To obtain detailed information on the temperature field and thermal stress field inside the solid oxide fuel cell (SOFC) fueled with partially pre-reformed methane. A three-dimensional geometric and mathematical model of the SOFC is implemented by using the finite element method in the commercial software COMSOL Multiphysics®. The coupling characteristics were analyzed for electrode chemical reaction, multi-component mass transfer, and heat transfer process under typical operating conditions, which was further applied for predicting and analyzing the thermal stress distribution. After model validation, parametric simulations are conducted to investigate how the methane pre-reforming percentage and flow arrangement affect the temperature and the thermal stress of SOFC. The simulated results show that reducing the methane pre-reforming percentages can decrease the temperature maximum and the variation range of the first principal stress, but will increase the possibility of carbon deposition. The maximum temperature of the counter-flow is about 20 K lower than that of the co-flow, and the first principal stress variation range of the counter-flow is 8.6 Mpa lower than that of the co-flow. The methane pre-reforming percentages have a significant effect on the heat transfer and the thermal stress, and the counter-flow can improve the temperature uniformity and reduce the thermal stress variation range.

To elucidate the thermofluid reacting environment and thermal stress inside a solid oxide fuel cell (SOFC), a three-dimensional SOFC model is implemented by using the finite element method in the commercial software COMSOL Multiphysics®, which contains both a geometric model of the full-cell structure and a mathematical model. The mathematical model describes heat and mass transfer, electrochemical reactions, internal reforming reactions, and mechanical behaviors that occur within the cell. A parameter study is performed focusing on the inlet fuel composition, where humidified hydrogen and methane syngas (the steam-to-carbon ratio is 3) as well as the local distribution of temperature, velocity, gas concentrations, and thermal stress are predicted and presented. The simulated results show that the fuel inlet composition has a significant effect on the temperature and gas concentration distributions. The high-temperature zone of the hydrogen-fueled SOFC is located at the central part of units 5, 6, and 7, and the maximum value is about 44 K higher than that of methane syngas-fueled SOFC. The methane-reforming and electrochemical reactions in the anode active layer result in a significant concentration gradient between the anode support layer and the active layer of the methane syngas-fueled SOFC. It is also found that the thermal stress distributions of different fuel inlet compositions are rather different. The maximum stress variation gradient between electrode layers of hydrogen SOFC is larger (44.2 MPa) than that of methanol syngas SOFC (14.1 MPa), but the remaining components have a more uniform stress distribution. In addition, the electrode layer of each fuel SOFC produces a significant stress gradient in the y-axis direction, and stress extremes appear in the corner regions where adjacent assembly components are in contact.

Intricate relationships between transport phenomena, reaction mechanisms, and mechanical aspects likely affect the durability of solid oxide fuel cell (SOFC) stack. This study presents a modeling framework that combines thermo-electro-chemo models (including the methanol conversion process and the electrochemical reactions of the carbon monoxide as well as the hydrogen) and a contact thermo-mechanical model that considers the effective mechanical properties of composite electrode material. Detailed parametric studies are performed focusing on the inlet fuel species (hydrogen, methanol syngas) and flow arrangements (co-flow, counter-flow) under typical operating conditions (operating voltage 0.7 V), and performance indicators of the cell, such as the high-temperature zone, current density, and maximum thermal stress were discussed for parameter optimization. The simulated results show that the high temperature zone of the hydrogen-fueled SOFC is located at the central part of units 5, 6, and 7, and the maximum value is about 40 K higher than that of methanol syngas-fueled SOFC. The charge transfer reactions can occur throughout the cathode layer. The counter-flow improves the trend of the current density distribution of hydrogen-fueled SOFC, while the effect on the current density distribution of methanol syngas-fueled SOFC is small. The distribution characteristics of the stress field within SOFC are extremely complex, and the inhomogeneity of the stress field distribution can be effectively improved by feeding methanol syngas. The counter-flow improves the stress distribution state of the electrolyte layer of methanol syngas-fueled SOFC, and the maximum tensile stress value is reduced by about 37.7%.