One promising way to produce hydrogen with low carbon emissions is to produce hydrogen electrochemically with low carbon intensity electricity. High temperature electrolysis using solid oxide cells offers higher electrical efficiency compared to low temperature electrolysis based on thermodynamics and dynamics of operation. Solid oxide electrolysis cell (SOEC) systems operate across endothermic and exothermic regions which presents additional complexity for thermal management since both heat addition and heat rejection is required depending upon the operating conditions. Due to the unique nature of SOEC systems, development of thermal management strategies for efficient and resilient hydrogen production is essential.
In this dissertation, a thermophysical SOEC system model is developed to assess the dynamic behavior of the SOEC stack and evaluate novel thermal management strategies implemented for the proposed SOEC system. With the proposed SOEC system configuration and thermal control strategies, with diverse cell degradation rates of 5, 7.5 and 10 mΩcm2kh-1, the system can maintain its beginning of life hydrogen production efficiency for at least 9, 6, and 4.5 years, respectively. The efficiency is maintained in the system despite cell degradation because the heat generated by irreversibilities caused by degradation is used by the electrochemical reactions in the immediate vicinity and at the operating temperature, simulating a reversible heat transfer from the electrochemical losses to the water splitting electrochemical reactions themselves.
To evaluate the resiliency of the proposed SOEC system, hot-standby and cold-start operations are investigated. The developed model shows that the proposed system can operate dynamically at very high current density ramp rate of 0.073 A/cm2 per minute in case of an urgent shutdown or start-up to and from hot-standby and can also safely manage the dynamics of a complete shutdown and cold-start operation. The model is further developed to simulate a 3-dimensional SOEC stack and its dynamic performance characteristics. With a 3-dimensional stack model, heater failure scenarios are investigated. To overcome stack heater failure scenarios, increasing inlet air temperature is suggested as the system can operate without large temperature gradients and maintain the system efficiency.
Co-electrolysis emerges as a promising solution for producing the precursor synthesis gas (syngas) for making a variety of hydrocarbons, targeting the integration with sectors of the economy that are difficult to decarbonize. To comprehensively investigate SOECs operating in co-electrolysis mode, an SOEC model is developed which encompasses both electrochemical and thermochemical pathways for CO and H2 (syngas) production from CO2 and water. The model is used to evaluate and compare the performance characteristics of electrolyte-supported and fuel electrode-supported cells. Fuel electrode thickness impacts the reaction pathways in co-electrolysis operation where higher contribution of electrochemical conversion of CO2 is found in thinner fuel electrode SOECs than that of thicker fuel electrode SOECs.