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.     

A study of solid oxide fuel cell stack failure by inducing abnormal behavior in a single cell test

It is well known that cell imbalance can lead to failure of batteries. Prior theoretical modeling has shown that similar failure can occur in solid oxide fuel cell (SOFC) stacks due to cell imbalance. Central to failure model for SOFC stacks is the abnormal operation of a cell with cell voltage becoming negative. For investigation of SOFC stack failure by simulating abnormal behavior in a single cell test, thin yttria-stabilized zirconia (YSZ) electrolyte, anode-supported cells were tested at 800 °C with hydrogen as fuel and air as oxidant with and without an applied DC bias. When under a DC bias with cell operating under a negative voltage, rapid degradation occurred characterized by increased cell resistance. Visual and microscopic examination revealed that delamination occurred along the electrolyte/anode interface. The present results show that anode-supported SOFC stacks with YSZ electrolyte are prone to catastrophic failure due to internal pressure buildup, provided cell imbalance occurs. The present results also suggest that the greater the number of cells in an SOFC stack, the greater is the propensity to catastrophic failure.     

Restoration of solid oxide fuel cell stacks after failure of partial cells

We investigated a solid oxide fuel cell stack that employs anode-supported planar cells in which two intermediate plates are installed every 10 cells to determine the influence of the separation and reconnection of the intermediate plates after high temperature operation. We showed that this separation and reconnection caused no significant degradation in stack performance. A 30-cell stack, which was constructed by removing two 10-cell sub-stacks from a 50-cell stack that had operated stably 1200 h, functioned well. The difference between the average voltages of the cells in the 50- and 30-cell stacks was less than 3% when the current density, fuel utilization, and oxygen utilization were 0.30 A cm⁻², 60%, and 15%, respectively. The 30-cell stack operated stably for about 1200 h with almost no degradation. These findings indicate that our stack can be restored after cells in the stack have broken down simply by removing the 10-cell sub-stacks that contain the broken cells and replacing them with undamaged 10-cell sub-stacks.     

Long-term evolution of mechanical performance of solid oxide fuel cell stack and the underlying mechanism

Mechanical performance analysis is important for ensuring the long-term reliability of solid oxide fuel cells (SOFCs). Thermal-mechanical models are constructed to conduct time-dependent mechanical performance analysis of SOFC stack with temperature field obtained by multiphysics modeling. The volume-averaged temperature field is used as comparison. The creep strains are examined with a time step of 10 h for 10,000 h. It reveals: (1) Uniform temperature significantly decreases the stresses, strains, failure probabilities of all stack components. (2) The failure probability of sealant reduced rapidly and the sealant becomes mechanically safer for long-term operation. (3) Creep strain is dominant for anode/sealant/interconnect, but negligible for electrolyte/cathode. All components are predictably safe against strain failure for 100,000 h (4) Creep strains of stack components interact with each other. Coupled analysis of creep strains of anode/sealant/interconnect is mandatory, but the creep strains of electrolyte/cathode may be neglected for studying mechanical evolutions.     

Effect of operating temperature on creep and damage in the bonded compliant seal of planar solid oxide fuel cell

This paper studies the effect of operating temperature on creep and damage in bonded compliant seal of solid oxide fuel cell by finite element method. A strain based creep damage model is used, and its feasibility to predict the creep damage behavior of the materials is verified firstly by the experimental data. The results show that the failure locates at the foil and the location varies with the temperature increasing. When the temperature is lower than 600 °C, there is nearly no crack occurs. When the temperature is 600 °C, the creep crack belongs to internal crack and the length is about 2.5 mm. While the temperature is 650 °C or higher, the crack locates at the foil surface and the length is larger than 25 mm at an operation time of 50,000 h. Compared to the size of the whole structure, an internal crack of 2.5 mm is small and the gas leakage will not happen. Therefore, it can satisfy the requirement of safe operation for more than 40,000 h. Thus, it recommends that the operating temperature should not be higher than 600 °C on the condition of insuring the power performance and operation cost of the SOFC.     

A model for oxidation-induced stress analysis of Ni-based anode-supported planar solid oxide fuel cell

A critical hurdle in realizing commercially viable anode-supported solid oxide fuel cell (SOFC) is the re-oxidation of cermet anode during the cell abnormal operation. In this paper, the analysis of energy dispersive X-ray spectroscopy on a partially oxidized half-cell demonstrates a particular inhomogeneous oxidation mechanism that a portion of anode near the air/anode interface is oxidized with a graded NiO content, while the remaining region hold a reduced status. Based on this observation, an analytical oxidation-induced stress model is developed to provide in-depth information about the mechanical behavior of the half-cell suffered from various oxidation. The dependences of the mechanical performance of half-cell on the NiO distribution and thickness of oxidation-graded zone are revealed. The results show that an increase in oxidation-graded zone elevates the stress level of electrolyte, but decreases the curvature under the same global degree of oxidation (DoO). In addition, the influence of thickness of oxidation-graded zone on the electrolyte failure probability is also investigated. According to these results, we conclude that the thickness of oxidation-graded zone should be as thin as possible in order to delay the electrolyte cracking.     

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.     

Measurement of the temperature distribution in a large solid oxide fuel cell short stack

During the operation of solid oxide fuel cells (SOFCs), nonhomogeneous electrochemical reactions in both electrodes and boundary conditions may lead to a temperature gradient in the cell which may result in the development of thermal stresses causing the failure of the cell. Thus, in this study, effects of operating parameters (current density, flow configuration and cell size) on the temperature gradient of planar SOFCs are experimentally investigated. Two short stacks are fabricated using a small (16 cm² active area) and a large size (81 cm² active area) scandia alumina stabilized zirconia (ScAlSZ) based electrolyte supported cells fabricated via tape casting and screen printing routes and an experimental set up is devised to measure both the performance and the temperature distribution in short stacks. The temperature distribution is found to be uniform in the small short stack; however, a significant temperature gradient is measured in the large short stack. Temperature measurements in the large short stack show that the temperature close to inlet section is relatively higher than those of other locations for all cases due to the high concentrated fuel resulted in higher electrochemical reactions hence the generated heat. The operation current is found to significantly affect the temperature distribution in the anode gas channel. SEM analyses show the presence of small deformations on the anode surface of the large cell near to the inlet after high current operations.     

Nonlinear model predictive control based on the moving horizon state estimation for the solid oxide fuel cell

As a nonlinear power generation device, the solid oxide fuel cell (SOFC) often operates under small window of operating conditions due to the constraints stemming from the environmental and safety considerations. The nonlinear model predictive control (NMPC) appears to be well suited control algorithm for this application. NMPC is a closed-loop feedback control scheme that predicts the open-loop optimal input based on the measurements and the setting trajectory. This work aims to develop a closed-loop feedback control strategy based on the NMPC controller for a planar SOFC. The current density, fuel and air molar flow rates are chosen as manipulated variables to control the output power, fuel utilization and temperature. The mole fraction and temperature of the exit gases are set as state variables, which can be estimated from the moving horizon estimation (MHE) method. The validation here is referred to robustness and stability of the controller, a typical case study has been conducted with the power output changes under constant fuel utilization and temperature. Simulation results show that the noise of the output is successfully filtered by the MHE. The NMPC controller works satisfactorily following the setting output trajectory.     

Thermal stress and probability of failure analyses of functionally graded solid oxide fuel cells

Thermal stresses and probability of failure of a functionally graded solid oxide fuel cell (SOFC) are investigated using graded finite elements. Two types of anode-supported SOFCs with different cathode materials are considered: NiO-YSZ/YSZ/LSM and NiO-YSZ/YSZ/GDC-LSCF. Thermal stresses are significantly reduced in a functionally graded SOFC as compared with a conventional layered SOFC when they are subject to spatially uniform and non-uniform temperature loads. Stress discontinuities are observed across the interfaces between the electrodes and the electrolyte for the layered SOFC due to material discontinuity. The total probability of failure is also computed using the Weibull analysis. For the regions of graded electrodes, we considered the gradation of mechanical properties (such as Young’s modulus, the Poisson’s ratio, the thermal expansion coefficient) and Weibull parameters (such as the characteristic strength and the Weibull modulus). A functionally graded SOFC showed the least probability of failure based on the continuum mechanics approach used herein.     

A novel direct carbon fuel cell by approach of tubular solid oxide fuel cells

A direct carbon fuel cell based on a conventional anode-supported tubular solid oxide fuel cell, which consisted of a NiO-YSZ anode support tube, a NiO-ScSZ anode functional layer, a ScSZ electrolyte film, and a LSM-ScSZ cathode, has been successfully achieved. It used the carbon black as fuel and oxygen as the oxidant, and a preliminary examination of the DCFC has been carried out. The cell generated an acceptable performance with the maximum power densities of 104, 75, and 47 mW cm⁻² at 850, 800, and 750 °C, respectively. These results demonstrate the feasibility for carbon directly converting to electricity in tubular solid oxide fuel cells.     

Evaluation of the redox stability of segmented-in-series solid oxide fuel cell stacks

The tolerance for the reduction and oxidation (redox) reactions of the segmented-in-series solid oxide fuel cells (SIS-SOFCs) has been investigated. In conventional anode-supported solid oxide fuel cells (SOFCs), the anode and the substrate are typically prepared from Ni-YSZ-based materials which exhibit a significant dimensional change because of the redox reaction and cannot retain their structure. The substrate of the SIS-SOFCs is prepared from Ni-doped MgO-based material, which has a high redox tolerance, and the SIS-SOFC exhibits a good performance after the redox cycles.The degradation rate is approximately 0.15% per cycle in a redox condition of start-and-stop operation without fuel supply. In the other redox condition (when the fuel supply is interrupted for 1.5 min), the voltage of the SIS-SOFCs remains almost constant. However, the voltage of SIS-SOFCs decreases with an increase in the reoxidation time of the interruption in the fuel supply. The high redox tolerance is attributed to the fact that the diffusion coefficients, mean free path, and existence of the Ni particles in the substrate can effectively deter the oxidation of the anode.     

Performance analysis of solid oxide fuel cell using reformed fuel

Fuelling SOFC with reformed fuel can be beneficial due to it being cheaper compared to pure hydrogen. A biomass fuel can be easily modeled as a reformed fuel, as it can be converted into H₂ and CO using gasification or biodegradation, the main composition of product from a reformer. Hence in this study it is assumed that feed to the fuel cell contains only H₂ and CO. A closed parametric model is formulated. Performance is analyzed with changes in temperature, pressure and fuel ratio; considering the possible voltage losses, like ohmic, activation, mass transfer and fuel crossover. Performance curves consisting of operating voltage, fuel utilization, efficiency, power density and current density are developed for both pure hydrogen and mixture of CO and H₂. Variations of open circuit voltage with temperature, power density with current density, operating voltage with current density and maximum power density with fuel utilization are also evaluated.     

Fabrication of solid oxide fuel cell anode electrode by spray pyrolysis

Large triple phase boundaries (TPBs) and high gas diffusion capability are critical in enhancing the performance of a solid oxide fuel cell (SOFC). In this study, ultrasonic spray pyrolysis has been investigated to assess its capability in controlling the anode microstructure. Deposition of porous anode film of nickel and Ce_0.9Gd_0.1O_1.95 on a dense 8 mol.% yttria stabilized zirconia (YSZ) substrate was carried out. First, an ultrasonic atomization model was utilized to predict the deposited particle size. The model accurately estimated the deposited particle size based on the feed solution condition. Second, effects of various process parameters, which included the precursor solution feed rate, precursor solution concentration and deposition temperature, on the TPB formation and porosity were investigated. The deposition temperature and precursor solution concentration were the most critical parameters that influenced the morphology, porosity and particle size of the anode electrode. Ultrasonic spray pyrolysis achieved homogeneous distribution of constitutive elements within the deposited particles and demonstrated capability to control the particle size and porosity in the range of 2-17 μm and 21-52%, respectively.     

Analysis of a solid oxide fuel cell and a molten carbonate fuel cell integrated system with different configurations

A solid oxide fuel cell with internal reforming operation is run at partial fuel utilization; thus, the remaining fuel can be further used for producing additional power. In addition, the exhaust gas of a solid oxide fuel cell still contains carbon dioxide, which is the primary greenhouse gas, and identifying a way to utilize this carbon dioxide is important. Integrating the solid oxide fuel cell with the molten carbonate fuel cell is a potential solution for carbon dioxide utilization. In this study, the performance of the integrated fuel cell system is analyzed. The solid oxide fuel cell is the main power generator, and the molten carbonate fuel cell is regarded as a carbon dioxide concentrator that produces electricity as a by-product. Modeling of the solid oxide fuel cell and the molten carbonate fuel cell is based on one-dimensional mass balance, considering all cell voltage losses. Primary operating conditions of the integrated fuel cell system that affect the system efficiencies in terms of power generation and carbon dioxide utilization are studied, and the optimal operating parameters are identified based on these criteria. Various configurations of the integrated fuel cell system are proposed and compared to determine the suitable design of the integrated fuel cell system.     

A three-dimensional numerical model of a single-chamber solid oxide fuel cell

The aim of this work is to analyze the hydrodynamic/electrochemical performance of a solid oxide fuel cell operating on nitrogen diluted hydrogen/oxygen mixture. In this respect, a three-dimensional numerical model of a single-chamber solid oxide fuel cell (SC-SOFC) is developed. The model incorporates the coupled effects of fluid flow in a rectangular duct with mass transport in porous electrodes, selective electrochemical reactions (i.e. hydrogen oxidation on anode and oxygen reduction on cathode) on individual electrodes while operating on nitrogen diluted hydrogen–oxygen mixture. Results show the effect of depletion of gaseous mixture due to hydrogen and oxygen consumption along the flow direction. The model can predict hydrodynamic/electrochemical effects by varying the porosity of the gas diffusion electrodes/catalyst layers. The model is formulated in COMSOL Multiphysics 3.4, a commercial Finite Element Method (FEM) based software package.     

Fabrication of hydrogen electrode supported cell for utilized regenerative solid oxide fuel cell application

A utilized regenerative solid oxide fuel cell (URSOFC) provides the dual function of performing energy storage and power generation, all in one unit. When functioning as an energy storage device, the URSOFC acts like a solid oxide electrolyzer cell (SOEC) in water electrolysis mode; whereby the electric energy is stored as (electrolyzied) hydrogen and oxygen gases. While hydrogen is useful as a transportation fuel and in other industrial applications, the URSOFC also acts as a solid oxide fuel cell (SOFC) in power generation mode to produce electricity when needed. The URSOFC would be a competitive technology in the upcoming hydrogen economy on the basis of its low cost, simple structure, and high efficiency. This paper reports on the design and manufacturing of its anode support cell using commercially available materials. Also reported are the resulting performance, both in electrolysis and fuel cell modes, as a function of its operating parameters such as temperature and current density. We found that the URSOFC performance improved with increasing temperature and its fuel cell mode had a better performance than its electrolysis mode due to a limited humidity inlet causing concentration polarization. In addition, there were great improvements in performance for both the SOFC and SOEC modes after the first test and could be attributed to an increase in porosity within the oxygen electrode, which was beneficial for the oxygen reaction.     

Performance improvement of bioethanol-fuelled solid oxide fuel cell system by using pervaporation

This work proposes an improvement in performance with respect to the electrical efficiency of a bioethanol-fuelled Solid Oxide Fuel Cell (SOFC) system by replacing a conventional distillation column by a pervaporation unit in the bioethanol purification process. The simulation study indicates that the membrane separation factor has a significant influence on the electrical power and heat energy required to generate a feed of 25 mol% ethanol in water to the reformer. The values of overall electrical efficiency of the SOFC systems with a distillation column and with a pervaporation unit are compared under the thermally self-sufficient condition (Q_net = 0) which offers their maximum electrical efficiency. At the base case, the SOFC system with a pervaporation unit provides an electrical efficiency of 42% compared with 34% achieved from the system with a distillation unit, indicating a significant improvement by using a pervaporation unit. An increase in ethanol recovery can further improve the overall electrical efficiency. The study also reveals that further improvement of the membrane selectivity can slightly enhance the overall efficiency of the SOFC system. Finally, an economic analysis of a bioethanol-fuelled SOFC system with pervaporation is suggested as the basis for further development.     

Entropy generation analysis in a monolithic-type solid oxide fuel cell (SOFC)

The aim of the paper is to investigate possible improvements in the geometry design of a monolithic solid oxide fuel cells (SOFCs) through analysis of the entropy generation terms. The different contributions to the local rate of entropy generation are calculated using a computational fluid dynamic (CFD) model of the fuel cell, accounting for energy transfer, fluid dynamics, current transfer, chemical reactions and electrochemistry. The fuel cell geometry is then modified to reduce the main sources of irreversibility and increase its efficiency.