Test Plan for Long-Term Operation of a Ten-Cell High Temperature Electrolysis Stack

This document defines a test plan for a long-term (2500 Hour) test of a ten-cell high-temperature electrolysis stack to be performed at INL during FY09 under the Nuclear Hydrogen Initiative. This test was originally planned for FY08, but was removed from our work scope as a result of the severe budget cuts in the FY08 NHI Program. The purpose of this test is to evaluate stack performance degradation over a relatively long time period and to attempt to identify some of the degradation mechanisms via post-test examination. This test will be performed using a planar ten-cell Ceramatec stack, with each cell having dimensions of 10 cm × 10 cm. The specific makeup of the stack will be based on the results of a series of shorter duration ten-cell stack tests being performed during FY08, funded by NGNP. This series of tests was aimed at evaluating stack performance with different interconnect materials and coatings and with or without brazed edge rails. The best performing stack from the FY08 series, in which five different interconnect/coating/edge rail combinations were tested, will be selected for the FY09 long-term test described herein

SYNGAS PRODUCTION VIA HIGH-TEMPERATURE CO-ELECTROLYSIS OF STEAM AND CARBON DIOXIDE IN A SOLID-OXIDE STACK

This paper presents results of recent experiments conducted at the INL studying coelectrolysis of steam and carbon dioxide in a 10-cell high-temperature solid-oxide electrolysis stack. Coelectrolysis is complicated by the fact that the reverse shift reaction occurs concurrently with the electrolytic reduction reactions. All reactions must be properly accounted for when evaluating results. Electrochemical performance of the stack was evaluated over a range of temperatures, compositions, and flow rates. The apparatus used for these tests is heavily instrumented, with precision mass-flow controllers, on-line dewpoint and CO2 sensors, and numerous pressure and temperature measurement stations. It also includes a gas chromatograph for analyzing outlet gas compositions. Comparisons of measured compositions to predictions obtained from a chemical equilibrium co-electrolysis model are presented, along with corresponding polarization curves. Results indicate excellent agreement between predicted and measured outlet compositions. Coelectrolysis significantly increases the yield of syngas over the reverse water gas shift reaction equilibrium composition. The process appears to be a promising technique for large-scale syngas production

The Concept and Analytical Investigation of CO2 and Steam Co-Electrolysis for Resource Utilization in Space Exploration

CO2 acquisition and utilization technologies will have a vital role in designing sustainable and affordable life support and in situ fuel production architectures for human and robotic exploration of Moon and Mars. For long-term human exploration to be practical, reliable technologies have to be implemented to capture the metabolic CO2 from the cabin air and chemically reduce it to recover oxygen. Technologies that enable the in situ capture and conversion of atmospheric CO2 to fuel are essential for a viable human mission to Mars. This paper describes the concept and mathematical analysis of a closed-loop life support system based on combined electrolysis of CO2 and steam (co-electrolysis). Products of the coelectrolysis process include oxygen and syngas (CO and H2) that are suitable for life support and synthetic fuel production, respectively. The model was developed based on the performance of a co-electrolysis system developed at Idaho National Laboratory (INL). Individual and combined process models of the co-electrolysis and Sabatier, Bosch, Boudouard, and hydrogenation reactions are discussed and their performance analyses in terms of oxygen production and CO2 utilization are presented

Progress In High Temperature Electrolysis At The Idaho National Laboratory

The United States is considering the development of a domestic hydrogen-based energy economy. Hydrogen is of particular interest as a secondary energy carrier because it has the potential to be storable, transportable, environmentally benign, and useful in many chemical processes. Obviously, before a hydrogen economy can be implemented, an efficient and environmentally friendly means for large scale hydrogen production must be identified, proven, and developed. Hydrogen is now produced primarily via steam reforming of methane. However, from a long-term perspective, methane reforming is not a viable process for large-scale production of hydrogen since such fossil fuel conversion processes consume non-renewable resources and emit greenhouse gases. The U. S. National Research Council has recommended the use of water-splitting technologies to produce hydrogen using energy derived from a nuclear reactor. For the past several years, the Idaho National Laboratory has been actively studying the use of solid oxide fuel cells in conjunction with nuclear power for large-scale, high-temperature, electrolytic hydrogen production

Engineering Process Model for High-Temperature Electrolysis System Performance Evaluation

In order to evaluate the potential hydrogen production performance of large-scale High-Temperature Electrolysis (HTE) operations, we have developed an engineering process model at INL using the commercial systems-analysis code HYSYS. Using this code, a detailed process flowsheet has been defined that includes all of the components that would be present in an actual plant such as pumps, compressors, heat exchangers, turbines, and the electrolyzer. Since the electrolyzer is not a standard HYSYS component, a custom one-dimensional electrolyzer model was developed for incorporation into the overall HYSYS process flowsheet. This electrolyzer model allows for the determination of the operating voltage, gas outlet temperatures, and electrolyzer efficiency for any specified inlet gas flow rates, current density, cell active area, and external heat loss or gain. The one-dimensional electrolyzer model was validated by comparison with results obtained from a fully 3-D computational fluid dynamics model developed using FLUENT. This report provides details on the one-dimensional electrolyzer model, the HYSYS process model for a 300 MW HTE plant, and some representative results of parametric studies performed using the HYSYS process model

HIGH-TEMPERATURE ELECTROLYSIS FOR HYDROGEN PRODUCTION FROM NUCLEAR ENERGY

An experimental study is under way to assess the performance of solid-oxide cells operating in the steam electrolysis mode for hydrogen production over a temperature range of 800 to 900ºC. Results presented in this paper were obtained from a ten-cell planar electrolysis stack, with an active area of 64 cm2 per cell. The electrolysis cells are electrolyte-supported, with scandia-stabilized zirconia electrolytes (~140 µm thick), nickel-cermet steam/hydrogen electrodes, and manganite air-side electrodes. The metallic interconnect plates are fabricated from ferritic stainless steel. The experiments were performed over a range of steam inlet mole fractions (0.1 - 0.6), gas flow rates (1000 - 4000 sccm), and current densities (0 to 0.38 A/cm2). Steam consumption rates associated with electrolysis were measured directly using inlet and outlet dewpoint instrumentation. Cell operating potentials and cell current were varied using a programmable power supply. Hydrogen production rates up to 90 Normal liters per hour were demonstrated. Values of area-specific resistance and stack internal temperatures are presented as a function of current density. Stack performance is shown to be dependent on inlet steam flow rate

Hydrogen Production from Nuclear Energy via High Temperature Electrolysis

This paper presents the technical case for high-temperature nuclear hydrogen production. A general thermodynamic analysis of hydrogen production based on high-temperature thermal water splitting processes is presented. Specific details of hydrogen production based on high-temperature electrolysis are also provided, including results of recent experiments performed at the Idaho National Laboratory. Based on these results, high-temperature electrolysis appears to be a promising technology for efficient large-scale hydrogen production

Idaho National Laboratory Experimental Research In High Temperature Electrolysis For Hydrogen And Syngas Production

The Idaho National Laboratory (Idaho Falls, Idaho, USA), in collaboration with Ceramatec, Inc. (Salt Lake City, Utah, USA), is actively researching the application of solid oxide fuel cell technology as electrolyzers for large scale hydrogen and syngas production. This technology relies upon electricity and high temperature heat to chemically reduce a steam or steam / CO2 feedstock. Single button cell tests, multi-cell stack, as well as multi-stack testing has been conducted. Stack testing used 10 x 10 cm cells (8 x 8 cm active area) supplied by Ceramatec and ranged from 10 cell short stacks to 240 cell modules. Tests were conducted either in a bench-scale test apparatus or in a newly developed 5 kW Integrated Laboratory Scale (ILS) test facility. Gas composition, operating voltage, and operating temperature were varied during testing. The tests were heavily instrumented, and outlet gas compositions were monitored with a gas chromatograph. The ILS facility is currently being expanded to ~15 kW testing capacity (H2 production rate based upon lower heating value)

CFD Model Of A Planar Solid Oxide Electrolysis Cell For Hydrogen Production From Nuclear Energy

A three-dimensional computational fluid dynamics (CFD) model has been created to model hightemperature steam electrolysis in a planar solid oxide electrolysis cell (SOEC). The model represents a single cell as it would exist in an electrolysis stack. Details of the model geometry are specific to a stack that was fabricated by Ceramatec2, Inc. and tested at the Idaho National Laboratory. Mass, momentum, energy, and species conservation and transport are provided via the core features of the commercial CFD code FLUENT2. A solid-oxide fuel cell (SOFC) model adds the electrochemical reactions and loss mechanisms and computation of the electric field throughout the cell. The FLUENT SOFC user-defined subroutine was modified for this work to allow for operation in the SOEC mode. Model results provide detailed profiles of temperature, Nernst potential, operating potential, anode-side gas composition, cathode-side gas composition, current density and hydrogen production over a range of stack operating conditions. Mean model results are shown to compare favorably with experimental results obtained from an actual ten-cell stack tested at INL

Demonstration and System Analysis of High Temperature Steam Electrolysis for Large-Scale Hydrogen Production Using SOFCs

At the Idaho National Engineering Laboratory, an integrated laboratory scale (ILS), 15 kW high-temperature electrolysis (HTE) facility has been developed under the U.S. Department of Energy Nuclear Hydrogen Initiative. Initial operation of this facility resulted in over 400 hours of operation with an average hydrogen production rate of approximately 0.9 Nm3/hr. The integrated laboratory scale facility is designed to address larger-scale issues such as thermal management (feed-stock heating, high-temperature gas handling), multiple-stack hot-zone design, multiple-stack electrical configurations, and other “integral” issues. Additionally, a reference process model of a commercial-scale high-temperature electrolysis plant for hydrogen production has been developed. The reference plant design is driven by a 600 megawatt thermal high-temperature helium-cooled reactor coupled to a direct Brayton power cycle. The electrolysis unit used to produce hydrogen consists of 4.01×106 cells with a per-cell active area of 225 cm2. A nominal cell area-specific resistance, ASR, value of 0.4 Ohm•cm2 with a current density of 0.25 A/cm2 was used, and isothermal boundary conditions were assumed. The overall system thermal-to-hydrogen production efficiency (based on the low heating value of the produced hydrogen) is 47.1% at a hydrogen production rate of 2.36 kg/s with the high-temperature helium-cooled reactor concept. This paper documents the initial operation of the ILS, with experimental details about heat-up, initial stack performance, as well as long-term operation and stack degradation. The paper will also present the optimized design for the reference nuclear-driven HTE hydrogen production plant which may be compared with other hydrogen production methods and power cycles to evaluate relative performance characteristics and plant economics