Modelling and Performance Evaluation of Solid Oxide Fuel Cell for Building Integrated Co‐ and Polygeneration

Models of fuel cell based combined heat and power systems, used in building energy performance simulation codes, are often based on simple black or grey box models. To model a specific device, input data from experiments are often required for calibration. This paper presents an approach for the theoretical derivation of such data. A generic solid oxide fuel cell (SOFC) system model is described that is specifically developed for the evaluation of building integrated co‐ or polygeneration. First, a detailed computational cell model is developed for a planar SOFC and validated with available numerical and experimental data for intermediate and high temperature SOFCs with internal reforming (IT‐DIR and HT‐DIR). Results of sensitivity analyses on fuel utilisation and air excess ratio are given. Second, the cell model is extended to the stack model, considering stack pressure losses and the radiative heat transfer effect from the stack to the air flow. Third, two system designs based on the IT‐DIR and HT‐DIR SOFCs are modelled. Electric and CHP efficiencies are given for the two systems, as well as performance characteristics, to be used in simulations of building integrated co‐ and polygeneration systems.     

固体氧化物燃料电池的研究进展

固体氧化物燃料电池(SOFC)是先进陶瓷材料的一种重要应用,可以通过电化学反应将燃料的化学能直接转换为电能。SOFC具有效率高、性能稳定、便携、低污染等优点,可以实现能源的有效清洁利用。本文结合国内外SOFC的研究情况,分析讨论了SOFC的技术优势、地方产业优势及产业难题,并结合国家政策方面对我国SOFC产业的未来发展做了展望。     

Experimental Study of Internal Reforming on Large‐area Anode Supported Solid Oxide Fuel Cells

The effect of endothermic internal steam reformation of methane and exothermic fuel cell reaction on the temperature of a planar‐type anode‐supported solid oxide fuel cell was experimentally investigated as a function of current density and fuel utilization. We fabricated a large‐area (22 × 33 cm²) cell and compared temperature profiles along the cell using 30 thermocouples inserted through the cathode end plate at 750 °C under various conditions (Uf ∼50% at 0.4 A cm⁻²; Uf ∼70% at 0.4 A cm⁻²; Uf ∼50% at 0.2 A cm⁻²) with hydrogen fuel and methane‐steam internal reforming. The endothermic effect due to internal reforming mainly occurs at the gas inlet region, so this process is not very effective to cool down the hot spot created by the exothermic fuel cell reaction. This eventually results in a larger temperature difference on the cell. The most moderate condition with regards to thermal gradient on the cell corresponds to high fuel utilization (Uf ∼70%) and low current density (∼0.2 A cm⁻²). The electrochemical performance was also measured, and it was found that the current–voltage characteristics are comparable for the cell operated under hydrogen fuel and internal steam reforming of methane because of lower polarization resistance with high partial pressure of water vapor.     

Modelling of a Pressure Element for Solid Oxide Fuel Cell Stack

The paper deals with the structural analysis of a corrugated pressure element for the SOFC stack. The aim of the element application is assurance of the fuel cell tightness and sufficient electrical contact between components by means of its uniform pressure. In this paper, a method of the pressure element modelling is proposed and results of its behaviour analysis for different assembly conditions (free ends, fixed ends and ends subjected to friction force) are presented. Vertical and horizontal stiffness of the corrugated element as a function of its geometrical parameters has been determined which facilitates computer simulation and engineering design of the element.     

Electrochemical Impedance Modeling of a Solid Oxide Fuel Cell Anode

A simulation package for the impedance response of SOFC anodes is presented here. The model couples the gas transport in gas channels and within a porous electrode with the electrochemical kinetics. The gas phase mass transport is modeled using mass conservation equations. A transmission line model (TLM), which is suitably modified to account for the electrode microstructural details, is used for modeling the impedance arising from the electrochemical reactions. In order to solve the system of nonlinear equations, an in‐house code based on the finite difference method was developed. Some of the model constants have been calibrated against experimental data. It is demonstrated that the simulation tool is capable of predicting the impedance response of an experimental data set obtained on symmetrical cells with Ni/ScYSZ SOFC anodes. A parametric study is also carried out using the developed simulation tool and the results are further discussed.     

Modeling a Reversible Solid Oxide Fuel Cell as a Storage Device Within AC Power Networks

A reversible solid oxide fuel cell (RSOFC) system, consisting of a RSOFC stack, heat store, and electrical inverters to convert DC to AC power, is shown by computer modeling to have the potential to efficiently store electrical energy. This paper describes the modeling of a single RSOFC, based on a proposed cell geometry, empirical data on the resistivities of the components, and calculation of activation and diffusion polarization resistances from electrochemical theory. Data from ac impedance spectroscopy measurements on symmetrical cells are used to model RSOFC impedance. A RSOFC stack is modeled by electrically linking the individual cells inside a pressurized vessel. A phase change heat store is added to improve energy storage efficiency. The model is implemented in MATLAB®/Simulink®. Two competing inverter control schemes are compared, trading off DC bus ripple against AC power quality. It is found that selection of appropriate DC bus capacitance is important in certain scenarios, with potential system cost implications. It is shown that the system can store electrical energy at an efficiency of 64% over a single discharge–charge cycle, i.e., hydrogen to electricity and heat to hydrogen.     

Thermodynamic Analysis of Solid Oxide Fuel Cell Gas Turbine Systems Operating with Various Biofuels

Solid oxide fuel cell–gas turbine (SOFC‐GT) systems provide a thermodynamically high efficiency alternative for power generation from biofuels. In this study biofuels namely methane, ethanol, methanol, hydrogen, and ammonia are evaluated exergetically with respect to their performance at system level and in system components like heat exchangers, fuel cell, gas turbine, combustor, compressor, and the stack. Further, the fuel cell losses are investigated in detail with respect to their dependence on operating parameters such as fuel utilization, Nernst voltage, etc. as well as fuel specific parameters like heat effects. It is found that the heat effects play a major role in setting up the flows in the system and hence, power levels attained in individual components. The per pass fuel utilization dictates the efficiency of the fuel cell itself, but the system efficiency is not entirely dependent on fuel cell efficiency alone, but depends on the split between the fuel cell and gas turbine powers which in turn depends highly on the nature of the fuel and its chemistry. Counter intuitively it is found that with recycle, the fuel cell efficiency of methane is less than that of hydrogen but the system efficiency of methane is higher.     

Direct Internal Reformation and Mass Transport in the Solid Oxide Fuel Cell Anode: A Pore‐scale Lattice Boltzmann Study with Detailed Reaction Kinetics

The solid oxide fuel cell (SOFC) allows the conversion of chemical energy that is stored in a given fuel, including light hydrocarbons, to electrical power. Hydrocarbon fuels, such as methane, are logistically favourable and provide high energy densities. However, the use of these fuels often results in a decreased efficiency and life. An improved understanding of the reactive flow in the SOFC anode can help address these issues. In this study, the transport and heterogeneous internal reformation of a methane based fuel is addressed. The effect of the SOFC anode's complex structure on transport and reactions is shown to exhibit a complicated interplay between the local molar concentrations and the anode structure. Strong coupling between the phenomenological microstructures and local reformation reaction rates are recognised in this study, suggesting the extension to actual microstructures may provide new insights into the reformation processes.     

Doped Germanate‐Based Apatites as Electrolyte for Use in Solid Oxide Fuel Cells

Apatite ceramics, known for their good electrical conductivities, have garnered substantial attention as an alternative electrolyte for solid oxide fuel cells (SOFCs). However, studies focusing on the electrochemical performances of SOFCs with apatities as electrolytes remain rare, partly due to their high sintering temperature. In this study, the effects of Mg²⁺, Al³⁺, Ga³⁺, and Sn⁴⁺ dopants on the characteristics of La_9.5Ge₆O_{26 ± δ} are examined and their potential for use as SOFC electrolytes evaluated. The results indicate that La_9.5Ge_5.5Al_0.5O₂₆ is stabilized into a hexagonal structure, while the La_9.5Ge_5.5Sn_0.5O_26.25, La_9.5Ge_5.5Ga_0.5O₂₆, and La_9.5Ge_5.5Mg_0.5O_25.75 ceramics reveal triclinic cells accompanied with the second phase La₂Sn₂O₇ or La₂GeO₅. The study further demonstrates that a high sintering temperature is needed for both the La_9.5Ge_5.5Mg_0.5O_25.75 and the La_9.5Ge_5.5Sn_0.5O_26.25 ceramics, and the worst electrical conductivity among the examined systems appears in the La_9.5Ge_5.5Ga_0.5O₂₆ ceramic. The La_9.5Ge_5.5Al_0.5O₂₆ ceramic is accordingly selected for cell evaluation due to its ability to reach densification at 1,350 °C, its good electrical conductivity of 0.026 S cm^–1 at 800 °C, and its acceptable thermal expansion coefficient of 10.1 × 10^–6 K^–1. The maximum power densities of the NiO‐SDC/La_9.5Ge_5.5Al_0.5O₂₆/LSCF‐SDC single cell are found to be respectively 0.22, 0.16, 0.11, and 0.07 W cm^–2 at 950, 900, 850, and 800 °C.     

A Novel Method for GDC Recovery During Solid Oxide Fuel Cell Manufacturing

There have been a tremendous research affects in recent years for alternative routes of electricity generation using some maximum yield technologies, increased reliability, and minimum pollution. From this point of view, the solid oxide fuel cells (SOFCs) are considered as the cleanest technologies for obtaining electrical energy generation. However, an important fraction of production is wasted during the manufacturing steps. From both economical and environmental point of view, recovery of waste GDC (Gd_0.1Ce_0.9O₃) materials is deemed important. Hence, it is the main purpose of the present study to develop a novel method to recover waste GDC materials and afterwards to produce a new SOFC (solid oxide fuel cell) from the recovered materials. The results showed that recovered GDC cell worked as efficient as the fresh materials, revealing the success of the recovery process proposed.     

The Case for Natural Gas Fueled Solid Oxide Fuel Cell Power Systems for Distributed Generation

Natural‐gas‐fueled solid oxide fuel cell (NGSOFC) power systems yield electrical conversion efficiencies exceeding 55% and may become a viable alternative for distributed generation (DG) if stack life and manufacturing economies of scale can be realized. Currently, stacks last approximately 2 years and few systems are produced each year because of the relatively high cost of electricity from the systems. PNNL has performed cost modeling for production of 270 kW (DC) NGSOFC power systems, sized for light industry or large box stores. If mass manufacturing (10.000 units per year) and a stack life of 15 years can be reached, the cost of electricity from an NGSOFC system is estimated to be about 8,2 ¢/kWh, well within the range of commercial and residential retail prices at the national level (9,9–10 ¢/kWh and 11–12 ¢/kWh, respectively). With 5 ¢/kWh in estimated additional benefits from DG, NGSOFC could be well positioned to replace the forecasted 59–77 gigawatts of capacity loss resulting from coal plant closures due to stricter emissions regulations and low natural gas prices.     

Effect of Creep of Ferritic Interconnect on Long‐Term Performance of Solid Oxide Fuel Cell Stacks

High‐temperature ferritic alloys are potential candidates as interconnect (IC) materials and spacers due to their low cost and coefficient of thermal expansion (CTE) compatibility with other components for most of the solid oxide fuel cells (SOFCs). However, creep deformation becomes relevant for a material when the operating temperature exceeds or even is less than half of its melting temperature (in degrees of Kelvin). The operating temperatures for most of the SOFCs under development are around 1,073 K. With around 1,800 K of the melting temperature for most stainless steel (SS), possible creep deformation of ferritic IC under the typical cell operating temperature should not be neglected. In this paper, the effects of IC creep behaviour on stack geometry change and the stress redistribution of different cell components are predicted and summarised. The goal of the study is to investigate the performance of the fuel cell stack by obtaining the changes in fuel‐ and air‐channel geometry due to creep of the ferritic SS IC, therefore indicating possible changes in SOFC performance under long‐term operations. The ferritic IC creep model was incorporated into software SOFC‐MP and Mentat‐FC, and finite element analyses (FEAs) were performed to quantify the deformed configuration of the SOFC stack under the long‐term steady‐state operating temperature. It was found that the creep behaviour of the ferritic SS IC contributes to narrowing of both the fuel‐ and the air‐flow channels. In addition, stress re‐distribution of the cell components suggests the need for a compliant sealing material that also relaxes at operating temperature.     

Long‐Term Stability Studies of Anode‐Supported Microtubular Solid Oxide Fuel Cells

A long‐term stability study of an anode‐supported NiO/YSZ‐YSZ‐LSM/YSZ microtubular cell was performed, under low fuel utilization conditions, using pure humidified hydrogen as fuel at the anode side and air at the cathode side. A first galvanometric test was performed at 766 °C and 200 mA cm^–2, measuring a power output at 0.5 V of ∼250 mW cm^–2. During the test, some electrical contact breakdowns at the anode current collector caused sudden current shutdowns and start‐up events. In spite of this, the cell performance remains unchanged. After a period of 325 h, the cell temperature and the current density was raised to 873°C and 500 mA cm^–2, and the cell power output at 0.5 V was ∼600 mW cm^–2. Several partial reoxidation events due to disturbance in fuel supply occurred, but no apparent degradation was observed. On the contrary, a small increase in the cell output power of about 4%/1,000 h after 654 h under current load was obtained. The excellent cell aging behavior is discussed in connection to cell configuration. Finally, the experiment concluded when the cell suffered irreversible damage due to an accidental interruption of fuel supply, causing a full reoxidation of the anode support and cracking of the thin YSZ electrolyte.     

Modeling and Parametric Study of a Single Solid Oxide Fuel Cell by Finite Element Method

A 2D isothermal axisymmetric model of an anode‐supported solid oxide fuel cell has been developed. The model, which is based on finite element approach, comprises electronic and ionic charge balance, Butler–Volmer charge transfer kinetic, flow distribution and gas phase mass balance in both channels and porous electrodes. The model has been validated using available experimental data coming from a single anode‐supported cell comprising Ni–YSZ/YSZ/LSM–YSZ as anode, electrolyte and cathode, respectively. Hydrogen and steam were used as fuel inlet and air as an oxidant. The validation has been carried out at 1 atm, 1,500 ml min^–1 air flow rate and three different operating conditions of temperature and fuel flow rate: 1,073 K and 400 ml min^–1, 1,073 K and 500 ml min^–1, and 1,003 K and 400 ml min^–1. The polarization and power density versus current density curves show a good agreement with the experimental data. A parametric analysis has been carried out to highlight which parameters have main effect on the overall cell performance as measured by polarization curve, especially focusing on the influence of two geometrical characteristics, temperature and some effective material properties.     

Effects of PH3 and CH3Cl Contaminants on the Performance of Solid Oxide Fuel Cells

Solid oxide fuel cells (SOFCs) have been considered as one of the most efficient power generators that can directly convert chemical energy in the natural gas, biomass, or coal‐derived gas to electrical energy. Various contaminants in syngas are capable to cause catalyst malfunction and cell performance drop, limiting fuel cell to a wide application. The effects of PH₃ and CH₃Cl fuel impurities on the electrochemical performance of SOFCs are investigated at various testing conditions. Performance drop caused by the addition of 10 ppm PH₃ remains identical in pure hydrogen and simulated coal‐derived syngas at 750 °C, but a slight increase is observed when the cells are fueled syngas at 850 °C. The presence of CH₃Cl in syngas causes cell degradation to a larger extent at 850 °C. Moreover, the cooperative influences of PH₃ and CH₃Cl impurities in hydrogen are also studied at 750, 800, and 850 °C. The addition of CH₃Cl can stop and remove PH₃ poisoning behavior, which is associated with each contaminant concentrations and operational temperatures. The related mechanism has been deeply analyzed and diagnosed.     

Enhanced Performance of Solid Oxide Fuel Cell by Manipulating the Orientation of Cylindrical Pores in Anode Substrate

Effect of the orientation of cylindrical pores within an anode has been studied on the performance of anode‐supported solid oxide fuel cell (SOFC). Paper‐fibers are used as pore‐former and highly oriented cylindrical pores are formed within the anode prepared by uniaxial compaction. A thick anode brick is fabricated followed by cutting in different directions to obtain anode substrates with desirable orientation of pores. When the orientation of cylindrical pores is perpendicular to the anode surface, the gas transport is significantly improved so that the reduction rate of the NiO/YSZ anode is considerably accelerated and the cell concentration polarization is minimized. The corresponding single cell exhibits a maximum power density as high as 1.54 W cm^–2 in hydrogen and 0.90 W cm^–2 in nitrogen diluted methane at 800 °C. The result indicates that the output performance of anode‐supported cells could be significantly improved by manipulating the orientation of pores.     

Effects of Microstructural Functional Layers on Flat‐Tubular Solid Oxide Fuel Cells

The functional layer of a flat‐tubular solid oxide fuel cell (SOFC) is examined using a three‐dimensional microscale electrode model. SOFC electrodes essentially include two types of layers: a structural layer and a functional layer. The structural layers, which are the anode support layer and the cathode current collector layer, are composed of large particles with a high porosity that facilitates gas diffusion. The functional layers consist of small particles with a low porosity that increases the triple phase boundary (TPB) reaction area and reduces the activation overpotential. In the model, the particle diameter and functional layer thickness are adjusted and analyzed. The effects of the two parameters on the performance of the functional layer are monitored in the contexts of several multilateral approaches. Most reactions occurred near the electrode–electrolyte interface; however, an electrode design that included additional TPB areas improved the electrode performance. The role of the functional layer in a flat‐tubular SOFC is examined as a function of the functional layer particle size and thickness. The performance of a cell could be enhanced by preparing a functional layer using particles of optimal size and thickness, and by operating the device under conditions optimized for these parameters.     

Analysis of Leakages in a Solid Oxide Fuel Cell Stack in a System Environment

A solid oxide fuel cell (SOFC) stack can exhibit both anodic and cathodic leakages, i.e. a fuel leak from the anode side and an air leak from the cathode side of the stack, respectively. This study describes the results of an in‐situ leakage analysis conducted for a planar SOFC stack during 2000 hours of operation in an actual system environment. The leakages are quantified experimentally at nominal system operating conditions by conducting composition analysis and flow metering of gases for both fuel and air subsystems. Based on the calculated atomic hydrogen‐to‐carbon ratio of the fuel and air gases, it is found that the fuel leakages are mostly selective by nature: the leaking fuel gas does not have the same composition as the fuel system gas. A simple diffusive leakage model, based on the leakage being driven by concentration differences weighted by diffusion coefficients, is applied to quantify the amount of leakages. The leakage model provides a good correspondence with the experimental results of the gas analysis.     

A Performance Prediction Tool for Solid Oxide Fuel Cells after Single Redox Cycle

The effects of anode support fabrication parameters on the cell performance and the redox behavior of the cell are investigated experimentally and theoretically. In the experimental program, an yttria stabilized zirconia based anode supported membrane electrode group (MEG) is developed via the tape casting, co‐sintering and screen printing methodologies. For comparison, various anode supported cells with different electrolyte thickness and anode support porosities are also fabricated. In the theoretical study, a mathematical model is developed to represent the fluid flow, the heat transfer, the species transport and the electrochemical reaction in solid oxide fuel cells. In addition, a redox model representing the mechanical damage in the electrochemical reaction zones due to redox cycling is developed by defining a damage function as a function of strain and a damage coefficient. The effects of anode support porosity and the electrolyte thickness on the cell performance and redox stability of the cells are numerically investigated. The experimental results are compared with the numerical results to validate the mathematical model. Finally, a predictive tool, which is valid for the ranges of the cell fabrication parameters investigated, is developed to estimate the electrochemical performance after single redox cycle.     

Effect of Anode off‐gas Recycling on Reforming of Natural Gas for Solid Oxide Fuel Cell Systems

The effect of anode off‐gas recycling (AOGR) on the characteristic performance of a natural gas reformer equipped with a precious metal catalyst is investigated experimentally. The reformer is operated both with synthetic AOGR gas and in steam reforming (SR) conditions. The characteristic performance in SR and AOGR mode are compared with equilibrium, and it is found that equilibrium is more readily achieved in AOGR mode. The reformer is used for extended periods of time (100–1,000 h) in conditions where carbon formation is thermodynamically possible to measure any changes in characteristic performance. No significant change in the performance is observed due to carbon formation or catalyst deactivation. The reformer could be successfully implemented in a 10 kW SOFC system with an anode off‐gas recycling loop.