Small scale SOFC systems | EPFL Graph Search

The increasing cost of carbon based fuels pushes the electricity generation market towards more efficient electricity generation technologies. In this context, fuel cells offer the opportunity to increase efficiency and lower CO2 and NOx emissions, in particular with co-generation units. The complexity, as well as the number and different combinations of components involved with a SOFC stack make their analysis impossible without dedicated tools. The simultaneous consideration of economic and thermodynamic considerations is a key challenge for engineers and decision makers. The present work contributes to the development of design tools for fuel cells and energy systems. A detailed model of fuel cell stack and a model of a complete system were developed. Based on a commercial CFD code, additional routines were implemented to model the electro-chemical behavior of a fuel cell as well as the reforming reaction schemes. The model is able to predict cell behavior under various fuel feeds. The detailed 3-D model of stack repeat unit allowed to identify weaknesses of a first stack geometry. With the combination of experimental observations and modeling activities, specific problems of the existing concept were identified and a new geometry designed, together with the corresponding stack concept. A new stack design is presented with successful experiments up to 1 kWe. Besides the stack, a co-generation fuel cell system is composed of multiple components such as heat exchangers, reformer, recycle loops... The number, the type and size of those components influence the system costs but also its efficiencies (thermal and electrical). A multi-objective thermo-economic optimization methodology was defined, allowing to optimize at the same time the configuration and operating parameters of a system. This method was applied to two sizes of co-generators : a 1 kW unit and a 30 kW unit. HTceramix SA (Yverdon, Switzerland) is developing part of a co-generation unit. The work indicates the potential improvement of their prototype. The 1 kW unit was optimized in a first phase on thermal and electrical efficiencies, and in a second phase on electrical efficiency and installed costs. Those two results indicate the influence of the objective function selection on the results. The high operating temperature of Solid Oxide Fuel Cells (SOFC) offers good opportunity for coupling with a gas turbine. A simple concept of pressurized SOFC-µGT was studied and optimized, for an net electrical output of 30 kW. The simple layout described in this work allows present technical feasibility of the concept. Moreover, the costs of electricity, lower than 0.20$/kWh, makes it economically viable solutions. The methodology and the tools developed allow the engineer to explore the solution space through optimal configurations, in order to select those fitting with its priorities and technical constraints.

Thermo-economic Optimization of a Solid Oxide Fuel Cell, Gas Turbine Hybrid System

Nordahl Autissier, Daniel Favrat, François Maréchal, Francesca Palazzi, Jan Van Herle

Background: The electricity production market benefits from combined cycles with their high efficiency. In the lower power range, Fuel Cells are a good candidate to combine with gas turbines. Such systems can achieve efficiencies of 60% and more. High temperature Solid Oxide Fuel Cells (SOFC) offer good opportunities for this coupling. A systematic method to select a design according to user specifications is presented. Method of approach: The most attracting configurations of this technology coupling are identified using a thermo-economic multi-objective optimization approach. The SOFC model includes detailed computation of losses of the electrodes and thermal management. The system is integrated using pinch based methods. A thermo-economic method is then used to compute the integrated system performances, size and cost. This allows to perform the optimization of the system with regard to two objectives: minimize the specific cost and maximize the efficiency. Results: Optimization results prove the existence of designs with costs from 2400

/kW for a 44\% efficiency to 6700

/kW for a 70% efficiency. Several design options are analysed regarding fuel processing, pressure ratio or turbine inlet temperature among others. Conclusions: A pressurized SOFC-

\mu

GT hybrid cycle has been modeled for design purposes. Combining state-of-the-art planar SOFC with high speed micro gas turbine sustained by air bearings. The proposed optimization method allows to identify the most interesting design configurations to reach high efficiencies for a given cost.

2005

Integrated Solid Oxide Fuel Cell

Emanuele Facchinetti

Distributed power generation and cogeneration of heat and power is an attractive way toward a more rational conversion of fossil and bio fuels. Solid oxide fuel cell (SOFC) – gas turbine (GT) hybrid systems are emerging as the most promising candidates enabling the achievement of a cleaner and more efficient conversion of a large variety of resources across a broad power range covering from small to medium scale applications. This thesis introduces an innovative concept of SOFC-GT hybrid system that allows reaching efficiencies higher than the state of the art while enabling the carbon dioxide separation and avoiding fuel cell pressurisation technical issues. Several hybrid system design alternatives based on this concept are analysed through a thermodynamic optimisation approach combining process modelling, advanced process integration techniques and multi-objective optimisation. A number of optimal hybrid system configurations are determined for different design targets. The results consistently demonstrate the higher energy conversion performance and flexibility enabled with respect to the state of the art. The innovative concept analysis is extended to two applications for which SOFC-GT hybrid cycles are expected to provide the most significant impact toward sustainability: the small scale distributed generation and the conversion of renewable resources. A simplified version of the new hybrid system layout is especially developed for small scale distributed generation, typical of residential building applications (5-10 kWel). Experimental data are used to prove the technical feasibility of the system and to assess the performance potentially achievable with currently feasible technologies. The results of the analysis underline that energy conversion efficiencies higher than traditional centralised power generation can be achieved even at such a small scale. A systematic process integration and optimisation approach is used to assess the energy conversion performance of the original SOFC-GT hybrid cycle fuelled with hydrothermally gasified wet waste biomass. The analysis highlights the considerable potential of the integrated system that allows for converting wet waste biomass into electricity with First Law efficiency higher than 60% while simultaneously enabling the separation of the biogenic carbon dioxide.

EPFL2012

Solid oxide fuel cell stack simulation and optimization, including experimental validation and transient behavior

Diego Larrain

This thesis presents the development of models for the simulation and optimization of the design of a planar solid oxide fuel cell (SOFC) stack. Fuel cells produce electric power directly from a fuel by electrochemical reactions. The high efficiencies demonstrated make them a promising technology for energy conversion. The main challenges lie with reliability and cost reduction. Some applications demand at the same time strong requirements on the compactness of the system and its ability to load following. The models have been developed to represent the novel stack proposed by HTceramix SA (Yverdon, Switzerland) which is tested and partly developed at the Laboratoire d'Energétique Industrielle (LENI). The model has been created in a way which allows its use for design optimization: this requires detailed and validated outputs to gain insight in the behavior of a new stack design and computational efficiency to allow sensitivity studies and optimization. Electrochemistry, mass and heat transfer phenomena are combined with a 2D fluid motion description to obtain a generalized model which can be applied to a large range of geometries. An efficient stack modeling approach is proposed. Validation of the model has been carried out with measurements and a 3D computational fluid dynamics model. A methodology based on parameter estimation has been used to identify kinetic parameters and other uncertain parameters. Local temperature measurements and a local current density measurement have been performed and also used for model validation. The 2D model has been successfully validated showing good agreement with both the experiments and the detailed 3D model. Simulation of the novel stack geometry (counter-flow) has allowed to identify the main problems arising from this compact geometry where the non-homogeneous velocity field creates stagnant zones which limit the operation at high efficiency. The simulated temperatures are characterized by important gradients and excessive level values (>850°C) for an intermediate temperature SOFC (700-800°C). This motivated to work on an alternative geometry, which based on simulation results, solves most of the problems previously identified. The thesis presents several examples of the influence of design on the system performance and reliability. Transient simulations have been performed and the design choice had only a small impact on the transient behavior which presents intrinsically an important thermal inertia. On the contrary, degradation behavior is dependent on the design. Stack degradation has been simulated by including the metal interconnect degradation into the stack model. The approach has allowed to identify a new criterion to express degradation consistently for different test conditions. To assist stack design, new approaches are necessary. The geometry of a stack was initially determined by a number of decision variables (such as cell area, thickness of the channels and interconnects) on which extensive sensitivity analysis were conducted. This method is of limited use as each of the objectives on stack design led to different solutions. To overcome this limitation, multi-objective optimization has been applied to the stack design problem. Application of this method is new in this field and different optimization strategies are tested. The results from the optimization allow to identify a clear trade-off between the compactness of the stack and the temperature level (and therefore the degradation).

EPFL2005