Degradation Phenomena of Metal-Anode Interface in Metal-Supported SOFCs

In this chapter, the construction, principle of operation, types and production technologies of SOFCs are presented and characterized. Three main types of SOFC are described according to the type of support layer responsible for the mechanical strength of the cell: electrolyte-supported solid oxide fuel cells (ES-SOFC), anode-supported solid oxide fuel cells (AS-SOFC), and metal-supported solid oxide fuel cells (MS-SOFC). Base and raw materials for particular functional layers of solid oxide fuel cells are characterized, i.e., anode, electrolyte, and cathode layers. Thick- and thin-film technologies for the production of particular elements of SOFC fuel cells are presented. Using the example of technology developed in the Institute of Power Engineering Ceramic Department CEREL, the production technology of anode-supported solid oxide fuel cells and the method of characterizing the microstructure and electrochemical properties of the produced cells are presented.

Direct internal reforming (DIR) operation provides many benefits for solid oxide fuel cells (SOFCs) by eliminating the need for an extra reformer. Anode-supported SOFCs (AS-SOFCs) are commonly used for DIR operations. However, the strong endothermic reforming reactions at the cell entrance may result in large thermal stresses and lead to premature failure. In this study, a two-dimensional model was developed to analyze the differences between the AS-SOFC and the new generation metal-supported SOFC (MS-SOFC) in DIR operations. The model considered the coupling effects of the chemical/electrochemical reactions, the mass/charge/heat transport processes and the thermal mechanical stress. The distributions of temperature, species composition, current density and thermal stress were determined and compared for both structures. The failure probability of the cell was estimated by stress distributions. The results showed that the MS-SOFC led to a gentler temperature distribution and a smaller failure probability with slight performance increase compared to the AS-SOFC.

In this paper the operation and performance of a high temperature solid oxide fuel cell (SOFC) stack on biomass syn-gas from a demonstration biomass gasification combined heat and power (CHP) plant is investigated. The objective of this work is to develop a computer simulation model of a biomass-SOFC CHP system, flexible enough for use in industry, capable of predicting system performance under various operating conditions and using diverse fuels. The biomass gasifier is of the dual fluidised bed (DFB) type with steam as the gasifying agent and is operated at atmospheric pressure. The tubular SOFC configuration, developed by Siemens Power Generation Inc (SPGI), is selected. It is considered to be the most advanced design and is approaching commercialisation. The SOFC stack model, developed using the chemical process flowsheet simulator Aspen Plus, is of equilibrium type and is based on Gibbs free energy minimisation. The SOFC model performs heat and mass balances and considers the ohmic, activation and concentration losses for the voltage calculation. Data available in the literature on the SPGI SOFC operating on natural gas is used to validate the model. The system model predicts thermodynamic condition and composition of all internal flow streams, the heat generated by the SOFC stack, voltage (V), current (I) and efficiency. Operating parameters are varied over a wide range, parameters such as fuel utilisation factor (Uf), current density (j) and steam to carbon ratio (STCR) have significant influence. The results indicate that there must be a trade-off between voltage, efficiency and power with respect to j and the SOFC stack should be operated at low STCR and high Uf, within certain limits. SOFC stack operation on biomass syn-gas is compared to operation on natural gas and as expected there is a drop in performance, which is attributed to increased input fuel and air flow due to the lower quality of the fuel gas. The optimum realistic operating conditions with regard to SOFC stack performance are identified. High electrical efficiencies are predicted making these systems very attractive for CHP applications.

Metal-supported solid oxide fuel cells (SOFCs) have the advantage of the thermal shock resistance and higher mechanical strength compared with anode-supported SOFCs. In this study, Ni-Fe metal was used as supporting metal. The supporting metal was initially prepared in oxide form of NiO-Fe2O3, and co-sintered with Gd-doped ceria electrolyte at 1350ºC for 3h in air and later reduced to Ni-Fe metal. Two different cells were prepared and compared to see the effect of the thickness of the electrolyte and the role of the electrode on the performance of the cell.

This paper reports the results from the European project PROSOFC (funded by FCH-JU, FP7). Within the project an innovative methodology for a production and reliability oriented SOFC cell and stack design is developed. In particular the PROSOFC project aims at improving the robustness, manufacturability, efficiency and cost of SOLIDpowers state-of-the-art SOFC stacks so as to reach market entry requirements. The key issues are the mechanical robustness of solid oxide fuel cells (SOFCs), and the delicate interplay between cell properties, stack design, and operating conditions of the SOFC stack. The novelty of the project lies in combining state of the art methodologies for cost-optimal reliability-based design (COPRD) with actual production optimization. To achieve the COPRD beyond state of the art multi-physical modeling concepts were developed and validated for significantly improved understanding of the production and operation of SOFC stacks. The most critical failure modes for stack operation were identified in order to align the experimental investigations to generate suitable data for modelling these failures. The multi-physics model allows a probabilistic approach to consider statistical variations in production, material and operating parameters for the optimization phase. The project provides a methodology for 3D description of spatial distribution of material properties based on a random field models. The key for the whole methodology are validating experiments, homogenized models on multiple levels of the SOFC system (cell, interconnect, sealings) and introduction of extensive test programs specified by the COPRD methodology. The probabilistic models were related to the experimentally obtained properties of base materials to establish a statistical relationship between the material properties and the most relevant load effects in view of potential damage/failure based on multi-physics simulation can be established. Software algorithms for meta models that allow the detection of relationships between input parameters (materials, loading, etc.) and output parameters and to perform a sensitivity analysis were developed and implemented. The capabilities of the methodology for COPRD being developed is illustrated on two practical cases. A procedure based on meta models has been developed to estimate elastic, primary and secondary creep model parameters from 4-point bending tests. The goal is to (i) account for the effects of the friction between the sample and the rollers, anticlastic curvature, contact point shift and large deflection, which can affect the accuracy of the measurements, and (ii) measure properties which cannot be obtained using closed-form analytical solutions. This could be achieved by model-based parameter estimation with a 3-D continuum finite-element (FE) model, at the cost of very high running time. The proposed approach is computationally much more efficient. It starts with a sensitivity analysis to generate distributed meta models of the displacement at the inner rollers during loading-unloading cycles and creep measurements simulated by the 3-D FE model. The optimization problem for parameter estimation is then solved using the meta models. The accuracy of the approach was tested using a set of numerical experiments and comparison with results from 3-D imaging and computational homogenization. The experiments on Ni-YSZ samples were then analyzed. For the stochastic investigation of the thermo-electrochemical behavior of the stack a multi-physics stack model implemented in gPROMS and Fluent was linked and controlled automatically by optiSlang to perform a sensitivity analysis. The outcome is (i) the identification of the most relevant production and operating parameters which can have a significant impact on the stack lifetime and (ii) meta models of the efficiency and of the 3-D temperature distribution generated in the view of optimization. The tests show for instance that the accuracy of the 3-D meta model of the temperature distribution is sufficient to identify the minimum of variations in the spatial distribution of the temperature during cycling between full and part load by using sets of operating conditions for optimization.

Generally, the manufacturing technology of fuel cell units is considered to satisfy the current commercialization requirements. However, achieving a high-performance and durable stack design is still an obstacle in its commercialization. The solid oxide fuel cell (SOFC) stack is considered to have performance characteristics that are distinct from the proton exchange membrane fuel cell (PEMFC) stacks. Within the SOFC stack, vapor is produced on the anode side instead of the cathode side and high flow resistance within the fuel flow path is recommended. In this paper, a 3D multiphysics model for a one-cell SOFC stack with the interdigitated channels for fuel flow path and conventional paralleled line-type rib channels for air flow path is firstly developed to predict the multiphysics distribution details. The model consists of all the stack components and couples well the momentum, species, and energy conservation and the quasi-electrochemical equations. Through the developed model, we can get the working details within those SOFC stacks with the above interdigitated flow channel features, such as the fuel and air flow feeding qualities over the electrode surface, hydrogen and oxygen concentration distributions within the porous electrodes, temperature gradient distribution characteristics, and so on. The simulated result shows that the multiphysics field distribution characteristics within the SOFC and PEMFC stacks with interdigitated flow channels feature could be very different. The SOFC stack using the paralleled line-type rib channels for air flow path and adopting the interdigitated flow channels for the fuel flow path can be expected to have good collaborative performances in the multiphysics field. This design would have good potential application after being experimentally confirmed.

Reviewing metal supported solid oxide fuel cells for efficient electricity generation with biofuels for mobility

Solid oxide fuel cell (SOFC) stacks were operating with metallic interconnects that separate each cells. Metallic interconnects play an important role in gas flow system and heat transfer mechanism, because its geometry makes gas flow channel and it has a high thermal conductivity. Many researcher design the flow channel for optimizing the cell performance like a ratio of height and width, channel to channel distance, or new type channels. For high conversion efficiency, most solid oxide fuel cell in power generation application operate at high fuel utilization and low current condition. However, high fuel utilization condition makes a large gradient of chemical potential by fuel depletion and it induces a low cell performance and a large chemical stress in flow direction. This phenomena can be observed at high performance cell or high operating temperature condition, because almost fuel is consumed at upstream of fuel channel by high electrochemical reaction kinetics and most cell area has a low chemical potential environment. Therefore, even distribution of electrochemical reaction rate is important. In this study we reduce the gradient of chemical potential by using diffuser-shape fuel channel, and optimize the diffuser-shape by design study. In chemical species conservation law, higher flow velocity at upstream makes higher convective flux in flow direction compared to diffusive flux in cell-thickness direction, and it can reduce the electrochemical reaction rate at reacting electrode. Optimized diffuser-shape fuel flow channel from this study may enhance the performance and the durability of solid oxide fuel cell stacks.

Parametric exergy analysis of a tubular Solid Oxide Fuel Cell (SOFC) stack through finite-volume model

Recent developments in control and integration of solid oxide fuel cells: From stack to system

This review critically evaluates recent advancements in electrocatalytic technologies aimed at enhancing the efficiency of metal-supported Solid Oxide Fuel Cells (SOFCs) for biofuel-powered mobility applications. The study aims to elucidate the impact of these innovations on the performance, durability, and stability of SOFCs in transportation and portable energy systems. By integrating experimental findings, computational simulations, and practical applications, this work highlights the pivotal role of advanced electrocatalysts in optimizing SOFC functionality. Key developments, such as the incorporation of perovskite-based materials and exsolved nanoparticle catalysts, have demonstrated remarkable improvements in electrochemical performance and operational longevity. Specifically, lanthanum-strontium cobalt ferrite (LSCF)-based cathodes demonstrated a 30% increase in power output and a 25% enhancement in long-term stability under biofuel operating conditions. Furthermore, computational modeling has played a crucial role in refining catalyst designs, achieving a 45% reduction in degradation rates. These advancements underscore the potential of biofuel-driven SOFCs as a sustainable energy solution for transportation. However, future research must address challenges related to scalability, cost-effectiveness, and economic competitiveness to fully realize their practical implementation.

The Solid oxide fuel cell (SOFC) is an electrochemical energy-conversion device which offers tremendous promise for delivering high electrical efficiency and significant environmental benefits in terms of fuel flexibility, as well as clean and efficient electric power generation. However, the state-of-the-art SOFC cell currently involves expensive and time-consuming multi-step manufacturing processes including tape casting, screen printing, shaping, lamination, sintering, etc. In addition, SOFC stacks are usually assembled with pre-fabricated cells, metal interconnects, and glass-ceramic sealing. These indispensable components add extra layers of complexity to the stack structure’s fabrication and maintenance, significantly increasing the size and weight of the final product. These intrinsic limitations on the current planar stack cannot be easily removed by traditional manufacturing processes. However, as additive manufacturing (AM) technologies start to mature and show increasing market penetration, it lends itself admirably to breaking the limits on high-power-density SOFC stack manufacturing. Storagenergy’s SOFC project is developing an all-ceramic AM-SOFC by a high-speed AM process of multiple materials. The developed technology allows the fabrication of robust and compact AM-SOFC stacks with unique features such as monolithic architecture with embedded novel micro flow channels and thinner elements (anode, cathode, electrolyte, and interconnect) by only three production steps (3D printing, sintering, and catalyst infiltration) without the need for subsequent assembly of individual layers and indispensable components. This simplification of the fabrication process is expected to reduce the cost of the SOFC and increase SOFC design flexibility and manufacturing reliability.

As a promising clean energy conversion device, solid oxide fuel cells (SOFCs) could efficiently utilize multiple fuels and have been applied in stationary power generation and other fields. However, the high operating temperature limits the use of SOFCs in the transportation sector. Consequently, reducing the operating temperature is a key focus in SOFCs development. In recent years, metal-supported SOFCs (MS-SOFCs) have received significant attention because of intermediate operating temperatures. MS-SOFCs offer advantages such as simple and reliable sealing, rapid start-up, and high power density, making MS-SOFCs a promising option for transportation applications. However, for commercial applications, the methods to enhance performance, improve durability and mitigate degradation need to be further studied. This paper comprehensively reviews the state of the art approaches to performance improvement, durability under various conditions and different fuel reforming methods. Finally, it highlights the prospects and challenges for future advancements in this field.

The paper presents the scheme of mini CHP with methane reformer and planar solid oxide fuel cells (SOFC) stack. The mini CHP produces electricity, superheated steam, hot air and methane for the reformer and it also preheats cathode air used in the SOFC stack as an oxidant. Moreover, the scheme’s mathematical model is constructed. The thermochemical reactor with impeded fluidized bed for autothermal steam reforming of methane (reformer) studied experimentally is the key element in producing synthesis gas – fuel for the SOFC stack. The research indicates that synthesis gas containing 55% of hydrogen can be derived using the reactor. Through mathematical modeling, the entire reactor’s principal dimensions as well as flow rates of air, water and methane were adjusted to the methane reforming for the mini CHP studied. The paper includes the heat balances of the reformer, SOFC stack and waste heat boiler that produces the superheated steam, hot air and methane for the reformer as well as preheated cathode air. These balances were instrumental for calculating the useful product fraction in the reformer, fraction of hydrogen oxidized in the SOFC anode channel, electric gross efficiency, anode temperature, exothermic effect of synthesis gas hydrogen oxidation by air oxygen, excess entropy and Gibbs free energy change at standard conditions, SOFC electromotive force (EMF), specific flow rate of standard fuel for heat, and power generation. The simulation study has shown that the hydrogen oxidation products temperature in the SOFC anode channel is 850ºС, electric gross efficiency 61.0%, single fuel cell EMF 0.985 V, fraction of hydrogen oxidized in the SOFC anode channel 64.6%, specific flow rate of standard fuel for power generation 0.16 kg/(kW·h), for heat generation 44.7 kg/GJ. All the specific parameters are in good agreement with other publications results.

In this study, both long term durability and thermal properties (e.g., Thermal conductivity and diffusivity) test are executed on a large area of 10×10×1.2 cm molybdenum (Mo)-containing nickel (Ni)-based alloy-supported solid oxide fuel cell (SOFC). The porous interconnected networks of Ni-Mo alloy are made of introducing pyrolyzable filler during fabrication processes. The functional layers of cell is prepared by using an atmospheric plasma spraying technology. The 10×10 cm2 MS-SOFC with effective electrode area of 81 cm2 shows the open circuit voltages is 1.09 V at 700°C. The measured maximum output powers (@0.8 V) of this cell is 44.6 W at 700 °C respectively. In the long term durability test, the cell voltages are measured in a constant current mode (400 mA/cm2) for ~2600 h at 700 °C. The thermal conductivity (@25-300°C) of porous alloy substrate (7.5% pyrolyzable filler) sintered at 1250°C is in the range of 9.8–12 W/m.K.