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Design and Modeling of An Integrated Combined Plant With SOFC For Hydrogen and Ammonia Generation
Design and Modeling of An Integrated Combined Plant With SOFC For Hydrogen and Ammonia Generation
Design and Modeling of An Integrated Combined Plant With SOFC For Hydrogen and Ammonia Generation
ScienceDirect
highlights
A novel combined plant with SOFC is developed for hydrogen and ammonia generation.
Modeled system is investigated thermodynamically with energy and exergy efficiencies.
Parametric analysis is conducted to determine the how the effect of each parameter on the system's performance.
Overall energy and exergy efficiency of this modeled plant is 61.04% and 57.13%, respectively.
Article history: Because of the requirement of the utilization of energy resources in a way that is both
Received 18 October 2021 effective and efficient, solid oxide fuel cells have become a notable preference due to their
Received in revised form advantages such as high efficiency and use with different fuels. In addition, the integration
10 January 2022 of these systems in the production of alternative fuels such as hydrogen and ammonia are
Accepted 31 January 2022 important for a sustainable future to combat environmental problems. For this reason, the
Available online 18 February 2022 main intention of this paper is to introduce a new plant combining the different systems
that use the solid oxide fuel cell for a cleaner and sustainable future. In the modeled work,
Keywords: a solid oxide fuel cell, a gas turbine, an organic Rankine cycle, a Kalina cycle with ejector, a
Combined plant hydrogen generation and storage process, a wood steaming plant, and an ammonia pro-
Energy duction system is integrated, to generate useful products. Detailed thermodynamic
Exergy modeling is performed through energy and exergy methods, to determine the performance
Solid oxide fuel cell of the advised system and subsystem. Moreover, energy efficiency, exergy efficiency, and
Hydrogen exergy destruction analyses methods are applied to each sub-plant and the whole system
Ammonia separately. In addition, parametric research is carried out to examine the effects of
modifying key parameters on the plant's and subsystems' performance. Looking at the
analysis results, the amount of the hydrogen and ammonia generation capacities of this
work are 0.0085 kgs1and 0.2023 kgs1, respectively. In addition, the modeled power plant
produces a power rate of about 20,180 kW. As a result, this proposed study is calculated to
have 61.04% energy efficiency, and 57.13% exergy efficiency.
© 2022 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.
* Corresponding author.
E-mail addresses: fatihyilmaz@isparta.edu.tr (F. Yilmaz), muratozturk@isparta.edu.tr (M. Ozturk).
https://doi.org/10.1016/j.ijhydene.2022.01.249
0360-3199/© 2022 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.
31912 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 7 ( 2 0 2 2 ) 3 1 9 1 1 e3 1 9 2 6
SOFC-based new design multigeneration model from the and ammonia production. Moreover, the main innovative
perspective of energetic and exergetic analysis. As a result, aspect of this work is the operation of the ORC and Kalina sub-
they discovered that the total plant's energy and exergetic cycles as well as hydrogen production and storage with the
efficiencies are 69.86% and 47.4%, respectively. waste heat obtained from the SOFC-based system. Another
The authors, Al-Hamed and Dincer [19] examined a new innovative perspective is the use of some of the hydrogen
design SOFC powering plant for clean locomotives, with produced in ammonia generation. In addition, its main moti-
regards to energy and exergy examines. In this study, they vation is to design a more sustainable system by using the
designed the use of exhaust heat from an ammonia-SOFC exhaust gas in the SOFC-GT cycle at the maximum level,
integrated model to separate hydrogen from ammonia to reducing environmental emissions. Furthermore, the modeled
generate on-board hydrogen. According to the results of their new design work displays the following originalities, in order to
thermodynamic analysis, the energy and exergy perfor- addressed literature gaps:
mances of the entire model are 61.1% and 66.3%, respectively.
In another study by the same authors [20] investigated a To introduce a SOFC-GT-based combined plant integrated
design and optimization of the SOFC-engine powering plant with an ORC, a Kalina cycle, hydrogen production and
for cleaner locomotives. The plant they modeled includes a storage, ammonia production, and wood steaming units.
SOFC-GT with a Partially-Premixed-Compression-Ignition Modeling the effective use of exhaust gas to achieve
(PPCI) engine, an ORC, a heater, and a reversible heat pump beneficial outputs in a sustainable benign way.
system. Based on results, they highlighted that the modeled Design and analysis of generating the various useful
plant is %15 more efficient than the SOFC-GT system. products, such as hydrogen ammonia, cooling, power and
Tukenmez et al. [21] modeled a multigeneration system hot water, using the exhaust gas.
that is integrated with SOFC for hydrogen generation. In this Conducting thorough thermodynamic modeling with en-
system they proposed, they integrated both the renewable ergy and exergy efficiency methods to investigate the
energy source and the SOFC system and then carried out a whole performance of the integrated plant.
comprehensive performance evaluation of the integration of To implement a parametric work to examine the effect of
waste heat management with different sub-systems. In the some significant factors on the modeled plant and
light of their analysis results, it is stated that the energy and subsystems.
exergy efficiency of the whole plant is 56.48% and 54.06%, and
the total hydrogen production capacity of the whole system is
0.0642 kg/s. In a study by Ma et al. [22], they investigated a new
design SOFC assisted combined power, heating, and cooling Designed system layout and definition
system in terms of thermodynamic evaluation. They have
integrated the solar energy system into the fuel cell subsystem In this paper, a multigeneration plant is designed to purpose
with the aim of generating gradual and highly efficient power. to generate power, cooling, hot water, hydrogen, and
In cooling mode, they found the energy and exergy efficiency ammonia assisted by SOFC and also is schematized in Fig. 1.
of the proposed combined plant to be 78.02% and 45.92%. Cao As shown from this schematic layout of modeled plant, the
et al. [23] examined a thermodynamic performance evaluation model consisting of the SOFC plant, gas turbine plant (GTP),
of the integrated plant with hydrogen generation and storage ORC plant (ORCP), Kalina power plant with ejector (KPP), wood
unit. They designed the SOFC based ejector cooling system for steaming plant (WSP), ammonia production plant (APP), and
hydrogen production. Also, they employed comprehensive also hydrogen production and compression process (CHPP).
energy, economic and environmental evaluations. The The main energy carrier of this integrated cycle is the SOFC
modeled plant's exergy efficiency is 30.2% and thermal effi- integrated gas turbine cycle. In this model, SOFC, gas turbine,
ciency is 60.4%. ORC plant, Kalina power plant are used for power generation,
As a result of a brief literature survey, it is possible to state on the other hand, the PEM electrolyzer is also used for
that there are numerous studies on SOFC-based cogeneration generating hydrogen gas. Furthermore, hot water production
and trigeneration systems. However, although there are studies takes place in the condenser 1 part that of the ORC cycle. Each
on SOFC supported integrated (more than three useful prod- system is thermally connected to the other and works
ucts), i.e, multigeneration systems, it is not enough. In short, simultaneously. Basically, for the various subsystems inte-
the reason why SOFC was chosen as the energy source in this grated to employed to the different aim, for example, SOFC is
study is that it has advantages such as high performance, long- integrated for thermal energy as well as power generation,
term stability and low emission, and relatively low exergy ORC for power generation, Kalina cycle for power and cooling
destruction. In this case, there is still a need for more generation, PEM electrolysis for hydrogen production, and
comprehensive studies on SOFC-based multigeneration sys- then ammonia reactor for ammonia production. Also, further,
tems, especially for the way to increase system performance. hot air is obtained with the heat exchanger and this wood will
Considering energy efficiency and environmental aspects, be used for purposes such as steaming.
more studies on integrated systems and a comprehensive ex- To begin with, in the multigeneration plant, the air and fuel
amination of performance enhancement criteria are required. (states 1 and 5) are compressed and preheated, then entering
In this framework, the key difference of this proposed study the SOFC. Here, the electrochemical reaction occurs and DC
from the literature is to examine the SOFC-GT based multi- power is produced. Subsequently, the high pressure and
generation plant, from the point of energy and exergy effi- temperature burned gas at state 13 enters the gas turbine to
ciencies, for power, hot water, cooling, compressed hydrogen generate power. Then, it passes through HEX-1, HEX-2, HEX33,
31914 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 7 ( 2 0 2 2 ) 3 1 9 1 1 e3 1 9 2 6
Fig. 1 e Schematic lay out of the methane-fed SOFC combined plant for multigeneration with hydrogen production.
generator, evaporator, economizer, and HEX4 respectively as that, at state 48, water at about 80 C and some of the elec-
exhausting heat at state 14, transfers its thermal energy to tricity obtained from the subsystems (excess part) enters the
subsystems, and finally goes to the environment. PEM electrolysis and an electrochemical reaction occurs here.
In addition, ORC, one of the subsystems, performs power Hydrogen and oxygen gases are produced as a result of this
and also hot water production. The generator between states process. While some of the produced hydrogen is sent to the
17e18 transfers the thermal energy it receives from the storage tank with a three-way valve, the other part is sent to
exhausted gas to the ORC plant and the thermal energy the ammonia production process. Conversely, the oxygen
required for the run of the system is met from here. R245fa produced can be used in many health fields. On the other
refrigerant, which is the working fluid, is used in this sub- hand, HEX-5 is used in the wood steaming unit by making use
system. Afterward, the evaporator and economizer at states of the last heat of the waste heat. Briefly, the hydrogen storage
18e19 provide the thermal energy required for the Kalina process consists of three hydrogen compressors and three
cycle with ejector. This sub-cycle is a cycle that works with the intercoolers and is sent to the tank as the compressed phase
ammonia-water mixture and has attracted attention in recent that is about 25 C temperature and about 75,000 kPa pressure
years. The main design purpose is power and cooling gener- at point 57. Hydrogen is stored here and used later if needed.
ation here. Finally, at state 65 compressed hydrogen and compressed
Furthermore, at state 19, the still high-temperature waste nitrogen at state 67, enters the ammonia reactor. Here,
heat HEX-4 enters to heat the pure water from state 47. After ammonia is generated in consequence of the reaction that
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 7 ( 2 0 2 2 ) 3 1 9 1 1 e3 1 9 2 6 31915
lCx1 Hy1 þ xO2 O2 þ xN2 N2 þ xH2 O H2 O þ xCO2 CO2 þ xAr Ar / yCO2 CO2 þ yN2 N2 þ yO2 O2 þ yH2 O H2 O þ yNO NO þ yCO CO þ yAr Ar (16)
yCO2 ¼ lx1 þ xCO2 yCO (17)
yN2 ¼ xN2 yNO (18)
Table 2 e The voltage equations utilized for estimating
the SOFC effectiveness [34]. ly1
yH2 O ¼ xH2 O þ (19)
2
Voltage Equations
Cell voltage Vc ¼ Vn Vloss ¼ Vn ðVohm þVact þVcon Þ
" # ly1 lCO lNO
Nernst voltage Dg0 T12
0:5
pO yO2 ¼ xO2 lx1 (20)
Vn ¼ þR ln pH2;12 2;4
4 2 2
2F 2F pH2 O;12
pH2;12 ¼ PH2;12 =Po
yAr ¼ xAr (21)
pO2;4 ¼ PO2;4 =Po
pH2 O;12 ¼ PH2 O;12 =Po
nfuel
Ohmic voltage Vohm ¼ ðra da þrc dc þre de þrin din Þxj l¼
#1 nair
h9:5x107 1150
ra ¼ exp , da ¼ 0:0005
T12 T12 PEM electrolyzer
#
1
h4:2x107 1200
rc ¼ exp , dc ¼ 0:00005
T12 T12 To hydrogen generation, the PEM electrolysis method is a
h
10300 i1 commonly known approach. The produced hydrogen and
re ¼ 33400exp , de ¼ 0:00001
T12 oxygen rate as per the mole can be expressed mathematically
#1
h9:3x106 1100 as follows [35]:
rin ¼ exp , din ¼ 0:003
T12 T12
Activation voltage Vact ¼ Vact;a þ Vact;c N_ O2;out ¼ J 4F (22)
T12 j
Vact;a ¼ R Arcsin , joa ¼ 0:65x104
F
joa
N_ H2;out ¼ J 2F ¼ N_ H2 O;reacted (23)
T12 j
Vact;c ¼ R Arcsin , joc ¼ 0:25x104
F joa Here, J and F are current density and faraday constant. The
Concentration Vcon ¼ Vcon;a þ Vcon;c electrical energy required for PEM to decompose water into
voltage T12
Vcon;a ¼ R ln 1 hydrogen and oxygen molecules can be modeled as in Eq. (22)
2F
following:
j PH2 ;12 j
þln 1 þ
jas PH2 O;12 Jas
Q_ e ¼ JV (24)
T12 j
Vcon;c ¼ R ln 1
2F jcs In this equation, Q_ e is defined as required electrical power.
2FPH2 ;12 Daeff 100000
Jas ¼ , Daeff ¼ 0:2x104 To sum up, V is the PEM voltage, and can be clarified as [35];
RT12 La
4FPO2 ;4 Dceff 100000
Jcs ¼ , Dceff ¼ 0:05x104 V ¼ Vo þ Vact;a þ Vact;c þ Vohm (25)
P4 PO2 ;4
RT12 Lc
P4 where, Vo is the reversible voltage, and can be modeled as:
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 7 ( 2 0 2 2 ) 3 1 9 1 1 e3 1 9 2 6 31917
W_ net;KPP þ Q_ cooling
azFhact;i 1 a zFhact;i hKPP ¼ (37)
J ¼ Jo;i exp exp ; i ¼ a; c (28) m18 h18 m_ 19 h19
_
RT RT
and
Eact;i
ref
Jo;i ¼ Ji exp ; i ¼ a; c (29) W _ cooling Q_
_ net;KPP þ Ex
RT jKPP ¼ (38)
m_ 18 ex18 m_ 19 ex19
In Eq. (25), Vohm is the ohmic loss, and can be explained as,
using whole ohmic resistance (Rohm ) and then can be calcu-
lated as follows:
Ammonia production plant (APP)
Vohm ¼ JRohm (30)
m_ 68 h68
Energetic and exergetic effectiveness of overall plant and hAPP ¼ (39)
_ _
m64 h64 þ m66 h66 þ W _ HC1 þ W_ NC
subsystems
and
In this subsection, this integrated system modeled includes
seven subsystems, the energetic and exergetic efficiencies of m_ 68 ex68
jAPP ¼ (40)
m_ 64 ex64 þ m_ 66 ex66 þ W _ HC1 þ W_ NC
each are investigated separately, and then the mathematical
formulations are written as follows:
Compressed hydrogen production plant (CHPP)
SOFC plant
m_ 49 h49 þ m_ 57 h57
hCHPP ¼ (41)
m_ 48 h48 þ W_ PEM þ W _ HC2 þ W _ HC3 þ W_ HC4
W_ SOFC þ m_ 13 h13
hSOFC ¼ (31)
m_ 1 h1 þ m_ 5 h5 þ m_ 8 h8 þ W _ AC þ W_ P1 þ W_ FC and
W_ net;ORC
hORCP ¼ (35)
m_ 17 h17 m_ 18 h18
and
W _ heating Q_ þ Ex
_ net þ m_ 49 ex49 þ Ex _ cooling Q_ þ Ex
_ steaming Q_ þ m_ H exH þ m_ NH exNH
jCHPP ¼ 2 2 3 3
(46)
m_ 1 h1 þ m_ 5 h5 þ m_ 8 h8
Model validation relative error was quite low, indicating that the results ob-
To emphasize the validity and precision of the conclusions tained are consistent with the studies reviewed in the
produced from thermodynamic analyses in theoretical in- literature.
vestigations, model validation is a reasonable method used by
many researchers. SOFC, ORC plant, and Kalina power plant,
which are the most important sub-plants of this integrated Results and discussion
system, are power generation cycles, and the model verifica-
tion of these cycles with some studies in the literature has In this subpart, energy and exergy methodologies are used to
been made and presented in this subsection. To begin with, conduct detailed thermodynamic modeling of the SOFC-
the SOFC subcycle is validated in the literature by the study assisted multigeneration plant. For this aim, energetic effi-
presented by Ma et al. [33], and is tabulated in Table 3. At the ciency, exergetic efficiency, irreversibility, and the amount of
same SOFC anode and cathode inlet and outlet values, the the beneficial products of the overall plant and subsystem are
exergy performance of the model developed by Ma et al. [33], is parametrically examined. Furthermore, parametric work is
46.73%, while the exergy efficiency that we examined and employed to identify how the influence of some important
simulated is 47.51%. Under these conditions, the relative error factors changing on the performance behavior of the planned
is 1.67%, which is a consistent result for model validation. model and subsystem. With the assumptions highlighted in
In addition, another power generation cycle is the Kalina Table 1, a mathematical model is created using the EES soft-
cycle. With this modeled sub-cycle, the literature study that is ware and the results obtained from the thermodynamic
presented by Ghaebi et al. [36] model validation is conducted analysis, i.e., the values of each point, are presented in Table 6.
and highlighted in Table 4. Looking at Table 4, in the same Looking at Table 6, the thermodynamic values of each point of
parameters of the Kalina plant, the exergy performance of the the recommended integrated plant above presented in Fig. 1,
study modeled by Ghaebi et al. [36] is 16.69%, while the exergy are calculated by EES.
performance of our modeled system is 17.08%. Looking at
these values, the relative error is calculated as %2.3, and it
should be noted that this value is consistent for the model
validation. Table 4 e Validation outputs for Kalina power plant with
In conclusion, for the last model validation part in this the study of Ghaebi et al. [36].
subsection, ORC subcycle with 245fa fluid is considered. Table Values [36]
5 presents the model validation of our modeled ORC subcycle,
Kalina turbine inlet temperature 190 C
with the work that Safari and Dincer [37] suggested in the Kalina turbine inlet pressure 1750 kPa
literature. In the same inlet and outlet conditions of the ORC Kalina turbine outlet temperature 172 C
turbine, the exergy efficiency of the study presented by Safari Kalina turbine outlet pressure 1167 kPa
and Dincer is 18.43%, while the exergy efficiency of this study Ejector exit temperature 102.85 C
is 18.65%. In between with these papers, the relative error is Ejector exit pressure 30.87 kPa
Mixer exit temperature 61.75 C
1.19%, and this value is within the range suitable for model
Mixer exit pressure 30.87 kPa
Exergetic performance of Kalina plant 16.69%
Simulated exergetic performance 17.08%
Table 3 e Validation outputs for SOFC plant with the Error 2.33%
study of Ma et al. [33].
Values [33]
Compressed air inlet temperature for cathode 426.85 C Table 5 e Validation outputs for ORC plant with the study
Compressed air inlet pressure for cathode 810.6 kPa of Safari and Dincer [37].
Mixing fuel inlet temperature for anode 426.85 C
Values [37]
Mixing fuel inlet pressure for anode 810.6 kPa
Compressed air exit temperature for cathode 946.85 C ORC turbine inlet temperature 160 C
Compressed air exit pressure for cathode 810.6 kPa ORC turbine inlet pressure 2500 kPa
Mixing fuel exit temperature for anode 946.85 C ORC turbine outlet temperature 73.14 C
Mixing fuel exit pressure for anode 810.6 kPa ORC turbine outlet pressure 100 kPa
Exergetic performance of SOFC 46.73% Energetic performance of ORC 18.43%
Simulated exergetic performance 47.51% Simulated energetic performance 18.65%
Error 1.67% Error 1.19%
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 7 ( 2 0 2 2 ) 3 1 9 1 1 e3 1 9 2 6 31919
Table 6 e (continued )
State point T ( C) P (kPa) m_ (kg/s) h (kJ/kg) s (kJ/kgK) X (%)
64 80 101.3 0.05197 4723 55.81 e
65 250 10,000 0.05197 7261 45.96 e
66 45 101.3 0.238 505.8 6.903 e
67 250 10,000 0.238 543 6.044 e
68 250 10,000 0.2023 1936 5.464 e
69 18 101.3 0.1672 75.56 0.2675 e
70 18.2 350 0.1672 76.63 0.2704 e
71 138.9 350 0.1672 2732 6.941 e
Accompanied by the values in Table 6, the consequences of SOFC power generation rate is higher than other sub-cycles.
the thermodynamic analysis, i.e., energy efficiency, exergy ef- The heating and cooling capacities of this designed system
ficiency, and irreversibility, are given in Table 7, for the sub- are 4962 kW and 154 kW. In conclusion, the hydrogen and
systems and the whole plant. While the energy and exergy ammonia generation capacities of the overall plant are 0.0085
performances of the SOFC model are 44.86% and 41.63%, and 0.2023 kg per second, respectively.
respectively, also its reversibility rate is determined as As coming to the parametric evaluation results, to begin
11,086 kW. Also, the energy and exergy efficiency of another with, it should be emphasized that the ambient point tem-
subsystem, ORC, is listed as 17.26% and 14.85%. Furthermore, perature changing is a significant factor to determine the
the exergetic performance of the overall study is 57.13%, while impact on the performance behavior of any thermal plant
the energetic performance is 61.04%. Referring to the irrevers- design. In this context, the effect of ambient point tempera-
ibility of among the subcycles, the highest and lowest irre- ture change on the performances of the proposed model and
versibilities are determined in the SOFC unit and ORC plant. It subsystems, respectively, are examined and illustrated in
should be reported that more irreversibility occurs due to irre- Fig. 2 and Fig. 3. Referring Fig. 2, the energetic efficiency of the
versibility in parts with high-temperature changes. On the
other hand, the values of the useful outputs obtained with this
designed plant are presented in Table 8. The power generation
quantities of SOFC, GT, ORCT, and KT are 12,743 kW, 6331 kW,
752 kW, and 354 kW, respectively. It is clearly shown that the
Fig. 9 e Variation of the modeled systems' beneficial Fig. 11 e Variation of the exergy destruction rate of the
products in line with different SOFC operating overall plant and subsystems in line with different SOFC
temperatures. operating temperatures.
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 7 ( 2 0 2 2 ) 3 1 9 1 1 e3 1 9 2 6 31923
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Ac : Active surface area, m2
Thermodynamic analysis of fuel-cell-based combined
ex: Specific exergy, kJ/kg
cooling, heating, and power system integrated solar energy
_ Exergy rate, kW
Ex:
and chemical looping hydrogen generation. Energy
F: Faraday constant (C/mol)
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h: Specific enthalpy, kJ/kg
j.energy.2021.121974.
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p: Partial pressure (kPa)
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_ Heat transfer rate, kW
Q:
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R: Universal gas constant, kJ/kmol K
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T: Temperature, oC- K
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Vact : Activation polarization (V)
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Vc : Cell voltage (V)
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