Abstract: Methods for fabricating an interconnect for a fuel cell stack that include providing a protective layer over at least one surface of an interconnect formed by powder pressing pre-alloyed particles containing two or more metal elements and annealing the interconnect and the protective layer at elevated temperature to bond the protective layer to the at least one surface of the interconnect.

Abstract: A fuel cell system and method, the system including power generating fuel cells disposed in a stack, each power generating fuel cell including an anode, a cathode, and an electrolyte, a sensing fuel cell including an anode, a cathode, and an electrolyte, and a fuel processor configured to purify a fuel provided to the power generating fuel cells and the sensing fuel cell. The anode of the sensing fuel cell is thinner than the anodes of the power generating fuel cells.

Abstract: A fuel cell system and method for using a peak shaving gas, the system including: a fuel inlet configured to receive fuel from a fuel source; a catalytic partial oxidation (CPOx) reactor configured to at least partially oxidize the fuel during startup of the system; a blower configured to provide air to the CPOx reactor; a gas analyzer configured to determine a composition of fuel provided to the CPOx reactor from the fuel inlet; an oxidation catalyst configured to reduce an O2 content of fuel received from the CPOx reactor; a reforming catalyst configured to partially reform fuel received from the oxidation catalyst; and a stack of fuel cells configured to generate electricity using fuel received from the reforming catalyst.

Abstract: During a steady-state mode of operating a fuel cell system, a system power is generated by fuel cells and is provided via a steady-state bus to a first BOP load, to a second BOP load, and to a power grid via a transformer and via at least one of a bi-directional first inverter or a bi-directional second inverter. During startup mode operation of the fuel cell system, external power from the power grid is provided via the transformer, via one of the first or second inverters and via a startup bus to the first BOP load and the second BOP load.

Abstract: A fuel cell column includes first and second fuel cell stacks, a fuel manifold disposed between the first and second fuel cell stacks and configured to provide fuel to the first and second fuel cell stacks, and first and second dielectric separators located between the fuel manifold and the respective first and second fuel cell stacks, and configured to electrically isolate the respective first and second fuel cell stacks from the fuel manifold. The first and second dielectric separators each include a top layer of a ceramic material, a bottom layer of the ceramic material, a middle layer disposed between the top and bottom layers and including a material having a lower density and a higher dielectric strength than the ceramic material, and glass or glass ceramic seals which connect the middle layer to the top and bottom layers.

Abstract: A cross-flow interconnect and a fuel cell stack including the same, the interconnect including fuel inlets and outlets that extend through the interconnect adjacent to opposing first and second peripheral edges of the interconnect; an air side; and an opposing fuel side. The air side includes an air flow field including air channels that extend in a first direction, from a third peripheral edge of the interconnect to an opposing fourth peripheral edge of the interconnect; and riser seal surfaces disposed on two opposing sides of the air flow field and in which the fuel inlets and outlets are formed. The fuel side includes a fuel flow field including fuel channels that extend in a second direction substantially perpendicular to the first direction, between the fuel inlets and outlets; and a perimeter seal surface surrounding the fuel flow field and the fuel inlets and outlets.

Abstract: A method of operating a power generation system, such as a fuel cell power generation system, includes providing a first electrical power up to a threshold amount of power to a load from at least one power module via a plurality of DC/DC converters and a DC power bus, determining whether electrical power from a utility is available, and providing a second electrical power from the at least one power module to a rectifier path via a plurality of DC/AC inverters in response to determining that the electrical power from the utility is available. The second electrical power includes electrical power generated by the at least one power module in excess of the threshold amount of electrical power.

Abstract: A method of transporting a battery module includes transporting the battery module containing at least one battery and a backplane disposed in a cabinet to an operating site such that the at least one battery is electrically isolated from the backplane during the transporting, installing the battery module at the operating site, and electrically connecting the at least one battery to the backplane after the transporting.

Abstract: A solid oxide fuel cell (SOFC) system and method, the system including a power module configured to receive a fuel from a fuel conduit of the system, the power module including a fuel cell stack, a module conduit fluidly connecting the fuel conduit and the stack, and a fuel control valve (FCV) configured to control a flow rate of the fuel in the module conduit. The system also includes a first detector configured to detect a first Wobbe Index (WI) of the fuel in the fuel conduit, and a controller configured to control the FCV to change the fuel flow rate based on whether the detected first WI indicates a change in the composition of the fuel.

Abstract: A method of making an interconnect for a solid oxide fuel cell stack includes providing an iron rich material containing at least 25 wt. % iron into channels of a mold, providing a powder containing 4-6 wt. % Fe, 0-1 wt. % Y and balance Cr into the mold over the iron rich material containing at least 25 wt. % iron, compacting the iron rich material containing at least 25 wt. % iron and the powder comprising 4-6 wt. % Fe, 0-1 wt. % Y and balance Cr in the mold to form the interconnect, and sintering the interconnect to form a sintered interconnect having iron rich regions having an iron concentration greater than 10% in ribs of the interconnect.

Abstract: Systems, methods, and devices of the various embodiments provide a hardware and software architecture enabling electrochemical impedance spectroscopy (“EIS”) to be performed on multiple electrochemical devices, such as fuel cells, at the same time without human interaction with the electrochemical devices and to use EIS to dynamically monitor the performance of a fuel cell system. Embodiment methods may include determining an impedance of a set of fuel cells using electrochemical impedance spectroscopy, determining an ohmic polarization of the set of fuel cells from the impedance, determining a concentration polarization of the set of fuel cells from the impedance, comparing the ohmic polarization of the set of fuel cells to a first threshold, comparing the concentration polarization of the set of fuel cells to a second threshold, and initiating a corrective action when the ohmic polarization is above the first threshold or when the concentration polarization is below the second threshold.

Abstract: A fuel cell system includes at least one of plural electrochemical pump separators to separate carbon dioxide from a fuel exhaust stream or a combination of a gas separator and a fuel exhaust cooler located outside a hotbox.

Abstract: A fuel cell stack assembly and method of operating the same are provided. The assembly includes a fuel cell stack column and side baffles disposed on opposing sides of the column. The side baffles and the fuel cell stack may have substantially the same coefficient of thermal expansion at room temperature. The side baffles may have a laminate structure in which one or more channels are formed.

Abstract: A power generating system includes power modules disposed in vertically stacked levels, exhaust plenums that extend vertically through the levels of power modules and are configured to receive exhaust output from the power modules, and an exhaust conduit that extends horizontally across an uppermost level of the power modules and is fluidly connected to the exhaust plenums.

Abstract: A fuel cell system including power modules including fuel cells, and an exhaust flue connected to the power modules. The exhaust flue includes an outer duct configured to receive relatively cool cabinet exhaust from the power modules, and an inner duct disposed inside of the outer duct and configured to receive relatively hot reaction exhaust from the power modules.

Abstract: A fuel cell system component ink includes a fuel cell system component powder, a solvent including propylene carbonate (PC), and a binder including polypropylene carbonate (PPC).

Abstract: A method of operating a power generator having a first electrical output electrically connected to a utility grid and a second electrical output electrically connected to a load includes detecting if the first electrical output of the power generator is electrically disconnected from the utility grid, and electrically connecting at least a neutral line of the first electrical output to ground in response to detecting that the first output is electrically disconnected from the utility grid.

Abstract: A fuel cell device includes at least one fuel cell column containing first and second fuel cell stacks, a fuel manifold located between the first and second fuel cell stacks and configured to provide fuel to the first and second fuel cell stacks, and a dielectric material located to electrically isolate the first and second fuel cell stacks from the fuel manifold.

Abstract: Various embodiments include methods and systems for implementing managing a microgrid system. The system may include a plurality of power module clusters, a plurality of uninterruptable power modules, a plurality of bidirectional direct current (DC)/DC converters, and a DC power bus. Each one of the power module clusters of the plurality of power module clusters may be electrically connected in parallel to an uninterruptable power module of the plurality of uninterruptable power modules and a first end of a bidirectional DC/DC converter of the plurality bidirectional DC/DC converters, and a second end of each one of the bidirectional DC/DC converters of the plurality of bidirectional DC/DC converters may be electrically connected to the DC power bus. In some embodiments, the plurality of bidirectional DC/DC converters may be electrically connected to in parallel by the DC power bus or in series via a DC power bus ring.

Abstract: Various embodiments include fuel cell interconnects having a fuel distribution portion having an inlet opening, a fuel collection portion having an outlet opening, and a primary fuel flow field containing channels, wherein the fuel distribution portion comprises at least one raised feature defining a fuel distribution flow path, and the fuel distribution flow path is not continuous with the channels in the primary fuel flow field. The at least one raised feature may include, for example, a network of ribs and/or dots. Further embodiments include interconnects having a fuel distribution portion with a variable surface depth to provide variable flow restriction and/or a plenum with variable surface depth and raised a raised relief feature on the cathode side, and/or varying flow channel depths and/or rib heights adjacent a fuel hole.