for measuring the total power plant output. The aim of this paper is to provide a simulation model for the optimal selection of the operative parameters of HRSG and SOFC for the IGFC system by comparing it with other models. The simulation model should be flexible enough for use in future development and capable of predicting system performance under various operating conditions.     

Auxiliary power unit based on a solid oxide fuel cell and fuelled with diesel

An auxiliary power unit (APU) is presented that is fuelled with diesel, thermally self-sustaining, and based on a solid oxide fuel cell (SOFC). The APU is rated at 1 kW electrical, and can generate electrical power after a 3 h warm-up phase. System features include a “dry” catalytic partial oxidation (CPOX) diesel reformer, a 30 cell SOFC stack with an open cathode, and a porous-media afterburner. The APU does not require a supply of external water. The SOFC stack is an outcome of a development partnership with H.C. Starck GmbH and Fraunhofer IKTS, and is discussed in detail in an accompanying paper.     

Modeling of solid oxide fuel cells for dynamic simulations of integrated systems

Solid oxide fuel cell (SOFC) stacks are at the core of complex and efficient energy conversion systems for distributed power generation. Such systems are currently in various stages of development. These power plants of the future feature complicated configurations, because the fuel cell demands for a complex balance of plant. Moreover, proposed SOFC-based systems for stationary applications are often connected to additional components and subsystems, such as a gasifier with its gas-cleaning section, a gas turbine, and a heat recovery system for thermal cogeneration or additional power production. For the simplest SOFC configurations, and more so for complex integrated systems, the dynamic operation of the power plant is challenging, especially because the fluctuating electrical load of distributed energy systems demand for reliable transient operation. Issues related to dynamic operation must be studied in the early design stage and simulation results can be used to optimize the system configuration, taking into account transient behavior. This paper presents the development and the validation of a non-linear dynamic lumped-parameters model of a SOFC stack suitable for integration into models of complex power plants. Particular emphasis is placed on the systematic approach to model development. The model is implemented using the open-source Modelica language, which allows for a high degree of flexibility and modularity, the main features of the model herein presented. The SOFC stack model will be incorporated into ThermoPower, a freely distributed library of reusable software components for the modeling of thermo-hydraulic processes and power plants.     

Performance analysis for the part-load operation of a solid oxide fuel cell–micro gas turbine hybrid system

In this paper, the performance evaluation of a solid oxide fuel cell (SOFC)–micro gas turbine (MGT) hybrid power generation system under the part-load operation was studied numerically. The present analysis code includes distributed parameters model of the cell stack module. The conversions of chemical species for electrochemical process and fuel reformation process are considered. Besides the temperature distributions of the working fluids and each solid part of cell module by accounting heat generation and heat transfers, are taken into calculation. Including all of them, comprehensive energy balance in the cell stack module is calculated. The variable MGT rotational speed operation scheme is adopted for the part-load operation. It will be made evident that the power generation efficiency of the hybrid system decreases together with the power output. The major reason for the performance degradation is the operating temperature reduction in the SOFC module, which is caused by decreasing the fuel supply and the heat generation in the cells. This reduction is also connected to the air flow rate supplement. The variable MGT rotational speed control requires flexible air flow regulations to maintain the SOFC operating temperature. It will lead to high efficient operation of the hybrid system.     

Numerical study of a flat-tube high power density solid oxide fuel cell: Part I. Heat/mass transfer and fluid flow

The flat-tube high power density (HPD) solid oxide fuel cell (SOFC) is a new design developed by Siemens Westinghouse, based on their formerly developed tubular type SOFC. It has increased power density, but still maintains the beneficial feature of secure sealing of a tubular SOFC. In this paper, a three-dimensional numerical model to simulate the steady state heat/mass transfer and fluid flow of a flat-tube HPD-SOFC is developed. In the numerical computation, governing equations for continuity, momentum, mass, and energy conservation are solved simultaneously. The highly coupled temperature, concentration and flow fields of the air stream and the fuel stream inside and outside the different chambers of a flat-tube HPD-SOFC are investigated. The variation of the temperature, concentration and flow fields with the current output is studied. The heat/mass transfer and fluid flow modeling and results will be used to simulate the overall performance of a flat-tube HPD-SOFC, and to help optimize the design and operation of a SOFC stack in practical applications.     

Evaluation of hydrogen and methane-fuelled solid oxide fuel cell systems for residential applications: System design alternative and parameter study

Design-point and part-load characteristics of a solid oxide fuel cell (SOFC) system, fuelled by methane and hydrogen, are investigated for its prospective use in the residential application. As a part of this activity, a detailed SOFC cell model is developed, evaluated and extended to a stack model. Models of all the required balance of plant components are also developed and are integrated to build a system model. Using this model, two system base cases for methane and hydrogen fuels are introduced. Cogeneration relevant performance figures are investigated for different system configurations and cell parameters i.e. fuel utilization, fuel flow rate, operation voltage and extent of internal fuel reforming. The results show high combined heat and power efficiencies for both cases, with higher thermal-to-electric ratio and lower electric efficiency for the hydrogen-fuelled cases. Performance improvements with radiation air pre-heaters and anode gas recycling are presented and the respective application limits discussed.