Engineering topics

Koeppel, Brian J

Publications and source records attributed to Koeppel, Brian J.

7 records

DOE OSTI2013

A general approach to develop reduced order models for simulation of solid oxide fuel cell stacks

A reduced order modeling approach based on response surface techniques was developed for solid oxide fuel cell stacks. This approach creates a numerical model that can quickly compute desired performance variables of interest for a stack based on its input parameter set. The approach carefully samples the multidimensional design space based on the input parameter ranges, evaluates a detailed stack model at each of the sampled points, and performs regression for selected performance variables of interest to determine the responsive surfaces. After error analysis to ensure that sufficient accuracy is established for the response surfaces, they are then implemented in a calculator module for system-level studies. The benefit of this modeling approach is that it is sufficiently fast for integration with system modeling software and simulation of fuel cell-based power systems while still providing high fidelity information about the internal distributions of key variables. This paper describes the sampling, regression, sensitivity, error, and principal component analyses to identify the applicable methods for simulating a planar fuel cell stack.

Pan, Wenxiao↗

DOE OSTI2011

NUMERICAL MODELING OF CATHODE CONTACT MATERIAL DENSIFICATION

Numerical modeling was used to simulate the constrained sintering process of the cathode contact layer during assembly of solid oxide fuel cells (SOFCs). A finite element model based on the continuum theory for sintering of porous bodies was developed and used to investigate candidate low-temperature cathode contact materials. Constitutive parameters for various contact materials under investigation were estimated from dilatometry screening tests, and the influence of processing time, processing temperature, initial grain size, and applied compressive stress on the free sintering response was predicted for selected candidate materials. The densification behavior and generated stresses within a 5-cell planar SOFC stack during sintering, high temperature operation, and room temperature shutdown were predicted. Insufficient constrained densification was observed in the stack at the proposed heat treatment, but beneficial effects of reduced grain size, compressive stack preload, and reduced thermal expansion coefficient on the contact layer densification and stresses were observed.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2011

EFFECT OF GEOMETRY AND OPERATING PARAMETERS ON SIMULATED SOFC STACK TEMPERATURE UNIFORMITY

A uniform temperature field is desirable in the solid oxide fuel cell stack to avoid local hot regions that contribute to material degradation, thermal stresses, and differences in electrochemical performance. Various geometric and operational design changes were simulated by numerical modeling of co-flow and counter-flow multi-cell stacks, and the effects on stack maximum temperature, stack temperature difference, and maximum cell temperature difference were characterized. The results showed that 40-60% on-cell steam reforming of methane and a reduced reforming rate of 25-50% of the nominal rate was beneficial for a more uniform temperature field. Fuel exhaust recycling up to 30% was shown to be advantageous for reforming fuels and co-flow stacks with hydrogen fuel, but counter-flow stacks with hydrogen fuel showed higher temperature differences. Cells with large aspect ratios showed a more uniform temperature response due to either the strong influence of the inlet gas temperatures or the greater thermal exchange with the furnace boundary condition. Improved lateral heat spreading with thicker interconnects was demonstrated, but greater improvements towards a uniform thermal field for the same amount of interconnect mass could be achieved using thicker heat spreader plates appropriately distributed along the stack height.

03 NATURAL GAS↗

DOE OSTI2011

Modeling of On-Cell Reforming Reaction for Planar SOFC Stacks

Planar Solid Oxide Fuel Cell (SOFC) stack is known to suffer thermal problem from high stack temperature during operation to generate high current. On-Cell Reforming (OCR) phenomenon is often used to reduce stack temperature by an endothermic reaction of steam-methane reforming process. RIST conducted single-cell experiment to validate modeling tool to simulate OCR performance including temperature measurement. 2D modeling is used to check reforming rate during OCR using temperature measurement data, and 3D modeling is used to check overall thermal performance including furnace boundary conditions.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2011

A Quasi-Two-Dimensional Electrochemistry Modeling Tool for Planar Solid Oxide Fuel Cell Stacks

A two-dimensional numerical model is presented for the efficient computation of the steady-state current density, species concentration, and temperature distributions in planar solid oxide fuel cell stacks. The model reduction techniques, engineering approximations, and numerical procedures used to simulate the stack physics while maintaining adequate computational speed are discussed. The results of the model for benchmark cases with and without on-cell methane reformation are presented with comparisons to results from other research described in the literature. The capabilities, performance, and scalability of the model for the study of large multi-cell stacks are then demonstrated.

03 NATURAL GAS↗

DOE OSTI2010

Modeling of Electrochemistry and Steam-Methane Reforming Performance for Simulating Pressurized Solid Oxide Fuel Cell Stacks

This paper examines the electrochemical and on-cell steam-methane reforming performance of the solid oxide fuel cell when subjected to pressurization. Pressurized operation boosts the Nernst potential and decreases the activation polarization, both of which serve to increase cell voltage and power while lowering the heat load and operating temperature. A model considering the activation polarization in both the fuel and air electrodes was adopted to address this effect on the electrochemical performance. Both the increase in methane conversion kinetics and the increase in equilibrium methane concentration, which are competing effects of pressurization on steam-methane reforming, are considered in a new rate expression. The models were then applied in simulations to preview how the distributions of reforming rate, temperature, and current density can potentially be changed within stacks operating at elevated pressure. A generic 10 cm counter-flow stack model was created and used for the simulations of pressurized operation. The predictions showed improved thermal and electrical performance with increased operating pressure. The average and maximum cell temperatures decreased by 3% while the cell voltage increased by 9% as the operating pressure was increased from 1 to 10 atmospheres.

electrochemistry↗

DOE OSTI2010

Analyses of Large Coal-Based SOFCs for High Power Stack Block Development

This report summarizes the numerical modeling and analytical efforts for SOFC stack development performed for the coal-based SOFC program. The stack modeling activities began in 2004, but this report focuses on the most relevant results obtained since August 2008. This includes the latter half of Phase-I and all of Phase-II activities under technical guidance of VPS and FCE. The models developed to predict the thermal-flow-electrochemical behaviors and thermal-mechanical responses of generic planar stacks and towers are described. The effects of cell geometry, fuel gas composition, on-cell reforming, operating conditions, cell performance, seal leak, voltage degradation, boundary conditions, and stack height are studied. The modeling activities to evaluate and achieve technical targets for large stack blocks are described, and results from the latest thermal-fluid-electrochemical and structural models are summarized. Modeling results for stack modifications such as scale-up and component thickness reduction to realize cost reduction are presented. Supporting modeling activities in the areas of cell fabrication and loss of contact are also described.

electrochemistry↗