U.S. DOE fossil energy fuel cells program

The U.S. Department of Energy's (DOE) Office of Fossil Energy's (FE) National Energy Technology Laboratory (NETL), in partnership with private industry, educational institutions and national laboratories, is leading the development and demonstration of high efficiency, high temperature solid oxide fuel cells (SOFCs) and fuel cell turbine (FCT) hybrid power generation systems for stationary markets including auxiliary power units (APUs), distributed generation (DG) and large, coal-based central power plants. The DOE FE fuel cells program has three aspects: the Solid State Energy Conversion Alliance (SECA), Fuel Cell Coal Based Systems for central power, and the High Temperature Electrochemistry Center (HiTEC). The SECA goal is to decrease SOFC system cost to US$ 400 per kilowatt (kW) by 2010 for stationary markets. DOE FE is ultimately concerned with coal-based central power plants such as FutureGen. The goal is to aggregate SECA-type fuel cells into larger systems and to produce a very high efficiency megawatt-class FCT hybrid for testing at FutureGen. The low-cost, US$ 400 kW⁻¹ SECA FCT hybrid is a key component to achieving 60% efficiency by 2020. Advanced aspects of solid oxide technology are part of HiTEC R&D. Technical progress and advances are discussed for all three program aspects.     

Distributed generation—Molten carbonate fuel cells

High efficiency and ultra-clean molten carbonate fuel cell (MCFC) technology development by FuelCell Energy, with support from the U.S. Department of Energy (DOE), has progressed to commercial power plants for stationary applications such as distributed generation. Lessons learned from this development will also be valuable to DOE for the ongoing Solid State Energy Conversion Alliance (SECA) solid oxide fuel cell (SOFC) development and cost reduction, for fuel cell turbine hybrids, and for hydrogen economy development with FutureGen.     

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.     

Process simulation of a SOFC and double bubbling fluidized bed gasifier power plant

The development of reliable fuel cells power plant based on renewable fuels stands out as one of the promising energy systems solutions for the future. Indeed fuel cells can increase the efficiency and the cleaning of the electrical energy production from renewable fuels. Process simulations of advanced power plants fed by low cost renewable fuels like biomass waste are a key step to develop renewable resources based on high temperature fuel cells applications. The aim of this work is to predict the component behaviour of a specific power plant mainly composed of a small indirectly heated gasifier and a Solid Oxide Fuel Cell (SOFC) and fed by chestnut coppice, waste available in great quantity in Central Italy, as well as in several other European regions. The plant's thermodynamic behaviour is analysed by means of the process simulator CHEMCAD© in which particular models for the SOFC and the gasifier have been developed in FORTRAN by the authors and then interfaced to commercial software. The results of the predictive model are presented and discussed, showing the possibility of an extremely interesting “carbon neutral” small plant configuration with high electrical and global efficiency exclusively based on the use of low cost renewable resources.     

Optimal integration strategies for a syngas fuelled SOFC and gas turbine hybrid

This article aims to develop a thermodynamic modelling and optimization framework for a thorough understanding of the optimal integration of fuel cell, gas turbine and other components in an ambient pressure SOFC-GT hybrid power plant. This method is based on the coupling of a syngas-fed SOFC model and an associated irreversible GT model, with an optimization algorithm developed using MATLAB to efficiently explore the range of possible operating conditions. Energy and entropy balance analysis has been carried out for the entire system to observe the irreversibility distribution within the plant and the contribution of different components. Based on the methodology developed, a comprehensive parametric analysis has been performed to explore the optimum system behavior, and predict the sensitivity of system performance to the variations in major design and operating parameters. The current density, operating temperature, fuel utilization and temperature gradient of the fuel cell, as well as the isentropic efficiencies and temperature ratio of the gas turbine cycle, together with three parameters related to the heat transfer between subsystems are all set to be controllable variables. Other factors affecting the hybrid efficiency have been further simulated and analysed. The model developed is able to predict the performance characteristics of a wide range of hybrid systems potentially sizing from 2000 to 2500 W m⁻² with efficiencies varying between 50% and 60%. The analysis enables us to identify the system design tradeoffs, and therefore to determine better integration strategies for advanced SOFC-GT systems.     

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.     

A performance analysis of integrated solid oxide fuel cell and heat recovery steam generator for IGFC system

Solid oxide fuel cell (SOFC) is a promising technology for electricity generation. Sulfur-free syngas from a gas-cleaning unit serves as fuel for SOFC in integrated gasification fuel cell (IGFC) power plants. It converts the chemical energy of fuel gas directly into electric energy, thus high efficiencies can be achieved. The outputs from SOFC can be utilized by heat recovery steam generator (HRSG), which drives the steam turbine for electricity production. The SOFC stack model was developed using the process flow sheet simulator Aspen Plus, which is of the equilibrium type. Various ranges of syngas properties gathered from different literature were used for the simulation. The results indicate a trade-off efficiency and power with respect to a variety of SOFC inputs. The HRSG located after SOFC was included in the current simulation study with various operating parameters. This paper describes IGFC power plants, particularly the optimization of HRSG to improve the efficiency of the heat recovery from the SOFC exhaust gas and to maximize the power production in the steam cycle in the IGFC system. HRSG output from different pressure levels varies depending on the SOFC output. The steam turbine efficiency was calculated for measuring the total power plant output. The aim of this paper is to provide a simulation model for the optimal selection of the operative parameters of HRSG and SOFC for the IGFC system by comparing it with other models. The simulation model should be flexible enough for use in future development and capable of predicting system performance under various operating conditions.     

A review of solid oxide fuel cell component fabrication methods toward lowering temperature

The solid oxide fuel cells (SOFCs) emerge as an alternative power generation system for high-scale stationary application and power plant station. The SOFC consumption leads to the high-efficiency energy production that forms variety of fuels up to 60% energy conversion; the operation system does not involve the burning process and minimizes the air pollution. Also, the aptitude to provide the cogenerative energy production from the heat waste during the operation process serve SOFC as an attractive green technology and environmentally friendly. However, the SOFC consumption remains limited for transportation and portable applications because the simple design of power source compartment is still the major hurdle in each SOFC component development and commercialization. Therefore, the appropriate fabrication method of each SOFC component is important to achieve the reliability of the SOFC application for the small-scale power generation design. In this paper, an overview of the design types and SOFC components and properties following electrode, electrolyte, interconnect and sealant are discussed and summarized. As the third-generation fuel cells, which entice the commercialization stage, this paper concentrates more on the fabrication method of each SOFC components that were explored including the working principle, advantage, disadvantage and several previous works on each fabrication method, which are described to finding the appropriate fabrication method toward lowering the operating temperature and develop the simple design of SOFC power sources system for the transportation and portable application. The targeted market power production of SOFC system for transportation application is about 5 kW and 250 W for portable application.     

Performance analysis of hybrid solid oxide fuel cell and gas turbine cycle (part II): Effects of fuel composition on specific work and efficiency

The model of the hybrid solid oxide fuel cell (SOFC) and gas turbine (GT) cycle is used to evaluate the impacts of the inlet fuel composition on the specific work and efficiency of the cycle. In order to perform the analysis, the system fueled with methane is considered as the reference case. For alternative cases, methane is partially replaced with hydrogen, carbon dioxide, carbon monoxide, and nitrogen with an increment of 5% at each step. The results indicate that the trend of the variations and the magnitude of the changes depend on the replacing gases. The specific work and efficiency of the SOFC, GT, and cycle as a whole for the cycle with and without anode recirculation can increased, decreased, or remain unaffected when methane is replaced with these species. All these trends are justified by investigating the system's operational parameters. This study confirms the importance of the fuel composition impacts on the SOFC–GT cycle performance.     

A performance analysis of integrated solid oxide fuel cell and heat recovery steam generator for IGFC system

Solid oxide fuel cell (SOFC) is a promising technology for electricity generation. Sulfur-free syngas from a gas-cleaning unit serves as fuel for SOFC in integrated gasification fuel cell (IGFC) power plants. It converts the chemical energy of fuel gas directly into electric energy, thus high efficiencies can be achieved. The outputs from SOFC can be utilized by heat recovery steam generator (HRSG), which drives the steam turbine for electricity production. The SOFC stack model was developed using the process flow sheet simulator Aspen Plus, which is of the equilibrium type. Various ranges of syngas properties gathered from different literature were used for the simulation. The results indicate a trade-off efficiency and power with respect to a variety of SOFC inputs. The HRSG located after SOFC was included in the current simulation study with various operating parameters. This paper describes IGFC power plants, particularly the optimization of HRSG to improve the efficiency of the heat recovery from the SOFC exhaust gas and to maximize the power production in the steam cycle in the IGFC system. HRSG output from different pressure levels varies depending on the SOFC output. The steam turbine efficiency was calculated for measuring the total power plant output. The aim of this paper is to provide a simulation model for the optimal selection of the operative parameters of HRSG and SOFC for the IGFC system by comparing it with other models. The simulation model should be flexible enough for use in future development and capable of predicting system performance under various operating conditions.     

Design of highly efficient coal-based integrated gasification fuel cell power plants

Integrated gasification fuel cell (IGFC) technology combining coal gasification and solid oxide fuel cell (SOFC) is believed to be the only viable solution to achieving U.S. Department of Energy (DOE)’s performance goal for next generation coal-based power plants, producing electricity at 60% efficiency (coal HHV-AC) while capturing more than 90% of the evolved CO₂. Achieving this goal is challenging even with high performance SOFCs; design concepts published to date have not demonstrated this performance goal. In this work an IGFC system concept consisting of catalytic hydro-gasification, proven low-temperature gas cleaning and hybrid fuel cell-gas turbine power block (with SOFC operating at about 10 bar) is introduced. The system is demonstrating an electricity efficiency greater than 60% (coal HHV basis), with more than 90% of the carbon present in the syngas separated as CO₂ amenable to sequestration. A unique characteristic of the system is recycling de-carbonized, humidified anode exhaust back to the catalytic hydro-gasifier for improved energy integration. Alternative designs where: (1) anode exhaust is recycled directly back to SOFC stacks, (2) SOFC stack operating pressure is reduced to near atmospheric and (3) methanation reactor in the reactor/expander topping cycle is removed, have also been investigated and the system design and performance differences are discussed.     

Design and eco-technoeconomic analyses of SOFC/GT hybrid systems accounting for long-term degradation effects

This study compares two SOFC/GT (solid oxide fuel cell with gas turbine) hybrid systems to that of two standalone SOFC systems via eco-technoeconomic analyses that account for long-term degradation effects. Four cases were examined: 1) standalone SOFC plant without a steam bottoming cycle; 2) standalone SOFC plant with a steam bottoming cycle; 3) SOFC/GT hybrid plant without a steam bottoming cycle; and 4) SOFC/GT with a steam bottoming cycle. This study employed a real-time 1D SOFC model with an empirical degradation calculation integrated with steady-state balance-of-plant models. Simulations used Matlab Simulink R2017a, Aspen Plus V10, and Python 3.7.4 with a pseudo steady-state approach. The results showed that, with some trade-offs, the SOFC/GT hybrid plant with the steam bottoming cycle is the best option, with an overall efficiency of 44.6% _LHV, an LCOE (levelized cost of electricity) of $US 77/MWh, and a CCA (cost of CO₂ avoided) of -$US 49.3/tonneCO₂e. The sensitivity analysis also indicated that SOFC/GT hybrid plants were less sensitive to SOFC price compared to standalone SOFC plants. The sensitivity analysis indicated that using a larger gas turbine and replacing the SOFC stack less frequently was the better design choice for the SOFC/GT hybrid plant.     

A computational fluid dynamics and finite element analysis design of a microtubular solid oxide fuel cell stack for fixed wing mini unmanned aerial vehicles

Computational fluid dynamics (CFD) and finite element analysis (FEA) are important modelling and simulation techniques to design and develop fuel cell stacks and their balance of plant (BoP) systems.The aim of this work is to design a microtubular solid oxide fuel cell (SOFC) stack by coupling CFD and FEA models to capture the multiphysics nature of the system. The focus is to study the distribution of fluids inside the fuel cell stack, the dissipation of heat from the fuel cell bundle, and any deformation of the fuel cells and the stack canister due to thermal stresses, which is important to address during the design process. The stack is part of an innovative all-in-one SOFC generator with an integrated BoP system to power a fixed wing mini unmanned aerial vehicle. Including the computational optimisation at an early stage of the development process is hence a prerequisite in developing a reliable and robust all-in-one SOFC generator system. The presented computational model considers the bundle of fuel cells as the heat source. This could be improved in the future by replacing the heat source with electrochemical reactions to accurately predict the influence of heat on the stack design.     

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.     

The modeling of a standalone solid-oxide fuel cell auxiliary power unit

In this research, a Simulink model of a standalone vehicular solid-oxide fuel cell (SOFC) auxiliary power unit (APU) is developed. The SOFC APU model consists of three major components: a controller model; a power electronics system model; and an SOFC plant model, including an SOFC stack module, two heat exchanger modules, and a combustor module. This paper discusses the development of the nonlinear dynamic models for the SOFC stacks, the heat exchangers and the combustors. When coupling with a controller model and a power electronic circuit model, the developed SOFC plant model is able to model the thermal dynamics and the electrochemical dynamics inside the SOFC APU components, as well as the transient responses to the electric loading changes. It has been shown that having such a model for the SOFC APU will help design engineers to adjust design parameters to optimize the performance. The modeling results of the SOFC APU heat-up stage and the output voltage response to a sudden load change are presented in this paper. The fuel flow regulation based on fuel utilization is also briefly discussed.     

Thermodynamic modeling and exergy investigation of a hydrogen-based integrated system consisting of SOFC and CO2 capture option

The current study deals with the thermodynamic modeling of an innovative integrated plant based on solid oxide fuel cell (SOFC) with liquefied natural gas (LNG) cold energy supply. For the suggested innovative plant the energy, and exergy simulations are fully extended and the plant comprehensively analyzed. According to mathematical simulations of the proposed plant, a MATLAB code has been extended. The results indicate that under considered initial conditions, the efficiencies of SOFC and net power generation calculated 58% and 78%, respectively and the CO₂-capture rate is obtained 79 kg/h. This study clearly shows that the integrated system reached high efficiency while having zero emissions. In addition, the efficiencies and net amount of power generation, cooling or heating output and SOFC power generation are discussed in detail as a function of different variables such utilization factor, air/fuel ratio, or SOFC inlet temperature. For enhancing the power production efficiency of SOFC, the net electricity, and CCHP exergy efficiency the plant should run in higher utilization factor and lower air/fuel ration also it's important to approximately set SOFC temperature to its ideal temperature.     

A methodology for thermo-economic modeling and optimization of solid oxide fuel cell systems

In the context of stationary power generation, fuel cell-based systems are being foreseen as a valuable alternative to thermodynamic cycle-based power plants, especially in small scale applications. As the technology is not yet established, many aspects of fuel cell development are currently investigated worldwide. Part of the research focuses on integrating the fuel cell in a system that is both efficient and economically attractive. To address this problem, we present in this paper a thermo-economic optimization method that systematically generates the most attractive configurations of an integrated system. In the developed methodology, the energy flows are computed using conventional process simulation software. The system is integrated using the pinch based methods that rely on optimization techniques. This defines the minimum of energy required and sets the basis to design the ideal heat exchanger network. A thermo-economic method is then used to compute the integrated system performances, sizes and costs. This allows performing the optimization of the system with regard to two objectives: minimize the specific cost and maximize the efficiency. A solid oxide fuel cell (SOFC) system of 50 kW integrating a planar SOFC is modeled and optimized leading to designs with efficiencies ranging from 34% to 44%. The multi-objective optimization strategy identifies interesting system configurations and their performance for the developed SOFC system model.The methods proves to be an attractive tool to be used both as an advanced analysis tool and as support to decision makers when designing new systems.     

System modeling of an air-independent solid oxide fuel cell system for unmanned undersea vehicles

To examine the feasibility of a solid oxide fuel cell (SOFC)-powered unmanned undersea vehicle (UUV), a system level analysis is presented that projects a possible integration of the SOFC stack, fuel steam reformer, fuel/oxidant storage and balance of plant components into a 21-in. diameter UUV platform. Heavy hydrocarbon fuel (dodecane) and liquid oxygen (LOX) are chosen as the preferred reactants. A maximum efficiency of 45% based on the lower heating value of dodecane was calculated for a system that provides 2.5 kW for 40 h. Heat sources and sinks have been coupled to show viable means of thermal management. The critical design issues involve proper recycling of exhaust steam from the fuel cell back into the reformer and effective use of the SOFC stack radiant heat for steam reformation of the hydrocarbon fuel.     

Fuel cell system modeling for solid oxide fuel cell/gas turbine hybrid power plants, Part I: Modeling and simulation framework

A sustainable future power supply requires high fuel-to-electricity conversion efficiencies even in small-scale power plants. A promising technology to reach this goal is a hybrid power plant in which a gas turbine (GT) is coupled with a solid oxide fuel cell (SOFC). This paper presents a dynamic model of a pressurized SOFC system consisting of the fuel cell stack with combustion zone and balance-of-plant components such as desulphurization, humidification, reformer, ejector and heat exchangers. The model includes thermal coupling between the different components. A number of control loops for fuel and air flows as well as power management are integrated in order to keep the system within the desired operation window. Models and controls are implemented in a MATLAB/SIMULINK environment. Different hybrid cycles proposed earlier are discussed and a preferred cycle is developed. Simulation results show the prospects of the developed modeling and control system.     

Thermo-economic modeling 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 gas turbine power plant, operating at 30% efficiency, in order to improve system efficiencies and economics. The SOFC system is indirectly coupled to the gas turbine power plant, paying careful attention 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 20.6 MW at 49.9% efficiency. The model also predicts a break-even per-unit energy cost of USD 4.65 ¢ kWh⁻¹ for the hybrid system based on futuristic mass generation SOFC costs. This shows that SOFCs may be indirectly integrated into existing GT power systems to improve their thermodynamic and economic performance.