Optimization of Novel Variable-Channel-Width Solid Oxide Electrolysis Cell (SOEC) Design for Enhanced Hydrogen Production

This study presents a novel solid oxide electrolysis cell (SOEC) design with variable channel widths to optimize thermal management and electrochemical performance for enhanced hydrogen production. Using high-fidelity computational modeling in COMSOL Multiphysics 6.1, five distinct channel width configurations were analyzed, with a baseline model validated against experimental data. The simulations showed that modifying the channel geometry, particularly in Scenario 2, significantly improved hydrogen production rates by 6.8% to 29% compared to a uniform channel design, with the effect becoming more pronounced at higher voltages. The performance enhancement was found to be primarily due to improved fluid velocity regulation, which increased reactant residence time and enhanced mass transport, rather than a significant thermal effect, as temperature distribution remained largely uniform across the cell. Additionally, the inclusion of a dedicated heat transfer channel was shown to improve current density and overall efficiency, particularly at lower voltages. While a small increase in voltage raised internal cell pressure, the variable-width designs, especially those with widening channels, led to greater hydrogen output, albeit with a corresponding increase in system energy consumption due to higher pressure. Overall, the findings demonstrate that strategically designed variable-width channels offer a promising approach to optimizing SOEC performance for industrial-scale hydrogen production.