Fuel cell module, system, and process

Abstract

A fuel cell module (100) is provided for generating electricity, which includes at least three annular segments (102) in a successively stacked arrangement that are operative to form a casing (104). The casing includes therein a fuel cell chamber (106) having a fuel inlet (108), a depleted fuel outlet (140), and a plurality of fuel cells (112) comprised of an electrolyte layer (118) between an anode layer (120) and a cathode layer (122). Each of the fuel cells extends through all three of the segments. The segments include at least one electrically insulating segment (156) stacked between two electrically conductive segments (146, 148). The electrically conductive segments correspond to positive and negative terminal segments, to which the fuel cells inside the module are electrically connected, and to which an electrical load (2216) outside the module may be electrically connected.

Description

Docket No. 2024P00519WOFUEL CELL MODULE, SYSTEM, AND PROCESS

[0001] The present application is directed to systems for facilitating transformations between chemical energy and electrical energy, such as fuel cells and electrolyzers, and in particular to solid oxide fuel cell (SOFC) systems. A fuel cell converts chemical energy directly into electrical energy (e.g., electrochemically oxidizing hydrogen to produce an electrical current). Whereas an electrolyzer operates in the opposite direction (e.g., using electricity to compel the separation of hydrogen and oxygen from water molecules). Fuel cells and electrolyzers both comprise a cathode and an anode separated by an electrolyte, which enable these conversions to take place.

[0002] For example, with respect to fuel cells at the cathode oxygen is ionized, and the oxide ions migrate through the electrolyte to the anode. At the anode, hydrogen is ionized, and the hydrogen ions react with the oxide ions to form water and release electrons. The released electrons then travel from the anode to the cathode through a load-containing connection, thereby completing the circuit and providing a small amount of direct electrical current. A fuel cell-based power generation system typically comprises many electrically interconnected fuel cells. Such systems supply a hydrogen-bearing fuel gas to the anode, and an oxidant gas (e.g. air, oxygen) to the cathode. A schematic arrangement of one such system, which uses SOFCs, is described in U.S. Pat. No. 4,395,468, which is hereby incorporated herein by reference in its entirety. SOFC technology is distinguished from other fuel cell types by its solid-state ceramic structure and its high operating temperature, nominally l,000°C. The electrolyte of an SOFC, for example, may be comprised of a ceramic material such as yttria-stabilized zirconia (YSZ) or other ceramic material that an operating temperature between 600°C and 1300°C, becomes non- conductive for electrons, but conductive to oxygen ions.

[0003] When operated in a cogeneration system at atmospheric pressure, SOFC systems may have an electrical efficiency of between 40-50%. Pressurized SOFC systems (e.g., at greater than 3 bar absolute) integrated with a gas turbine (so called PSOFC / GT hybrid systems) may achieve electrical efficiencies of approximately 60-70%. In the PSOFC / GT hybrid, the pressurized SOFC is an electrochemical topping cycle that not only generates electric power but also supplants the gas turbine's combustor. The hot pressurized exhaust from the SOFC is expanded by the gas turbine to generate additional electric power. In addition, when configured for the cogeneration of process steam and / or hot water, overall system fuel effectiveness mayDocket No. 2024P00519WO exceed 85%. Examples of such systems are shown in U.S. Patent No. 5,573,867 issued Nov. 12, 1996; U.S. Patent No. 5,741,605 issued April 21, 1998; U.S. Patent No. 6,764,784 B2 issued July 20, 2004; and U.S. Patent No. 8,673,519 B2 issued March 18, 2014, which are hereby incorporated hereby by reference herein in their entirety.

[0004] Thus, SOFC technology has the potential to generate electricity at efficiencies higher than any known alternative power generation system, thereby significantly reducing the consumption of fuel (e.g., natural gas and / or hydrogen) and reducing and / or eliminating production of carbon dioxide and air pollutants.

[0005] However, prior designs of cogeneration PSOFC / GT hybrid systems have been uneconomical to manufacture and operate due to the complexity and fragility of their fuel cells. To the inventors' knowledge, no commercially operated megawatt scale PSOFC / GT hybrid systems have been built for these reasons. Thus, PSOFC / GT hybrid technology may benefit from improvements in order to become commercially viable. And such improvements may benefit other types of fuel cell systems and electrolyzers.

[0006] Variously disclosed embodiments include systems and methods directed to improving the designs for facilitating transformations between chemical energy and electrical energy, such as fuel cells and electrolyzers, and in particular to solid oxide fuel cell (SOFC) designs.

[0007] In one aspect, a fuel cell module for generating electricity includes at least three annular segments in a successively stacked arrangement, which are operative to form a casing, including therein a fuel cell chamber having a fuel inlet, a depleted fuel outlet, and a plurality of fuel cells comprised of an electrolyte layer between an anode layer and a cathode layer, which fuel cells extend through all three of the segments.

[0008] In such an aspect, the at least three annular segments include at least one electrically insulating segment stacked between two electrically conductive segments. In such aspects the electrically insulating segment may be a ceramic segment and the electrically conductive segment may be a metal or metal alloy segment. Also, in such aspects, the electrically conductive segments correspond to positive and negative terminal segments, to which the fuel cells inside the module are electrically connected, and to which an electrical load outside the module may be electrically connected.

[0009] In one or more aspects the fuel cell module for generating electricity may comprise at least three annular ceramic and / or metal segments in a successively stacked arrangement, which are operative to form a casing, including therein: a fuel cell chamber having a fuel inlet, aDocket No. 2024P00519WO depleted fuel outlet, and a plurality of tubular fuel cells, wherein each fuel cell includes a fuel cell wall in surrounding relation of a longitudinally extending inner channel that is closed on one end, which fuel cell walls are comprised of an electrolyte layer between an anode layer and a cathode layer. The fuel cell module may also include an air outlet chamber having an air outlet; and an air inlet chamber having an air inlet. The fuel cell chamber may be formed by stacking at least one annularly shaped ceramic segment between two annularly shaped metal segments, which metal segments are respectively an anode terminal segment and a cathode terminal segment that are operatively electrically coupled to the anode layers and the cathode layers of the fuel cells, which fuel cells extend through all three of the ceramic segment, the cathode terminal segment, and the anode terminal segment.

[0010] In one or more aspects, the tubular fuel cells may be solid oxide fuel cells (SOFCs) including a ceramic electrolyte or molten carbonate fuel cells (MCFC). In some aspects, the fuel cells may be proton exchange membrane (PEM) fuel cells and / or planar fuel cells.

[0011] In one or more aspects, the inner channels of the tubular fuel cells may have a generally cylindrical-shape or a generally triangular-shape.

[0012] In one or more aspects, the segments may be in sealing engagement sufficient to prevent leakage of fuel and air between the segments to below 10'3mbar*l / s during electrical generation by the fuel cells.

[0013] In one or more aspects, the cathode layers of the fuel cells extend adjacent the inner channels of the fuel cells, which inner channels are in fluid communication with the air inlet and the air outlet, and wherein the anode layers of the fuel cells extend adjacent outer channels along the fuel cells, which outer channels are in fluid communication with the fuel inlet and the depleted fuel outlet included. In such aspects the fuel cell module may further comprise: a plurality of air feed conduits that extend through the air outlet chamber and into the inner channels of the fuel cell; a first partition; and a second partition. The first partition: is mounted within at least one segment; separates the fuel cell chamber from the air outlet chamber; supports the fuel cells; and includes apertures through which the air feed conduits traverse the first partition. The second partition: is mounted within at least one segment; separates the air outlet chamber from the air inlet chamber; supports the air feed conduits; and includes apertures aligned with the air feed conduits to enable air to flow from the air inlet chamber into the air feed conduits.Docket No. 2024P00519WO

[0014] In one or more aspects the first partition may be in sealing engagement with the at least one segment to which it is mounted and the fuel cell walls are in sealing engagement with the first partition sufficiently to prevent leakage of fuel into the inner channels of the fuel cells and to prevent leakage of air into the external channels along the fuel cells to below 10’3mbar*l / s. during electrical generation by the fuel cells.

[0015] In one or more aspects the second partition may be in sealing engagement with walls of the air feed conduits to facilitate directing air from the air inlet to flow through the air feed conduits into the inner channels of the fuel cells, and subsequently into the air outlet chamber and out the air outlet.

[0016] In one or more aspects, the at least one of the first partition or the second portion have multi-plate configurations including an upper support plate and a lower ground plate that supports the upper support plate when mounted to a segment, wherein the upper support plate includes a plurality of receptacles for receiving at least one of fuel cells or air feed conduits therein in sealing engagement therewith.

[0017] In one or more aspects, at least one ceramic segment may include at least one circumferential step / shoulder portion, wherein the first partition and / or the second partition includes an outer circumferential edge portion that extends into sealing engagement with the at least one circumferential step / shoulder portions of the at least one ceramic segment.

[0018] In one or more aspects, at least one ceramic segment may include at least two adjacent circumferential step / shoulder portions, which cooperatively form with a further segment, an inner circumferential channel that includes the outer circumferential edge portion therein.

[0019] In one or more aspects, the adjacent surfaces of at least two adjacent stacked segments may include cooperating circumferential step / shoulder portions for receiving a seal therebetween such that portions of the adjacent edges traverse each other in an axial direction in which the adjacent segments are stacked.

[0020] In one or more aspects, the fuel cell module may include at least six segments in the successively stacked arrangement, which are operative to form the casing, wherein the fuel cell chamber is formed by a stack of at least two ceramic segments on opposite sides of each of the anode terminal segment and the cathode terminal segment, wherein the fuel inlet and the fuel outlet are incorporated into different ceramic segments that form the fuel cell chamber.

[0021] In one or more aspects, the fuel cell module may include at least six segments in the successively stacked arrangement, which are operative to form the casing, wherein the air inletDocket No. 2024P00519WO chamber and the air outlet chamber are formed by at least two ceramic segments stacked together in sealing engagement, wherein a first one of these two ceramic segments include the air inlet, wherein a second one of these two ceramic segments includes the air outlet.

[0022] In one or more aspects, the fuel cell module may include at least eight segments in the successively stacked arrangement, which are operative to form the casing, wherein at least five of the segments are annular segments which collectively circumferentially extend around at least portions of the fuel cell chamber and the air outlet chamber.

[0023] In one or more aspects, at least one of the fuel inlet, the depleted fuel outlet, the air outlet, and the air inlet may include a ceramic pipe portion that extends from an external wall of a segment, wherein the pipe portion includes a flange portion, wherein the flange portion is comprised of at least one of a ceramic, a metal, or a combination thereof.

[0024] In one or more aspects, the pipe portion may include a conical-shaped channel that narrows in diameter from the external wall towards the flange portion.

[0025] In one or more aspects, the metal segments may be comprised of nickel, nickel-copper, and / or a nickel alloy, wherein the ceramic segments may be comprised of alumina.

[0026] In one or more aspects, a method for generating electricity using the fuel cell module may comprise an act of fuel comprising hydrogen flowing from the fuel inlet, adjacent the anode layer of the fuel cells, and exiting as depleted fuel through the depleted fuel outlet of the fuel cell module. Such a method may further comprise an act of air comprising oxygen flowing from the air inlet, through the air feed conduits, adjacent the cathode layer of the fuel cells, and exiting through the air outlet of the fuel cell module. Such a method may also include an act of carrying out an electrochemical process using the hydrogen and oxygen with the fuel cells to produce steam that exits the depleted fuel outlet and to generate an electrical current through a load operatively electrically connected to external portions of the anode terminal segment and the cathode terminal segment of the fuel cell module.

[0027] In one or more aspects, a fuel cell system for generating electricity may comprise: a pressure vessel including an inert gas chamber; a plurality of fuel cell modules positioned within the inert gas chamber, wherein each fuel cell module is comprised of at least two annular segments 102 in a successively stacked arrangement that form a casing, wherein the casing includes a plurality of fuel cells; and at least one controller. The controller may be configured to cause: an air source to provide air to each fuel cell module; a fuel source to provide fuel to each fuel cell module; and an inert gas source to provide an inert gas into theDocket No. 2024P00519WO inert gas chamber external to the fuel cell modules. While the fuel cell modules carry out an electrochemical process with their fuel cells, the controller may further be configured to cause maintaining gas pressures of the inert gas adjacent external walls of the segments of each of the fuel cell modules greater than a maximum of the gas pressures of the fuel and air adjacent the internal walls of the segments of each fuel cell module. In such aspects, the relatively higher inert gas pressure exterior to the fuel cell module relative to the gas pressures within each fuel cell module prevents or at least reduces leakage of fuel and air out of the fuel cell module into the inert gas chamber between the segments.

[0028] In one or more aspects, the inert gas may include less than 0.1% by volume of gases that are chemically reactive with the fuel or the air.

[0029] In one or more aspects, the inert gas may include 99% by volume of at least one of nitrogen, argon, carbon dioxide, or any combination thereof.

[0030] In one or more aspects, the at least one controller may be configured to cause: the air source to provide air to each fuel cell module at a gas pressure of at least 0.5 bar absolute; and the fuel source to provide fuel to each fuel cell module at a gas pressure of at least 0.5 bar absolute.

[0031] In one or more aspects, maintaining gas pressures of the inert gas may occur while the fuel cell modules carry out the electrochemical process with their fuel cells operating at temperatures from 30°C to above 900°C.

[0032] In one or more aspects, maintaining gas pressures of the inert gas may occur at least while the maximum of the gas pressures of the fuel and air is at least 0.5 bar absolute.

[0033] In one or more aspects, the at least one controller may be configured to cause the system to respectively maintain gas pressures of the inert gas adjacent external walls of the segments of each of the fuel cell modules greater than the maximum of the gas pressures of the fuel and air adjacent the internal wall of the segments of each fuel cell module by at least 0.01 bar absolute, alternatively at least 0.1 bar absolute, alternatively by at least 0.5 bar absolute, alternatively by a least 3.0 bar absolute, or alternatively by a least 5.0 bar absolute

[0034] In one or more aspects, the inert gas source includes a gas cylinder including nitrogen at a pressure of at least 10 bar absolute.Docket No. 2024P00519WO

[0035] In one or more aspects, the fuel cells include an inner channel around which all three of a cathode layer, an electrolyte layer and an anode layer extend at least partially annularly in surrounding relation of the inner channel.

[0036] In one or more aspects, each of the fuel cell modules may include an anode terminal segment and a cathode terminal segment in the successively stacked arrangement that are operatively electrically coupled to the anode layers and the cathode layers of the fuel cells within the fuel cell modules and are operatively electrically coupled to the anode and cathode terminals of each other fuel cell module within the inert gas chamber.

[0037] In one or more aspects, the anode terminal segment and the cathode terminal segment may be annularly-shaped metal rings, wherein each of the anode terminal segment and the cathode terminal segment at stacked between ceramic segments in the successively stacked arrangement, wherein the fuel cells extend through both the cathode terminal segment and the anode terminal segment.

[0038] In one or more aspects, the ceramic segments may be comprised of alumina.

[0039] In one or more aspects, the anode terminal segment and the cathode terminal segment may be comprised of nickel, nickel-copper and / or a nickel alloy.

[0040] In one or more aspects, a method for generating electricity using the fuel cell system may comprising through operation of at least one controller: causing the air source to provide air to each fuel cell module; causing the fuel source to provide fuel to each fuel cell module; causing the inert gas source to provide an inert gas into the inert gas chamber external to the fuel cell modules. Also, while the fuel cell modules carry out an electrochemical process to generate electricity with their fuel cells, the method may include through operation of the at least one controller maintaining gas pressures of the inert gas adjacent external walls of the segments of each of the fuel cell modules greater than a maximum of the gas pressures of the fuel and air adjacent the internal walls of the segments of each fuel cell module. In such aspects, the relatively higher inert gas pressure exterior to the fuel cell module relative to the gas pressures within each fuel cell module prevents or at least reduces leakage of fuel and air out of the fuel cell module into the inert gas chamber between the segments.

[0041] One or more aspects may also include a fuel cell module for generating electricity with air feed regulation of temperature differentials comprising a fuel cell chamber having a fuel inlet, a depleted fuel outlet, and a plurality of tubular fuel cells. Each fuel cell includes a fuel cell wall in surrounding relation of a longitudinally extending inner channel that is closed onDocket No. 2024P00519WO one end, which fuel cell walls are comprised of an electrolyte layer between an anode layer and a cathode layer, wherein the cathode layers of the fuel cells extend adjacent the inner channels of the fuel cells. The fuel cell module may also include: an air outlet chamber having an air outlet; and an air inlet chamber having an air inlet, wherein the inner channels are in fluid communication with the air inlet and the air outlet, wherein the anode layers of the fuel cells extend adjacent outer channels along the fuel cells, which outer channels are in fluid communication with the fuel inlet and the depleted fuel outlet. The fuel cell module may also include a plurality of air feed conduits that extend through the air outlet chamber and into the inner channels of the fuel cells, which air feed conduits include annular walls having apertures therethrough for feeding air into the inner channels.

[0042] In one or more aspects, the flow rates of air through each air feed conduit in a first one of at least two different sets of the air feed conduits differs by at least 5% relative to the flow rates of air through each air feed conduit in a second one of the at least two different sets of air feed conduits so as to at least partially reduce temperature differentials within the fuel cell module when operating to generate electricity.

[0043] In one or more aspects, the resulting flow rates of air through each air feed conduit in a first set of the air feed conduits differs by at least 10%, alternatively by at least 15%, alternatively by at least 25%, alternatively by at least 50% relative to the resulting flow rates of air through each air feed conduit in a second set of air feed conduits.

[0044] In one or more aspects, the fuel cell module may further comprise: a first partition and a second partition. The first partition may be configured such that it: separates the fuel cell chamber from the air outlet chamber; supports the fuel cells; and includes apertures through which or adjacent thereto the air feed tubes traverse the first partition. The second partition may be configured such that it: separates the air outlet chamber from the air inlet chamber; supports the air feed conduits; and includes apertures aligned with the air feed conduits to enable air to flow from the air inlet chamber into the air feed conduits.

[0045] In one or more aspects, at least one of: the sizes and / or shape of channels through the air feed conduits; the sizes and / or shape of the apertures in the second partition that are aligned with the air feed conduits; the sizes and / or shape of the apertures through the walls of the air feed conduits; the sizes and / or shape of the apertures through the first partition; the number of apertures through the walls of the air feed conduits; the spacing arrangement of apertures through the walls of the air feed conduits; or any combination thereof, may vary between the atDocket No. 2024P00519WO least two different sets of the air feed conduits so as to at least partially reduce temperature differentials within the fuel cell module when operating to generate electricity relative to a lack of variation thereof.

[0046] In one or more aspects, the minimum diameters of the channels through the air feed conduits may vary between the at least two different sets of the air feed conduits.

[0047] In one or more aspects, the minimum diameters of the apertures in the second partition that are aligned with the air feed conduits may vary between the at least two different sets of the air feed conduits.

[0048] In one or more aspects, the minimum diameters of the apertures through the walls of the air feed conduits may vary between the at least two different sets of the air feed conduits.

[0049] In one or more aspects, the minimum diameters of the apertures through the first partition through which air passes adjacent the air feed conduits may vary between the at least two different sets of the air feed conduits.

[0050] In one or more aspects, the number of apertures through the walls of the air feed conduits may vary between the at least two different sets of the air feed conduits.

[0051] In one or more aspects, the number of apertures through the walls of the air feed conduits may vary between the at least two different sets of the air feed conduits by at least 10%, alternatively by at least 25%, alternatively by at least 50%.

[0052] In one or more aspects, the spacing arrangement of apertures through the walls of the air feed conduits may vary between the at least two different sets of the air feed conduits.

[0053] In one or more aspects, a fuel cell system for generating electricity with compression compensation for thermal expansion may comprise: a pressure vessel; and a plurality of fuel cell modules positioned within the pressure vessel, wherein each fuel cell module is comprised of at least two annular segments in a successively stacked arrangement that form a casing, wherein the casing includes a plurality of fuel cells therein. The fuel cell system may further include a compression system that compresses the at least two segments together of each fuel cell; and at least one controller. The at least one controller may be configured to: cause the fuel cell modules to increase or decrease in temperature in order to carry out or cease carrying an electrochemical process that generates electricity with their fuel cells; and control operation of the compression system to regulate the application of compression forces acting on the atDocket No. 2024P00519WO least two segments of each fuel cell module based on received measurements reflective of the thermal expansion or contraction of the segments of the fuel cell modules.

[0054] In one or more aspects, the at least one controller may be configured to regulate the application of compression forces by the compression system based on the received measurement to both prevent or at least minimize cracking of at least portions of the fuel cell modules due the thermal expansion of the segments, and maintain a gas tight seal between the segments of the fuel cells modules during thermal expansion and contraction of the segments.

[0055] In one or more aspects, maintaining the gas-tight seal prevents leakage of fuel and air between the segments to below 10'3mbar*l / s. during electrical generation by the fuel cells.

[0056] In one or more aspects, the compression system may include at least one of a pneumatically or hydraulically operated compression system.

[0057] In one or more aspects, the measurements may include temperature readings reflective of the temperature of at least one segment of at least one fuel cell module.

[0058] In one or more aspects, the measurements may include compression force readings acting on the segments of at least one of the fuel cell modules.

[0059] In one or more aspects, the measurements may include distance or location readings reflective of the amount of thermal expansion or contraction of the segments of at least one of the fuel cell modules.

[0060] In one or more aspects, a method for generating electricity using the fuel cell system may comprise through operation of the at least one controller: causing the fuel cell modules to increase or decrease in temperature in order to carry out or cease carrying an electrochemical process that generates electricity with their fuel cells; controlling operation of the compression system to regulate the application of compression forces acting on the at least two segments of each fuel cell module based on received measurements reflective of the thermal expansion or contraction of the segments of the fuel cell modules.

[0061] In one or more aspects, the method may further comprise regulating the application of compression forces based on the received measurement to both prevent or at least minimize cracking of at least portions of the fuel cell modules due the thermal expansion of the segments, and maintain a gas tight seal between the segments of the fuel cells modules during thermal expansion and contraction of the segments.Docket No. 2024P00519WO

[0062] In one or more aspects, a fuel cell module for generating electricity with a multi-plate support partition may comprise at least two annular segments in a successively stacked arrangement, which are operative to form a casing, including therein a fuel cell chamber having a fuel inlet, a depleted fuel outlet, and a plurality of tubular fuel cells, wherein each fuel cell includes a fuel cell wall in surrounding relation of a longitudinally extending inner channel that is closed on one end, which fuel cell walls are comprised of an electrolyte layer between an anode layer and a cathode layer. The formed casing may further include: an air outlet chamber having an air outlet; and an air inlet chamber having an air inlet, wherein the cathode layers of the fuel cells extend adjacent the inner channels of the fuel cells, which inner channels are in fluid communication with the air inlet and the air outlet, and wherein the anode layers of the fuel cells extend adjacent outer channels along the fuel cells, which outer channels are in fluid communication with the fuel inlet and the depleted fuel outlet. The formed casing may also include: a plurality of air feed conduits that extend through the air outlet chamber and into the inner channels of the fuel cells; and at least one partition. The at least one partition may be configured such that it: is mounted within at least one segment; separates at least two of said chambers; and comprises a ground plate and a support plate, which support plate is supported by the ground plate. The ground plate and the support plate may include apertures therethrough that are operatively aligned and are sized to form receptacles that: receive at least one of the fuel cells or the air feed conduits through the apertures of the support plate in supporting engagement with the ground plate; and enable gases to pass through the apertures of the ground plate and the support plate into and / or out of at least one of the fuel cells or the air feed conduits.

[0063] In one or more aspects, the at least one partition may include a first partition that: separates the fuel cell chamber from the air outlet chamber; supports the fuel cells in its receptacles; enables air feed conduits to traverse the first partition through the receptacles and into the inner channels of the fuel cells; and enables air to traverse the first partition through the receptacles from the inner channels of the fuel cells into the air outlet chamber.

[0064] In one or more aspects, the at least one partition may include a second partition that: separates the air outlet chamber from the air inlet chamber; supports the air feed conduits in its receptacles; and enables air to traverse the second partition through the receptacles from the air inlet chamber into the air feed conduits.Docket No. 2024P00519WO

[0065] In one or more aspects, the apertures of the support plate may include a beveled annular inner surface that widens in diameter towards the ground plate to form an annular cavity in the receptacles adjacent to the fuel cells or air feed conduits for providing a sealing material that fixes the fuel cells or air feed conduits in sealing engagement with the support plate.

[0066] In one or more aspects, the lower edges of the fuel cells or the air feed conduits may include an annular flange that is supported by the ground plate, wherein the apertures of the support plate include an annular slot in the receptacles adjacent to the fuel cells or air feed conduits that receives the flanges and locks the fuel cells or air feed conduits in the receptacles.

[0067] In one or more aspects, at least one of the fuel cells or the air feed conduits are in sealing engagement within the receptacles via a seal material.

[0068] In one or more aspects, the seal material may include glass solder.

[0069] In one or more aspects, the interface between two stacked segments may form an inner circumferential channel, wherein the ground plate and the support plate form an outer circumferential edge portion that extends in sealing engagement within the inner circumferential channel.

[0070] In one or more aspects, the circumferential edge portion is in sealing engagement within the inner circumferential channel via a seal material.

[0071] In one or more aspects, a fuel cell system for generating electricity with carbon capture may comprise a fuel cell module including therein: a fuel cell chamber having a fuel inlet, a depleted fuel outlet, and a plurality of tubular fuel cells, wherein each fuel cell includes a fuel cell wall in surrounding relation of a longitudinally extending inner channel that is closed on one end, which fuel cell walls are comprised of an electrolyte layer between an anode layer and a cathode layer. The fuel cell module may also include: an air outlet chamber having an air outlet; and an air inlet chamber having an air inlet, wherein the fuel cell, air outlet, and air inlet chambers are configured to segregate and facilitate separately exhausting the depleted fuel gases and the depleted air from the fuel cell module. The fuel cell system may further include:

[0072] an oxyfuel combustor configured to burn the depleted fuel comprising H2, CO, CO2, with an external source of O2 other than from diluted air to produce a superheated mixture of steam and CO2; an air superheater configured to extract heat from the superheated mixture for use with heating the depleted air exhausting from the fuel cell module sufficiently to produce a superheated diluted air that is usable to drive a turbine to generate electricity; and a condenserDocket No. 2024P00519WO configured to condense the steam in the mixture to water and thereby cause water and CO2 to substantially separate from each other.

[0073] In one or more aspects, the chambers may be separated by partitions that are operatively configured to prevent the mixture of depleted fuel and depleted air to below 10’3mbar*l / s during electrical generation by the fuel cells.

[0074] In one or more aspects, the cathode layers of the fuel cells extend adjacent the inner channels of the fuel cells, which inner channels are in fluid communication with the air inlet and the air outlet, and wherein the anode layers of the fuel cells extend adjacent outer channels along the fuel cells, which outer channels are in fluid communication with the fuel inlet and the depleted fuel outlet.

[0075] In one or more aspects, the fuel cell system may include: a plurality of air feed conduits that extend through the air outlet chamber and into the inner channels of the fuel cells; a first partition; and a second partition. The first partition may be configured such that it: is mounted within at least one segment; separates the fuel cell chamber from the air outlet chamber; supports the fuel cells; and includes apertures through which the air feed conduits traverse the first partition. The second partition may be configured such that it: is mounted within at least one segment; separates the air outlet chamber from the air inlet chamber; supports the air feed conduits; and includes apertures aligned with the air feed conduits to enable air to flow from the air inlet chamber into the air feed conduits.

[0076] In one or more aspects, the fuel cell system may further comprise an anode exhaust cooler configured to further remove heat from the mixture prior to reaching the condenser.

[0077] In one or more aspects, the fuel cell system may further comprise a CO2 compressor configured to move a portion of the separated out CO2 through a recycle heater and to the oxyfuel combustor in order to be included with the depleted fuel when being burned to produce the superheated mixture of steam and CO2, wherein the recycle heater heats the CO2 using removed heat from the anode exhaust cooler.

[0078] In one or more aspects, the fuel cell system may further comprise a steam generator configured to use heat from the anode exhaust cooler to produce superheated steam from water, that is combined with the superheated depleted air for driving the turbine.

[0079] In one or more aspects, the steam generator may include an economizer to preheat the water, a vaporizer to vaporize the preheated waste to steam, and a superheater to boost the temperature of the steam prior to being combined with the superheated depleted air.Docket No. 2024P00519WO

[0080] In one or more aspects, the fuel cell system may further include a turbine.

[0081] In one or more aspects, a method of generating electricity and capturing CO2 with the fuel cell system may comprise: electrochemically generating electricity with a fuel cell module comprising a plurality of fuel cells using an oxidizer comprising air and a fuel comprising of H2, CO, CO2, and steam; exhausting depleted fuel, which is at least partially diluted of H2 through a depleted fuel outlet; exhausting depleted air, which is at least partially diluted of O2 through an air outlet, while preventing mixture of the depleted fuel with the depleted air; burning with an oxyfuel combustor the depleted fuel with an external source of O2 other than from diluted air to produce a superheated mixture of steam and CO2; heating with an air superheater the depleted air to produce superheated depleted air, using heat extracted from the superheated mixture; driving a turbine with the superheater depleted air to generate electricity; and condensing with a condenser the steam in the mixture to water and thereby cause the water and CO2 to separate from each other.

[0082] In one or more aspects, the method may further comprise: moving with a CO2 compressor a portion of the separated out CO2 through a recycle heater and to the oxyfuel combustor in order to be included with the depleted fuel when being burned to produce the superheated mixture of steam and CO2; heating with the recycle heater the CO2 using heat from the superheated mixture.

[0083] In one or more aspects, the method may further comprise: producing superheated steam from water with a steam generator using heat from the superheated mixture; and driving the turbine with both the superheated depleted air and the superheated steam.

[0084] One or more aspects may also include a non-transitory computer readable medium encoded with processor executable instructions that when executed by at least one processor in the at least one controller, cause the at least one controller to carry out the methods of one or more aspects described herein.

[0085] In view of the above-described aspects and the more detailed description that follows below, it should be appreciated that the many novel technical features described herein solve various technical problems associated with prior fuel cell, electrolyzer, and / or SOFC technology and achieve a practical technical effect. For example, the successively stacked arrangement of the segments allows for uniformity and harmonization of thermal expansion in a manner that both maintains gas-tightness between the segments and avoids / minimizes the potential for cracking as the fuel cell module experiences wide temperature changes and highDocket No. 2024P00519WO external pressures during it lifecycle (e.g., from -20°C to 1500°C; up to 20 bar absolute over many years).

[0086] In addition, example embodiments provide reduction of complexity, material costs, shipping costs, assembly / disassembly / service times, and / or weight (e.g., due to the reduction of parts; the increased use of ceramic refractory materials; and the overall modularization and simplification of the design).

[0087] In addition, the example embodiments may achieve a faster kick-start of the fuel cell module due to a lower mass of fuel cell stack which needs to get heated up. Furthermore, the use of ceramic materials in the segments provides an electrical insulation material with a high temperature stability at operating conditions between electrically conductive terminal segments.

[0088] Furthermore, the example designs for the fuel cell module and fuel cell system may increase stack efficiency due to optimization of cooling air, by reduction of fuel leakages (e.g., from several percent to 0%). This also leads to an improvement of product safety. In addition, the separation of fuel and oxidant exhausts via the design of the fuel cell module, beneficially enables the inclusion of carbon capture processes with minor reductions on efficiently.

[0089] The described fuel cell system also provides the fuel cell modules with a lower internal pressure than the inert gas (i.e., a nitrogen safety atmosphere) external to the fuel cell modules within the pressure vessel. Based on use of the inert gas as well as the slight overpressure, a safety barrier against fire & explosion is created. Also, in case one or more of the fuel cell modules start to leak, the inert gas is biased to flow into the fuel cell module and block or at least reduce the electro-chemical fuel cell reaction therein (i.e., forming a failsafe design).

[0090] The foregoing has outlined rather broadly the technical features and characteristics of the present disclosure so that those skilled in the art may better understand the detailed description that follows. Additional features and advantages of the disclosure will be described hereinafter that form the subject of the claims. Those skilled in the art will appreciate that they may readily use the conception and the specific embodiments disclosed as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. Those skilled in the art will also realize that such equivalent constructions do not depart from the spirit and scope of the disclosure in its broadest form.

[0091] Also, before undertaking the Detailed Description below, it should be understood that various definitions for certain words and phrases are provided throughout this patent document,Docket No. 2024P00519WO and those of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases. While some terms may include a wide variety of embodiments, the appended claims may expressly limit these terms to specific embodiments.BRIEF DESCRIPTION OF THE DRAWINGS

[0092] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0093] FIG. 1 illustrates a functional block diagram of an example fuel cell module that facilitates generating electricity.

[0094] FIG. 2 illustrates a cross-sectional view of an example cylindrical tubular fuel cell usable in the example fuel cell module.

[0095] FIG. 3 illustrates a cross-sectional view of an example delta-shaped tubular solid oxide fuel cell usable in the example fuel cell module.

[0096] FIG. 4 illustrates an outer isometric view of an example fuel cell module.

[0097] FIG. 5 illustrates a cross-sectional view of the example fuel cell module shown in FIG. 4.

[0098] FIG. 6 illustrates an isometric view of an example air inlet segment that forms portions of the fuel cell module.

[0099] FIG. 7 illustrates an isometric view of an example metal terminal segment that forms portions of a fuel cell chamber of the fuel cell module.

[0100] FIG. 8 illustrates an isometric view of a set of two metal terminal segments including internal and external electrical conductors.

[0101] FIG. 9 illustrates a cross-sectional view of an example port of an example segment.

[0102] FIG. 10 illustrates a cross-sectional view of an alternative embodiment of the example port.

[0103] FIG. 11 illustrates a cross-sectional view of a further alternative embodiment of the example port.

[0104] FIG. 12 illustrates a cross-sectional view of another alternative embodiment of the example port.Docket No. 2024P00519WO

[0105] FIG. 13 illustrates a cross-sectional view of an example seal arrangement between two adjacent segments.

[0106] FIG. 14 illustrates a cross-sectional view of an example seal arrangement between two adjacent segments and an internal partition.

[0107] FIG. 15 illustrates an isometric view of an example first partition, that separate the fuel cell chamber from the air outlet chamber.

[0108] FIG. 16 illustrates an isometric view of an example second partition, that separates the outlet air chamber from the inlet air chamber.

[0109] FIG. 17 illustrates a cross-sectional view of the second partition showing receptacles that receive air feed conduits.

[0110] FIG. 18 illustrates a bottom view of the second partition showing apertures that extend through the receptacles.

[0111] FIG. 19 illustrates an alternative embodiment of a partition comprising multiple plates.

[0112] FIG. 20 illustrates a configuration of the multi-plate partition for fixing and supporting components thereto.

[0113] FIG. 21 illustrates an alternative configuration of the multi-plate partition for fixing and supporting components thereto.

[0114] FIG. 22 illustrates a functional block diagram of an example fuel cell system that facilitates generating electricity.

[0115] FIG. 23 illustrates an example compression system 162 for compressing segments of fuel cell modules.

[0116] FIG. 24 illustrates a functional block diagram of a fuel cell carbon capture system.

[0117] FIG. 25 illustrates a functional block diagram of an alternative fuel cell carbon capture system.

[0118] FIG. 26 illustrates a functional block diagram of a steam boosting configuration usable with a fuel cell carbon capture system.

[0119] FIG. 27 illustrates a flow diagram of an example methodology for generating electricity using an example fuel cell module.Docket No. 2024P00519WO

[0120] FIG. 28 illustrates a flow diagram of an example methodology for generating electricity via a fuel cell system that includes a plurality of fuel cell modules located in a pressure vessel filled with an inert gas.

[0121] FIG. 29 illustrates a flow diagram of an example methodology for controlling operation of a compression system that compresses together segments of the fuel cell module.

[0122] FIG. 30 illustrates a flow diagram of an example methodology for carrying out carbon capture with the fuel cell module.DETAILED DESCRIPTION

[0123] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in this description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0124] Various technologies that pertain to systems and methods will now be described with reference to the drawings, where like reference numerals represent like elements throughout. The drawings discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged apparatus. It is to be understood that functionality that is described as being carried out by certain system elements may be performed by multiple elements. Similarly, for instance, an element may be configured to perform functionality that is described as being carried out by multiple elements. The numerous innovative teachings of the present application will be described with reference to exemplary non-limiting embodiments.

[0125] The following description is directed to fuel cells such as solid oxide fuel cell (SOFC) components and systems used to generate electricity. SOFC are a type of fuel cell that includes a ceramic, such as yttria-stabilized zirconia (YSZ). However, it is to be understood that the aspects of the modules, systems, components, and processes described herein may also be applied to other types of fuel cell systems (including proton exchange member fuel cells,Docket No. 2024P00519WO alkaline fuel cells, phosphoric acid fuel cells, molten carbonate fuel cells, and direct methanol fuel cells) as well as reversible fuel cell systems and electrolyzer systems.

[0126] FIG. 1 shows a schematic view of an example embodiment of a fuel cell module 100 that facilitates the operation of fuel cells 112 therein of various types and configurations, including SOFCs. In addition, as will be discussed in more detail with respect to FIG. 22, a plurality of such fuel cell modules may be integrated into a fuel cell system 2200. It should also be appreciated that alternative embodiments may use other types of fuel cells such as molten carbonate fuels cells (MCFC) or proton-exchange membrane (PEM) fuel cells.

[0127] The fuel cell module 100 includes a plurality of annularly shaped segment 102 in a successively stacked arrangement that are operative to form a casing 104 having a plurality of chambers therein. One of such chambers includes a fuel cell chamber 106 that houses a plurality of fuel cells 112. In many of the examples described herein such fuel cells are tubular shaped. However, it should be appreciated that in alternative embodiments, the fuel cell module may be configured for use with planar-shaped fuel cells. Also, although, FIG. 1 shows the segments being stacked one on top of the other in a vertical stacking direction, in alternative embodiments the segments may be successively stacked in other stacking directions (e.g., horizontally or at some other angle provided there exists sufficient structure / forces to hold the stack together at such alternative stacking directions).

[0128] In an example embodiment, the fuel cell module may include at least three successively stacked segments 102, such as at least one electrically insulating ceramic segment 156 between at least two electrically conductive metal segments 146, 148. Further embodiments of the fuel cell module may include at least five successively stacked segments 102, such as at least three ceramic segments 154, 156, 158 and at least two metal segments 146, 148. However, it should be appreciated that example embodiments may include less or more segments that are successively stacked together to form the fuel cell module. For example, embodiments may include additional ceramic segments above, between, and / or below the metal segments 146, 148. Alternative embodiments may also include additional metal segments in addition to or in place of the ceramic segments described herein. Further in some embodiments, portions of the segments may include additional materials (e.g., metal, ceramic, or other high temperature materials capable of enabling the fuel cell module to operate at temperatures above 800°C).Docket No. 2024P00519WO

[0129] Thus, as used herein a ceramic segment corresponds to a segment (or the ceramic portions of a multi-material segment) comprised of at least one ceramic material that extends continuously annularly (i.e., in a ring) to form wall portions of the casing. In addition, as used herein a metal segment corresponds to a segment (or the metal / metal alloy portions of a multimaterial segment) comprised of one or more metals / metal alloys that extends continuously annularly (i.e., in a ring) to form wall portions of the casing.

[0130] The fuel cell chamber itself may be formed by stacking at least one ceramic segment 156 (having an annular shape) between the two metal segments (each having an annular shape), which two metal segments are respectively referred to herein as the anode terminal segment 146 and the cathode terminal segment 148 (and more generally as metal terminal segments). With this arrangement of stacked segments with annular shapes, the fuel cells extend through both the cathode terminal segment and the anode terminal segment and the at least one ceramic segment 156 therebetween.

[0131] As schematically illustrated in FIG. 1, the two metal terminal segments 146, 148 are operatively electrically coupled to anode layers 120 and cathode layers 122 of the fuel cells 112 via electrical connections 150, 152. Thus, these metal terminal segments correspond respectively to the negative and positive electrical connection poles of the fuel cell module itself. In FIG. 1 , the anode terminal segment is depicted as being above the cathode terminal segment. However, in alternative embodiments the metal terminal segment depicted with reference numeral 146 may correspond to the cathode terminal segment, and likewise the metal terminal segment depicted with reference numeral 148 may correspond to the anode terminal segment. Also, it should be appreciated that the electrical arrangement of the fuel cells and these metal terminals segments is merely for illustration purposes. Implementations of these connections may have a variety of arrangements, which electrically connect fuel cells with metal terminal segments in series and / or parallel to achieve a desired voltage output for the fuel cell module.

[0132] The fuel cell chamber may also include a fuel inlet 108 for receiving a supply of a hydrogen carrying gas, which is referred to herein as a fuel. Also, the fuel cell chamber may include a depleted fuel outlet, through which depleted fuel (i.e., fuel that is at least partially depleted of hydrogen) may pass out of the fuel cell module. Each fuel cell in this example is tubular in shape, and thus includes a fuel cell wall 114 in surrounding relation of aDocket No. 2024P00519WO longitudinally extending inner channel 116. In this described embodiment, the inner channels116 are closed at one end (e.g., the upper end in this example).

[0133] The casing further includes an air inlet chamber 130, a plurality of air feed conduits 134, and an air outlet chamber 126. The air inlet chamber may include an air inlet 132 for receiving a supply of an oxygen caring gas, which is referred to herein as air 164. The air outlet chamber 126 may include an air outlet 128, through which depleted air 166 exiting the fuel cells (i.e., depleted of some oxygen) exits the fuel cell module. The air feed conduits 134 may be positioned to direct air from the air feed chamber to flow into the inner channels 116 of the fuel cells 112. To reach the inner channels 116, the air feed conduits 134 pass through the air outlet chamber 126 in this described example. It should also be noted that the air feed conduits may include conduit holes 160 through their conduit walls, in various positions along their axial lengths, which distribute air at different locations along the inner channels 116 of the fuel cells. The relative spacing and / or density of the conduit holes 160 may vary. For example, there may be a higher density of conduit holes 160 per surface area of conduit wall closer to the closed ends of the inner channel 116, to facilitate a generally more uniform distribution of air along the cathode layer 122.

[0134] As is known in the art of fuel cell systems, the fuel cell walls are comprised of an electrolyte layer 118 between the anode layer 120 and the cathode layer 122, which are suitably selected to enable the fuel cells to generate an electrical current from the supply of fuel flowing adjacent the anode layer and the supply of air flowing adjacent the cathode layer. It should be appreciated that fuel 138 (bearing hydrogen and potentially other gases such as steam, CO and CO2 mixed with the hydrogen) from the fuel inlet 108 is directed through outer channels 124 adjacent the anode layers 120 of the fuel cells. Depleted fuel 140 comprising fuel gas that is a least partially depleted of hydrogen) and steam 142 (produced via the electrochemical fuel cell process) may then be directed out the depleted fuel outlet 110.

[0135] To facilitate routing of the air through the inner channel 116, and to facilitate segregation of the air from the fuel, the fuel cell module may include a first partition 136 and a second partition 144. The first partition may be mounted within at least one segment (such as ceramic segment 158), in order to separate the fuel cell chamber 106 from the air outlet chamber 126. The first partition 136 may be configured to support the lower ends of the fuel cells thereon in sealing engagement therewith. In addition, the first partition may include apertures through which the air feed conduits traverse the first partition.Docket No. 2024P00519WO

[0136] The second partition 144 may be mounted within at least one segment (such as ceramic segment 158 or another segment positioned below ceramic segment 158) in order to separate the air outlet chamber 126 from the air inlet chamber 130. In addition, the second partition may be configured to support the lower ends of the air feed conduits thereon and in sealing enragement therewith. In addition, the second partition may include apertures aligned with the air feed conduits to enable air (shown by dashed arrows) to flow from the air inlet chamber into the air feed conduits.

[0137] The described segments are in sealing engagement via seals and / or sealing forces to enable the engagement between the segments to be substantially gas-tight. Such sealing forces may be provided by gravitation forces from the weight of the segments themselves and / or via an external compression systems 162, such as a mechanical spring-based clamp system, a pneumatic pressure system, and / or a hydraulic pressure system, that compress the stack of segments together in the direction that the segments are stacked (e.g., such as in the vertical direction shown in FIG. 1).

[0138] It should be appreciated that segments will undergo thermal expansion and contraction when their temperatures and pressures are raised and lowered between and operating temperatures and pressures (e.g., from - 20°C up to 1500°C; up to 20 bar absolute). Thus, the compression system 162 may be configured to compensate for and permit thermal expansion of the segments in the direction of stacking to avoid cracking of the segments, while continuing to apply sufficient compression forces to maintain a gas-tight sealing between the segments. This may be done automatically mechanically via the configuration of the compression system 162, and / or via control of the compression system by at least one controller responsive to measurements reflective of thermal expansion and / or contraction of the segments of the fuel cell module.

[0139] The word “gas-tight” is used herein to describe gas sealing capabilities of the segments and sealing arrangement of the partitions inside the casing that segregate the fuel cell chamber, the air inlet chamber, and / or the air outlet chamber. It should be understood, that gas-tight in these contexts corresponds to a sufficient level of sealing to reduce leakage of gases across a seal to below a certain threshold at particular temperatures and pressure differentials across the applicable seals. For example, the stacked ceramic and metal segments may be in sealing engagement sufficient to prevent leakage of fuel and air between the segments to below 10'31Docket No. 2024P00519WO mbar*l / s. during electrical generation by the fuel cells at their intended operating temperature and pressure ranges for the particular type of fuel cell design.

[0140] It should be noted that the word “air” is intended to be construed broadly in this description and in the claims to refer to an oxidant gas that comprises oxygen in a suitable concentration to facilitate the formation of oxygen ions at the cathode layer. Such air may correspond to ambient air that contains oxygen (typically about 21%). Such air may also correspond to oxygen itself. In addition, air may correspond to a gas other than ambient air or pure oxygen, but which still has an oxygen content sufficient to enable the fuel cell module to operate and produce electrical power.

[0141] It should also be noted that the word “fuel” is to be construed broadly in this description and in the claims to refer to a gas that provides hydrogen in a suitable concentration to enable the fuel cell module to operate and produce electrical power. In addition to the fuel corresponding to hydrogen gas itself, the fuel may include other gases, for example such as CO, CO2, and steam that are produced when methane gas is steam reformed to produce hydrogen). Further, the fuel may include methane or another hydrogen containing gas, which is cracked to release the hydrogen (and other gases) via suitably high operating temperatures of the fuel cell module itself.

[0142] In addition, the word “ceramic” with respect to the material used to form the described ceramic segments and / or other electrically insolating elements of the fuel cell module casing, should be construed broadly in this description and in the claims to refer to inorganic and nonmetallic materials capable of maintaining its solid shape and function at high temperatures (e.g., above 800°C) and provide at such temperatures good chemical resistance and electrical insulator properties (e.g., I x I O5Q x m). Examples of such ceramic materials may include alumina ceramics comprised of aluminum oxide and / or other ceramic materials (made from natural and / or synthetic raw materials). However, it should be apreciated that in alternative applications, the described fuel cell module may be used with fuel cells that operate at much lower temperatures (e.g., < 500°C, ambient temperatures). In such applications, the described ceramic segments may be comprised of other types of materials (other than ceramics) that function as electrical insulators.

[0143] Furthermore, the word “metal” with respect to the material used to form the described metal segments and / or other electrically conductive elements of the fuel cell module casing, should be construed broadly in this description and in the claims to refer to metal and metalDocket No. 2024P00519WO alloys that are capable of maintaining their mechanical functions at the intended operating temperatures of the fuel cell module with low electrical resistivity at such temperatures (e.g., below 300 pQ x cm). Examples of such metals that may be used for the described metal segments (or other metal components) may include nickel, nickel-copper, and / or nickel-based alloys including, for example, the commercially available Inconel 718 superalloy or other metal or metal alloy that is suitable for high temperatures applications (e.g., above 800°C.).However, in embodiments where the fuel cell module is used with fuel cells that operate at much lower temperatures (e.g., < 500°C, ambient temperatures), other types of metals or materials may be used to form the described terminal segments or other conductive components including copper and stainless steel. Further in other alternative embodiments, in place of metal, terminal segments or other electrical components may be made of an electrically conductive ceramic or other conducting materials.

[0144] As discussed previously, the described fuel cells may be tubular in shape. Such a tubular shape distinguishes them from planner fuel cells typically used in relatively lower temperate fuel cell arrangements (such as proton exchange membrane - PEM fuel cells.)

[0145] FIG. 2 illustrates schematically generally cylindrical-shaped tubular fuel cell 200 that may be used in some embodiments of the fuel cell modules described herein. In this example, the cross-section of the fuel cell is generally circular. The internal surfaces of the fuel cell walls 114 include the cathode layer 122. The external surfaces of the fuel cell walls 114 include the anode layer. In this example, the described inner channels 116 (through which air is supplied) corresponds to the interior of the fuel cell 200. The described outer channels 124 (adjacent which fuel is supplied) corresponds to spaces externally adjacent to the fuel cell walls 114.

[0146] However, it should be appreciated that in alternative embodiments, the relative locations of the cathode layer and the anode layers maybe reversed. In such alternative embodiments, the fuel cell module may likewise be reconfigured to route fuel and air in a manner that is compatible with such an alternative design of the fuel cells and which still prevents (or at least minimizes) leakage of air and fuel into the same chambers.

[0147] FIG. 3 depicts an example implementation 300 of a set of fuel cells, in which each fuel cell in the set does not have a cylindrical shape. Rather the fuel cells are delta-shaped (i.e., generally triangular-shaped). In this example, the set of delta-shaped fuel cells includes a plurality of fuel cells (such as eight in the example) that are connected in side-by-side relation to each other.Docket No. 2024P00519WO

[0148] Similar to the cylindrical-shaped fuel cell depicted in FIG. 2, the delta-shaped fuel cells of FIG. 3 include a cathode layer 122 that extends adjacent the internal surfaces of the fuel cell walls 114 that surround the inner channel 116. Also, similar to the cylindrical-shaped fuel cell depicted in FIG. 2, the delta-shaped fuel cells of FIG. 3 include an anode layer 120 that extends adjacent the exterior surfaces of the fuel cell walls (that surround inner channel 116 through which air passes therethrough) The side-by-side arrangement of the delta-shaped fuel cells forms the previously described outer channels 124 (through which fuel flows adjacent thereto).

[0149] Thus, in both examples of tubular shaped fuel cells depicted in FIG. 2 and FIG. 3, the fuel cells include an inner channel 116 around which all three of the cathode layer 122, electrolyte layer 118 and anode layer 120 extend at least partially annularly in surrounding relation of the inner channel 116. Other examples of tubular fuel cell designs that may be used are shown in U.S. Patent Application Publication No. 2008 / 0003478 Al dated January 3, 3008, which is hereby incorporated herein by reference in its entirety.

[0150] It should be noted that the side-by-side connected arrangement of the delta-shaped fuel cells forms (vie their adjacent planar fuel cell walls 114) a generally planar surface 302. This planar surface 302 may include an applied electrically conductive metal sheet or layer (referred to therein as an interconnector layer 304). This interconnector layer enables multiple sets of the delta-shaped fuel cell sets to be positioned adjacent to each other (in a bundle) so as to be in serial electrical connection via having their respective anode layers 112 be in electrical connection with the interconnection layer of an adjacent set of fuel cells. Possible example implementation of this fuel cell bundle arrangement is illustrated in U.S. Patent no. 8,673,519 B2 issued March 18, 2014, which is hereby incorporated herein by reference in its entirety.However, it should be appreciated that alternative embodiments may include other numbers and arrangements of fuel cells in series and / or parallel electrical connection to produce an overall desired voltage and current output.

[0151] Referring back to FIG. 1, the example design of the fuel cell module simplifies the electrical connection of the internal bundles of fuel cells to external electrical loads. Internally, the resulting negative pole of the bundles of fuel cells may be electrically connected to the anode terminal segment 146 and the resulting positive pole of the bundles of fuel cells may be electrically connected to the cathode terminal segment 148. For example, internally electrically conductive wires / sheets / plates may be mounted between the inner surfaces of the terminalsDocket No. 2024P00519WO146, 148 and the respective anode and cathode portions of the fuel cell bundles. In this arrangement, an electrical load can then be externally connected to the terminals 146, 148 of the fuel cell module in order to receive the electrical current generated by the internal fuel cells, without the need to pass individual wires through ducts in the walls of the housing in order to connect the internal fuel cells to the outside world.

[0152] It should be appreciated that example implementations of the fuel cell module shown schematically in FIG. 1 , may have a variety of shapes and sizes to house different numbers and types of tubular fuel cells. An isometric view of one possible example implementation 400 of a fuel cell module for housing bundles of the delta-shaped fuel cells is shown in FIG. 4. This example includes at least nine successively stacked segments.

[0153] Also, FIG. 5 depicts a cross-sectional view 500 of this example fuel cell module 400. In this embodiment, the fuel cell module includes two consecutively stacked middle ceramic segments 404, 406 positioned between the two metal terminal segments 146, 148. The middle ceramic segments function as electrical insulators that are operative to electrically isolate the anode terminal segment 146 from the cathode terminal segment 148 (i.e., the poles of the fuel cell module).

[0154] The fuel cell module 400 also includes an upper or top segment 402, which correspond to a ceramic segment having an integrally formed fuel inlet 108 (and may be referred to herein as fuel inlet segment 402). The fuel cell module 400 may also include a relatively lower ceramic segment 408 having an integrally formed depleted fuel outlet 110 (and may be referred to herein as a depleted fuel outlet segment 408). The fuel cell module 400 may also include another relatively lower ceramic segment for mounting the first partition 136 (shown in FIG. 1 and FIG. 5) that separates the fuel cell chamber 106 from the air outlet chamber 126 (which may be referred to herein as a partition mounting segment 410).

[0155] In addition, the fuel cell module 400 may include a further relatively lower ceramic segment 412 having an integrally formed air outlet 128 (and may be referred to herein as an air outlet segment 412). The fuel cell module 400 may have an even further relatively lower ceramic segment 414 having an integrally formed air inlet 132 (and may be referred to herein as an air inlet segment 414). In this example, the air inlet segment may also be configured for internally mounting the second partition 144 (shown in FIG. 1 and FIG. 5) that separates the air outlet chamber 126 from the air inlet chamber 130. All of these described segments includeDocket No. 2024P00519WO annular portions which together form walls of the casing, and which (in combination) encase the described fuel cell chamber 106, the air outlet chamber 126, and the air inlet chamber 130.

[0156] It should be noted that the fuel cells 112 and the air feed conduits 134 extend stacking direction of the segments (upwardly in FIG. 4 and FIG. 5) from the respective first partition 136 and second partition 144. To assist with maintaining these elongated components in their parallel arrangement, the fuel cell module may include further support members 502, 504 (e.g., brackets, plates) mounted within the segments that limit lateral movement of the fuel cells and air feed conduits. Such support members may include holes therethrough for receiving and supporting the fuel cells and air feed conduits. Such support members may also include additional holes or channels therethrough to enable gases (i.e., fuel, air, steam) to traverse these support members in the particular chamber in which they are mounted.

[0157] In addition, although the fuel cell module 400 is depicted with a generally rectangular box shape in FIG. 4 (with segments having a generally square or rectangular horizontal crosssections) it should be appreciated that alternative embodiments may have other shapes. For example, other casing shapes may include a generally cylindrical shape (e.g., with segments having generally circular horizontal cross sections), or any other shape (e.g., casings with elliptical, 6 or 8 or higher numbers of corners shapes at horizontal cross-sections).

[0158] The example fuel cell module 400 shown in FIG. 4 and FIG. 5 may be targeted for operating and generating electricity in SOFCs at internal pressures of the air and the fuel greater than 0.5 bar absolute, alternatively greater than 3 bar absolute, further alternatively between 5 and 10 bar absolute, and further alternatively above 5 bar absolute, at temperatures above 30°C, alternatively above 800°C, and further alternatively between 900°C and 1400°C. However, it should be appreciated that embodiment of the depicted fuel cell module may be used with fuel cells that operate at lower or higher temperatures and / or pressures.

[0159] Referring now to FIG. 6 and FIG. 7, isometric views of example implementations of a ceramic segment 600 and a metal terminal segment 700 are illustrated. The ceramic segment 600 shown in FIG. 6 corresponds to an air inlet segment 414 having an air inlet 132. Such an air inlet 132 may be formed integral with the annular body of the air inlet segment (via a suitable casting or molding process) to form a one-piece component comprised of a common ceramic material. It should be appreciated that the previously described air outlet segment 412, fuel inlet segment 402, and depleted fuel outlet segment 408 may have a similar shape andDocket No. 2024P00519WO construction with an outlet or inlet placed in a similar or alternative location on the body of its segment. It should also be appreciated that some ceramic segments may not include any ports.

[0160] The metal terminal segment 700 shown in FIG. 7 represents an example of the anode terminal segment 146 or cathode terminal segment 148 described previously. The metal terminal segment 700 may include internal attachment features (threaded holes, projections) on the inside of the segment to which internal electrical conductors may be connected on the inside of the segment. The metal terminal segment 700 may also include external attachment features to which external electrical conductors may be connected on the outside of the segment. Such conductors may provide portions of the electrical connections needed to suitably connect an external load to the internal fuel cells of the fuel cell. Also in further embodiments, such internal and external conductors may be welded or otherwise formed integral with the terminal segments (e.g., via casting or 3D-printing).

[0161] FIG. 8 shows an example embodiment of a set of the anode and cathode terminal segments 146, 148 including example implementations of internal electrical conductors 802 and external electrical conductors 804. In this example, the internal electrical conductors 802 correspond to plates fixed to the inner walls of metal terminal segments, such as the cathode terminal segment 148 shown in FIG. 8. Such a plate may be configured to extend to and electrically couple to the effective cathode of the combined set of fuel cells bundles that extend through the metal terminal segments (such as those depicted in FIG. 4). Likewise, the anode terminal segment 146 may similarly include internal electrical conductors 802 mounted thereto that are in the form of a plate that extends to and electrically couple to the effective anode of the combined set of fuel cells bundles.

[0162] As shown in FIG. 8, external electrical conductors 804 may have the form of bars configured to extend to and electrically couple to the other portions a fuel cell system. For example, such bars may extend to the metal terminal segments of adjacent fuel cell modules included in a common pressure vessel (examples of which will be described in more detail with respect to FIG. 22 and FIG. 23.). Such bars may also extend to portions of an electrical bus of a fuel cell system (which connects such a system to an intended electrical load).

[0163] However, it should also be appreciated that such internal and external electrical conductors connected to the metal terminal segments may have other forms (including that of cables, wires) or any other form capable of conducting electricity between the metal terminalDocket No. 2024P00519WO segments and internal and external electrical components of the fuel cell module and associated system.

[0164] To facilitate a gas-tight seal with ceramic segments, the described terminal segments 146, 148 may include annular channels 806 on opposed sides, which receive gaskets or other types of seals. However, as illustrated in FIG. 7, in other embodiments the surfaces of the terminal segments, which interface with the ceramic segments may be planar. In additional, as will be discussed in more detail below with respect to ceramic segments in FIG. 13, the terminal segments may include other forms of surfaces for sealing and / or interlocking with ceramic segments including cooperating beveled or radiused surfaces, a key and slot configuration, or any other type of sealing connection that can form and maintain a gas-tight seal at the interface between stacked segments across large temperature changes (e.g., from ambient temperate to temperatures greater than 800°C).

[0165] As discussed previously, some of the segments of the fuel cell module may include ports that enable air or fuel to move into and / out of the fuel cell module. FIG. 9 shows a cross- sectional view of an example port 900 in a segment 102, illustrating that the entire body of the port and its segment are formed as one molded / cast unit out of the same material (such as a ceramic material). In this example, the port corresponds to an air inlet 132, and includes a cylindrical ceramic pipe portion 902 including a cylindrical-shaped channel 904 therein that provides an opening through an internal wall 906 of the segment. In an example embodiment, the pipe portion may have a circular cross-sectional shape that extends from an external wall 908 of the segment to an outer flange portion 910. The previously described fuel inlet 108, depleted fuel 140, and air outlet 128 may have a similar integral construction with their corresponding segments.

[0166] It should be appreciated that the shape and location of the port on a segment may vary depending on the desired design of the fuel cell module and the desired manner in which further components (such as pipes, adapters, collars) are attached to the port. In one example embodiment, the port may be compatible with one or more standards (e.g., DIN EN 1092-1). In alternative embodiments, the port may have other cross-sectional shapes such a rectangular or ellipsoid shape.

[0167] It should also be appreciated that alternative embodiments of an inlet or outlet port for a segment may not be formed completely from the same ceramic material as the segment and / or as one-piece with the segment body. Rather, the ceramic pipe portion and flange of the portDocket No. 2024P00519WO may be formed separately and joined to the external wall 908 of the segment at a location that includes a desired entry / exit hole through the wall of the segment. Also, the described ports may be comprised of other or additional materials.

[0168] For example, FIG. 10 shows a cross-section view of an example port 1000 corresponding in shape to the port 900 depicted in FIG. 9, but with a flange portion 1004 comprised of a metal or other material or type of ceramic (e.g., than that of the ceramic material of the segment 102). Such a flange may be comprised of a nickel-based alloy or other metal that provides the flange portion 1004 with a relatively higher resistance to cracking or chipping in response to adapters, collars or other mounting components being repeatedly engaged / disengaged to / from the port. Such a metal flange portion 1004 may be separately formed and joined to the ceramic pipe portion 1002 of the port or formed via another manufacturing process. For example, a ceramic material may be cast around the metal flange before finishing the manufacturing of the ceramic body.

[0169] FIG. 11 shows a cross-section view of an example port 1100 with a conical-shaped pipe portion 1102 and a corresponding conical-shaped channel 1104 that narrows in diameter from the external wall 1106 of the segment 102 towards the flange portion 1108. Such a conical shape may be used for the air outlet or depleted fuel outlet ports to enhance the accumulation and flow of such gases out of the fuel cell module.

[0170] FIG. 12 shows a cross-sectional view of an example port 1200 corresponding in shape to the port 1100 depicted in FIG. 11, but with a flange portion 1202 comprised of a metal or other material or type of ceramic (similar to that shown and described with respect to FIG. 10).

[0171] As discussed previously with respect to FIG. 1, during operation of the fuel cell module the described segments are in sealing engagement with each other to form a gas-tight casing with respect to the connections between segments. To facilitate achieving the desired level of gas-tightness, the segments may be urged together with external forces (e.g., via clamping, gravity, pneumatics, hydraulics) such that contacting surface of the segments themselves achieve gas-tightness. However, it should also be appreciated that the fuel cell module may further include annularly arranged seals between surfaces of the segments to enhance gas-tightness. FIG. 13, illustrates a cross-sectional view 1300 of two adjacently stacked segments 1304, 1306, include a seal 1302 therebetween.

[0172] In this example, the annular adjacent surfaces of the segments have cooperating circumferential step / shoulder portions 1308, 1310 for receiving the seal therebetween. As aDocket No. 2024P00519WO result, portions of the adjacent edges of the segments traverse each other in an axial direction in which the adjacent segments are stacked. However, it should be appreciated that in alternative embodiments, the annular adjacent surfaces of the segments may have other seal / gasket supporting or receiving contours and configurations (e.g., facing annular adjacent edges of the segments may include annular channels therein for receiving an annularly applied sealing material or gasket).

[0173] As discussed previously with respect to FIG. 1 and FIG. 5, the fuel cell module may include first and second partitions mounted within segments to separate the fuel cell chamber, air outlet chamber, and air inlet chambers from each other. Such partitions may also be in sealing engagement with one or more segments to prevent the mixture of fuel and air within the fuel cell module. FIG. 14 illustrates example contours 1400 of adjacent surfaces of two stacked segments 1406, 1408 that are configured to support and seal a partition 1404. In this example the upper segment 1406 may have an annular lower edge with step / shoulder portions 1410 similar to that shown in FIG. 13. However, in this example, the lower segment 1408 may have two step / shoulder portions 1412, 1414 to enable sealing engagement with the upper segment 1406 and to cooperatively form with the upper segment an inner circumferential channel 1416 for receiving an outer circumferential edge portion 1418 of the partition 1404. To achieve gastightness between chambers on either side of the partition 1404, the described arraignment may include a seal 1402 between the adjacent annular ends of the segments 1406, 1408, and the outer circumferential edge portion 1418 of the partition.

[0174] It should be appreciated that seals between segments and for the described partitions (and for sealed components connected to the partitions such as fuel cells and air feed conduits) may be comprised of nickel or nickel alloy bands or strips, metal, glass or glass-ceramics solder, or other high temperature seal or gasket materials that are operative to maintain the desired gas tightness at the operating conditions of the fuel cell module. The partitions themselves may be comprised of a ceramic material as well (such as alumina or another ceramic) to reduce fabrication costs. However, it should be appreciated that such partitions may be made from metal (such as a nickel or nickel alloys or other metal that is operable to function as a partition at the operating temperatures of the fuel cell module.)

[0175] FIG. 15 illustrates an isometric view 1500 of an example implementation of the described first partition 136 that is mounted in the fuel cell module to separate the fuel cell chamber from the air outlet chamber. As discussed previously with respect to partitions inDocket No. 2024P00519WO general, this first partition 136 includes an outer circumferential edge portion 1418 that is placed in sealing engagement with the particular segment that supports the partition. In addition, the partition includes a plurality of individual receptacles 1502 for receiving and supporting in sealing engagement therewith the ends of fuel cells mounted thereon. In this example, the receptacles have delta-contours corresponding to the delta-shaped contours of the fuel cell sets shown in FIG. 3.

[0176] In alternative embodiments, the receptacles 1502 may have other shapes. For example, the first partition 136 may include circular shaped receptacles to accommodate the cylindrical shaped tubular fuel cells shown in FIG. 2. Although not visible in FIG. 15, it should be apreciated that the receptacles 1502 include apertures that extend through the first partition 136 for receiving the previously described air feed conduits (as depicted in FIG. 1).

[0177] In example embodiments, the receptacles may be in sealing engagement with the fuel cells via the high temperature seals described previously or other suitable sealing materials including, for example, metal or glass solder. As a result, the first partition 136 will be in sealing engagement with the at least one segment to which it is mounted and the fuel cell walls will be in sealing engagement with the first partition, sufficiently to prevent leakage of fuel into the inner channels of the fuel cells and to prevent leakage of air into the external channels along the fuel cells to below 10'3mbar*l / s during electrical generation by the fuel cells at their intended operating temperature and pressure ranges for the particular type of fuel cell design.

[0178] FIG. 16 illustrates an isometric view 1600 of an example implementation of the described second partition 144 that is mounted in the fuel cell module to separate the air outlet chamber from the air inlet chamber. As discussed previously with respect to partitions in general, this second partition 144 includes an outer circumferential edge portion 1418 that is placed in sealing engagement with the particular segment that supports the partition. In addition, the partition includes a plurality of individual receptacles 1602 for receiving and supporting in sealing engagement therewith the ends of air feed conduits mounted thereon. In this example, the receptacles have circular contours to corresponding to cylindrical contours of air feed conduits. However, in other embodiments the contour of the receptacles and air feed conduits may have other shapes. Although not visible in FIG. 16, it should be apreciated that the receptacle 1602 include relatively narrower lower apertures therein that extend through the second partition 144 for enabling the flow of air from the air inlet chamber to enter the air feed conduits mounted in the receptacles. In example embodiments, the receptacle 1602 may be inDocket No. 2024P00519WO sealing engagement with the air feed conduits (e.g., via the high temperature seals described previously or other suitable sealing materials including, for example, metal or glass solder).

[0179] FIG. 17 illustrates a cross-sectional view 1700 of the second partition 144 showing example contours of the receptacles 1702, 1704 that receive and support air feed conduits. Such receptacles may include a funnel-shaped portion 1706 that helps guide an air feed conduit into a cylindrical-shaped portion 1708. In addition, each receptacle includes the previously mentioned relatively narrower lower aperture 1710, 1712 that extends through the remainder of the partition, in order to provide a passageway for air to traverse the partition through the receptacle and into the air feed conduit.

[0180] It should be noted that the apertures 1710, 1712 of the receptacles 1702, 1702, 1704 may have different diameters in order to regulate the flow rate of air through the fuel cell module. For example, the partition may include at least two different sets 1714, 1716 of receptacles for the air feed conduits. Each set may include a respectively differently sized aperture 1712, 1712 to control the flow of air therethrough.

[0181] For example, the apertures 1712 of the receptacles in the second set 1716, may cause a flow rate through their associated air feed conduits that are at least 5% greater (via a larger diameter) than the flow rate of air through the associated air feed conduits in the first set 1714 of receptacles. In further embodiments the air flow rates within the air feed conduits between the at least two sets of receptacles may alternatively differ by 10%, alternatively by at least 15%, alternatively by at least 25%, alternatively by at least 50%, alternatively by a least 100% relative to the resulting flow rates of air through each air feed conduit in a second one of the at least two different sets of air feed conduits.

[0182] Such sets of receptacles with larger apertures may be positioned in locations that require additional cooling to at least partially reduce temperature differentials within the fuel cell module when operating to generate electricity.

[0183] For example, FIG. 18 illustrates a bottom view 1700 of the second partition 144 showing the apertures that extend through the receptacles for the two sets 1714, 1716 of receptacles for air feed conduits. In this example, the location and arrangement of the first set 1714 of receptacles (with relatively narrower aperture 1710) may require a lower air flow rate in order to maintain temperatures in its corresponding fuel cells that are relatively closer to the temperatures of the fuel cells associated with the second 1716 of receptacles. It should be appreciated that any suitable arrangement of different sets of receptacles with different air flowDocket No. 2024P00519WO rates for the air feed conduits may be used to minimize temperature differentials within a fuel cell module.

[0184] It should also be appreciated that the flow rate of air through the air feed conduits may be regulated via other variations in the design of the fuel cell module in addition to (or instead of) adjusting the sizes and / or shape of the apertures in the second partition that are aligned with the air feed conduits. For example, the sizes and / or shape of channels through the air feed conduits may differ for different sets of air feed conduits. Also, the sizes and / or shape of the apertures through the walls of the air feed conduits may differ for different sets of air feed conduits. Also, the sizes and / or shape of the apertures through the first partition (that supports the fuel cells) may differ for different sets of air feed conduits. In addition, the number of apertures through the walls of the air feed conduits may differ for different sets of air feed conduits. Further, the spacing arrangement of apertures through the walls of the air feed conduits may differ for different sets of air feed conduits. In example embodiments, any combination of these or any other flow rate control measures for at least two different sets of the air feed conduits may be used in order to at least partially reduce temperature differentials within the fuel cell module when operating to generate electricity relative to a lack of variation thereof.

[0185] In example embodiments, the minimum diameters and / or the inner contours of these various apertures may be adjusted to control the flow rates of air therethrough. Also, in examples where the number of apertures through the walls of the air feed conduits varies between the at least two different sets of the air feed conduits, such numbers may vary between sets by at least 10%, alternatively by at least 25%, and alternatively by at least 50%.

[0186] FIG. 14, to FIG. 18 illustrate examples of partitions 1404 in the form of single plates comprised. However, in alternative embodiments a partition may be comprised of multiple parts or plates, such as the multi-plate 1902 configuration shown in a cross-sectional view 1900 in FIG. 19. In this example, the partition may be comprised of a top support plate 1904 and a bottom ground plate 1906 that together form an outer circumferential edge portion 1418, which extends into the inner circumferential channel 1416 formed at the interface between two stacked segments.

[0187] This multi-plate configuration facilities both supporting and fixing components such as fuel cells and / or air feed conduits to the partition. For example, FIG. 20 illustrates an example 2000 of a tubular fuel cell 112 inserted into a receptacle 1502 of a partition 1404 having theDocket No. 2024P00519WO multi-plate configuration. The ground plate 1906 may support the lower edges of the fuel cell in addition to supporting the support plate 1904. As illustrated in FIG. 20, the receptacle 1502 may be formed by operatively aligned and sized apertures 2004 in the support plate and the ground plate. The apertures in the support plate may have a beveled annular inner surface that widens in diameter towards the ground plate 1906. This beveled inner wall contour of the receptacle provides an annular cavity 2002 adjacent the fuel cell wall 114 for providing a sealing material such as a metal or glass solder, that fixes the fuel cell in sealing engagement with the support plate 1904. Although fuel cells are illustrated in this example, it should be appreciated that air feed conduits (or other components) may be mounted to a multi-plate configuration of a partition in a similar manner.

[0188] FIG. 21 illustrates an example 2100 of an alternative multi-plate configuration for a partition 1404, in which the lower edges of the fuel cell wall 114 include an annular flange 2102 at its lower edge. Such a flange may be supported by the ground plate 1906. Also, the support plate 1904 may include an annular slot 2104 in the receptacle 1502 that receives the flanges 2102 and enables fixing and sealing (e.g., via metal or glass soldering) the fuel cell 112 to the support plate 1904 and to lock the fuel cell in the receptacles. It should be appreciated that air feed conduits may be mounted to a multi-plate configuration of a partition in a similar manner.

[0189] In these multi-plate configuration examples, gaskets or seals between the upper support plate 1904 and the lower ground plate 1906 can optionally be omitted when the upper support plate is used to seal the partition to a surrounding segment and is used to seal the mounted components (such as fuel cells or air feed conduits). It should also be appreciated that that these described configurations for supporting and fixing components to partitions, permits mounting a relatively large number of fuel cells (e.g., 72 vs. 8) within a fuel cell module in one single mounting operation. For example, seventy-two fuel cells may be fixed to the described partition 1404 and the entire partition and bundles of fuel cells may be lowered into a lower portion of the casing at one time as a single submodule, rather than individually mounting individual fuel cells or individual sets of eight fuel cells into the casing

[0190] It should be appreciated that multiple fuel cell modules may be integrated into a larger fuel cell system for generating electricity. FIG. 22 illustrates an example schematic view of an embodiment of such a fuel cell system 2200. The system may comprise a pressure vessel 2202 including an inert gas chamber 2204 therein. Within this inert gas chamber, the system mayDocket No. 2024P00519WO comprise a plurality of fuel cell modules 100, such as those previously described with respect to FIG. 1, FIG. 4, and FIG. 5 (or alternative embodiments thereof). Such fuel cell modules may be connected electrically in series and / or parallel (via their respective terminal segments 146, 148) within the pressure vessel to provide desired voltage and current levels to a load 2216. It should be understood that the load 2216 is to be construed broadly and may correspond to electrical devices connected to an electrical grid / microgrid, an inverter, a data center, a ship, building, or another other type of electrical components and system that can utilize a current to carry out work.

[0191] The example system may include at least one air source 2206 configured to provide air into the air inlet 132 of each fuel cell module to produce an air pressure within the inner channels of its fuel cells appropriate for the type of fuel cell process being carried out. Furthermore, the system may include at least one fuel source 2212 configured to provide fuel into the fuel inlet 108 of each fuel cell module to produce a fuel pressure within the outer channels of its fuel cells that likewise are appropriate for the type of fuel cell process being carried out. For example, with respect to pressurized SOFCs, such pressures associated with the supplied air or fuel may be at least 0.5 bar absolute, at least 3 bar absolute, alternatively at least 5 bar absolute, further alternatively at least 8 bar absolute.

[0192] In addition, the system may include an inert gas source 2214 configured to provide an inert gas into an inert gas inlet 2208 of the pressure vessel. Such an inert gas may include less than 0.1% by volume of gases that are chemically reactive with the fuel or the air in the fuel cell module at the operating temperatures and pressures of a fuel cell module. Examples of such an inert gas may include a gas that includes 99% by volume of at least one of nitrogen, argon, carbon dioxide, or any combination thereof. The inert gas source may include, for example, a gas cylinder or a tank of liquid nitrogen, that is suitably configured to supply the nitrogen to the pressure vessel.

[0193] The fuel cell system may also include at least one electronic and / or mechanical controller 2230, control valves 2232, and / or sensors (e.g., temperature, pressure and / or position sensors), which are configured to control the operation of the fuel cell system described herein (e.g., such as the supply of fuel and air to the fuel cell modules, the supply of inert gas to the inert gas chamber, a fuel cell module compression system, and / or other components and processes of a fuel cell system.Docket No. 2024P00519WO

[0194] During operation of the fuel cell system, the controller may be operative to cause the fuel cell system to maintain gas pressures of the inert gas adjacent external walls of the segments of each of the fuel cell modules greater than a maximum of the gas pressures of the fuel and air adjacent the internal walls of the segments of each fuel cell module by at least 0.01 bar absolute, or alternatively by at least 0.1, at least 0.5, at least 1.0, at least 3.0, or at least 5.0 bar absolute. For example, when the maximum of the gas pressures of the fuel and air is at least 3 bar absolute such as 8 bar absolute, the controller may be configured to ensure that the pressure level of the inert gas within the inert gas chamber is at least 8.01 bar absolute, or alternatively at least 8.1, at least 8.5, at least 9.0, or at least 11.0 bar absolute (such as via adjusting inert gas pressure levels provided by the inert gas source 2214). Additionally or alternatively for example, when the inert gas chamber is at least 8 bar absolute, such as 8.0 bar absolute, the controller may be configured to ensure that the maximum of the gas pressures of the fuel and air in each of the fuel cell modules (and associated fuel and air pipes / manifolds in the inert gas chamber) is at most 7.99 absolute bar, or alternatively at most 7.9, 7.5, 7.0, or 5.0 bar absolute (such as via adjusting the fuel and / or air pressure levels provided by the air source 2206 and / or fuel source 2212).

[0195] The relatively higher inert gas pressure adjacent external walls 2210 of the fuel cell modules relative to the gas pressures within each fuel cell module prevents or at least reduces leakage of fuel and air out of the fuel cell module into the inert gas chamber between the segments. This overpressure creates a safety barrier against fire & explosion. Also, in case one or more of the fuel cell modules start to leak between the segments (or elsewhere), the inert gas is biased to flow into the fuel cell module and block / reduce the electro-chemical fuel cell reaction therein (i.e., forming a failsafe design).

[0196] In the event the inert gas pressure level within the pressure vessel is detected (via a suitable pressure sensor and controller) to fall below a predetermined threshold, the system may take various actions including boosting the nitrogen level and / or ceasing the flow of fuel and / or air into the fuel cell modules. For example, the system may include a backup supply of nitrogen (e.g., via a gas cylinder filled with nitrogen at greater than 10 bar absolute). The controller may actuate a valve to direct nitrogen from the backup supply to quickly restore the inert gas pressure levels inside in the inert gas chamber.

[0197] It should be appreciated that the fuel cell system includes various pipes (individual or part of manifolds), which direct gases into and out of the fuel cell modules. For example, at31Docket No. 2024P00519WO least one fuel inlet 2220 of the pressure vessel may be connected to the fuel inlets 108 of each of the fuel cell modules via one or more pipes 2218, which directs fuel from the fuel source 2212 into the fuel cell modules. In addition, at least one air inlet 2226 of the pressure vessel may be connected to the air inlets 132 of each of the fuel cell modules via one or more pipes 2218, which directs air from the air source 2206 into the fuel cell modules.

[0198] In example embodiments, the fuel and air sources may correspond to tanks, further pipelines, control valves, and / or other structures that are operative to supply a flow of fuel and air under the control of at least one controller. The pressure vessel may also include at least one depleted fuel outlet 2222 connected to the depleted fuel outlet 110 of each of the fuel cell modules via one or more pipes 2218, which collects depleted fuel and steam exiting the fuel cell modules. In addition, the pressure vessel may include at least one air outlet 2224 connected to each of the air outlets 128 of the fuel cell modules via one or more pipes 2218, which collects air exiting the fuel cell modules. In example embodiments, these variously described pipes, inlets, and outlets may also be gas-tight so as to prevent air and fuel from leaking out and into the inert gas chamber 2204.

[0199] Example embodiments of the fuel cell system may include fuel reformers and / or other systems that are configured to separate out hydrogen (or other fuel gas) from the depleted gas outlets and insert them back into the gas streams to the fuel inlets of the fuel cell modules. Similarly steam from the depleted fuel outlets may be separated out and routed to further systems that are operative to use the thermal energy contained therein (e.g., a steam turbine configured to generate electricity, a CO2capture system).

[0200] It should be appreciated that a fuel cell module operating at its normal operating temperatures (e.g., above 800°C for pressurized SOFCs), is operative to generate sufficient heat via its electrochemical fuel cell process to maintain these operating temperatures. However, to reach these operating temperatures at startup (e.g., from ambient temperatures), example embodiments of the system may further comprise at least one heater 2228. Such a heater may be configured to raise the temperature of at least one of the fuel or air that is supplied to each fuel cell module to greater than the minimum temperature threshold that is sufficient to enable the fuel cells themselves to maintain or raise the temperatures of the fuel cell modules to their normal operating temperatures (e.g., greater than 800°C for an example embodiment of pressurized SOFCs).Docket No. 2024P00519WO

[0201] As discuss previously, the segments of a fuel cell module are in sealing engagement via seals and / or sealing forces to enable the engagement between the segments to be substantially gas-tight. Such sealing forces may be provided by a compression systems 162, such as a mechanical clamp system, a pneumatic pressure system, and / or a hydraulic pressure system, that compresses the stack of segments together.

[0202] FIG. 23 shows an example illustration 2300 of such a compression system 162 mounted within the previously described pressure vessel 2202. The compression system may include one or more pneumatically or hydraulically expansion / contraction members (e.g., such as cylinders) that are positioned to selectively apply compression forces to the stack of segments of one or more respective fuel cell modules 100. In this example compression systems for each fuel cell module may be mounted to a wall of the pressure vessel via one or more braces 2302. The fuel cell module may include a ceramic cap on the stacked segments, which distributes the compression forces generally uniformly and annularly to the walls of the segments. The opposite ends of the fuel cell module may be supported by the pressure vessel as well via suitable braces and / or a support platform 2304.

[0203] In the example shown in FIG. 23, the support platform 2304 corresponds to a movable carriage that slides along tracks 2306 supported by the pressure vessel. Such a movable carriage facilitates servicing the fuel cell system, by enabling a set of high temperature and dangerous fuel cell modules to be safely transported out of an opening / doorway of the pressure vessel. Once the carriage is at least partially moved outside of the pressure vessel, one or more of such fuel cells modules can be serviced, removed, and / or replaced, before returning the carriage to a position fully inside the pressure vessel.

[0204] In addition, as discuss previously with respect to FIG. 1 , it should be appreciated that segments will undergo thermal expansion and contraction when their temperatures are raised and lowered between ambient and their relatively higher operating temperatures and pressures (e.g., from - 20°C up to 1500°C; up to 20 bar absolute in some SOFC embodiments). The previously described one or more controllers 2230 may be configured to control the inputs of fuel and air to regulate these temperatures and to start and stop the fuel cell system from operating to generation electricity.

[0205] In addition to these functions, the one or more controllers 2230 may further be operative to control operation of the compression system to regulate the application of compression forces acting on the segments of each fuel cell module 100 based on receivedDocket No. 2024P00519WO measurements reflective of the thermal expansion or contraction of the segments of the fuel cell modules. This may be carried out to compensate for and permit thermal expansion of the segments to avoid cracking of the segments, while continuing to apply sufficient forces to maintain a gas-tight sealing between the segments.

[0206] The measurements used to control the compression systems may include temperature readings (e.g., from thermocouple sensors) that are reflective of the temperatures of the segments. Such measurements may also include compression force readings (e.g., from pressure sensors) that are acting on the segments. Also, these measurements may include distance or location readings (from suitable position sensors) that are reflective of the amount of thermal expansion or contraction of the segments.

[0207] From the above discussion, it is apparent that the described embodiments of the fuel cell module and system have many advantages. For example, the separation of air and fuel via the sealed chambers of the fuel cell module design in combination with the closed-end tubular fuel cells, enables a considerably simplified stack geometry and structure that enables implementation of a failsafe system. In addition, this design for the fuel cell module provides advantageous features for carbon capture.

[0208] For example, FIG. 24 shows an example functional block diagram of a fuel cell system with carbon capture 2400. Here the system may employ features of the fuel cell module 100 described previously, and in particular employs at least the aspects of the fuel cell module that outputs depleted air separately from the depleted fuel. However, it should be appreciated that the fuel cell module may include other features described herein and may further be adapted to accommodate other types of fuel cell processes (atmospheric SOFC as well as pressurized SOFC hybrid systems with turbocomponents).

[0209] In this example, the fuel cell module may continue to include a fuel inlet 108, a depleted fuel outlet 110, an air inlet 132, and a depleted air outlet 128 (and the internal chambers and closed-end tubular fuel cell arrangement, which enables maintaining segregation of the depleted fuel from the depleted air). However, in this example it should be understood that in addition to hydrogen, the fuel 138 provided to the fuel inlet 108 also includes additional gases including CO, CO2 2414, and steam 142. These fuel gases 1418 (with carbon content) may be produced by steam reforming of methane or other carbon containing gas as a hydrogen fuel source before entering the fuel cell module. It should also be appreciated that the gases exiting the depleted fuel outlet 110, will include depleted H2 content as well as the original CO, CO2, steam andDocket No. 2024P00519WO additional steam produced as part of the electrochemical fuel cell process. Such gases exiting the depleted fuel outlet 110 are also referred to herein as anode exhaust gas 2420.

[0210] As shown in Fig 24, the carbon capture portion of the system 2400 may include an oxyfuel combustor 2402, an air superheater 2404 (i.e., a first heat exchange), an anode exhaust cooler 2406, (i.e., a second heat exchange) and a condenser 2408, which carry out the processes of oxyfuel combustion, heat recovery, and separation of water / vapor phase and CO2 by cooling and condensation. The resulting system and process, enables efficient storage of the emissionrelevant exhaust gas components in a high-purity form and offers possibilities for heat recovery and limitation of efficiency losses for pressurized hybrid systems (e.g., that employ a turbine 2410).

[0211] It should be appreciated that by maintaining separation between the anode exhaust gas (which includes depleted H2 content) and the depleted air in the fuel cell module (which includes depleted 02 content), the fuel cell module 100 lacks an internal tail gas burner / combustion zone where H2 in the anode exhaust gas is burred with O2 in the depleted air before exiting the module. Thus, the anode exhausted gases that leave the fuel cell module of the present disclosure, have a relatively lower temperature compared to if the fuel cell module had a design that employed such a combustion zone.

[0212] In system 2400, this missing internal combustion zone is replaced by a separate oxyfuel burner 2402 that is external to the fuel cell module. However, rather than directly using the depleted air exiting the depleted air outlet 128 to burn the remaining H2 in the anode exhaust gas exiting the depleted fuel outlet 110, the oxyfuel burner instead uses a separate relatively pure source of oxygen 2412 (i.e., without or with only trace amounts of nitrogen or other gases typically found in ambient air or with a purity range range greater than 90% oxygen by volume) to burn the H2. The source of pure oxygen can be diverse, including stored oxygen produced from electrolyzers or another source).

[0213] In this described system, the anode exhaust gas is stoichiometrically and completely oxidized in the oxyfuel combustor 2402 to produce a highly superheated steam / CCh mixture (i.e., CO + O2 -> CO2 and 2H2+ O2 -> 2H2O).

[0214] The air superheater 2404 is then used to exchange heat content from this mixture with the depleted air 166 exhausting from the depleted air outlet 128. As a result, the temperature of the depleted air 166 increases and reduces the negative effect of the missing combustion zone. Such superheated depleted air may then be used to carry out further processes, such as driving aDocket No. 2024P00519WO turbine 2410 and associated generator (such as in a pressurize SOFC hybrid system) in order to generate electricity in addition to that generated by the fuel cell module itself.

[0215] In further stages, heat may be further transferred from the steam / CCh mixture via the anode exhaust cooler 2406 to about the boiling point of the steam. Subsequently, a condenser 2408 may be used to condense water from the mixture, which separates out the CO2 phase by the different aggregate states. The output of the condenser is high-purity water and CO2. In example embodiments, this separation can be carried out both atmospherically and under increased pressure.

[0216] In further alternative embodiments, the described system may employ a further expansion phase, where portions of the separated out CO2 can be recirculated to the oxyfuel combustor for cooling and mass increase. This recirculation cools the medium and reduces its mass. As a result, the thermal load is beneficially reduced. However, the temperature in the depleted air after superheating is also reduced, which negatively results in power losses in downstream turbo components and higher demands on the heat exchanger for air preheating.

[0217] FIG. 25 shows a functional block diagram of such a fuel cell and carbon capture system 2500, which extends the system shown in FIG. 24 to recirculate CO2 in order to reduce the thermal load. This recirculation may be driven by a CO2 compressor 2502. The recirculated CO2 may be preheated in advance in a recycle heater 2504 using heat, for example, from the steam / CCh mixture via the anode exhaust cooler 2406. This described anode exhaust cooler 2406 and recycle heater 2504 may correspond to a suitably designed heat exchanger which carries out both functions of cooling the steam / CCh mixture and heating the recirculated CO2. This measure reduces the drop in temperature level for the superheated depleted air, which is detrimental to downstream processes. The recirculated quantity can be adjusted or controlled according to an optimum operating point in terms of design and / or operation.

[0218] In further alternative embodiments, the described system may include a steam generator and feed water pump that is used to vaporize and superheat a certain amount of water. The waste heat generated by the separation process may be used for this purpose. The amount of generated steam may be used as a steam booster to partially compensate for the mass flow loss caused by the separation of the media flow.

[0219] For example, FIG. 26 shows a functional block diagram 2600 of an example steam boosting adaption to the previously described anode exhaust cooler 2406. In this example, the mass-reducing effect of the exhaust gas (by omitting a combustor from the fuel cell module),Docket No. 2024P00519WO can be partially compensated by combining superheated steam 2602 in combination with superheated depleted air 166 for driving a turbine 2410 in a pressured SOFC hybrid system.

[0220] To generate this superheated steam, the anode exhaust cooler may be equipped with a steam generator 2604, which carries out the functions of preheating, vaporizing, and superheating water using the waste heat from the anode exhaust cooler. This steam generator may include a water feed pump that moves water firstly to an economizer 2606 (preheater), then to a vaporizer 2608 (evaporator), and further to a superheater 2610 (heat exchanger). These components are arranged and thermally coupled in such a way that the necessary heat can be provided below the temperature level required to carry out the steam generation functions described. The temperature profiles and the heat exchange of the hot side / anode exhaust gas 2420 (comprising CO2 and steam) and the cold side / steam generation are harmonized via the design and process control. The pressure level of the generated steam can be produced with low parasitic losses via the feedwater pump.

[0221] Referring now to FIG. 27, FIG. 28, FIG. 29 and FIG. 30, methodologies 2700, 2800, 2900, and 3000 are illustrated that facilitate generating electricity using the fuel cell modules and systems described herein. While the methodologies are described as being a series of acts that are performed in a sequence, it is to be understood that the methodologies may not be limited by the order of the sequence. For instance, unless stated otherwise, some acts may occur in a different order than what is described herein. In addition, in some cases, an act may occur concurrently with another act. Furthermore, in some instances, not all acts may be required to implement a methodology described herein. In addition, it should be appreciated that these described methodologies may include additional acts and / or alternative acts corresponding to the features and aspects described previously with respect to the fuel cell modules and systems described herein.

[0222] With reference to FIG. 27, the methodology may start at 2702 and may include an act 2704 in which fuel comprising hydrogen flows from the fuel inlet, adjacent the anode layer of the fuel cells, and exits as depleted fuel through the depleted fuel outlet of the fuel cell module. The methodology may also include an act 2706 in which air comprising oxygen flows from the air inlet, through the air feed conduits, adjacent the cathode layer of the fuel cells, and exits through the air outlet of the fuel cell module. In addition, the methodology may include an act 2708 of carrying out an electrochemical process with the fuel cells using the hydrogen and oxygen to produce steam that exits the depleted fuel outlet and to generate an electrical currentDocket No. 2024P00519WO through a load operatively electrically connected to external portions of the anode terminal segment and the cathode terminal segment of the fuel cell module. At 2710 the methodology may end.

[0223] With reference to FIG. 28, the methodology 2800 may start at 2802 and is followed by several acts involving operation of at least one controller. These acts include an act 2804 of causing the air source to provide air to each fuel cell module. These acts also include an act 2806 of causing the fuel source to provide fuel to each fuel cell module. In addition, the acts include an act 2808 of causing the inert gas source to provide an inert gas into the inert gas chamber external to the fuel cell modules. Further, the acts include an act 2810 in which while the fuel cell modules carry out an electrochemical process to generate electricity with their fuel cells, maintaining gas pressures of the inert gas adjacent external walls of the segments of each of the fuel cell modules greater than a maximum of the gas pressures of the fuel and air adjacent the internal walls of the segments of each fuel cell module. With these acts, the relatively higher inert gas pressure external to the fuel cell modules relative to the gas pressures within each fuel cell module prevents or at least reduces leakage of fuel and air out of the fuel cell module into the inert gas chamber between the segments. At 2812, the methodology may end.

[0224] With reference to FIG. 29, the methodology 2900 may start at 2902 and is followed by several acts involving operation of at least one controller. These acts include an act 2904 of causing the fuel cell modules to increase or decrease in temperature in order to carry out or cease carrying an electrochemical process that generates electricity with their fuel cells. These acts also include an act 2908 of controlling operation of the compression system to regulate the application of compression forces acting on the at least two segments of each fuel cell module based on received measurements reflective of the thermal expansion or contraction of the segments of the fuel cell modules. At 2908, the methodology may end.

[0225] It should be appreciated that the term controller should be construed broadly in the description and claims to correspond to a hardware device that is configured to control the operation of one or more other hardware devices and / or processes associated with the described fuel cell modules and fuel cell systems. An electronic version of such a controller may include, for example, one or more circuits, processors, memory, data stores, communication buses, input / output devices, and / or other hardware that controls system hardware. Such system hardware may be controlled by the processor of the controller operating based onDocket No. 2024P00519WO software / firmware instructions stored in a memory, set points, inputs, sensor data, temperature data, pressure readings, and / or any other data received by the processor associated with the fuel cell systems and fuel cell modules. In example embodiments, such a controller may correspond to a programmable logic controller (PLC), or another type of computing system including a special purpose or general purpose microprocessor, or CPU. It should be appreciated that the memory associated with the processor of the controller may correspond to an internal or external volatile or nonvolatile processor memory (e.g., main memory, RAM, and / or CPU cache), that is included in the processor and / or in operative connection with the processor. Such a memory may also correspond to non-transitory nonvolatile data stores (e.g., flash drives, SSDs, NVMEs, hard drives, ROMs, EPROMs, optical discs / drives, databases, or other non- transitory computer readable media) in operative connection with the processor.

[0226] With reference to FIG. 30, the methodology 3000 may start at act 3004 and may include an act 3004 of electrochemically generating electricity with a fuel cell module comprising a plurality of fuel cells using an oxidizer comprising air and a fuel comprising of H2, CO, CO2, and steam. Also, the methodology may include an act 3006 of exhausting depleted fuel, which is at least partially diluted of H2 through a depleted fuel outlet and an act 3008 of exhausting depleted air, which is at least partially diluted of O2 through an air outlet. These exhausting acts may be carried out while preventing mixture of the depleted fuel with the depleted air.

[0227] In addition, the methodology may include an act of act 3010 of burning with an oxyfuel combustor the depleted fuel with an external source of O2 other than from diluted air to produce a superheated mixture of steam and CO2. Further, the methodology may include an act 3012 of heating with an air superheated the depleted air to produce superheated depleted air, using heat extracted from the superheated mixture.

[0228] In this example embodiment, the methodology includes an act 3014 of driving a turbine with the superheater depleted air to generate electricity and an act 3016 of condensing with a condenser the steam in the mixture to water and thereby cause the water and CO2 to substantially separate from each other. At 3016, the methodology may end.

[0229] Although an exemplary embodiment of the present disclosure has been described in detail, those skilled in the art will understand that various changes, substitutions, variations, and improvements disclosed herein may be made without departing from the spirit and scope of the disclosure in its broadest form.Docket No. 2024P00519WO

[0230] None of the description in the present application should be read as implying that any particular element, step, act, or function is an essential element, which must be included in the claim scope: the scope of patented subject matter is defined only by the allowed claims. Moreover, none of these claims are intended to invoke a means plus function claim construction unless the exact words "means for" are followed by a participle.

[0231] Also, it should be understood that the words or phrases used herein should be construed broadly, unless expressly limited in some examples. For example, the terms “including,” “having,” and “comprising,” as well as derivatives thereof, mean inclusion without limitation. The singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Further, the term “and / or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. The term “or” is inclusive, meaning and / or, unless the context clearly indicates otherwise. The phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like. Furthermore, while multiple embodiments or constructions may be described herein, any features, methods, steps, components, etc. described with regard to one embodiment are equally applicable to other embodiments absent a specific statement to the contrary.

[0232] Also, although the terms "first", "second", "third" and so forth may be used herein to refer to various elements, information, functions, or acts, these elements, information, functions, or acts should not be limited by these terms. Rather these numeral adjectives are used to distinguish different elements, information, functions or acts from each other. For example, a first element, information, function, or act could be termed a second element, information, function, or act, and, similarly, a second element, information, function, or act could be termed a first element, information, function, or act, without departing from the scope of the present disclosure.

[0233] In addition, the term "adjacent to" may mean: that an element is relatively near to but not in contact with a further element; or that the element is in contact with the further portion, unless the context clearly indicates otherwise. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Terms “about” or “substantially” or like terms are intended to cover variations in a value that are within normalDocket No. 2024P00519WO industry manufacturing tolerances for that dimension, amount, number, quantity, and / or measurement. If no industry standard is available, a variation of twenty percent would fall within the meaning of these terms unless otherwise stated.

[0234] Further, open ended ranges such as greater than or less than a particular value should be construed as having unspecified minimums and maximums that are physically possible and reasonable based on the context of the range and example being described. For example, a limitation such as less than 50% (or less than 50 ppm) by weight should be construed as having a lower bound that may be as low as 0% (or 0 ppm) by weight respectively, unless described in a manner or example that conveys a different lower bound. Similarly for example, a percentage range of greater than 50% (or greater than 50 ppm) by weight should be construed as having an upper bound that may be up to 100% (or 1 million ppm) by weight respectively, unless described in a manner or example that conveys a different upper bound.

Claims

Docket No. 2024P00519WOCLAIMSWhat is claimed is:

1. A fuel cell module (100) for generating electricity comprising: at least three annular ceramic and / or metal segments (102) in a successively stacked arrangement, which are operative to form a casing (104), including therein: a fuel cell chamber (106) having a fuel inlet (108), a depleted fuel outlet, and a plurality of tubular fuel cells (112), wherein each fuel cell includes a fuel cell wall (114) in surrounding relation of a longitudinally extending inner channel (116) that is closed on one end, which fuel cell walls are comprised of an electrolyte layer (118) between an anode layer (120) and a cathode layer (122); an air outlet chamber (126) having an air outlet (128); and an air inlet chamber (130) having an air inlet (132), wherein the fuel cell chamber is formed by stacking at least one annularly shaped ceramic segment between two annularly shaped metal segments, which metal segments are respectively an anode terminal segment (146) and a cathode terminal segment (148) that are operatively electrically coupled to the anode layers and the cathode layers of the fuel cells, which fuel cells extend through all three of the ceramic segment, the cathode terminal segment, and the anode terminal segment.

2. The fuel cell module of claim 1, wherein the tubular fuel cells are solid oxide fuel cells (SOFCs) including a ceramic electrolyte, molten carbonate fuel cells (MCFC), or proton exchange membrane (PEM) fuel cells.

3. The fuel cell module of claim 1 or 2, wherein the inner channels of the fuel cells have a generally cylindrical-shape or a generally triangular-shape.

4. The fuel cell module of any one of claims 1 to 3, wherein the segments are in sealing engagement sufficient to prevent leakage of fuel and air between the segments to below 10'3mbar*l / s during electrical generation by the fuel cells.

5. The fuel cell module of any one of claims 1 to 4, wherein the cathode layers of the fuel cells extend adjacent the inner channels of the fuel cells, which inner channels are in fluid communication with the air inlet and the air outlet, and wherein the anode layers of the fuelDocket No. 2024P00519WO cells extend adjacent outer channels (124) along the fuel cells, which outer channels are in fluid communication with the fuel inlet and the depleted fuel outlet included, further comprising: a plurality of air feed conduits (134) that extend through the air outlet chamber and into the inner channels of the fuel cells; a first partition (136) that: is mounted within at least one segment; separates the fuel cell chamber from the air outlet chamber; supports the fuel cells; and includes apertures through which the air feed conduits traverse the first partition; and a second partition (144) that: is mounted within at least one segment; separates the air outlet chamber from the air inlet chamber; supports the air feed conduits; and includes apertures aligned with the air feed conduits to enable air to flow from the air inlet chamber into the air feed conduits.

6. The fuel cell module of claim 5, wherein the first partition is in sealing engagement with the at least one segment to which it is mounted and the fuel cell walls are in sealing engagement with the first partition sufficiently to prevent leakage of fuel into the inner channels of the fuel cells and to prevent leakage of air into the external channels along the fuel cells to below 10'3mbar*l / s. during electrical generation by the fuel cells.

7. The fuel cell module of claim 5 or 6, wherein the second partition is in sealing engagement with walls of the air feed conduits to facilitate directing air from the air inlet to flow through the air feed conduits into the inner channels of the fuel cells, and subsequently into the air outlet chamber and out the air outlet.

8. The fuel cell module of any one of claims 5 to 7, wherein the at least one of the first partition or the second portion have multi-plate configurations including an upper support plate (1904) and a lower ground plate (1906) that supports the upper support plate when mounted to a segment, wherein the upper support plate includes a plurality of receptacles (1502) for receiving at least one of fuel cells or air feed conduits therein in sealing engagement therewith.Docket No. 2024P00519WO9. The fuel cell module of any one of claims 5 to 8, wherein at least one ceramic segment includes at least one circumferential step / shoulder portion (1310), wherein the first partition and / or the second partition includes an outer circumferential edge portion (1414, 1418) that extends into sealing engagement with the at least one circumferential step / shoulder portions of the at least one ceramic segment.

10. The fuel cell module of claim 9, wherein the at least one ceramic segment includes at least two adjacent circumferential step / shoulder portions (1412, 1414), which cooperatively form with a further segment, an inner circumferential channel (1416) that includes the outer circumferential edge portion therein.

11. The fuel cell module of any one of claims 5 to 10, wherein the adjacent surfaces of at least two adjacent stacked segments (1304, 1306) include cooperating circumferential step / shoulder portions (1308, 1310) for receiving a seal (1302) therebetween such that portions of the adjacent edges traverse each other in an axial direction in which the adjacent segments are stacked.

12. The fuel cell module of any one of claims 1 to 11, wherein the fuel cell module includes at least six segments in the successively stacked arrangement, which are operative to form the casing, wherein the fuel cell chamber is formed by a stack of at least two ceramic segments on opposite sides of each of the anode terminal segment and the cathode terminal segment, wherein the fuel inlet and the fuel outlet are incorporated into different ceramic segments that form the fuel cell chamber.

13. The fuel cell module of any one of claims 1 to 12, wherein the fuel cell module includes at least six segments in the successively stacked arrangement, which are operative to form the casing, wherein the air inlet chamber and the air outlet chamber are formed by at least two ceramic segments stacked together in sealing engagement, wherein a first one of these two ceramic segments include the air inlet, wherein a second one of these two ceramic segments includes the air outlet.

14. The fuel cell module of any one of claims 1 to 13, wherein the fuel cell module includes at least eight segments in the successively stacked arrangement, which are operative to form the casing, wherein at least five of the segments are annular segments which collectivelyDocket No. 2024P00519WO circumferentially extend around at least portions of the fuel cell chamber and the air outlet chamber.

15. The fuel cell module of any one of claims 1 to 14, wherein at least one of the fuel inlet, the depleted fuel outlet, the air outlet, and the air inlet include a ceramic pipe portion (902) that extends from an external wall (908) of a segment, wherein the pipe portion includes a flange portion (910), wherein the flange portion is comprised of at least one of a ceramic, a metal, or a combination thereof.

16. The fuel cell module of any one of claims 1 to 15, wherein the pipe portion includes a conical-shaped channel (1104) that narrows in diameter from the external wall (1106) towards the flange portion (1108).

17. The fuel cell module of any one of claims 1 to 16, wherein the metal segments are comprised of nickel, nickel-copper, and / or a nickel alloy, wherein the ceramic segments are comprised of alumina.

18. A method for generating electricity using the fuel cell module of any one of claims 1 to 17 comprising: fuel comprising hydrogen flowing from the fuel inlet, adjacent the anode layer of the fuel cells, and exiting as depleted fuel through the depleted fuel outlet of the fuel cell module; air comprising oxygen flowing from the air inlet, through the air feed conduits, adjacent the cathode layer of the fuel cells, and exiting through the air outlet of the fuel cell module; and carrying out an electrochemical process using the hydrogen and oxygen with the fuel cells to produce steam that exits the depleted fuel outlet and to generate an electrical current through a load (2216) operatively electrically connected to external portions of the anode terminal segment and the cathode terminal segment of the fuel cell module.

19. A fuel cell system (2200) for generating electricity comprising: a pressure vessel (2202) including an inert gas chamber (2204); a plurality of fuel cell modules (100) positioned within the inert gas chamber, wherein each fuel cell module is comprised of at least two annular segments (102) in a successively stacked arrangement that form a casing (104), wherein the casing includes a plurality of fuel cells (112); at least one controller (2230) configured to cause:Docket No. 2024P00519WO an air source (2206) to provide air to each fuel cell module; a fuel source (2212) to provide fuel to each fuel cell module; an inert gas source (2214) to provide an inert gas into the inert gas chamber external to the fuel cell modules; and while the fuel cell modules carry out an electrochemical process with their fuel cells, maintaining gas pressures of the inert gas adjacent external walls of the segments of each of the fuel cell modules greater than a maximum of the gas pressures of the fuel and air adjacent the internal walls of the segments of each fuel cell module, whereby the relatively higher inert gas pressure exterior to the fuel cell module relative to the gas pressures within each fuel cell module prevents or at least reduces leakage of fuel and air out of the fuel cell module into the inert gas chamber between the segments.

20. The fuel cell system of claim 19, wherein the fuel cells are tubularly-shaped solid oxide fuel cells (SOFCs) including a ceramic electrolyte, are molten carbonate fuel cells (MCFC), or are proton-exchange membrane (PEM) fuel cells.

21. The fuel cell system of claim 19 or 20, wherein the inert gas includes less than 0.1% by volume of gases that are chemically reactive with the fuel or the air.

22. The fuel cell system of any one of claims 19 to 21, wherein the inert gas includes 99% by volume of at least one of nitrogen, argon, carbon dioxide, or any combination thereof.

23. The fuel cell system of any one of claims 19 to 22, wherein the at least one controller is configured to cause: the air source to provide air to each fuel cell module at a gas pressure of at least 0.5 bar absolute; and the fuel source to provide fuel to each fuel cell module at a gas pressure of at least 0.5 bar absolute.

24. The fuel cell system of any one of claims 19 to 23, wherein maintaining gas pressures of the inert gas occurs while the fuel cell modules carry out the electrochemical process with their fuel cells operating at temperatures from 30°C to above 900°C.Docket No. 2024P00519WO25. The fuel cell system of any one of claims 19 to 24, wherein maintaining gas pressures of the inert gas occurs at least while the maximum of the gas pressures of the fuel and air is at least 0.5 bar absolute.

26. The fuel cell system of any one of claims 19 to 25, wherein the at least one controller is configured to cause the system to respectively maintain gas pressures of the inert gas adjacent external walls of the segments of each of the fuel cell modules greater than the maximum of the gas pressures of the fuel and air adjacent the internal wall of the segments of each fuel cell module by at least 0.01 bar absolute, alternatively at least 0.1 bar absolute, alternatively by at least 0.5 bar absolute, alternatively by a least 3.0 bar absolute, or alternatively by a least 5.0 bar absolute27. The fuel cell system of any one of claims 19 to 26, wherein the inert gas source includes a gas cylinder including nitrogen at a pressure of at least 10 bar absolute.

28. The fuel cell system of any one of claims 19 to 27, wherein the segments of the fuel cell modules are in sealing engagement sufficient to prevent leakage of fuel and air between the segments to below 10'3mbar*l / s. during electrical generation by the fuel cells.

29. The fuel cell system of any one of claims 19 to 28, wherein the fuel cells include an inner channel (116) around which all three of a cathode layer (122), an electrolyte layer (118) and an anode layer (120) extend at least partially annularly in surrounding relation of the inner channel (H6).

30. The fuel system of any one of claims 19 to 29, wherein each of the fuel cell modules includes an anode terminal segment (146) and a cathode terminal segment (148) in the successively stacked arrangement that are operatively electrically coupled to the anode layers and the cathode layers of the fuel cells within the fuel cell modules and are operatively electrically coupled to the anode and cathode terminals of each other fuel cell module within the inert gas chamber.

31. The fuel cell system of claim 30, wherein the anode terminal segment and the cathode terminal segment are annularly-shaped metal rings, wherein each of the anode terminal segment and the cathode terminal segment at stacked between ceramic segments in the successivelyDocket No. 2024P00519WO stacked arrangement, wherein the fuel cells extend through both the cathode terminal segment and the anode terminal segment.

32. The fuel cell system of claim 31, wherein the ceramic segments are comprised of alumina.

33. The fuel cell system of any one of claims 30 to 32, wherein the anode terminal segment and the cathode terminal segment are comprised of nickel, nickel-copper and / or a nickel alloy.

34. A method for generating electricity using the fuel cell system of any one of claims 19 to 33 comprising through operation of at least one controller: causing the air source to provide air to each fuel cell module; causing the fuel source to provide fuel to each fuel cell module; causing the inert gas source to provide an inert gas into the inert gas chamber external to the fuel cell modules; and while the fuel cell modules carry out an electrochemical process to generate electricity with their fuel cells, maintaining gas pressures of the inert gas adjacent external walls of the segments of each of the fuel cell modules greater than a maximum of the gas pressures of the fuel and air adjacent the internal walls of the segments of each fuel cell module, whereby the relatively higher inert gas pressure exterior to the fuel cell module relative to the gas pressures within each fuel cell module prevents or at least reduces leakage of fuel and air out of the fuel cell module into the inert gas chamber between the segments.

35. A non-transitory computer readable medium encoded with processor executable instructions that when executed by at least one processor in the at least one controller, cause the at least one controller to carry out the method of claim 34.

36. A fuel cell module (100) for generating electricity with air feed regulation of temperature differentials comprising: a fuel cell chamber (106) having a fuel inlet (108), a depleted fuel outlet (110), and a plurality of tubular fuel cells (112), wherein each fuel cell includes a fuel cell wall (114) in surrounding relation of a longitudinally extending inner channel (116) that is closed on one end, which fuel cell walls are comprised of an electrolyte layer (118) between an anode layer (120) and a cathode layer (122), wherein the cathode layers of the fuel cells extend adjacent the inner channels of the fuel cells; an air outlet chamber (126) having an air outlet (128);Docket No. 2024P00519WO an air inlet chamber (130) having an air inlet (132), wherein the inner channels are in fluid communication with the air inlet and the air outlet, wherein the anode layers of the fuel cells extend adjacent outer channels (124) along the fuel cells, which outer channels are in fluid communication with the fuel inlet and the depleted fuel outlet; and a plurality of air feed conduits (134) that extend through the air outlet chamber and into the inner channels of the fuel cells, which air feed conduits include annular walls having apertures therethrough for feeding air into the inner channels, wherein the flow rates of air through each air feed conduit in a first one of at least two different sets of the air feed conduits differs by at least 5% relative to the flow rates of air through each air feed conduit in a second one of the at least two different sets of air feed conduits so as to at least partially reduce temperature differentials within the fuel cell module when operating to generate electricity.

37. The fuel cell module of claim 36, wherein the fuel cells are tubularly-shaped solid oxide fuel cells (SOFCs), including a ceramic electrolyte.

38. The fuel cell module of claim 36 or 37, wherein the inner channels of the fuel cells have a generally cylindrical-shape or a generally triangular-shape.

39. The fuel cell module of any one of claims 36 to 38, wherein the resulting flow rates of air through each air feed conduit in a first one of the at least two different sets of the air feed conduits differs by at least 10%, alternatively by at least 15%, alternatively by at least 25%, alternatively by at least 50% relative to the resulting flow rates of air through each air feed conduit in a second one of the at least two different sets of air feed conduits.

40. The fuel cell module of any one of claims 36 to 39, further comprising: a first partition (136) that: separates the fuel cell chamber from the air outlet chamber; supports the fuel cells; and includes apertures through which or adjacent thereto the air feed tubes traverse the first partition; and a second partition (144) that: separates the air outlet chamber from the air inlet chamber; supports the air feed conduits; andDocket No. 2024P00519WO includes apertures aligned with the air feed conduits to enable air to flow from the air inlet chamber into the air feed conduits, wherein at least one of: the sizes and / or shape of channels through the air feed conduits, the sizes and / or shape of the apertures in the second partition that are aligned with the air feed conduits, the sizes and / or shape of the apertures through the walls of the air feed conduits, the sizes and / or shape of the apertures through the first partition, the number of apertures through the walls of the air feed conduits, the spacing arrangement of apertures through the walls of the air feed conduits, or any combination thereof, varies between the at least two different sets of the air feed conduits so as to at least partially reduce temperature differentials within the fuel cell module when operating to generate electricity relative to a lack of variation thereof.

41. The fuel cell module of claim 40, wherein the minimum diameters of the channels through the air feed conduits varies between the at least two different sets of the air feed conduits.

42. The fuel cell module of claim 40 or 41, wherein the minimum diameters of the apertures in the second partition that are aligned with the air feed conduits varies between the at least two different sets of the air feed conduits.

43. The fuel cell module of any one of claims 40 to 42, wherein the minimum diameters of the apertures through the walls of the air feed conduits varies between the at least two different sets of the air feed conduits.

44. The fuel cell module of any one of claims 40 to 43, wherein the minimum diameters of the apertures through the first partition through which air passes adjacent the air feed conduits varies between the at least two different sets of the air feed conduits.

45. The fuel cell module of any one of claims 40 to 44, wherein the number of apertures through the walls of the air feed conduits varies between the at least two different sets of the air feed conduits.Docket No. 2024P00519WO46. The fuel cell module of any one of claims 40 to 45, wherein the number of apertures through the walls of the air feed conduits varies between the at least two different sets of the air feed conduits by at least 10%, alternatively by at least 25%, alternatively by at least 50%.

47. The fuel cell module of any one of claims 40 to 46, wherein the spacing arrangement of apertures through the walls of the air feed conduits varies between the at least two different sets of the air feed conduits.

48. A fuel cell module (100) for generating electricity with a multi-plate support partition comprising: at least two annular segments (102) in a successively stacked arrangement, which are operative to form a casing (104), including therein: a fuel cell chamber (106) having a fuel inlet (108), a depleted fuel outlet, and a plurality of tubular fuel cells (112), wherein each fuel cell includes a fuel cell wall (114) in surrounding relation of a longitudinally extending inner channel (116) that is closed on one end, which fuel cell walls are comprised of an electrolyte layer (118) between an anode layer (120) and a cathode layer (122); an air outlet chamber (126) having an air outlet (128); an air inlet chamber (130) having an air inlet (132), wherein the cathode layers of the fuel cells extend adjacent the inner channels of the fuel cells, which inner channels are in fluid communication with the air inlet and the air outlet, and wherein the anode layers of the fuel cells extend adjacent outer channels (124) along the fuel cells, which outer channels are in fluid communication with the fuel inlet and the depleted fuel outlet; a plurality of air feed conduits (134) that extend through the air outlet chamber and into the inner channels of the fuel cells; and at least one partition (136, 144) that: is mounted within at least one segment; separates at least two of said chambers; and comprises a ground plate (1906) and a support plate (1904), which support plate is supported by the ground plate, wherein the ground plate and the support plate include apertures (2004) therethrough that are operatively aligned and are sized to form receptacles (1502) that:Docket No. 2024P00519WO receive at least one of the fuel cells or the air feed conduits through the apertures of the support plate in supporting engagement with the ground plate; and enable gases to pass through the apertures of the ground plate and the support plate into and / or out of at least one of the fuel cells or the air feed conduits.

49. The fuel cell module of claim 48, wherein the at least one partition includes: a first partition (136) that: separates the fuel cell chamber from the air outlet chamber; supports the fuel cells in its receptacles; enables air feed conduits to traverse the first partition through the receptacles and into the inner channels of the fuel cells; and enables air to traverse the first partition through the receptacles from the inner channels of the fuel cells into the air outlet chamber;50. The fuel cell module of claim 48 or 49, wherein the at least one partition includes: a second partition (144) that: separates the air outlet chamber from the air inlet chamber; supports the air feed conduits in its receptacles; and enables air to traverse the second partition through the receptacles from the air inlet chamber into the air feed conduits.

51. The fuel cell module of any one of claims 48 to 50, wherein the apertures of the support plate include a beveled annular inner surface that widens in diameter towards the ground plate to form an annular cavity (2002) in the receptacles adjacent to the fuel cells or air feed conduits for providing a sealing material that fixes the fuel cells or air feed conduits in sealing engagement with the support plate.

52. The fuel cell module of any one of claims 48 to 51, wherein the lower edges of the fuel cells or the air feed conduits include an annular flange (2102) that is supported by the ground plate, wherein the apertures of the support plate includes an annular slot (2104) in the receptacles adjacent to the fuel cells or air feed conduits that receives the flanges and locks the fuel cells or air feed conduits in the receptacles.

53. The fuel cell module of any one of claims 48 to 52, wherein at least one of the fuel cells or the air feed conduits are in sealing engagement within the receptacles via a seal material.Docket No. 2024P00519WO54. The fuel cell module of claim 53, wherein the seal material includes glass solder.

55. The fuel cell module of any one of claims 48 to 54, wherein the interface between two stacked segments forms an inner circumferential channel (1416), wherein the ground plate and the support plate form an outer circumferential edge portion that extends in sealing engagement within the inner circumferential channel.

56. The fuel cell module of claim 55, wherein the circumferential edge portion is in sealing engagement within the inner circumferential channel via a seal material.

57. The fuel cell module of claim 56, wherein the seal material includes glass solder.

58. The fuel cell module of claim 56, wherein the inner channels of the fuel cells have a generally cylindrical-shape or a generally triangular-shape.

59. A fuel cell system for generating electricity with carbon capture comprising: a fuel cell module, including therein: a fuel cell chamber (106) having a fuel inlet (108), a depleted fuel outlet, and a plurality of tubular fuel cells (112), wherein each fuel cell includes a fuel cell wall (114) in surrounding relation of a longitudinally extending inner channel (116) that is closed on one end, which fuel cell walls are comprised of an electrolyte layer (118) between an anode layer (120) and a cathode layer (122); an air outlet chamber (126) having an air outlet (128); and an air inlet chamber (130) having an air inlet (132), wherein the fuel cell, air outlet, and air inlet chambers are configured to segregate and facilitate separately exhausting the depleted fuel gases and the depleted air from the fuel cell module, an oxyfuel combustor (2402) configured to burn the depleted fuel comprising H2, CO, CO2, with an external source of O2 other than from diluted air to produce a superheated mixture of steam and CO2; an air superheater (2404) configured to extract heat from the superheated mixture for use with heating the depleted air exhausting from the fuel cell module sufficiently to produce a superheated diluted air that is usable to drive a turbine (2410) to generate electricity; and a condenser (2408) configured to condense the steam in the mixture to water and thereby cause water and CO2 to substantially separate from each other.Docket No. 2024P00519WO60. The fuel cell system of claim 59, wherein the tubular fuel cells are solid oxide fuel cells (SOFCs), including a ceramic electrolyte.

61. The fuel cell system of claim 59 or 60, wherein the inner channels of the fuel cells have a generally cylindrical-shape or a generally triangular-shape.

62. The fuel cell system of any one of claims 59 to 61, wherein the chambers are separated by partitions that are operatively configured to prevent the mixture of depleted fuel and depleted air to below 10'3mbar*l / s during electrical generation by the fuel cells.

63. The fuel cell system of any one of claims 59 to 62, wherein the cathode layers of the fuel cells extend adjacent the inner channels of the fuel cells, which inner channels are in fluid communication with the air inlet and the air outlet, and wherein the anode layers of the fuel cells extend adjacent outer channels (124) along the fuel cells, which outer channels are in fluid communication with the fuel inlet and the depleted fuel outlet, further comprising: a plurality of air feed conduits (134) that extend through the air outlet chamber and into the inner channels of the fuel cells; a first partition (136) that: is mounted within at least one segment; separates the fuel cell chamber from the air outlet chamber; supports the fuel cells; and includes apertures through which the air feed conduits traverse the first partition; and a second partition (144) that: is mounted within at least one segment; separates the air outlet chamber from the air inlet chamber; supports the air feed conduits; and includes apertures aligned with the air feed conduits to enable air to flow from the air inlet chamber into the air feed conduits.

64. The fuel cell system of any one of claims 59 to 63, further comprising an anode exhaust cooler (2406) configured to further remove heat from the mixture prior to reaching the condenser.Docket No. 2024P00519WO65. The fuel cell system of any one of claims 59 to 64, further comprising a CO2 compressor (2502) configured to move a portion of the separated out CO2 through a recycle heater (2504) and to the oxyfuel combustor in order to be included with the depleted fuel when being burned to produce the superheated mixture of steam and CO2, wherein the recycle heater heats the CO2 using removed heat from the anode exhaust cooler.

66. The fuel cell system of any one of claims 59 to 64, further comprising a steam generator (2604) configured to use heat from the anode exhaust cooler to produce superheated steam (2602) from water, that is combined with the superheated depleted air (166) for driving the turbine.

67. The fuel cell system of any one of claim 66, wherein the steam generator includes an economizer (2606) to preheat the water, a vaporizer (2608) to vaporize the preheated waste to steam, and a superheater (2610) to boost the temperature of the steam prior to being combined with the superheated depleted air.

68. The fuel cell system of any one of claims 59 to 66, further comprising the turbine.

69. A method of generating electricity and capturing CO2 with the fuel cell system of any one of claims 59 to 68 comprising: electrochemically generating electricity with a fuel cell module (100) comprising a plurality of fuel cells (1242) using an oxidizer comprising air and a fuel comprising of H2, CO, CO2, and steam; exhausting depleted fuel, which is at least partially diluted of H2 through a depleted fuel outlet (110); exhausting depleted air, which is at least partially diluted of O2 through an air outlet (128), while preventing mixture of the depleted fuel with the depleted air; burning with an oxyfuel combustor (2402) the depleted fuel with an external source of O2 other than from diluted air to produce a superheated mixture of steam and CO2; heating with an air superheater (2404) the depleted air to produce superheated depleted air, using heat extracted from the superheated mixture; driving a turbine (2410) with the superheater depleted air to generate electricity; and condensing with a condenser (2408) the steam in the mixture to water and thereby cause the water and CO2 to separate from each other.Docket No. 2024P00519WO70. The method of claim 69, further comprising: moving with a CO2 compressor (2502) a portion of the separated out CO2 through a recycle heater (2504) and to the oxyfuel combustor in order to be included with the depleted fuel when being burned to produce the superheated mixture of steam and CO2; and heating with the recycle heater the CO2 using heat from the superheated mixture.

71. The method of claim 69, further comprising: producing superheated steam (2602) from water with a steam generator (2604) using heat from the superheated mixture; and driving the turbine with both the superheated depleted air and the superheated steam.

72. A fuel cell system (2200) for generating electricity with compression compensation for thermal expansion comprising: a pressure vessel (2202); a plurality of fuel cell modules (100) positioned within the pressure vessel, wherein each fuel cell module is comprised of at least two annular segments (102) in a successively stacked arrangement that form a casing (104), wherein the casing includes a plurality of fuel cells (112) therein; a compression system (162) that compresses the at least two segments together of each fuel cell module; and at least one controller (2230) configured to: cause the fuel cell modules to increase or decrease in temperature in order to carry out or cease carrying an electrochemical process that generates electricity with their fuel cells; and control operation of the compression system to regulate the application of compression forces acting on the at least two segments of each fuel cell module based on received measurements reflective of the thermal expansion or contraction of the segments of the fuel cell modules.

73. The fuel cell system of claim 72, wherein the fuel cells are tubularly-shaped solid oxide fuel cells (SOFCs) including a ceramic electrolyte, molten carbonate fuel cells (MCFC), or proton exchange membrane (PEM) fuel cells.

74. The fuel cell system of claim 72 or 73, wherein the at least one controller is configured to regulate the application of compression forces by the compression system based on the receivedDocket No. 2024P00519WO measurement to both prevent or at least minimize cracking of at least portions of the fuel cell modules due the thermal expansion of the segments, and maintain a gas tight seal between the segments of the fuel cells modules during thermal expansion and contraction of the segments.

75. The fuel cell system of any one of claims 72 to 74, wherein maintaining the gas-tight seal prevents leakage of fuel and air between the segments to below 10'3mbar*l / s. during electrical generation by the fuel cells.

76. The fuel cell system of any one of claims 72 to 75, wherein the compression system includes at least one of a pneumatically or hydraulically operated compression system.

77. The fuel cell system of any one of claims 72 to 76, wherein the measurements include temperature readings reflective of the temperature of at least one segment of at least one fuel cell module.

78. The fuel cell system of any one of claims 72 to 77, wherein the measurements include compression force readings acting on the segments of at least one of the fuel cell modules.

79. The fuel cell system of any one of claims 72 to 78, wherein the measurements include distance or location readings reflective of the amount of thermal expansion or contraction of the segments of at least one of the fuel cell modules.

80. The fuel cell system of any one of claims 72 to 79, wherein each fuel cell module includes at least three annular segments in the successively stacked arrangement.

81. The fuel cell system of any one of claims 72 to 80, wherein each fuel cell module includes at least six annular segments in the successively stacked arrangement.

82. A method for generating electricity using the fuel cell system of any one of any one of claims 72 to 81 comprising through operation of the at least one controller: causing the fuel cell modules to increase or decrease in temperature in order to carry out or cease carrying an electrochemical process that generates electricity with their fuel cells; and controlling operation of the compression system to regulate the application of compression forces acting on the at least two segments of each fuel cell module based on received measurements reflective of the thermal expansion or contraction of the segments of the fuel cell modules.Docket No. 2024P00519WO83. A method of claim 82, further comprising regulating the application of compression forces based on the received measurement to both prevent or at least minimize cracking of at least portions of the fuel cell modules due the thermal expansion of the segments, and maintain a gas tight seal between the segments of the fuel cells modules during thermal expansion and contraction of the segments.

84. A non-transitory computer readable medium encoded with processor executable instructions that when executed by at least one processor in the at least one controller, cause the at least one controller to carry out the method of claim 82 or 83.

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