Abstract: This invention pertains to a reinforced porous metal substrate that finds utility in a backbone-structured metal-supported electrochemical cell and to methods of fabricating the reinforced porous metal substrate. In another aspect, this invention pertains to a backbone-structured metal-supported electrochemical cell repeat unit constructed by weld sealing or diffusion bonding the reinforced porous metal substrate to a metal frame. In another aspect, this invention pertains to an electrochemical cell and stack.

Abstract: A thermally integrated hotbox apparatus combining a steam reformer, a plurality of solid oxide fuel cell (SOFC) stacks, a plurality of oxidant manifolds, and at least one heat extractor. The steam reformer occupies a central position in the hotbox, around which are disposed in spaced-apart relation a plurality of SOFC stacks. A burner may be associated with the steam reformer, either within or outside the hotbox. An oxidant manifold is disposed between each pair of adjacent SOFC stacks. A heat exchanger is incorporated between an SOFC stack and an oxygen manifold. The hotbox design optimally captures thermal heat from the SOFC stacks for use in producing steam and operating the endothermic steam reformer. The apparatus reduces duty cycle of the burner, which produces heat and steam needed for operation of the endothermic steam reformer.

Abstract: A clad porous metal substrate for use in a metal-supported electrochemical cell, wherein a metal support layer of defined porosity is clad on top and bottom sides with a layer containing a metal and/or a metal oxide. A metal-supported electrochemical half-cell and a metal-supported electrochemical cell are also described.

Abstract: A thermally integrated hotbox apparatus combining a steam reformer, a plurality of solid oxide fuel cell (SOFC) stacks, a plurality of oxidant manifolds, and at least one heat extractor. The steam reformer occupies a central position in the hotbox, around which are disposed in spaced-apart relation a plurality of SOFC stacks. A burner may be associated with the steam reformer, either within or outside the hotbox. An oxidant manifold is disposed between each pair of adjacent SOFC stacks. A heat exchanger is incorporated between an SOFC stack and an oxygen manifold. The hotbox design optimally captures thermal heat from the SOFC stacks for use in producing steam and operating the endothermic steam reformer. The apparatus reduces duty cycle of the burner, which produces heat and steam needed for operation of the endothermic steam reformer.

Abstract: A thermally integrated hotbox apparatus combining a steam reformer, a plurality of solid oxide fuel cell (SOFC) stacks, a plurality of oxidant manifolds, and at least one heat extractor. The steam reformer occupies a central position in the hotbox, around which are disposed in spaced-apart relation a plurality of SOFC stacks. A burner may be associated with the steam reformer, either within or outside the hotbox. An oxidant manifold is disposed between each pair of adjacent SOFC stacks. A heat exchanger is incorporated between an SOFC stack and an oxygen manifold. The hotbox design optimally captures thermal heat from the SOFC stacks for use in producing steam and operating the endothermic steam reformer. The apparatus reduces duty cycle of the burner, which produces heat and steam needed for operation of the endothermic steam reformer.

Abstract: An integrated power generation system including: a hotbox containing a steam reformer and at least one solid oxide fuel cell (SOFC) stack; a condenser, a combustor, a heater, and a turbomachine comprising a compressor and an expander. The steam reformer is configured to convert a hydrocarbon fuel and steam into a stack fuel. The SOFC stack is configured to convert the stack fuel into a first anode waste gas. The condenser functions to remove water from the first anode waste gas, thereby producing a second anode waste gas of higher fuel energy density. The combustor bums the second anode waste gas with release of exothermic heat. The heater thermally transmits heat from an expanded combustion product to water collected in the condenser, so as to generate steam. A steam line fluidly connects the heater to the steam reformer.

Abstract: A solid oxide fuel cell system includes a first fuel cell tube, a flame tip protection member and a current conduction member. The first fuel cell tube has a flame end. The flame end has exit opening. The fuel cell tube is configured to deliver combustible gas to the flame tip region generating a flame kernel. The flame protection member is configured to inhibit at least one of mass transfer and heat transfer between the fuel cell tube and the flame tip region. The current conduction member is disposed through the exit opening of the flame end of the first fuel cell tube.

Abstract: A method for forming a solid oxide fuel cell brazed to a current collector includes heating the solid oxide fuel cell, the current collector, and a primary brazing slurry above a brazing temperature and subsequently cooling the solid oxide fuel cell, the current collector and the primary brazing slurry below the brazing temperature. The method further includes heating the solid oxide fuel cell, the current collector and the secondary brazing slurry above the brazing temperature and subsequently cooling the solid oxide fuel cell primarily brazed to the current collector and the secondary brazing slurry below the brazing temperature.

Abstract: A fuel cell system includes a plurality of fuel cell tubes, each fuel cell tube being configured to input fuel at an inlet opening and output exhaust at an exhaust opening. The fuel cell system further includes a current collecting, system comprising an interconnect member disposed through the exhaust opening. The interconnect member electrically connects an inner electrode of a first fuel cell tube to an electrode of a second fuel cell tube.

Abstract: A method for operating a fuel cell system includes monitoring a signal indicative of a water level within the fuel cell system. The method further includes determining an anode air flow rate based on the monitored signal indicative of water level. The method further includes controlling the anode air actuator based on the determined anode air flow rate.

Abstract: An aerial vehicle is configured to operate in a base fuel cell operating mode and a fuel cell boost operating mode. A method for controlling the aerial includes providing a base fuel cell upper power limit. The method further includes controlling the fuel cell power level below the base fuel cell upper power limit when the aerial vehicle is operating in the base fuel cell operating mode. The method further includes operating the fuel cell above the base upper fuel cell power limit when the aerial vehicle is operating in the fuel cell boost operating mode.

Abstract: A solid oxide fuel cell module includes a fuel cell tube comprising an inner anode, an outer cathode, and an electrolyte disposed between the inner anode and the outer cathode. The inner anode includes a plurality of hollow rod current conducting members embedded in a bulk anode.

Abstract: A fuel cell stack configured to input raw fuel from a fuel source to produce electrical energy includes a fuel cell comprising an anode, an electrolyte, and a cathode. The anode defines an anode chamber, and a hydrogen separation member is disposed within the anode chamber. The hydrogen separation member has a first side and a second side. The first side of the hydrogen separation member defines a raw fuel chamber. The hydrogen separation member transfer hydrogen between the first side and the second side to provide hydrogen fuel to the anode of the fuel cell, while inhibiting the transportation of gas molecules between the first side and the second side.

Abstract: Disclosed herein is a solid oxide fuel cell including an electrochemical cell, a first fuel reformer, and a first feed tube. The electrochemical cell includes an anode, a cathode, and an electrolyte. The anode at least partially defines an anode chamber. The anode is configured to convert a reformed fuel to an exhaust fluid comprising water. The fuel reformer is configured to receive raw fuel and to convert raw fuel to reformed fuel. The fuel reformer is disposed within the anode chamber. The first feed tube is disposed within the anode chamber. The first feed tube is configured to route raw fuel downstream the first fuel reformer such that raw fuel reacts with water of the exhaust fluid.

Abstract: A solid oxide fuel cell module includes a fuel cell tube comprising an inner anode, an outer cathode, and an electrolyte disposed between the inner anode and the outer cathode. The inner anode includes a plurality of hollow rod current conducting members embedded in a bulk anode.

Abstract: A solid oxide fuel cell module includes a fuel cell tube defining a fuel cell tube inner chamber. The fuel cell tube includes a fuel cell tube inlet, a fuel cell tube outlet, and an active portion comprising an anode layer, a cathode layer, and an electrolyte layer. The active portion is configured to react an oxidizing fluid and a reducing fluid to generate an electromotive force. The solid oxide fuel cell module further includes an internal reforming member disposed within the fuel cell tube, the internal reforming member being configured to receive raw fuel and convert raw fuel to reformed fuel. The solid fuel cell tube further includes an anode current collector disposed within the fuel cell tube, the anode current collector connected to the anode layer of the anode current collector and providing support to the internal reforming member such that the internal reforming member retains a desired position within the fuel cell tube.

Abstract: A solid oxide fuel cell includes a tube, a spacer element, a catalytic substrate and an anode current collector. The solid oxide fuel cell further includes a spacer element disposed within the tube. The solid oxide fuel cell further includes a catalytic substrate disposed within the anode current collector electrically contacting the anode of the tube and providing an electrical current path inside the tube past the catalytic substrate to the inlet opening.

Abstract: A solid oxide fuel cell module includes a fuel cell tube defining a fuel cell tube inner chamber. The fuel cell tube includes a fuel cell tube inlet, a fuel cell tube outlet, an active portion, and an inner current carrier. Oxidizing fluid and reducing fluid react with the active portion to generate an electromotive force. The active portion includes an inner electrode; an outer electrode; and an electrolyte disposed between the inner electrode and the outer electrode. The inner current carrier is disposed between the tube inlet and the active portion. The inner current carrier has a temperature gradient when the active portion is at an active portion steady-state operating temperature. The solid oxide fuel cell module further includes a fuel feed tube routing fuel through the fuel cell tube inlet to the fuel cell tube inner chamber.

Abstract: A solid oxide fuel cell stack includes a solid oxide fuel cell tube and a reformer inside the tube. The tube includes a plurality of electrochemical cells electrically connected in series. Each electrochemical cell includes an electrolyte disposed between an interior anode and an exterior cathode. The fuel reformer is configured to convert a hydrocarbon fuel to a fuel cell fuel comprising hydrogen such that hydrogen is provided to an anode of the solid oxide fuel tube.

Abstract: A solid oxide fuel cell stack includes a first fuel cell tube, a second fuel cell tube, and an interconnect member. The first fuel cell tube further includes an active area having a plurality of electrochemical cells connected in series, a first cathode lead disposed between the plurality of electrochemical cells connected in series and a first fuel cell tube inlet and a first anode lead disposed between the plurality of electrochemical cells connected in series and a first fuel cell tube outlet. The second fuel cell tube includes a second fuel cell tube comprising an active area having a plurality of electrochemical cells connected in series, a second anode lead disposed between a plurality of electrochemical cells connected in series and a first fuel cell tube inlet and a second cathode lead disposed between the plurality of electrochemical cells connected in series and a first fuel cell tube outlet.