Modelling Mass Transport in Anode-Supported Solid Oxide Fuel Cells

Understanding and accurately modelling mass transport phenomena in anode-supported solid oxide fuel cells (SOFCs) is essential for improving efficiency and mitigating performance losses due to concentration polarization. This study presents a one-dimensional, isothermal, multi-component diffusion framework based on the Stefan–Maxwell (SM) formulation to evaluate hydrogen, water vapour, and nitrogen transport in two different porous ceramic support materials: calcia-stabilized zirconia (CSZ) and magnesia magnesium aluminate (MMA). Both SM binary and SM ternary models are implemented to capture species interactions under varying hydrogen concentrations and operating temperatures. The SM formulation enables direct calculation of concentration polarization as well as the spatial distribution of gas species across the anode support’s thickness. Simulations are conducted for two representative fuel mixtures—20% H2 (steam-rich, depleted fuel) and 50% H2 (steam-lean)—across a temperature range of 500–1000 °C and varying electrode thicknesses. They are validated against experimental data from the literature, and the influence of electrode thickness and fuel composition on polarization losses is systematically assessed. The results show that the ternary SM model provides superior accuracy in predicting overpotentials, especially under low-hydrogen conditions where multi-component interactions dominate. MMA consistently exhibits lower polarization losses than CSZ due to enhanced gas diffusivity. This work offers a validated, computationally efficient framework for evaluating mass transport limitations in porous anode supports and offers insights for optimizing electrode design and operational strategies, bridging the gap between simplified analytical models and full-scale multiphysics simulations.