Optimal and Secure Operation of a μ‑CHP Solid Oxide Fuel Cell System

Performance optimization and operational safety of solid oxide fuel cell (SOFC) systems are crucial for long-term operation and lifespan prolongation. However, optimal and secure operation under real-world conditions remains challenging. This study demonstrates a fast constraint-adaptation real-time optimization methodology that optimizes the electrical and combined-heat-and-power (CHP) efficiencies of a μ-CHP SOFC system across power targets, using transient measurements and a simplified dynamic model despite significant plant-model mismatch. The algorithm converged to power targets within four iterations (15 min), achieving at least 5% relative improvement in electrical efficiency through multi-input manipulation. Optimizing CHP efficiency increased hot water production by 20%. The algorithm remained robust against natural gas grid fluctuations and programmed control-subsystem interruptions while maintaining secure operation without safety shutdowns, demonstrating its maturity for optimal and safe operation of real-world SOFC systems.