ABSTRACT
Abstract
Electrochemical cell systems (51) and electrochemical cell processes are described as applicable to power generation or electrolysis modes with systems that have a containment vessel interior space multiple electrochemical cell stack, stack inlet plenum (43) that can accommodate thermal expansion and contraction in an economical way and that can provide a substantially equivalent environment for each stack inlet as well as can include, if desired, either or all of a vessel external compression stack mount possibly configured as a cathode outlet manifold (111) configured as a stack mount, a fully accommodative thermal expansion-contraction electrochemical cell stack mount possibly configured with external springs (91), and even the possibility of an axial flow adjuster such as a gradation plate (99) for better operation.
Description
PRIORITY CLAIM
This application is a PCT International Patent Application claiming priority to and the benefit of U.S. Provisional Application No. 63/297,525, filed Jan. 7, 2022, such patent application and any priority case hereby incorporated herein by reference in their entirety.
GOVERNMENT LICENSE RIGHTS
This invention was made with government support under ARPA-E INTEGRATE contract DE-AR0000956 awarded by the Department of Energy. The government has certain rights in the invention.
FIELD OF THE INVENTION
The inventive technology described herein generally relates to the field of electrochemical cell processes and integrated Solid Oxide Fuel Cell (SOFC) stacks (or other type of fuel cells) including Gas Turbine (GT) systems intended for high efficiency power production as well as Solid Oxide Electrolyzer Cells (SOEC)(or other type of electrolyzers) intended for gas or hydrogen production. This document serves as a disclosure of several embodiments related to an integrated Solid Oxide Fuel Cell (SOFC) stack (or other type of fuel cell) and Gas Turbine (GT) system intended for a variety of purposes, including high efficiency power production and electrolysis developed by the inventors. Further, while some of the embodiments are related to the integrated SOFC/GT system, others could be used in isolation with a standalone pressurized or unpressurized SOFC, SOEC, or other type of fuel cell system. Furthermore some of the embodiments may be used as part of an SOEC electrolyzer system such as for gas or hydrogen production. This inventive technology also relates to systems and methods for integrated Solid Oxide Fuel Cell (SOFC) stack (or other type of fuel cell) and Gas Turbine (GT) systems intended for high efficiency power production used in isolation with a standalone SOFC (or other type of fuel cell) system or integrated to a SOFC/GT system.
BACKGROUND OF THE INVENTION
Solid Oxide Fuel Cells are advanced high-temperature (between, but not limited to, 500-1000° C.) electrochemical devices which may efficiently convert fuel (predominantly hydrogen) into electricity. While relatively efficient, SOFC's high operating temperature, their need for a constant flow of hot air to supply oxygen for the electrochemical reaction, and the fact that not all the fuel supplied to the SOFC be consumed may leave areas for system and efficiency improvements. Both the waste heat, and the unconsumed fuel, may be utilized to increase system efficiency by integrating a gas turbine into the system. Additionally, while the SOFC ultimately consumes hydrogen in the electrochemical reaction, the system's high operating temperatures may also be conducive to reforming fuels such as natural gas into hydrogen which may be consumed within the SOFC stack. Solid Oxide Electrolyzer Cells (SOEC's) are closely related to SOFCs and effectively reverse the process to convert steam and electricity into hydrogen (which may be used as a fuel) and oxygen. They may also produce some power. Many of the embodiments disclosed herein are applicable to SOEC's as well as SOFC's. In this document SOFC is often used as a generic term which should be understood to encompasses both SOFC's and SOEC's.
SUMMARY OF THE INVENTION
In general, the inventive technology may involve both apparatus and methods in a variety of embodiments to achieve efficient and robust integrated Solid Oxide Fuel Cell (SOFC) stack (or other type of fuel cell) and Gas Turbine (GT) systems intended for high efficiency power production and also to achieve integrated solid oxide electrolyzer cell (SOEC) systems to produce gases, fuels, possibly oxygen, and hydrogen. The invention can apply to a variety of different type of electrochemical cells and processes. For example disclosed are technologies that are applicable to planar solid oxide fuel cell stacks and solid oxide electrolysis stacks, and stacks which operate at high temperature (perhaps 600 to 900° C.). These stacks may be comprised of a multitude of ceramic planar components (oxygen ion conducting ceramic electrolyte plates) with electrodes on opposite faces. These planar solid oxide cells typically are stacked and sealed with metallic interconnects, current collectors, and shims to define gas flow paths such that two different gases can be flowed on opposite faces of each of the planar cells and electrochemical reactions can be made to happen. Various types of solid oxide electrochemical systems and cells can be used in the embodiments within both general concepts of a power generating system such as a solid oxide fuel cell or an electrolysis system such as a solid oxide electrolysis cell. Details of the different types are mentioned later.
While one goal includes creating a high efficiency power generation system by integrating an SOFC with a CT, the methods and system architecture disclosed go beyond that goal and are applicable in a host of other contexts. The objectives of the inventing team were primarily to develop a system design which maximized system efficiency while eventually producing the system at an economically viable price point, and secondarily to minimize complexity and maximize robustness. Further, this technology is now expanded to encompass Solid Oxide Electrolyzer or Electrolysis Cells (SOEC's), which may be closely related to SOFC's and which effectively reverse the process to convert steam and electricity into hydrogen (which may be used as a fuel) and oxygen. Many of the embodiments disclosed herein are applicable to SOEC's as well as SOFC's, so, in this document SOFC is often used as a generic term which encompasses both SOFC's and SOEC's.
BRIEF DESCRIPTION OF THE FIGS.
FIG. 1 is an exemplary embodiment of a base system schematic.
FIG. 2 is an exemplary embodiment of a system schematic illustrating power export.
FIG. 3 is an exemplary embodiment of a system schematic illustrating startup and shutdown components.
FIG. 4 is an exemplary embodiment of a solid oxide fuel cell assembly and pressure vessel.
FIG. 5 is another exemplary embodiment of a solid oxide fuel cell assembly and pressure vessel.
FIG. 6 is an exemplary embodiment of a solid oxide fuel cell flow path.
FIG. 7 is an exemplary embodiment of a solid oxide fuel cell stack shelf.
FIG. 8 is an exemplary illustration of a conventional cathode flow and stack temperature distribution.
FIG. 9 is an exemplary illustration of a simplified representation of cathode flow and stack temperature distribution for one embodiment of the present technology.
FIG. 10 is an exemplary illustration of an example gradated flow distribution for one embodiment of the present technology.
FIG. 11 is an exemplary embodiment of an axial flow adjuster in one embodiment of the present technology.
FIG. 12 is an exemplary embodiment of an SOEC system schematic.
FIG. 13 is an exemplary illustration of a stack compression mechanism.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
It should be understood that embodiments include a variety of aspects, which may be combined in different ways. The following descriptions are provided to list elements and describe some of the embodiments of the application. These elements are listed with initial embodiments; however, it should be understood that they may be combined in any manner and in any number to create additional embodiments. The variously described examples and preferred embodiments should not be construed to limit the embodiments of the application to only the explicitly described systems, techniques, and applications. The specific embodiment or embodiments shown are examples only. The specification should be understood and is intended as supporting broad claims as well as each embodiment, and even claims where other embodiments may be excluded. Importantly, disclosure of merely exemplary embodiments is not meant to limit the breadth of other more encompassing claims that may be made where such may be only one of several methods or embodiments which could be employed in a broader claim or the like. Further, this description should be understood to support and encompass descriptions and claims of all the various embodiments, systems, techniques, methods, devices, and applications with any number of the disclosed elements, with each element alone, and also with any and all various permutations and combinations of all elements in this or any subsequent application.
Generally, electrochemical cell systems can be most basically understood as having first function and second function electrodes. One type of electrode can be considered as having a first function, and another type of electrode can be considered as having a second function. For example, from a fluid and chemical perspective one type of electrode cell collection can be what herein is termed an oxygen cell collection that has a function of conducting an oxygen-involved operation or function and another type of electrode cell collection can be termed a fuel cell collection that has a function of conducting a fuel-involved operation or function. In these types of first and second functions, either the oxygen-type or the fuel-type can be considered as the first function because such cells can operate in reverse orders. Further, the oxygen can serve to foster a fuel oxidation type of event, and the fuel can be an appropriately compatible substance, likely any hydrogen or carbon containing substance, often both such as a hydrocarbon containing substance. Similarly from an electrical perspective, the first and second functions can be those of a cathode and an anode where, again, either can be configured as the first function and the opposite one can be configured as the second function-types of electrode. As is known, electrodes can be layered or configured in stacks which may be comprised of pluralities of first function electrode elements and pluralities of second function electrode elements. As is known, such electrode stacks in these types of cell stacks have inlets and outlets for each of the two types of electrodes. Thus, the stacks may include a stack first function electrode inlet such as for the first function electrode stack, a stack first function electrode outlet again for the first function electrode stack, a stack second function electrode inlet such as for the second function electrode stack, and a stack second function electrode outlet also for the second function electrode stack. These type of inlets can be understood from FIG. 6 where the first function electrode element is configured as a cathode element in an oxygen stack and thus the first function electrode inlet is shown as the area at the beginning of the arrow as the cathode inlet ( 121 ) and the corresponding first function electrode outlet is shown as the area at the end of the arrow as the cathode outlet flowing into the outlet plenum ( 221 ). Similarly the second function electrode element, perhaps configured as an anode element in a fuel stack, could have a second function electrode inlet and a corresponding second function electrode outlet such as can be understood from FIG. 13 . These inlet and outlet areas an be manifolded as explained later.
Using a solid oxide fuel cell (SOFC) as an initial design, one embodiment of the base system schematic for the Solid Oxide Fuel Cell (SOFC) and Gas Turbine (GT) system is shown in FIG. 1 . This system ( 51 ) may be comprised of multiple components of course including the SOFC stacks ( 7 ). These are made up of individual electrochemical cells ( 52 ) fluidically connected in series, as one option, to form stacks ( 53 ), which may then electrically connect via interconnection ( 34 ) in series and/or parallel to produce part of the system's electrical power. An important aspect of SOFCs may be that the electrochemical reaction may be effectively exothermic. Whatever portion of the fuel's energy consumed within the stack is not converted into electricity, may be converted into heat which may be released into the stack and principally carried away by the anode and cathode streams. The SOFC stacks may be integrated into the middle of the gas turbine flow path ( 35 ) both to maximize system thermodynamic efficiency, and to enable the stacks ( 53 ) to operate under pressurized conditions in a pressurized area ( 36 ) to improve their electrochemical efficiency. In some embodiments other optimized benefits may also be present due to integrating SOFC stacks into the middle of the gas turbine flow path. Due to the mechanical design of the SOFC stacks they may operate with relatively low differential pressure between their interior ( 38 ) and exterior ( 40 ), as such they may be placed within a pressure vessel ( 9 ) pressurized by the cathode inlet flow ( 41 ) or operated under ambient pressure. This pressure vessel ( 9 ), or more generally, a containment vessel ( 9 ) can be configured to removably contain at least a portion of the plurality of connected individual electrochemical cell stacks, and may also serve as an intake plenum ( 43 ), or more precisely, a containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum such as for the first function electrode stack, in this embodiment depicted as element ( 43 ). In this manner the intake plenum ( 43 ) or containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum, can serve to ensure even flow distribution and to recover additional heat lost by hotter components within the pressure vessel ( 9 ) assembly.
As can be understood, by using the more generic terms first function and second function relative to the electrodes, various different configurations are encompassed. For example, the oxygen electrode elements can be configured in a stack. This stack of oxygen electrode elements can be considered a stack of first function electrode elements. And this can provide cathode elements. And the fuel electrode elements can also be configured in a stack and this stack of fuel electrode elements can be considered a stack of second function electrode elements, and furthermore, this stack can provide anode elements. This type of configuration could present a SOFC system. Electrically reversing functions, a stack of oxygen electrode elements can be considered a stack of first function electrode elements and can provide the anode elements, and the stack of fuel electrode elements can be considered a stack of second function electrode elements and can provide the cathode elements. This type of configuration could present a SOEC system. The chemically opposite can be true as well, a stack of fuel electrode elements can be considered a stack of first function electrode elements and can provide the cathode elements, and a stack of oxygen electrode elements can be considered a stack of second function electrode elements and can provide the anode elements. This type of configuration could present a SOEC syste
PRIORITY CLAIM
This application is a PCT International Patent Application claiming priority to and the benefit of U.S. Provisional Application No. 63/297,525, filed Jan. 7, 2022, such patent application and any priority case hereby incorporated herein by reference in their entirety.
GOVERNMENT LICENSE RIGHTS
This invention was made with government support under ARPA-E INTEGRATE contract DE-AR0000956 awarded by the Department of Energy. The government has certain rights in the invention.
FIELD OF THE INVENTION
The inventive technology described herein generally relates to the field of electrochemical cell processes and integrated Solid Oxide Fuel Cell (SOFC) stacks (or other type of fuel cells) including Gas Turbine (GT) systems intended for high efficiency power production as well as Solid Oxide Electrolyzer Cells (SOEC)(or other type of electrolyzers) intended for gas or hydrogen production. This document serves as a disclosure of several embodiments related to an integrated Solid Oxide Fuel Cell (SOFC) stack (or other type of fuel cell) and Gas Turbine (GT) system intended for a variety of purposes, including high efficiency power production and electrolysis developed by the inventors. Further, while some of the embodiments are related to the integrated SOFC/GT system, others could be used in isolation with a standalone pressurized or unpressurized SOFC, SOEC, or other type of fuel cell system. Furthermore some of the embodiments may be used as part of an SOEC electrolyzer system such as for gas or hydrogen production. This inventive technology also relates to systems and methods for integrated Solid Oxide Fuel Cell (SOFC) stack (or other type of fuel cell) and Gas Turbine (GT) systems intended for high efficiency power production used in isolation with a standalone SOFC (or other type of fuel cell) system or integrated to a SOFC/GT system.
BACKGROUND OF THE INVENTION
Solid Oxide Fuel Cells are advanced high-temperature (between, but not limited to, 500-1000° C.) electrochemical devices which may efficiently convert fuel (predominantly hydrogen) into electricity. While relatively efficient, SOFC's high operating temperature, their need for a constant flow of hot air to supply oxygen for the electrochemical reaction, and the fact that not all the fuel supplied to the SOFC be consumed may leave areas for system and efficiency improvements. Both the waste heat, and the unconsumed fuel, may be utilized to increase system efficiency by integrating a gas turbine into the system. Additionally, while the SOFC ultimately consumes hydrogen in the electrochemical reaction, the system's high operating temperatures may also be conducive to reforming fuels such as natural gas into hydrogen which may be consumed within the SOFC stack. Solid Oxide Electrolyzer Cells (SOEC's) are closely related to SOFCs and effectively reverse the process to convert steam and electricity into hydrogen (which may be used as a fuel) and oxygen. They may also produce some power. Many of the embodiments disclosed herein are applicable to SOEC's as well as SOFC's. In this document SOFC is often used as a generic term which should be understood to encompasses both SOFC's and SOEC's.
SUMMARY OF THE INVENTION
In general, the inventive technology may involve both apparatus and methods in a variety of embodiments to achieve efficient and robust integrated Solid Oxide Fuel Cell (SOFC) stack (or other type of fuel cell) and Gas Turbine (GT) systems intended for high efficiency power production and also to achieve integrated solid oxide electrolyzer cell (SOEC) systems to produce gases, fuels, possibly oxygen, and hydrogen. The invention can apply to a variety of different type of electrochemical cells and processes. For example disclosed are technologies that are applicable to planar solid oxide fuel cell stacks and solid oxide electrolysis stacks, and stacks which operate at high temperature (perhaps 600 to 900° C.). These stacks may be comprised of a multitude of ceramic planar components (oxygen ion conducting ceramic electrolyte plates) with electrodes on opposite faces. These planar solid oxide cells typically are stacked and sealed with metallic interconnects, current collectors, and shims to define gas flow paths such that two different gases can be flowed on opposite faces of each of the planar cells and electrochemical reactions can be made to happen. Various types of solid oxide electrochemical systems and cells can be used in the embodiments within both general concepts of a power generating system such as a solid oxide fuel cell or an electrolysis system such as a solid oxide electrolysis cell. Details of the different types are mentioned later.
While one goal includes creating a high efficiency power generation system by integrating an SOFC with a CT, the methods and system architecture disclosed go beyond that goal and are applicable in a host of other contexts. The objectives of the inventing team were primarily to develop a system design which maximized system efficiency while eventually producing the system at an economically viable price point, and secondarily to minimize complexity and maximize robustness. Further, this technology is now expanded to encompass Solid Oxide Electrolyzer or Electrolysis Cells (SOEC's), which may be closely related to SOFC's and which effectively reverse the process to convert steam and electricity into hydrogen (which may be used as a fuel) and oxygen. Many of the embodiments disclosed herein are applicable to SOEC's as well as SOFC's, so, in this document SOFC is often used as a generic term which encompasses both SOFC's and SOEC's.
BRIEF DESCRIPTION OF THE FIGS.
FIG. 1 is an exemplary embodiment of a base system schematic.
FIG. 2 is an exemplary embodiment of a system schematic illustrating power export.
FIG. 3 is an exemplary embodiment of a system schematic illustrating startup and shutdown components.
FIG. 4 is an exemplary embodiment of a solid oxide fuel cell assembly and pressure vessel.
FIG. 5 is another exemplary embodiment of a solid oxide fuel cell assembly and pressure vessel.
FIG. 6 is an exemplary embodiment of a solid oxide fuel cell flow path.
FIG. 7 is an exemplary embodiment of a solid oxide fuel cell stack shelf.
FIG. 8 is an exemplary illustration of a conventional cathode flow and stack temperature distribution.
FIG. 9 is an exemplary illustration of a simplified representation of cathode flow and stack temperature distribution for one embodiment of the present technology.
FIG. 10 is an exemplary illustration of an example gradated flow distribution for one embodiment of the present technology.
FIG. 11 is an exemplary embodiment of an axial flow adjuster in one embodiment of the present technology.
FIG. 12 is an exemplary embodiment of an SOEC system schematic.
FIG. 13 is an exemplary illustration of a stack compression mechanism.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
It should be understood that embodiments include a variety of aspects, which may be combined in different ways. The following descriptions are provided to list elements and describe some of the embodiments of the application. These elements are listed with initial embodiments; however, it should be understood that they may be combined in any manner and in any number to create additional embodiments. The variously described examples and preferred embodiments should not be construed to limit the embodiments of the application to only the explicitly described systems, techniques, and applications. The specific embodiment or embodiments shown are examples only. The specification should be understood and is intended as supporting broad claims as well as each embodiment, and even claims where other embodiments may be excluded. Importantly, disclosure of merely exemplary embodiments is not meant to limit the breadth of other more encompassing claims that may be made where such may be only one of several methods or embodiments which could be employed in a broader claim or the like. Further, this description should be understood to support and encompass descriptions and claims of all the various embodiments, systems, techniques, methods, devices, and applications with any number of the disclosed elements, with each element alone, and also with any and all various permutations and combinations of all elements in this or any subsequent application.
Generally, electrochemical cell systems can be most basically understood as having first function and second function electrodes. One type of electrode can be considered as having a first function, and another type of electrode can be considered as having a second function. For example, from a fluid and chemical perspective one type of electrode cell collection can be what herein is termed an oxygen cell collection that has a function of conducting an oxygen-involved operation or function and another type of electrode cell collection can be termed a fuel cell collection that has a function of conducting a fuel-involved operation or function. In these types of first and second functions, either the oxygen-type or the fuel-type can be considered as the first function because such cells can operate in reverse orders. Further, the oxygen can serve to foster a fuel oxidation type of event, and the fuel can be an appropriately compatible substance, likely any hydrogen or carbon containing substance, often both such as a hydrocarbon containing substance. Similarly from an electrical perspective, the first and second functions can be those of a cathode and an anode where, again, either can be configured as the first function and the opposite one can be configured as the second function-types of electrode. As is known, electrodes can be layered or configured in stacks which may be comprised of pluralities of first function electrode elements and pluralities of second function electrode elements. As is known, such electrode stacks in these types of cell stacks have inlets and outlets for each of the two types of electrodes. Thus, the stacks may include a stack first function electrode inlet such as for the first function electrode stack, a stack first function electrode outlet again for the first function electrode stack, a stack second function electrode inlet such as for the second function electrode stack, and a stack second function electrode outlet also for the second function electrode stack. These type of inlets can be understood from FIG. 6 where the first function electrode element is configured as a cathode element in an oxygen stack and thus the first function electrode inlet is shown as the area at the beginning of the arrow as the cathode inlet ( 121 ) and the corresponding first function electrode outlet is shown as the area at the end of the arrow as the cathode outlet flowing into the outlet plenum ( 221 ). Similarly the second function electrode element, perhaps configured as an anode element in a fuel stack, could have a second function electrode inlet and a corresponding second function electrode outlet such as can be understood from FIG. 13 . These inlet and outlet areas an be manifolded as explained later.
Using a solid oxide fuel cell (SOFC) as an initial design, one embodiment of the base system schematic for the Solid Oxide Fuel Cell (SOFC) and Gas Turbine (GT) system is shown in FIG. 1 . This system ( 51 ) may be comprised of multiple components of course including the SOFC stacks ( 7 ). These are made up of individual electrochemical cells ( 52 ) fluidically connected in series, as one option, to form stacks ( 53 ), which may then electrically connect via interconnection ( 34 ) in series and/or parallel to produce part of the system's electrical power. An important aspect of SOFCs may be that the electrochemical reaction may be effectively exothermic. Whatever portion of the fuel's energy consumed within the stack is not converted into electricity, may be converted into heat which may be released into the stack and principally carried away by the anode and cathode streams. The SOFC stacks may be integrated into the middle of the gas turbine flow path ( 35 ) both to maximize system thermodynamic efficiency, and to enable the stacks ( 53 ) to operate under pressurized conditions in a pressurized area ( 36 ) to improve their electrochemical efficiency. In some embodiments other optimized benefits may also be present due to integrating SOFC stacks into the middle of the gas turbine flow path. Due to the mechanical design of the SOFC stacks they may operate with relatively low differential pressure between their interior ( 38 ) and exterior ( 40 ), as such they may be placed within a pressure vessel ( 9 ) pressurized by the cathode inlet flow ( 41 ) or operated under ambient pressure. This pressure vessel ( 9 ), or more generally, a containment vessel ( 9 ) can be configured to removably contain at least a portion of the plurality of connected individual electrochemical cell stacks, and may also serve as an intake plenum ( 43 ), or more precisely, a containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum such as for the first function electrode stack, in this embodiment depicted as element ( 43 ). In this manner the intake plenum ( 43 ) or containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum, can serve to ensure even flow distribution and to recover additional heat lost by hotter components within the pressure vessel ( 9 ) assembly.
As can be understood, by using the more generic terms first function and second function relative to the electrodes, various different configurations are encompassed. For example, the oxygen electrode elements can be configured in a stack. This stack of oxygen electrode elements can be considered a stack of first function electrode elements. And this can provide cathode elements. And the fuel electrode elements can also be configured in a stack and this stack of fuel electrode elements can be considered a stack of second function electrode elements, and furthermore, this stack can provide anode elements. This type of configuration could present a SOFC system. Electrically reversing functions, a stack of oxygen electrode elements can be considered a stack of first function electrode elements and can provide the anode elements, and the stack of fuel electrode elements can be considered a stack of second function electrode elements and can provide the cathode elements. This type of configuration could present a SOEC system. The chemically opposite can be true as well, a stack of fuel electrode elements can be considered a stack of first function electrode elements and can provide the cathode elements, and a stack of oxygen electrode elements can be considered a stack of second function electrode elements and can provide the anode elements. This type of configuration could present a SOEC system. Once again, electrically reversing the prior stated functions, a stack of fuel electrode elements can be considered a stack of first function electrode elements and can provide the anode elements, and a stack of oxygen electrode elements can be considered a stack of second function electrode elements and can provide the cathode elements. This type of configuration could present a SOFC system.
Electrochemical cell stacks may include a plurality of connected individual electrochemical cell stacks which may be connected fluidically, electrically, or most likely both. Here, for example, the plurality of connected individual electrochemical cell stacks can be configured as stacks selected from: series electrically connected electrochemical cell stacks; series fluidically connected electrochemical cell stacks; parallel electrically connected electrochemical cell stacks; parallel fluidically connected electrochemical cell stacks; and any permutations and combinations of the above even in a particular system. Thus in establishing a system for operation, configurations can be selected, purchased, operated, or even individually built so that the system can be considered as providing series electrically connected electrochemical cell stacks; providing series fluidically connected electrochemical cell stacks; providing parallel electrically connected electrochemical cell stacks; providing parallel fluidically connected electrochemical cell stacks; and any permutations and combinations of these.
Further, turbomachinery ( 1 , 2 , 3 ) may be an additional component within some systems. A compressor ( 2 ) and/or a turbine ( 3 ) can supply potentially required compressed air ( 44 ) from an air inlet ( 15 , 16 ) to support both the gas turbine cycle, as well as the SOFC. The turbine ( 3 ) can take the pressurized and heated exhaust stream ( 45 ) and can create mechanical power used, in part, to power the turbomachinery's compressor ( 2 ), while the turbine's remaining power may be converted into electricity via an electric generator ( 1 ). This motor/generator ( 1 ) may operate both as a generator to produce electricity while the system is operational, and as a motor to power the compressor ( 2 ) during startup and perhaps shutdown.
Due to physics, the turbine ( 3 ) may be unable to extract all the available heat from the combustor exhaust stream ( 45 ). To improve efficiency a turbine recuperator ( 4 ) may be added to transfer much of the remaining heat from the turbine exhaust ( 46 ) to the compressor exhaust ( 47 ) where it may be recirculated within the system ( 51 ) and also exhausted ( 17 ). The SOFC stacks ( 53 ) may require a relatively high operating temperature to facilitate the electrochemical reactions, and consequently the incoming cathode flow ( 41 ), such as from the compressor ( 2 ) may need to be pre-heated sufficiently to prevent undesirable cooling of the stack ( 53 ). Part of the electrochemical cell system may thus involve the step of utilizing a turbine recuperator ( 4 ) in part of a process. The turbine recuperator ( 4 ) may be capable of supplying some, or most, of this preheat depending on how the system ( 51 ) is operated. If the turbine inlet temperature is relatively high, and the turbine's pressure ratio relatively low (and consequently the turbine outlet temperature is high), then the turbine recuperator ( 4 ) may supply most of the preheat to the cathode inlet flow ( 41 ). However, if the turbine inlet temperature is lower, or the pressure ratio is higher, then the system may further include a cathode recuperator ( 5 ) which may be integrated into the system or may be utilized by the system ( 51 ) to transfer additional heat from the cathode outlet stream ( 48 ) to the inlet stream ( 41 ).
In some embodiments, the system ( 51 ) may be supplied by various, possibly gaseous fuels ( 49 ) including natural gas. In embodiments utilizing natural gas, the fuel ( 49 ) may first pass through a desulfurizer ( 14 ) to remove sulfur which could contaminate the catalyst in the SOFC, or may include a step of utilizing a desulfurizer or even desulfurizing to achieve the same. Further, fuel may be metered by a main natural gas valve ( 13 ), and may then enter the system ( 51 ) as the principal fuel source. In some embodiments it may be beneficial that the fuel be properly conditioned by some type of conditioner ( 50 ) before entering the SOFC stack ( 53 ) to ensure the stack ( 53 ) operates effectively and robustly as intended. In some embodiments, important considerations for the stack ( 53 ) as it relates to fueling may include: having the SOFC's electrochemical reaction predominantly directly consume hydrogen, and having the stack constructed with catalysts ( 54 ) which may convert such as methane and water into carbon monoxide and hydrogen in a strongly endothermic (heat absorbing) reaction which if it occurs in too great a concentration may cause overcooling and may damage through thermally induced stresses. Further, hydrocarbons higher than methane may have an increased propensity to cause detrimental carbon depositions (coking).
In some embodiments, a reformer ( 10 ) may be included in this system or may be involved as a step in the operation of the system ( 51 ) to condition the fuel ( 49 ) before it enters the SOFC stacks ( 53 ) to help address stack fueling issues. A reformer ( 10 ) may also be included as a catalyst reactor ( 55 ) which may support several reactions including reactions such as converting higher hydrocarbons and water into carbon monoxide and hydrogen, perhaps using endothermic reactions, converting methane and water into carbon monoxide and hydrogen, perhaps using the endothermic methane steam reforming reaction, and converting carbon monoxide and water into carbon dioxide and hydrogen using the exothermic water gas shift reaction. The water and heat required to facilitate these reactions may be supplied by: recirculating, such as by having a recirculation ( 56 ) of a portion of the anode effluent ( 57 ) (which may contain heat from the system, and water from the SOFC's electrochemical reaction); and mixing that recirculation with the fresh natural gas ( 58 ) which then may flow into the reformer ( 10 ). The reformer ( 10 ) may be an adiabatic (or near adiabatic, minimizing heat or mass transfer of the system) device in which the inlet gas ( 60 ) species and temperature, in conjugation with the equilibrium chemistry between the various reactions, may determine the composition and temperature at the reformer's outlet ( 61 ).
Flow recirculation ( 62 ) may be used by means of a recirculation blower ( 11 ) or an ejector. By setting the amount of anode effluent recirculation ( 57 ), the conditions at the reformer outlet ( 61 ) can be controlled. This flowrate may be set to ensure all higher hydrocarbons are cracked, that sufficient hydrogen is recirculated inflow recirculation ( 62 ) to prevent localized fuel depletion within the stacks ( 53 ), and to leave an appropriate amount of methane in the stream ( 48 ) to help cool the SOFC to enable more power to be produced, but not so much that the stacks ( 53 ) are overcooled and damaged. In an adiabatic design, the outlet of the reformer ( 10 ) may be significantly cooler than the inlet ( 63 ) due to endothermic reactions and may be heated up to the SOFC's operating temperature to prevent damage to the stacks ( 53 ). This may be accomplished with the anode heat exchanger ( 6 ) which may heat the anode inlet ( 64 , 421 ) with the cathode outlet stream ( 48 ). In such embodiments, the step of utilizing an anode heat exchanger ( 6 ) in part of the process may be included.
A fraction of the fuel ( 49 ) supplied to the SOFC may remain unconsumed as it leaves the stacks ( 53 ). Whatever fuel is not recirculated by the recirculation blower ( 11 ) may flow into a combustor ( 12 ), thus providing the step of utilizing a combustor ( 12 ), where it may be mixed with air or the like from the cathode exhaust in the cathode outlet stream ( 48 ), and burned. This combustion process may both consume the remaining fuel ( 65 ), and may further heat the already hot cathode exhaust in cathode outlet stream ( 48 ), which may then flow into the turbine ( 3 ) to extract a degree of the remaining power.
FIG. 2 is an exemplary embodiment of another SOFC-type system ( 51 ) with a schematic illustrating power export. FIG. 2 adds select components which may be beneficial to control and export power from the SOFC and motor/generator ( 1 ). Control of power flow to and from the motor/generator ( 1 ), and consequently turbomachinery speed, may be accomplished through power electronics ( 18 ) which may include a drive, perhaps a variable frequency drive ( 66 ). Similarly, the load placed on the SOFC, and consequently power produced by, and fuel consumed within, the stacks ( 53 ) may be accomplished through a separate set of power electronics ( 18 ). In some embodiments, the system ( 51 ) may be capable of exporting power either as DC or AC and in either islanding or grid-synced modes. In an embodiment exporting AC power, especially to voltages common in industrial settings such as 480V three phase, the voltages, such as from the motor generator ( 1 ), or a generator and the SOFC may need to be boosted by power electronics ( 18 ) to a higher level such as 750V. In the case of an AC system, an inverter ( 20 ) may be used to create the required frequency/voltage from the DC Bus. To stabilize the DC bus ( 19 ), batteries ( 21 ) may be connected to the bus through their own battery power electronics ( 67 ). For grid ( 22 ) connected systems, the system ( 51 ) may be operated in such a manner that the supervisory control system ( 68 ) (with or without operator input( 69 )) may command that a certain amount of power be generated and exported. However, for islanding systems, the system ( 51 ) may need to respond reactively to the external electric loads placed on it. In this case, to prevent the SOFC/GT system from undergoing rapid transients, batteries ( 21 ) may be used to supply the short-term electrical demands while the supervisory control system ( 68 ) slowly adjusts the power output from the system ( 51 ) to both supply external loads such as its grid ( 22 ) or otherwise, and to recharge the batteries ( 21 ) as required.
FIG. 3 is an exemplary embodiment of a SOFC-type system ( 51 ) schematic illustrating and including startup components ( 70 ) and shutdown components ( 71 ) which would be connected as those skilled in the art would well understand. In some embodiments, additional components may be beneficial to start up and shut down the system ( 51 ), and may be included as additional safety mechanisms, as shown in FIG. 3 . Once the system ( 51 ) is fully operational it may become thermally self-sustaining. However, to reach the point where the SOFC may begin to produce power (and generate excess heat) the stacks ( 53 ) may first need to be sufficiently heated. This heating may be accomplished primarily through a resistive pressure vessel startup pre-heater ( 27 ) attached directly to the pressure vessel ( 9 ). The pressure vessel ( 9 ) itself may be the largest thermal heat sink within the system ( 51 ) and may be pre-heated such as by pressure vessel startup pre-heater ( 27 ) to prevent heat being drawn from the stacks ( 53 ). As the pressure vessel's shell ( 8 ) heats up, so do all the components within the vessel (including the stacks ( 53 ) and piping). This approach can allow the system ( 51 ) to be smoothly heated without firing any other equipment. In some embodiments, an additional source of heat may also come from the cathode startup pre-heater ( 26 ) if desired.
In some embodiments, to start up the GT system ( 51 ) partially independent of the SOFC, the reformer ( 10 ) may be deired to be at the appropriate inlet conditions before fueling, and so a supplemental natural gas valve ( 28 ) may be included to supply fuel ( 49 ) directly to the combustor ( 12 ). Once the SOFC stacks ( 53 ) and reformer ( 10 ) exceed a certain temperature during startup and shutdown, the catalysts ( 54 ) may need to be protected from oxygen to prevent degradation. This may be accomplished through a purging system ( 72 ) with gas ( 30 ) which may primarily supply nitrogen to displace atmospheric or other oxygen. Secondarily, a small amount of hydrogen may be added to the flow via as a first reaction supplement ( 73 ) such as to create a reducing environment to consume any oxygen which may leak into the system (especially through the SOFC assembly). This purging flow ( 74 ) may be supplied into the system ( 51 ) during startup and shut down by a valve that introduces a flow of reducing gas( 29 ). Such a reducing gas can have a variety of compositions, including but not limited to compositions such as 5% (or other percentages) of H 2 in N 2 as but one example. For the reformer ( 10 ) to begin converting higher hydrocarbons to lower molecular weight species, and perhaps creating the hydrogen required to initialize the SOFC, some water ( 33 ) may first need to be mixed via a second reactor supplement ( 75 ) (with or without a first reactor supplement ( 73 )) with the fuel ( 49 ) before it enters the reformer. This may be accomplished via a startup steam generator ( 32 ) and metered by a H 2 O valve ( 31 ).
In support of system safety, several additional valves may be incorporated into the system. First, there may be a bleed air valve ( 23 ). This valve ( 23 ) may serve two key functions, but is not limited to these functions. First, in the event that the compressor ( 2 ) approaches a destructive stall/surge event, the valve ( 23 ) may be opened to increase flow from the compressor ( 2 ) and move the compressor condition away from its stall/surge condition or line. Second, in the event that the load on the motor/generator ( 1 ) is lost when the system ( 51 ) is operational, which could otherwise cause over speeding of the turbomachinery, ( 1 , 2 , 3 ) the bleed air bypass valve ( 23 ) may be opened to add additional load to the compressor to compensate for the loss of the generator load. A hot air bypass valve ( 25 ) may be added to allow flow from the compressor ( 2 ) via compressor exhaust to largely bypass the SOFC during startup and shutdown. As this hot air bypass valve ( 25 ) may then be slowly closed so an increasing percentage of flow from the hot air bypass compressor as compression exhaust ( 47 ) may be diverted through the SOFC until all flow passes through the compressor to the SOFC path once the valve ( 25 ) is fully closed. In some embodiments, a cold air bypass valve ( 24 ) may be added to the system to bypass flow around the turbine recuperator ( 4 ) to help further control temperatures within the system.
Note that the components and configuration described above are not an exhaustive list of all components required or possible for operation or system configurations. In certain embodiments the present technology may include but is not limited to select variants on the system architecture detailed below:
The recirculation blower ( 11 ) may be replaced by an ejector ( 78 ). An ejector ( 78 ) can be a device which may entrain flow from a suction port by accelerating then decelerating flow from a motive stream. In this case the motive flow, and the power to drive the ejector, ( 78 ) may come from the incoming fuel or perhaps natural gas flow ( 77 ) while the suction port could be connected to the anode outlet ( 29 , 521 ) or anode manifold outlet ( 79 ). This approach has the potential to be cheaper and more robust than the recirculation blower, ( 11 ) however it removes one control variable and may be less efficient. The number of SOFT stacks, ( 53 ) and their electrical configuration and type, is completely variable based on the desired system efficiency and cost. Similarly, the power produced by the turbomachinery ( 1 , 2 , 3 ) relative to the SOFC is variable. The reformer ( 10 ) may be isothermal (e.g., external heat transfer maintains the internal gas at a constant temperature) rather than adiabatic. In this case the amount of external reforming could likely be reduced resulting in less methane to cool the stack ( 53 ). However, under certain conditions this may be desirable and would also eliminate the need for an anode heat exchanger ( 6 ). If sufficient heat is present in the turbine outlet, or turbine exhaust, ( 46 ) via the GT flow path ( 35 ), or sufficient heat may passively be transferred from the components within the pressure vessel ( 9 ) to the cathode inlet stream, or flow ( 41 ) then the cathode recuperator may be able to be removed. Removing this component may be desirable as it may add additional pressure drop (e.g., power loss) to the system ( 51 ) as well as additional external heat loss (due to the increased surface area) and added system cost. The cathode pre-heater ( 26 ) may be removed and only the pressure vessel pre-heater ( 27 ) used. This may reduce the response time of adding additional heat into the gas flow, but it can remove a component (added cost) and can reduce the pressure drop through the system ( 51 ). The hot and cold air bypass valves ( 25 , 24 ) may potentially be removed depending on the control strategies employed for startup, shutdown, and load transients. This system ( 51 ) may also be powered by alternative fuels, ( 49 ) and alternate fuel streams, or incoming fuel flows ( 77 ). If a hydrogen fuel stream was available, then the reformer ( 10 ) could be eliminated, and the hydrogen used directly. With a change in the reformer ( 10 ) formulation, other hydrocarbon fuels may also be used. The fuel stream or flow ( 77 ) may be pre-heated via the system's exhaust ( 17 ) or exhaust gas stream or through a heat exchanger with any other flow path in the system. The system may be operated unpressurized rather than pressurized. The system may operate in reverse such as in converting steam (or steam and carbon dioxide) and electricity into oxygen and hydrogen (or hydrogen and carbon monoxide) as part of an SOEC system, as those skilled in the art would readily understand.
In some embodiments, due to the SOFC (and SOEC) stack's ( 53 ) mechanical design, systems ( 51 ) may generally have roughly the same internal and external pressures to minimize the mechanical stress and stack leakage which could otherwise be induced by a differential pressure. As the stacks ( 53 ) within the SOFC/GT system operate under pressure, this may necessitate housing the stacks within a pressure vessel ( 9 ). Given that the stacks ( 53 ) are hot, and may be placed within a pressure vessel, ( 9 ) careful design is beneficial in creating the system ( 51 ). Some of the considerations in this regard may include:
To ensure consistent operation, the cathode and anode flow distribution between the various stacks ( 53 ) may need to be uniform. This may be difficult to achieve due to the complexity of manifolding all the stacks ( 53 ) in a confined area while also minimizing pressure drop (which has a direct impact on system efficiency). To maximize efficiency, it may be essential that the pressure vessel ( 9 ) is well insulated against external heat losses and this has specific sub considerations:
The pressure vessel ( 9 ) may be pressurized by a gas turbine ( 3 ) meaning there may be a pressuring at flow path ( 80 ) between the two elements. Prior work has shown that any insulation within the pressure vessel ( 9 ) has the potential to become dislodged and enter the turbine ( 3 ) or other components which can be damaged. As the system ( 51 ) is shutting down the pressure within the pressure vessel ( 9 ) drops. If this occurs too rapidly any insulation within the pressure vessel may undergo explosive decompression as the air trapped within and behind the insulation expands, that may result in damage to the insulation The mechanical structure within the pressure vessel ( 9 ) can be quite complex and may be difficult to insulate.
Any leaks of hydrogen or other fuels into the pressure vessel ( 9 ) may potentially become quite dangerous, especially if they were to accumulate to explosive levels within a portion of the pressure vessel ( 9 ) without much air flow or become trapped and concentrated within a section of internal insulation. As the system ( 51 ) heats up to operating temperature, significant thermal growth often occurs causing all the stacks ( 53 ) to move away from one another. This may pose challenges for any manifolding and support structure within the pressure vessel ( 9 ). It may be beneficial to carefully design the system ( 51 ) to ensure that the thermal growth of components inside the vessel ( 9 ) do not cause thermally induced stresses that may damage the hardware. During shutdown there may be a potential for compressed cathode air to flow backwards through the compressor ( 20 ) as the internal pressurized gas expands and escapes back to atmosphere. If flow through the cathode portion of the stack ( 53 ) is reversed during this event, and combustion products enter the stack, ( 53 ) this may damage the SOFC. The stacks may require a compression force to prevent the individual cell layers from separating. A compression mechanism ( 81 ) may be required to also survive as the stack thermally expands to operating temperature, and more challengingly survive the hot conditions within the stack ( 53 ) or pressure vessel ( 9 ) without adversely affecting the compression force.
FIG. 4 is an exemplary embodiment of a solid oxide fuel cell assembly ( 82 ) and pressure vessel ( 9 , 100 ). In such a system, some of the above considerations may be taken into account such as in the pressure vessel embodiment shown in FIG. 4 . As implemented here, it may be beneficial to utilize the pressure vessel ( 100 ) which may be a âcontainment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenumâ itself as the cathode intake plenum ( 200 ). This may provide several advantages including ensuring a uniform flow distribution between the various stacks, ( 53 ), ensuring a unform flow distribution within each stack between the various cells ( 52 ), and the like. It can also eliminate the sizable cathode manifolding which may otherwise be required to distribute flow to or from the various stacks ( 53 ). With this design, all components within the pressure vessel ( 100 ) may be surrounded by cathode inlet flow ( 41 ) before this flow enters the stacks ( 53 ). This may allow the cathode inlet flow ( 41 ) to recover a degree of heat from the surrounding components which may otherwise be lost. This may also serve to add additional heat to the incoming cathode air of the cathode inlet flow ( 41 ) and may eliminate an otherwise costly cathode recuperator ( 5 ).
As especially shown in FIG. 13 , configurations can be selected, purchased, operated, or built so that the system can be considered as establishing a âcontainment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenumâ and even providing a plenum that accomplishes the steps of fully surrounding and containing each of the plurality of stack first function electrode inlets.
In further embodiments, a system may be configured to also or separately fully surround and contain the plurality of stack second function electrode outlets. Further, systems can include a variety of manifolds. There can be: a first function electrode outlet manifold likely connected to each of the stack first function electrode outlets; a second function electrode inlet manifold likely connected to each of the stack second function electrode inlets; and a second function electrode outlet manifold likely connected to each of the stack second function electrode outlets. Similarly, configurations can be selected, purchased, or built so that the system can be considered as establishing a first function electrode outlet manifold, connecting the first function electrode outlet manifold to each of the stack first function electrode outlets, establishing a second function electrode inlet manifold, and connecting the second function electrode inlet manifold to each of the stack second function electrode inlets, and establishing a second function electrode outlet manifold, and connecting the second function electrode outlet manifold to each of the stack second function electrode outlets. When such manifolds are included, the system can be configured to accomplish the steps of surrounding at least a portion of the second function electrode inlet manifold, and surrounding at least a portion of the second function electrode outlet manifold. Other embodiments may also include a âcontainment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenumâ configured to surround each of the second function electrode inlet manifold, and the second function outlet manifold. Further embodiments may be configured to establish a substantially equivalent environmental intake condition for each of the plurality of first function electrode elements or may include a step of establishing a substantially equivalent environmental inlet condition for each of the first function electrode elements.
In some embodiments with the cathode inlet flow ( 41 ) surrounding all the components, the internal temperatures may range between 750-850° C. with the cooler temperatures exterior to the stack, ( 53 ) and the hotter temperatures at the stack's ( 53 ) outlet ( 83 ) (due to the heat released within the SOFC). This approach is referred to here as the âhot pressure vesselâ concept. With this embodiment all or most of the insulation ( 300 ) may now be placed on the pressure vessel's exterior. This may have several advantages including greatly simplifying the insulation's ( 300 ) design (e.g., it may be placed around a relativity smooth cylindrical body, rather than surrounding the intricate components within the pressure vessel ( 100 )). Placing the insulation outside of the pressure vessel ( 100 ) may eliminate the possibility of the insulation ( 300 ) experiencing explosive decompression or otherwise entering the air stream and damaging components within the system ( 51 ). Similarly, by not placing the insulation ( 300 ) within the pressure vessel, hydrogen and other fuels cannot become trapped within the insulation ( 300 ) creating a potential hazard. Further, any hydrogen which leaks from the anode manifolding into the pressure vessel ( 100 ) may immediately combust due to the presence of oxygen in the cathode intake plenum containing the cathode inlet flow ( 41 ) well above hydrogen's autoignition temperature of 585° C. (while this sounds dangerous, it may be preferable to a large amount of fuel collecting and detonating within the pressure vessel ( 100 )).
In another embodiment, another advantage of the hot pressure vessel concept is that the majority of the system's capacitance (volume) may be held within the cathode intake plenum containing the cathode inlet flow ( 41 ). During a rapid depressurization, flow may leave through both the GT's compressor ( 2 ) and turbine ( 3 ). However, as the cathode intake plenum containing the cathode inlet flow ( 41 ) may be the largest reservoir of compressed air, this air may flow both through the stack ( 53 ) to the turbine, ( 3 ) and backwards to the compressor ( 2 ). As such, reverse flow through the stacks ( 53 ) should not occur.
FIG. 5 is another exemplary embodiment of a solid oxide fuel cell assembly ( 82 ) and pressure vessel ( 9 ). In some embodiments, as the system heats to operating temperature, all components within a heated area, perhaps within the pressure vessel ( 9 ), may expand away from one another. To address this, embodiments can include a fully accommodative thermal expansion-contraction electrochemical cell stack mount. Through such a mount, the system may be capable of substantially fully, or fully accommodatively thermally expanding and contracting the plurality of connected individual electrochemical cell stacks within the containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum as temperatures change to and from ambient to maximum operating temperature. As also shown in FIG. 5 , beyond just accommodating thermal expansion and contraction of the stacks, embodiments can have elements to address expansion and contraction of manifolds as well. As shown in FIG. 5 , the pressure vessel ( 9 ), and even the stack first function electrode inlet plenum ( 43 ), may be sized to include not only any or all (as shown) of the various manifolds, but each of their thermal expansions and contractions. In such an embodiment, the manifolds can be totally, mostly, or partially within the containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum. Further the manifolds can be designed as substantially fully accommodative thermal expansion-contraction manifolds such as with accordion type expansion tubes, expansion joints, or other known elements. Further, the pressure vessel ( 9 ) or stack first function electrode inlet plenum ( 43 ) can have a fully dimensionally accommodative thermal expansion-contraction interior space. And, as can be understood from FIG. 13 where only some of the manifold(s) is/are inside the plenum (such as anode inlet manifold ( 89 ) and anode outlet manifold ( 90 )), systems can be operated to achieve any or all of the steps of: substantially fully accommodatively thermally expanding and contracting at least a portion of a second function electrode inlet manifold within the containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum; substantially fully accommodatively thermally expanding and contracting at least a portion of the second function electrode outlet manifold within said containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum; or the like with respect to any of the manifolds.
As mentioned above, embodiments can include a fully accommodative thermal expansion-contraction electrochemical cell stack mount. This can accommodate expansion-contraction of the stacks themselves. As shown in FIGS. 4 , 5 and 6 , embodiments may include mounting all the stacks ( 53 ) on a manifold, perhaps such as the cathode outlet manifold ( 111 ) which then may act as a principal support structure (as shown in FIG. 5 ) with or without a shelf on the manifold. More generally, embodiments of the invention may be configured to include any or all of: a substantially singular thermal expansion coefficient mount, a manifold stack mount, and/or a stack shelf on which each of the plurality of connected individual electrochemical cell stacks may be mounted. A manifold stack mount, one examples of which can be the cathode outlet manifold ( 111 ) used as a mount as shown, may be a first function electrode outlet manifold stack mount, a second function electrode inlet manifold stack mount, or a second function electrode outlet manifold stack mount. The step of mounting the plurality of connected individual electrochemical cell stacks by a substantially singular thermal expansion coefficient mount, such as by using a singular material, may allow more uniform expansion-contraction to be accommodated. Additionally, in operating a system the step of utilizing a manifold stack mount may be achieved, and this may include utilizing a first function electrode outlet manifold stack mount, utilizing a second function electrode inlet manifold stack mount, or utilizing a second function electrode outlet manifold stack mount. There may be multiple benefits to configurations generally having an electrochemical cell support manifold, and perhaps: an electrochemical cell support outlet manifold or achieving the step of supporting the electrochemical cell stacks by a first function electrode outlet manifold; having a first function electrode outlet manifold stack mount; establishing a first function electrode outlet manifold stack mount; having a substantially fully accommodative thermal expansion-contraction second function electrode outlet manifold; or substantially fully accommodatively thermally expanding and contracting the second function electrode outlet manifold within the containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum. First, using but one example, as nothing is constraining the cathode outlet manifold ( 111 ) from expanding along the length of the pressure vessel, ( 9 ) it may be free to expand without inducing internal mechanical stresses. This may eliminate the need for expensive expansion joints on the cathode side in this design. Second, by incorporating both the cathode outlet manifold, ( 111 ) and the stack support structure, into a single component such as the pressure vessel ( 9 ), the system's complexity, size, and cost may be reduced. Additionally, the cathode outlet manifold ( 111 ) may support the stack assembly ( 82 ) when the structure is cooled, and the pressure vessel body retracted such as on a roller element ( 222 ) via a step of rolling componentry within a containment vessel, on a slide element (such as shown in FIG. 4 ) via a step of sliding componentry with a containment vessel, or some other type of interface, enabling easy access.
Also visible in FIG. 5 is one potential supporting and mounting structure ( 333 ) approach for the stacks ( 53 ). Two (or more/less) stacks ( 53 ) may be mounted loosely to a shelf ( 334 ) (allowing for thermal growth), with a total of three shelfs (though more or less are possible) are shown in FIG. 5 . In some embodiments, this may include a stack shelf on which each of the plurality of connected individual electrochemical cell stacks are mounted or may include the step of utilizing a stack shelf on which each of the plurality of connected individual electrochemical cell stacks are mounted. In some embodiments, these shelves ( 334 ) may then be mounted to the cathode outlet header ( 335 ) of the cathode outlet (or other) manifold ( 111 ). A cross-sectional view of the shelf ( 334 ) and mounting structure ( 533 ) is shown in FIG. 6 . This shows how the cathode inlet and flow ( 121 ) enters though the front of the stacks, ( 53 ) and then flows into an outlet plenum ( 221 ) where flows from two stacks may be combined before exiting into the cathode outlet manifold ( 321 ).
Due to the SOFC stacks' ( 53 ) design (alternating anode, electrolyte, cathode, current collector, flow path, and seal layers fused together) a compressive load may be required to prevent separation of the various elements due to thermal expansion and pressure forces. This is shown as a gravity load in FIGS. 4 , 5 , 6 and 11 , and a spring compressive load in FIGS. 7 and 13 . To prevent damage to the stack, several hundred pounds (a few hundred kilograms) of compressive force may be required. This force (within some bounds) may be maintained from the point when the stack ( 53 ) is first fused together during assembly, though transport and installation, all the way to operating temperature within the SOFC/GT system, ( 51 ) and back down to ambient temperature. This challenge is exacerbated by the high temperature environment which the compre
CLAIMS
Claims ( 24 )
What is claimed is:
1 . An electrochemical cell system for use in either power generation or electrolysis modes comprising:
a plurality of connected individual electrochemical cell stacks, each of said plurality of connected individual electrochemical cell stacks comprising:
a plurality of first function electrode elements;
a plurality of second function electrode elements;
a stack first function electrode inlet;
a stack first function electrode outlet;
a stack second function electrode inlet;
a stack second function electrode outlet,
a first function electrode outlet manifold connected to each of said stack first function electrode outlets; a substantially fully accommodative thermal expansion-contraction second function electrode inlet manifold connected to each of said stack second function electrode inlets; a substantially fully accommodative thermal expansion-contraction second function electrode outlet manifold connected to each of said stack second function electrode outlets; a containment vessel configured to removably contain at least a portion of said plurality of connected individual electrochemical cell stacks; and a fully dimensionally accommodative thermal expansion-contraction containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum configured to establish a substantially equivalent environmental intake condition for each of said plurality of first function electrode elements.
2 . An electrochemical cell system as described in claim 1 and further comprising:
an at least part vessel external compressive stack mount; and
a thermal barrier configured to substantially thermally isolate said at least part vessel external compressive stack mount.
3 . An electrochemical cell system as described in claim 1 and further comprising an electrochemical cell support manifold.
4 . An electrochemical cell system as described in claim 3 wherein said electrochemical cell support manifold comprises a manifold stack mount selected from:
a first function electrode outlet manifold stack mount;
a second function electrode inlet manifold stack mount; and
a second function electrode outlet manifold stack mount.
5 . An electrochemical cell system as described in claim 1 wherein said electrochemical cells comprise electrical power generation electrochemical cells.
6 . An electrochemical cell system as described in claim 1 wherein said electrochemical cells comprise gaseous substance generation electrochemical cells.
7 . An electrochemical cell system as described in claim 6 and further comprising a steam input.
8 . An electrochemical cell system as described in claim 7 and further comprising substantially fully accommodative thermal expansion-contraction electrochemical cell slide element.
9 . An electrochemical cell system as described in claim 1 and further comprising at least one electrochemical cell stack axial flow adjuster.
10 . An electrochemical cell system as described in claim 9 wherein said at least one electrochemical cell stack axial flow adjuster comprises at least one gradated distribution plate.
11 . An electrochemical cell system for use in either power generation or electrolysis modes comprising:
a plurality of connected individual electrochemical cell stacks, each of said plurality of connected individual electrochemical cell stacks comprising:
a plurality of first function electrode elements;
a plurality of second function electrode elements;
a stack first function electrode inlet;
a stack first function electrode outlet;
a stack second function electrode inlet;
a stack second function electrode outlet,
a containment vessel configured to removably contain at least a portion of said plurality of connected individual electrochemical cell stacks; and a containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum.
12 . An electrochemical cell system as described in claim 11 wherein each of said first function electrode elements comprise oxygen electrode elements, and wherein each of said second function electrode elements comprise fuel electrode elements.
13 . An electrochemical cell system as described in claim 12 and further comprising substantially fully accommodative thermal expansion-contraction manifolds, and wherein said containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum comprises a fully dimensionally accommodative thermal expansion-contraction interior space.
14 . An electrochemical cell system as described in claim 11 wherein said containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum is configured to establish a substantially equivalent environmental intake condition for each of said plurality of first function electrode elements.
15 . An electrochemical cell system as described in claim 14 and further comprising a first function electrode outlet manifold.
16 . An electrochemical cell system as described in claim 14 and further comprising a substantially singular thermal expansion coefficient mount.
17 . An electrochemical cell system as described in claim 14 and further comprising a compressive stack mount.
18 . An electrochemical cell system as described in claim 17 wherein said compressive stack mount comprises an at least part vessel external compressive stack mount.
19 . An electrochemical cell system as described in claim 18 wherein said at least part vessel external compressive stack mount comprises an at least part vessel external spring element.
20 . An electrochemical cell system as described in claim 18 and further comprising a thermal barrier configured to substantially thermally isolate said at least part vessel external compressive stack mount.
21 . An electrochemical cell system as described in claim 11 wherein said electrochemical cells comprise electrochemical cells selected from: proton exchange membrane cells, direct methanol cells, alkaline cells, phosphoric acid cells, molten carbonate cells, solid oxide cells, solid oxide protonic conducting cells, and high temperature proton exchange membrane cells.
22 . An electrochemical cell system as described in claim 11 and further comprising a fully accommodative thermal expansion-contraction electrochemical cell stack mount.
23 . An electrochemical cell system as described in claim 11 and further comprising at least one electrochemical cell stack axial flow adjuster.
24 . An electrochemical cell process comprising the steps of:
providing a plurality of connected individual electrochemical cell stacks, said plurality of connected individual electrochemical cell stacks each stack having:
a plurality of first function electrode elements;
a plurality of second function electrode elements;
a stack first function electrode inlet;
a stack first function electrode outlet;
a stack second function electrode inlet; and
a stack second function electrode outlet,
fully containing said plurality of connected individual electrochemical cell stacks by a containment vessel; and establishing a containment vessel interior space multiple electrochemical cell stack, stack first function electrode inlet plenum within which is contained said plurality of stack first function electrode inlets.
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