Abstract: An solid oxide fuel cell stack having a metallic layer and a glass layer, and a method for preventing or reducing a chemical reaction between a metallic layer and a glass layer are disclosed. The solid oxide fuel cell stack has a barrier layer disposed between the metallic layer and the glass layer. The barrier layer includes alumina and a phosphate. The phosphate includes an aluminum dihydrogen phosphate, an aluminum-containing phosphate, a phosphate of an element of the metallic layer, a phosphate of an element of the glass layer, or combinations thereof. The method includes disposing a barrier layer between the metallic layer and the glass layer.

Abstract: A method and apparatus for detecting oxidation in at least one planar fuel cell stack that includes a multitude of cells is described. The height of the stack is measured to determine if there has been an increase from a previously-measured height. Such an increase correlates with the oxidation of at least some of the planar cells. In some cases, the fuel flow rate or airflow rate to each fuel cell stack can be adjusted, based in part on the oxidation detection technique. A power delivery system with at least two fuel cell stacks is also described, and it includes a stack height-measurement system, a health monitor for the fuel cell stacks, and a load balancer or airflow regulator.

Abstract: A distributed fault management system includes at least one sensor associated with a fuel cell system and at least one first fault management computing device coupled to the at least one sensor. The at least one first fault management computing device is configured to receive data associated with a first fault condition. The at least one first fault management computing device is further configured to generate a resolution to the first fault condition and transmit at least one resolution command signal to at least one second fault management computing device. The at least one resolution command signal configures the at least one second fault management computing device to use the resolution to resolve a second fault condition in a similar manner.

Abstract: An intermediate solid oxide fuel cell (SOFC) stage and methods for inspecting an assembled portion of an SOFC are presented. One method for inspecting an assembled portion of an SOFC includes applying a pneumatic constraint to a fluid, where the fluid is in communication with the assembled portion of the SOFC, determining a quality control parameter of the assembled portion of the SOFC in response to the pneumatic constraint, and ascertaining health of the assembled portion of the SOFC based on the quality control parameter. The assembled portion of the SOFC includes a metallic interconnect, where the metallic interconnect includes a flow field.

Abstract: An integrated fuel cell system includes fuel cells, fuel heat exchangers, air heat exchangers, and tail gas oxidizers. The tail gas oxidizers oxidize a (second) portion of fuel received from the fuel cells with effluent that is output from the fuel cells. Fuel cell stacks are fluidly coupled with the fuel heat exchangers and the tail gas oxidizers such that the fuel that is output from the fuel cells is split into a first portion that is directed back into the fuel heat exchangers and a second portion that is directed into the tail gas oxidizers.

Abstract: An article having a metallic layer and a glass layer, and a method for preventing or reducing a chemical reaction between a metallic layer and a glass layer are disclosed. The article has a barrier layer disposed between the metallic layer and the glass layer. The barrier layer includes alumina and a phosphate. The phosphate includes an aluminum dihydrogen phosphate, an aluminum-containing phosphate, a phosphate of an element of the metallic layer, a phosphate of an element of the glass layer, or combinations thereof. The method includes disposing a barrier layer between the metallic layer and the glass layer.

Abstract: A fuel cell system is disclosed, which includes an anode recirculation loop having a fuel cell stack for generating power, a flowmeter, a current sensor and a processor. The flowmeter is configured for measuring a fuel flow rate provided into the anode recirculation loop. The current sensor is configured for measuring a current drawn from the fuel cell stack. The processor is configured for determining a steam to carbon ratio in the anode recirculation loop based on the measured fuel flow rate and the measured current. The fuel cell system further includes a temperature sensor for measuring a temperature in the anode recirculation loop. The process is configured for determining the steam to carbon ration further based on the measured temperature. A method for operating the fuel cell system and a fuel cell power plant are also disclosed.

Abstract: A formed substrate assembly includes an air flow form plate, a fuel flow form plate, and an anode. The fuel flow form plate is positioned over the air flow form plate. The fuel flow form plate partially defines a plurality of first channels. The fuel flow form plate also defines a plurality of second channels. The plurality of second channels defines a plurality of apertures, where a portion of the apertures extend from the plurality of second channels to the plurality of first channels. The anode is positioned over the fuel flow form plate. The anode partially defines the plurality of first channels such that the fuel flow form plate and the anode define the plurality of first channels. The portion of the plurality of apertures is configured to channel a flow of fuel from the plurality of second channels to the plurality of first channels.

Abstract: A solid oxide fuel cell stack having a metallic layer and a glass layer, and a method for preventing or reducing a chemical reaction between the metallic layer and the glass layer are disclosed. The solid oxide fuel cell stack has a barrier layer disposed between the metallic layer and the glass layer. The barrier layer includes alumina and a phosphate. The phosphate includes an aluminum dihydrogen phosphate, an aluminum-containing phosphate, a phosphate of an element of the metallic layer, a phosphate of an element of the glass layer, or combinations thereof. The method includes disposing a barrier layer between the metallic layer and the glass layer.

Abstract: An electric power generation system includes a fuel cell module. The fuel cell module includes a fuel cell and a compression plate. The compression plate includes a surface contacting the fuel cell. A support plate is opposite the compression plate. The compression plate is movable in relation to the support plate. A pressurized fluid container is disposed between the compression plate and the support plate. The pressurized fluid container includes a casing defining an internal space configured to contain pressurized fluid. The electric power generation system further includes a pressurized fluid source and a fluid line coupled to the pressurized fluid source and the pressurized fluid container.

Abstract: A fuel cell system and a control method thereof are disclosed. The system includes a fuel cell stack having an anode and a cathode, an anode recirculation loop including the anode, a fuel supply device for providing a fuel gas via a fuel feed path, an air supply device for providing air to the cathode, an anode blower and a switching element. The loop has a first path and a second path, and the anode is arranged in the second path. During normal operation of the system, the fuel feed path and the first path are combined to form the second path, and the second path is split into the first path and a fuel exhaust path. The anode blower is configured for driving circulation through the loop. The switching element is located in at least one of the first path and the combining point and is configured to force the fuel gas to flow through the second path to the fuel exhaust path in the event of failure of the anode blower.

Abstract: A fuel cell system is disclosed, which includes an anode recirculation loop comprising a fuel cell stack for generating power, a flowmeter for measuring a fuel flow rate of a fuel provided into the anode recirculation loop, a current measuring device for measuring a current drawn from the fuel cell stack, a recycle ratio measuring device for measuring a recycle ratio in the anode recirculation loop, and a processor for estimating a fuel utilization of the fuel cell stack based on the measured fuel flow rate, the measured current and the measured recycle ratio. Methods for operating the fuel cell system are also disclosed.

Abstract: A fuel cell based power generation system is presented. The fuel cell based power generation system includes a fuel cell assembly configured to generate a DC power, at least one assembly switching element configured to operatively couple the fuel cell assembly to a first DC bus, at least one converter coupled between the first DC bus and an electrical grid, a plurality of auxiliary loads operatively coupled to the first DC bus at a location between the at least one assembly switching element and the at least one converter, where at least one of the plurality of auxiliary loads is configured to receive power from the fuel cell assembly via the at least one assembly switching element, and a controller operatively coupled to the at least one converter, where the controller is configured to allow a voltage of the first DC bus to fluctuate within a range of voltage values.

Abstract: A multi-stack fuel cell system includes upper and lower housings defining interior chambers in corresponding upper and lower stacks of fuel cells are disposed. A heat exchanger assembly is fluidly coupled with the interior chambers. The heat exchanger assembly receives input fuel and/or input air from outside of the housings and receives outgoing fuel and/or outgoing air from the fuel cells. The heat exchanger assembly heats the input fuel and/or the input air, and/or cools the outgoing fuel and/or the outgoing air. The heat exchanger assembly may be disposed between the upper and lower housings. The upper housing an upper stack of fuel cells and/or the heat exchanger assembly may assist in compressing the fuel cells in the lower stack against each other.

Abstract: Temperature control system and method for a fuel cell system are disclosed. The temperature control system includes a state detector, a control selector, a normal controller and an internal model controller. The state detector determines whether the fuel cell system is in a leakage condition based on a dynamic transfer function from an air flowrate provided to the fuel cell system to a fuel cell temperature. The control selector selects to switch between the normal controller and the internal model controller based on a determined result. The normal controller is configured for controlling an air flowrate of the fuel cell system which is not in the leakage condition. The internal model controller is configured for controlling the air flowrate of the fuel cell system in the leakage condition to control the fuel cell temperature. A fuel cell system with the temperature control system is also disclosed.

Abstract: Power generation systems and associated methods for generating electric power using a cascaded fuel cell are provided. The power generation system may include a first fuel cell, a second fuel cell, a splitting mechanism, a first fuel path, and a second fuel path. The First fuel cell is configured to generate first anode and first cathode tail gas streams. The splitting mechanism is configured to split the first anode tail gas stream into first and second portions. The first fuel path is configured to receive hydrocarbon fuel stream downstream of splitting mechanism, mix with the first portion to form a mixed stream, and circulate the mixed stream to the first fuel cell. The second fuel path is configured to feed the second portion to the second fuel cell. The first and second fuel cells are configured to generate electric power by using the mixed stream and the second portion respectively.

Abstract: A method and apparatus for detecting oxidation in at least one planar fuel cell stack that includes a multitude of cells is described. The height of the stack is measured to determine if there has been an increase from a previously-measured height. Such an increase correlates with the oxidation of at least some of the planar cells. In some cases, the fuel flow rate or airflow rate to each fuel cell stack can be adjusted, based in part on the oxidation detection technique. A power delivery system with at least two fuel cell stacks is also described, and it includes a stack height-measurement system, a health monitor for the fuel cell stacks, and a load balancer or airflow regulator.

Abstract: The power generation system includes a fuel-cell subsystem having a fuel-cell configured to generate an electrical power. The power generation system further includes a power electronics subsystem electrically coupled to the fuel-cell subsystem and configured to process at least a portion of the electrical power generated by the fuel-cell subsystem. The power generation system also includes a first conduit fluidly coupled to the power electronics subsystem and configured to supply at least a portion of a fuel stream to the power electronics subsystem. The power electronics subsystem is configured to heat the portion of the fuel stream to form a pre-heated fuel stream. Moreover, power generation system includes a second conduit fluidly coupled to the power electronics subsystem and the fuel-cell subsystem and configured to supply the pre-heated fuel stream to the fuel-cell subsystem. The fuel-cell is configured to generate the electrical power using the pre-heated fuel stream.