Emulation tests of dynamics and control for a turbocharged SOFC system

•Innovative turbocharged SOFC system for fuel cell pressurization.•Emulator test rig for tests in cyber-physical mode.•Experiments showed acceptable thermal stress and no other critical conditions.•The control system was demonstrated robust and able to avoid risky conditions. This work regards experimental emulation activities for a Solid Oxide Fuel Cell (SOFC) pressurized by a turbocharger, focusing attention on the control system validation. The SOFC-based plant considered here was developed to couple high efficiency (due to pressurization) with reasonable capital costs. In detail, significant cost decrease (against SOFC hybrid plants including a microturbine) can be obtained with a turbocharger, due to large mass manufacturing process for these machines. Moreover, to pursue the zero emission target, the system was sized to operate with a renewable source fuel (biogas). Since this system has integration problems due to critical dynamic and control aspects, the University of Genoa designed and installed an experimental facility based on the coupling between a pressure vessel with a commercial turbocharger. The fuel cell is emulated equipping the vessel with a burner (to obtain the SOFC temperature range) and with inert ceramic material (to generate the same dynamic response). The tests presented in this work were obtained with this emulation rig operated in cyber-physical mode: the hardware interacted in real-time mode with previously validated software for components not physically included in the rig. The results demonstrated the system feasibility for load changes and validated the proposed control system, showing robustness and good prevention of critical conditions, such as SOFC thermal stress.