Fault-tolerant control for steam fluctuation in SOFC system with reforming units

Faults of solid oxide fuel cell (SOFC) systems can affect the characteristics of the stack and inhibit SOFC system commercialization. It has been found that the temperature fluctuation of the burner caused by fluctuation of steam flow rate would greatly affect the temperature of SOFC system and even exceed the safe operation range. Firstly, this paper introduces a mathematical model for the process of steam and natural gas reforming in a real SOFC system. Secondly, the cause of the burner temperature fluctuation is analyzed, and the model to simulate this faulty situation is established. Then, the Bayesian regularization neural network is used for fault diagnosis and good test results are obtained. Finally, fuzzy fault-tolerant control strategy is designed for the thermal safety problem of SOFC system. The simulation results validate the effectiveness of the proposed fault-tolerant control strategy.     

Parameter optimization study on SOFC‐MGT hybrid power system

This paper mainly studied the solid oxide fuel cell (SOFC)–micro gas turbine (MGT) hybrid power system. The key parameters that greatly influence the overall system performance have been studied and optimized. The thermodynamic potential of improving the hybrid system performance by integrating SOFC with the advanced thermal cycle system is analyzed. The optimization rules of main parameters of SOFC‐MGT hybrid power system with the turbine inlet temperature (TIT) of MGT as a constraint condition are revealed. The research results show that TIT is a key parameter that limits the electrical efficiency of hybrid power system. With the increase of the cell number, both the power generation efficiency of the hybrid cycle power system and TIT increase. Regarding the hybrid system with the fixed cell number, in order to get a higher electrical efficiency, the operating temperature of SOFC should be enhanced as far as possible. However, the higher operating temperature will result in the higher TIT. Increasing of fuel utilization factor is an effective measure to improve the performance of hybrid system. At the same time, TIT increases slightly. Both the electrical efficiency of hybrid power system and TIT reduce with the increase of the ratio of steam to carbon. The achievements obtained from this paper will provide valuable information for further study on SOFC‐MGT hybrid power system with high efficiency. Copyright © 2010 John Wiley & Sons, Ltd.     

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.     

Thermodynamic,exergoeconomic and exergoenvironmental analyses and optimization of a solid oxide fuel cell-based trigeneration system

This study proposes a trigeneration system based on solid oxide fuel cell (SOFC) for generating power, cooling and heating simultaneously. The system mainly contains a SOFC, a gas turbine (GT), an organic Rankine cycle (ORC), a steam ejector refrigerator (SER) and a heat exchanger. The thermodynamic, exergoeconomic and exergoenvironmental models of proposed trigeneration system are developed, and the effects of design parameters on system performances are analyzed. The results indicate that the system average product cost and environmental impact per unit of exergy increase with SOFC inlet temperature and working pressure, the pinch point temperature difference and evaporating pressure of Generator, while decrease with the current density of fuel cell. Finally, optimization is performed to achieve the optimal exergy-based performance. It is revealed that though the system exergy efficiency is decreased by 7.64% after optimization, the system average product cost and environmental impact per unit of exergy are significantly reduced.     

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.     

Design and partial load exergy analysis of hybrid SOFC–GT power plant

This paper presents a full and partial load exergy analysis of a hybrid SOFC–GT power plant. The plant basically consists of: an air compressor, a fuel compressor, several heat exchangers, a radial gas turbine, mixers, a catalytic burner, an internal reforming tubular solid oxide fuel cell stack, bypass valves, an electrical generator and an inverter. The model is accurately described. Special attention is paid at the calculation of SOFC overpotentials. Maps are introduced, and properly scaled, in order to evaluate the partial load performance of turbomachineries. The plant is simulated at full-load and part-load operation, showing energy and exergy flows trough all its components and thermodynamic properties at each key-point. At full-load operation a maximum value of 65.4% of electrical efficiency is achieved. Three different part-load strategies are introduced. The off-design operation is achieved handling the following parameters: air mass flow rate, fuel mass flow rate, combustor bypass, gas turbine bypass, avoiding the use of a variable speed control system. Results showed that the most efficient part-load strategy corresponded to a constant value of the fuel to air ratio. On the other hand, a lower value of net electrical power (34% of nominal load) could be achieved reducing fuel flow rate, at constant air flow rate. This strategy produces an electrical efficiency drop that becomes 45%.     

Performance optimization of polymer electrolyte membrane fuel cells using the Nelder-Mead algorithm

The direct-search simplex method for function optimization has been adapted to performance optimization of polymer electrolyte membrane fuel cells (PEMFCs). The established method is strongly application oriented and uses only experimentally determined data for optimization. It is not restricted to discrete parameters optimums and does not require the use of third-party software or computational resources. Hence, it is easy to implement in fuel cell testing stations. The optimization consists of finding, for a given fuel cell load, an optimum set of values of the 7 fuel cell operating parameters: the fuel cell temperature, the reactants' stoichiometric ratios, the reactants' inlet relative humidity, and the reactants' outlet pressures, resulting in the highest fuel cell performance. The performance is measured using a scalar function of the operating parameters and the load and can be defined according to needs.Two PEMFC performance functions: the fuel cell voltage and the system-related fuel cell efficiency were optimized using the procedure for practically sized PEMFC stacks of two designs. With respect to the nominal operating conditions defined as optimal for each stack design by its manufacturer, the gains from the optimization procedure were up to over 12% and up to over 7% for the stack voltage and efficiency, respectively. The validation of the procedure involved 5 stack specimens and four laboratories and consistent results were obtained.     

Thermal modeling of a solid oxide fuel cell and micro gas turbine hybrid power system based on modified LS-SVM

For a solid oxide fuel cell (SOFC) integrated into a micro gas turbine (MGT) hybrid power system, SOFC operating temperature and turbine inlet temperature are the key parameters, which affect the performance of the hybrid system. Thus, a least squares support vector machine (LS-SVM) identification model based on an improved particle swarm optimization (PSO) algorithm is proposed to describe the nonlinear temperature dynamic properties of the SOFC/MGT hybrid system in this paper. During the process of modeling, an improved PSO algorithm is employed to optimize the parameters of the LS-SVM. In order to obtain the training and prediction data to identify the modified LS-SVM model, a SOFC/MGT physical model is established via Simulink toolbox of MATLAB6.5. Compared to the conventional BP neural network and the standard LS-SVM, the simulation results show that the modified LS-SVM model can efficiently reflect the temperature response of the SOFC/MGT hybrid system.     

Modeling and analysis of a 5 kWe HT-PEMFC system for residential heat and power generation

We present a high-temperature proton exchange membrane fuel cell (HT-PEMFC) system model that accounts for fuel reforming, HT-PEMFC stack, and heat-recovery modules along with heat exchangers and balance of plant (BOP) components. In the model developed for analysis, the reaction kinetics for the fuel reforming processes are considered to accurately capture exhaust gas compositions and reactor temperatures under various operating conditions. The HT-PEMFC stack model is simplified from the three-dimensional HT-PEMFC CFD models developed in our previous studies. In addition, the parasitic power consumption and waste heat release from the various BOP components are calculated based on their heat-capacity curves. An experimental fuel reforming reactor for a 5.0 kW_e HT-PEMFC system was tested to experimentally validate the fuel reforming sub model. The model predictions were found to be in good agreement with the experimental data in terms of exhaust gas compositions and bed temperatures. Additionally, the simulation revealed the impacts of the burner air-fuel ratio (AFR) and the steam reforming reactor steam-carbon ratio on the system performance and efficiency. In particular, the combined heat and power efficiency of the system increased up to 78% when the burner AFR was properly adjusted. This study clearly illustrates that an HT-PEMFC system requires a high degree of thermal integration and optimization of the system configuration and operating conditions.     

Fuzzy-based multi-objective optimization of DMFC system efficiencies

To improve the fuel efficiency and total exergetic efficiency of a non-isothermal direct methanol fuel cell (DMFC) system, the multi-objective optimization problem is addressed in this article. Under incommensurable multiple goals, the fuzzy inference with two-phase procedures is applied for finding the locally Pareto-optimal solution. Through an iterative optimization programming, a piecewise optimal control action is effectively generated at each time period. Finally, the optimal operating manner by manipulating anode inlet temperature is successfully demonstrated by the dynamic simulation.     

Optimization of a solid oxide fuel cell and micro gas turbine hybrid system

For a solid oxide fuel cell (SOFC) and micro gas turbine (MGT) hybrid system, optimal control of load changes requires optimal dynamic scheduling of set points for the system's controllers. Thus, this paper proposes an improved iterative particle swarm optimization (PSO) algorithm to optimize the operating parameters under various loads. This method combines the iteration method and the PSO algorithm together, which can execute the discrete PSO iteratively until the control profile would converge to an optimal one. In MATLAB environment, the simulation results show that the SOFC/MGT hybrid model with the optimized parameters can effectively track the output power with high efficiency. Hence, the improved iterative PSO algorithm can be helpful for system analysis, optimization design, and real‐time control of the SOFC/MGT hybrid system. Copyright © 2011 John Wiley & Sons, Ltd.     

Performance characteristics of a robust and compact propane-fueled 150 W-class SOFC power-generation system

A propane-fueled solid-oxide fuel-cell-based system is an extraordinary type of technology for stationary mobile power generation given that it offers higher efficiency, silent operation and clean conversion of hydrocarbon fuels. In this study, we designed and developed a 150 W-class tubular SOFC power-generation system integrated with a catalytic partial reformer (CPOX) for the propane fuel and heat exchangers with the goal of making a robust and compact system for portable power applications. Micro-tubular SOFC cells were fabricated by ceramic processing and the cells were assembled in the form of a short stack. The CPOX nano-catalyst CeO₂Zr₂O₃/Pt supported on γ-Al₂O₃ was prepared and tested for its propane-reforming characteristics under the present operating conditions. The CPOX catalyst was used in the integrated reformer, and the performance of the 150 W-class SOFC power-generation system operating on propane fuel was studied. The rapid startup and temperature sustainability of the short stack were also monitored and stable stack temperatures were achieved within 20 min. Long-term galvanostatic operation of the power-generation system was also conducted to investigate the durability of the system. This study confirms that propane-fueled robust and compact 150 W-class power-generation systems are suitable for portable applications and that the role of efficient CPOX catalysts is crucial for high performance of the stack when operating on propane fuel.     

Numerical analysis of output characteristics of tubular SOFC with internal reformer

In the solid oxide fuel cell (SOFC) system, the internal reforming of raw fuel will act as an efficient cooling system. To realize this cooling system, a special design of the internal reformer is required to avoid the inhomogeneous temperature distribution caused by the strong endothermic reforming reaction at the entrance of the internal reformer. For this purpose, a tubular internal reformer with adjusted catalyst density can be inserted into the tubular SOFC stack. By arranging this, the raw fuel flows along the axis of the internal reformer to be moderately reformed and returns at the end of the internal reformer as a sufficiently reformed fuel.In this paper, the output characteristics of this configuration are simulated using mathematical models, in which one-dimensional temperature and molar distributions are computed along the flow direction. By properly mounting the catalyst density in the internal reformer, the temperature distribution of the cell stack becomes moderate, and the power generation efficiency and the exhaust gas temperature are higher. Effects of other operating conditions such as fuel recirculation, fuel inlet temperature, air recirculation and air inlet temperature are also examined under the condition where the maximum temperature of the stack is kept at 1300 K by adjusting the air flow rate. Under this condition, these operating conditions exert a considerable effect on the exhaust temperature but have a slight effect on the efficiency.     

Inverse neural network based control strategy for absorption chillers

This paper proposes a novel, model-based control strategy for absorption cooling systems. First, a small-scale absorption chiller was modelled using artificial neural networks (ANNs). This model takes into account inlet and outlet temperatures as well as the flow rates of the external water circuits. The configuration 9-6-2 (9 inputs, 6 hidden and 2 output neurons) showed excellent agreement between the prediction and the experimental data (R² > 0.99 and RMSE < 0.05%). This type of ANN model is used to explain the behaviour of the system when operating conditions are measured and these measurements are available. A control strategy was also developed by using the inverse artificial neural network (ANNi) method. For a particular output (cooling load) the ANNi calculates the optimal unknown parameter(s) (controlling temperatures and flow rates). An optimization method was used to fit the unknown parameters of the ANNi method. The very low percentage of error and short computing time make this methodology suitable for the on-line control of absorption cooling systems.     

Effects of operating and design parameters on the performance of a solid oxide fuel cell–gas turbine system

We present a steady‐state thermodynamic model of a hybrid solid oxide fuel cell (SOFC)–gas turbine (GT) cycle developed using a commercial process simulation software, AspenPlus?. The hybrid cycle model incorporates a zero‐dimensional macro‐level SOFC model. A parametric study was carried out using the developed model to study the effects of system pressure, SOFC operating temperature, turbine inlet temperature, steam‐to‐carbon ratio, SOFC fuel utilization factor, and GT isentropic efficiency on the specific work output and efficiency of a generic hybrid cycle with and without anode recirculation. The results show that system pressure and SOFC operating temperature increase the cycle efficiency regardless of the presence of anode recirculation. On the other hand, the specific work decreases with operating temperature. Overall, the model can successfully capture the complex performance trends observed in hybrid cycles. Copyright © 2010 John Wiley & Sons, Ltd.     

Influence of current densities in SOFC and PEFC stacks on a SOFC–PEFC combined system

A solid oxide fuel cell (SOFC)–polymer electrolyte fuel cell (PEFC) combined system was investigated by numerical simulation. Here, the effect of the current densities in the SOFC and the PEFC stacks on the system's performance is evaluated under a constant fuel utilization condition. It is shown that the SOFC–PEFC system has an optimal combination of current densities, for which the electrical efficiency is highest. The optimal combination exists because the cell voltage in one stack increases and that of the other stack decreases when the current densities are changed. It is clarified that there is an optimal size of the PEFC stack in the parallel-fuel-feeding-type SOFC–PEFC system from the viewpoint of efficiency, although a larger PEFC stack always leads to higher electrical efficiency in the series-fuel-feeding-type SOFC–PEFC system. The 40 kW-class PEFC stack is suitable for the 110 kW-class SOFC stack in the parallel-fuel-feeding type SOFC–PEFC system.     

Performance analysis and temperature gradient of solid oxide fuel cell stacks operated with bio-oil sorption-enhanced steam reforming

A high temperature gradient within a solid oxide fuel cell (SOFC) stack is considered a major challenge in SOFC operations. This study investigates the effects of the key parameters on SOFC system efficiency and temperature gradient within a SOFC stack. A 40-cell SOFC stack integrated with a bio-oil sorption-enhanced steam reformer is simulated using MATLAB and DETCHEM. When the air-to-fuel ratio and steam-to-fuel ratio increase, the stack average temperature and temperature gradient decrease. However, a decrease in the stack temperature steadily reduces the system efficiency owing to the tradeoff between the stack performance and thermal balance between heat recovered and consumed by the system. With an increase in the bio-oil flow rate, the system efficiency decreases because of the lower resident time for the electrochemical reaction. This is not, however, beneficial to the maximum temperature gradient. To minimize the temperature gradient of the SOFC stack, a decrease in the bio-oil flow rate is the most effective way. The maximum temperature gradient can be reduced to 14.6 K cm⁻¹ with the stack and system efficiency of 76.58 and 65.18%, respectively, when the SOFC system is operated at an air-to-fuel ratio of 8, steam-to-fuel ratio of 6, and bio-oil flow rate of 0.0041 mol s⁻¹.     

Numerical evaluation of a parallel fuel feeding SOFC–PEFC system using seal-less planar SOFC stack

We propose a system that combines a seal-less planar solid oxide fuel cell (SOFC) stack and polymer electrolyte fuel cell (PEFC) stack. In the proposed system, fuel for the SOFC (SOFC fuel) and fuel for the PEFC (PEFC fuel) are fed to each stack in parallel. The steam reformer for the PEFC fuel surrounds the seal-less planar SOFC stack. Combustion exhaust heat from the SOFC stack is used for reforming the PEFC fuel. We show that the electrical efficiency in the SOFC–PEFC system is 5% higher than that in a simple SOFC system using only a seal-less planar SOFC stack when the SOFC operation temperature is higher than 973 K.     

Improvement of hollow cylinders on the conversion of coal mine methane to hydrogen in packed bed burner

Coal mine methane (CMM) combustion in the porous media burner (PMB) of boiler system contributes to the simultaneous production of hydrogen and heat, and the hydrogen can be used as the main raw materials for solid oxide fuel cell (SOFC). In this study, the double-layer burners were built by filling the downstream with the hollow cylinders of different sizes and pore numbers due to the high porosity of hollow-structure units compared with the common packed bed of pellets. The distributions of temperature, species concentration and reforming efficiency were obtained on the consideration of operating condition and preheating temperature. Results shows that the reforming efficiency of the 10-6-10 mm cylinder burner was optimal in all one-pore cylinder burners with the highest concentration of 12.3% (H₂) and 8.8% (CO). As for the packed bed of 8 mm cylinders, the four-pore cylinder burner showed the highest peak temperature and maximum yields of hydrogen. With the increasing of preheating temperature, the stabilization time of the flame propagating decreased. Moreover, the peak temperature and reforming efficiency increased with the increasing of the inlet velocity and the largest efficiency of 54.2% appeared at the velocity of 18 cm/s in the 10 mm cylinder burner.     

Experimental simulation on the integration of solid oxide fuel cell and micro-turbine generation system

Solid oxide fuel cell (SOFC) is characterized in high performance and high temperature exhaust, and it has potential to reach 70% efficiency if combined with gas turbine engine (GT). Because the SOFC is in developing stage, it is too expensive to obtain. This paper proposes a feasibility study by using a burner (Comb A) to simulate the high temperature exhaust gas of SOFC. The second burner (Comb B) is connected downstream of Comb A, and preheated hydrogen is injected to simulate the condition of sequential burner (SeqB). A turbocharger and a water injection system are also integrated in order to simulate the situation of a real SOFC/GT hybrid system. The water injection system is used to simulate the water mist addition at external reformer.