Search Results (501)

This study presents a first-of-its-kind investigation into retrofitting domestic vessels with a novel hybrid system integrating a Solid Oxide Fuel Cell (SOFC) and an Internal Combustion Engine (ICE). Using a Lake Ferry and an Island Ferry as case studies, three power-sharing scenarios (10–20% SOFC contribution) were examined for cruise and port operations. The results show that increasing the SOFC power share enhances overall system efficiency, reducing daily fuel energy consumption by up to 9% while achieving SOFC efficiencies of 58–60% in port. The design analysis confirms the physical retrofit feasibility for both vessels, with all scenarios occupying 72–92% of available machinery space. However, increasing the SOFC share from 10% to 15–20% raised total system weight by 10–20% and volume by 12–27%. Economically, the system demonstrates strong viability for high-utilization vessels, with Levelized Cost of Energy (LCOE) values of 236–248 EUR/MWh, while the sensitivity analysis highlights the SOFC capital cost as the dominant economic driver. Environmentally, the hybrid system achieves annual CO₂ reductions of 46–51% and NOx reductions of 51–62% compared to conventional diesel systems, with zero NOx emissions in port. The SOFC-ICE hybrid system proves to be a robust transitional pathway for maritime decarbonization, particularly for vessels with significant port-side operating hours. Full article

Solid oxide fuel cell (SOFC) and gas turbine (GT) hybrid systems exhibit inherent system uncertainties and unmodeled dynamics during operation, which compromise the accuracy of predicting gas turbine power. This poses challenges for system operation analysis and energy management. To enhance the prediction accuracy and stability of gas turbine power in SOFC/GT hybrid systems, a power prediction method capable of incorporating total system disturbance information is investigated. This study constructs a high-fidelity simulation model of an SOFC/GT hybrid system to generate gas turbine power prediction datasets. With fuel utilization (FU) as the input and gas turbine power as the output, this system is assumed to be a first-order dynamic system. Building upon this foundation, an extended state observer (ESO) is employed to extract the total system disturbance ($f$) that affects the power output of the gas turbine, excluding fuel utilization. The total disturbance $f$ and fuel utilization are used as inputs to a Backpropagation (BP) neural network to construct a disturbance-aware power prediction model. The predictive performance of the proposed method is evaluated by comparison with a BP neural network without disturbance estimation information and several benchmark models. Simulation results indicate that incorporating the disturbance term estimated by ESO enhances both the accuracy and stability of the BP neural network’s power prediction, particularly under operating conditions characterized by significant power fluctuations. Quantitatively, when comparing the predictive model with disturbance included to the model without disturbance, including the disturbance reduces the prediction error by approximately 89.33% (MSE) and 67.34% (RMSE), while the coefficient of determination R² increases by 0.1132, demonstrating a substantial improvement in predictive performance under the same test conditions. The research findings indicate that incorporating disturbance information into data-driven prediction models represents a viable modeling approach, providing effective support for predicting gas turbine power in SOFC/GT hybrid systems. Full article

The discovery of cathode materials that simultaneously exhibit high oxygen-reduction activity, robust stability, and low cost is pivotal to moving solid oxide fuel cells (SOFCs) from the laboratory into commercial deployment. To address this challenge, we compile the largest perovskite dataset to date parameterized by the oxygen tracer surface exchange coefficient (k^*). Using only readily obtainable elemental and structural descriptors, we develop machine-learning models that surpass existing approaches in both accuracy and computational efficiency. Specifically, by integrating Mahalanobis-distance-based applicability-domain analysis with random forest-enhanced property descriptors and support vector regression, we high-throughput-screen 1.3 million ABO3 compositions and curate a candidate list that balances thermodynamic stability, cost, and oxygen-reduction activity. Beyond prediction accuracy, SHAP interpretation reveals strong physical correlations between the enhanced descriptors and k^*, highlighting the coefficient of thermal expansion, O p-band center, and A-site ionic radius as the dominant factors governing oxygen exchange kinetics. Finally, we identify 209 promising perovskite cathodes predicted to outperform LSC in the low-temperature regime, offering promising directions for experimental realization of practical low-temperature SOFCs. Full article

In this study, a high-fidelity, full-scale three-dimensional Computational Fluid Dynamics (CFD) model was developed to analyze the effects of U-type and Z-type interconnection configurations on flow and distribution uniformity within a 4 × 1 kW planar solid oxide fuel cell (SOFC) stack composed of 40 unit cells. Mesh independence was verified using the Richardson extrapolation method. The results reveal that on the anode (fuel inlet) side, the Z-type configuration exhibits significantly better flow and pressure uniformity than the U-type configuration and shows low sensitivity to variations in fuel utilization (${\mathrm{U}}_f$ = 0.3–0.8), maintaining stable flow distribution under different conditions. On the cathode (air inlet) side, however, the U-type configuration demonstrates superior flow stability at an air utilization rate of 0.3. Therefore, it is recommended to employ the Z-type configuration for the anode and the U-type configuration for the cathode to achieve more uniform gas distribution and enhanced operational stability. These findings provide valuable insights for optimizing the design and operation of solid oxide fuel cells (SOFCs) and offer guidance for the development of more efficient fuel cell systems. Full article

This review examines modern approaches to layer formation in solid oxide fuel cells (SOFCs), focusing on traditional, thin-film, and additive manufacturing methods. A systematic comparison of technologies, including slip casting, screen printing, CVD, PLD, ALD, HiPIMS, inkjet, aerosol, and microextrusion printing, is provided. It is shown that traditional methods remain technologically robust but are limited in their capabilities for miniaturization and interfacial architecture design. Modern thin-film and additive approaches provide high spatial accuracy, improved ion-electron characteristics, and flexibility in the design of multilayer structures; however, they require addressing issues related to scalability, ink stability, interfacial compatibility, and reproducibility. Particular attention is paid to interfacial engineering methods, such as functionally graded layers, nanostructured infiltration, and temperature-controlled 3D printing. Key challenges are discussed, including thermal instability of materials, the limited gas impermeability of ultra-thin electrolytes, and degradation during long-term operation. Development prospects lie in the integration of hybrid methods, the digitalization of deposition processes, and the implementation of intelligent control of printing parameters. The presented analysis forms the basis for further research into the scalable and highly efficient production of next-generation SOFCs designed for low-temperature operation and long-term operation in future energy systems. Full article

Due to the increasingly severe energy crisis and extreme climate conditions in recent years, the development and use of alternative clean energy sources have become increasingly important. This study evaluates the energy performance of applying residential solid oxide fuel cells (SOFCs) in a typical passive-designed residential village house in Xi’an. Furthermore, the study integrates photovoltaic (PV) systems and storage batteries with a solid oxide fuel cell co-generation system (SOFC-CGS) to enhance its overall energy performance. The results show that when the SOFC-CGS operates independently, it can provide stable electricity. However, due to its limited capacity, it only meets 43% of the total energy demand and cannot fully satisfy the heating requirements. In this energy supply scenario, the SOFC-CGS heating efficiency reaches 25%, the power generation efficiency reaches 42%, and the overall efficiency reaches 67%. After integrating the PV battery system with the SOFC-CGS, the addition of photovoltaic and battery systems boosts the energy self-sufficiency rate by 32 percent, reaching 75%. In other words, this clean energy combination can cover 75% of the household’s traditional energy consumption. In addition, the heating efficiency increases by 2 percentage points to 27%, the power generation efficiency rises by 4 percent to 46%, and the overall system efficiency improves by 6 percent to reach 73%. Furthermore, the utilization rate of the photovoltaic battery system also rises from 25% to 73%: an increase of 48 percent. Therefore, according to the analysis results, integrating PV and storage batteries with the SOFC-CGS proves to be a profitable and efficient solution for application in passive-designed village houses in Xi’an. Full article

The paper presents the experimental results of applying a novel protective coating made from Mn_1.7Cu_1.3-xFe_xO₄, compared to commercial spinels Mn_1.5Co_1.5O₄ and MnCo₂O₄, as a key component responsible for preventing chromium diffusion and slowing the increase in area-specific resistance (ASR) in solid oxide fuel cells (SOFCs). The layers of selected materials were deposited on Crofer 22APU steel by electrophoretic deposition (EPD) on small samples and by roll painting on full-scale interconnects. The coatings were evaluated by measuring the ASR of small samples for short and long runs (1000 h), as well as real-scale interconnects assembled in a SOFC stack composed of three cells, measuring 11 × 11 cm², which operated for 1000 h at 670 °C. The collected data on the electrochemical performance of the stack allowed for estimation of the degradation rates of all the repeating units, revealing benefits from using (Mn,Cu,Fe)₃O₄ as a coating. The results are compared to the literature reports. Post-mortem analysis by the SEM-EDS technique allowed for investigation of Cr diffusion levels. Full article

Metallic interconnects are key components in planar solid oxide fuel cell (SOFC) stacks. In the present study, we evaluated four Fe-Cr powder metallurgy (PM) alloy specimens, obtained from a domestic manufacturer, at nominal compositions (in wt%) of 5% Fe-95% Cr, 30% Fe-70% Cr, 50% Fe-50% Cr, and 78% Fe-22% Cr. These specimens were tested and evaluated for use in SOFC stack applications. The verification items included coefficient of thermal expansion measurements, high-temperature oxidation resistance and weight gain tests, mechanical strength tests, high-temperature sealant bonding and leakage rate measurements, and high-temperature electrical property (i.e., area-specific resistance) measurements. In addition, the specimens’ microstructures and elemental compositions were observed and analyzed. The test results indicate that the Fe content of the Fe-Cr powder metallurgy alloys influences various properties, while Cr also plays a significant role in high-temperature oxidation resistance. Among the four alloy specimens, the 78Fe-Cr alloy exhibited all of the aforementioned advantages, including a suitable coefficient of thermal expansion of 12.4 × 10⁻⁶/°C, excellent high-temperature oxidation resistance, a thermal weight-gain rate of 5.31 × 10⁻¹⁴ g²/cm⁴·s, a remarkably low high-temperature area-specific resistance of 7.04 mΩ·cm², and superior bonding and interfacial stability with the GC9 glass–ceramic sealant, achieving a very low leakage rate of 3.47 × 10⁻⁶ mbar·l/s/cm. These results indicate that the 78Fe-Cr powder metallurgy alloy performs excellently and is the most promising candidate for metallic interconnects in SOFC stack applications. Full article

The solid oxide fuel cell–gas turbine (SOFC-GT) hybrid system is confronted with challenges related to system integration and coordinated control. In this study, a Controller Hardware-in-the-Loop Simulation (C-HILS) platform is constructed to validate its digital solutions. The C-HILS platform integrates the Advanced Process Simulation System (APROS), LabVIEW 2020 programming software, NI PXI hardware, and a distributed control system (DCS). Specifically, bidirectional data transmission between the simulation software and the DCS is facilitated through LabVIEW and PXI, leveraging the OLE for Process Control (OPC) protocol and physical Input and Output (I/O) channels. The dynamic SOFC-GT model developed in APROS demonstrates good consistency with design values, with relative errors below 4%. The DCS configuration employs PID controllers to achieve control over total power, SOFC fuel utilization, and gas turbine rotational speed. Experiments under transient conditions reveal that, despite discrepancies in dynamic responses between C-HILS and full-digital simulations, both can achieve stable control. This C-HILS platform effectively integrates virtual models with physical hardware, offering a reliable environment for verifying SOFC-GT control strategies and digital solutions, and thus facilitating the digital transformation of energy systems. Full article

Bioethanol can be efficiently produced from lignocellulosic biomass via two-phase processes, consisting of enzymatic hydrolysis and fermentation. To enhance economic and energy efficiency, a system combining separate hydrolysis and fermentation of biomass with a direct-ethanol solid oxide fuel cell (SOFC) is proposed in this work. The system comprises six units: a pretreatment reactor unit, a conditioning unit, a high-solids hydrolysis unit, a seed train unit, an ethanol recovery unit, and an SOFC unit. Exergy analysis based on a thermodynamic model indicates a total exergy efficiency of approximately 0.72. Within the high-solids hydrolysis unit, one piece of equipment exhibits the lowest exergy efficiency of 0.21, at a biomass flux of 71,510 kg/h. The other main exergy destruction exists in the conditioning unit and is followed by seed train unit, accounting for 5.61 and 2.77 of total exergy destruction ratios, respectively. In addition, the tentative parametric analysis for reaction kinetics is performed with varying reaction orders. The results indicate that ammonia gas in a specific unit can follow first- or second-reaction order, whereas acetic acid and sulfuric acid exhibit zero-reaction order, due to the gradual conversion of cellulose to glucose. This work provides key insights for the practical design and operation of the proposed separate hydrolysis and fermentation–SOFC system. Full article

This scoping review evaluates the literature on options for planar solid oxide cell (SOC) performance optimization, with a focus on applied fabrication methods and design enhancements. Literature identification, selection, and charting followed PRISMA-ScR guidelines to ensure transparency, reproducibility, and comprehensive coverage, while also enabling the identification of research gaps beyond the scope of narrative reviews. We analyze the influence of fabrication methods on cell and component characteristics and evaluate optimization approaches identified in the literature. Subsequent discussion explores how design innovations intersect with fabrication choices. The surveyed literature reveals a broad spectrum of manufacturing methods, including conventional processes, thin-film deposition, infiltration, and additive manufacturing. Our critical assessment of scalability revealed that reduction in operating temperature, improving robustness, and electrochemical performance are the main optimization objectives for SOC designs. Regarding production cost, production scale-up, and process control, inkjet, electrophoretic deposition, and solution aerosol thermolysis appeared to be promising manufacturing methods for design enhancements. By combining the PRISMA-ScR evidence map with a synthesis focused on scalability and process control, this review provides practical insights and a strong foundation for future SOC research and scale-up, also for evolving the field of proton-conducting cells. Full article

Conventional energy resources have been constrained by their inefficient utilization and present a severe impact on the human living environment, and there is an urgent need to develop energy technologies with high efficiency, low carbon emissions, and environmental cleanliness. Solid oxide fuel cells (SOFCs) have been recognized as a highly efficient and clean energy conversion device that directly converts chemical energy in fuels into electricity, holding promising prospects for addressing the issues of low efficiency and environmental concerns associated with conventional energy resources. However, under practical operation conditions, the cathodes of SOFCs are often exposed to various contaminations including working environment-induced degradation, cathode poisoning, and corrosion. This review summarizes the severe performance degradation of SOFC cathodes caused by CO₂ poisoning, analyzes recent research findings on cathode durability under CO₂-containing atmospheres, and provides an overview of the reported strategies for enhancing CO₂ tolerance. Full article

Solid oxide fuel cell (SOFC) technology is an electrochemical power generation apparatus that enables the direct conversion of chemical fuel energy into electrical energy. To address the issue of thermal cycling stability, which is critical for commercialization, a thermal cycling stability test was performed on a NiO/YSZ anode-supported SOFC button cell. This study investigates the influence of key thermal cycling parameters (heating/cooling rate and number of thermal cycles) on the cell’s electrochemical performance and microstructure evolution. The main findings are as follows: thermal cycling adversely affects the electrochemical performance of the SOFC, with the degree of degradation directly correlated to both the number of cycles and the heating/cooling rate. After 20 thermal cycles at a rate of 5 °C/min, the peak power density decreased by 20.57%. Furthermore, thermal cycling leads to an increase in both ohmic and activation polarization, with the performance degradation predominantly governed by the rise in ohmic polarization. It was demonstrated that the number of thermal cycles has a more significant impact on ohmic losses than the heating/cooling rate. This work offers valuable insight into the degradation mechanisms induced by thermal cycling in SOFC button cells. Full article

Integrated additional cooling channels offer precise thermal management for solid-oxide fuel cells (SOFCs), mitigating temperature gradients. This research studies the thermal–hydraulic performance of cooling channels integrated between SOFC interconnectors, including a Diamond-type triply periodic minimal surface (TPMS), a conventional topology-optimized structure, and a topology-optimized lattice-filled structure. A conjugate heat transfer analysis is employed to investigate the influences of flow rate within the range of Reynolds numbers from 300 to 5000, and the effects of coolant type, including air and liquid metals, as well as the impacts of structural material. The results demonstrate that the topology-optimized lattice-filled structure, generating high turbulence mixing, achieves superior temperature uniformity, especially at high flow rates, despite having higher thermal resistance and pressure loss than the conventional topology-optimized design. The coolant types show the largest influence on thermal–hydraulic performance, and the use of liquid gallium in the conventional optimized design obtains the best temperature uniformity, yielding differences between the maximum and minimum temperatures of less than 5 K. Moreover, the higher-thermal-conductivity material improves temperature uniformity, even at low flow rates. Overall, the optimized-baffle designs in the conventional topology-optimized model, utilizing high-conductivity coolant and structural materials, could be the most suitable for thermal management of the SOFC. Full article