Modelling and Performance Evaluation of Solid Oxide Fuel Cell for Building Integrated Co‐ and Polygeneration

Models of fuel cell based combined heat and power systems, used in building energy performance simulation codes, are often based on simple black or grey box models. To model a specific device, input data from experiments are often required for calibration. This paper presents an approach for the theoretical derivation of such data. A generic solid oxide fuel cell (SOFC) system model is described that is specifically developed for the evaluation of building integrated co‐ or polygeneration. First, a detailed computational cell model is developed for a planar SOFC and validated with available numerical and experimental data for intermediate and high temperature SOFCs with internal reforming (IT‐DIR and HT‐DIR). Results of sensitivity analyses on fuel utilisation and air excess ratio are given. Second, the cell model is extended to the stack model, considering stack pressure losses and the radiative heat transfer effect from the stack to the air flow. Third, two system designs based on the IT‐DIR and HT‐DIR SOFCs are modelled. Electric and CHP efficiencies are given for the two systems, as well as performance characteristics, to be used in simulations of building integrated co‐ and polygeneration systems.     

SOFC Thermal Transients: Modeling by Application of Experimental System Identification Techniques

Solid oxide fuel cell (SOFC) is one of the most promising technologies for future power generation. In order to make this technology marketable, many issues as cost reduction, durability, and operational management have to be overcome. Therefore, the understanding of thermodynamic and electrochemical mechanisms, that govern the SOFC behavior in steady‐state and in transient operation, becomes fundamental. In this context, the modeling of fuel cell (FC) thermal transient is of great interest because it can predict the temperature time variation, useful to the dimensioning of auxiliary devices and to avoid unwanted operational states affecting cell durability. In the present study, a 0‐D model of SOFC thermal transients was developed by applying system identification techniques, starting from experimental tests carried out on a stack made up of four single cells. Moreover, it was successfully validated in reference to further experimental data. The model allows to evaluate, in term of dynamic response, the effect of the main operating parameters on FC temperature. As further result, some control/regulation considerations useful to limit thermal stresses were proposed.     

Thermodynamic Analysis of Solid Oxide Fuel Cell Gas Turbine Systems Operating with Various Biofuels

Solid oxide fuel cell–gas turbine (SOFC‐GT) systems provide a thermodynamically high efficiency alternative for power generation from biofuels. In this study biofuels namely methane, ethanol, methanol, hydrogen, and ammonia are evaluated exergetically with respect to their performance at system level and in system components like heat exchangers, fuel cell, gas turbine, combustor, compressor, and the stack. Further, the fuel cell losses are investigated in detail with respect to their dependence on operating parameters such as fuel utilization, Nernst voltage, etc. as well as fuel specific parameters like heat effects. It is found that the heat effects play a major role in setting up the flows in the system and hence, power levels attained in individual components. The per pass fuel utilization dictates the efficiency of the fuel cell itself, but the system efficiency is not entirely dependent on fuel cell efficiency alone, but depends on the split between the fuel cell and gas turbine powers which in turn depends highly on the nature of the fuel and its chemistry. Counter intuitively it is found that with recycle, the fuel cell efficiency of methane is less than that of hydrogen but the system efficiency of methane is higher.     

The Performance of SOFC Model Under Different Three‐phase Load Conditions

In this paper, the dynamic performance of a modified thermal based dynamic model of a solid oxide fuel cell (SOFC) is presented under different three‐phase load conditions. The modified thermal based fuel cell model contains ohmic, activation and concentration voltage losses, thermal dynamics, methanol reformer and fuel utilization factor limiting stage. SOFC model and the power conditioning unit (PCU), which consists of a DC‐DC boost converter, a DC‐AC inverter, their controller, transformer and filter, are developed on Matlab/Simulink environment. The simulation results show that the real and reactive power management of the inverter is performed successfully in an AC power system with the proposed thermal based SOFC model under three‐phase load conditions such as ohmic loads, switched ohmic−inductive loads and a three‐phase induction motor. Finally, the three‐phase induction motor is performed both no load and load conditions. The simulation results show that the modified thermal based fuel cell model provides an accurate representation of the dynamic and steady state behavior of the fuel cell under different three‐phase load conditions.     

Numerical Investigation into Thermofluidic and Electrochemical Characteristics of Tubular‐type SOFC

Three‐dimensional simulations based on a multi‐physics model are performed to examine the thermofluidic and electrochemical characteristics of a tubular, anode‐supported solid oxide fuel cell (SOFC). The simulations focus on the local transport characteristics of the cathode and anode gases and the distribution of the temperature field within the fuel cell. In addition, the electrochemical properties of the SOFC are systematically examined for a representative range of inlet gas temperatures and pressures. The validity of the numerical model is confirmed by comparing the results obtained for the correlation between the power density and the current density with the experimental results presented in the literature. Overall, the present results show that the performance of the tubular SOFC is significantly improved under pressurised conditions and a higher operating temperature.     

Test Rig for Hybrid System Emulation: New Real‐Time Transient Model Validated in a Wide Operative Range

This paper reports an entirely new simulation tool for a hybrid system emulator facility built by the Thermochemical Power Group (TPG) at the University of Genoa, Italy. This new software was developed with the following targets: real‐time performance, good stability level and high calculation reliability. In details, to obtain real‐time performance a new approach based on 0‐D technique was chosen also for components usually analysed with 1‐D or 2‐D tools (e.g. the recuperator). These are essential key aspects to operate it in hardware‐in‐the‐loop mode or to evaluate predictive results for long transient operations. This work was based on collaboration between the University of Manchester, UK and the University of Genoa, Italy. The activity was carried out with a test rig composed of the following technology: a microturbine package able to produce up to 100 kWe and modified for external connections, external pipes designed for several purposes (by‐pass, measurement or bleed), and a high temperature modular vessel necessary to emulate the dimension of an SOFC stack. The real‐time transient model of this facility was developed inside the Matlab‐Simulink environment with the following modelling approach: a library of components allows to reach a high level of flexibility and an user‐friendly approach. This model includes the machine control system as an essential device to analyse further layouts (new components in the rig) and hardware‐in‐the‐loop operations. The experimental data collected in the laboratory by TPG were used to validate the simulation tool. The results calculated with the model were satisfactory compared with experimental data considering both steady‐state and transient operations. The most important innovative aspects of this work are related to this wide validation range (not only small power steps, but the whole operative range was considered) obtaining real‐time performance and considering microturbine conditions different from standard operations (additional pressure and temperature losses and unusual thermal capacitance). The modelling simplified approach used for such a complex system is an important innovative aspect, because usually the model reliability performance is obtained with more complex (and not real‐time) tools. This work is based on an innovative modelling approach based on 0‐D tools able to operate in real‐time mode (as necessary for hardware‐in‐the‐loop tests) with an accuracy level comparable with more complex and more time consuming software. This validated tool is an important base for future calculations to study innovative hybrid system layouts. For instance, TPG is planning to analyse the option of increasing fuel cell pressure and performance with a booster system (e.g. a turbocharger).     

The Development and Application of a Novel Optimisation Strategy for Solid Oxide Fuel Cell‐Gas Turbine Hybrid Cycles

A combined power system with solid oxide fuel cell (SOFC) and gas turbine (GT) is modelled and analysed thermodynamically in this paper. A novel optimisation strategy including the design of optimal parameters is proposed and applied to the hybrid system. Different sources of irreversible losses are specified, and entropy analyses are used to indicate the multi‐irreversibilities existing, and to assess the work potentials of the system. Expressions of the power output and efficiency for both the subsystems and the SOFC‐GT hybrid system are derived. The optimal performance characteristics are presented and discussed in detail through a parametric analysis. The developed model is expected to provide not only a convenient tool to determine the optimal system performance and component irreversibility, but also an appropriate basis to design similar complex hybrid power plants. This new approach can be further extended to other energy conversion settings and electrochemical systems. Decision makers should therefore find the methodology contained in this paper useful in the comparison and selection of advanced heat recovery systems.     

Technical Analysis of an Eco‐Friendly Hybrid Plant With a Microgas Turbine and an MCFC System

This article refers to a Molten Carbonate Fuel Cell (MCFC) system coupled to a plant with a microgas turbine and a heat recovery system for obtaining a small sized hybrid system in co‐generative arrangement. MCFC are devices capable of concentrating carbon dioxide (CO₂) produced in anode exhaust gases. If they are handled conveniently, it is possible to separate and store the surplus CO₂ produced by the plant instead of emitting it into the atmosphere. From the simulation model of the MCFC system, previously developed by the authors, a zero‐dimensional and stationary simulation model for the whole hybrid system was formulated and implemented in the same language. By the simulation model of the MCFC system it has been possible to make a parametric analysis of the hybrid plant to find some optimal operating conditions of the fuel cell(s) that maximise the performance of the entire hybrid plant. In addition, the separation of the CO₂ surplus produced by the hybrid plant was simulated by the model and then the emissions of carbon monoxide (CO) and nitrogen oxides (NO_x) from the same plant were evaluated.     

A Control‐oriented Dynamic Model Adapted to Variant Steam‐to‐carbon Ratios for an SOFC with Exhaust Fuel Recirculation

The steam‐to‐carbon ratio (S/C) is a typical disturbance parameter in the operation of solid oxide fuel cell (SOFC) power generation system. A planar SOFC with a pre‐reformer and exhaust fuel recirculation system is investigated in this work. A lumped, nonlinear dynamic model is developed for the SOFC with consideration both of the spatial effect and the variant S/Cs. The dynamic model is deduced based on a fitting function so‐called Exponential Association Function, which is employed to describe the spatial distribution of state variables in SOFC. Three parameters of the fitting function are identified to integrate the spatial effect and S/C effect in the model. The parameters of Exponential Association Function are determined by function fitting on three‐dimensional numerical data at the sample operation points. Carbon formation activity is analysed using the simulation results and thermodynamic data. Dynamic simulation is implemented with the help of software MATLAB/SIMULINK. The results show that the developed model has good performance in predicting the responses of the state variables and catching the changes of S/C.     

Analysis of Leakages in a Solid Oxide Fuel Cell Stack in a System Environment

A solid oxide fuel cell (SOFC) stack can exhibit both anodic and cathodic leakages, i.e. a fuel leak from the anode side and an air leak from the cathode side of the stack, respectively. This study describes the results of an in‐situ leakage analysis conducted for a planar SOFC stack during 2000 hours of operation in an actual system environment. The leakages are quantified experimentally at nominal system operating conditions by conducting composition analysis and flow metering of gases for both fuel and air subsystems. Based on the calculated atomic hydrogen‐to‐carbon ratio of the fuel and air gases, it is found that the fuel leakages are mostly selective by nature: the leaking fuel gas does not have the same composition as the fuel system gas. A simple diffusive leakage model, based on the leakage being driven by concentration differences weighted by diffusion coefficients, is applied to quantify the amount of leakages. The leakage model provides a good correspondence with the experimental results of the gas analysis.     

Control Loop Design and Control Performance Study on Direct Internal Reforming Solid Oxide Fuel Cell

A solid oxide fuel cell (SOFC) stack is a complicated nonlinear power system. Its system model includes a set of partial differential equations that describe species, mass, momentum and energy conservation, as well as the electrochemical reaction models. The validation and verification of the control system by experiment is very expensive and difficult. Based on the distributed and lumped model of a one‐dimensional SOFC, the dynamic performance with different control loops for SOFC is investigated. The simulation result proves that the control system is appropriate and feasible, and can effectively satisfy the requirement of variable load power demand. This simulation model not only can prevent some latent dangers of the fuel cell system but also predict the distributed parameters' characteristics inside the SOFC system.     

A Mathematical Model of SOFC: A Proposal

The mathematical model of the solid oxide fuel cell (SOFC) is presented. The new approach for modeling the voltage of SOFC is proposed. Electrochemical, thermal, electrical, and flow parameters are collected in the 0D mathematical model. The aim was to combine all cell working conditions in as a low number of factors as possible and to have the factors relatively easy to determine. A validation process for various experimental data was made and adequate results are shown. The presented model was validated for various fuel mixtures in relatively wide ranges of parameters as well as for various cell design parameters (e.g. electrolyte thickness, anode porosity, etc.). A distinction is made between the “design‐point” and “off‐design operation”.     

Exergoeconomic Analysis of a Combined Ammonia Based Solid Oxide Fuel Cell System

An exergoeconomic study of an ammonia‐fed solid oxide fuel cell (SOFC) based combined system for transportation applications is presented in this paper. The relations between capital costs and thermodynamic losses for the system components are investigated. The exergoeconomic analysis includes the SOFC stack and system components, including the compressor, microturbine, pressure regulator, and heat exchangers. A parametric study is also conducted to investigate the system performance and costs of the components, depending on the operating temperature, exhaust temperature, and fuel utilization ratio. A parametric study is performed to show how the ratio of the thermodynamic loss rate to capital cost changes with operating parameters. For the devices and the overall system, some practical correlations are introduced to relate the capital cost and total exergy loss. The ratio of exergy consumption to capital cost is found to be strongly dependent on the current density and stack temperature, but less affected by the fuel utilization ratio.     

Fuzzy Logic Applied to the Inverter of a SOFC Power Plant

Solid‐oxide fuel cell (SOFC) units normally supply power to the local load centers but the excess power can also be exported to the regional power grid, adding to the capacity and stability of the overall grid system. A SOFC power plant is equipped with a pulse width modulation (PWM) inverter. This paper presents the design of a new fuzzy logic regulator for a three‐phase inverter, using the strategy of an inverter flux vector control method. Criteria for designing the fuzzy controller are given and a comparison with the hysteresis method is presented. The flux vector approach is to generate the command pulses for low ripple current and constant switching frequency.     

Spatial Distribution of Electrochemical Performance in a Segmented SOFC: A Combined Modeling and Experimental Study

Spatially inhomogeneous distribution of current density and temperature in solid oxide fuel cells (SOFC) contributes to accelerated electrode degradation, thermomechanical stresses, and reduced efficiency. This paper presents a combined experimental and modeling study of the distributed electrochemical performance of a planar SOFC. Experimental data were obtained using a segmented cell setup that allows the measurement of local current‐voltage characteristics, gas composition and temperature in 4 × 4 segments. Simulations were performed using a two‐dimensional elementary kinetic model that represents the experimental setup in a detailed way. Excellent agreement between model and experiment was obtained for both global and local performance over all investigated operating conditions under varying H₂/H₂O/N₂ compositions at the anode, O₂/N₂ compositions at the cathode, temperature, and fuel utilization. A strong variation of the electrochemical performance along the flow path was observed when the cell was operated at high fuel utilization. The simulations predict a considerable gradient of gas‐phase concentrations along the fuel channel and through the thickness of the porous anode, while the gradients are lower at the cathode side. The anode dominates polarization losses. The cell may operate locally in critical operating conditions (low H₂/H₂O ratios, low local segment voltage) without notably affecting globally observed electrochemical behavior.     

Analysis of Design Parameters in Anode‐Supported Solid Oxide Fuel Cells Using Response Surface Methodology

Achieving high performance from a solid oxide fuel cell (SOFC) requires optimal design based on parametric analysis. In this paper, design parameters, including anode support porosity, thicknesses of electrolyte, anode support, and cathode functional layers of a single, intermediate temperature, anode‐supported planar SOFC, are analyzed. The response surface methodology (RSM) technique based on an artificial neural network (ANN) model is used. The effects of the cell parameters on its performance are calculated to determine the significant design factors and interaction effects. The obtained optimum parameters are adopted to manufacture the single units of an SOFC through tape casting and screen‐printing processes. The cell is tested and its electrochemical characteristics, which show a satisfactory performance, are discussed. The measured maximum power density (MPD) of the fabricated SOFC displays a promising performance of 1.39 W cm^–2. The manufacturing process planned to fabricate the SOFC can be used for industrial production purposes.     

SOFC Power Plants,the Siemens‐Westinghouse Approach

In 1998 Siemens AG (SAG) took over the tubular S olid O xide F uel C ell (SOFC) technology from Westinghouse. This merger placed SAG under the responsibility of Siemens Westinghouse Power Corporation (SWPC), and gave them the opportunity to concentrate on this technology as the most promising fuel cell option for the emerging distributed power market. A first full scale 100 kW demonstration plant in a “district heating” cycle, without integrated micro gas turbines, accumulated more than 15000 hours and is still working. All the expectations with respect to the design parameters and the operation behavior have been met or even exceeded. The first 220 kW “all electric” cycle demonstration plant with integrated micro gas turbine has successfully passed the factory tests. Additional field units are under contract which together with the above two pioneering demonstration plants will accumulate all the necessary learning experience to design a standardized SOFC product. In addition to the demonstration program, a research and development (R&D) program is being pursued. The outcome of both programs, the demonstration as well as the R&D, is expected to close the gap between the current high cost and the market price in order to enable substantial market penetration.     

The Error in Gas Temperature Measurements with Thermocouples: Application on an SOFC System Heat Exchanger

Aim of this work is to model and study the behavior of thermocouples as they are used in the measurement of gas temperatures in solid oxide fuel cell systems. Due to the high temperature regime in such systems, the effect of radiation and conduction from surrounding solids may bias the measurements with important consequences on control, performance, and cell durability. In order to study these effects a mathematical model of a working thermocouple was developed and it was integrated in that of a heat exchanger, which was part of a larger SOFC system. The enhanced heat exchanger's model was then validated with measurements from a test on a real system. The possibility to overcome the bias and to have a more correct approximation of the real gas temperatures is discussed.     

Thermodynamic Analysis of an Integrated SOFC,Solar ORC and Absorption Chiller for Tri‐generation Applications

Thermodynamic performance assessment of an integrated tri‐generation energy system for power, heating and cooling production is conducted through energy and exergy analyses. Sustainability assessment is performed and some parametric studies are undertaken to analyze the impact of system parameters and environmental conditions on the system performance. The tri–generation system consists of (a) an internal reforming tubular type solid oxide fuel cell (IR‐SOFC), which works at ambient pressure and fueled with syngas, (b) a combustor and a air heat exchanger, (c) a heat recovery and steam generation unit (HRSG), (d) a two‐ stage Organic Rankine cycle (ORC) driven by exhaust gases of SOFC, (e) parabolic trough solar collectors (PTSC), and (f) a lithium‐bromide absorption chiller (AC) cycle driven by exhaust gases from SOFC unit. The largest irreversibility occurs at the SOFC unit due to high temperature requirement for reactions. Fuel utilization factor, recirculation ratio, dead state conditions, and solar unit parameters have influential effects on the system efficiencies. Energy and exergy efficiencies of tri‐generation unit become 85.1% and 32.62%, respectively, for optimum SOFC stack and environmental conditions. The overall system energy and exergy efficiencies are 56.25% and 15.44% higher than that of conventional SOFC systems, respectively.     

Fuel Cell Vehicle Simulation – Part 1: Benchmarking Available Fuel Cell Vehicle Simulation Tools

Fuel cell vehicle simulation is one method for systematic and fast investigation of the different vehicle options (fuel choice, hybridization, reformer technologies). However, a sufficient modeling program, capable of modeling the different design options, is not available today. Modern simulation programs should be capable of serving as tools for analysis as well as development. Shortfalls of the existing programs, initially developed for internal combustion engine hybrid vehicles, are: (i)Insufficient modeling of transient characteristics; (ii) Insufficient modeling of the fuel cells system; (iii) Insufficient modeling of advanced hybrid systems; (iv) Employment of a non‐causal (backwards looking) structure; (v) Significant shortcomings in the area of controls. In the area of analysis, a modeling tool for fuel cell vehicles needs to address the transient dynamic interaction between the electric drive train and the fuel cell system. Especially for vehicles with slow responding on‐board fuel processor, this interaction is very different from the interaction between a battery (as power source) and an electric drive train in an electric vehicle design. Non‐transient modeling leads to inaccurate predictions of vehicle performance and fuel consumption. When applied in the area of development, the existing programs do not support the employment of newer techniques, such as rapid prototyping. This is because the program structure merges control algorithms and component models, or different control algorithms (from different components) are lumped together in one single control block and not assigned to individual components as they are in real vehicles. In both cases, the transfer of control algorithms from the model into existing hardware is not possible. This paper is the first part of a three part series and benchmarks the “state of the art” of existing programs. The second paper introduces a new simulation program, which tries to overcome existing barriers. Specifically it explicitly recognizes the dynamic interaction between fuel cell system, drive train and optional additional energy storage.