Thermochemical model and experimental validation of a tubular SOFC cell comprised in a 1 kWel stack designed for μCHP applications

Being aware of the needs for clean highly efficient micro combined heat and power (μCHP) systems for single and multifamily households, the Italian Ministry of Industry launched in 2009 the EFESO Project aiming to develop and operate four SOFC prototypes. An imperative part of the project foresaw computational modeling to optimize operating conditions of the power modules and pinpoint potential drawbacks in its design. This article deals with a 3-dimensional thermochemical model of a single SOFC tubular geometry cell comprised in a 1kW_el stack operating under similar conditions to the characterized power module. An analysis is presented on the effects of current density distribution, temperature distribution in the cell and pressure drop in the air and fuel channels, being these the most critical variables when operating the SOFC-powered μCHP system. This model will serve as a platform to generate a model of the whole stack which will be further validated by means of experimental activities.     

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.     

Novel hybrid serpentine-interdigitated flow field with multi-inlets and outlets of gas flow channels for PEFC applications

In our previous study, a novel flow field design for a polymer electrolyte fuel cell (PEFC) called “Hybrid Serpentine-Interdigitated (HSI)” had been proposed. Although it was very promising in terms of performance and pressure drop, it still had a major drawback of the low oxygen concentration area. To improve its design and performance, three HSI configurations with different numbers of gas inlet and outlet, namely one inlet and one outlet HSI (1-IO HSI), one inlet and two outlets HSI (1I-2O HSI) and two inlets and two outlets HSI (2-IO HSI) were numerically investigated and compared with the conventional single channel serpentine (1S). The investigation on the cell performance and other transport behaviors has been carried out using CFD techniques via ANSYS FLUENT software. At a practical operating potential of about 0.6 V of 50 cm² PEFCs, the 2-IO HSI offered the best distributions of oxygen, current density and water due to the shorter channel length. More importantly, the 2-IO HSI could contribute to a reduction in cathode pressure drop by 90%, as compared with the 1S, resulting in the enhancement in the net power output by 6%, approximately.     

Micro-cogeneration application of a high-temperature PEM fuel cell stack operated with polybenzimidazole based membranes

High temperature Proton Exchange Membrane Fuel Cells (HT-PEMFC) have attracted the attention of researchers in recent years due to their advantages such as working with reformed gases, easy heat management and compatibility with micro-cogeneration systems. In this study, it is aimed to designed, manufactured and tested of the HT-PEMFC stack based on Polybenzimidazole/Graphene Oxide (PBI/GO) composite membranes. The micro-cogeneration application of the PBI/GO composite membrane based stack was investigated using a reformat gas mixture containing Hydrogen/Carbon Dioxide/Carbon Monoxide (H₂/CO₂/CO). The prepared HT-PEMFC stack comprises 12 cells with 150 cm² active cell area. Thermo-oil based liquid cooling was used in the HT-PEMFC stack and cooling plates were used to prevent coolant leakage between the cells. As a result of HT-PEMFC performance studies, maximum 546 W and 468 W power were obtained from PBI/GO and PBI membranes based HT-PEMFC stacks respectively. The results demonstrate that introducing GO into the PBI membranes enhances the performance of HT-PEMFC technology and demonstrated the potential of the HT-PEMFC stack for use in micro-cogeneration applications. It is also underlined that the developed PBI/GO composite membranes have the potential as an alternative to commercially available PBI membranes in the future.     

Investigation of hydrogen production using wood pellets gasification with steam at high temperature over 800 °C to 1435 °C

A fixed-bed gasifier was developed to study the effects of steam flow rate and temperature on the hydrogen production during biomass gasification at high temperature over 800 °C to 1435 °C. An optimum steam flow rate for peak of hydrogen yield was found. As temperature increases, amount of hydrogen increases first, subsequently decreases and then increases again with a maximum peak of hydrogen yield at 917 °C. In the temperatures of 1018 °C through 1435 °C post the peak hydrogen production increases with temperature. The maximum volume fraction of hydrogen and hydrogen production ratio are 60% and 76%, respectively. Chemical equilibrium calculation was also done using ASPEN software, which demonstrates that the more the steam flow rate, the lower the temperature for maximum hydrogen yield; the higher the temperature, the lower the effect of steam flow rate. The results are expected to develop high temperature gasification technology.     

Sm0.5Sr0.5CoO3 + Sm0.2Ce0.8O1.9 composite cathode for cermet supported thin Sm0.2Ce0.8O1.9 electrolyte SOFC operating below 600 °C

The cathode is a key component in low temperature solid oxide fuel cells. In this study, composite cathode, 75 wt.% Sm_0.5Sr_0.5CoO₃ (SSC) + 25 wt.% Sm_0.2Ce_0.8O_1.9 (SDC), was applied on the cermet supported thin SDC electrolyte cell which was fabricated by tape casting, screen-printing, and co-firing. Single cells with the composite cathodes sintered at different temperatures were tested from 400 to 650 °C. The best cell performance, 0.75 W cm⁻² peak power operating at 600 °C, was obtained from the 1050 °C sintered cathode. The measured thin SDC electrolyte resistance R_s was 0.128 Ω cm² and total electrode polarization R_p(a + c) was only 0.102 Ω cm² at 600 °C.     

PMMA-assisted synthesis of Li1−xNi0.5Mn1.5O4−δ for high-voltage lithium batteries with expanded rate capability at high cycling temperatures

In this work, poly(methyl methacrylate) (PMMA), a non-surfactant polymer was used to synthesize nonstoichiometric Li_0.82Ni_0.52Mn_1.52O_4−δ (0 ≤ δ ≤ 0.25) spinels. The presence of the polymer was found to be beneficial with a view to facilitating the use of the spinel in electrodes for lithium batteries. Thus, PMMA allowed spinel particles of a high crystallinity and uniform size and shape to be obtained, and particle size to be tailored by using an appropriate calcining temperature and time. By controlling these variables, spinels in nanometric, submicrometric and micrometric particle sizes were prepared and characterized by chemical analysis, X-ray diffraction, electron microscopy, thermogravimetry and nitrogen adsorptions measurements. The spinels were obtained as highly crystalline phases with lithium and oxygen deficiency and some cation disorder as revealed by chemical analysis, thermogravimetric and XRD data. Their electrochemical performance in two-electrode cells was tested at room temperature and 50 °C over a wide range of charge/discharge rates (from C/4 to 4C). Cell performance was found to depend on particle size rather than on structural properties. Thus, the spinel best performing at 50 °C was that consisting of submicrometric particles, which delivered a high capacity and exhibited the best capacity retention and rate capability. Particles of submicronic size share the advantages of nanometric particles (viz. the ability to withstand high charge/discharge rates) and micrometric particles (a high capacity and stability at low rates).