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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Improving Cost and Efficiency of the Scalable Solid Oxide Fuel Cells Power System

The objective of this project was to design and develop a 20kW range small-scale solid oxide fuel cells (SOFC) power system for applications such as data centers and commercial buildings. The original plan included a 5,000 hours demonstration and a Techno-Economic Analysis (TEA) which were dropped as part of project termination. The original project plan was to use a stack with a cross-flow cell design which had previously been tested for 500 hours at a community college in Malta, NY. However, it was decided to move to the advanced R-SOFC co-flow cell developed under Department of Energy Award DE-FE0031971. The advanced cell design has the advantage of a larger active area for the same manufacturing footprint which results in fewer required cells for the same stack power, hence a higher volumetric power density (kW/L) and lower cost per kW than the original cross-flow cell design. A full SOFC system Simulink model was developed and calibrated with testing data from a fuel cell stack and BOP (balance of plant) components. The simulation results from the calibrated model showed an acceptable match with the experimental data. A structural analysis conducted for various load scenarios indicated no high stress areas for all spatial directions. Major electrical system components were acquired, built and successfully tested. System sensors were verified and validated against controls. Safety checks, a diagnostic check, PID tuning, and control software commissioning tasks were also conducted. The power electronics prototype was delivered and trial testing completed. Balance of Plant component testing and simulation work was conducted to characterize Reformer-Heat Exchanger heat transfer and backpressure and reformer catalyst methane conversion and product selectivity. Simulations were conducted to design the Anode and Cathode fluid passages and size the air-air and fuel-fuel heat exchangers. A Burner operation map was created from test data and the Anode Gas Recirculation blower was tested to evaluate its durability. The SOFC system used a horizontal style design where components sit directly on a casting with a direct connection to the skid. This design has efficient packaging and a small footprint with approximate dimensions of 750 mm x 700 mm x 1700 mm. An SOFC system was built and successfully tested at the Malta, NY facility The system for over 500 hours under load of which over 300 hours was at full load of 20 kW.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS2004

Solid Oxide Fuel Cell Seal Development at NASA Glenn Research Center

Researchers at NASA GRC are confronting the seal durability challenges of Solid Oxide Fuel Cells by pursuing an integrated and multidisciplinary development effort incorporating thermo-structural analyses, advanced materials, experimentation, and novel seal design concepts. The successful development of durable hermetic SOFC seals is essential to reliably producing the high power densities required for aerospace applications.

Steinetz, Bruce M.↗
DOE OSTI2024

Cyber-Physical Simulation of an Innovative Solid Oxide Electrolysis Cell - Gas Turbine (SOEC-GT) Hybrid Energy System

To produce green hydrogen at scale and at low cost, the solid oxide electrolysis cell (SOEC) systems would be tied to renewable power sources (mainly solar and wind), leveraging zero-carbon electricity at low prices and even nearly free during overgeneration scenarios. However, due to the intermittency of renewable power generation, the SOEC system is subjected to rapid load transitions that occur not only in diurnal cycles but also in short timeframes (e.g., sub-minute). This can result in fast degradation and thus greatly reduce the SOEC’s lifetime. Our team at the National Energy Technology Laboratory has demonstrated that the anode air flow can have a crucial role in SOEC thermal management. Typically, a higher air flow rate can help to mitigate the local temperature gradient distortion during rapid load transitions. To move a large amount of air, the gas turbine (GT; i.e., compressor-turbine-generator set) has been regarded as the most mature and efficient technology. In this presentation, we show the configuration and preliminary results of an innovative SOEC-GT hybrid energy system in a cyber-physical simulation (CPS) approach.

Zhang, Biao↗
DOE OSTI2026

Integration of Solid Oxide Fuel Cell Systems Into Artificial Intelligence Data Centers

This report presents the results of a techno-economic analysis (TEA) that evaluates the economic benefits of integrating solid oxide fuel cell (SOFC) systems with artificial intelligence (AI) data centers. The analysis was completed in two phases: a scoping-level analysis was performed to identify impactful integration opportunities, followed by a more detailed TEA. Results show that, due to their modularity, SOFC can meet the 99.999% availability requirement of data centers with minimal additional costs. Heat integration via absorption chillers decreases data center electricity consumption at the tradeoff of increased water consumption. Higher SOFC exhaust temperatures are important for achieving larger electricity savings. Finally, power electronics integration with SOFC direct current electricity can reduce electricity consumption by 9 percent and reduce water consumption by 6.4 percent.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS2005

Crystallization Kinetics of a Solid Oxide Fuel Cell Seal Glass by Differential Thermal Analysis

Crystallization kinetics of a barium calcium aluminosilicate glass (BCAS), a sealant material for planar solid oxide fuel cells, have been investigated by differential thermal analysis (DTA). From variation of DTA peak maximum temperature with heating rate, the activation energy for glass crystallization was calculated to be 259 kJ/mol. Development of crystalline phases on thermal treatments of the glass at various temperatures has been followed by powder x-ray diffraction. Microstructure and chemical composition of the crystalline phases were investigated by scanning electron microscopy and energy dispersive spectroscopic (EDS) analysis. BaSiO3 and hexacelsian (BaAl2Si2O8) were the primary crystalline phases whereas monoclinic celsian (BaAl2Si2O8) and (Ba(x), Ca(y))SiO4 were also detected as minor phases. Needle-shaped BaSiO3 crystals are formed first, followed by the formation of other phases at longer times of heat treatments. The glass does not fully crystallize even after long term heat treatments at 750 to 900 C.

Bansal, Narottam P.↗
NASA NTRS2005

Combustion Synthesis of Sm0.5Sr0.5CoO3-x and La0.6Sr0.4CoO3-x Nanopowders for Solid Oxide Fuel Cell Cathodes

Nanopowders of Sm0.5Sr0.5CoO(3-x) (SSC) and La0.6Sr0.4CoO(3-x) (LSC) compositions, which are being investigated as cathode materials for intermediate temperature solid oxide fuel cells, were synthesized by a solution-combustion method using metal nitrates and glycine as fuel. Development of crystalline phases in the as-synthesized powders after heat treatments at various temperatures was monitored by x-ray diffraction. Perovskite phase in LSC formed more readily than in SSC. Single phase perovskites were obtained after heat treatment of the combustion synthesized LSC and SSC powders at 1000 and 1200 C, respectively. The as-synthesized powders had an average particle size of ~12 nm as determined from x-ray line broadening analysis using the Scherrer equation. Average grain size of the powders increased with increase in calcination temperature. Morphological analysis of the powders calcined at various temperatures was done by scanning electron microscopy.

Bansal, Narottam P.↗
DOE OSTI2025

Stress evolution and creep deformation in solid-oxide electrolysis cell systems – Dynamic modeling and multi-objective optimization to maximize stack life and efficiency

Here, this study develops a thermal stress model of solid-oxide electrolysis cells (SOECs) including a model for creep strain and failure probability that is integrated with a dynamic plant-wide model of a hydrogen production process. Uncertainties in key material properties of the cell are quantified to assess their impact on stress profile variability. The oxygen electrode is found to have about 10 times higher failure probability compared to the fuel electrode. The study shows that if the stack operation is not optimized, cycling operation would lead to stress build-up eventually leading to catastrophic failure. A dynamic optimization problem is set up for obtaining the optimal operational profile considering a variable hydrogen production rate. Due to the tradeoff between the efficiency and stress build-up, the dynamic optimization problem is multi-objective. It is observed that the optimizer can considerably reduce the stress build-up (i.e., can increase the stack life) albeit at the cost of a lower efficiency thus exhibiting strong tradeoffs between capital and operating costs. For example, if the stack would be replaced in 0.5 yr, specific energy requirement would be 48.5 kWh/kg H 2 while for a stack replacement time of about 6 yr, the specific energy requirement rises by about 4.2 %.

SOEC↗
DOE OSTI2026

Roll-to-Roll Manufacturing of Solid Oxide Fuel Cells

The overall goal of this project is to develop a high-volume electrode electrolyte assembly (EEA) production capability to significantly increase throughput of solid oxide fuel cell (SOFC) manufacturing and reduce the cost while maintaining the same level of performance. Specifically, four approaches will be adopted: 1) optimization of the lamination process and correlation of the EEA properties and performance with the lamination conditions; 2) scale up of the lamination process and demonstration of >10 ft of EEA; 3) further increase of the EEA throughput via slot-die coating and demonstration of > 5 m/min in coating the thick anode layer; and 4) minimization of the anode thickness to reduce material cost.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Techno-Economic Analysis of Large-Scale Hydrogen Production from Solid Oxide Electrolysis Cell Systems

The objective of this study is to establish a detailed techno-economic analysis to assess the effectiveness of incremental technology improvements needed for solid oxide electrolysis cell (SOEC) technology to achieve the U.S. DOE’s Hydrogen Shot goal of hydrogen production at less than $1 per kilogram. The pathway considers incremental technology improvements to key system parameters, with system performance and cost assessed for each pathway step. Briefly, the steps include cell voltage degradation rate improvements, operational current density increases, operating temperature reduction, improved steam utilization, increased system capacity factor, and reduced cell/stack capital costs. Each step is assessed at both atmospheric and pressurized (8 bar) operating conditions. To supplement assessment at each of these discrete stepwise improvements, sensitivity studies are conducted to understand the relative impact of each parameter and identify avenues for additional cost reductions. System efficiency and levelized costs of hydrogen (LCOH) for each case are presented. For the end-of-pathway case, which includes all the incremental research and development improvements, the cost of hydrogen produced is reduced by 50 percent from the state-of-the-art case.

08 HYDROGEN↗
NASA NTRS2004

Thermodynamic Modeling of a Solid Oxide Fuel Cell to Couple with an Existing Gas Turbine Engine Model

The Controls and Dynamics Technology Branch at NASA Glenn Research Center are interested in combining a solid oxide fuel cell (SOFC) to operate in conjunction with a gas turbine engine. A detailed engine model currently exists in the Matlab/Simulink environment. The idea is to incorporate a SOFC model within the turbine engine simulation and observe the hybrid system's performance. The fuel cell will be heated to its appropriate operating condition by the engine s combustor. Once the fuel cell is operating at its steady-state temperature, the gas burner will back down slowly until the engine is fully operating on the hot gases exhausted from the SOFC. The SOFC code is based on a steady-state model developed by The U.S. Department of Energy (DOE). In its current form, the DOE SOFC model exists in Microsoft Excel and uses Visual Basics to create an I-V (current-voltage) profile. For the project's application, the main issue with this model is that the gas path flow and fuel flow temperatures are used as input parameters instead of outputs. The objective is to create a SOFC model based on the DOE model that inputs the fuel cells flow rates and outputs temperature of the flow streams; therefore, creating a temperature profile as a function of fuel flow rate. This will be done by applying the First Law of Thermodynamics for a flow system to the fuel cell. Validation of this model will be done in two procedures. First, for a given flow rate the exit stream temperature will be calculated and compared to DOE SOFC temperature as a point comparison. Next, an I-V curve and temperature curve will be generated where the I-V curve will be compared with the DOE SOFC I-V curve. Matching I-V curves will suggest validation of the temperature curve because voltage is a function of temperature. Once the temperature profile is created and validated, the model will then be placed into the turbine engine simulation for system analysis.

Brinson, Thomas E.↗
DOE OSTI2025

An Active Oxygen Electrode for Proton-Conducting Solid Oxide Electrolysis Cells with High Faradaic Efficiency

Addressing the challenges posed by inferior electrochemical performance at low temperatures and the uncertain Faradaic efficiency (FE) represents a pivotal undertaking in the development of high performance and efficient proton-conducting solid oxide electrolysis cells (P-SOECs). In this work, a novel oxygen electrode material BaCo0.8Zr0.1Zn0.1O3-d (BCZZ) is first designed and synthesized. At 600 °C, P-SOECs with BCZZ oxygen electrode achieve an electrolysis current density of 1.98 A cm-2 with an ˜90% FE at 1.3 V. Utilizing 1-inch P-SOECs as a reliable platform, the effect of extrinsic operating conditions (i.e., steam concentration, voltage, current density, and temperature) and intrinsic properties of P-SOECs (i.e., electrolyte material and electrolyte thickness) on FE are further systemically investigated, both experimentally and theoretically.

08 - HYDROGEN↗
NASA NTRS2006

A Theoretical Solid Oxide Fuel Cell Model for System Controls and Stability Design

As the aviation industry moves towards higher efficiency electrical power generation, all electric aircraft, or zero emissions and more quiet aircraft, fuel cells are sought as the technology that can deliver on these high expectations. The Hybrid Solid Oxide Fuel Cell system combines the fuel cell with a microturbine to obtain up to 70 percent cycle efficiency, and then distributes the electrical power to the loads via a power distribution system. The challenge is to understand the dynamics of this complex multi-discipline system, and design distributed controls that take the system through its operating conditions in a stable and safe manner while maintaining the system performance. This particular system is a power generation and distribution system and the fuel cell and microturbine model fidelity should be compatible with the dynamics of the power distribution system in order to allow proper stability and distributed controls design. A novel modeling approach is proposed for the fuel cell that will allow the fuel cell and the power system to be integrated and designed for stability, distributed controls, and other interface specifications. This investigation shows that for the fuel cell, the voltage characteristic should be modeled, but in addition, conservation equation dynamics, ion diffusion, charge transfer kinetics, and the electron flow inherent impedance should also be included.

Kopasakis, George↗
NASA NTRS2008

A Theoretical Solid Oxide Fuel Cell Model for Systems Controls and Stability Design

As the aviation industry moves toward higher efficiency electrical power generation, all electric aircraft, or zero emissions and more quiet aircraft, fuel cells are sought as the technology that can deliver on these high expectations. The hybrid solid oxide fuel cell system combines the fuel cell with a micro-turbine to obtain up to 70% cycle efficiency, and then distributes the electrical power to the loads via a power distribution system. The challenge is to understand the dynamics of this complex multidiscipline system and the design distributed controls that take the system through its operating conditions in a stable and safe manner while maintaining the system performance. This particular system is a power generation and a distribution system, and the fuel cell and micro-turbine model fidelity should be compatible with the dynamics of the power distribution system in order to allow proper stability and distributed controls design. The novelty in this paper is that, first, the case is made why a high fidelity fuel cell mode is needed for systems control and stability designs. Second, a novel modeling approach is proposed for the fuel cell that will allow the fuel cell and the power system to be integrated and designed for stability, distributed controls, and other interface specifications. This investigation shows that for the fuel cell, the voltage characteristic should be modeled but in addition, conservation equation dynamics, ion diffusion, charge transfer kinetics, and the electron flow inherent impedance should also be included.

Kopasakis, George↗
NASA NTRS2007

Glass/BNNT Composite for Sealing Solid Oxide Fuel Cells

A material consisting of a barium calcium aluminosilicate glass reinforced with 4 weight percent of boron nitride nanotubes (BNNTs) has shown promise for use as a sealant in planar solid oxide fuel cells (SOFCs).

Bansal, Narottam P.↗
DOE OSTI2025

System Analysis of an Internal Combustion Engine (ICE) - Solid Oxide Fuel Cell (SOFC) Hybrid Cycle

The variability of renewable energy sources poses challenges for reliable grid operation. Conventional thermal power sources, though reliable, often lack operational flexibility. Hybrid energy systems that integrate Solid Oxide Fuel cells (SOFC) with Internal Combustion Engines (ICE) offer a promising solution by achieving relatively higher efficiency and grid-following capability. This study investigates performance of a 100-kW pressurized SOFC-ICE hybrid cycle. In this configuration, unutilized SOFC fuel is used to drive the engine, with a turbocharger providing air supply and an external reformer generating syngas. System components were numerically modeled using MATLAB/SIMULINK for the SOFC and reformer, and EBSILON® for the ICE and balance of plant. Parametric studies varied fuel utilization (70-90%), reformer temperature (600 – 1000K), anode off-gas recirculation (0 – 70%), and current density (0.2 – 0.55 A/cm2). Results show that the SOFC and ICE operate as thermally independent topping and bottoming cycles, achieving peak efficiency of 62% under optimized conditions.

hybrid↗
NASA NTRS2011

Sol-Gel Synthesis of La(0.6)Sr(0.4)CoO(3-x) and Sm(0.5)Sr(0.5)CoO(3-x) Cathode Nanopowders for Solid Oxide Fuel Cells

Nanopowders of La(0.6)Sr(0.4)CoO(3-x) (LSC) and Sm(0.5)Sr(0.5)CoO(3-x) (SSC) compositions, which are being investigated as cathode materials for intermediate temperature solid oxide fuel cells (IT-SOFC) with La(Sr)Ga(Mg)O(3-x) (LSGM) as the electrolyte, were synthesized by low-temperature sol-gel method using metal nitrates and citric acid. Thermal decomposition of the citrate gels was followed by simultaneous DSC/TGA methods. Development of phases in the gels, on heat treatments at various temperatures, was monitored by x-ray diffraction. Solgel powders calcined at 550 to 1000 C consisted of a number of phases. Single perovskite phase La(0.6)Sr(0.4)CoO(3-x) or Sm(0.5)Sr(0.5)CoO(3-x) powders were obtained at 1200 and 1300 C, respectively. Morphological analysis of the powders calcined at various temperatures was done by scanning electron microscopy. The average particle size of the powders was approx.15 nm after 700 C calcinations and slowly increased to 70 to 100 nm after heat treatments at 1300 to 1400 C.

Bansal, Narottam P.↗
DOE OSTI2026

The structure, composition, and performance impact of a YSZ-GDC interdiffusion layer in solid oxide electrolysis cells

This study provides a combined experimental and computational investigation into the structure and impact of the cation interdiffusion layer that appears at the gadolinium doped ceria (GDC)/yttria stabilized zirconia (YSZ) interface in solid oxide electrolysis cells (SOECs). Scanning transmission electron microscopy (STEM) illustrates that a ∼0.4 μm interdiffusion layer (IDL) with an intermixed cation distribution and fine grain size forms upon sintering. STEM identifies that the interdiffusion layer exists in the cubic fluorite structure despite changes in cation composition. The interdiffusion layer microstructure formed during sintering does not change during SOEC testing at either 1.3V or heightened voltage pulse testing. Modeling predicts that ionic conductivity may decrease in the interdiffusion layer due to Coulombic trapping between mobile oxygen vacancies and excess Gd 3+ acceptor dopants. Yet, the density and continuous nature of the layer should benefit cell stability by substantially reducing the formation of SrZrO 3 , which is corroborated by STEM and Synchrotron X-ray diffraction (XRD). We conclude that the interdiffusion layer acts as a beneficial barrier to Sr diffusion, when operating in a regime where electrolyte void formation is not observed.

organic↗
NASA NTRS1996

The TMI Regenerative Solid Oxide Fuel Cell

Energy storage and production in space requires rugged, reliable hardware which minimizes weight, volume, and maintenance while maximizing power output and usable energy storage. Systems generally consist of photovoltaic solar arrays which operate (during sunlight cycles) to provide system power and regenerate fuel (hydrogen) via water electrolysis and (during dark cycles) fuel cells convert hydrogen into electricity. Common configurations use two separate systems (fuel cell and electrolyzer) in conjunction with photovoltaic cells. Reliability, power to weight and power to volume ratios could be greatly improved if both power production (fuel cells) and power storage (electrolysis) functions can be integrated into a single unit. The solid oxide fuel cell (SOFC) based design integrates fuel cell and electrolyzer functions and potentially simplifies system requirements. The integrated fuel cell/electrolyzer design also utilizes innovative gas storage concepts and operates like a rechargeable 'hydrogen-oxygen battery'. Preliminary research has been completed on improved H2/H20 electrode (SOFC anode/electrolyzer cathode) materials for regenerative fuel cells. Tests have shown improved cell performance in both fuel and electrolysis modes in reversible fuel cell tests. Regenerative fuel cell efficiencies, ratio of power out (fuel cell mode) to power in (electrolyzer mode), improved from 50 percent using conventional electrode materials to over 80 percent. The new materials will allow a single SOFC system to operate as both the electolyzer and fuel cell. Preliminary system designs have also been developed to show the technical feasibility of using the design for space applications requiring high energy storage efficiencies and high specific energy. Small space systems also have potential for dual-use, terrestrial applications.

Cable, Thomas L.↗