Effect of Creep of Ferritic Interconnect on Long‐Term Performance of Solid Oxide Fuel Cell Stacks

High‐temperature ferritic alloys are potential candidates as interconnect (IC) materials and spacers due to their low cost and coefficient of thermal expansion (CTE) compatibility with other components for most of the solid oxide fuel cells (SOFCs). However, creep deformation becomes relevant for a material when the operating temperature exceeds or even is less than half of its melting temperature (in degrees of Kelvin). The operating temperatures for most of the SOFCs under development are around 1,073 K. With around 1,800 K of the melting temperature for most stainless steel (SS), possible creep deformation of ferritic IC under the typical cell operating temperature should not be neglected. In this paper, the effects of IC creep behaviour on stack geometry change and the stress redistribution of different cell components are predicted and summarised. The goal of the study is to investigate the performance of the fuel cell stack by obtaining the changes in fuel‐ and air‐channel geometry due to creep of the ferritic SS IC, therefore indicating possible changes in SOFC performance under long‐term operations. The ferritic IC creep model was incorporated into software SOFC‐MP and Mentat‐FC, and finite element analyses (FEAs) were performed to quantify the deformed configuration of the SOFC stack under the long‐term steady‐state operating temperature. It was found that the creep behaviour of the ferritic SS IC contributes to narrowing of both the fuel‐ and the air‐flow channels. In addition, stress re‐distribution of the cell components suggests the need for a compliant sealing material that also relaxes at operating temperature.     

The Effects of Operating Conditions on the Performance of a Solid Oxide Steam Electrolyser: A Model‐Based Study

To support the development of hydrogen production by high temperature electrolysis using solid oxide electrolysis cells (SOECs), the effects of operating conditions on the performance of the SOECs were investigated using a one‐dimensional model of a cathode‐supported planar SOEC stack. Among all the operating parameters, temperature is the most influential factor on the performance of an SOEC, in terms of both cell voltage and operation mode (i.e. endothermic, thermoneutral and exothermic). Current density is another influential factor, in terms of both cell voltage and operation mode. For the conditions used in this study it is recommended that the SOEC be operated at 1,073 K and with an average current density of 10,000 A m^–2, as this results in the stack operating at almost constant temperature along the cell length. Both the steam molar fraction at the inlet and the steam utilisation factor have little influence on the cell voltage of the SOEC but their influence on the temperature distribution cannot be neglected. Changes in the operating parameters of the SOEC can result in a transition between endothermic and exothermic operation modes, calling for careful temperature control. The introduction of air into the anode stream appears to be a promising approach to ensure small temperature variations along the cell.     

PEM Fuel Cell Stack Cold Start Thermal Model

For passenger fuel cell vehicles (FCVs), customers will expect to start the vehicle and drive almost immediately, implying a very short system warmup to full power. While hybridization strategies may fulfill this expectation, the extent of hybridization will be dictated by the time required for the fuel cell system to reach normal operating temperatures. Quick‐starting fuel cell systems are impeded by two problems: (i) the freezing of residual water or water generated by starting the stack at below freezing temperatures and (ii) temperature‐dependent fuel cell performance, improving as the temperature reaches the normal range. Cold start models exist in the literature; however, there does not appear to be a model that fully captures the thermal characteristics of the stack during sub‐freezing startup conditions. Existing models lack the following features: (i) modeling of stack internal heating methods (other than stack reactions) and their impact on the stack temperature distribution and (ii) modeling of endplate thermal mass effect on end cells and its impact on the stack temperature distribution. Unlike a lumped model, which may use a single temperature as an indicator of the stack's thermal condition, a model considering individual cell layers can reveal the effect of the endplate thermal mass on the end cells, and accommodate the evaluation of internal heating methods that may mitigate this effect. This paper presents and discusses results from simulations performed with a new, layered model.     

Pressurized Operation of a Planar Solid Oxide Cell Stack

Solid oxide cells (SOCs) can be operated either as fuel cells (SOFC) to convert fuels to electricity or as electrolyzers (SOEC) to convert electricity to fuels such as hydrogen or methane. Pressurized operation of SOCs provide several benefits on both cell and system level. If successfully matured, pressurized SOEC based electrolyzers can become more efficient both energy‐ and cost‐wise than PEM and Alkaline systems. Pressurization of SOFCs can significantly increase the cell power density and reduce the size of auxiliary components. In the present study, a SOC stack was successfully operated at pressures up to 25 bar. The pressure dependency of the measured current‐voltage (I–V) curves and impedance spectra on the SOC stack are analyzed and the relation between various system parameters and pressure is derived. With increasing pressure the open circuit voltage (OCV) and the reaction kinetics (electrode performance) increases for thermodynamic and kinetic reasons, respectively. Further, the summit frequency of the gas concentration impedance arc and the pressure difference across the stack and heat exchangers is seen to decrease with increasing pressure following a power‐law expression. Finally a durability test was conducted at 10 bar.     

Investigation of Impactors on Cell Degradation Inside Planar SOFC Stacks

The impactors on cell degradation inside planar SOFC stacks were investigated using both coated and uncoated Fe–16Cr alloys as the interconnects under stable operating conditions at 750 °C and thermal cycling conditions from 750 to 200 °C. It was found that cell degradation inside the stack is primarily dependent on the interfacial contact between the cathode current‐collecting layer and the interconnect. Additionally, cell degradation is found to be independent of the high‐temperature oxidation and Cr vaporization of the interconnects during stack operation, as the stacks are well sealed. The coating on the interconnect can further improve the contact between the cell cathode and the interconnect when the latter is properly embedded into the current‐collecting layer.     

Effect of Contact between Electrode and Interconnect on Performance of SOFC Stacks

This work investigates the effect of contact between electrodes and alloy interconnects on output performance of solid oxide fuel cell (SOFC) stacks. The measured maximum output power density (p_max) of the unit cell increases from 0.07 to 0.1 W cm^–2 by increasing the tip area of the interconnect from 40 to 60 cm². The p_max increases from 0.07 to 0.15 W cm^–2 upon the addition of nickel foam and Ag mesh on the anode and cathode side, respectively. An additional (La_0.75Sr_0.25)_0.95MO_3–σ cathode current collecting layer is re‐printed on the original cathode current collecting layer, which aims to further improve the performance of the stack and individual cell. The performance of a 3‐cell short stack assembled by the cells with a new cathode current collecting layer is evaluated by measuring the current–voltage curve. The results indicate that the p_max values of the stack and individual cells are enhanced from 0.07 to 0.37 W cm^–2 and 0.15 to 0.5 W cm^–2 at 850 °C, respectively. The performance of the whole stack and individual cells is greatly improved due to the interconnect embedded in the re‐printed new cathode current collecting layer.     

Kinetics of crack healing and self-repair behaviors in a sealant glass for SOFC applications

A sealant is required for the solid oxide fuel cell (SOFC) to maintain hermeticity at high operating temperatures, keep fuel and oxidant from mixing, and avoid shorting of the cell stack. Glass and glass–ceramic materials are widely used as a sealant because their properties can be tailored to meet the stringent requirements of SOFC stack, but they are susceptible to cracking. In contrast, a promising concept of self-repairable glass for seals is pursued for making reliable seals that can self-repair cracks at the SOFC operating temperatures. This concept is studied through measuring crack-healing kinetics and independent measurement of glass viscosity for relating to the observed self-repair. The cracks on the glass surface are created using a Vickers indenter to achieve a well-defined crack geometry, and then the glass is exposed to elevated temperatures for different length of times to study the crack-healing kinetics. The crack-healing kinetics is compared with the predictions of our theoretical model and found to be in good agreement. In addition, glass viscosity is extracted from the healing kinetics and compared with the independent measurement of viscosity measured from the dilatometry and sintering data to further validate the crack-healing theoretical model. These results are presented and discussed.     

Effect of Contact Method between Interconnects and Electrodes on Area Specific Resistance in Planar Solid Oxide Fuel Cells

In this work, interconnect/electrode sheet/interconnect sandwiches are assembled by designing interfacial contact between interconnects and electrodes for planar solid oxide fuel cells (SOFCs). Their area specific resistance (ASR) values of different contact methods under isothermal oxidation and thermal cycling are recorded by four‐point method. The ASR of SUS430/Ni–YSZ/SUS430 anode sandwich with NiO current collecting layer is close to that of anode sandwich without NiO current collecting layer during isothermal operation, but smaller and more stable during thermal cycling. Meanwhile, the lowest ASR is obtained in SUS430/LSM–YSZ/SUS430 cathode sandwich with LSM coated interconnect and LSM current collecting layer among various contact methods between interconnects and cathodes, and remains constant under isothermal oxidation and thermal cycling. Contact resistance between cathodes and interconnects is the main source of the SOFC stack resistance. A real stack with three anode‐supported cells is assembled and tested under thermal cycling to verify the effect of different contact methods between interconnects and electrodes on performance of stack repeating unit. The degradation rate and ASR values of repeating unit inside the stack indicate that the contact between LSM coated interconnect and LSM current collecting layer on cathode side is the optimized contact.     

Dynamic Modeling of Reversible Solid Oxide Cells

Reversible solid oxide cells (rSOCs) are highly efficient devices, which allow either the generation of electric power or the storage of energy via fuel production. In this paper, the characteristics of the mode switch are investigated by applying a dynamic 3D stack model. The responses of temperature, current density, and species mole fractions regarding a switch from storage (SOEC) to generation mode (SOFC) are examined in detail. Additionally, the impact of using excess air and continuous voltage variations to limit temperature gradients and fluctuations during the mode switch are analyzed.     

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.     

Stack Modelling of a Molten Carbonate Fuel Cell (MCFC)

A model of a molten carbonate fuel cell (MCFC) stack including internal steam reforming is presented. It comprises a symmetric section of the stack, consisting of one half indirect internal reforming unit (IIR) and four fuel cells. The model describes the gas phase compositions, the gas and solid temperatures and the current density distribution within the highly integrated system. The model assumptions, the differential equations and boundary conditions as well as the coupling equations used in the model are shown. The strategy to solve the system of partial differential equations is outlined. The simulation results show that the fuel cells within the stack operate at different temperatures. This is expected to have an impact on the voltages as well as the degradation rates within the individual fuel cells.     

Oxygen Dissociation and Interfacial Transfer Rate on Performance of SOFCs with Metal‐Added (LaSr)(CoFe)O3‐(Ce,Gd)O2 – δ Cathodes

A solid oxide fuel cell (SOFC) unit is constructed with Ni‐Ce_0.9Gd_0.1O_{2 – δ} (GDC) as the anode, yttria‐stabilised zirconia (YSZ) as the electrolyte and Pt, Ag or Cu‐added La_0.58Sr_0.4Co_0.2Fe_0.8O_{3 – δ} (LSCF)–GDC as the cathode. The current–voltage measurements are performed at 800 °C. Cu addition leads to best SOFC performance. LSCF–GDC–Cu is better than LSCF–GDC and much better than GDC as the material of the cathode interlayer. Cu content of 2 wt.‐% leads to best SOFC performance. A cathode functional layer calcined at 800 °C is better than that calcined at higher temperature. Metal addition increases the O₂ dissociation reactivity but results in an interfacial resistance for O transfer. A balance between the rates of O₂ dissociation and interfacial O transfer is needed for best SOFC performance.     

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.     

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.     

Direct Operation of IP‐Solid Oxide Fuel Cell with Hydrogen and Methane Fuel Mixtures under Current Load Cycle Operating Condition

The effects of methane concentration and current load cycle on the performance and durability of integrated planar solid oxide fuel cell (IP‐SOFC) obtained from Rolls Royce Fuel Cell Systems Ltd (RRFCS) has been investigated. The IP‐SOFC was operated with hydrogen–methane fuel mixture with up to 20% methane concentration at 900 °C for short term operation of the cells with high methane concentration increased the voltage of the IP‐SOFC due to increase in Gibbs free energy. However, it degraded the performance of the IP‐SOFC in long term operation due to carbon deposition on the anode surface. The current load cycle tests were carried out with 95% H₂–5% CH₄ and 80% H₂–20% CH₄ fuel mixtures at 900 °C with a constant current of 1 A. At low methane concentration, the decrease in the IP‐SOFC voltage was observed after operating nine current load cycles (384 h). At higher methane concentration, the voltage of IP‐SOFC decreased by almost 30% just after one current load cycle (48 h) due to faster carbon deposition. So future work is therefore required to identify viable alternative materials and optimum operating conditions.     

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.     

固体氧化物燃料电池的变工况特性

以大面积电池和千瓦级电堆为研究对象,在确定的燃料成分、流量、和工作温度下,系统研究了电流阶梯变化、电流脉冲变化、电堆热启停以及冷热循环(冷启停)等工况下电堆的输出性能。结果表明:在小电流区域,电堆的电压和功率能够快速跟踪电流变化;在大电流区域,电池的电压出现波动和弛豫,电堆的功率也出现弛豫。热启停实验结果表明,SOFC电堆对电流的on-off变化具有足够的耐受性,一定数量的热启停不会导致电堆性能的明显衰减。而冷热循环会导致应力释放,引起接触电阻变化,从而使电堆性能衰减,5次以上热循环可使应力释放趋于缓和。     

Modelling the impact of creep on the probability of failure of a solid oxide fuel cell stack

In solid oxide fuel cell (SOFC) technology a major challenge lies in balancing thermal stresses from an inevitable thermal field. The cells are known to creep, changing over time the stress field. The main objective of this study was to assess the influence of creep on the failure probability of an SOFC stack. A finite element analysis on a single repeating unit of the stack was performed, in which the influence of the mechanical interactions, the temperature-dependent mechanical properties and creep of the SOFC materials are considered. Moreover, stresses from the thermo-mechanical simulation of sintering of the cells have been obtained and were implemented into the model of the single repeating unit. The significance of the relaxation of the stresses by creep in the cell components and its influence on the probability of cell survival was investigated. Finally, the influence of cell size on the failure probability was investigated.     

In suit Investigation of Anode Support on Cell Performance Reduced under Various Temperatures for Planar Solid Oxide Fuel Cells

The performance of anode support of Ni‐YSZ reduced from room temperature (T_R) to working temperature (T_w) and at T_w in anode‐supported planar solid oxide fuel cell was investigated quantitatively in situ. A 2 μm thick Pt voltage probe was embedded at the interface between the anode support and the function anode in the cell. Results showed that the power densities of the stack that was reduced from T_R to T_w (stack 1) and stack reduced at T_w (stack 2) were 0.343 W cm⁻² and 0.583 W cm⁻² with the corresponding fuel utilization of 36.28% and 63.87%, respectively, under the operating voltage of 0.8 V. The degradation rate of stack 1 was 7.76 times more than that of stack 2 when the stack was discharged under a constant current of 0.476 Acm⁻² for 100 h. Ni particles agglomerated in the anode support of the cell inside stack 1, whereas Ni particles in the anode support of the cell inside stack 2 were evenly distributed. The performance of stack 1 was poor mainly because of the increasing ohmic and polarization resistances caused by Ni agglomeration and decreasing porosity of the anode support.     

Development of a Micro Temperature Sensor and 3D Temperature Analysis for a Proton Exchange Membrane Fuel Cell

This study examines the development of micro in situ sensors and analyzed the through‐plane temperature of a fuel cell. Temperature sensing inside a fuel cell is important in fuel cell diagnosis and analysis. Temperature sensors must be adequately small, so that fuel cell performance is maintained and the temperature anywhere inside the cell can be flexibly measured. In this study, a temperature sensor based on a micro‐electromechanical system (MEMS) is designed and fabricated to achieve these objectives. The micro temperature sensor was installed inside a cell to measure through‐plane temperature. The current and voltage of the fuel cell with the micro temperature sensor were measured and compared with those of a fuel cell without the sensor to analyze the effect of the sensor on fuel cell performance. The developed temperature sensor is of resistance temperature detector (RTD) type, with a flexible substrate of polyimide, high sensitivity, and easy installation characteristics. After calibration of the sensors, three sensors were inserted into the cell to measure the through‐plane temperature, and the polarization curve of the cell with and without the micro sensor was compared. Finally, a 3D computational fluid dynamics (CFD) model of a fuel cell was developed and analyzed by comparison of the measured temperature results to determine the accuracy of the model.