Abstract: An electrochemical cell system includes electrochemical cell columns arranged in an annular configuration over a support, each cell column having a front side that faces away from a center of the annular configuration, a back side that faces the center of the annular configuration, and opposing first and second sides that connect the front and back sides, and multi-component baffle assemblies located between adjacent cell columns and including at least one air bypass mitigation feature configured to reduce or prevent air from flowing between the cell columns.

Abstract: A controller for a solid oxide electrolyzer cell (SOEC) system, the controller being configured to receive a target operating temperature, receive a readback temperature value, and output a temperature setpoint command to each of a plurality of heaters.

Abstract: A method includes outputting an alternating current (AC) waveform from an inverter module to a plurality of loads, outputting a fault waveform from the inverter module to a first load of the plurality of loads in response to a fault condition associated with the first load, and outputting the AC waveform from the inverter module to at least some of the plurality of loads if the fault condition is cleared before a recovery period expires or disconnecting the inverter module from the plurality of loads if the fault condition is not cleared before the recovery period expires.

Abstract: Systems and methods for facilitating a medium voltage microgrid operation to manage critical loads are disclosed. The system includes at least two fuel cell systems that operate in one of at least two operating modes including a grid-forming mode and a grid-following mode, based on an operation of at least two utility feeders of a grid. The system includes a controller that receives values corresponding to electrical parameter(s) from at least two utility circuit breakers and a load circuit breaker, detects availability status of the utility circuit breakers to supply power to corresponding at least two portions of the critical load, and a connection status of the load circuit breaker, based on the values, and facilitates the at least two fuel cell systems to operate in one of the at least two operating modes. Further, the system is scalable, redundant, and reliable, and reliability and redundancy are customizable.

Abstract: An auxiliary circuit to inject fault current to a grid is provided. The circuit includes a pair of transformers including a first transformer and a second transformer, and a pair of SCRs including a first SCR and a second SCR. Each SCR remains in an OFF state and an ON state when AC voltage of the grid is in normal range and fault range, respectively. The circuit includes a capacitor electrically connected between the first transformer, the second transformer, and the first SCR. The circuit includes a diode biased by the second transformer and the capacitor to enable charging of the capacitor to a peak of AC voltage during one polarity of AC voltage when the AC voltage is in normal range. The capacitor discharges via the first SCR and the first transformer by injecting the fault current into the grid when the AC voltage is in the fault range.

Abstract: A method for operating a fuel cell system includes drawing a base level DC electric energy from a first fuel cell of a first type to a combined DC bus, measuring a DC voltage at the combined DC bus, determining whether the DC voltage at the combined DC bus falls short of a DC voltage threshold, and drawing a variable DC electric energy from a second fuel cell of a second type different from the first type in response to determining that the DC voltage at the combined DC bus falls short of the DC voltage threshold.

Abstract: A method of operating a solid oxide electrolyzer system includes providing a water inlet stream to at least one solid oxide electrolyzer cell (SOEC), generating a wet hydrogen product stream from the at least one SOEC, providing the wet hydrogen product stream to at least one hydrogen pump, generating a compressed hydrogen product and an unpumped effluent in the at least one hydrogen pump, and recycling at least a portion of the unpumped effluent upstream of the at least one hydrogen pump.

Abstract: A modular electrolyzer system including a power module and a generator module wherein the power module and the generator module are integrated with a hydrogen collection component and a steam delivery component, the hydrogen collection component and the steam delivery component being disposed on a structural base.

Abstract: A method of sealing a glow plug of a fuel cell system, the glow plug including a housing and a heating element extending from a first end of the housing. The method includes inserting the heating element into a sealing element having an annular base and a tubular collar extending from the base and forming a fluid-tight connection between the glow plug and the fuel cell system by attaching the collar to the heating element and by attaching the base to the first end of the housing.

Abstract: A method of making an interconnect for an electrochemical cell stack includes providing the interconnect, and creep flattening the interconnect prior to placing the interconnect into the electrochemical cell stack.

Abstract: A fuel cell system includes a fuel cell stack, an anode tail gas oxidizer (ATO), an ATO injector configured to mix a first portion of an anode exhaust from the fuel cell stack with a cathode exhaust from the fuel cell stack and to provide a mixture of the first portion of the anode exhaust and the cathode exhaust into the ATO, an anode exhaust conduit which is configured to provide the first portion of the anode exhaust into the ATO injector, and cathode exhaust conduit which is configured to provide at least a portion of the cathode exhaust from the fuel cell stack into the ATO injector. The ATO injector includes injector tubes or injection apertures.

Abstract: Embodiments of the present disclosure provide control systems and methods to reduce wastage of energy associated with fuel cell systems. The method includes transmitting DC power from a plurality of fuel cells of a set of power modules to a centralized DC bus through a first set of DC-DC converters. The method includes operating a second set of DC-DC converters to provide an output DC power by boosting a voltage level of the DC power from the centralized DC bus and further operating a first set of DC-AC inverters to convert the DC power from the second set of DC-DC converters to AC power. The method includes transmitting the AC power from the first set of DC-AC inverters to a grid. The AC power is transmitted to the grid at substantially unity power factor due to combined effect of switching modulation and MPPT of the first set of DC-AC inverters.

Abstract: Various embodiments manage a fuel cell IT grid system to maintain fuel cell temperatures above a threshold temperature. The system may include power modules each including a fuel cell, DC/DC converters each connected to a power module, a DC power bus connected to the DC/DC, IT loads each connected to the DC power bus, a load balancing load connected to the DC power bus, and a control device connected to a first power module. The control device may determine whether a temperature of the first power module exceeds the temperature threshold, determine whether an electrical power output of the power modules exceeds an electrical power demand of the IT loads in response to the temperature exceeding the temperature threshold, and direct excess electrical power output to the load balancing load in response to the electrical power output exceeding the electrical power demand.

Abstract: A method of forming a fuel cell system heat exchanger includes flattening opposing ends of a corrugated heat exchange plate to form opposing flattened ends, and welding the flattened ends to structural components of the fuel cell system. The flattening may include using a hydraulic press or a bead roller.

Abstract: A microgrid includes a power system configured to output system power and an automatic transfer switch (ATS). The ATS includes a normal terminal that is electrically connected to a grid power line configured to receive grid power from a power utility, an emergency terminal that is electrically connected to a system power line configured to receive system power from the power system, and a load terminal that is electrically connected to a critical load line configured to provide power to a critical load. The microgrid also includes a bypass line electrically connected to the system power line and the critical load line, so as to bypass the ATS, and a circuit breaker configured to control power flow through the bypass line.

Abstract: A centrifugal blower includes a motor located in a motor housing, an impeller, and a volute. The volute directly contacts the motor housing such that the volute is configured to actively cool the motor during operation.

Abstract: A method of operating a fuel cell system includes providing fuel and air to a stack of fuel cells located in a hotbox, operating the stack to generate an anode exhaust and a cathode exhaust, in a startup mode, providing a first amount of the anode exhaust and the cathode exhaust to an anode tail gas oxidizer (ATO) located in the hotbox to oxidize the anode exhaust and to generate heat which is provided to the stack, and in a steady-state mode, stopping providing the anode exhaust to the ATO or providing to the ATO a second amount of the anode exhaust which is smaller than the first amount, and providing the anode exhaust and the cathode exhaust outside the hotbox.

Abstract: Various embodiments disclose a glow plug for a solid oxide fuel cell system. The glow plug includes a housing having a first end portion and a second end portion. The glow plug includes a heating element longitudinally disposed in the housing, extending from the second end portion of the housing towards the first end portion and extending outwardly from the housing for igniting fuel. Further, the glow plug includes a pair of coiled wires electrically connected to the heating element. Further, the glow plug includes a potting compound disposed within the second end portion of the housing for securing electrical coupling of the pair of coiled wires with the heating element. Furthermore, the glow plug includes a sealing element configured to form an air-tight connection between the housing and the heating element. The sealing element is positioned on top of the potting compound.

Abstract: A membrane electrode assembly (MEA) includes an ionically-conductive proton exchange membrane. Further, the MEA includes an anode contacting a first side of the membrane. The anode includes an anode gas diffusion layer (GDL). Further, the anode includes a first anode catalyst layer containing first catalyst particles, a hydrophobic polymer bonding agent, and a first ionomer bonding agent that lacks functional chains on a molecular backbone. The anode also includes a second anode catalyst layer containing second catalyst particles and a second ionomer bonding agent that includes functional chains on a molecular backbone. The MEA also includes a cathode contacting a second side of the membrane and comprising third catalyst particles and a cathode GDL.

Abstract: A method of forming a fuel cell interconnect includes depositing a Cr alloy powder, sintering the Cr alloy powder, and repeating the depositing and the sintering to form the fuel cell interconnect. The Cr alloy powder may include a pre-alloyed powder containing from about 4 wt. % to about 6 wt. % Fe, and from about 94 wt. % to about 96 wt. % Cr.