international journal of hydrogen energy xxx (xxxx) xxx

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Simulation of hydrogen and coal gas fueled

flat-tubular solid oxide fuel cell (FT-SOFC)

Fethi Mustafa Cimen a,*, Berre Kumuk a,b, Mustafa Ilbas a

a
Gazi University, Department of Energy Systems Engineering, Ankara, Turkey
b
Tarsus University, Department of Mechanical Engineering, Mersin, Turkey

highlights

The performance of the FT-SOFC was investigated in terms of different operating temperatures and different fuel usage.

A higher power was obtained compared to coal gas feed as a result of FT-SOFC's running with hydrogen feed.

Analyzes at different temperatures showed that the FT-SOFC performance improved with the increase in temperature.

It has been observed that the fuel type and the operating temperature have a significant effect on FT-SOFC performance.

article info abstract

Article history: Solid oxide fuel cells (SOFCs) are considered an important technology in terms of high
Received 4 May 2021 efficiency and clean energy generation. Flat-tubular solid oxide fuel cell (FT-SOFC) which is
Received in revised form a combination of tubular and planar cell geometries stands out with its performance values
29 July 2021 and low costs. In this study, the performance of an FT-SOFC is analyzed numerically by
Accepted 31 July 2021 using finite element method-based design as a result of changing parameters by using
Available online xxx different fuels which are pure hydrogen and coal gas with various proportions of CO. In
addition, cell performance values for different temperatures were analyzed and inter-
Keywords: preted. Analyzes have been performed by using COMSOL Multiphysics software. The rates
Flat-tubular of CO composition used are 10%, 20%, and 40%, respectively. In addition, the air was used
Solid oxide fuel cell as the oxidizer in all cases. The cell voltage and average cell power of the FT-SOFC were
Numerical analysis examined under the 800  C operating condition. The maximum power value and current
density value were obtained as 710 W/m2 and 1420 A/m2 for the flat-tubular cell, respec-
tively. As a result of the study, it was observed that the maximum cell power densities
increased with increasing temperature. Analysis results showed that FT-SOFCs have
suitable properties for different fuel usage and different operating temperatures. High-
performance values and design features in different operating conditions are expected to
make FT-SOFC the focus of many studies in the future.
© 2021 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.

* Corresponding author.
E-mail address: fethimustafacimen@gazi.edu.tr (F.M. Cimen).
https://doi.org/10.1016/j.ijhydene.2021.07.231
0360-3199/© 2021 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.

Please cite this article as: Cimen FM et al., Simulation of hydrogen and coal gas fueled flat-tubular solid oxide fuel cell (FT-SOFC), In-
ternational Journal of Hydrogen Energy, https://doi.org/10.1016/j.ijhydene.2021.07.231
2 international journal of hydrogen energy xxx (xxxx) xxx
Introduction
Fuel cells used in many power generation systems are effi-
cient and clean devices that transform the energy of a fuel into
electrical work through electrochemical reactions without
any combustion process. Fuel cells consist of an electrolyte
and two electrodes called cathode and anode around this
layer. There are different types of fuel cells, depending on the
type of electrolyte they use, the temperature range in which
the cell operates, and the type of electro-chemical reactions
that ocur [1]. However, SOFCs stand out in high-temperature
applications [2]. SOFCs can also be designed in different ge-
ometries. The flat-tube geometry enables the sealing property
in a SOFC. Also, a reduction in cell resistance can be achieved
with additions to the cell structure and the cathode layer can
be thinner to reduce concentration losses. When compared
with other geometries, the control of the level of ohmic losses
could not be achieved at this level [3]. Another feature of FT-
SOFCs is that the space between the cell stacks is minimized
and becomes more compressed due to the shape of the cell [4].
Studies in the literature have mainly been done using planar
and tubular geometries. However, there are fewer studies on
flat-tube geometries. For this reason, it is aimed to contribute
to the literature by choosing the flat-tube model in the study.
The performance of a fuel cell is greatly influenced by the
properties of the material used as electrolytes, cell designs,
electrodes, and manufacturing processes. In previous studies,
different materials have been investigated as supporting
components of SOFCs. Yttria stabilized zirconia, LSM, and Ni/
YSZ cermets were identified as the most commonly used
electrolyte, cathode, and anode materials. The studies on fuel
cells, it is aimed to increase efficiency and provide material
diversity, as well as commercialization and cost reduction.
There are many theoretical [5e9] and experimental [10e13]
studies on this subject in the literature. Besides, COMSOL is a
frequently used program in solid oxide fuel cell modeling
_
[14e17]. Ilbas ‚ and Kümük developed a model that includes
conservation laws and analyzes the performance of SOFCs
with different support points numerically as a result of
changing parameters. They showed that the cathode-
supported SOFC had better operating characteristics in
terms of operating parameters and support thickness [18].
Hussain et al. have modeled and simulated using COMSOL
Multiphysics software in their studies. A SOFC design with a
planar structure suitable for medium-temperature operations
has been made. The simulations performed revealed the
improved performance of the SOFC. It is seen that the
maximum power value is between 3.3 and 4 kW/m2 as a result
of the significant increase in temperature and remains high.
The results showed that the current density ranges from 6700
to 5500 A/m2 with a temperature increase [19]. Park et al. have
developed an anode-supported FT-SOFC with a conductive
and dense interconnection film. The interconnection exhibi-
ted low resistance and high stability in both parts. The anode-
supported flat-tubular cell with ceramic interconnection
showed a high power density of 360 mW/cm2 at 850  C [20].
Colclasure et al. have developed an anode-supported tubular
SOFC model. They observed the temporal profiles of chemical
composition, temperature, velocity, and current density on
Please cite this article as: Cimen FM et al., Simulation of hydrogen and coal gas fueled flat-tubular solid oxide fuel cell (FT-SOFC), In-
ternational Journal of Hydrogen Energy, https://doi.org/10.1016/j.ijhydene.2021.07.231
cell performance through physically-based conservation and
heat transfer equations [21]. Razbani et al. have created a
comprehensive numerical model of a planar cross-flow elec-
trolyte supported SOFC. They concluded that methane-free
biogas provides a better current density distribution across
_
the cell than hydrogen [22]. Ilbas ‚ and Kümük investigated the
effects of changing parameters on cell properties in the
cathode supported SOFC model. As a result of the study, they
proved that coal gases with low calorific values can be used as
fuel input in SOFCs. They also showed that as temperature,
pressure, and hydrogen concentration increased, the power
density of the fuel cell similarly increased [23]. Kemm et al.
investigated the applicability of planar and tubular cells for
constant power generation by examining their thermal and
electrochemical performance under different operating con-
ditions. In addition to power density transitions in fuel cells,
they compared the relaxation times and transient tempera-
ture gradients in the cell [24]. Zhang et al. investigated the
performance and stability of a large FT-SOFC with symmet-
rical double-sided cathodes directly filled with methane. As a
result of the study, they concluded that the thick anode sup-
port and internal channels of the double-sided cathode
formed an efficient microreactor for steam reforming and
methane-CO selectivity was achieved with a high conversion
rate [25]. Afshari and Barzi observed the dynamic response of
two SOFCs to change in inlet air mass flow rate. They devel-
oped a dynamic model based on computational fluid dy-
namics principles for planar and tubular SOFC design. They
concluded that the effect of inlet airflow conditions on tubular
SOFC performance was more pronounced than their effect on
a planar SOFC [26]. Suzuki et al. produced 1.3 cm wide and
0.2 cm thick micro FT-SOFCs using dip coating and a cost-
effective extrusion method. The cell was examined up to the
operating temperatures at 700  C and illustrated a power
density of 0.1 and 0.55 W/cm2 by using hydrogen as a fuel,
respectively. The effect of fuel flow rate was also investigated
at different operating temperatures and its strong effect at
higher operating temperatures was concluded [27]. Park et al.
focused on the issue of convection and electrochemical re-
actions in their study using numerical methods. The numer-
ical results have formed an estimate of the physical properties
of the geometry, electrochemical reaction models, and valid
equations. It was stated that the cell power of FT-SOFC
increased due to the decrease in the activation threshold in
electrochemical reactions with the increase in temperature.
Also, it was emphasized that thickening the support layer for
the case of strengthening the cell mechanics will decrease the
transfer rate in flow and increase the polarizations. This sit-
uation negatively affects cell performance. Increasing the
hydrogen concentration results in a higher rate of mass
transfer. Thus, it was reported that FT-SOFC provides more
uniform and higher current density distribution [28].
Several studies regarding experimental and numerical
modeling of different SOFC's types are mentioned above.
Among the others, flat-tube geometry enables a reduction in
cell resistance and low concentration losses. Also, they have
control of the level of ohmic losses. However, there is very little
done on flat-tube SOFC powered with hydrogen and different
fuels. Consequently, in this numerical study, a FT-SOFC model
was developed to observe the effect of temperature change
 international journal of hydrogen energy xxx (xxxx) xxx 3

and fuel type on cell performance. The main purpose of the where r is the density, ε represents porosity, keff stands for
study is to determine the effect of changing parameters on the effective thermal conductivity, T is temperature, ST represents
power and voltage values of the fuel cell geometry created overvoltage.
based on three-dimensional mathematical modeling. The Mass conservation is determined by the following
performance of FT-SOFC was investigated at different oper- equation,
ating temperatures (800  C, 900  C, and 1000  C) and fueled by  " !#
different fuels which are contained different CO percentages. v rCk v  v vCk vCk
þ grui C ¼
k
rDeff
k
þ (4)
As a result of these analyzes, performance curves were drawn vt vxi vxi vxj vxi
and the hydrogen and oxygen mole fractions were examined.
This study forms the basis for future experimental studies. where r is the density of the gas mixture and u is the velocity.
C shows the species concentration, Deff shows the effective
diffusivity.
Mathematical model The electrochemical reactions occurring in the anode
and cathode layers of the fuel cell system are shown in
The purpose of the model is to make analyzes virtually by equations (5)e(7).
creating a stable three-dimensional numerical fuel cell model.
H2 þ O2 /H2 O þ 2e (5)
In addition, modeling consists of examining the effects of
geometry, fuel type, and operating parameters on fuel cell
CO þ O2 /CO2 þ 2e (6)
performance. For this study, a 3D numerical model of
hydrogen and coal gas-fed FT-SOFC with a fuel gas supply
1
channel and a double-sided cathode electrode plate was þ 2e /O2 (7)
2O2
developed using COMSOL Multiphysics. The model consists of
electrolyte, fuel, and air electrodes. The flow of the reacting
gases has been arranged according to the conservation
Material and method
equations.
Basic conservation laws are used to analyze the dynamic
In this study, an FT-SOFC model was created using COMSOL
structure of fluids. These laws can be written in differential
Multiphysics software. In this section, the model used for
forms. Conservation principles are applied in the flow region
analysis is briefly mentioned.
called the control volume. The control volume is the discrete
The relevant processes are defined in the program since
part selected for flow analysis, from which the flow enters and
the FT-SOFC model requires electrochemical processes. A
exits at the surfaces. By integrating the laws of conservation,
description of the anode and cathode products that constitute
the control volume defines the changes in momentum, en-
the input and output masses of the species involved in inflow
ergy, and mass that it contains as a whole. Likewise, an
events has been made. The model consists of electrolyte, fuel,
infinite number of small control volumes stacked one after
and air electrodes, and a fuel gas feeder. The input parameters
another along the flow can be analyzed with the conservation
for the created model are given in Table 1.
laws in differential form.
In this study, a single chamber FT-SOFC was designed by
Governing equations are given Eqs (1)e(4):
flattening the tubular SOFC geometry. The flat-tube geometry is
Conservation of mass for the reactant gas flows both anode
divided into chambers by ribs. The number of ribs in geometry
and cathode flow channel is governed by continuity equation
plays a decisive role in determining the number of chambers.
given below.
The ribs, which have electronic conductivity, function to shorten


 the current path in the circuit. Thus, unlike cylindrical geometry,
v εeff r v εeff rui electrons can easily flow not only circumferentially but also
þ ¼ Sm (1)
vt vxi through the ribs and use this short path. As a result of all these
where r and u show the density of gas mixture and velocity of conditions, the maximum power density of the cell increases.
flow, respectively. Sm is the mass source term and εeff is The sectional view of the FT-SOFC model created is given
effective porosity. in Fig. 1.
Momentum conservation is described by Navier-Stokes
equations for Newtonian fluids given below.


    Table 1 e Input parameters.

v reff ui v reff uj ui vP v vui vuj
þ ¼ þ meff þ þ Sdi (2) Anode electrode thickness 0.25 mm
vt vxj vxi vxj vxj vxi Cathode electrode thickness 0.25 mm
where r is the density and u is the velocity of the gas mixture. Electrolyte thickness 0.5 mm
Tube length 10 mm
P and m show the pressure and the dynamic viscosity,
Anode permeability 1E-10 m2
respectively. S is the source term. Cathode permeability 1E-10 m2
Energy conservation is determined by the following Porosity 0.4
equation, Cell voltage 0.95 V


    Electrolyte conductivity 5 S/m
v rCp T v εrCp T v vT vT Current collector conductivity 5000 S/m
þ ui ¼ keff þ þ ST (3)
vt vxi vxj vxj vxi Initial cell polarization 0.05 V

Please cite this article as: Cimen FM et al., Simulation of hydrogen and coal gas fueled flat-tubular solid oxide fuel cell (FT-SOFC), In-
ternational Journal of Hydrogen Energy, https://doi.org/10.1016/j.ijhydene.2021.07.231
4 international journal of hydrogen energy xxx (xxxx) xxx
Fig. 1 e The sectional view of the flat-tubular solid oxide
fuel cell model.
Meshing
In order to perform the field decomposition, the area where
the management equations are applied is filled with a pre-
determined mesh or grid. The network consists of grid points
and elements where unknown physical quantities are evalu-
ated. The main advantage of structured grids is simplicity in
terms of application development, calculation, and visuali-
zation. The automatic connection information shows that the
configured grids require the least amount of memory for given
network size and the corresponding simulation is faster.
However, structured grids can represent a serious limitation
for practical engineering purposes, especially when the ge-
ometry is complex and high resolution is needed in certain
areas of the area. It is very important to construct a network
structure consisting of a sufficient number of elements for a
simulation that can calculate accurately and in the shortest
time. In this study, a predefined physically controlled
networking method was used to increase accuracy. The
reason for this method is that a physically controlled tech-
nique can play an important role in reducing user-defined
errors. Fig. 2 shows the mesh structure created.
Fig. 2 e Schematic drawing of the cell meshing.
Please cite this article as: Cimen FM et al., Simulation of hydrogen and coal gas fueled flat-tubular solid oxide fuel cell (FT-SOFC), In-
ternational Journal of Hydrogen Energy, https://doi.org/10.1016/j.ijhydene.2021.07.231
Results and Discussions
In this study, the power, current, and voltage values of the FT-
SOFC model were investigated. These examinations were
carried out repeatedly for different temperature values.
Firstly, the data showing the change in average current den-
sity/cell voltage and average cell power/average current den-
sity of the FT-SOFC at 800  C temperature and 1 atm pressure
were analyzed. In the next process, cell operation perfor-
mance was investigated by changing the temperature values
of 800  C, 900  C, and 1000  C. In the next section, power values
for different fuel types are analyzed. Pure hydrogen and coal
gases containing different proportions of CO were used in the
analyzes. Pure hydrogen was used as a fuel for analysis at
different temperatures. Then, performance comparisons of
coal gases were made using 40%, 20%, and 10% CO, Fuel A, Fuel
B, and Fuel C, respectively. Besides, air was used as the
oxidizer in all analyzes.
Model validation
The model created was validated and explained by the work of
Masciandaro et al. [29]. The reason for this is the limited
number of experimental studies on flat-tubular SOFCs in the
literature so far. In addition, the fact that the created model
has a single chamber and size differences reduce the rate of
similarity with the studies in the literature. The present
design has higher power densities than SOFCs with tubular
geometry in the literature. This is due to the increase in the
diffusion field of hydrogen. On the other hand, it is expected to
have a lower power density than planar SOFCs. However, it is
thought that FT-SOFCs can compete with planar SOFCs when
compared in terms of impermeability and cost. Accordingly,
as is clear from Fig. 3, the result of the study confirmed that
the numerical results were parallel to those of Masciandaro
et al. There are some discrepancies between these studies
because of cell lengths, geometries, and operating parameters
have different values.
Fig. 3 e Verification of the power curves of the model in
terms of numerical values with the work of Masciandaro
et al. [29].
 international journal of hydrogen energy xxx (xxxx) xxx
Polarization curve
The polarization curve is a graph that includes losses
incurred during mass transport, ohmic losses, and activation
losses. The first part of this graph defines the activation area,
which indicates that the reaction is quite fast. The middle
part of the curve is an almost straight line describing the
ohmic losses. These losses are caused by electrolyte resis-
tance. The end zone of the graph shows the concentration
losses in the fuel cells.
Fig. 4 shows the polarization curve of the FT-SOFC at an
operating pressure of 1 atm and temperature of 800  C. Cell
voltage is 0.8 V while the average current density is approxi-
mately 225 A/m2. However, when the average current density
is around 1980 A/m2, the voltage value decreases to 0.3 V. One
of the most significant parameters affecting performance in
SOFCs is the operating temperature. Besides, in Fig. 4, the
voltage losses of the FT-SOFC were analyzed at three different
operating temperature values as 900  C and 1000  C. Also, the
polarization curve was examined. The voltage of the cell
decreased with increasing average current density. At 0.8 V
voltage, it is seen that average current densities for 900  C and
1000  C are 280 A/m2, and 340 A/m2, respectively. When the
average current density reaches 1980 A/m2, the cell voltage
value is 0.3 V. At this point, the same average current density
was compared for all three operating temperatures. It was
observed that as the temperature increased, the average cur-
rent density value of the high-temperature curve increased at
the same cell voltage. It has been observed that higher cell
voltage was obtained, especially at low current densities, due
to the decrease in the ohmic resistance of the cell at high-
temperature values.
Cell power
In Fig. 4, the characteristics of the FT-SOFC are examined at
three different operating temperatures of 800  C, 900  C, and
Fig. 4 e The polarization and power curves of the FT-SOFC at 800  C, 900  C, and 1000  C.
Please cite this article as: Cimen FM et al., Simulation of hydrogen and coal gas fueled flat-tubular solid oxide fuel cell (FT-SOFC), In-
ternational Journal of Hydrogen Energy, https://doi.org/10.1016/j.ijhydene.2021.07.231
5
1000  C. The graph showing the change in cell power
depending on the losses and current density is seen in the
figure. The power curves for all three temperatures showed an
increasing profil until the peak and a decreasing profile after
this value. The highest average power value for operating
temperatures of 800  C, 900  C, and 1000  C was obtained as
710 W/m2 at 1420 A/m2, 730 W/m2 at 1460 A/m2, and 750 W/m2
at 1500 A/m2, respectively. The highest power value has been
reached at 1000  C operating conditions since the increasing
temperature causes a decrease in the cell resistance.
Hydrogen mole fraction
One of the most important factors affecting the performance
of SOFCs is operating temperature. The conductivity of
ceramic materials used in SOFCs increases with increasing
temperature. Analyzes were carried out at temperatures of
800, 900, and 1000  C to observe the effect of operating tem-
perature on the performance of the FT-SOFC. Fig. 5 shows the
hydrogen distributions that vary with temperature.
As expected, hydrogen distribution increases when the
temperature is increased. The increase in hydrogen con-
sumption can be explained by the fact that the temperature
increase facilitates the electrochemical reactions occurring in
the fuel cell. This situation had a positive effect on cell
performance.
Oxygen mole fraction
Fig. 6 shows the varying oxygen distributions depending on
different operating temperatures. When Fig. 6 is examined, it
is seen that oxygen consumption is fast at the entrance of the
cathode layer and then slows down. Cell performance
decrease as the decrease in diffusion rates over time decrease
the reaction rates over time. In this case, the performance of a
SOFC also depends on the amount of diffused fuel and
oxidizing agents.
6 international journal of hydrogen energy xxx (xxxx) xxx

Fig. 5 e The distributions of hydrogen concentrations at 800  C (a), 900  C (b), and 1000  C (c).

Fig. 6 e The distributions of oxygen concentrations at 800  C (a), 900  C (b), and 1000  C (c).

Fig. 7 e Power values for different types of fuels.

Please cite this article as: Cimen FM et al., Simulation of hydrogen and coal gas fueled flat-tubular solid oxide fuel cell (FT-SOFC), In-
ternational Journal of Hydrogen Energy, https://doi.org/10.1016/j.ijhydene.2021.07.231
 international journal of hydrogen energy xxx (xxxx) xxx
Performance values for different fuel usage
In previous parts, analysis was made using hydrogen as a fuel
for FT-SOFC. In this section, an analysis has been carried out
with Fuel A (40%CO and 60%H2), B (20%CO and 80%H2) and C
(10%CO and 90%H2) as fuel, and the results are compared. In
Fig. 7, power densities for hydrogen and coal gas containing
different proportions of CO can be seen. It is obvious that
hydrogen has a higher power value than coal gas. When using
Fuel A, better performance was observed than Fuel B and Fuel
C, because the higher the hydrogen content increased the
electrochemical reactions. When the coal gases are examined
within themselves, it is seen that as the CO percentage in-
creases, the power decreases in parallel with this increase. For
Fuel C, the maximum power value was obtained as 680 W/m2
at 1360 A/m2. These values are 550 W/m2 at 920 A/m2 and
420 W/m2 at 700 A/m2 for Fuel B and A, respectively.
As a result of the analyzes the FT-SOFC is found to have
high electrochemical performance as other types of SOFCs
(planar and tubular) have. As known, SOFC shows high per-
formance at high temperatures. Also, the FT-SOFC has high
performance as the conductivity of the electrolyte is
improving and the ohmic resistances are considerably
reduced at high temperatures. In addition, the FT-SOFC is also
very suitable for use with different fuels. However, the higher
the hydrogen content, the higher its performance is observed.
Conclusions
In this study, average cell power, polarization curves, and
average current density values of the FT-SOFC model have
been numerically simulated at operating temperatures of
800  C, 900  C, and 1000  C.
In the analysis, it was observed that the flat-tube geometry
was affected by temperature changes. However, the average
power density increases with increasing temperature in the
fuel cell configuration. This is due to the increase in electrolyte
conductivity and the significant decrease in ohmic resistances
at high temperatures. Due to the shorter current path of flat-
tube SOFCs, ohmic losses are less visible. For this reason,
the predicted power density of the flat tube is higher than the
tubular geometries found in the literature. In addition, the
flat-tubular SOFC has a simpler design. This situation provides
a cost reduction. Also, there is no need for sealing material in
FT-SOFC. In this respect, it is more advantageous than planar
SOFCs in the literature. FT-SOFC, which is the flattened shape
of tubular fuel cells, thus increases the contact surface of
hydrogen. This provides better diffusion of hydrogen. And as a
result, an increase in cell maximum power occurs.
As a result of the analyzes performed for the FT-SOFC at
1000  C operating temperature, it has been observed that the
average current density changes up to 1980 A/m2 and the
average cell power reaches 750 W/m2 which is the peak value
at approximately 1500 A/m2. Then, it was observed that the
power value decreased up to 590 W/m2. In the present study,
the performance values were investigated by using coal gases
containing different amounts of CO besides hydrogen. The
highest performance value has been reached by the hydrogen
fed model, and the lowest performance value has been
Please cite this article as: Cimen FM et al., Simulation of hydrogen and coal gas fueled flat-tubular solid oxide fuel cell (FT-SOFC), In-
ternational Journal of Hydrogen Energy, https://doi.org/10.1016/j.ijhydene.2021.07.231
7
reached by the coal gas model with the highest CO content
(40%). FT-SOFCs that combine the advantages of other SOFC
types stand out with their high power density, sealing area,
and high resistance against expansions.
Declaration of competing interest
The authors declare that they have no known competing
financial interests or personal relationships that could have
appeared to influence the work reported in this paper.
Acknowledgment
We would like to thank Nigde Omer Halisdemir University for
allowing us to use software and computer facilities.
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