Performance evaluation of different configurations of biogas-fuelled SOFC micro-CHP systems for residential applications

Three configurations of solid oxide fuel cell (SOFC) micro-combined heat and power (micro-CHP) systems are studied with a particular emphasis on the application for single-family detached dwellings. Biogas is considered to be the primary fuel for the systems studied. In each system, a different method is used for processing the biogas fuel to prevent carbon deposition over the anode of the cells used in the SOFC stack. The anode exit gas recirculation, steam reforming, and partial oxidation are the methods employed in systems I–III, respectively. The results predicted through computer simulation of these systems confirm that the net AC electrical efficiency of around 42.4%, 41.7% and 33.9% are attainable for systems I–III, respectively. Depending on the size, location and building type and design, all the systems studied are suitable to provide the domestic hot water and electric power demands for residential dwellings. The effect of the cell operating voltage at different fuel utilization ratios on the number of cells required for the SOFC stack to generate around 1 kW net AC electric power, the thermal-to-electric ratio (TER), the net AC electrical and CHP efficiencies, the biogas fuel consumption, and the excess air required for controlling the SOFC stack temperature is also studied through a detailed sensitivity analysis. The results point out that the cell design voltage is higher than the cell voltage at which the minimum number of cells is obtained for the SOFC stack.     

Characterization of a novel, highly integrated tubular solid oxide fuel cell system using high-fidelity simulation tools

A novel, highly integrated tubular SOFC system intended for small-scale power is characterized through a series of sensitivity analyses and parametric studies using a previously developed high-fidelity simulation tool. The high-fidelity tubular SOFC system modeling tool is utilized to simulate system-wide performance and capture the thermofluidic coupling between system components. Stack performance prediction is based on 66 anode-supported tubular cells individually evaluated with a 1-D electrochemical cell model coupled to a 3-D computational fluid dynamics model of the cell surroundings. Radiation is the dominate stack cooling mechanism accounting for 66-92% of total heat loss at the outer surface of all cells at baseline conditions. An average temperature difference of nearly 125 °C provides a large driving force for radiation heat transfer from the stack to the cylindrical enclosure surrounding the tube bundle. Consequently, cell power and voltage disparities within the stack are largely a function of the radiation view factor from an individual tube to the surrounding stack can wall. The cells which are connected in electrical series, vary in power from 7.6 to 10.8 W (with a standard deviation, σ = 1.2 W) and cell voltage varies from 0.52 to 0.73 V (with σ = 81 mV) at the simulation baseline conditions. It is observed that high cell voltage and power outputs directly correspond to tubular cells with the smallest radiation view factor to the enclosure wall, and vice versa for tubes exhibiting low performance. Results also reveal effective control variables and operating strategies along with an improved understanding of the effect that design modifications have on system performance. By decreasing the air flowrate into the system by 10%, the stack can wall temperature increases by about 6% which increases the minimum cell voltage to 0.62 V and reduces deviations in cell power and voltage by 31%. A low baseline fuel utilization is increased by decreasing the fuel flowrate and by increasing the stack current demand. Simulation results reveal fuel flow as a poor control variable because excessive tail-gas combustor temperatures limit fuel flow to below 110% of the baseline flowrate. Additionally, system efficiency becomes inversely proportional to fuel utilization over the practical fuel flow range. Stack current is found to be an effective control variable in this type of system because system efficiency becomes directly proportional to fuel utilization. Further, the integrated system acts to dampen temperature spikes when fuel utilization is altered by varying current demand. Radiation remains the dominate heat transfer mechanism within the stack even if stack surfaces are polished lowering emissivities to 0.2. Furthermore, the sensitivity studies point to an optimal system insulation thickness that balances the overall system volume and total conductive heat loss.     

Thermodynamic assessment of solid oxide fuel cell system integrated with bioethanol purification unit

A solid oxide fuel cell system integrated with a distillation column (SOFC–DIS) has been proposed in this article. The integrated SOFC system consists of a distillation column, an EtOH/H₂O heater, an air heater, an anode preheater, a reformer, an SOFC stack and an afterburner. Bioethanol with 5 mol% ethanol was purified in a distillation column to obtain a desired concentration necessary for SOFC operation. The SOFC stack was operated under isothermal conditions. The heat generated from the stack and the afterburner was supplied to the reformer and three heaters. The net remaining heat from the SOFC system (Q_SOFC,Net) was then provided to the reboiler of the distillation column. The effects of fuel utilization and operating voltage on the net energy (Q_Net), which equals Q_SOFC,Net minus the distillation energy (Q_D), were examined. It was found that the system could become more energy sufficient when operating at lower fuel utilization or lower voltage but at the expense of less electricity produced. Moreover, it was found that there were some operating conditions, which yielded Q_Net of zero. At this point, the integrated system provides the maximum electrical power without requiring an additional heat source. The effects of ethanol concentration and ethanol recovery on the electrical performance at zero Q_Net for different fuel utilizations were investigated. With the appropriate operating conditions (e.g. C_EtOH = 41%, U_f = 80% and EtOH recovery = 80%), the overall electrical efficiency and power density are 33.3% (LHV) and 0.32 W cm⁻², respectively.     

One thousand-hour long term characteristics of a propane-fueled solid oxide fuel cell hot zone

One thousand-hour continuous test of a propane-fueled portable solid oxide fuel cell (SOFC) based hot zone has been successfully performed in order to assess the degradation characteristics of its performance. Comparing the different operating modes, the degradation rate based on constant current mode was three times lower than that based on constant voltage mode. The stack power output initially increased 3.7% during the first 34 h probably due to electrode activation processes improving cell performance under polarization during the early stage of operation, and then gradually decreased. It has been clearly illustrated that operating condition of constant current is more beneficial to the long term performance test. Further, based on thermodynamics analysis, the electromotive force of nickel oxidation is 13.2 V for the stack voltage at the stack temperature of 740 °C. From the initial current-power curve data, it can be derived that if the hot zone durability test was performed at constant current of 9 A from the beginning, the stack degradation rate would be 15% per 1000 h. The 1000-h durability test and analysis can better understand how to run longer term stability on the hot zone and guide the optimization of hot zone operating conditions.     

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.     

Highly efficient and durable anode-supported SOFC stack with internal manifold structure

We have developed a solid oxide fuel cell (SOFC) stack with an internal manifold structure. The stack, which is composed of 25 anode-supported 100-mm-diameter SOFCs, provided an electrical conversion efficiency of 56% (based on the lower heating value of methane, which was used as a fuel) and an output of 350 W when the fuel utilization, current density, and operating temperature were 75%, 0.3 A cm⁻², and 1073 K, respectively. The electrical efficiency and the output were maintained for 1100 h. The cell voltage fluctuation was ±2% for 25 cells. The relationship between average cell voltage and current density in the 25-cell stack was as almost the same as that in the 1- and 10-cell stacks, which suggests that our stack provides almost the same cell performance regardless the number of the cells.     

Voltage reversal during microbial fuel cell stack operation

Microbial fuel cells (MFC) can be used to directly generate electricity from organic matter, but the voltage produced by a single reactor is only ∼0.5 V. Voltage can be increased by stacking cells, i.e. by linking individual reactors in series, as is commonly done with hydrogen fuel cells, to provide a higher voltage output. A two-cell air-cathode MFC stack tested here produced a working voltage of 0.9 V (external load 500 Ω) and had an open circuit voltage (OCV) of 1.3 V when operated in fed batch mode under substrate-sufficient conditions. When multiple cells are stacked together, however, charge reversal can result in the reverse polarity of one or more cells and a loss of power generation. We investigated the causes of charge reversal and the impact of prolonged reversal on power generation using a two air-cathode MFCs stack. When voltage began to decline at the end of a fed batch cycle, we observed voltage reversal with one cell producing a working voltage of 0.6 V, and the other cell having a reversed voltage of −0.58 V, producing only a minimal stack voltage of 0.02 V. The reason for the voltage reversal was shown to be fuel starvation, resulting in a loss of bacterial activity. Voltage reversal adversely affected bacteria on the anode of the affected cell, as shown by a relative decrease in cell performance following a cycle of starvation (no feeding). The control of voltage reversal will be crucial for long-term operation of MFCs in series. Rapid feeding of a cell can restore positive voltage generation, but the long-term impact of charge reversal will be inactivation of bacteria and it will require that the affected cells be short-circuited to maintain stack power production. A better understanding of the long term effects of voltage reversal on power generation by MFC stacks is needed in order to efficiently increase voltage production by using stacked MFC systems.     

A novel design and performance of cone-shaped tubular anode-supported segmented-in-series solid oxide fuel cell stack

A novel design of cone-shaped tubular segmented-in-series solid oxide fuel cell (SOFC) stack is presented in this paper. The cone-shaped tubular anode substrates are fabricated by slip casting technique and the yttria-stabilized zirconia (YSZ) electrolyte films are deposited onto the anode tubes by dip coating method. After sintering at 1400 °C for 4 h, a dense and crack-free YSZ film with a thickness of about 7 μm is successfully obtained. The single cell, NiO-YSZ/YSZ (7 μm)/LSM-YSZ, provides a maximum power density of 1.78 W cm⁻² at 800 °C, using moist hydrogen (75 ml min⁻¹) as fuel and ambient air as oxidant.A two-cell-stack based on the above-mentioned cone-shaped tubular anode-supported SOFC is fabricated. Its typical operating characteristics are investigated, particularly with respect to the thermal cycling test. The results show that the two-cell-stack has good thermo-mechanical properties and that the developed segmented-in-series SOFC stack is highly promising for portable applications.     

Cold start dynamics and temperature sliding observer design of an automotive SOFC APU

This paper presents a dynamic model for studying the cold start dynamics and observer design of an auxiliary power unit (APU) for automotive applications. The APU is embedded with a solid oxide fuel cell (SOFC) stack which is a quiet and pollutant-free electric generator; however, it suffers from slow start problem from ambient conditions. The SOFC APU system equips with an after-burner to accelerate the start-up transient in this research. The combustion chamber burns the residual fuel (and air) left from the SOFC to raise the exhaust temperature to preheat the SOFC stack through an energy recovery unit. Since thermal effect is the dominant factor that influences the SOFC transient and steady performance, a nonlinear real-time sliding observer for stack temperature was implemented into the system dynamics to monitor the temperature variation for future controller design. The simulation results show that a 100 W APU system in this research takes about 2 min (in theory) for start-up without considering the thermal limitation of the cell fracture.     

Development of 1 kW class solid oxide fuel cell stack using anode-supported planar cells

We have developed a 1 kW class solid oxide fuel cell (SOFC) stack composed of 50 anode-supported planar 120-mm-diameter SOFCs. Intermediate plates, which exhibited negligible deformation under operating conditions, were placed in the stack to cancel out the cumulative error related to the position and angle of the stack parts. The stack provided an electrical conversion efficiency of 54% (based on the lower heating value (LHV) of the methane used as a fuel) and an output of 1120 W when the fuel utilization, current density, and operating temperature were 67%, 0.28 A cm⁻², and 1073 K, respectively. The stack operated stably for almost 700 h.     

Development and characteristics of a 400 W-class direct methanol fuel cell stack

In this study, a 400 W-class direct methanol fuel cell (DMFC) stack is developed for large size portable applications and its operating behaviors under the various conditions are monitored. The DMFC stack comprising of 42-cells is assembled with graphite bipolar plates and membrane–electrode assemblies (MEAs) having an active area of 138 cm² per each. The stack is operated by varying the concentrations of methanol, stoichiometry (λ), and the electric load. In addition, other associated factors, such as voltage and temperature distributions along the individual unit cells, pressure drops inside the stack, voltage behaviors in response to the dynamic change of the electric load and the pHs of the effluent solutions from the outlets of both electrodes, are also studied in a detailed manner. The stack produces a power of 400 W under an operating condition of feeding 0.8 M methanol and 34 l/min air at 1 atm, and uniform distributions of temperature and voltage prevail in all the 42 unit cells. A long-term operation coupled with performance restoration processes shows that a typical single cell used in this stack is able to run with a good stability for more than 500 h without any substantial degradation in the performance.     

Thermo-economic optimization of an indirectly coupled solid oxide fuel cell/gas turbine hybrid power plant

Power generation using gas turbine (GT) power plants operating on the Brayton cycle suffers from low efficiencies, resulting in poor fuel to power conversion. A solid oxide fuel cell (SOFC) is proposed for integration into a 10-MW GT power plant, operating at 30% efficiency, in order to improve system efficiencies and economics. The SOFC system is indirectly coupled to the GT, in order to minimize the disruption to the GT operation. A thermo-economic model is developed to simulate the hybrid power plant and to optimize its performance using the method of Lagrange Multipliers. It predicts an optimized power output of 18.9 MW at 48.5% efficiency, and a breakeven per-unit energy cost of USD 4.54 ¢ kW h⁻¹ for the hybrid system based on futuristic mass generation SOFC costs.     

Polymer electrolyte fuel cell mini power unit for portable application

This paper describes the design, realisation and test of a power unit based on a polymer electrolyte fuel cell, operating at room temperature, for portable application. The device is composed of an home made air breathing fuel cell stack, a metal hydride tank for H₂ supply, a dc–dc converter for power output control and a fan for stack cooling. The stack is composed by 10 cells with an active surface of 25 cm² and produces a rated power of 15 W at 6 V and 2 A. The stack successfully runs with end-off fed hydrogen without appreciable performance degradation during the time. The final assembled system is able to generate 12 W at 9.5 V, and power a portable DVD player for 3 h in continuous. The power unit has collected about 100 h of operation without maintenance.     

Thermo-economic modeling of a solid oxide fuel cell/gas turbine power plant with semi-direct coupling and anode recycling

Power generation using gas turbine (GT) power plants operating on the Brayton cycle suffers from low efficiencies, resulting in poor fuel to power conversion. A solid oxide fuel cell (SOFC) is proposed for integration into a 10 MW gas turbine power plant, operating at 30% efficiency in order to improve system efficiencies and economics. The SOFC system is semi-directly coupled to the gas turbine power plant, with careful attention paid to minimize the disruption to the GT operation. A thermo-economic model is developed for the hybrid power plant, and predicts an optimized power output of 21.6 MW at 49.2% efficiency. The model also predicts a breakeven per-unit energy cost of USD 4.70 ¢/kWh for the hybrid system based on futuristic mass generation SOFC costs. Results show that SOFCs can be semi-directly integrated into existing GT power systems to improve their thermodynamic and economic performance.     

An integrated power generation system combining solid oxide fuel cell and oxy-fuel combustion for high performance and CO2 capture

An integrated power generation system combining solid oxide fuel cell (SOFC) and oxy-fuel combustion technology is proposed. The system is revised from a pressurized SOFC-gas turbine hybrid system to capture CO₂ almost completely while maintaining high efficiency. The system consists of SOFC, gas turbine, oxy-combustion bottoming cycle, and CO₂ capture and compression process. An ion transport membrane (ITM) is used to separate oxygen from the cathode exit air. The fuel cell operates at an elevated pressure to facilitate the use of the ITM, which requires high pressure and temperature. The remaining fuel at the SOFC anode exit is completely burned with oxygen at the oxy-combustor. Almost all of the CO₂ generated during the reforming process of the SOFC and at the oxy-fuel combustor is extracted from the condenser of the oxy-combustion cycle. The oxygen-depleted high pressure air from the SOFC cathode expands at the gas turbine. Therefore, the expander of the oxy-combustion cycle and the gas turbine provides additional power output. The two major design variables (steam expander inlet temperature and condenser pressure) of the oxy-fuel combustion system are determined through parametric analysis. There exists an optimal condenser pressure (below atmospheric pressure) in terms of global energy efficiency considering both the system power output and CO₂ compression power consumption. It was shown that the integrated system can be designed to have almost equivalent system efficiency as the simple SOFC-gas turbine hybrid system. With the voltage of 0.752 V at the SOFC operating at 900 °C and 8 bar, system efficiency over 69.2% is predicted. Efficiency penalty due to the CO₂ capture and compression up to 150 bar is around 6.1%.     

Experimental analysis of dynamic characteristics on the PEM fuel cell stack by using Taguchi approach with neural networks

This study determines the optimum operating parameters for a proton exchange membrane fuel cell (PEMFC) stack to obtain small variation and maximum electric power output using a robust parameter design (RPD). The operating parameters examined experimentally are operating temperatures, operating pressures, anode/cathode humidification temperatures, and reactant flow rates. First, the dynamic Taguchi method is used to obtain the maximum and stable power density against the different current densities, which are regarded as the systemic inputs considered a signal factor. The relationship between control factors and responses in the PEMFC stack is determined using a neural network. The discrete parameter levels in the dynamic Taguchi method can be divided into desired levels to acquire real optimum operating parameters. Based on these investigations, the PEMFC stack is operated at the current densities of 0.4–0.8 A/cm². Since the voltage shift is quite small (roughly 0.73–0.83 V for each single cell), the efficiency would be higher. In the range of operation, the operating pressure, the cathode humidification temperature and the interactions between operating temperature and operating pressure significantly impact PEMFC stack performance. As the operating pressure increasing, the increments of the electric power decrease, and power stability is enhanced because the variation in responses is reduced.     

Energy and exergy analyses of a combined ammonia-fed solid oxide fuel cell system for vehicular applications

In this study, both energetic and exergetic performances of a combined heat and power (CHP) system for vehicular applications are evaluated. This system proposes ammonia-fed solid oxide fuel cells based on proton conducting electrolyte (SOFC-H⁺) with a heat recovery option. Fuel consumption of combined fuel cell and energy storage system is investigated for several cases. The performance of the portable SOFC system is studied in a wide range of the cell’s average current densities and fuel utilization ratios. Considering a heat recovery option, the system exergy efficiency is calculated to be 60-90% as a function of current density, whereas energy efficiency varies between 60 and 40%, respectively. The largest exergy destructions take place in the SOFC stack, micro-turbine, and first heat exchanger. The entropy generation rate in the CHP system shows a 25% decrease for every 100 °C increase in average operating temperature.     

燃料重整固体氧化物燃料电池发电系统性能分析及多变量参数优化

以燃料重整的固体氧化物燃料电池发电系统为研究对象,通过数值模拟方法对固体氧化物燃料电池发电系统的性能、(火用)损、(火用)效率以及多变量运行参数优化进行了分析。研究结果表明：重整反应中燃料利用系数、电池工作温度、水碳比、电堆电流密度等参数对系统性能影响显著;电堆工作在不同电流密度下都有其对应的最佳工作温度、最佳燃料利用系数工况点;水碳比会改变重整反应产氢量,从而影响电化学反应速率,空气加热器的(火用)损所占份额最大;优化后的系统效率及(火用)效率为0.480 9和0.462 6,效率提升约4%。     

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.     

Efficiency gain of solid oxide fuel cell systems by using anode offgas recycle - Results for a small scale propane driven unit

The transfer of high electrical efficiencies of solid oxide fuel cells (SOFC) into praxis requires appropriate system concepts. One option is the anode-offgas recycling (AOGR) approach, which is based on the integration of waste heat using the principle of a chemical heat pump.The AOGR concept allows a combined steam- and dry-reforming of hydrocarbon fuel using the fuel cell products steam and carbon dioxide. SOFC fuel gas of higher quantity and quality results. In combination with internal reuse of waste heat the system efficiency increases compared to the usual path of partial oxidation (POX).The demonstration of the AOGR concept with a 300 Wel-SOFC stack running on propane required: a combined reformer/burner-reactor operating in POX (start-up) and AOGR modus; a hotgas-injector for anode-offgas recycling to the reformer; a dynamic process model; a multi-variable process controller; full system operation for experimental proof of the efficiency gain.Experimental results proof an efficiency gain of 18 percentage points (η·POX = 23%, η·AOGR = 41%) under idealized lab conditions. Nevertheless, further improvements of injector performance, stack fuel utilization and additional reduction of reformer reformer O/C ratio and system pressure drop are required to bring this approach into self-sustaining operation.