Planar Solid Oxide Fuel Cell Stack Research Articles

Direct oxidative coupling of methane into ethylene in a catalyst-enhanced planar solid oxide fuel cell stack reactor

This study presents an efficient method to convert methane into valuable olefins using a Solid Oxide Fuel Cell (SOFC) membrane reactor. Methane, abundant in natural and shale gas, serves as a sustainable feedstock due to its favorable carbon-hydrogen ratio. The SOFC membrane reactor eliminates costly air separation units and safety risks associated with explosive methane-oxygen mixtures. A planar SOFC stack achieves over 30 % methane conversion, 40 % ethylene selectivity, and power generation capabilities. Optimization with mixed-conducting ceramics enhances electrical performance without compromising catalytic activity. The stack's scalability is demonstrated, with the 5-cell configuration surpassing the 2-cell setup. This innovative approach offers a sustainable solution to methane waste, producing high-value chemicals while reducing environmental impact.

Analysis of mass transfer characteristics in a planar solid oxide fuel cell with a chaotic flow channel

The flow channel design is crucial for the heat and mass transfer of reactants in a solid oxide fuel cell (SOFC), which ultimately affects the overall performance of the cell. To improve the gas transport characteristics and temperature uniformity, a chaotic flow channel with orthogonal corrugation is adopted for the design of a planar SOFC stack, and the influence of different wave parameters is evaluated. The results show that the chaotic flow channel induces secondary flow through the superposition of orthogonal waves, which reduces the low-oxygen region and enhances the local electrochemical reaction. The output power is improved in the chaotic flow channel by increasing the amplitude or decreasing the wavelength. The output power density with amplitude of 0.3 mm and wavelength of 1.2 mm at 0.5 V is increased by about 25.16 %. Meanwhile, the effective mass transfer coefficient and mass transfer efficiency is enhanced by 148 % and 378 %, respectively. Additionally, the chaotic structure improves the uniformity of oxygen and temperature. This study helps to improve the understanding of the gas transport processes within the flow channel and provides a basis for the design and optimization of SOFC flow channels.

Damage Modeling of Solid Oxide Fuel Cells Accounting for Redox Effects

This work applies a multiscale mechanistic damage model developed for brittle ceramics and implemented in commercial finite element (FE) packages via user subroutines to study progressive damage in solid oxide fuel cells (SOFC) subjected to thermomechanical loading under normal operating and shutdown conditions including redox effects. The damage model captures the micromechanics of stiffness reduction due to material porosity change and microcracking and integrates the as-obtained stiffness reduction law into a continuum damage mechanics (CDM) formulation for the evolution of microcracks up to fracture. The volumetric “swelling” that occurs during redox is treated in constitutive modeling similarly to thermal expansion, but swelling strains are irreversible. This damage model was first validated through predictions of strength and stress-strain response for the SOFC electrode materials. Next, it has been applied to predict the potential for degradation in a generic planar SOFC stack with large active area cells. Multicell stack models were simulated in both co-flow and counter-flow configurations. In addition, a constant temperature redox cycle was also simulated to capture overall cell electrode damage due to volumetric swelling of the nickel (Ni)-based anode in the anode-supported cells.

A novel interconnect design for thermal management of a commercial-scale planar solid oxide fuel cell stack

Solid oxide fuel cell (SOFC) is a promising technology for stable power supply with high efficiency and high quality heat utilization, but it still faces the technical challenge of low long-term durability caused by thermal imbalance of its stack. An effective, novel thermal management method is urgently required for its market deployment. This study proposes a novel interconnect design for effective thermal management and elucidates the influence of its design variables on internal thermal conditions and heat transfer characteristics of a 1-kW planar SOFC stack. Three-dimensional thermo-fluid simulations are performed on the new stack design employing the novel interconnect and the conventional stack design for comparison. The new design is developed for the purpose of uniform in-plane (horizontal) temperature distribution by modifying the displacement of gas manifolds. At the repeating-unit scale, due to the reduced thermal resistance for horizontal heat transfer of the new stack, its in-plane temperature deviation decreases by 35–60 °C. At the stack scale with 30 unit-cells stacked vertically, the average temperature increases by 30 °C, and the vertical temperature difference decreases by 50 °C. Such thermal fields are the combined results of reduced gaseous convection and enhanced vertical solid-phase conduction through each repeating unit. In the new stack, the amount of heat transferred to the gas within each repeating unit is generally decreased, but is recuperated by increasing solid conduction through metallic interconnects. The relatively weakened gaseous heat transfer of the new design provides more thermal load at the lowest unit of the stack than the reference design, which promotes gas pre-heating prior to reaching the unit-cells and hence results in the elevated stack temperature. Such gas pre-heating also reduces the temperature difference in the vertical direction of the new design. The lower temperature differences both in horizontal and vertical directions enable the new stack to reduce its thermal imbalance and potentially to improve long-term durability.

Damage Modeling of Solid Oxide Fuel Cells Accounting for Redox Effects

This paper applies a multiscale mechanistic damage model developed for porous brittle ceramics and implemented in finite element analysis (FEA) packages [1] to study progressive damage in solid oxide fuel cells (SOFC) subjected to thermomechanical loading under operating and shutdown states. The damage model captures the micromechanics of stiffness reduction due to material porosity change and microcracking and integrates the as-obtained stiffness reduction law into a continuum damage mechanics (CDM) formulation for the evolution of microcracks up to fracture. An Eshelby-Mori-Tanaka approach (EMTA) [2-3] is first used to model the ceramic containing pores and aligned microcracks regarded as inclusions with negligible stiffness. The stiffness of the actual porous ceramic is obtained from the EMTA solution averaged over all possible microcrack orientations using an orientation averaging method. The evolution of microcracking damage is described by a CDM formulation derived from our previous model [4]. Apart from the operating and shutdown states, additional damage that may occur due to reduction and re-oxidation (redox cycling) of Ni/YSZ anodes is also studied. The reduction of NiO into Ni leads to changes in volume and porosity of the anode layer that consequently change its physical and thermomechanical properties. The volume change or volumetric “swelling” during redox cycling may affect the structural integrity of the anode and may cause fracture of the electrolyte under high tensile stresses leading to operational failure for SOFCs. In the constitutive relations, volumetric swelling is treated in a similar way to thermal expansion using the models developed in Refs [5-6] for fusion energy ceramic materials. However, while thermal expansion vanishes if temperature change tends to zero, swelling is irreversible and significantly contributes to degrade SOFC stacks during redox cycling.This damage model was implemented in the commercial FEA software ABAQUS© and ANSYS© via user subroutines. First, it has been validated through predictions of strength and stress-strain response for the typical SOFC ceramic materials. Figs 1(a) and 1(b) show the predicted stress-strain responses as a function of temperature for dense NiO/YSZ and Ni/YSZ, respectively. These figures also illustrate the predicted responses at 750°C with prescribed initial values of porosity. The damage model predicts significant reductions in strength and elastic modulus with higher initial porosity and higher temperatures, and the predicted trends are in good agreement with the experimental findings [7-8].Next, the damage model was applied to predict the potential for degradation in a generic planar SOFC stack with large active area cells modeled in ANSYS. Stack models with single and multi-cells were simulated in both co-flow and counter-flow configurations. The thermomechanical loads representing the operating and shutdown conditions were simulated. The realistic thermal gradients that occur in an operating stack were imposed in the models by solving the electrochemistry under various operating conditions using the in-house SOFC multiphysics code (SOFC MP-3D) [9-10]. In addition to the operating and shutdown conditions, a constant temperature redox cycle was also simulated to capture overall cell electrode damage due to volumetric swelling of the Ni/YSZ anode in the anode supported cells. The results from single cell stack models showed little damage at operating and shutdown conditions which could be attributed to enough out-of-plane support for the PEN assembly. The results from the multicell stacks (Fig. 2) showed higher damage in counter-flow configuration. Within the stack, the top cells experienced the highest damage and the middle cells experienced the lowest. Overall, no significant damage that may lead to total failure of the cells was observed in the multicell stack models with the operating conditions considered in this study.

Effects of Flow Channel Arrangement and Electrolyte Thickness on Thermal Stress for Planar Solid Oxide Fuel Cell Stacks

Typical operating temperature for solid oxide fuel cells (SOFC) is between 700~800°C. A large temperature gradient and thermal stress caused by internal losses and electrochemical reactions may cause SOFC stack performance degradation and even structural damage, which has become a hindrance to its applications.In this study, a three-dimensional multiphysics CFD (computational fluid dynamics) model is developed and applied for a planar SOFC stack to study the temperature and thermal stress distribution, as well as effects of structure and design parameters, including the flow channel arrangement (e.g., co- and count-flow) and thickness of the electrolyte layer. The stack is composed of three-unit cells, metallic interconnect layers, sealing and anode/cathode current collectors.The simulation results reveal that the temperature difference in the counter-flow mode is smaller and the thermal stress is lower than those in the co-flow mode. The overall performance of the stack is better when the electrolyte layer thickness becomes smaller, but the stack temperature and the temperature gradient become higher. In addition, a large temperature gradient due to the thin electrolyte layer leads to a significant increase of the thermal stress in the electrolyte. The findings and research method from this study can be applied to optimize the design of the stack structures, by consideration of the maximum thermal stress and its distribution.AcknowledgementsThis work is supported by the National Key Research and Development Project of China (2018YFB1502204), the Ningbo major special projects of the Plan “Science and Technology Innovation 2025” (2018B10048).

Effects of Flow Channel Arrangement and Electrolyte Thickness on Thermal Stress for Planar Solid Oxide Fuel Cell Stacks

Typical operating temperature for a solid oxide fuel cell (SOFC) ranges from 700°C to 800°C. A large temperature gradient and thermal stress are induced by internal losses and electro-chemical reactions, resulting in significant structural damage and performance degradation of a SOFC stack, which has become a hindrance to its applications. In this study, a three-dimensional multi-physics CFD model is developed and employed to study the temperature and thermal stress distribution of a planar SOFC stack, then effects of the structure design parameters are investigated, including the flow channel arrangement (i.e., co- and cross-flow) and thickness of the electrolyte layer. The stack modeled is composed of three-unit cells, metallic interconnect layers, sealing components, and anode/cathode current collectors. The simulation results show that the temperature difference in the co-flow case is smaller and the thermal stress is lower than those predicted in the cross-flow. The overall performance of the stack improves as the thickness of the electrolyte layer decreases, but the temperature and its gradient inside the stack become higher. In addition, a large temperature gradient is observed inside the thin electrolyte layer, which leads to a significant increase of the thermal stress. The findings and the research methods in this study can be applied to design and optimize the stack structures by considering the temperature and the thermal stress distribution.

Progress in Glass-Ceramic Seal for Solid Oxide Fuel Cell Technology

Solid oxide fuel cells (SOFCs) have emerged as promising energy conversion devices nowadays. SOFC consists of several components such as cathode, anode, electrolyte, interconnects, and sealing materials. In planar SOFC stack construction, the sealant and interconnection functions play an important role. Glass and ceramics are quite popularly used as SOFC sealing materials to achieve several functions including preventing leakage of fuel and oxidants in the stack and electrically isolating cells in the stack. In this review, material preparation, material composition, ceramic properties especially thermal properties are compared from various systems that have been developed previously. The main challenges and complexities in the functional part of SOFC sealants include: (i) chemical incompatibility and instability in the oxidizing and reducing environment by adjusting the value of the thermal expansion coefficient (CTE) with the interconnecting material during SOFC operation, and (ii) insulation of oxidizing fuels and gases by matching CTE anode and cathode. Also, the sealant glass transition determines the maximum permissible working temperature of the SOFC. The choice of method and analysis will provide data on various ceramic attributes. The search for thermal attributes consisting of Glass transition (Tg), Deformation temp (Td), Crystallization temp (Tx), Melting pt (Tm) became a focus on SOFC sealant development.

High performance of ceramic current collector fabricated at 550 °C through in-situ joining of reduced Mn1.5Co1.5O4 for metal-supported solid oxide fuel cells

A well-connected and high-porosity current collector layer fabricated at a low temperature of 550 °C is designed for metal-supported solid oxide fuel cells (SOFCs). Reduced Mn1.5Co1.5O4 (MCO) powders are used as the binder through the reforming of MCO in the air atmosphere. A high conductivity phase La0.6Sr0.4Co0.2Fe0.8O3 (LSCF) is added to keep the porous frame microstructure and decease the ohmic polarization of the current collector layer. Three current collector layers are prepared: MCO, MCO/LSCF, and LSCF. The working state of each current collector layer in planar SOFC stack is reproduced by special experimental design; the performance is tested in the range of 550–750 °C. The results show that the current collector layer for SOFC is achieved at low temperatures using the reduction-oxidation properties of MCO, and the performance is improved by adding high conductivity phase LSCF. The gas distribution at the cathode side is also simulated for designing a high performance SOFC.

Multiphysical modelling of planar solid oxide fuel cell stack layers

Anode supported (ASC) and electrolyte supported cells (ESC) represent the most common cell concepts in solid oxide fuel cell (SOFC) technology. In ASCs, mechanical manageability is provided by a porous nickel/yttria-stabilized zirconia (Ni/YSZ) substrate, whereas in ESCs a self-supporting dense YSZ electrolyte is applied. Naturally, the electrical loss contributions arising in ASCs and ESCs differ in quantity, leading to different temperature profiles within planar SOFC stacks.A two-dimensional, finite element method model was developed which considers the underlying chemical and physical processes, and calculates both the electrical performance and the thermal distribution of planar SOFC stack layers operated with reformate fuels. It was then validated by comparing simulation results with extensively measured (i) temperature profiles in SOFC stacks, (ii) gas composition changes along the fuel gas channel of planar ASCs, and (iii) current-voltage characteristics in a temperature range from 650 °C to 800 °C.The subsequent numerical study reveals (i) the different performances of ASC and ESC, (ii) the impact of operation conditions on performance and temperature profile and (iii) how the individual loss contributions generate temperature distributions in the stack layer.

Two-dimensional temperature distribution estimation for a cross-flow planar solid oxide fuel cell stack

The uniform temperature distribution of a cross-flow planar solid oxide fuel cell (SOFC) stack plays an essential role in stack thermal safety and electrical property. However, because of the strict requirements in stack sealing struture, it is hard to acquire the temperature inside the stack using thermal detection devices within an acceptable cost. Therefore, accurately estimating the two-dimensional (2-D) temperature distribution of the cross-flow stack is crucial for its thermal management. In this paper, Firstly, a 2-D mechanism model of a cross-flow planar SOFC stack is established. The stack is divided into 5*5 nodes along the gas flow directions, which can reflect the stack states with moderate computational burden. Then, experimental test data is utilized to modify and validate the stack model, guaranteeing the model accuracy as well as the reliability of model-based state estimator design. Finally, easily-measured stack inputs and outputs are selected, and a temperature distribution estimator combined with unscented kalman filter (UFK) approach is developed to achieve accurate and fast temperature distribution estimation of a cross-flow SOFC stack. Simulation results demonstrate that the UKF-based temperature distribution estimator can precisely and quickly achieve the temperature distribution estimation of the cross-flow stack under both static state and dynamic state changes and is applicable to cross-flow stacks with different size or cell number as well, the maximum estimated absolute error is less than 0.15 K with an absolute error rate of 0.015%, which indicates the developed estimator has good estimation performances.

Modeling of a planar SOFC performances using artificial neural network

The Planar Solid Oxide Fuel Cell (PSOFC) is one of the renewable energy technologies that is important as the main source for distributed generation and can play a significant role in the conventional electrical power generation. PSOFC stack modeling is performed in order to provide a platform for the optimal design of fuel cell systems. It is explained by the structure and operating principle of the PSOFC for the modeling purposes. PSOFC model can be developed using Artificial Neural Network approach. The data required to train the neural net-work model is generated by simulating the existing PSOFC model in the MATLAB/ Simulink software. The Radial Basis Function (RBF) and Multilayer Perceptron (MLP) neural networks are the most useful techniques in many applications and will be applied in developing the PSOFC model. A detailed analysis is presented on the best ANN network that gives the greatest results on the performances of the PSOFC. The simulation results show that Multilayer Perceptron (MLP) gives the best outcomes of the PSOFC performance based on the smallest errors and good regression analysis.

Demonstration of a kW-scale solid oxide fuel cell-calciner for power generation and production of calcined materials

Carbonate looping (CaL) has been shown to be less energy-intensive when compared to mature carbon capture technologies. Further reduction in the efficiency penalties can be achieved by employing a more efficient source of heat for the calcination process, instead of oxy-fuel combustion. In this study, a kW-scale solid oxide fuel cell (SOFC)-integrated calciner was designed and developed to evaluate the technical feasibility of simultaneously generating power and driving the calcination process using the high-grade heat of the anode off-gas. Such a system can be integrated with CaL systems, or employed as a negative-emission technology, where the calcines are used to capture CO2 from the atmosphere. The demonstration unit consisted of a planar SOFC stack, operating at 750 °C, and a combined afterburner/calciner to combust hydrogen slip from the anode off-gas, and thermally decompose magnesite, dolomite, and limestone. The demonstrator generated up to 2 kWel,DC power, achieved a temperature in the range of 530–550 °C at the inlet of the afterburner, and up to 678 °C in the calciner, which was sufficient to demonstrate full calcination of magnesite, and partial calcination of dolomite. However, in order to achieve the temperature required for calcination of limestone, further scale-up and heat integration are needed. These results confirmed technical feasibility of the SOFC-calciner concept for production of calcined materials either for the market or for direct air capture (DAC).

Scale‐up of Solid Oxide Fuel Cells with Magnetron Sputtered Electrolyte

AbstractThe possibility of fabricating large‐area solid oxide fuel cells (SOFC) with thin film electrolyte using a commercial physical vapor deposition technology is investigated. Yttria‐stabilized zirconia (YSZ)/gadolinium‐doped ceria (GDC) bilayer electrolyte is successfully deposited on a 10 × 5 cm2 commercial NiO/YSZ anode support by reactive magnetron sputtering. The microstructure of the fuel cells was studied by scanning electron microscopy. Current‐voltage characteristics of fuel cells at a temperature of 750°C and their power stability under electrical load were investigated. Single cells with La0.6Sr0.4Co0.2Fe0.8O3/ Gd0.1Ce0.9O1.95 (LSCF/GDC) cathode had an open cell voltage of 1.14 V and a maximum power density of 490 mW cm−2 at 750 °C using H2/N2 gas mixture as fuel and air as the oxidant. Three‐cell planar SOFC stack using 10 × 5 cm2 anode‐supported unit cells with power density of 450 mW cm−2 at a voltage of 0.7 V per cell has been assembled and tested.

General Regulation of Air Flow Distribution Characteristics within Planar Solid Oxide Fuel Cell Stacks

For solid oxide fuel cell (SOFC) stacks with a planar design, different structural designs were found to cause very different distribution trends of air flow rates fed to the piled cell units. Many implied optimization guidelines, which were independent of the specific structures, were achieved and verified by extensive 3D multiphysics simulations of the large-scale air flow path models. These conclusions could be very helpful for providing generality in practical structural design and parameter choice for planar SOFC stacks.

Numerical simulation of cell-to-cell performance variation within a syngas-fuelled planar solid oxide fuel cell stack

The cell-to-cell voltage variation in a planar solid oxide fuel cell (SOFC) stack is numerically investigated, considering the coupling effect of the heat transfer and uniform mass flow rate distribution between cells. The model integrates validated three-dimensional electro-chemical button cell sub-models with the structure of a real counter-flow planar SOFC stack. A uniform characteristic diagram is defined to analyse the variation of the cell voltage distribution in a planar SOFC stack. A quantitative index of uniformity is proposed to compare and explain the difference in the cell voltage distribution uniformity in planar SOFC stacks. The simulation results indicate that the distribution characteristics of the cell voltage within a planar SOFC stack are primarily determined by the combined effects of the mass flow rate distribution and temperature distribution. The mass flow rate distribution dominates the overall cell voltage distribution trend, and the temperature distribution mainly dominates the cell voltage distribution of the cell near the top and bottom of the stack due to the thermal effects. The simulation results also indicate the relative uniform cell voltage distribution in planar SOFC stacks in the case of using syngas as a fuel instead of hydrogen.

SOFC regulation at constant temperature: Experimental test and data regression study

The operating temperature of solid oxide fuel cell stack (SOFC) is an important parameter to be controlled, which impacts the SOFC performance and its lifetime. Rapid temperature change implies a significant temperature differences between the surface and the mean body leading to a state of thermal shock. Thermal shock and thermal cycling introduce stress in a material due to temperature differences between the surface and the interior, or between different regions of the cell. In this context, in order to determine a control law that permit to maintain constant the fuel cell temperature varying the electrical load and the infeed fuel mixture, an experimental activity were carried out on a planar SOFC short stack to analyse stack temperature. Specifically, three different anodic inlet gas compositions were tested: pure hydrogen, reformed natural gas with steam to carbon ratio equal to 2 and 2.5. By processing the obtained results, a regression law was defined to regulate the air flow rate to be provided to the fuel cell to maintain constant its operating temperature varying its operating conditions.

The effect of fuel utilization on heat and mass transfer within solid oxide fuel cells examined by three-dimensional numerical simulations

The thermo-fluid reacting environment and local thermodynamic state in solid oxide fuel cell (SOFC) stacks were examined by using three-dimensional numerical simulations. Enhancing the performance and durability of the SOFC stacks is essential when a high fuel utilization scheme is implemented to increase the system efficiency and lower system operating costs. In this study, numerical simulations were conducted to elucidate the effect of fuel utilization on heat and mass transfer as the fuel utilization is raised. A high-fidelity three-dimensional physical model was developed incorporating elementary electrochemical reaction kinetics by assuming rate-limiting steps and spatially-resolved conservation equations. The model considers planar anode-supported SOFC stacks and is validated against their electrochemical performance experimentally measured. A parametric study with respect to fuel utilization was conducted by varying a fuel flow rate while maintaining other operating conditions constant. Results show that, when increasing the fuel utilization, a narrow and non-uniform electrochemical reaction zone is observed near the fuel inlet, resulting in substantial depletion of hydrogen in the downstream fuel flow and thus raising the partial pressure of oxygen in the anode. This subsequently lowers the electrochemical potential gradient across the electrolyte and hence induces a large gradient of ionic current density along the cell. Convective flow through porous electrodes also results in pressure gradients in the direction of both cell thickness and length. In addition, the heat balance between conduction through metallic interconnects, convection by gases and the heat generated from charged-species transport and electrochemical reactions determines a temperature gradient along the cell and its maximum location. All of these gradients may induce chemical, mechanical and thermal stresses on SOFC materials and corresponding degradation.

Planar SOFC system modelling and simulation including a 3D stack module

A solid oxide fuel cell (SOFC) system consists of a fuel cell stack with its auxiliary components. Modelling an entire SOFC system can be simplified by employing standard process flowsheeting software. However, no in-built SOFC module exists within any of the commercial flowsheet simulators. In Amiri et al. (Comput. Chem. Eng., 2015, 78:10–23), a rigorous SOFC module was developed to fill this gap. That work outlined a multi-scale approach to SOFC modelling and presented analyses at compartment, channel and cell scales. The current work extends the approach to stack and system scales. Two case studies were conducted on a simulated multilayer, planar SOFC stack with its balance of plant (BoP) components. Firstly, the effect of flow maldistribution in the stack manifold on the SOFC's internal variables was examined. Secondly, the interaction between the stack and the BoP was investigated through the effect of recycling depleted fuel. The results showed that anode gas recycling could be used for managing the gradients within the stack, while also improving fuel utilisation and water management.

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

AbstractA 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.