Maximizing thermal integration performance in SOFC CHP systems: A top-down approach to configuration-parameter cooptimization

Despite significant interest in optimizing solid oxide fuel cell (SOFC) combined heat and power (CHP) systems, a gap exists in systematic, top-down methods for refining configuration designs for thermal integration. Here we introduce a novel approach to construct optimal SOFC CHP layouts, focusing on both ideal and practical scenarios. In ideal scenario, the optimized system achieves an overall energy efficiency of 94 %, with an 89.8 % increase in exergy level of heat output compared to initial case. In practical scenario, the framework identifies the thermal capacity matching pattern for streams and the interrelationship between operation parameters and system configuration. Key parameters including the relative temperature levels between SOFC electrochemical and reforming reactions, steam-to-carbon ratio, and stack fuel utilization are found critical for enhancing thermal integration. The practical optimized layout achieves an overall efficiency of 92 % and a 65.1 % increase in exergy output than initial case, while also ensuring a streamlined configuration suitable for engineering applications. This framework provides thermodynamic insights for SOFC CHP system configuration and parameter codesign. It can serve as a tool enhancing both theoretical understanding and practical feasibility of SOFC system technologies.