Development of 1 kW SOFC power package for dual-fuel operation

A compact SOFC power generation system was developed by integrating a 1 kW SOFC stack and balance-of-plant. The system was designed for dual-fuel operation using both natural gas (NG) and liquefied petroleum gas (LPG). An adiabatic pre-reformer was employed in a fuel processing system to convert C₂₊ hydrocarbons in the fuel into CH₄-rich gas which was further processed in a main reformer to produce H₂-rich gas for the SOFC stack. The SOFC system was operated for 350 h under thermally self-sustaining condition, and on-load fuel switching from NG to LPG was carried out during the operation. The system performance was not significantly affected by NG/LPG composition ratios and the performance was stable during continuous operation in NG or LPG.     

Performance analysis of a 5 kW PEMFC with a natural gas reformer

Power systems based on fuel cells have been considered for residential and commercial applications in energy Distributed Generation (DG) markets. In this work we present an experimental analysis of a power generation system formed by a 5 kW proton exchange membrane fuel cell (PEMFC) unit and a natural gas reformer (fuel processor) for hydrogen production. The performance analysis developed simultaneously the energy and economic viewpoints and enabled the determination of the best technical and economic conditions of this energy generation power plant, and the best operating strategies, enabling the optimization of the overall performance of the stationary cogeneration fuel cell unit. It was determined the electrical performance of the cogeneration system in function of the design and operational power plant parameters. Additionally, it was verified the influence of the activation conditions of the fuel cell electrocatalytic system on the system performance. It also appeared that the use of hydrogen produced from the natural gas catalytic reforming provided the system operation in excellent electrothermal stability conditions resulting in increase of the energy conversion efficiency and of the economicity of the cogeneration power plant.     

Design of a methanol reformer for on-board production of hydrogen as fuel for a 3 kW High-Temperature Proton Exchange Membrane Fuel Cell power system

The method of Computational Fluid Dynamics is used to predict the process parameters and select the optimum operating regime of a methanol reformer for on-board production of hydrogen as fuel for a 3 kW High-Temperature Proton Exchange Membrane Fuel Cell power system. The analysis uses a three reactions kinetics model for methanol steam reforming, water gas shift and methanol decomposition reactions on Cu/ZnO/Al₂O₃ catalyst. Numerical simulations are performed at single channel level for a range of reformer operating temperatures and values of the molar flow rate of methanol per weight of catalyst at the reformer inlet. Two operating regimes of the fuel processor are selected which offer high methanol conversion rate and high hydrogen production while simultaneously result in a small reformer size and a reformate gas composition that can be tolerated by phosphoric acid-doped high temperature membrane electrode assemblies for proton exchange membrane fuel cells. Based on the results of the numerical simulations, the reactor is sized, and its design is optimized.     

Design of 3 kW integrated power generation system from solar and biogas

Energy/Power is an important element of social and economic development. Without availability of energy at a reasonable price, there is little prospect of developing the country's economy and people's living conditions. A quarter of Pakistani population have no access to electricity, and currently a shortage of 5.0–7.0 GW power supply causes load shedding/blackout problems. In Pakistan, most of the power is generated from non-renewable sources like natural gas etc. Pakistan receives almost 15.525 × 10¹⁴ kW-hour of solar energy per year and sunshine duration is normally 8.0–10.0 h per day. Animal/farm wastes are readily available in Pakistan. Residues from these sources produce 103.0 billion m³ of biogas per year that is equivalent to 63.20 TWh. The objective of this study is energy production by using easily available indigenous resources. In this study a 3.0 kW integrated solar/biogas power generation system consist of 2.84 kW solar system and 4.0 m³ biogas system is designed and installed. This paper also present simulation model of system. A hybrid inverter is used to convert DC power of photovoltaic modules and the battery bank in to AC power and combines with the output power of biogas generator. Performance of the hybrid system are analysed from May 1, 2018 to June 15, 2018. During the test maximum power produce by the integrated system is 1.10 kW in morning, 2.14 kW in noon and 1.16 kW in afternoon.     

An internal reformer for a pressurised SOFC system

A novel reformer design has been demonstrated that converts the methane required for a multi kilowatt SOFC stack. Results show the influence of temperature and the benefits of operating at elevated pressure on the reforming-catalyst fundamental reaction kinetics. Due to the high heat demand of the steam reforming reaction, efficient heat transfer between the SOFC stack and the reforming catalyst is essential. Parameters such as the volume/surface area ratio, choice of catalyst, and catalyst metal loading are key to the design, and these have been determined through a combination of computer modelling and experimental measurements. The thermal properties of the unit have been evaluated over a range of temperatures and fuel compositions that simulate system operating-conditions in the final product.     

Optimization of a 30 kW SOFC combined heat and power system with different cycles and hydrocarbon fuels

Solid oxide fuel cells (SOFCs) could generate power cleanly and efficiently by using a wide range of fuels. Through the recovery and utilization of the energy in the SOFC tail gas, SOFC combined heat and power (CHP) systems achieve efficient cascade utilization of fuels. In this article, an efficient 30 kW SOFC CHP system with multiple cycles is designed based on a commercial kw-level SOFC device. The energy and substances could be recycled at multiple levels in this system, which makes the system do not need external water supply anymore during working. Meanwhile, the performance, fuel applicability, flexibility and reliability of the system are investigated. Finally, an optimized operating condition is confirmed, in which the electrical efficiency is 54.0%, and the thermoelectric efficiency could reach 88.8% by using methanol as fuel.     

Evaluation of cost reduction potential for 1 kW class SOFC stack production: Implications for SOFC technology scenario

Recently, a commercial version of a residential solid oxide fuel cell (SOFC) system with a flat tubular cell has been developed. However, the system cost still remains very high, which is a barrier to its widespread use. In this study, the potential for cost reductions in SOFC stack production was investigated in order to contribute to the viability of the widespread use of such residential SOFC systems in future. A cost analysis of 700 W SOFC stack production based on a process integration modeling was conducted. The present bottom–up approach enabled us to perform a sensitivity analysis with a variety of parameters in terms of cell design, the production process and cell performance. This allowed us to investigate the effects of these factors on the production cost, thereby revealing the quantitative impact of each technological improvement on the cost reduction potential. The present analysis also revealed innovation pathways which could result in technology scenarios where residential SOFC systems could reach a break-even point in comparison with the baseload electricity cost. The analysis of the cost reduction potential presented here provides a useful viewpoint for developing a research strategy for state-of-the-art SOFC technology.     

Fabrication and operation of a 1 kW class anode-supported flat tubular SOFC stack

A 1 kW class anode-supported flat tubular SOFC stack for intermediate temperature (700–800 °C) operation was fabricated and operated in this study. For this purpose, we fabricated anode-supported flat tubular cells by optimization of the current collecting method and the induction brazing process. After that, we designed a compact fuel and air manifold by adopting a simulation technique to uniformly supply fuel and air gas into the stack and a unique seal and insulation method to make a more compact stack. To assemble the stack, the prepared anode-supported flat tubular cells with an effective electrode area of 90 cm² were connected in series to 30 bundles, in which one unit bundle consists of two flat tubular cells connected in parallel. The performance of the stack in 3% humidified H₂ and air at 750 °C showed a maximum electrical power of 921 W (fuel utilization ratio = 25.2%).     

Temperature and hydrogen flow rate controls of diesel autothermal reformer for 3.6 kW PEM fuel cell system with autoignition delay time analysis

In this paper catalyst temperature and hydrogen flow rate controls are an area of interest for autothermal reforming (ATR) of diesel fuel to provide continuous and necessary hydrogen flow to the on-board fuel cell vehicle system. ATR control system design is important to ensure proper and stable performance of fuel processor and fuel cell stack. Fast system response is required for varying load changes in the on-board fuel cell system. To cope with control objectives, a combination of PI and PID controllers are proposed to keep the controlled variables on their setpoints. ATR catalyst temperature is controlled with feedback PID controller through variable OCR (oxygen to carbon ratio) manipulation and kept to the setpoint value of 900 °C. Additionally diesel auto-ignition delay time is implemented through fuel flow rate delay to avoid complete oxidation of fuel. Hydrogen flow rate to the fuel cell stack is kept to setpoint of required hydrogen flow rate according to fuel cell load current using PI controller. An integrated dynamic model of fuel processor and fuel cell stack is also developed to check the fuel cell voltage. Product gas composition of 35, 18 and 4% is achieved for hydrogen, nitrogen, and carbon dioxide, respectively. The results show fast response capabilities of fuel processor following the fuel cell load change and successfully fulfills the control objectives.     

Durability test and degradation behavior of a 2.5 kW SOFC stack with internal reforming of LNG

Forschungszentrum Jülich has demonstrated SOFC stacks and systems ranging from 50 W to 20 kW. Previous studies have shown the reproducible stable long-term performance of the F10-design short stacks developed in Forschungszentrum Jülich. Within this work, a 2.5 kW F20-stack consisting of eighteen cells was assembled, and tested at a furnace temperature of 700 °C mainly with the simulated reformate gas, which corresponds to 10% pre-reforming of liquefied natural gas (LNG). The current density and fuel utilization were mostly kept at 0.5 A cm⁻² and 70%, respectively. The purpose was to investigate the behavior of the stack in the kW-range for at least 5000 h with internal reforming of LNG or methane at a fuel utilization of at least 60%. A voltage degradation rate of around 0.3%/1000 h was obtained during the operation with pre-reformed LNG. The stack performance under normal working conditions and an unplanned redox cycle, as well as the results from post mortem analysis are discussed.     

Interactive heat transfer characteristics of 5 kW class shell-and-tube methane steam reformer with intermediate temperature heat source

A 5 kW class shell and tube methane steam reformer (MSR) with intermediate temperature heat source was evaluated to find a correlation between the methane conversion and heat transfer performance. First, performance evaluation of MSR1 was conducted by varying experimental conditions such as reformer reactant flow rate, steam to carbon ratio (SCR), inlet temperature of reforming zone, and inlet temperature of heat source. Sensitivity study of overall heat transfer coefficient was also carried out to find the major parameter affecting the heat transfer. Next, the heat transfer performance and methane conversion rate of MSR1 and 2 were compared. Both reformers have the same gas hourly space velocity (GHSV) in the form of shell and tube heat exchangers, but are designed to compare the heat transfer characteristics of the reformer by designing with the different heat transfer areas. The results show that the main factors affecting the performance of the reformer are load, heat source inlet temperature, and heat transfer area.     

Energy and exergy analyses of an integrated SOFC and coal gasification system

This paper examines an integrated gasification and solid oxide fuel cell (SOFC) system with a gas turbine and steam cycle that uses heat recovery of the gas turbine exhaust. Energy and exergy analyses are performed with two different types of coal. For the two different cases, the energy efficiency of the overall system is 38.1% and 36.7%, while the exergy efficiency is 27% and 23.2%, respectively. The effects of changing the reference temperature on the exergy destruction and exergy efficiency of different components are also reported. A parametric study on the effects of changing the pressure ratio on the component performance is presented.     

In situ regeneration of the Ni-based catalytic reformer of a 5 kW PEMFC system

The paper reports the results of on-site regeneration catalytic bed of the natural gas reformer in a 5 kW PEM fuel cell system. The Ni catalyst previously poisoned by sulphur from the available natural gas, could be re-activated by injection of pure water steam, following the method developed for industrial reformers using the same metal catalyst: this method was shown to be perfectly efficient, provided no natural gas was fed during the operation. Results of the tests conducted are presented and discussed in relation to published data on S-sorption on Ni surfaces.     

Development of preheating methodology for a 5 kW HT-PEMFC system

Compared to the low-temperature proton exchange membrane fuel cell (LT-PEMFC) system, the high-temperature proton exchange membrane fuel cell (HT-PEMFC) system has a simple balance of plant (BOP) configuration and high heat recovery efficiency. However, to commercialize this system, the start-up time should be shortened. This study aims to develop a preheating methodology for the 5 kW HT-PEMFC system, which is the target system. The entire start-up time of this system is dominated by the warm-up time of the stack among various other system components. An advanced preheating method was experimentally verified by combining three heating methods of the stack: coolant heating, reaction heating, and air heating. Additionally, considering the power consumption of the target system, a method to reduce the warm-up time was proposed. Ultimately, we found that the combined coolant and reaction heating method was the best. Furthermore, a case study revealed that using an oil heater with variable heating capacity on the target system can reduce the start-up time by 23% compared to a fixed capacity heater.     

Assessment of the reactor network approach for integrated modelling of an SOFC system

Incorporation of Solid-oxide fuel cells (SOFC) into hybrid systems with CHP capabilities is an attractive option for clean and efficient decentralised electricity generation. SOFC system operation on practical liquid fuels requires an efficient preparation system for the formation of a homogeneous reformate mixture. This can be accomplished with the use of a stabilized cool flame vapouriser (SCFV) combined with a thermal partial oxidation (T-POX) reformer, and such systems are already under development. The successful and efficient thermochemical operation of an SOFC system requires an accurate determination of the optimum conditions for each constituent component (e.g. fuel processing unit, fuel cell stack, off-gas burner) and for the integrated system. The present work demonstrates a computational methodology for the thermochemical assessment of a novel SOFC system operated on liquid fuels. Simulations have been performed, both at component and system levels, using a reactor network approach, involving a simplified flow and mixing representation, while retaining full detailed chemistry. Computations are performed at a component level with reactor networks specially formulated for the SCFV and the T-POX reactors, derived on the basis of CFD calculations, coupled with detailed kinetic mechanisms for n-heptane, a reasonable diesel fuel surrogate. Model predictions are compared against experimental data, wherever possible. The individual components are integrated at a system level and parametric analyses are performed so as to determine optimum conditions for efficient and clean operation.     

Experimental investigation of 1 kW solid oxide fuel cell system with a natural gas reformer and an exhaust gas burner

An experimental investigation is performed to establish the optimal operating conditions of a porous media after-burner integrated with a 1 kW solid oxide fuel cell (SOFC) system fed by a natural gas reformer. The compositions of the anode off-gas and cathode off-gas emitted by the SOFC when operating with fuel utilizations in the range 0-0.6 are predicted using commercial GCTool software. The numerical results are then used to set the compositions of the anode off-gas and cathode off-gas in a series of experiments designed to clarify the effects of the fuel utilization, cathode off-gas temperature and excess air ratio on the temperature distribution within the after-burner. The experimental results show that the optimal after-burner operation is obtained when using an anode off-gas temperature of 650 °C, a cathode off-gas temperature of 390 °C, a flame barrier temperature of 700 °C, an excess air ratio of 2 and a fuel utilization of U_f = 0.6. It is shown that under these conditions, the after-burner can operate in a long-term, continuous fashion without the need for either cooling air or any additional fuel other than that provided by the anode off-gas.     

Experimental analysis of optimal performance for a 5 kW PEMFC system

This paper investigates the issue of performance optimization for proton exchange membrane fuel cell (PEMFC) system. In PEMFC system, the system efficiency is the key parameters to evaluate the system performance which is sensitive to the air flow rate. Thus, the careful selection of the air flow rate is crucial to ensure efficient, reliable and durable operation of the PEMFC system. In this paper, the dynamic response of the system under variable air flow rate is studied in detail by means of experiments on the built 5 kW PEMFC system with 110 cells and a catalyst active area of 250 cm². The oxygen excess ratio (OER) is defined to indicate the state of oxygen supply. The experimental results show that the maximum efficiency is existed under certain net current. The OER conditions have the optimal characteristic for system efficiency. Through the optimization of system performance, the system efficiency can be increased by 12.2% on average. At the same time, the system dynamic characteristic under oxygen starvation and oxygen saturation are analyzed in detail based on the experimental data.     

Maximizing the efficiency of a HT-PEMFC system integrated with glycerol reformer

The efficiency and output power density of an integrated high temperature polymer electrolyte fuel cell system and glycerol reformer are studied. The effects of reformer temperature, steam to carbon ratio (S/C), fuel cell temperature, and anode stoichiometric ratio are examined. An increase in anode stoichiometric ratio will reduce CO poisoning effect at cell’s anode but cause lower fuel utilization towards energy generation. High S/C operation requires large amount of the energy available, however, it will increase anode tolerance to CO poisoning and therefore will lead to enhanced cell performance. Consequently, the optimum gas composition and flow rate is very dependent on cell operating current density and temperature. For example, at low current densities, similar efficiencies were obtained for all the S/C ratio studied range at cell temperature of 423.15 K, however, at cell temperature of 448.15 K, low S/C ratio provided higher efficiency in comparison to high S/C ratio. High S/C is essential when operating the cells at high current densities where CO has considerable impact on cell performance. Optimal conditions that provide the maximum power density at a given efficiency are reported.     

Performance characteristics of a robust and compact propane-fueled 150 W-class SOFC power-generation system

A propane-fueled solid-oxide fuel-cell-based system is an extraordinary type of technology for stationary mobile power generation given that it offers higher efficiency, silent operation and clean conversion of hydrocarbon fuels. In this study, we designed and developed a 150 W-class tubular SOFC power-generation system integrated with a catalytic partial reformer (CPOX) for the propane fuel and heat exchangers with the goal of making a robust and compact system for portable power applications. Micro-tubular SOFC cells were fabricated by ceramic processing and the cells were assembled in the form of a short stack. The CPOX nano-catalyst CeO₂Zr₂O₃/Pt supported on γ-Al₂O₃ was prepared and tested for its propane-reforming characteristics under the present operating conditions. The CPOX catalyst was used in the integrated reformer, and the performance of the 150 W-class SOFC power-generation system operating on propane fuel was studied. The rapid startup and temperature sustainability of the short stack were also monitored and stable stack temperatures were achieved within 20 min. Long-term galvanostatic operation of the power-generation system was also conducted to investigate the durability of the system. This study confirms that propane-fueled robust and compact 150 W-class power-generation systems are suitable for portable applications and that the role of efficient CPOX catalysts is crucial for high performance of the stack when operating on propane fuel.