Fuelcell Energy Inc FCEL

SOFC progress

[3.1417]

Diesel fuel cell APU provides an efficient energy management for commercial vehicles.

https://youtu.be/IVFELrcVQaM

Patents by Assignee Versa Power Systems, Ltd.

Cell materials variation in SOFC stacks to address thermal gradients in all planes

Patent number: 9190669

Abstract: A solid oxide fuel cell, and methods for modifying the temperature thereof, the fuel cell having a plurality of planar layered fuel cell units, an electrically conductive flow separator plate disposed between each of the fuel cell units, and a cathode contact material element disposed between each cathode electrode of the fuel cell units and each electrically conductive flow separator plate. The cathodes of the individual fuel cell units are modified such that the operating temperatures of the cathodes are matched with the temperatures they experience based upon their locations in the fuel cell stack. The modification involves adding to the cathode contact material and/or cathode at least one alloying agent which modifies the temperature of the cathode electrodes based upon the location of the cathode electrodes within the fuel cell stack. These alloying agents react with a component of the cathode electrode to form alloys.

Type: Grant

Filed: July 17, 2007

Date of Patent: November 17, 2015

Assignee: VERSA POWER SYSTEMS, LTD.

Inventors: Anthony Wood, Zheng Tang

SYSTEMS AND METHODS FOR PREVENTING CHROMIUM CONTAMINATION OF SOLID OXIDE FUEL CELLS

Publication number: 20150270557

Abstract: In some embodiments, a solid oxide fuel system is provided. The solid oxide fuel cell system may include a chromium-getter material. The chromium-getter material may react with chromium to remove chromium species from chromium vapor. The solid oxide fuel cell system may also include an inert substrate. The chromium-getter material may be coated onto the inert substrate. The coated substrate may remove chromium species from chromium vapor before the chromium species can react with a cathode in the solid oxide fuel cell system.

Type: Application

Filed: March 20, 2014

Publication date: September 24, 2015

Applicant: Versa Power System Ltd.

Inventors: Hongpeng He, Anthony Wood

CATHODE CONTACT LAYER DESIGN FOR PREVENTING CHROMIUM CONTAMINATION OF SOLID OXIDE FUEL CELLS

Publication number: 20150270558

Abstract: In embodiments, a fuel cell stack is provided that includes an interconnect between a first fuel cell and a second fuel cell, and a contact layer in contact with, and disposed between, an electrode of the first fuel cell and the interconnect. The contact layer may include a chromium-getter material. This chromium-getter material may consist of lanthanum oxide, lanthanum carbonate, and/or calcium carbonate.

Type: Application

Filed: March 20, 2014

Publication date: September 24, 2015

Applicant: Versa Power System Ltd.

Inventors: Anthony Wood, Hongpeng He, Tahir Joia

Electrically conductive fuel cell contact material

Patent number: 8962218

Abstract: A multilayer contact approach for use in a planar solid oxide fuel cell stack includes at least 3 layers of an electrically conductive perovskite which has a coefficient of thermal expansion closely matching the fuel cell material. The perovskite material may comprise La1-xEx Co0.6Ni0.4O3 where E is a alkaline earth metal and x is greater than or equal to zero. The middle layer is a stress relief layer which may fracture during thermal cycling to relieve stress, but remains conductive and prevents mechanical damage of more critical interfaces.

Type: Grant

Filed: January 14, 2011

Date of Patent: February 24, 2015

Assignee: Versa Power Systems, Ltd.

Inventors: Xinge Zhang, Anthony Wood, Michel Riou

Fuel cell shutdown with steam purging

Patent number: 8722270

Abstract: The present invention relates to an apparatus for steam purging a solid oxide fuel cell stack. Purging the SOFC stack with steam has a physical flushing effect, removing carbon monoxide containing reformate and free oxygen gas from the anode area thereby reducing the potential for nickel oxide or nickel carbonyl formation.

Type: Grant

Filed: January 14, 2011

Date of Patent: May 13, 2014

Assignee: Versa Power Systems, Ltd.

Inventors: Michael Pastula, James Smith, Quincy Yueh Feng Chiang

High performance cathode with controlled operating temperature range

Patent number: 8313875

Abstract: In a solid oxide fuel cell having an anode, a cathode, and a dense electrolyte disposed between the anode and the cathode, the cathode having a ceramic-ionic conducting phase of a plurality of ionic conducting particles and a metallic phase of a plurality of metallic particles. The metallic phase includes a metal alloy having an oxide-to-metal transition temperature in the range of about 600° C. to about 800° C. With this cathode, solid oxide fuel cell operating temperatures as low as about 600° C. may be possible.

Type: Grant

Filed: October 2, 2006

Date of Patent: November 20, 2012

Assignee: Versa Power Systems, Ltd.

Inventors: Anthony Wood, Zheng Tang, Sofiane Benhaddad, Tahir Joia, Kyle Marcotte, David Waldbillig

Thermally integrated fuel cell system

Patent number: 8268491

Abstract: A thermally integrated fuel cell system includes a stack zone, a burner zone and a low temperature zone. The fuel is combined with steam and passed sequentially through a primary reformer and a secondary reformer or a radiative fuel heat exchanger. Air may be passed sequentially through an afterburner heat exchanger and a radiative air heat exchanger such that the radiative heat exchanger may be used to heat the stack zone. The stack exhaust is combusted in an afterburner. Afterburner exhaust heats the primary reformer, the high temperature air heat exchanger, the low temperature air heat exchanger and steam generator. The stack zone includes the stacks, the secondary reformer and the radiative heat exchanger. The burner zone includes the afterburner which includes a start burner, the primary reformer and the high temperature air heat exchanger. The low temperature zone includes the low temperature air heat exchanger and a steam generator.

Type: Grant

Filed: May 18, 2012

Date of Patent: September 18, 2012

Assignee: Versa Power Systems, Ltd.

Inventors: Michael Pastula, Andrea Tylczak, Pawel Fronc, Marc Dionne, Glenn Price, Bryce Sharman, Casey Brown, Kevin Marchand

THERMALLY INTEGRATED FUEL CELL SYSTEM

Publication number: 20120231360

Abstract: A thermally integrated fuel cell system includes a stack zone, a burner zone and a low temperature zone. The fuel is combined with steam and passed sequentially through a primary reformer and a secondary reformer or a radiative fuel heat exchanger. Air may be passed sequentially through an afterburner heat exchanger and a radiative air heat exchanger such that the radiative heat exchanger may be used to heat the stack zone. The stack exhaust is combusted in an afterburner. Afterburner exhaust heats the primary reformer, the high temperature air heat exchanger, the low temperature air heat exchanger and steam generator. The stack zone includes the stacks, the secondary reformer and the radiative heat exchanger. The burner zone includes the afterburner which includes a start burner, the primary reformer and the high temperature air heat exchanger. The low temperature zone includes the low temperature air heat exchanger and a steam generator.

Type: Application

Filed: May 18, 2012

Publication date: September 13, 2012

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Michael PASTULA, Andrea TYLCZAK, Bryce SHARMAN, Casey BROWN, Kevin MARCHAND, Pawel FRONC, Marc DIONNE, Glenn PRICE

Deactivation of SOFC anode substrate for direct internal reforming

Patent number: 8216738

Abstract: A SOFC includes a cathode electrode, a solid oxide electrolyte, an anode electrode, and a hydrocarbon fuel inlet. The SOFC is configured for internal reforming of a hydrocarbon fuel at the anode electrode. The SOFC is configured to limit an interaction between the hydrocarbon fuel and the anode electrode adjacent to the hydrocarbon fuel inlet, or to limit an area of the anode electrode exposed to the hydrocarbon fuel adjacent to the hydrocarbon fuel inlet, or to provide a gradual introduction of the hydrocarbon fuel to the anode electrode.

Type: Grant

Filed: May 18, 2007

Date of Patent: July 10, 2012

Assignee: Versa Power Systems, Ltd.

Inventors: Casey Brown, Wei Dong, Vlad Kalika, Scott Sherman, Scott Thompson

Preconditioning treatment to enhance redox tolerance of solid oxide fuel cells

Patent number: 8202670

Abstract: A high temperature, redox tolerant fuel cell anode electrode and method of fabrication in which the anode electrode is pre-conditioned by application of an initial controlled redox cycle to the electrode whereby an initial re-oxidation of the anode electrode is carried out at temperatures less than or equal to about 650° C.

Type: Grant

Filed: September 19, 2011

Date of Patent: June 19, 2012

Assignee: Versa Power Systems, Ltd.

Inventors: Anthony Wood, David Waldbillig

Thermally integrated fuel cell system

Patent number: 8202656

Abstract: A thermally integrated fuel cell system includes a stack zone, a burner zone and a low temperature zone. The fuel is combined with steam and passed sequentially through a primary reformer and a secondary reformer or a radiative fuel heat exchanger. Air may be passed sequentially through an afterburner heat exchanger and a radiative air heat exchanger such that the radiative heat exchanger may be used to heat the stack zone. The stack exhaust is combusted in an afterburner. Afterburner exhaust heats the primary reformer, the high temperature air heat exchanger, the low temperature air heat exchanger and steam generator. The stack zone includes the stacks, the secondary reformer and the radiative heat exchanger. The burner zone includes the afterburner which includes a start burner, the primary reformer and the high temperature air heat exchanger. The low temperature zone includes the low temperature air heat exchanger and a steam generator.

Type: Grant

Filed: September 30, 2009

Date of Patent: June 19, 2012

Assignee: Versa Power Systems, Ltd.

Inventors: Michael Pastula, Andrea Tylczak, Pawel Fronc, Marc Dionne, Glenn Price, Bryce Sharman, Casey Brown, Kevin Marchand

PRECONDITIONING TREATMENT TO ENHANCE REDOX TOLERANCE OF SOLID OXIDE FUEL CELLS

Publication number: 20120009507

Abstract: A high temperature, redox tolerant fuel cell anode electrode and method of fabrication in which the anode electrode is pre-conditioned by application of an initial controlled redox cycle to the electrode whereby an initial re-oxidation of the anode electrode is carried out at temperatures less than or equal to about 650° C.

Type: Application

Filed: September 19, 2011

Publication date: January 12, 2012

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Anthony Wood, David Waldbillig

Preconditioning treatment to enhance redox tolerance of solid oxide fuel cells

Patent number: 8029946

Abstract: A high temperature, redox tolerant fuel cell anode electrode and method of fabrication in which the anode electrode is pre-conditioned by application of an initial controlled redox cycle to the electrode whereby an initial re-oxidation of the anode electrode is carried out at temperatures less than or equal to about 650° C.

Type: Grant

Filed: July 28, 2009

Date of Patent: October 4, 2011

Assignee: Versa Power Systems, Ltd.

Inventors: Anthony Wood, David Waldbillig

ELECTRICALLY CONDUCTIVE FUEL CELL CONTACT MATERIAL

Publication number: 20110111319

Abstract: A multilayer contact approach for use in a planar solid oxide fuel cell stack includes at least 3 layers of an electrically conductive perovskite which has a coefficient of thermal expansion closely matching the fuel cell material. The perovskite material may comprise La1-xExCo0.6Ni0.4O3 where E is a alkaline earth metal and x is greater than or equal to zero. The middle layer is a stress relief layer which may fracture during thermal cycling to relieve stress, but remains conductive and prevents mechanical damage of more critical interfaces.

Type: Application

Filed: January 14, 2011

Publication date: May 12, 2011

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Xinge Zhang, Anthony WOOD, Michel RIOU

FUEL CELL SHUTDOWN WITH STEAM PURGING

Publication number: 20110111310

Abstract: The present invention relates to an apparatus for steam purging a solid oxide fuel cell stack. Purging the SOFC stack with steam has a physical flushing effect, removing carbon monoxide containing reformate and free oxygen gas from the anode area thereby reducing the potential for nickel oxide or nickel carbonyl formation.

Type: Application

Filed: January 14, 2011

Publication date: May 12, 2011

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Michael PASTULA, James SMITH, Quincy Yueh Feng CHIANG

Electrically conductive fuel cell contact material

Patent number: 7892698

Abstract: A multilayer contact approach for use in a planar solid oxide fuel cell stack includes at least 3 layers of an electrically conductive perovskite which has a coefficient of thermal expansion closely matching the fuel cell material. The perovskite material may comprise La1-x Ex Co0.6Ni0.4O3 where E is a alkaline earth metal and x is greater than or equal to zero. The middle layer is a stress relief layer which may fracture during thermal cycling to relieve stress, but remains conductive and prevents mechanical damage of more critical interfaces.

Type: Grant

Filed: July 15, 2004

Date of Patent: February 22, 2011

Assignee: Versa Power Systems, Ltd.

Inventors: Xinge Zhang, Anthony Wood, Michel Riou

Cell materials variation in SOFC stacks to address thermal gradients in all planes

Patent number: 9190669

Abstract: A solid oxide fuel cell, and methods for modifying the temperature thereof, the fuel cell having a plurality of planar layered fuel cell units, an electrically conductive flow separator plate disposed between each of the fuel cell units, and a cathode contact material element disposed between each cathode electrode of the fuel cell units and each electrically conductive flow separator plate. The cathodes of the individual fuel cell units are modified such that the operating temperatures of the cathodes are matched with the temperatures they experience based upon their locations in the fuel cell stack. The modification involves adding to the cathode contact material and/or cathode at least one alloying agent which modifies the temperature of the cathode electrodes based upon the location of the cathode electrodes within the fuel cell stack. These alloying agents react with a component of the cathode electrode to form alloys.

Type: Grant

Filed: July 17, 2007

Date of Patent: November 17, 2015

Assignee: VERSA POWER SYSTEMS, LTD.

Inventors: Anthony Wood, Zheng Tang

SYSTEMS AND METHODS FOR PREVENTING CHROMIUM CONTAMINATION OF SOLID OXIDE FUEL CELLS

Publication number: 20150270557

Abstract: In some embodiments, a solid oxide fuel system is provided. The solid oxide fuel cell system may include a chromium-getter material. The chromium-getter material may react with chromium to remove chromium species from chromium vapor. The solid oxide fuel cell system may also include an inert substrate. The chromium-getter material may be coated onto the inert substrate. The coated substrate may remove chromium species from chromium vapor before the chromium species can react with a cathode in the solid oxide fuel cell system.

Type: Application

Filed: March 20, 2014

Publication date: September 24, 2015

Applicant: Versa Power System Ltd.

Inventors: Hongpeng He, Anthony Wood

CATHODE CONTACT LAYER DESIGN FOR PREVENTING CHROMIUM CONTAMINATION OF SOLID OXIDE FUEL CELLS

Publication number: 20150270558

Abstract: In embodiments, a fuel cell stack is provided that includes an interconnect between a first fuel cell and a second fuel cell, and a contact layer in contact with, and disposed between, an electrode of the first fuel cell and the interconnect. The contact layer may include a chromium-getter material. This chromium-getter material may consist of lanthanum oxide, lanthanum carbonate, and/or calcium carbonate.

Type: Application

Filed: March 20, 2014

Publication date: September 24, 2015

Applicant: Versa Power System Ltd.

Inventors: Anthony Wood, Hongpeng He, Tahir Joia

Electrically conductive fuel cell contact material

Patent number: 8962218

Abstract: A multilayer contact approach for use in a planar solid oxide fuel cell stack includes at least 3 layers of an electrically conductive perovskite which has a coefficient of thermal expansion closely matching the fuel cell material. The perovskite material may comprise La1-xEx Co0.6Ni0.4O3 where E is a alkaline earth metal and x is greater than or equal to zero. The middle layer is a stress relief layer which may fracture during thermal cycling to relieve stress, but remains conductive and prevents mechanical damage of more critical interfaces.

Type: Grant

Filed: January 14, 2011

Date of Patent: February 24, 2015

Assignee: Versa Power Systems, Ltd.

Inventors: Xinge Zhang, Anthony Wood, Michel Riou

Fuel cell shutdown with steam purging

Patent number: 8722270

Abstract: The present invention relates to an apparatus for steam purging a solid oxide fuel cell stack. Purging the SOFC stack with steam has a physical flushing effect, removing carbon monoxide containing reformate and free oxygen gas from the anode area thereby reducing the potential for nickel oxide or nickel carbonyl formation.

Type: Grant

Filed: January 14, 2011

Date of Patent: May 13, 2014

Assignee: Versa Power Systems, Ltd.

Inventors: Michael Pastula, James Smith, Quincy Yueh Feng Chiang

High performance cathode with controlled operating temperature range

Patent number: 8313875

Abstract: In a solid oxide fuel cell having an anode, a cathode, and a dense electrolyte disposed between the anode and the cathode, the cathode having a ceramic-ionic conducting phase of a plurality of ionic conducting particles and a metallic phase of a plurality of metallic particles. The metallic phase includes a metal alloy having an oxide-to-metal transition temperature in the range of about 600° C. to about 800° C. With this cathode, solid oxide fuel cell operating temperatures as low as about 600° C. may be possible.

Type: Grant

Filed: October 2, 2006

Date of Patent: November 20, 2012

Assignee: Versa Power Systems, Ltd.

Inventors: Anthony Wood, Zheng Tang, Sofiane Benhaddad, Tahir Joia, Kyle Marcotte, David Waldbillig

Thermally integrated fuel cell system

Patent number: 8268491

Abstract: A thermally integrated fuel cell system includes a stack zone, a burner zone and a low temperature zone. The fuel is combined with steam and passed sequentially through a primary reformer and a secondary reformer or a radiative fuel heat exchanger. Air may be passed sequentially through an afterburner heat exchanger and a radiative air heat exchanger such that the radiative heat exchanger may be used to heat the stack zone. The stack exhaust is combusted in an afterburner. Afterburner exhaust heats the primary reformer, the high temperature air heat exchanger, the low temperature air heat exchanger and steam generator. The stack zone includes the stacks, the secondary reformer and the radiative heat exchanger. The burner zone includes the afterburner which includes a start burner, the primary reformer and the high temperature air heat exchanger. The low temperature zone includes the low temperature air heat exchanger and a steam generator.

Type: Grant

Filed: May 18, 2012

Date of Patent: September 18, 2012

Assignee: Versa Power Systems, Ltd.

Inventors: Michael Pastula, Andrea Tylczak, Pawel Fronc, Marc Dionne, Glenn Price, Bryce Sharman, Casey Brown, Kevin Marchand

THERMALLY INTEGRATED FUEL CELL SYSTEM

Publication number: 20120231360

Abstract: A thermally integrated fuel cell system includes a stack zone, a burner zone and a low temperature zone. The fuel is combined with steam and passed sequentially through a primary reformer and a secondary reformer or a radiative fuel heat exchanger. Air may be passed sequentially through an afterburner heat exchanger and a radiative air heat exchanger such that the radiative heat exchanger may be used to heat the stack zone. The stack exhaust is combusted in an afterburner. Afterburner exhaust heats the primary reformer, the high temperature air heat exchanger, the low temperature air heat exchanger and steam generator. The stack zone includes the stacks, the secondary reformer and the radiative heat exchanger. The burner zone includes the afterburner which includes a start burner, the primary reformer and the high temperature air heat exchanger. The low temperature zone includes the low temperature air heat exchanger and a steam generator.

Type: Application

Filed: May 18, 2012

Publication date: September 13, 2012

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Michael PASTULA, Andrea TYLCZAK, Bryce SHARMAN, Casey BROWN, Kevin MARCHAND, Pawel FRONC, Marc DIONNE, Glenn PRICE

Deactivation of SOFC anode substrate for direct internal reforming

Patent number: 8216738

Abstract: A SOFC includes a cathode electrode, a solid oxide electrolyte, an anode electrode, and a hydrocarbon fuel inlet. The SOFC is configured for internal reforming of a hydrocarbon fuel at the anode electrode. The SOFC is configured to limit an interaction between the hydrocarbon fuel and the anode electrode adjacent to the hydrocarbon fuel inlet, or to limit an area of the anode electrode exposed to the hydrocarbon fuel adjacent to the hydrocarbon fuel inlet, or to provide a gradual introduction of the hydrocarbon fuel to the anode electrode.

Type: Grant

Filed: May 18, 2007

Date of Patent: July 10, 2012

Assignee: Versa Power Systems, Ltd.

Inventors: Casey Brown, Wei Dong, Vlad Kalika, Scott Sherman, Scott Thompson

Preconditioning treatment to enhance redox tolerance of solid oxide fuel cells

Patent number: 8202670

Abstract: A high temperature, redox tolerant fuel cell anode electrode and method of fabrication in which the anode electrode is pre-conditioned by application of an initial controlled redox cycle to the electrode whereby an initial re-oxidation of the anode electrode is carried out at temperatures less than or equal to about 650° C.

Type: Grant

Filed: September 19, 2011

Date of Patent: June 19, 2012

Assignee: Versa Power Systems, Ltd.

Inventors: Anthony Wood, David Waldbillig

Thermally integrated fuel cell system

Patent number: 8202656

Abstract: A thermally integrated fuel cell system includes a stack zone, a burner zone and a low temperature zone. The fuel is combined with steam and passed sequentially through a primary reformer and a secondary reformer or a radiative fuel heat exchanger. Air may be passed sequentially through an afterburner heat exchanger and a radiative air heat exchanger such that the radiative heat exchanger may be used to heat the stack zone. The stack exhaust is combusted in an afterburner. Afterburner exhaust heats the primary reformer, the high temperature air heat exchanger, the low temperature air heat exchanger and steam generator. The stack zone includes the stacks, the secondary reformer and the radiative heat exchanger. The burner zone includes the afterburner which includes a start burner, the primary reformer and the high temperature air heat exchanger. The low temperature zone includes the low temperature air heat exchanger and a steam generator.

Type: Grant

Filed: September 30, 2009

Date of Patent: June 19, 2012

Assignee: Versa Power Systems, Ltd.

Inventors: Michael Pastula, Andrea Tylczak, Pawel Fronc, Marc Dionne, Glenn Price, Bryce Sharman, Casey Brown, Kevin Marchand

PRECONDITIONING TREATMENT TO ENHANCE REDOX TOLERANCE OF SOLID OXIDE FUEL CELLS

Publication number: 20120009507

Abstract: A high temperature, redox tolerant fuel cell anode electrode and method of fabrication in which the anode electrode is pre-conditioned by application of an initial controlled redox cycle to the electrode whereby an initial re-oxidation of the anode electrode is carried out at temperatures less than or equal to about 650° C.

Type: Application

Filed: September 19, 2011

Publication date: January 12, 2012

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Anthony Wood, David Waldbillig

Preconditioning treatment to enhance redox tolerance of solid oxide fuel cells

Patent number: 8029946

Abstract: A high temperature, redox tolerant fuel cell anode electrode and method of fabrication in which the anode electrode is pre-conditioned by application of an initial controlled redox cycle to the electrode whereby an initial re-oxidation of the anode electrode is carried out at temperatures less than or equal to about 650° C.

Type: Grant

Filed: July 28, 2009

Date of Patent: October 4, 2011

Assignee: Versa Power Systems, Ltd.

Inventors: Anthony Wood, David Waldbillig

ELECTRICALLY CONDUCTIVE FUEL CELL CONTACT MATERIAL

Publication number: 20110111319

Abstract: A multilayer contact approach for use in a planar solid oxide fuel cell stack includes at least 3 layers of an electrically conductive perovskite which has a coefficient of thermal expansion closely matching the fuel cell material. The perovskite material may comprise La1-xExCo0.6Ni0.4O3 where E is a alkaline earth metal and x is greater than or equal to zero. The middle layer is a stress relief layer which may fracture during thermal cycling to relieve stress, but remains conductive and prevents mechanical damage of more critical interfaces.

Type: Application

Filed: January 14, 2011

Publication date: May 12, 2011

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Xinge Zhang, Anthony WOOD, Michel RIOU

FUEL CELL SHUTDOWN WITH STEAM PURGING

Publication number: 20110111310

Abstract: The present invention relates to an apparatus for steam purging a solid oxide fuel cell stack. Purging the SOFC stack with steam has a physical flushing effect, removing carbon monoxide containing reformate and free oxygen gas from the anode area thereby reducing the potential for nickel oxide or nickel carbonyl formation.

Type: Application

Filed: January 14, 2011

Publication date: May 12, 2011

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Michael PASTULA, James SMITH, Quincy Yueh Feng CHIANG

Electrically conductive fuel cell contact material

Patent number: 7892698

Abstract: A multilayer contact approach for use in a planar solid oxide fuel cell stack includes at least 3 layers of an electrically conductive perovskite which has a coefficient of thermal expansion closely matching the fuel cell material. The perovskite material may comprise La1-x Ex Co0.6Ni0.4O3 where E is a alkaline earth metal and x is greater than or equal to zero. The middle layer is a stress relief layer which may fracture during thermal cycling to relieve stress, but remains conductive and prevents mechanical damage of more critical interfaces.

Type: Grant

Filed: July 15, 2004

Date of Patent: February 22, 2011

Assignee: Versa Power Systems, Ltd.

Inventors: Xinge Zhang, Anthony Wood, Michel Riou

Fuel cell shutdown with steam purging

Patent number: 7892687

Abstract: The present invention relates to a method and apparatus for steam purging a solid oxide fuel cell stack. Purging the SOFC stack with steam has a physical flushing effect, removing carbon monoxide containing reformate and free oxygen gas from the anode area thereby reducing the potential for nickel oxide or nickel carbonyl formation.

Type: Grant

Filed: April 14, 2005

Date of Patent: February 22, 2011

Assignee: Versa Power Systems, Ltd.

Inventors: Michael Pastula, James Smith, Quincy Yueh Feng Chiang

HIGH TEMPERATURE GAS SEALS

Publication number: 20100239961

Abstract: A flexible seal for use in a solid oxide fuel cell stack is formed from a fibre matrix with a plurality of solid particles through tape casting method. The fibres and particles are preferably ceramic and may be formed from alumina or zirconia. The seal may be formed by forming a slurry of fibres, particles, a binder and a non-aqueous solvent, tape casting the slurry, drying the tape seal, die-cutting, prior to installation in the fuel cell stack.

Type: Application

Filed: June 1, 2010

Publication date: September 23, 2010

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Robert BRULE, Xinge ZHANG, Dhanwant CHAHAL, Zheng TANG

High temperature gas seals

Patent number: 7799419

Abstract: A flexible seal for use in a solid oxide fuel cell stack is formed from a fiber matrix with a plurality of solid particles through tape casting method. The fibers and particles are preferably ceramic and may be formed from alumina or zirconia. The seal may be formed by forming a slurry of fibers, particles, a binder and a non-aqueous solvent, tape casting the slurry, drying the tape seal, die-cutting, prior to installation in the fuel cell stack.

Type: Grant

Filed: December 23, 2003

Date of Patent: September 21, 2010

Assignee: Versa Power Systems, Ltd.

Inventors: Robert Brule, Xinge Zhang, Dhanwant Chahal, Zheng Tang

Thermally integrated SOFC system

Patent number: 7749628

Abstract: A thermally integrated fuel cell system includes a stack zone, a burner zone and a low temperature zone. The fuel is combined with steam and passed sequentially through a primary reformer and a secondary reformer. Air is split into two parallel streams and preheated in a low temperature heat exchanger. One air stream passes to a high temperature heat exchanger while the other passes to a radiative heat exchanger. The air and fuel streams are equalized in an equalization heat exchanger before entering the fuel cell stacks. The stack exhaust is combusted in an afterburner. Afterburner exhaust heats the primary reformer, the high temperature heat exchanger, the low temperature heat exchanger and steam generator. The stack zone includes the stacks, the secondary reformer, the radiative heat exchanger and the equalization heat exchanger. The burner zone includes the afterburner, the primary reformer and the high temperature heat exchanger.

Type: Grant

Filed: December 15, 2006

Date of Patent: July 6, 2010

Assignee: Versa Power Systems, Ltd.

Inventors: Michael Pastula, Andrea Tylczak, Pawel Fronc, Marc Dionne, Glenn Price, Bryce Sharman, Casey Brown

PRECONDITIONING TREATMENT TO ENHANCE REDOX TOLERANCE OF SOLID OXIDE FUEL CELLS

Publication number: 20100028747

Abstract: A high temperature, redox tolerant fuel cell anode electrode and method of fabrication in which the anode electrode is pre-conditioned by application of an initial controlled redox cycle to the electrode whereby an initial re-oxidation of the anode electrode is carried out at temperatures less than or equal to about 650° C.

Type: Application

Filed: July 28, 2009

Publication date: February 4, 2010

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Anthony Wood, David Waldbillig

THERMALLY INTEGRATED FUEL CELL SYSTEM

Publication number: 20100015476

Abstract: A thermally integrated fuel cell system includes a stack zone, a burner zone and a low temperature zone. The fuel is combined with steam and passed sequentially through a primary reformer and a secondary reformer or a radiative fuel heat exchanger. Air may be passed sequentially through an afterburner heat exchanger and a radiative air heat exchanger such that the radiative heat exchanger may be used to heat the stack zone. The stack exhaust is combusted in an afterburner. Afterburner exhaust heats the primary reformer, the high temperature air heat exchanger, the low temperature air heat exchanger and steam generator. The stack zone includes the stacks, the secondary reformer and the radiative heat exchanger. The burner zone includes the afterburner which includes a start burner, the primary reformer and the high temperature air heat exchanger. The low temperature zone includes the low temperature air heat exchanger and a steam generator.

Type: Application

Filed: September 30, 2009

Publication date: January 21, 2010

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Michael Pastula, Andrea Tylczak, Pawel Fronc, Marc Dionne, Glenn Price, Bryce Sharman, Casey Brown, Kevin Marchand

Thermally integrated fuel cell stack

Patent number: 7615298

Abstract: A thermally integrated fuel cell system includes a stack zone, a burner zone and a low temperature zone. The fuel is combined with steam and passed sequentially through a primary reformer and a secondary reformer or a radiative fuel heat exchanger. Air may be passed sequentially through an afterburner heat exchanger and a radiative air heat exchanger such that the radiative heat exchanger may be used to heat the stack zone. The stack exhaust is combusted in an afterburner. Afterburner exhaust heats the primary reformer, the high temperature air heat exchanger, the low temperature air heat exchanger and steam generator. The stack zone includes the stacks, the secondary reformer and the radiative heat exchanger. The burner zone includes the afterburner which includes a start burner, the primary reformer and the high temperature air heat exchanger. The low temperature zone includes the low temperature air heat exchanger and a steam generator.

Type: Grant

Filed: January 27, 2005

Date of Patent: November 10, 2009

Assignee: Versa Power Systems, Ltd.

Inventors: Michael Pastula, Andrea Tylczak, Bryce Sharman, Casey Brown, Kevin Marchand, Pawel Fronc, Marc Dionne, Glenn Price

Flexible high temperature cables

Patent number: 7557300

Abstract: A high-temperature, flexible conductive cable is formed from a solid copper core, sheathed and hermetically sealed in a flexible stainless steel sheath, which may be corrugated.

Type: Grant

Filed: July 5, 2004

Date of Patent: July 7, 2009

Assignee: Versa Power Systems, Ltd.

Inventors: Scott Thompson, Trevor Kwasnycia, Sofiane Benhaddad

Solid oxide fuel cell stack with floating cells

Patent number: 7553579

Abstract: A solid oxide fuel cell stack includes a fuel cell unit consisting of a fuel cell framed by a cell holder plate and upper and lower cushioning elements. The fuel cell unit is stacked with flow field seals and solid flow separator plates. The fuel cell thus floats without direct contact with rigid stack elements.

Type: Grant

Filed: April 4, 2003

Date of Patent: June 30, 2009

Assignee: Versa Power Systems Ltd.

Inventors: Steven Couse, Zheng Tang

Cell materials variation in SOFC stacks to address thermal gradients in all planes

Publication number: 20080081229

Abstract: A solid oxide fuel cell having a plurality of planar layered fuel cell units, an electrically conductive flow separator plate disposed between each of the fuel cell units, and a cathode contact material element disposed between each cathode electrode of the fuel cell units and each electrically conductive flow separator plate. The cathodes of the individual fuel cell units are modified such that the operating temperatures of the cathodes are matched with the temperatures they experience based upon their locations in the fuel cell stack. The modification involves adding to the cathode contact material and/or cathode at least one alloying agent which modifies the temperature of the cathode electrodes based upon the location of the cathode electrodes within the fuel cell stack. These alloying agents react with a component of the cathode electrode to form alloys.

Type: Application

Filed: July 17, 2007

Publication date: April 3, 2008

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Anthony Wood, Zheng Tang

High performance cathode with controlled operating temperature range

Publication number: 20080081243

Abstract: In a solid oxide fuel cell having an anode, a cathode, and a dense electrolyte disposed between the anode and the cathode, the cathode having a ceramic-ionic conducting phase of a plurality of ionic conducting particles and a metallic phase of a plurality of metallic particles. The metallic phase includes a metal alloy having an oxide-to-metal transition temperature in the range of about 600° C. to about 800° C. With this cathode, solid oxide fuel cell operating temperatures as low as about 600° C. may be possible.

Type: Application

Filed: October 2, 2006

Publication date: April 3, 2008

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Anthony Wood, Zheng Tang, Sofiane Benhaddad, Tahir Joia, Kyle Marcotte, David Waldbillig

Solid oxide fuel cell with external manifolds

Patent number: 7291415

Abstract: A solid oxide fuel cell stack may include repeating fuel cell units each having a planar fuel cell, an interconnect, a cathode contact layer disposed between sealing strips, and an anode contact layer disposed between sealing strips. The sealing strips have end extensions which overlap with corner extensions on the interconnect. The extensions stack to form vertical columns which enclose the external manifolds, along with a manifold plate.

Type: Grant

Filed: November 23, 2004

Date of Patent: November 6, 2007

Assignee: Versa Power Systems, Ltd.

Inventors: Scott Sherman, Zheng Tang

Electrode pattern for solid state ionic devices

Patent number: 7255953

Abstract: A solid oxide fuel cell electrode is stable during thermal cycling and includes a plurality of discrete geometric elements lightly packed on the electrolyte surface. Preferably, the geometric elements are regular hexagons, creating a “Thoneycomb” pattern electrode.

Type: Grant

Filed: August 30, 2001

Date of Patent: August 14, 2007

Assignee: Versa Power Systems, Ltd.

Inventors: Zheng Tang, Debabrata Ghosh

THERMALLY INTEGRATED SOFC SYSTEM

Publication number: 20070148513

Abstract: A thermally integrated fuel cell system includes a stack zone, a burner zone and a low temperature zone. The fuel is combined with steam and passed sequentially through a primary reformer and a secondary reformer. Air is split into two parallel streams and preheated in a low temperature heat exchanger. One air stream passes to a high temperature heat exchanger while the other passes to a radiative heat exchanger. The air and fuel streams are equalized in an equalization heat exchanger before entering the fuel cell stacks. The stack exhaust is combusted in an afterburner. Afterburner exhaust heats the primary reformer, the high temperature heat exchanger, the low temperature heat exchanger and steam generator. The stack zone includes the stacks, the secondary reformer, the radiative heat exchanger and the equalization heat exchanger. The burner zone includes the afterburner, the primary reformer and the high temperature heat exchanger.

Type: Application

Filed: December 15, 2006

Publication date: June 28, 2007

Applicant: VERSA POWER SYSTEMS, LTD.

Inventors: Michael PASTULA, Andrea TYLCZAK, Pawel FRONC, Marc DIONNE, Glenn PRICE, Bryce SHARMAN, Casey BROWN

Electrically conductive fuel cell contact materials

Patent number: 7190568

Abstract: A multilayer contact approach for use in a planar solid oxide fuel cell stack includes at least 3 layers of an electrically conductive perovskite which has a coefficient of thermal expansion closely matching the fuel cell material. The perovskite material may comprise La1-xEx Co0.6Ni0.4O3 where E is a alkaline earth metal and x is greater than or equal to zero. The middle layer is a stress relief layer which may fracture during thermal cycling to relieve stress, but remains conductive and prevents mechanical damage of more critical interfaces.

Type: Grant

Filed: November 16, 2004

Date of Patent: March 13, 2007

Assignee: Versa Power Systems Ltd.

Inventors: Anthony Wood, Zheng Tang, Tahir Joia

Thermally integrated SOFC system

Patent number: 7169495

Abstract: A thermally integrated fuel cell system includes a stack zone, a burner zone and a low temperature zone. The fuel is combined with steam and passed sequentially through a primary reformer and a secondary reformer. Air is split into two parallel streams and preheated in a low temperature heat exchanger. One air stream passes to a high temperature heat exchanger while the other passes to a radiative heat exchanger. The air and fuel streams are equalized in an equalization heat exchanger before entering the fuel cell stacks. The stack exhaust is combusted in an afterburner. Afterburner exhaust heats the primary reformer, the high temperature heat exchanger, the low temperature heat exchanger and steam generator. The stack zone includes the stacks, the secondary reformer, the radiative heat exchanger and the equalization heat exchanger. The burner zone includes the afterburner, the primary reformer and the high temperature heat exchanger.

Type: Grant

Filed: May 6, 2003

Date of Patent: January 30, 2007

Assignee: Versa Power Systems, Ltd.

Inventors: Michael Pastula, Andrea Tylczak, Pawel Fronc, Marc Dionne, Glenn Price, Bryce Sharman, Casey Brown