Intra-fuel cell stack measurements of transient concentration distributions

Intra-fuel-cell measurements are required to understand detailed fuel-cell chemistry and physics, validate models, optimize system design and control, and realize enhanced efficiency regimes; in comparison, conventional integrated fuel-cell supply and effluent measurements are fundamentally limited in value. Intra-reactor measurements are needed for all fuel cell types. This paper demonstrates the ability of a capillary-inlet mass spectrometer to resolve transient species distributions within operating polymer-electrolyte-membrane (PEM) fuel cells and at temperatures typical of solid-oxide fuel cells (SOFC). This is the first such demonstration of a diagnostic that is sufficiently minimally invasive as to allow measurements throughout an operating fuel cell stack. Measurements of transient water, hydrogen, oxygen and diluent concentration dynamics associated with fuel-cell load switching suggest oxygen-limited chemistry. Intra-PEM fuel cell measurements of oxygen distribution at various fuel-cell loads are used to demonstrate concentration gradients, non-uniformities, and anomalous fuel cell operation.     

Single solid oxide fuel cell modeling and optimization

In this paper a dynamic model of a single solid oxide fuel cell (SOFC) is developed using a volume element methodology. It consists of a set of algebraic and ordinary differential equations derived from physical laws (e.g., the first law of thermodynamics, Fick's law, and Fourier's law), which allow for the prediction of the temperature and pressure spatial distribution inside the single SOFC, as functions of geometric and operating parameters. The thermodynamic model is coupled with an electrochemical model that is capable of determining the voltage, current, and power output. Based on the simulation results, the internal configuration (structure of the positive electrode-electrolyte-negative electrode assembly) and the operating conditions (air stoichiometric ratio and fuel utilization factor), as well as their impact on the performance of the single SOFC are discussed. Optimal geometric and operating parameters are obtained so that electrical power of the single SOFC at the nominal operating point is maximized. The method used is general and the fundamental optimization results are sharp, showing up to a 357% single SOFC performance variation within the studied parameters’ range, therefore these findings show the potential to use the model as a tool for future SOFC design, simulation and optimization.     

Thermal-stress analyses of an operating planar solid oxide fuel cell with the bonded compliant seal design

A thermo-electrochemical-structure model has been proposed in the present work to investigate the thermal behavior and the thermal-stress of a solid oxide fuel cell (SOFC) with the bonded compliant seal (BCS) design. A comprehensive numerical simulation model, employing the finite-volume approach, has been developed for the three-dimensional, multi-component, electrochemically, and chemically reacting flow of a single planar SOFC unit cell. The cell temperature predicted by the finite-volume model is imported to a finite-element model to estimate the thermal-stress with the BCS design. Effects of the cell voltage and the temperature non-uniformity on the thermal-stress of the SOFC have been investigated. Numerical results obtained from the present study show that an assumed isothermal SOFC configuration leads to an underestimate of the thermal-stress by 28% for the cell and 37% for the metal frame in comparison with those in practical operating conditions. Two factors are identified to be responsible for the thermal-stress. One is the residual stress, and the other is the temperature gradient. The dominant factor for the thermal-stress depends on the location and the cell voltage.     

Optimization of single SOFC structural design for maximum power

This paper improves previously published models by the authors for a single solid oxide fuel cell (SOFC), and introduces a procedure to optimize its external configuration and operating conditions, so that the net power is maximized. The previous models are hereby improved to include: i) a constant offset overpotential in total potential drop; ii) heat generation associated with all the potential losses; iii) temperature-dependent thermo-physical properties of fuel and air, and iv) pumping power to maximize fuel cell performance. The thermodynamic model is derived from physical laws (e.g., the first law of thermodynamics, Fick's law, Fourier's law) to obtain the temperature and pressure spatial distribution in the SOFC. The electrochemical model is validated by direct comparison with experimental data from the Pacific Northwest National Laboratory (PNNL), and allows for the computation of the SOFC voltage, current, and power output. Based on the simulation results, the structural design, the active three phase boundaries regions at the electrodes and the fuel utilization factor, and their impact on the SOFC performance are discussed. Subjected to fixed total volume, the optimal geometric and operating parameters are pursued so that the net power of the SOFC is maximized through a 4-way-optimization procedure. The method used is general and the numerically obtained maxima are sharp, taking into account that up to a 631% single SOFC performance variation was observed within the studied parameters' range. The fixed volume constraint was then relaxed, and the effect of total volume variation on performance was investigated, delivering the general optimal parameters for the 4-way maximized SOFC net power output within the studied total dimensionless fuel cell volume range. These findings show the potential to use the model as a tool for future SOFC design, simulation and optimization.     

Anode gas recirculation behavior of a fuel ejector in hybrid solid oxide fuel cell systems: Performance evaluation in three operational modes

In this paper, a theoretical model for the performance monitoring and fault detection of fuel ejectors in the hybrid solid oxide fuel cell (SOFC) system is proposed. The procedures of using the model to analyze ejector properties such as the primary mass flow rate, the secondary mass flow rate, the recirculation ratio and steam to carbon ratio (STCR) are introduced. Based on the model, the anode gas recirculation performances of a hybrid SOFC system are studied under various operating conditions. Results show that the model can be used to evaluate the performance of ejector not only in the critical mode but also in the subcritical and back flow modes, which is especially useful at SOFC off-design operating conditions such as start up, load changes and shut down.     

A CFD-based model of a planar SOFC for anode flow field design

This study presents a 3D CFD model of a planar SOFC with internal reforming for anode flow field design. The developed model reflects the influence of various factors on fuel cell performance including flow field design and kinetics of chemical and electrochemical reactions. The case study illustrates applications of the CFD model for planar SOFC with different anode flow field designs. Simulation results indicate the importance of the anode flow field design for planar SOFCs. The model is useful for optimization of fuel cell design and operating conditions.     

ANN–supported control strategy for a solid oxide fuel cell working on demand for a public utility building

The idea of control strategy of SOFC operating to meet demand of a public utility building was presented. The strategy was formulated with the support of Artificial Neural Network. The network was used to predict the demand for electricity. The calculations were carried out on the example of a building of the Institute of Heat Engineering Warsaw University of Technology. The control strategy is influenced by various factors depending on changes in market conditions and operating characteristics of the cell. We can define different objective functions eg: working for own needs, for maximum profit and maximum service life. The article presents a simulation of SOFC operation for demand profile of the IHE building from the selected time period.     

Numerical simulation of a closed wet cooling tower with novel design

A closed wet cooling tower with novel design was proposed and numerically investigated. The studied cooling tower consists of two main parts: one heat and mass transfer unit (HMTU) and one heat transfer unit (HTU). In the HMTU, copper tubes are arranged as heat transfer tubes while plastic tubes are collocated to enlarge the mass transfer area between the spray water and the airflow. In the HTU, only copper tubes are adopted as heat transfer tubes. Heat and mass transfer process takes place among the process water, airflow and spray water in the HMTU, while in the HTU only heat transfer between the process water and the spray water is observed. A transient one dimensional distributed-parameter model was adopted to evaluate the cooling tower performance under different operating conditions. Determination of heat and mass transfer coefficients, as well as the influence of Lewis number on the cooling tower performance, was presented.     

Theoretical analysis of reversible solid oxide fuel cell based on proton-conducting electrolyte

A single reversible solid oxide fuel cell (RSOFC) can accomplish two functions: (1) as a solid oxide steam electrolyzer (SOSE) for hydrogen production and (2) as a solid oxide fuel cell (SOFC) for power generation. An electrochemical model was developed to study the performance of an RSOFC based on a proton-conducting electrolyte (RSOFC-H). In both SOSE and SOFC modes, the hydrogen electrode-supported configuration was identified as the most favorable design to achieve high energy conversion efficiency of RSOFC-H. For comparison, in a previous study on conventional RSOFC based on an oxygen ion-conducting electrolyte (RSOFC-O), the hydrogen electrode-supported configuration was found to be favorable in the SOFC mode but such configuration would cause high concentration overpotential in the SOSE mode. Thus, the oxygen electrode-supported configuration was desirable for RSOFC-O operating in the SOSE mode. The results obtained in this study show that RSOFC-H has a natural advantage over RSOFC-O in terms of structural design. The modeling study signifies the difference between RSOFC-H and RSOFC-O and can serve as a useful tool for further design optimization.     

Application of a detailed dimensional solid oxide fuel cell model in integrated gasification fuel cell system design and analysis

Integrated gasification fuel cell (IGFC) systems that combine coal gasification and solid oxide fuel cells (SOFC) are promising for highly efficient and environmentally sensitive utilization of coal for power production. Most IGFC system analysis efforts performed to-date have employed non-dimensional SOFC models, which predict SOFC performance based upon global mass and energy balances that do not resolve important intrinsic constraints of SOFC operation, such as the limits of internal temperatures and species concentrations. In this work, a detailed dimensional planar SOFC model is applied in IGFC system analysis to investigate these constraints and their implications and effects on the system performance. The analysis results further confirm the need for employing a dimensional SOFC model in IGFC system design. To maintain the SOFC internal temperature within a safe operating range, the required cooling air flow rate is much larger than that predicted by the non-dimensional SOFC model, which results in a larger air compressor design and operating power that significantly reduces the system efficiency. Options to mitigate the challenges introduced by considering the intrinsic constraints of SOFC operation in the analyses and improve IGFC design and operation have also been investigated. Novel design concepts that include staged SOFC stacks and cascading air flow can achieve a system efficiency that is close to that of the baseline analyses, which did not consider the intrinsic SOFC limitations.     

Numerical characterization of a microscale solid-oxide fuel cell

In this study, a single unit of planar micro-solid-oxide fuel cell (μSOFC) is investigated numerically to evaluate the influences of flow channel design, oxygen composition, and thermal operating conditions on cell performance. Four flow channel designs are examined under the co-flow configuration: serpentine, double serpentine, rod bundle, and oblique rib. For all designs, the contacts areas of interconnect to electrodes are kept consistent to maintain the ohmic losses at the same level. To characterize the mass transport effects, there are three different compositions, 100% O₂, 50% O₂/50% N₂ and air, fed to the cathode inlet. Different thermal conditions, adiabatic and isothermal, are applied to the outer boundary of the μSOFC and the results are compared. The outcomes suggest that both thermal conditions and oxidant composition show remarkable influences on μSOFC performance. Under adiabatic conditions, the rise of cell temperature causes a decrease in reversible voltage, deteriorating the overall cell competence. When oxygen is diluted with nitrogen, local gas diffusion becomes dominant to the cathode reaction. Bulk flow, on the other hand, plays a minor role in cell performance since there is little deviation in the polarization curves for all flow channel designs, even at high current densities. For comparison, the flow visualization technique is employed to observe the transport phenomena in various flow channel designs. The flow patterns are found to resemble the concentration distribution, providing a useful tool to design μSOFCs.     

Energy and exergy analysis of simple solid-oxide fuel-cell power systems

Two, simple, solid-oxide fuel-cell (SOFC) power systems fed by hydrogen and methane, respectively, are examined. While other models available in the literatures focus on complicated hybrid SOFC and gas-turbine (GT) power systems, this study focuses on simple SOFC power systems with detailed thermodynamic modeling of the SOFC. All performance-related parameters of the fuel-cell such as respective resistivity of the components, anode and cathode exchange current density, limiting current density, flow diffusivity, etc. are all expressed as a function of temperature, while the flow through of each nodes of the system is described as a function of thermodynamic state. Full analysis of the energy and exergy at each node of the system is conducted and their respective values are normalized by the lower heating value (LHV) of the fuel and its chemical exergy, respectively. Thus, the normalized electrical energy outputs directly indicate the first law and second law efficiencies, respectively, of the fuel-cell power systems.     

Performance analysis and parametric study of a solid oxide fuel cell fueled by carbon monoxide

A theoretical model of the solid oxide fuel cell (SOFC) fueled by carbon monoxide is adopted and validated, in which the activation overpotential, concentration overpotential, and ohmic overpotential are regarded as the main sources of voltage losses. Based on the thermodynamic-electrochemical analysis, mathematical expressions of some performance parameters such as the cell potential, power output, efficiency, and entropy production rate are derived. The effects of microstructure parameters such as the electrode porosity, tortuosity, pore size, grain size, etc. on the electrochemical performance characteristics of the SOFC are revealed. Moreover, the effects of some operation conditions such as the current density, anode inlet gas molar fraction, operating temperature, and operating pressure on some important performance parameters of the SOFC are also discussed. It is found that there exist some optimal values of microstructure parameters and operating conditions at which the better performance can be expected. The results obtained in the paper may provide some theoretical guidance for the design and operation of practical SOFCs fueled by coal-derived gases.     

Performance of a square, cross-corrugated, polymer film, compact, heat-exchanger with potential application in fuel cells

This paper describes an experimental investigation of the performance characteristics of a novel, cross-corrugated, polymer film, compact, heat-exchanger (PFCHE) made from poly ether ether ketone (PEEK). The aim is to develop Jh and f correlations over a range of Reynolds numbers under laminar conditions to be used in alternative heat-exchanger designs for potential applications in the fuel-cell industry. The incentive for adopting these designs is the huge weight, energy and cost savings involved. Design correlations for square units are key tools in obtaining alternative designs for applications that are presently monopolized by metallic heat-exchangers. The design correlations are establised and then used to perform case studies in selected applications in the fuel-cell industry to suit the fluids and the configuration.     

A study on performance of solid oxide fuel cell‐organic Rankine cycle combined system

This study presents an energetic performance analysis for a combined power generation system consisting of a solid oxide fuel cell (SOFC) and an organic Rankine cycle (ORC). In order to simulate the SOFC–ORC combined system under steady‐state conditions, a mathematical model is developed. The developed model is used to determine the potential effects caused by the changes of the design parameters on the energetic performance of the combined system. As design parameters, turbine inlet pressure, condenser temperature, fuel utilization, current density, compressor pressure ratio, and cell operating temperature are taken into account. In this regard, the electrical power and First Law efficiency are estimated by parametrical analysis and discussed comprehensively. Results of these analyses show that the efficiency is increased about 14–25% by recovering SOFC waste heat through ORC based on investigated design parameter conditions. Copyright © 2008 John Wiley & Sons, Ltd.     

Performance analysis of a PEM fuel cell unit in a solar–hydrogen system

In this paper, energy and exergy analyses for a 1.2 kWp Nexa PEM fuel cell unit in a solar-based hydrogen production system is undertaken to investigate the performance of the system for different operating conditions using experimental setup and thermodynamic model. From the model results, it is found that there are reductions in energy and exergy efficiencies (about 14%) with increase in current density. These are consistent with the experimental data for the same operating conditions. A parametric study on the system and its parameters is undertaken to investigate the changes in the efficiencies for variations in temperature, pressure and anode stoichiometry. The energy and exergy efficiencies increase with pressure by 23% and 15%, respectively. No noticeable changes are observed in energy and exergy efficiencies with increase in temperature. The energy and exergy efficiencies decrease with increase in anode stoichiometry by 17% and 14%, respectively. These observations are reported for the given range of current density as 0.047–0.4 A/cm². The results and analyses show that the PEM fuel-cell system has lower exergy efficiencies than the corresponding energy efficiencies due to the irreversibilities that are not considered by energy analysis. In comparison with experimental data, the model is accurate in predicting the performance of the proposed fuel-cell system. The parametric and multivariable analyses show that the option of selecting appropriate set of conditions plays a significant role in improving performance of existing fuel-cell systems.     

Artificial intelligence based structural optimization of solid oxide fuel cell with three-dimensional reticulated trapezoidal flow field

Three-dimensional Reticulated trapezoidal flow field (RTFF) is promising in improving the performance and durability of the solid oxide fuel cell (SOFC). However, the structural complexity makes it challenging for the geometry configuration of the splitter and mixer. To this end, an intelligent optimization framework is proposed by coupling artificial neural network (ANN) and non-dominated sorting genetic algorithm-II (NSGA-II), in order to maximize the net power density and oxygen uniformity simultaneously. The ANN prediction model is trained to obtain the computationally efficient surrogate model of the computational fluid dynamics (CFD) numerical simulation. NSGA-II is used for the multi-objective optimization of the RTFF structural parameters. The results illustrate that the prediction model is of high prediction precision and generalization capability. In comparison to SOFC with conventional parallel flow fields (CPFF), the degree of the performance improvement of SOFC with optimized RTFF depends on the working condition, i.e., fuel and air flow rates and operating temperatures. The SOFC with the optimal RTFF achieves a higher molar concentration of oxygen and a more uniform distribution of oxygen and current density than the CPFF SOFC. The proposed optimization framework provides an efficient design method for the development of the next-generation SOFC flow field.     

Thermodynamic model and parametric analysis of a tubular SOFC module

Solid oxide fuel cells (SOFCs) have been considered in the last years as one of the most promising technologies for very high-efficiency electric energy generation from natural gas, both with simple fuel cell plants and with integrated gas turbine-fuel cell systems. Among the SOFC technologies, tubular SOFC stacks with internal reforming have emerged as one of the most mature technology, with a serious potential for a future commercialization. In this paper, a thermodynamic model of a tubular SOFC stack, with natural gas feeding, internal reforming of hydrocarbons and internal air preheating is proposed. In the first section of the paper, the model is discussed in detail, analyzing its calculating equations and tracing its logical steps; the model is then calibrated on the available data for a recently demonstrated tubular SOFC prototype plant. In the second section of the paper, it is carried out a detailed parametric analysis of the stack working conditions, as a function of the main operating parameters. The discussion of the results of the thermodynamic and parametric analysis yields interesting considerations about partial load SOFC operation and load regulation, and about system design and integration with gas turbine cycles.     

Numerical modeling and parametric analysis of solid oxide fuel cell button cell testing process

In laboratory studies of solid oxide fuel cell (SOFC), performance testing is commonly conducted upon button cells because of easy implementation and low cost. However, the comparison of SOFC performance testing results from different labs is difficult because of the different testing procedures and configurations used. In this paper, the SOFC button cell testing process is simulated. A 2‐D numerical model considering the electron/ion/gas transport and electrochemical reactions inside the porous electrodes is established, based on which the effects of different structural parameters and configurations on SOFC performance testing results are analyzed. Results show that the vertical distance (H) between the anode surface and the inlet of the anode gas channel is the most affecting structure parameter of the testing device, which can lead to up to 18% performance deviation and thus needs to be carefully controlled in SOFC button cell testing process. In addition, the current collection method and the configuration of gas tubes should be guaranteed to be the same for a reasonable and accurate comparison between different testing results. This work would be helpful for the standardization of SOFC button cell testing.     

Dynamic temperature modeling of an SOFC using least squares support vector machines

Cell temperature control plays a crucial role in SOFC operation. In order to design effective temperature control strategies by model-based control methods, a dynamic temperature model of an SOFC is presented in this paper using least squares support vector machines (LS-SVMs). The nonlinear temperature dynamics of the SOFC is represented by a nonlinear autoregressive with exogenous inputs (NARXs) model that is implemented using an LS-SVM regression model. Issues concerning the development of the LS-SVM temperature model are discussed in detail, including variable selection, training set construction and tuning of the LS-SVM parameters (usually referred to as hyperparameters). Comprehensive validation tests demonstrate that the developed LS-SVM model is sufficiently accurate to be used independently from the SOFC process, emulating its temperature response from the only process input information over a relatively wide operating range. The powerful ability of the LS-SVM temperature model benefits from the approaches of constructing the training set and tuning hyperparameters automatically by the genetic algorithm (GA), besides the modeling method itself. The proposed LS-SVM temperature model can be conveniently employed to design temperature control strategies of the SOFC.