Effect of the geometrical size on time dependent failure probability of the solid oxide fuel cell

The time dependent failure probabilities (TDFP) of solid oxide fuel cell (SOFC) under different geometrical sizes are analyzed by a creep and damage related probability prediction constitutive model. The results demonstrate that sealant is the most possible failure component of the SOFC under different geometrical sizes. Increasing the sealant thickness or width can decrease the TDFP of the sealant. While the cathode thickness and electrolyte thickness have little effect on the TDFP of SOFC components. Decreasing the anode thickness, frame thickness can reduce the TDFP of the sealant. The sealant thickness and frame thickness can greatly affect the life of the SOFC stack. Based on the TDFP analysis of SOFC, it recommends that the sealant thickness should not be smaller than 0.1 mm, the frame thickness should not be less than 0.4 mm considering the stiffness requirement.     

Preparation of Pr2NiO4+δ-La0.6Sr0.4CoO3-δ as a high-performance cathode material for SOFC by an impregnation method

As a Ruddlesden-Popper (RP) phase solid oxide fuel cell (SOFC) cathode material, Pr₂NiO_4+δ (PNO) is a critical challenge for SOFC commercialization due to the lack of oxygen vacancies and insufficient redox reaction (ORR) activity. In this paper, various concentrations of La_0.6Sr_0.4CoO_3-δ (LSC) nanoparticles are coated on the surface of PNO by an impregnation method, and the ORR kinetics of PNO is found to be improved by constructing a composite cathode with heterointerfaces. The formation of the heterointerface effectively enhances the transfer of interstitial oxygen in the PNO and the oxygen vacancies in LSC, which can promote the conduction of O^2? in the cathode and thus improves the ORR activity of the material. When the impregnation concentration of LSC reached C_LSC = 0.2 mol L^?1, the ORR activity can reach the highest level. At 700 °C, the area-specific resistance of PNO-LSC reaches 0.024 Ω cm², which is 83.4% lower than that of PNO (0.145 Ω cm²). And the peak power density of PNO-LSC reaches 0.618 W cm^?2, which is 1.89 times larger than that of PNO (0.327 W cm^?2). Therefore, the construction of composite cathodes with heterointerfaces via impregnation provides an alternative strategy for enhancing the ORR activity of the cathode materials in SOFC.     

Effect of holding time in brazing cooling process on creep life of the solid oxide fuel cell with bonded compliant seal

In present paper, effect of holding time at 600 °C during the brazing cooling process on creep life of solid oxide fuel cell (SOFC) with bonded compliant seal (BCS) is investigated by the finite element method. The research indicates that creep crack initiation time in BCS structure increases significantly with the holding time increasing. Compared with that the traditional cooling method during the brazing process, the creep crack initiation time can be prolonged more than twice by the holding time of 150 h with the operating temperature of 600 °C, it increases from 14,949 h to 31,911 h. When the operating temperature is 800 °C, the creep crack initiation time of SOFC can hardly be affected if the holding time exceeds 10 h. Based on the creep damage analysis and considering the cost of the SOFC manufacturing process, it is recommended that the holding time should not be exceeded 300 h if the operating temperature is below 750 °C. And when the operating temperature is 800 °C, the recommended holding time should not be longer than 10 h. The research of the present paper can provide theoretical guidance for the long life manufacturing and reliability operation of SOFC.     

Modeling and simulation of solid oxide fuel cell based on the volume–resistance characteristic modeling technique

Solid oxide fuel cell (SOFC) is a complicated system with heat and mass transfer as well as electrochemical reactions. The real-time dynamic simulation of SOFC is still a challenge up to now. This paper develops a one-dimensional mathematical model for direct internal reforming solid oxide fuel cell (DIR-SOFC). The volume–resistance (V–R) characteristic modeling technique is introduced into the modeling of the SOFC system. Based on the V–R modeling technique and the modular modeling idea, ordinary differential equations meeting the quick simulation are obtained from partial differential equations. This model takes into account the variation of local gas properties. It can not only reflect the distributed parameter characteristics of SOFC, but also meet the requirement of the real-time dynamic simulation. The results indicate that the V–R characteristic modeling technique is valuable and viable in the SOFC system, and the model can be used in the quick dynamic and real-time simulation.     

Simulation of creep and damage in the bonded compliant seal of planar solid oxide fuel cell

Planar solid oxide fuel cell (SOFC) operates at high temperature and requires a good creep strength to ensure the structure integrity. This paper presents a creep and damage analysis of a bonded compliant seal (BCS) structure of a planar SOFC considering the effect of as-bonded residual stress and thermal stress, as well as the effect of filler metal and foil thickness. A modified continuum creep-damage model is used in the finite element simulation. It demonstrates that the BCS structure meets the requirement of the long-term operation at the high temperature of 600 °C with an appropriate braze bonding process. The results show that the failure location is not in the region of maximum creep deformation due to the effect of high level multi-axial stress which drastically decreases the multi-axial ductility. Reasonably reducing the thickness of filler metal and foil can decrease the damage of the BCS structure. Based on the consideration of creep and damage, it is proposed that the thickness of filler metal and foil should not exceed 0.1 and 0.05 mm, respectively.     

Importance of pressure gradient in solid oxide fuel cell electrodes for modeling study

The pressure gradients in the electrodes of a solid oxide fuel cell (SOFC) are frequently neglected without any justification in calculating the concentration overpotentials of the SOFC electrodes in modeling studies. In this short communication, a comparative study has been conducted to study the effect of pressure gradients on mass transfer and the resulting concentration overpotentials of an SOFC running on methane (CH₄) fuel. It is found that the pressure gradients in both anode and cathode are significant in the fuel cell electrochemical activities. Neglecting the anode pressure gradient in the calculation can lead to underestimation of the concentration overpotential by about 20% at a typical current density of 5000 A m⁻² and at a temperature of 1073 K. The deviation can be even larger at a higher temperature. At the cathode, neglecting the pressure gradient can result in overestimation of the concentration overpotential by about 10% under typical working conditions.     

A pressurized ammonia-fed planar anode-supported solid oxide fuel cell at 1–5 atm and 750–850°C and its loaded short stability test

Ammonia is a useful energy carrier for solid oxide fuel cell (SOFC) with advantages over hydrogen. Understanding of the performance and stability of ammonia-fed SOFC operated at elevated pressure (p) is an important step towards the development of high-efficiency hybrid SOFC power system with micro gas turbine (MGT). This paper reports cell performance, electrochemical impedance spectra (EIS), and stability measurements of a pressurized ammonia-fed anode-supported SOFC at p = 1–5 atm and T = 750–850°C using a planar (50 × 50 mm²) single-full-cell (400 μm Ni-YSZ anode/3 μm YSZ electrolyte/12 μm LSC-GDC cathode). The full cell together with metallic frames and current collectors are sandwiched by a pair of rib-channel flow distributors (interconnectors) in a high-pressure testing facility. Results show that pressurization and increasing temperature enhance the ammonia-fed SOFC performance significantly having almost the same power densities as those of hydrogen/nitrogen-fed SOFC, as substantiated and explained by EIS data and an equivalence circuit model where the effects of p and T on ohmic, gas diffusion, and gas conversion impedances are shown. Moreover, the loaded short (10 h) stability tests at 700°C and 0.8 V for 1 atm/3 atm cases reveal no/little power degradation, where the microstructures without any crack within the scale of SEM observation and nearly the same element atomic percentages of Ni-YSZ anode surfaces from EDX spectra are found. These results suggest that the pressurized ammonia-fed SOFC is a promising candidate for the hybrid SOFC-MGT power generation.     

Reformer faults in SOFC systems: Experimental and modeling analysis,and simulated fault maps

The effects of fuel processor faults in an solid oxide fuel cell (SOFC) system are analyzed. Focusing on a laboratory-size SOFC system, a reformer fault is investigated both experimentally and through a model; comparison between experimental and modeling results is presented and discussed. The results show that some types of reformer faults can be dangerous, because they can give rise to local thermal gradients as large as 10–20·10² K/m or more in the SOFC stack. Simulation results show that SOFC stacks employing metallic interconnects are expected to withstand faults of larger magnitude than SOFC stacks employing ceramic interconnects. Fault maps are presented and discussed, which can be the basis for the development of a fault detection and isolation (FDI) tool.     

Novel hybrid two-stage alkali metal thermoelectric converter and thermally regenerative electrochemical cycle to exploit waste heat of solid oxide fuel cell: Performance assessment and optimization

An innovative combination of a two-stage alkali metal thermoelectric converter (TAMTEC), and thermally regenerative electrical cycle (TREC) is employed to utilize the high-quality heat dissipated from solid oxide fuel cell (SOFC) for further electricity production. The superiority and effectiveness of the SOFC-TAMTEC-TREC system are verified compared to existing SOFC-based hybrid systems and sole SOFC. The performance of the system based on energy, exergy, and economic indicators is evaluated by varying the main design parameters. Parametric assessment demonstrates that the SOFC-TAMTEC-TREC system can reach the maximum power density of 12126 W m^?2 with energy and exergy efficiencies of 47.13% and 50.46% as TAMTEC proportional constant increases to 10^7.5 m² and rising SOFC pore and gain diameters to 3.77 × 10^?6 m and 2.5 × 10^?6 m, respectively reduce the cost rate density of system by 3.55 $ h^?1 m^?2. Furthermore, to achieve the maximum power density and exergy efficiency, and minimum cost rate density, NSGA-III multi-criteria optimization, and decision-making techniques are conducted. Outcomes indicate that Shannon entropy leads to the maximum power density of 8597.2 W m^?2 with a 35.94% enhancement relative to a single SOFC and 1 $ h^?1 m^?2 increment in cost rate density of the hybrid system, while LINMAP and TOPSIS ascertain the minimum increase in the cost rate density by 0.6 $ h^?1 m^?2 with 31.04% improvement in power density relative to single SOFC.     

Integration of solid oxide fuel cell and palladium membrane reactor: Technical and economic analysis

This paper presents a technical and economic analysis of a solid oxide fuel cell system equipped with a palladium membrane reactor (PMR–SOFC) with the aim of determining the benefits of such an integrated unit over the conventional reformer module (CON-SOFC). The performance of both SOFC systems under the conditions for energetically self-sustaining operation (Q_NET = 0) was achieved by varying the fuel utilization for each operating voltage. Two types of fuels, i.e., methane and desulphurized biogas, are considered. The simulation results show that the maximum power density of the CON-SOFC fuelled by methane (0.423 W/cm²) is higher than that of the CON-SOFC fuelled by biogas (0.399 W/cm²) due to the presence of CO₂ in biogas. For the PMR–SOFC, it is found that the operation at a higher permeation pressure offers higher power density because lower fuel utilization is required when operating the SOFC at the energy self-sustained condition. When the membrane reactor is operated at the permeation pressure of 1 bar, the methane-fuelled and biogas-fuelled PMR–SOFCs can achieve the maximum power density of 0.4398 and 0.4213 W/cm², respectively. Although the PMR–SOFC can offer higher power density, compared with the CON-SOFC, the capital costs of supporting units, i.e., palladium membrane reactor, high-pressure compressor, and vacuum pump, for PMR–SOFC need to be taken into account. The economic analysis shows that the PMR–SOFC is not a good choice from an economic viewpoint because of the requirement of a large high-pressure compressor for feeding gas to the membrane reactor.     

Biohythane as an energy feedstock for solid oxide fuel cells

Biogas (60%-CH₄, 40%- CO₂) is a potential source of renewable energy when used as energy feedstock for solid oxide fuel cells (SOFC), but releases biogenic CO₂ emissions. Hybrid SOFC performance can be affected by fuel composition and reformer performance. Biohythane (58%-CH₄, 35%-CO₂ and 7% H₂) can be a better alternative providing balance between energy and biogenic emissions. Biohythane performance is studied for a 120 kW SOFC stack using ASPEN process model and compared with other feed stocks. This work is the first to study and report on the application of biohythane in SOFC systems. Biohythane was found to produce less biogenic CO₂ emissions and 6% less CO at the reformer than biogas. Comparisons show that biohythane provides better efficiencies in hybrid SOFC systems. Sensitivity studies recommends operation of stack with biohythane at Steam to Carbon Ratio (STCR) = 2.0, i = 200 mA cm⁻² and U_F = 0.85 respectively.     

Mismatch effect of material creep strength on creep damage and failure probability of planar solid oxide fuel cell

The constraint effect with material parameters mismatch between every parts of planar solid oxide fuel cell (SOFC) plays an important role in the operation life. In this study, the mismatch effect of material creep strength coefficient on creep damage and failure probability of planar SOFC was investigated by finite element method. The results show that the maximum equivalent creep strain and failure probability of SOFC are located in the outer corner of sealant layer. With the increase of the creep strength coefficient of the sealant layer, the maximum creep damage, damage area and failure probability of the sealant layer all increase gradually. The creep strength coefficient of the sealant layer is suggested to be smaller than that of the frame material, which will improve service life of SOFC.     

Platinum sonoelectrodeposition on glassy carbon and gas diffusion layer electrodes

The electrodeposition of Pt on glassy carbon (GC) and gas diffusion layer (GDL) surfaces in dilute chloroplatinic acid solutions (10 mM PtCl₄²⁻ in 0.5 M NaCl) was performed potentiodynamically in the absence and presence of ultrasound (20 kHz) at various ultrasonic powers (up to 6 W) respectively and at (313 ± 2) K. In our conditions, it was found that platinum electrodeposition is an irreversible process which requires a substantial overpotential to drive the formation of Pt nuclei on the GC and GDL surfaces; however, under sonication Pt electrodeposition becomes more facile due to lower concentration and nucleation overpotentials and overall currents are significantly increased compared to silent conditions. It was also observed that the specific electrochemical surface area (SECSA) was significantly affected for Pt/GC and Pt/GDL electrodes prepared in the presence of rotation (GC only) and under sonication compared to those prepared under silent conditions. This finding was explained to be due to both larger and agglomerated platinum nanoparticles formed on the GC and GDL surface caused by forced convection. It was also found that ultrasound produced larger Pt nanoparticles on GC electrodes than those on GDL electrodes.     

Performance of an anode-supported solid oxide fuel cell with direct-internal reforming of ethanol

A theoretical study of a solid oxide fuel cell (SOFC) fed by ethanol is presented in this study. The previous studies mostly investigated the performance of ethanol-fuelled fuel cells based on a thermodynamic analysis and neglected the presence of actual losses encountered in a real SOFC operation. Therefore, the real performance of an anode-supported SOFC with direct-internal reforming operation is investigated here using a one-dimensional isothermal model coupled with a detailed electrochemical model for computing ohmic, activation, and concentration overpotentials. Effects of design and operating parameters, i.e., anode thickness, temperature, pressure, and degree of ethanol pre-reforming, on fuel cell performance are analyzed. The simulation results show that when SOFC is operated at the standard conditions (V = 0.65 V, T = 1023 K, and P = 1 atm), the average power density of 0.51 W cm⁻² is obtained and the activation overpotentials represent a major loss in the fuel cell, followed by the ohmic and concentration losses. An increase in the thickness of anode decreases fuel cell efficiency due to increased anode concentration overpotential. The performance of the anode-supported SOFC fuelled by ethanol can be improved by either increasing temperature, pressure, degree of pre-reforming of ethanol, and steam to ethanol molar ratio or decreasing the anode thickness and fuel flow rate at inlet. It is suggested that the anode thickness and operating conditions should be carefully determined to optimize fuel cell efficiency and fuel utilization.     

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.     

Performance analysis and optimization of a trigeneration process consisting of a proton-conducting solid oxide fuel cell and a LiBr absorption chiller

In this work, the trigeneration system, consisting of a proton-conducting solid oxide fuel cell (SOFC–H⁺) and a single-stage LiBr absorption chiller, was proposed. The SOFC–H⁺ and single-stage LiBr absorption chiller models were developed through Aspen Plus V10. From the sensitivity analysis, the results show that increases in temperature and fuel utilization can improve the performance of the SOFC–H⁺. Conversely, the air to fuel (A/F) molar ratio and pressure negatively affect the electrical efficiency and overall system efficiency. In the case of the absorption chiller, the coefficient of performance was increased and made stable according to a constant value when the generator temperature was increased from 90 to 100 °C. When the optimization was performed, it was found that the SOFC–H⁺ should be operated at 700 °C and 10 bar with fuel utilization of 0.8 and A/F molar ratio of 2 to achieve a maximum overall efficiency of 93.34%. For the energy and exergy analysis, a combined heat and power SOFC–H⁺ was found to have the highest energy and exergy efficiencies, followed by the trigeneration process. This indicates that the integration of the SOFC–H⁺ and LiBr absorption chiller is possible to efficiently produce electricity, heating and cooling.     

Electrochemical behaviors of Y-doped La0.7Sr0.3CrO3−δ anode in sulfur-containing fuel SOFC

Fuel gas containing sulfur to feed solid oxide fuel cell is a challenge for extending the application of SOFC. Yttrium doped into La_xSr_1−xCrO₃ as potential anode tolerant to H₂S was investigated by XRD, XPS and electrochemical impedance spectra (EIS). Good sinter characteristic for (La,Y)_0.7Sr_0.3CrO_3−δ (LYSC) observed by SEM contributes to the low ohmic loss (high conductivity) in SOFC fueled by H₂(3%)–H₂S(1%). Maximum power density of 20 mW/cm² and open circuit voltage of 0.95 V for SOFC with LYSC can be obtained at 700 °C. The results by EIS indicate charge transfer loss in polarization resistance dominates in the total resistance, especially lower than 650 °C. Compared to ohmic loss, polarization resistance in LYSC is still the main cause to hinder the improvement of SOFC performance. Thus, LYSC with doped non-variant valence Y maintains good sulfur tolerance determined by XPS without improved electro-catalytic activity as EIS suggest.     

Performance evaluation of La0.4Sr0.6Co0.2Fe0.7Nb0.1O3−δ as both anode and cathode material in solid oxide fuel cells

Solid oxide fuel cell (SOFC) has experienced a growing interest in the last few decades because of generating energy more efficiently than the conventional combustion of fossil fuels. By using the same material as anode and cathode of SOFC (symmetric fuel cell), the production of reliable and repeatable cells would be simpler. In this work, La_0.4Sr_0.6Co_0.2Fe_0.7Nb_0.1O_3−δ (LSCFN) perovskite has been prepared and evaluated as both cathode and anode material of symmetric fuel cell. The results of symmetric fuel cell show that a maximum peak power density of 500 mW cm⁻² has been achieved and the total electrode polarization resistances of the cell is only 0.22 Ω cm² at 850 °C which is much lower than that of typical symmetric fuel cell with La_0.75Sr_0.25Cr_0.5Mn_0.5O_3−δ as electrode material. All of these results indicate that LSCFN can potentially be a promising candidate for the electrode material of symmetric fuel cell.     

Creep oxidation behaviour and creep strength prediction for Alloy 617

Creep experimental data was obtained by a series of creep tests with different stress levels at 950 °C for Alloy 617. Oxidation behaviour was investigated by observing the microstructures of fractured specimens after the creep tests. Oxidation thickness was measured quantitatively with the creep rupture times, and the oxidation microstructures were represented by a SEM image. In addition, the long-term creep strength for Alloy 617 was predicted by using a multi-constant method with two C instead of the conventional one with a unique C in the Larson-Miller (LM) parameter. For 10⁵ h at 950 °C, the creep strength for the conventional method was 7.2 MPa, but for the multi-constant method it was reduced to 4.7 MPa. The conventional method did not thoroughly match with the creep rupture data, and revealed an overestimation for the prediction of the long-term creep strength. On the other hand, the multi-constant method revealed a good agreement with the creep rupture data, and its method was thus more accurate than the conventional one. This multi-constant analysis can be used to accurately predict the long-term creep rupture of Alloy 617.     

Global warming,environmental and sustainability aspects of a geothermal energy based biodigester integrated SOFC system

In this study, global warming, environmental and sustainability aspects of a geothermal energy based biodigester integrated SOFC system are parametrically analyzed. In this regard, a system is designed, consisting of three main subsystems such as Solid Oxide Fuel Cell, Anaerobic Digester, and a Heat Recovery Steam Generator. In order to investigate the global warming, environmental and sustainability aspects of the system, the energy and exergy analyses are performed, and the following indicators are taken into consideration, which are i) unit CO₂ emission, ii) environmental effect factor, iii) waste exergy ratio, iv) exergy destruction ratio, v) exergy recovery ratio, vi) exergetic sustainability index. Accordingly, the maximum exergetic sustainability index and exergy efficiency of the integrated system are calculated to be 0.486 and 0.367, respectively, in case the SOFC inlet temperature is equal to 633.3 °C while electric current density is 5500 A/m². On the other hand, the minimum exergy destruction ratio and the minimum environmental effect factor are obtained to be 0.74 and 2.33 while SOFC inlet temperature is 633.3 °C and SOFC current density is 8000 A/m². The minimum unit CO₂ emission of the whole system is determined to be 368.4 kg/MWh at 5500 A/m² of SOFC current density and 727 °C of SOFC inlet temperature while determined as 258.3 kg/MWh at 8000 A/m² of SOFC current density and 680 °C of SOFC inlet temperature. Thus, it can be said that such a system may be applied for reducing the CO₂ based global warming effects and improving the environmental sustainability.