Fuel composition transients in solid oxide fuel cell gas turbine hybrid systems for polygeneration applications

Abstract

The potential of Solid Oxide Fuel Cell Gas Turbine (SOFC/GT] hybrid systems for fuel flexibility makes this technology greatly attractive for system hybridization with various fuel processing units in advanced power generation systems and/or polygeneration plants. Such hybrid technologies open up the possibility and opportunities for improvement of system reliabilities and operabilities. However, SOFC/GT hybrid systems have not yet reached their full potential in term of capitalizing on the synergistic benefits of fuel cell and gas turbine cycles. Integrating fuel cells with gas turbine and other components for transient operations increases the risk for exposure to rapid and significant changes in process dynamics and performance, which are primarily associated with fuel cell thermal management and compressor surge. This can lead to severe fuel cell failure, shaft overspeed, and gas turbine damage. Sufficient dynamic control architectures should be made to mitigate undesirable dynamic behaviours and/or system constraint violations before this technology can be commercialized. But, adequate understanding about dynamic coupling interactions between system components in the hybrid configuration is essential. Considering this critical need for system identification of SOFC/GT hybrid in fuel flexible systems, this thesis investigates the dynamic performance of SOFC/GT hybrid technology in response to fuel composition changes. Hardware-based simulations, which combined actual equipment of direct-fired recuperated gas turbine system and simulated fuel cell subsystem, are used to experimentally investigate the impacts of fuel composition changes on the SOFC/GT hybrid system, reducing potentially large inaccuracies in the dynamic study. The impacts of fuel composition in a closed loop operation using turbine speed control were first studied for the purpose of simplicity. Quantification of safe operating conditions for dynamic operations associated with carbon deposition and compressor stall and surge was done prior to the execution of experimentation. With closed loop tests, the dynamic performance of SOFC/GT hybrid technology due to a transition in gas composition could be uniquely characterized, eliminating the interactive effects of other process variables and disturbances. However, for an extensive system analysis, open loop tests (without turbine speed control] were also conducted such that potential coupling impacts exhibited by the SOFC/GT hybrid during fuel transients could be explored. Detailed characterization of SOFC/GT dynamic performance was performed to identify the interrelationship of each fuel cell variable in response to fuel composition dynamics and their contributions to operability of the system. As a result of lowering LHV content in the fuel feed, which involved a transition from coal-derived syngas to humidified methane composition in the SOFC anode, the system demonstrated a dramatic transient increase in fuel cell thermal effluent with a time scale of seconds, resulting from the conversion of fuel cell thermal energy storage into chemical energy. This transient was highly associated with the dynamics of solid and gas temperatures, heat flux, heat generation in the fuel cell due to perturbations in methane reforming, water-gas shifting, and electrochemical hydrogen oxidation. In turn, the dramatic changes in fuel cell thermal effluent resulting from the anode composition changes drove the turbine transients that caused significant cathode airflow fluctuations. This study revealed that the cathode air mass flow change was a major linking event during fuel composition changes in the SOFC/GT hybrid system. Both transients in cathode air mass flow and anode composition significantly affected the hybrid system performance. Due to significant coupling between fuel composition transitions and cathode air mass flow changes, thermal management of SOFC/GT hybrid systems might be challenging. Yet, it was suggested that modulating cathode air flow offered promise for effective dynamic control of SOFC/GT hybrid systems with fuel flexibility.