Efficiency Maximization of a Direct Internal Reforming Solid Oxide Fuel Cell in a Two-Layer Self-Optimizing Control Structure

[Image: see text] Control system configuration is essential for the efficiency performance of a solid oxide fuel cell (SOFC). In this paper, we aim to report a novel two-layer self-optimizing control (SOC) system for the efficiency maximization of a direct internal reforming SOFC, where the efficiency index is defined as the profit of generated electricity penalized by carbon (CO(2)) emission. Based on the lumped-parameter model of the SOFC, comprehensive evaluations are carried out to identify the optimal controlled variables (CVs), the control of which at constant set-points can optimize the efficiency, in spite of operating condition changes. In the lower SOC layer, we configure single variables as the CVs. The results show that the stack temperature is the active constraint which should be controlled to maintain the cell performance. In addition, the outlet hydrogen composition is identified as the optimal CV. This result differs from several previous proposals, such as methane composition. In the presence of operating condition changes, the set-point of hydrogen composition is further automatically adjusted by the upper SOC layer, where a linear combination of the SOFC measurements is configured as the CV, giving negligible efficiency losses. The cascaded two-layer SOC structure is able to maximize the SOFC efficiency and reduce carbon emission without using online optimization techniques; meanwhile, it allows for smooth and safe operations. The validity of the new scheme is verified through both static and dynamic evaluations.