A 25 kW high-temperature electrolysis (HTE) flexible test facility has been developed at Idaho National Laboratory (INL) for performance evaluation of solid-oxide electrolysis cell (SOEC) stacks operating independently or in thermal integration with co-located systems. This facility is aimed at advancing the state of the art of HTE technology while demonstrating dynamic grid and thermal energy integration and operational characteristics. The 25 kW HTE flexible test station will provide a test bed for state-of-the-art HTE stack technologies from multiple industry partners. The test station will ultimately be integrated with a co-located thermal energy distribution and storage system within the INL Systems Integration Laboratory. The HTE test station will also be designed to communicate with co-located digital real-time simulators for dynamic performance evaluation and hardware-in-the-loop simulations in a dynamic microgrid environment. Operation of the 25 kW HTE system will be followed by deployment of a test skid with infrastructure support for up to 250 kW HTE turnkey systems. A detailed description of the 25 kW HTE system is provided along with results obtained from initial stack testing at the 5 kW scale. (C) 2020 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.

A series of 5 cm by 5 cm bi-supported Solid Oxide Electrolysis Cells (SOEC) were produced by NASA for the Idaho National Laboratory (INL) and tested under the INL High Temperature Steam Electrolysis program. The results from the experimental demonstration of cell operation for both hydrogen production and operation as fuel cells is presented. An overview of the cell technology, test apparatus and performance analysis is also provided.

Performance characterization and durability testing have been completed on two five-cell high-temperature electrolysis stacks constructed with advanced cell and stack technologies. The solid oxide cells incorporate a negative-electrode-supported multi-layer design with nickel-zirconia cermet negative electrodes, thin-film yttria-stabilized zirconia electrolytes, and multi-layer lanthanum ferrite-based positive electrodes. The per-cell active area is 100 cm2. The stack is internally manifolded with compliant seals. Treated metallic interconnects with integral flow channels separate the cells and electrode gases. Stack compression is accomplished by means of a custom spring-loaded test fixture. Initial stack performance characterization was determined through a series of DC potential sweeps in both fuel cell and electrolysis modes of operation. Results of these sweeps indicated very good initial performance, with area-specific resistance values less than 0.5 Ω.cm2. Long-term durability testing was performed with a test duration of 1000 hours. Overall performance degradation was less than 10% over the 1000-hour period. Final stack performance characterization was again determined by a series of DC potential sweeps at the same flow conditions as the initial sweeps in both electrolysis and fuel cell modes of operation. A final sweep in the fuel cell mode indicated a power density of 0.356 W/cm2, with average per-cell voltage of 0.71 V at a current of 50 A.

This paper examined the features of three typical thermal storage systems including: 1) direct storage of heat transfer fluid in containers, 2) storage of thermal energy in a packed bed of solid filler material, with energy being carried in/out by a flowing heat transfer fluid which directly contacts the packed bed, and 3) a system in which heat transfer fluid flows through tubes that are imbedded into a thermal storage material which may be solid, liquid, or a mixture of the two. The similarity of the three types of thermal storage systems was discussed, and generalized energy storage governing equations were introduced in both dimensional and dimensionless forms. The temperatures of the heat transfer fluid during energy charge and discharge processes and the overall energy storage efficiencies were studied through solution of the energy storage governing equations. Finally, provided in the paper are a series of generalized charts bearing curves for energy storage effectiveness against four dimensionless parameters grouped up from many of the thermal storage system properties including dimensions, fluid and thermal storage material properties, as well as the operational conditions including mass flow rate of the fluid, and the ratio of energy charge and discharge time periods. Engineers can conveniently look up the charts to design and calibrate the size of thermal storage tanks and operational conditions without doing complicated individual modeling and computations. It is expected that the charts will serve as standard tools for thermal storage system design and calibration. (C) 2011 Elsevier Ltd. All rights reserved.

An experimental study has been conducted to assess the performance of electrode-supported solid-oxide cells operating in the steam electrolysis mode for hydrogen production. Results presented in this paper were obtained from single cells, with an active area of 16 cm2 per cell. The electrolysis cells are electrode-supported, with yttria-stabilized zirconia (YSZ) electrolytes (∼10 μm thick), nickel-YSZ steam/hydrogen electrodes (∼1400 μm thick), and modified LSM or LSCF air-side electrodes (∼90 μm thick). The purpose of the present study is to document and compare the performance and degradation rates of these cells in the fuel cell mode and in the electrolysis mode under various operating conditions. Initial performance was documented through a series of voltage-current (VI) sweeps and AC impedance spectroscopy measurements. Degradation was determined through long-term testing, first in the fuel cell mode, then in the electrolysis mode. Results generally indicate accelerated degradation rates in the electrolysis mode compared to the fuel cell mode, possibly due to electrode delamination. The paper also includes details of an improved single-cell test apparatus developed specifically for these experiments.

Idaho National Laboratory (INL) is performing high-temperature electrolysis research to generate hydrogen using solid oxide electrolysis cells (SOECs). The project goals are to address the technical and degradation issues associated with the SOECs. This paper provides a summary of various ongoing INL and INL sponsored activities aimed at addressing SOEC degradation. These activities include stack testing, post-test examination, degradation modeling, and a list of issues that need to be addressed in future. Major degradation issues relating to solid oxide fuel cells (SOFC) are relatively better understood than those for SOECs. Some of the degradation mechanisms in SOFCs include contact problems between adjacent cell components, microstructural deterioration (coarsening) of the porous electrodes, and blocking of the reaction sites within the electrodes. Contact problems include delamination of an electrode from the electrolyte, growth of a poorly (electronically) conducting oxide layer between the metallic interconnect plates and the electrodes, and lack of contact between the interconnect and the electrode. INL’s test results on high temperature electrolysis (HTE) using solid oxide cells do not provide clear evidence of whether different events lead to similar or drastically different electrochemical degradation mechanisms. Post-test examination of the solid oxide electrolysis cells showed that the hydrogen electrode and interconnect get partially oxidized and become nonconductive. This is most likely caused by the hydrogen stream composition and flow rate during cool down. The oxygen electrode side of the stacks seemed to be responsible for the observed degradation due to large areas of electrode delamination. Based on the oxygen electrode appearance, the degradation of these stacks was largely controlled by the oxygen electrode delamination rate. Virkar and co-workers have developed a SOEC model based on concepts in local thermodynamic equilibrium in systems otherwise in global thermodynamic nonequilibrium. This model is under continued development. It shows that electronic conduction through the electrolyte, however small, must be taken into account for determining local oxygen chemical potential, within the electrolyte. The chemical potential within the electrolyte may lie out of bounds in relation to values at the electrodes in the electrolyzer mode. Under certain conditions, high pressures can develop in the electrolyte just under the oxygen electrode (anode)/electrolyte interface, leading to electrode delamination. This theory is being further refined and tested by introducing some electronic conduction in the electrolyte.

An experimental study is under way to assess the performance of electrode-supported solid-oxide cells operating in the steam electrolysis mode for hydrogen production over a temperature range of 800 to 900°C. Results presented in this paper were obtained from single cells, with an active area of 16 cm2 per cell. The electrolysis cells are electrode-supported, with yttria-stabilized zirconia (YSZ) electrolytes (∼10 μm thick), nickel-YSZ steam/hydrogen electrodes (∼1400 μm thick), and manganite (LSM) air-side electrodes. The experiments were performed over a range of steam inlet mole fractions (0.1–0.6), gas flow rates, and current densities (0 to 0.6 A/cm2). Steam consumption rates associated with electrolysis were measured directly using inlet and outlet dewpoint instrumentation. On a molar basis, the steam consumption rate is equal to the hydrogen production rate. Cell performance was evaluated by performing DC potential sweeps at 800, 850, and 900°C. The voltage-current characteristics are presented, along with values of area-specific resistance as a function of current density. Long-term cell performance is also assessed to evaluate cell degradation. Details of the custom single-cell test apparatus developed for these experiments are also presented.

The need for an infrastructure to provide hydrogen as a next generation energy carrier is ever increasing. High temperature solid oxide electrolysis cells (SOECs) have been proven to be a viable technology in the production of hydrogen [1]. With the increasing use of SOECs in various operating environments it is important to be able to specify the best SOEC for any given situation. We have developed a straightforward model to estimate cell performance in a timely and inexpensive manner. Composite electrode planer type SOEC models have been developed previously. It is a common assumption that all electrochemical reactions in these cells occur at the interface of the electrolyte and the electrode [2]. It has been shown by S. Gewies et al. [3] that the reactions occurring throughout a Ni/YSZ cermet electrode occur in a nonlinear fashion. Our one dimensional model has been developed to optimize SOECs with composite electrodes. This model takes into account ohmic, activation, and concentration polarizations. The electrochemical reaction that occurs within the electrode functional layers has been accounted for in the calculation of the concentration polarization. This is believed to give a more realistic view of the mass transfer that occurs in SOECs with composite electrodes via a simple and straightforward 1-D model.

The Idaho National Laboratory (INL) has been developing the concept of using solid oxide fuel cells as electrolyzers for large-scale, high-temperature (efficient), hydrogen production. This program is sponsored by the U.S. Department of Energy under the Nuclear Hydrogen Initiative. Utilizing a fuel cell as an electrolyzer introduces some inherent differences in cell operating conditions. In particular, the performance of fuel cells operated as electrolyzers degrades with time faster. This issue of electrolyzer cell and stack performance degradation over time has been identified as a major barrier to technology development. Consequently, the INL has been working together with Ceramatec, Inc. (Salt Lake City, Utah) to improve the long-term performance of high temperature electrolyzers. As part of this research partnership, the INL conducted a 2500 hour test of a Ceramatec designed and produced stack operated in the electrolysis mode. This report will provide a summary of experimental results for this long duration test.

A general thermodynamic analysis of hydrogen production based on thermal water splitting processes is presented. Results of the analysis show that the overall efficiency of any thermal water splitting process operating between two temperature limits is proportional to the Carnot efficiency. Implications of thermodynamic efficiency limits and the impacts of loss mechanisms and operating conditions are discussed as they pertain specifically to hydrogen production based on high-temperature electrolysis. Overall system performance predictions are also presented for high-temperature electrolysis plants powered by three different advanced nuclear reactor types, over their respective operating temperature ranges.

A system analysis has been performed to assess the efficiency and carbon utilization of a nuclear-assisted coal gasification process. The nuclear reactor is a high-temperature helium-cooled reactor that is used primarily to provide power for hydrogen production via high-temperature electrolysis. The supplemental hydrogen is mixed with the outlet stream from an oxygen-blown coal gasifier to produce a hydrogen-rich gas mixture, allowing most of the carbon dioxide to be converted into carbon monoxide, with enough excess hydrogen to produce a syngas product stream with a hydrogen/carbon monoxide molar ratio of about 2:1. Oxygen for the gasifier is also provided by the high-temperature electrolysis process. The results of the analysis predict 90.5% carbon utilization with a syngas production efficiency (defined as the ratio of the heating value of the produced syngas to the sum of the heating value of the coal plus the high-temperature reactor heat input) of 64.4% at a gasifier temperature of 1866 K for the high-moisture-content lignite coal considered. Usage of lower moisture coals such as bituminous can yield carbon utilization approaching 100% and 70% syngas production efficiency.

As part of the Next Generation Nuclear Plant (NGNP) project, an evaluation of a low-temperature heat-pump interface design for a nuclear-driven high-temperature electrolysis (HTE) hydrogen production plant was performed using the UniSim process analysis software. The low-temperature interface design is intended to reduce the interface temperature between the reactor power conversion system and the hydrogen production plant by extracting process heat from the low temperature portion of the power cycle rather than from the high-temperature portion of the cycle as is done with the current Idaho National Laboratory (INL) reference design. The intent of this design change is to mitigate the potential for tritium migration from the reactor core to the hydrogen plant, and reduce the potential for high temperature creep in the interface structures. The UniSim model assumed a 600 MWt Very-High Temperature Reactor (VHTR) operating at a primary system pressure of 7.0 MPa and a reactor outlet temperature of 900°C. The low-temperature heat-pump loop is a water/steam loop that operates between 2.6 MPa and 5.0 MPa. The HTE hydrogen production loop operated at 5 MPa, with plant conditions optimized to maximize plant performance (i.e., 800°C electrolysis operating temperature, area specific resistance (ASR) = 0.4 ohm-cm2, and a current density of 0.25 amps/cm2). An air sweep gas system was used to remove oxygen from the anode side of the electrolyzer. Heat was also recovered from the hydrogen and oxygen product streams to maximize hydrogen production efficiencies. The results of the UniSim analysis showed that the low-temperature interface design was an effective heat-pump concept, transferring 31.5 MWt from the low-temperature leg of the gas turbine power cycle to the HTE process boiler, while consuming 16.0 MWe of compressor power. However, when this concept was compared with the current INL reference direct Brayton cycle design and with a modification of the reference design to simulate an indirect Brayton cycle (both with heat extracted from the high-temperature portion of the power cycle), the latter two concepts had higher overall hydrogen production rates and efficiencies compared to the low-temperature heat-pump concept, but at the expense of higher interface temperatures. Therefore, the ultimate decision on the viability of the low-temperature heat-pump concept involves a tradeoff between the benefits of a lower-temperature interface between the power conversion system and the hydrogen production plant, and the reduced hydrogen production efficiency of the low-temperature heat-pump concept compared to concepts using high-temperature process heat.

The Idaho National Laboratory (INL) has been researching the application of solid-oxide electrolysis cell for large-scale hydrogen production from steam over a temperature range of 800 to 900oC. The INL has been testing various solid oxide cell designs to characterize their electrolytic performance operating in the electrolysis mode for hydrogen production. Some results presented in this report were obtained from cells, initially developed by the Forschungszentrum Julich and now manufactured by the French ceramics firm St. Gobain. These cells have an active area of 16 cm2 per cell. They were initially developed as fuel cells, but are being tested as electrolytic cells in the INL test stands. The electrolysis cells are electrode-supported, with ~10 µm thick yttria-stabilized zirconia (YSZ) electrolytes, ~1400 µm thick nickel-YSZ steam-hydrogen electrodes, and manganite (LSM) air-oxygen electrodes. The experiments were performed over a range of steam inlet mole fractions (0.1 to 0.6), gas flow rates, and current densities (0 to 0.6 A/cm2). Steam consumption rates associated with electrolysis were measured directly using inlet and outlet dewpoint instrumentation. On a molar basis, the steam consumption rate is equal to the hydrogen production rate. Cell performance was evaluated by performing DC potential sweeps at 800, 850, and 900°C. The voltage-current characteristics are presented, along with values of area-specific resistance as a function of current density. Long-term cell performance is also assessed to evaluate cell degradation. Details of the custom single-cell test apparatus developed for these experiments are also presented. NASA, in conjunction with the University of Toledo, has developed another fuel cell concept with the goals of reduced weight and high power density. The NASA cell is structurally symmetrical, with both electrodes supporting the thin electrolyte and containing micro-channels for gas diffusion. This configuration is called a bi-electrode supported cell or BSC. The electrodes are made by freeze-casting, a modified tape casting technique which creates the many micro-channels in the YSZ electrode green tape. This report presents results of the INL’s testing of this new solid oxide cell design as an electrolyzer. Gas composition, operating voltage, and other parameters were varied during testing. Results to date show the NASA cell to be a promising design for both high power-to-weight fuel cell and electrolyzer applications.

A process model of syngas production using high temperature electrolysis and biomass gasification is presented. Process heat from the biomass gasifier is used to improve the hydrogen production efficiency of the steam electrolysis process. Hydrogen from electrolysis allows a high utilization of the biomass carbon for syngas production. Based on the gasifier temperature, 94% to 95% of the carbon in the biomass becomes carbon monoxide in the syngas (carbon dioxide and hydrogen). Assuming the thermal efficiency of the power cycle for electricity generation is 50%, (as expected from GEN IV nuclear reactors), the syngas production efficiency ranges from 70% to 73% as the gasifier temperature decreases from 1900 K to 1500 K.

Design details of a compact heat exchanger and supporting hardware for heat recuperation in a high-temperature electrolysis application are presented. The recuperative heat exchanger uses a vacuum-brazed plate-fin design and operates between 300 and 800°C. It includes corrugated inserts for enhancement of heat transfer coefficients and extended heat transfer surface area. Two recuperative heat exchangers are required per each four-stack electrolysis module. The heat exchangers are mated to a base manifold unit that distributes the inlet and outlet flows to and from the four electrolysis stacks. Results of heat exchanger design calculations and assembly details are also presented.

An integrated laboratory scale, 15 kW high-temperature electrolysis facility has been developed at the Idaho National Laboratory under the U.S. Department of Energy Nuclear Hydrogen Initiative. Initial operation of this facility resulted in over 400 hours of operation with an average hydrogen production rate of approximately 0.9 Nm3/hr. The integrated laboratory scale facility is designed to address larger-scale issues such as thermal management (feed-stock heating, high-temperature gas handling), multiple-stack hot-zone design, multiple-stack electrical configurations, and other "integral" issues. This paper documents the initial operation of the ILS, with experimental details about heat-up, initial stack performance, as well as long-term operation and stack degradation.