U.S. patent application number 10/440006 was filed with the patent office on 2004-01-22 for method and apparatus for integrated water deionization, electrolytic hydrogen production, and electrochemical power generation.
Invention is credited to Merida-Donis, Walter Roberto.
Application Number | 20040013918 10/440006 |
Document ID | / |
Family ID | 26904241 |
Filed Date | 2004-01-22 |
United States Patent
Application |
20040013918 |
Kind Code |
A1 |
Merida-Donis, Walter
Roberto |
January 22, 2004 |
Method and apparatus for integrated water deionization,
electrolytic hydrogen production, and electrochemical power
generation
Abstract
The present invention is directed to an apparatus and method for
deionization and hydrogen fuel production in a fuel generation
mode, and electricity production in a power generation mode. In one
embodiment, a capacitive deionization (CDI) device receives water
and electrical energy to produce deionized water that is
transferred to a proton electrode membrane electrolysis (PEME)
device to produce hydrogen fuel by electrolysis. A storage system
receives the hydrogen. The hydrogen is transferred from the storage
system to a proton electrode membrane fuel cell (PEMFC) device that
produces electrical energy. In another embodiment, the PEME and the
PEMFC are functionally combined in a unitary regenerative fuel cell
(URFC). In still another embodiment, a humidification unit and the
CDI are functionally combined. In yet another embodiment, a CDI,
URFC and the humidification unit are combined in a single unitary
assembly.
Inventors: |
Merida-Donis, Walter Roberto;
(Victoria, CA) |
Correspondence
Address: |
Steven H. Arterberry, Esq.
DORSEY & WHITNEY LLP
Suite 3400
1420 Fifth Avenue
Seattle
WA
98101
US
|
Family ID: |
26904241 |
Appl. No.: |
10/440006 |
Filed: |
May 15, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10440006 |
May 15, 2003 |
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09875281 |
Jun 5, 2001 |
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6569298 |
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60209518 |
Jun 5, 2000 |
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Current U.S.
Class: |
205/637 ;
205/628; 429/422; 429/437; 429/444; 429/492; 429/515 |
Current CPC
Class: |
Y02T 90/40 20130101;
H01M 8/184 20130101; Y02T 90/12 20130101; H01M 8/065 20130101; Y02E
60/50 20130101; B60L 53/54 20190201; Y02A 20/212 20180101; C02F
2201/009 20130101; C02F 2001/46128 20130101; H01M 2250/20 20130101;
Y02E 60/36 20130101; C02F 2103/02 20130101; H01M 16/006 20130101;
H01M 8/04089 20130101; Y02E 60/10 20130101; Y02T 10/7072 20130101;
Y02T 10/70 20130101; C02F 1/4691 20130101; C25B 1/04 20130101 |
Class at
Publication: |
429/21 ; 205/628;
429/34; 429/32; 429/26 |
International
Class: |
H01M 008/18; H01M
008/10; H01M 008/04; C25C 001/02 |
Claims
1. An apparatus for the generation of electrical energy and the
production of hydrogen, comprising: a first system fluidly coupled
to a water source and electrically coupled to an electrical energy
source that receives water and electrical energy to produce
deionized water; and a second system operable in either a fuel
generation mode or a power generation mode, the second system being
fluidly coupled to the first system to receive deionized water and
being electrically coupled to the electrical energy source to
receive electrical energy to generate hydrogen and oxygen when the
system is operating in the fuel generation mode, the hydrogen being
received by a fluidly coupled hydrogen storage system, and the
second system receiving hydrogen from the hydrogen storage system
and an oxidizer from an oxidizer source that is fluidly coupled to
the second system and combining the hydrogen and the oxidizer to
generate electrical energy when the system is operating in the
power generation mode.
2. The apparatus according to claim I wherein the hydrogen storage
system is further comprised of a compressor that is fluidly coupled
to a plurality of storage vessels structured to contain hydrogen,
the compressor fluidly receiving the hydrogen generated during the
fuel generation mode and fluidly delivering the compressed hydrogen
to the storage vessels.
3. The apparatus according to claim I wherein the hydrogen storage
system is further comprised of a storage vessel containing a metal
hydride that is fluidly coupled to the second system.
4. The apparatus according to claim 1 wherein the second system is
further comprised of a humidification module that receives hydrogen
from the hydrogen storage system and oxidizer from the oxidizer
source to humidify the hydrogen and oxidizer prior to combination
in the second system.
5. The apparatus according to claim I further comprising a water
storage system fluidly coupled to the first system and the second
system, the water storage system further including a water storage
vessel to sealably contain deionized water.
6. The apparatus according to claim 1 wherein the electrical energy
source is further comprised of an electrical converter that is
electrically coupled to a utility grid and to the first system and
or the second system that receives alternating current from the
utility grid, and delivers direct current to the first and/or
second system.
7. The apparatus according to claim 1 wherein the second system is
further comprised of an electrical converter that is electrically
coupled to an electrical load that receives the electrical energy
generated by the second system and transfers the electrical energy
to the load when the second system is operating in the power
generation mode.
8. The apparatus according to claim 7 wherein the electrical load
is further comprised of a utility grid.
9. The apparatus according to claim 7 wherein the electrical load
is further comprised of a plurality of electric storage
devices.
10. The apparatus according to claim 7 wherein the electrical load
is further comprised of a prime mover in an electrically powered
vehicle.
11. The apparatus according to claim 1 wherein the first system is
further comprised of a capacitive deionization (CDI) device.
12. The apparatus according to claim 1 wherein the second system is
further comprised of a unitized regenerative fuel cell (URFC)
device.
13. The apparatus according to claim 1 wherein the second system is
further comprised of a proton exchange membrane fuel cell (PEMFC)
device that is fluidly coupled to a proton exchange membrane
electrolysis (PEME) device.
14. The apparatus according to claim 5 wherein the water storage
system is further comprised of a recirculation loop that is fluidly
coupled to the vessel and the second system that fluidly delivers
deionized water from the storage vessel to the second system and
fluidly returns at least a portion of the deionized water delivered
to the second system when the second system is operating in the
power generation mode.
15. The apparatus according to claim 14 wherein the recirculation
loop is further comprised of a pump fluidly coupled to the loop to
fluidly deliver the deionized water to the second system, and to
fluidly return to the storage vessel the at least a portion of the
water fluidly delivered to the second system.
16. The apparatus according to claim 15 wherein the recirculation
loop is further comprised of a heat exchanger.
17. The apparatus according to claim 1 further comprising an oxygen
storage system that is fluidly coupled to the second system that
fluidly receives the oxygen generated when the second system is
operating in the fuel generation mode, and fluidly delivers oxygen
to the second system when the system is operating in the power
generation mode.
18. The apparatus according to claim 17 wherein the oxygen storage
system is further comprised of a compressor that is fluidly coupled
to a plurality of storage vessels structured to contain oxygen, the
compressor fluidly receiving the oxygen generated during the fuel
generation mode and fluidly delivering the compressed oxygen to the
storage vessels.
19. The apparatus according to claim 1 wherein the oxidizer source
is further comprised of atmospheric air.
20. A power generation apparatus having a fuel generation mode for
generating hydrogen fuel, and a power generation mode for
generating electrical energy, comprising: a water deionizer that
receives electrical current from an electrical energy source and
water from a water source to produce deionized water; an
electrolyzer in fluid communication with the water deionizer that
receives the deionized water from the deionizer and electrical
current from the electrical energy source to decompose the
deionized water into hydrogen and oxygen while operating in the
fuel generation mode; a hydrogen storage system in fluid
communication with the electrolyzer that fluidly receives the
hydrogen produced by the electrolyzer while operating in the fuel
generation mode; and a fuel cell assembly that is in fluid
communication with a source of an oxidizer and in fluid
communication with the storage system that fluidly receives the
hydrogen from the storage system and fluidly receives the oxidizer
from the oxidizer source and combines the hydrogen and the oxidizer
to produce electrical energy while operating in the power
generation mode.
21. The apparatus according to claim 20 wherein the water deionizer
is further comprised of a capacitive deionization (CDI) device.
22. The apparatus according to claim 20 wherein the electrolyzer is
further comprised of a proton exchange membrane electrolysis (PEME)
device.
23. The apparatus according to claim 20 wherein the fuel cell
assembly is further comprised of a proton exchange membrane fuel
cell (PEMFC) device.
24. The apparatus according to claim 20 wherein the electrolyzer is
further comprised of a unitized regenerative fuel cell (URFC)
device.
25. The apparatus according to claim 20 wherein the fuel cell
assembly is further comprised of a unitized regenerative fuel cell
(URFC) device.
26. The apparatus according to claim 20 wherein the hydrogen
storage system is further comprised of a compressor that is in
fluid communication with a plurality of storage vessels, the
compressor fluidly receiving the hydrogen generated by the
electrolyzer and fluidly delivering the compressed hydrogen to the
storage vessels.
27. The apparatus according to claim 20 wherein the hydrogen
storage system is further comprised of a metal hydride storage
medium.
28. The apparatus according to claim 20 wherein the fuel cell
assembly is further comprised of a humidification module that is in
fluid communication with each of the deionizer, the storage system
and the oxidizer source to fluidly receive deionized water from the
deionizer to humidify the hydrogen fluidly received from the
storage system and the oxidizer fluidly received from the oxidizer
source.
29. The apparatus according to claim 20 further comprising a water
storage system in fluid communication with the deionizer and the
electrolyzer, the storage system including a water storage vessel
to sealably contain deionized water.
30. The apparatus according to claim 20 wherein the electrical
energy source is further comprised of an electrical converter in
electrical communication with a utility grid and in communication
with the deionizer and/or the electrolyzer that delivers direct
current to the deionizer and/or the electrolyzer.
31. The apparatus according to claim 20 wherein the fuel cell
assembly is further comprised of an electrical converter that is in
electrical communication with an electrical load that receives the
electrical energy generated by the fuel cell and transfers the
electrical energy to the load.
32. The apparatus according to claim 31 wherein the electrical load
is further comprised of a utility grid.
33. The apparatus according to claim 31 wherein the electrical load
is further comprised of a plurality of electrical storage
devices.
34. The apparatus according to claim 31 wherein the electrical load
is further comprised of a prime mover in an electrically powered
vehicle.
35. The apparatus according to claim 29 wherein the water storage
system is further comprised of a recirculation loop that is in
fluid communication with the vessel and the fuel cell assembly that
fluidly delivers deionized water from the storage vessel to the
fuel cell assembly and fluidly returns at least a portion of the
deionized water delivered to the fuel cell assembly.
36. The apparatus according to claim 35 wherein the recirculation
loop is further comprised of a pump fluidly coupled to the loop to
fluidly deliver the deionized water to the fuel cell assembly, and
to fluidly return to the storage vessel the at least a portion of
the water fluidly delivered to the fuel cell assembly.
37. The apparatus according to claim 36 wherein the recirculation
loop is further comprised of a heat exchanger.
38. The apparatus according to claim 20 further comprising an
oxygen storage system that is in fluid communication with the
electrolyzer and the fuel cell assembly that fluidly receives
oxygen from the electrolyzer and fluidly delivers oxygen to the
fuel cell assembly.
39. The apparatus according to claim 38 wherein the oxygen storage
system is further comprised of a compressor that is in fluid
communication with a plurality of storage vessels, the compressor
fluidly receiving the oxygen generated by the electrolyzer and
fluidly delivering the compressed oxygen to the storage
vessels.
40. An apparatus for water deionization and reactant conditioning,
comprising: a first electrode having a first surface, a second
opposing surface and a length, the first electrode further having a
plurality of spaced apart first passages for fluidly transporting
water, the first passages extending inwardly from the first surface
towards the second surface and having an electrosorptive material
layer disposed therein, and a plurality of spaced apart second
passages for fluidly transporting a reactant, the second passages
extending inwardly from the second surface towards the first
surface, the first and second passages extending along the length
of the first electrode and fluidly isolated from each other, the
first passages being in alternating disposition with respect to the
second passages; a second electrode having a first surface, a
second opposing surface and a length, the second electrode further
having a plurality of spaced apart first passages for transporting
deionized water, the first passages extending inwardly from the
first surface towards the second surface, and a plurality of spaced
apart second passages for transporting water, the second passages
extending inwardly from the. second surface towards the first
surface and having an electrosorptive material layer disposed
therein, the first and second passages extending along the length
of the second electrode and fluidly isolated from each other, the
first passages being in alternating disposition with respect to the
second passages; an electrically insulative, fluid permeable
membrane positioned between the first electrode and the second
electrode to permit fluid permeation between the second passages in
the first electrode and first passages in the second electrode; an
electrically insulative, non-fluid permeable layer disposed on the
first surface of the first electrode, and the second surface of the
second electrode; and a power supply with a first polarity and a
second polarity, the first polarity being electrically coupled to
the first electrode, and the second polarity being electrically
coupled to the second electrode.
41. The apparatus according to claim 40 wherein the electrosorptive
material layer disposed within the first passages in the first
electrode and the second passages in the second electrode is
comprised of a carbon aerogel composite.
42. The apparatus according to claim 40 further comprising a
discharging switch that is electrically coupled to the first
electrode and the second electrode that permits the first electrode
to be substantially electrically coupled to the second electrode
when actuated.
43. An apparatus for water deionization and reactant conditioning,
comprising: a first dielectric plate having a first surface, a
second opposing surface and a length, the first dielectric plate
further having a plurality of spaced apart first passages for
fluidly transporting water, the first passages extending inwardly
from the first surface towards the second surface, and a plurality
of spaced apart second passages for fluidly transporting a
reactant, the second passages extending inwardly from the second
surface towards the first surface, the first and second passages
extending along the length of the first dielectric plate and
fluidly isolated from each other, the first passages being in
alternating disposition with respect to the second passages; a
second dielectric plate having a first surface, a second opposing
surface and a length, the second dielectric plate further having a
plurality of spaced apart first passages for transporting deionized
water, the first passages extending inwardly from the first surface
towards the second surface, and a plurality of spaced apart second
passages for transporting water, the second passages extending
inwardly from the second surface towards the first surface, the
first and second passages extending along the length of the second
dielectric plate and fluidly isolated from each other, the first
passages being in alternating disposition with respect to the
second passages; a fluid permeable membrane positioned between the
first dielectric plate and the dielectric plate to permit fluid
permeation between the second passages in the first dielectric
plate and first passages in the dielectric plate; an
electrosorptive material layer disposed on the first surface of the
first dielectric plate, and the second surface of the second
dielectric plate; a first plate electrode disposed on the
electrosorptive layer on the first surface of the first plate that
substantially electrically contacts the layer; a second plate
electrode disposed on the electrosorptive layer on the second
surface of the second plate that substantially electrically
contacts the layer; and a power supply with a first polarity and a
second polarity, the first polarity being electrically coupled to
the first plate electrode, and the second polarity being
electrically coupled to the second plate electrode.
44. The apparatus according to claim 43 wherein the electrosorptive
material layer disposed on the first surface of the first
dielectric plate, and the second surface of the second dielectric
plate is comprised of a carbon aerogel composite.
45. The apparatus according to claim 43 further comprising a
discharging switch that is electrically coupled to the first plate
electrode and the second plate electrode that permits the first
plate electrode to be substantially electrically coupled to the
second plate electrode when actuated.
46. A method for producing hydrogen and generating electrical
energy therefrom, comprising: receiving water from a water source;
deionizing the water received to obtain deionized water;
dissociating the deionized water to obtain hydrogen; and combining
the hydrogen with an oxidizer in a fuel cell device to generate
electrical energy.
47. The method according to claim 46 wherein the step of receiving
water is further comprised of receiving water from a municipal
source of water.
48. The method according to claim 46 wherein the step of deionizing
is further comprised of: introducing the water received from the
water source into a capacitive deionization (CDI) device; and
applying an electric current to the CDI device to generate
deionized water.
49. The method according to claim 46 wherein the step of
dissociating the deionized water is further comprised of:
introducing the deionized water into an electrolyzer; and applying
an electric current to the electrolyzer to produce hydrogen.
50. The method according to claim 49 wherein the step of
introducing the deionized water into an electrolyzer is further
comprised of introducing the deionized water into a proton exchange
membrane electrolysis (PEME) device, and the step of applying an
electric current to the electrolyzer is further comprised of
applying an electric current to the PEME device.
51. The method according to claim 49 wherein the step of
introducing the deionized water into an electrolyzer is further
comprised of introducing the deionized water into a unitized
regenerative fuel cell (URFC) device, and the step of applying an
electric current to the electrolyzer is further comprised of
applying an electric current to the URFC device.
52. The method according to claim 46 wherein the step of combining
the hydrogen with an oxidizer in a fuel cell device is further
comprised of humidifying the hydrogen and the oxidizer with the
deionized water.
53. The method according to claim 46 wherein the step of combining
the hydrogen with an oxidizer in a fuel cell device is further
comprised of combining the hydrogen and the oxidizer in a proton
exchange membrane fuel cell (PEMFC) device.
54. The method according to claim 46 wherein the step of combining
the hydrogen with an oxidizer in a fuel cell device is further
comprised of combining the hydrogen and the oxidizer in a unitized
regenerative fuel cell (URFC) device.
55. The method according to claim 46 wherein the step of
dissociating the deionized water is further comprised of storing
the hydrogen obtained in a storage system.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. Provisional
Patent Application No. 60/209,518, filed Jun. 5, 2000.
TECHNICAL FIELD
[0002] The present invention generally relates to an integrated
apparatus for the production of gaseous fuel, purified water and
electrical power. More particularly, the present invention relates
to an integrated apparatus having a water deionization system
operatively coupled to an electrolytic hydrogen generator and a
fuel cell power plant.
BACKGROUND OF THE INVENTION
[0003] Fossil fuel combustion has been identified as a significant
contributor to numerous adverse environmental effects. For example,
poor local air quality, regional acidification of rainfall that
extends into lakes and rivers, and a global increase in atmospheric
concentrations of greenhouse gases (GHG), have all been associated
with the combustion of fossil fuels. In particular, increased
concentrations of GHG's are a significant concern since the
increased concentrations may cause a change in global temperature,
thereby potentially contributing to global climatic disruption.
Further, GHG's may remain in the earth's atmosphere for up to
several hundred years.
[0004] One problem associated with the use of fossil fuel is that
the consumption of fossil fuel correlates closely with economic and
population growth. Therefore, as economies and populations continue
to increase worldwide, substantial increases in the concentration
of GHG's in the atmosphere is expected. A further problem
associated with the use of fossil fuels is related to the
inequitable geographical distribution of global petroleum
resources. In particular, many industrialized economies are
deficient in domestic supplies of petroleum, which forces these
economies to import steadily increasing quantities of crude oil in
order to meet the domestic demand for petroleum derived fuels.
[0005] Fossil fuels are used for a variety of purposes, but the
most significant quantities of fossil fuels are dedicated to
low-temperature space heating, electricity generation and
transportation. Of these, transportation is the largest consumer of
fossil fuels. In 1996, for example, transportation accounted for
almost two-thirds of the 120 billion gallons of gasoline and 27
billion gallons of diesel fuel consumed in the United States. (US
Dept. of Energy, Energy Information Administration, Annual Energy
Review 1996, DOE/EIA-0384(96), Washington, D.C. (1997)).
Consequently, the transportation sector's large consumption of
fossil fuels coupled with a growing concern over the environmental
and geopolitical consequences surrounding the use of fossil fuels
are major driving forces stimulating the development of new
transportation technologies. While certain technologies aim to
coexist with current transportation technologies, others seek to
replace them entirely.
[0006] One of these new transportation technologies is the hybrid
diesel/electric and the gasoline/electric automobile. Hybrid
vehicles combine a small diesel or gas engine with an electrical
generator that provides electricity to a bank of storage batteries.
The storage batteries, in turn, provide power to an electric motor
that drives the wheels of the vehicle. Current hybrid vehicles are
capable of achieving 60 to 80 miles per gallon of fuel, thereby
reducing combustion emissions by using less fuel than conventional
internal combustion engine vehicles.
[0007] Another new transportation technology is directed to
improvements in fossil fuels. For example, the automotive and oil
industries are jointly developing a "clean diesel" fuel technology
that combines improved fuels with improved catalytic converters to
cooperatively yield a reduction in nitrous oxides, sulfur oxides,
carbon monoxide and particulate matter emissions. As a result,
emissions from the diesel engine have been reduced by as much as
90%.
[0008] Still another new transportation technology is the battery
powered electric vehicle (BPEV). Although BPEV's were introduced in
the early 1900s, they have historically had a negligible presence
in the consumer marketplace. Recently, however, some automobile
manufacturers have introduced electric vehicles, such as the
General Motors EV1.TM., the Ford RANGER.TM. EV pickup and the
Chrysler EPIC.TM. EV minivan. Despite substantial advances in low
weight materials, however, BPEV's still suffer from weight
limitations and poor performance. In particular, the low volumetric
and gravimetric energy densities found in storage batteries remains
a substantial barrier impeding the widespread use of BPEV's. These
low energy densities translate into short operational ranges
between recharging. Currently, a typical range for a BPEV is
between 75 and 130 miles. Further, BPEV's are limited principally
to light-duty applications, and require battery replacement every
few years, which necessitates the institution of recycling or
disposal programs to dispose of the depleted batteries.
[0009] The application of fuel cell technology to the BPEV may make
the BPEV practical by eliminating the drawbacks associated with the
use of storage batteries. Unlike a storage battery, a fuel cell
does not internally store energy, and does not consume materials
that are stored within the battery to generate electricity.
Instead, the fuel cell converts an externally supplied fuel and
oxidizer to electricity and reaction products. For example, in an
electrochemical fuel cell employing hydrogen as the fuel and oxygen
as the oxidizer, the reaction products are water and heat.
[0010] A total of six different fuel cell technologies have been
identified as being suited for power generation in stationary and
mobile applications. The details and operational characteristics of
each of these technologies have been extensively reviewed. (A. J.
Appleby and F. R. Foulkes, Fuel Cell Handbook, Krieger Publishing
Company, Malabar, Fla., USA (1993)). Of these, the Proton Exchange
Membrane Fuel Cell (PEMFC) has been identified as the most suitable
technology for vehicular applications.
[0011] Referring now to FIG. 1, a cross sectional, schematic view
of a PEMFC 10 according to the prior art is shown. The PEMFC cell
10 includes a centrally positioned membrane electrode assembly
(MEA) 101, which is comprised of an anode electrode layer 103, a
cathode electrode layer 104, an electrocatalyst layer 107 disposed
on the anode electrode layer 103, an electrocatalyst layer 108
disposed on the cathode electrode layer 104. The electrocatalyst
layers 107 and 108 promote the desired electrochemical reaction.
The polymer membrane electrode 102 is comprised of a material that
readily permits the transport of ions and solvent between the anode
electrode layer and the cathode electrode layer during operation of
the fuel cell, but is relatively impermeable to gases. A suitable
material for the polymer membrane electrode is the perfluorinated
polymer NAFION, manufactured by E.I. Dupont de Nemours & Co. of
Wilmington, Del. During operation of the PEMFC cell 10, hydrogen
flowing through fuel channels 109 formed in an anode flow field
plate 110 move through the anode electrode layer 103 and is
oxidized at the anode electrocatalyst layer 107 to yield electrons
to the anode electrode layer 103 and hydrogen ions, which migrate
through the MEA 101.
[0012] Still referring to FIG. 1, the electrochemical reaction for
hydrogen dissociation occurring at the layer 107 is given by
equation 1:
2H.sub.2 (g).fwdarw.4H.sup.++4e.sup.- (1)
[0013] At the same time, oxygen flowing through oxidizer channels
111 formed in a cathode flow field plate 112 move through the
cathode electrode layer 104 to combine with the hydrogen ions that
have migrated through the MEA 101 and electrons from the cathode
electrode layer 104 to form water. This electrochemical reaction is
given by equation 2:
O.sub.2(g)+4H.sup.++4e.sup.-.fwdarw.2H.sub.2O(l) (2)
[0014] The overall electrochemical reaction for the PEMFC 10
therefore given by equation 3:
2H.sub.2(g)+O.sub.2(g).fwdarw.2H.sub.2O(l) (3)
[0015] An electron current 113 travels from the anode flow field
plate 110 through an external electrical load 114 to the cathode
flow field plate 112 to provide electrons for the reaction
occurring at the cathode electrocatalyst layer 108. The DC current
thus produced may be converted into AC current and subsequently
used to power electrical devices requiring a supply of AC
current.
[0016] Single PEMFC cells 10 may be electrically coupled in
sequence to form a fuel cell stack with the individual cells 10
being electrically interconnected in series. One advantage of
serially interconnected stacks is that the voltage obtained from
the stack is a multiple of the number of cells 10 comprising the
stack. Alternatively, a parallel interconnection of individual
cells 10 is also possible. In a parallel-interconnected arrangement
of cells 10, the stack yields the individual cell 10 voltage, but
larger currents may be delivered. For purposes of illustration, a
serially connected stack arrangement is assumed, but other
interconnection methods may also be used, and are within the scope
of the present invention. Stacking is typically accomplished using
electrically conductive bipolar plates which act both as the anode
separator plate of one cell 10 and as the cathode separator plate
of the next cell 10 in the stack. The bipolar plates may also
combine the functions of anode and cathode flow field plates 110
and 112 when they are provided with fuel channels and oxidizer
channels.
[0017] Referring still to FIG. 1, since the MEA 101 consists of a
solid material, it must be kept wet so that ions can migrate
through the MEA 101. Therefore, the reactant streams are generally
humidified before they enter the fuel cell stack to maintain the
desired protonic conductivity. Humidification of the stack is an
important aspect of PEMFC operation because unequal humidification
levels can lead to uneven temperature distributions within the
stack. For example, in extreme cases, a system failure, including
the rupture of the separating membranes may occur as a result of
dry regions within the fuel cell stack. Consequently, current PEMFC
stack designs incorporate external or internal humidification
devices to ensure proper reactant humidification prior to the
delivery of the reactants to the electrochemically active regions.
External humidification can be achieved, for example, by flowing
the reactant streams through a sealed reservoir containing
deionized water. A porous nozzle at the bottom of the sealed
reservoir disperses the gases into small bubbles that travel to the
top of the reservoir and, in the process, capture and carry water
vapor. The temperature and pressure in the reservoir can be used to
control the desired humidification levels. U.S. Pat. No. 5,382,478
to Clarence and Wozniczka, for example, discloses an internal
humidification system that incorporates a dedicated humidification
module located upstream from the electrochemically active section
in a PEMFC stack. A drawback present in this approach is that a
sizeable fraction of the stack volume is devoted to reactant
conditioning.
[0018] FIG. 2 is a cross sectional, schematic view of a PEMFC
device 20 that utilizes an internal module for humidification of
the reactants according to the prior art. The assembly 20 includes
a PEMFC stack 201, an internal humidification module 202, an
electrochemically active region 203, a water deionization apparatus
204, which typically consists of an ion-exchange column, a
deionized water reservoir 205, a water recirculation pump 206, a
fuel storage system (not shown), and a heat exchanger 207. In the
assembly 20, deionized water is used to both condition the
reactants, and to serve as a heat exchange fluid in the cooling
system to maintain the PEMFC stack 201 at the desired operating
temperature. To accomplish both functions, water is concurrently
pumped through the humidification module 202 and through cooling
elements 208 positioned at evenly spaced locations in the
electrochemically active module 203.
[0019] Still referring to FIG. 2, a fuel stream containing hydrogen
is delivered to a fuel inlet port 209. In vehicular applications,
this port is typically connected to the on-board fuel storage
system (not shown). Similarly a stream of compressed oxidizer that
may be ambient air at moderate pressures (e.g., 30 psig) is
delivered to an oxidizer inlet port 210. Both reactants are
distributed internally to the electrochemically active region 203.
Excess reactants exit the PEMFC stack 201 through a fuel outlet
port 211 and an oxidizer outlet port 212. Usually, excess fuel is
recirculated by an appropriate pumping mechanism (not shown), while
excess oxidizer may be vented to the atmosphere.
[0020] Once the reactants reach the electrochemically active module
203, heat is produced as a byproduct of the electrochemical
reactions. A deionized water stream is delivered to a coolant inlet
port 213 and concurrently pumped through the humidification module
202, and the cooling elements 208 within the electrochemically
active module 203. The deionized water stream then exits the PEMFC
stack 201 through a coolant outlet port 214. The water flowing
through the cooling elements 208 receives the excess heat and
carries it to the heat exchanger 207, to cool the water to
approximately its original temperature. The water is then returned
to the deionized water reservoir 205 for recirculation. Product
water from the cathodic reaction and excess humidity in the unused
reactant streams are also deposited in the deionized water
reservoir 205. Proper thermal management is required to maintain
the stack within the specified operating temperature range.
[0021] The electricity produced by the device 20 is collected at a
positive terminal 215 and a negative terminal 216. A DC current may
then be delivered to a power-handling module 217 and may be
subsequently conditioned (e.g., converted to AC current) by a
power-conditioning module 218. After conditioning, the electric
current may be delivered to an electrical power consumer, such as a
vehicle propulsion system.
[0022] Referring now to FIG. 3, a partial cross sectional view of
an internal humidification module 202 is shown, according to the
prior art. Module 202 is comprised of a plurality of repetitive
humidification cells 301 formed by alternating separating plates
303 and water permeable membranes 302. The separating plates 303
include a plurality of parallel open-faced water channels 304 on
one side and a plurality of parallel open-faced reactant channels
305 on the opposing side. The reactant channels 305 typically carry
a fuel gas stream containing hydrogen 306, and an oxidizer gas
stream containing oxygen 307. The oxidizer channels extend between
an oxidizer inlet manifold opening (not shown) and an oxidizer
outlet manifold opening (also not shown), and may traverse the
plates 303 in a plurality of passes.
[0023] Still referring to FIG. 3, the water flowing in the water
channels 304 is deionized to avoid contamination of the permeable
membranes 302, and further to minimize the possibility of
electrical short-circuits within the active module 203 (as shown in
FIG. 2). In addition, this water is maintained at the same pressure
as the incoming reactants to minimize the mechanical stress on the
water permeable membranes 302 and also to prevent water boil-off
due to excess heat produced by the PEMFC stack 201 during peak
power production. In current implementations, these pressures are
relatively low (e.g., 30 psig for automotive applications). As
water flows through the water channels 304, it migrates across the
permeable membrane 302 and is evaporated upon exposure to the
flowing reactant gases. The rate of evaporation and, consequently,
the rate of reactant humidification is controlled by varying the
temperature and pressure of the flowing water, as well as the flow
rate of the incoming dry reactants. As the reactant gases travel
through the channels, the humidity present in the reactive gases
increases until the desired levels are reached, whereupon they are
be delivered to the electrochemically active section 203 (as shown
in FIG. 2).
[0024] Vehicular power plants based on the foregoing concepts have
been successfully demonstrated in fuel cell vehicles (FCV's).
However, the nature and timing of the transition to FCV's remains
unclear primarily due to uncertainties related to the supporting
hydrogen fuel generation infrastructure. There are several
approaches proposed for solving this infrastructure problem.
[0025] The first approach is a transitional approach. It is based
on the assertion that there is no economic incentive to develop a
direct hydrogen-refueling infrastructure until FCV's achieve some
threshold level of consumer penetration. Since consumers, on the
other hand, have no incentive to acquire FCV's unless they can
conveniently refuel them, the transitional approach proposes the
utilization of existing liquid hydrocarbon fuels, such as gasoline
and methanol, to power hydrogen fuel cell vehicles. Such a method
circumvents the need to establish a direct hydrogen-fueling
infrastructure, by using the existing liquid fuel distribution
system. This approach generally employs on-board fuel reformers
that operate while the vehicle is running, converting these
hydrocarbon fuels to a hydrogen-rich gas stream (a typical stream
consists of 75% hydrogen, 0.4% CO, with the rest being CO.sub.2).
This reformate stream is, in turn, delivered to the vehicle's fuel
cell power plant.
[0026] The leading fuel processor technologies employ partial
oxidation and high-temperature steam reforming. For example, Epyx
has developed a multiple-fuel processor (gasoline, ethanol,
methanol, natural gas, propane) employing partial oxidation. (W. P.
Teagan, J. Bentley, and B. Barnett, Cost Reductions of Fuel Cells
for Transport Applications: Fuel Processing Options, J. of Power
Sources, 71, pp. 80-85 (March 1998)). Hydrogen Bumer Technology
Inc. has also scheduled the first pre-commercial prototypes of its
F3P fuel processors. Despite recent breakthroughs and support from
the US Department of Energy, however, reforming processes still
result in the generation of GHG's and other harmful emissions.
While on-board reforming has the benefit of providing an immediate
solution to early adopters of FCV's, it re-introduces some of the
problems that FCV's were designed to eliminate, namely the
environmental and geopolitical difficulties associated with the
utilization of fossil fuels. While the use of methanol, instead of
gasoline, partially addresses these concerns, it creates the need
to implement an entirely new methanol production and refueling
infrastructure. The significant cost associated with this
undertaking makes this approach prohibitive for oil companies to
pursue. This is particularly significant if methanol will only play
a temporary role in the transition from a fossil fuel based economy
to a hydrogen-based economy.
[0027] The second approach proposes moving to a direct
hydrogen-refueling infrastructure at the outset. The difficulty
with such approach is that there is no economic incentive to build
an external infrastructure in the absence of consumer demand. A
highly centralized structure, in which hydrogen is produced in
large plants and shipped or piped to refueling stations seems
especially problematic, due to the very high capital costs. In
response, various groups have proposed the decentralized production
of hydrogen at the refueling point. Two principal methods of
hydrogen production have been proposed.
[0028] One method for developing a decentralized, direct
hydrogen-fueling infrastructure involves the utilization of
hydrocarbon fuels, such as methane, as a feedstock. Methane, the
major component in natural gas, is readily available in most urban
areas, through a pre-existing network of underground pipelines.
Small-scale methane reformers connected to these gas pipelines
could allow local gasoline stations to produce hydrogen on demand.
This method, while partially addressing some of the geopolitical
concerns associated with the use of imported oil, retains at least
one of the problems that FCV's were designed to eliminate, namely,
the environmental concerns associated with the utilization of
hydrocarbon fuels.
[0029] Another method involves producing hydrogen through the
electrolysis of water. In this process, electrical current is
provided to an electrolyzer to dissociate water into its hydrogen
and oxygen constituents. The resulting hydrogen gas is then
compressed or liquefied and delivered to the on-board storage
systems in FCV's. Stuart Energy Systems, of Ontario, Canada, for
example, has implemented hydrogen fuel cell-powered bus refueling
stations using this approach. While hydrogen is more costly to
produce through electrolysis than through methane reforming, the
approach has the advantage of potentially eliminating the use of
hydrocarbon fuels at the point of refueling. Furthermore, if the
electricity is produced through sustainable means, such as solar,
wind, hydroelectric, geothermal or nuclear power, then harmful
atmospheric emissions are removed throughout the entire energy
production chain. Thus, an approach using decentralized
electrolyzers minimizes infrastructure costs, because it relies
solely on electricity and water as feedstocks, both of which are
widely available in urban areas.
[0030] Currently, four methods for de-centralized electrolytic
hydrogen production are available:
[0031] i) Advanced alkaline water electrolysis (AWE),
[0032] ii) High temperature electrolysis (HTE)
[0033] iii) Inorganic membrane alkaline electrolysis (IME), and
[0034] iv) Solid polymer (e.g., proton exchange membrane)
electrolysis (PEME)
[0035] The principles of operation and current technical challenges
associated with each of these methods have been reviewed. (S.
Dutta, Technology Assessment of Advanced Electrolytic Hydrogen
Production, International Journal of Hydrogen Energy, Vol. 15, No.
6, pp. 379-386 (1990)). Presently, conventional alkaline water
electrolysis is the technology of choice for large-scale
electrolytic hydrogen production. However, IME and PEME appear to
be suitable options for generating hydrogen on-board regenerative
fuel cell vehicles (RFCV's). IME is based on the replacement of
conventional asbestos separators (in alkaline electrolysis) with a
thin, low-resistance polyantimonic membrane. See for example, U.S.
Pat. No. 4,253,936 to Vandenborre, which discloses a fabrication
method for these membranes. In a separate publication, Vandenborre
also identifies some of the challenges found in the early
development stages. (H. Vandenborre, R. Leysen, and H. Nackaerts,
Developments on IME-Alkaline Water Electrolysis, Int. J. Hydrogen
Energy, Vol. 8, No. 2, pp. 81-83 (1983)). IME technology is
currently being developed into commercial electrolysis products by,
for example, Hydrogen Systems, Inc., of Montreal, Quebec, Canada.
In addition, U.S. Pat. No. 4,636,291 and U.S. Pat. No. 4,356,231 to
Divisek et al., disclose advances in the design of diaphragm
separators required for IME. The use of non-noble metal catalysts
makes IME technology attractive when compared to solid polymer
systems that require more expensive noble catalysts (e.g.,
Platinum, and Platinum-Ruthenium alloys). However, PEME technology
is more compatible with the PEMFC power plants currently under
development by automotive manufacturers. Compared to PEMFC's, PEM
electrolyzers (PEME's) operate in an analogous but inverse manner.
In these devices, water and electricity are supplied to accomplish
the electrolytic separation of water molecules into their
constitutive elements, hydrogen and oxygen.
[0036] FIG. 4 is a schematic representation of a PEME cell 30
according to the prior art. A membrane electrode assembly (MEA) 401
similar to that described above for the PEMFC 10, which is shown in
FIG. 1, includes a cathode electrode layer 403 and an anode
electrode layer 404 having electrocatalyst layers 407 and 408. The
electrocatalyst layers 407 and 408 are generally comprised of Pt,
IrO.sub.2, or other alloys. During operation of the PEME cell 30, a
deionized water stream may be delivered to either side of PEME cell
30. Different approaches for water supply have been considered,
including static water feed, anode water feed, and cathode water
feed. The details of each of these methods have been reviewed.
(Mitlitsky et al., Applications and Development of High Pressure
PEM Systems, in Proceedings of the Portable Fuel Cells Conference,
Lucerne Switzerland, Jun. 21-23, 1999). In this description, and
merely for illustrative purposes, anode water feed is assumed.
Accordingly, a deionized water stream 409 is delivered to flow
field channels formed in an anode plate 410. This water migrates
through the anode electrode layer 404 and reaches the
electrocatalyst layer 408 where it is oxidized. The products of
this oxidization are molecular oxygen gas, hydrogen ions, and
electrons. The electrochemical reaction for oxygen evolution is
given by equation 4:
2H.sub.2O(l).fwdarw.O.sub.2(g)+4H.sup.++4e.sup.- (4)
[0037] The resulting hydrogen ions migrate through the membrane 402
and reach the electrocatalyst layer 407 on the cathode electrode
layer 403 to form molecular hydrogen. The product hydrogen is
collected in a hydrogen stream 411 that travels through a hydrogen
flow field channel formed in a cathode plate 412. The
electrochemical reaction for hydrogen evolution is given by
equation 5:
4H.sup.++4e.sup.-.fwdarw.2H.sub.2(g) (5)
[0038] For cells operating below the boiling point of water, the
overall electrochemical reaction is given by equation 6:
2H.sub.2O(l).fwdarw.2H.sub.2(g)+O2(g) (6)
[0039] For thermodynamic reasons, the foregoing reaction does not
occur spontaneously under ambient temperatures and pressures.
Consequently, energy must be supplied to promote the desired
reactions. Usually, the required energy is delivered in the form of
an electric current 413 provided by a power supply 414. The applied
voltages across the cell are usually between 1 and 2 volts. It
should be noted that the reactions in equations (4), (5) and (6)
correspond exactly to the reverse of the electrochemical processes
occurring in a PEMFC and described by equations (1), (2) and (3)
respectively.
[0040] Multiple single PEME cells 30 may be stacked to form a PEME
stack. Stacking is typically accomplished by using electrically
conductive bipolar plates that act both as the anode separator
plate of one PEME cell 30 and as the cathode separator plate of the
next PEME cell 30 in the stack. The cells 30 are further fluidly
and electrically interconnected during the operation of the PEME
stack.
[0041] Referring now to FIG. 5, a schematic view of a PEME system
40 according to the prior art is shown. The PEME system 40 is
generally comprised of a PEME stack 501 positioned between an anode
plate 506 and an opposing cathode plate 505. A hydrogen manifold
516 is positioned at the anode plate 506, and an oxygen manifold
517 is positioned at the cathode plate 505. The anode plate 506 and
the cathode plate 505 are coupled to a DC power supply through a DC
power input port 504. The PEME stack 501 is further coupled to a
water deionization module 503, which typically consists of filters
and an ion-exchange column, to deliver deionized water to the PEME
stack 501. Deionized water is also circulated through the PEME
stack 501 by a recirculation pump 512 for cooling, or other
purposes.
[0042] During operation of the PEME 40, externally supplied water
from municipal source flows through the water deionization module
503. The purified water stream 515 is delivered to a water storage
vessel 509 and subsequently distributed throughout the PEME stack
501 by static, anode, or cathode-feed methods. Presently, for
purposes of illustration, an anode-feed implementation is assumed.
However, other water feed methods would also be suitable
[0043] Still referring to FIG. 5, after water migrates through the
porous electrode substrates (not shown in FIG. 5) in the PEME stack
501, the water is decomposed into hydrogen and oxygen at the
catalytic sites. These gases are produced on opposite sides of the
MEA assemblies (not shown in FIG. 5) and separated by the
gas-impermeable, polymeric ionic conductor (also not shown in FIG.
5). The resulting two-phase mixture of hydrogen and water is
collected at the hydrogen manifold 516. Similarly, the two-phase
mixture of oxygen and water is collected at the oxygen manifold
517. The two-phase mixture of hydrogen and water 518 flows out of
the PEME stack 501 and through a check valve 520 to prevent the
two-phase mixture 518 from returning to the PEME stack 501. A phase
separator 514 that separates the hydrogen gas from the water
receives the mixture 518 from the check valve 520. The phase
separator 514 delivers the water to the vessel 509. Similarly, the
two-phase mixture of oxygen and water 519 flows out of the stack
501 and through a check valve 521 to prevent the two-phase mixture
519 from returning to the PEME stack 501. A phase separator 513
that separates the oxygen gas from the water receives the mixture
519 from the check valve 521. The phase separator 513 delivers the
water to the vessel. The product hydrogen flows from the phase
separator 514 into a condenser 511 to further remove water from the
hydrogen gas. The hydrogen is then routed through a hydrogen outlet
port 507, through a check valve 522 to a mechanical compression
system 523, which can be external to the PEME system 40. The
product hydrogen is then accumulated into a fuel storage system
524. For the purposes of this description, the storage system 524
is assumed to comprise a plurality of pressure vessels 525 with a
safety relief valve 526, a control valve 527, and a dispensing
regulator 528 fluidly coupled to the vessels 525. Burst discs 529
may be used to relieve excess gas pressure accumulated in the
vessels 525 by expelling the gas by bursting. The product oxygen
flows from the phase separator 513 into a condenser 510 to remove
the residual water. The oxygen is then routed through an oxygen
outlet port 508 to a leak valve 530. Alternatively, the oxygen
generated within the PEME stack 501 may be compressed and
accumulated in a suitable storage system similar to that used for
hydrogen.
[0044] PEME technology advantageously provides current densities
and energy efficiencies that are superior to conventional (e.g.,
alkaline) electrolysis. (M. Yamaguchi et al., Development of 2500
cm.sup.2 Solid Polymer Electrolyte Water Electrolyzer in WE-NET, in
Proceedings of the XII International Conference on Hydrogen Energy,
Buenos Aires, Argentina, 1998, pp.747-755). Further, the symmetry
between PEMFC's and PEME's suggests that these two technologies may
be combined into integrated, dual function devices. By integrating
PEMFC stacks with PEME stacks, it is possible to design systems
that can both produce electricity from hydrogen and oxygen, and
electrolytically regenerate these reactants from electricity and
water. Such a system is termed a regenerative fuel cell (RFC)
system. When such systems employ a single stack that may be
reversibly operated to function as either a PEMFC or a PEME, it is
termed a unitized regenerative fuel cell (URFC) system.
[0045] RFC's have been known for more than 20 years. For example,
U.S. Pat. No. 3,992,271 to Danzig, et al., and U.S. Pat. No.
3,981,745 to Stedman disclose methods for gas and power generation,
based on the foregoing concepts. However, neither of these patents
discloses a method for coupling water deionization technologies
with RFC's or URFC's. More recent developments include detailed
analyses performed in 1994 at Lawrence Livermore National
Laboratory (LLNL). These analyses determined that URFC's could be
used to design systems that are lighter and less complex than
regenerative fuel cell systems that employ separate (discrete)
stacks as fuel cells and electrolyzers. In collaboration with
commercial developers such as Proton Energy Systems of Rocky Hill,
Conn., a modified primary fuel cell device with a single cell has
been operated reversibly for thousands of cycles at LLNL with
negligible degradation. The URFC uses dual function electrodes,
where the oxidation and reduction electrodes reverse roles when
switching from charge to discharge, as, for example, within a
rechargeable battery, to achieve both the fuel cell and
electrolyzer functions. (F. Mitlitsky, B. Myers, and A. H.
Weisberg, Regenerative Fuel Cell Systems, Energy & Fuels, 12,
pp. 56-71 (1998)).
[0046] The combination of a PEME with a PEMFC, or the use of a URFC
in vehicular applications affords the vehicle the flexibility to
refuel the vehicle from an external, high pressure hydrogen source,
or by producing hydrogen fuel on-board the vehicle by coupling the
vehicle to an external supply of electricity and water. The
advantage of such vehicles, known as regenerative fuel cell
vehicles (RFCV's), is that they eliminate the requirement to
implement a very costly direct hydrogen-refueling infrastructure.
Thus, the RFCV is capable of carrying a hydrogen infrastructure
on-board, thereby eliminating the need for a dispersed network of
electrolyzers and other associated hardware. RFCV's, in effect, use
electrolytically generated hydrogen as a storage medium for
electrical energy.
[0047] The production of hydrogen fuel on-board passenger vehicles
was suggested as early as 1980. For example, U.S. Pat. No.
4,368,696 to Reinhart discloses a method for supplementing
vehicular fuel with an on-board hydrogen generation system.
According to the disclosed invention, heat derived from the exhaust
gases of an internal combustion engine is used to electrolyze water
into hydrogen and oxygen, which are then used to enhance the fuel
combustion in the vehicle's engine. Significantly, no disclosure of
an electrochemical method for electricity generation, or the use of
fuel cell and electrolyzers operating reversibly is present. More
recently, U.S. Pat. Nos. 5,813,222 and 5,953,908 to Appleby
disclose a method and apparatus for hydrogen generation. The
resulting hydrogen is used to heat a catalytic converter and reduce
vehicular emissions. U.S. Pat. No. 5,964,089 to Murphy, et al.
discloses diagnostic and control systems for on-board hydrogen
generation and delivery. U.S. Pat. Nos. 5,830,426, 5,690,902, and
5,510,201 to Werth disclose a method for generating hydrogen
on-board a FCV. However, the disclosure in the Werth patents is not
based on electrolysis. Instead it uses solid, metallic particles as
the raw materials for hydrogen production.
[0048] The implementation of on-board fuel production is most
effective if the fuel can be delivered at high pressure in order to
eliminate the need for an external hydrogen compression
infrastructure. Hydrogen fuel delivered to the consumer must
include not only the cost of production, but also include the costs
associated with the storage, transport, and dispensing of the
liquid hydrogen at approximately its normal boiling point (-423
degrees Fahrenheit or -253 degrees Celsius). The high costs
associated with liquefaction and the additional infrastructure
required to handle cryogenic liquids represent barriers that have
prevented liquefied hydrogen from being seriously considered as a
vehicular fuel.
[0049] Compressed hydrogen, however, has been successfully used in
FCV demonstration projects. Typically, the hydrogen fuel is stored
on-board the vehicle as a compressed gas at relatively high
pressures (e.g., between 2,000 and 5,000 psig), with the required
storage pressure being a function of the desired vehicular range.
According to recent studies, the higher efficiencies associated
with FCV's would make it possible to obtain a range of 380 mi
(611.6 km) with approximately 7.9 lbs. (3.6 kg) of hydrogen stored
on-board. For standard vehicular storage volumes and equipment,
this requirement translates into storage pressures of 3,000 psig or
greater. Accordingly, the hydrogen supplied to RFCV's must be
delivered and stored at these pressures. The utilization of a PEME
on board the vehicle can eliminate the need for external mechanical
compression by producing electrolytic hydrogen at the desired
pressures. This can be accomplished by pressurizing the hydrogen
compartments in the PEME stack. In this regard, at least two
approaches have been considered.
[0050] A first approach consists of balancing the pressure on both
sides of the electrolytic cells. This implies that both product gas
streams (hydrogen and oxygen) are delivered at high pressure. One
advantage of this approach is the elimination of large mechanical
stresses on the MEA due to large differential pressures across it.
One disadvantage is the extra cost of the high-pressure water
recirculation equipment and accessories.
[0051] A second approach consists of pressurizing the hydrogen
compartments while implementing anode (i.e., oxygen side) water
feed designs, and maintaining the oxygen compartments at relatively
low pressure (e.g., atmospheric pressure). The advantage of this
approach is the possibility of eliminating high-pressure water
recirculation equipment. The disadvantages of this approach include
the need for structural re-enforcement of the MEA structures, and
the need for microscopic modifications to the electrode substrates.
MEA reinforcement is required to maintain structural integrity so
that the resulting large differential pressures do not distort the
structure. Further, MEA reinforcement prevents membrane deformation
or a catastrophic cell failure from occurring (e.g., by rupture of
the polymeric ionic conductor). Microscopic modification of the
porous electrode substrates is required to minimize or eliminate
the migration of molecular hydrogen gas from the cathode
compartments to the anode compartments.
[0052] Many of the engineering challenges associated with the
foregoing approaches have been resolved and are disclosed in the
prior art. For example, U.S. Pat. No. 5,372,689 to Carlson et al.
discloses a method for membrane reinforcement in high-pressure
electrolysis. Similarly, U.S. Pat. No. 5,350,496 to Smith et al.
discloses a high-pressure oxygen generator. U.S. Pat. No. 5,342,494
to Shane et al. discloses a high purity hydrogen and oxygen
production apparatus. However, the foregoing inventions disclose
neither a connection with existing electricity and water grids, nor
the integration of new water purification technologies to
electrochemical hydrogen and electricity production.
[0053] The electrolytic production of hydrogen requires highly
purified water. Acceptable purity levels are typically
characterized by minimum values of electrical resistivity. Water
with an electrical resistivity equal to or greater than 1.0
M.OMEGA..multidot.cm is considered sufficiently pure, while higher
resistivities (e.g., >14 M.OMEGA..multidot.cm) are commonly
employed in some commercial applications. Water purification has
heretofore been carried out using a variety of conventional
processes such as ion exchange (IE), reverse osmosis (RO),
electrodialysis (EDI), electrodeposition (EDP), and filtering.
Filtering and IE methods have been successfully used in some FCV
demonstrations. In these methods, a mixed bed comprised of
activated carbon particles is included to remove any organic
compounds present in the water. Due to the unidirectional flow of
unpurified water in these devices, filters and ion-exchange columns
become saturated over time and must be replaced periodically. The
IE media in fuel cell buses, for example, is replaced every 4 to 6
months as part of preventative maintenance programs resulting in
added expense and downtime. Alternatively, the saturated EI columns
may be regenerated by removing them from the system and exposing
them to a flow of regeneration fluids such as concentrated
solutions of acids, bases, and salts. Typically, the appropriate
handling of these solutions requires dedicated facilities or
specially trained personnel. In addition, column regeneration
results in a significant secondary waste stream. These streams
typically include used anion and cation exchange resins,
contaminated solutions of high concentration, acids, bases, and
salts. Some of these substances and materials can be hazardous and
thus require proper recycling or disposal. Further, the energy
required to pump water through porous beds of finely divided media
can be significant. These requirements are typically proportional
to the amount of fluid flowing through the bed and manifest
themselves as large pressure drops across the beds. Accordingly, a
need exists to improve deionization methods used on-board
FCV's.
[0054] U.S. Pat. No. 5,425,858 and 5,954,937 to Farmer, which are
incorporated by reference herein, disclose an alternative
technology for water purification. This technology is based on a
capacitive deionizing (CDI) process in which water is passed
between electrodes kept at a potential difference of approximately
one volt. Ions are removed from the water by the imposed
electrostatic field and retained at the electrode surfaces. In
addition, some metal cations are removed by electrodeposition.
Electric dipoles are also attracted and trapped by the charged
electrode surfaces, and small suspended particles may be removed by
electrophoresis. Organic impurities also display an affinity to the
carbon surfaces and can therefore be removed by chemisorption. When
the electrodes become saturated in a CDI device, they are
electrostatically regenerated, and the contaminants are released
into a concentrated purge stream. Central to this process is a
monolithic electrosorptive material such as the carbon aerogel
composite materials developed by the Lawrence Livermore National
Laboratory. The details for forming the carbon aerogel composite
material may be found in Richardson et al., Capacitive Deionization
System, LLNL Publication UCRL-JC-125291, October 1996, and Farmer
et al., The Application of Carbon Aerogel Electrodes to
Desalination and Waste Management, LLNL Publication UCRL-JC-127004,
August 1997, which are incorporated by reference herein. Further
details concerning the formation of suitable carbon aerogel
composites are found in Wang, et al., Carbon Aerogel Composite
Electrodes, J. Anal. Chem. Vol. 65, pp. 2300-2303, (1993), and in
U.S. Pat. No. 5,260,855 to Pakala et al, which are incorporated by
reference herein.
[0055] FIG. 6 is a cross sectional view of a CDI device 50
according to the disclosure in the Farmer patents. Intermediate
electrodes 601 are positioned within a CDI stack 602 that is
retained between a pair of end electrodes 603 and 604 that
substantially abut insulator layers 609 and 610 that, in turn,
substantially abut a pair of end plates 605 and 606. Each
intermediate electrode 601 includes a pair of carbon aerogel
composite layers 607 that are bonded in an electrically conducting
manner to the intermediate electrodes 601. Sealing gaskets 616 are
interposed between the insulator layers 609 and 610 to prevent
water leakage from the device. The CDI device 50 is held in
compression by the rods 611 to form a leak tight assembly.
[0056] To produce deionized water from the device 50, a potential
difference is applied to each pair of adjacent electrodes 601 by
connecting them to a DC power supply (not shown). As a result, an
electrostatic field is generated between each pair of oppositely
charged electrodes 601. City water enters the CDI stack 602 through
an inlet port 614 and flows through the CDI stack 602 in the
direction indicated by the arrows A through N. As the water flows
through the compartments between the first pair of electrodes 601,
ionic contaminants are exposed to the electrostatic field and, as a
result, a fraction of these ionic species are held at the surface
of the aerogel composite layers 607. Negatively charged species are
attracted toward positively charged electrodes (the anodes), while
positively charged species are attracted toward the negatively
charged electrodes (the cathodes). This process is repeated as the
water flows into the adjacent chambers and, as a result, the water
stream is progressively purified. Once the desired purity level has
been reached, the deionized water stream is delivered through an
outlet port 615.
[0057] Still referring to FIG. 6, when the electrodes 601 become
saturated with the ionic contaminants, the CDI stack 602 becomes
fully charged. In contrast with conventional chemical regeneration
processes, the CDI stack 602 can be regenerated by purely
electrical methods. Disconnecting the DC power supply,
short-circuiting the anodes and cathodes to electrically discharge
all the cells, and flowing city water through the CDI stack 602 can
accomplish regeneration. The CDI cells thus release the ions
previously held at the charged electrodes and liberate them into
the regenerating stream until the CDI cells are fully regenerated.
Once this stage is reached, the deionization process may be
resumed.
[0058] Farmer discloses the production of high-purity water for
semiconductor processing in the foregoing manner, but does not
disclose the production of high-purity water as a feedstock for
water electrolysis. Furthermore, Farmer discloses neither an
application of these technologies for hydrogen generation on-board
vehicles, nor a method of integrating CDI stacks with PEME, PEMFC,
or URFC stacks.
[0059] From the foregoing discussion, it is evident that recent
developments in high-pressure PEM electrolysis, vehicular PEMFC
technology, and CDI water purification have demonstrated the
utility of the new technologies in many applications.
[0060] Accordingly, there is a need for a regenerative fuel cell
system that includes a proton exchange membrane electrolyzer (PEME)
and a proton exchange membrane fuel cell (PEMFC) to produce
electrical energy, where the deionized water is supplied to the
system by a CDI device. Further, there is a need for a regenerative
fuel cell system that includes a unitized regenerative fuel cell
(URFC) to produce electrical energy, where the deionized water is
supplied to the system by a CDI device.
SUMMARY OF THE INVENTION
[0061] The present invention is directed to an apparatus and method
for deionization and hydrogen fuel production in a fuel generation
mode, and electricity production in a power generation mode. In one
aspect of the invention, the apparatus operates in a fuel
generation mode, with a capacitive deionization (CDI) device
receiving water from a water source and electrical energy from a
source of electrical energy to produce deionized water that is
transferred to a proton electrode membrane electrolysis (PEME)
device to produce hydrogen fuel by electrolysis. A storage system
that is fluidly coupled to the PEME receives the hydrogen. With the
apparatus operating in a power generation mode, hydrogen is
transferred from the storage system to a humidification unit that
humidifies the hydrogen and an oxidizer prior to combination of the
hydrogen and oxygen in a proton electrode membrane fuel cell
(PEMFC) device that produces electrical energy. In another aspect,
the PEME and the PEMFC are functionally combined in a unitary
regenerative fuel cell (URFC) device. In still another aspect of
the invention, the humidification unit and the CDI are functionally
combined in a single unit that uses a plurality of
conductive-channeled plates as electrodes for water deionization
and for reactant flows. In yet another aspect, the channeled plates
are non-conductive, and a plurality of plate electrodes are used
for water deionization. In a further aspect, a CDI, URFC and the
humidification unit are combined in a single unitary assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0062] FIG. 1 is a cross sectional, schematic view of a proton
exchange membrane fuel cell (PEMFC) according to the prior art.
[0063] FIG. 2 is a cross sectional, schematic view of a PEMFC
device that utilizes an internal module for humidification of the
reactants according to the prior art.
[0064] FIG. 3 is a partial cross sectional view of an internal
humidification module according to the prior art.
[0065] FIG. 4 is a cross sectional, schematic view of a proton
exchange membrane electrolytic cell (PEME) according to the prior
art
[0066] FIG. 5 is a schematic view of a PEME system according to the
prior art.
[0067] FIG. 6 is a cross sectional view of a capacitive
deionization (CDI) device according to the prior art.
[0068] FIG. 7 is a schematic diagram of an integrated power
generation apparatus according to an embodiment of the
invention.
[0069] FIG. 8 is a schematic diagram of an integrated power
generation apparatus 80 according to another embodiment of the
invention.
[0070] FIG. 9 is a partial, cross sectional view of an integrated
CDI apparatus for water deionization and reactant conditioning
according to an embodiment of the invention.
[0071] FIG. 10 is a partial, cross sectional view of an integrated
CDI apparatus for water deionization and reactant conditioning
according to another embodiment of the invention.
[0072] FIG. 11 is a schematic diagram of an integrated power
generation apparatus according to still another embodiment of the
invention.
[0073] FIG. 12 is a partial cutaway, schematic diagram of an
integrated power generation apparatus according to still another
embodiment of the invention.
[0074] FIG. 13 a cross sectional, schematic view of the module
shown in FIG. 12.
DETAILED DESCRIPTION OF THE INVENTION
[0075] The present invention is generally directed to an integrated
power generation apparatus having a water deionization system for
the production of deionized water that is operatively coupled to an
electrolytic hydrogen generator to produce hydrogen by electrolysis
and having a fuel cell device for electricity production. Many of
the specific details of certain embodiments of the invention are
set forth in the following description and in FIGS. 7 through 13 to
provide a thorough understanding of such embodiments. One skilled
in the art will understand, however, that the present invention may
have additional embodiments, or that the present invention may be
practiced without several of the details described in the following
description. Moreover, in the following description of the
embodiments, unless specific reference is made to deionized water,
it is understood that the water is in a relatively untreated or
unprocessed state, as would be received, for example, from a
municipal water distribution system.
[0076] FIG. 7 is a schematic diagram of an integrated power
generation apparatus 70 according to an embodiment of the
invention. The apparatus 70 is comprised of a PEME stack 801, a
PEMFC stack 802, and a CDI stack 803 that are operatively coupled
to produce hydrogen fuel from a water source during a fuel
generation mode, and electricity and water during a power
generation mode. The internal details and operation of the PEME
stack 801, the PEMFC stack 802, and the CDI stack 803 have been
previously described, and thus, for the sake of brevity, will not
again be described in detail.
[0077] In the fuel generation mode, water is delivered to the CDI
stack 803 from an input source 702. The source 702 may be either a
potable or non-potable source, but is generally a municipal water
source. The water flow rate should be at least sufficient to match
the rate of water consumption in the PEME stack 801. However,
larger flow rates may be required to accommodate cooling
requirements, and to compensate for evaporation and other forms of
water loss. The water enters the CDI stack 801 and is progressively
deionized as it passes through the stack 803. Once the water stream
has reached a predetermined purity level, it is delivered to the
PEME stack 801. In order to decompose the deionized water into
hydrogen and oxygen, electrical current must be applied to the PEME
stack 801. The apparatus 70 therefore receives electrical current
from an external source 704. Since the electrical current received
from the external source 704 may not be compatible with the
electrical requirements of the PEME stack 801, a power converter
709 is interposed between the source 704 and the apparatus 70 to
ensure electrical compatibility. For example, if the source 704 is
a utility grid that provides an alternating current, the converter
709 provides an appropriate direct current to the PEME stack 801 at
a compatible voltage. Accordingly, the converter 709 may include
transformers, rectifiers, or other power conditioning apparatus as
required.
[0078] During the fuel generation mode, two-phase mixtures of
hydrogen and water 805, and oxygen and water 806 generated by
electrolysis in the stack 801 are collected and flow out of the
PEME stack 801 through heat exchangers 813 and 814, which remove
heat present in the two-phase mixtures 805 and 806 incurred by the
electrolytic processes within the stack 801. The heat exchangers
813 and 814 may be cooled by water supplied from the source 702, or
alternatively, the heat exchangers 813 and 814 may be cooled by
air, or other gases. Check valves 807 and 808 receive the mixtures
805 and 806 from the heat exchangers 813 and 814 and prevent the
two-phase mixtures 805 and 806 from returning to the PEME stack
801. A water-hydrogen phase separator 809, and a water-oxygen phase
separator 810 separate the liquid and gaseous components in the
two-phase mixtures 805 and 806. The deionized water collected at
the water-oxygen phase separator 810 and the water-hydrogen phase
separator 809 may be deposited in a water level controller
reservoir 815 and stored for further use. A floating level sensor
816 may monitor the water level in the reservoir 815. Additionally,
a heat exchanger 844 may be used to remove residual water vapor in
the gas leaving the water-oxygen phase separator 810, and a similar
heat exchanger 845 may be used to remove residual water vapor in
the gas leaving the water-hydrogen phase separator 809.
[0079] The oxygen generated by the PEME stack 801 may then be
vented through a leak valve 817 located in line 841, or accumulated
in a storage system (not shown) that may include a compressor that
receives the oxygen from the PEME stack 801 and transfers the
compressed oxygen to a plurality of storage vessels. The apparatus
70 may transfer the hydrogen fuel generated in the PEME stack 801
to a fuel storage system 706 through a fuel storage line 840. The
fuel storage system 706 may store hydrogen as a compressed gas, or
alternatively, as a metal hydride. As the total internal pressure
within the fuel storage system 706 increases, the pressure is
monitored by a pressure sensor 818 in the line 840 that is coupled
to a control system (not shown). When a predetermined gas storage
pressure within the system 706 has been achieved, the sensor 818
transfers a signal to the control system and the electrolytic
processes within the PEME stack 801 are halted by disconnecting the
DC power supplied by the converter 709 from the PEME stack 801.
Once the fuel generation is completed, the PEME stack 801 may be
depressurized by closing a valve 820 on the hydrogen supply line,
and venting a small amount of hydrogen fuel though a regulated leak
valve 821 connected to a hydrogen vent line 822.
[0080] Still referring to FIG. 7, with the apparatus 70 still
operating in the fuel generation mode, a pump 812 pumps deionized
water from the reservoir 815 to the PEME stack 801 through a
two-position valve 825. As shown in FIG. 7, the valve 825 directs
deionized water from the reservoir 815 to the PEME stack 801. The
water pumped from the reservoir 815 may be the sole source of
deionized water supplied to the PEME stack 801, or it may be used
to supplement the deionized water provided by the CDI stack 803. In
the present embodiment, an anode-feed design is used, with water
being fed to the oxygen side of the electrolysis cells within the
PEME stack 801. However, other water-feed methods, such as static
feed or cathode feed may be used in the present embodiment. With
the anode water feed design, the pressure in the oxygen
compartments in the PEME stack 801 may be maintained at a pressure
level that is lower than the pressure in the hydrogen compartments
in the PEME stack 801. This "imbalanced pressure design" eliminates
high-pressure water recirculation equipment (pumps, fittings, etc)
on the anode (oxygen) side of each electrolytic cell in the PEME
stack 801, since this side may be maintained at a pressure that is
relatively close to atmospheric pressure. However, large
differential pressures across the MEA structures within the PEME
stack 801 may be developed, and consequently, MEA structures in the
imbalanced pressure stack design must be re-enforced to withstand
pressure differentials created by the hydrogen pressurization.
Other designs, however, are possible. For example, the hydrogen
compartments may not be pressurized, so that the low-pressure
hydrogen is delivered to a mechanical compression system (not
shown) before being transferred to the fuel storage system 706.
[0081] By producing hydrogen fuel at low pressure, the need for
high-pressure recirculation and sealing equipment is eliminated.
Alternatively, both sides of the electrolytic cells in the PEME
stack 801 may be simultaneously pressurized to achieve a
predetermined hydrogen fuel delivery pressure. In this "balanced
pressure" design, the high pressure PEME stack 801, the PEMFC stack
802 and the CDI stack 803 are enclosed in a suitable containment
vessel, with feedthroughs through the containment vessel for
electrical and fluid connections. In this design, the water
supplied from the source 702 must be increased in pressure so that
it generally exceeds the containment pressure. Still another
balanced pressure design is implemented with a pair of water
recirculation loops, each loop supplying recirculated water to one
of the product gas compartments. The balanced pressure PEME design
is advantageous because it balances the pressure across the gas
compartments, thus eliminating the need for MEA reinforcement.
[0082] After each fuel generation, a sensor 824 determines the
saturation level of the electrosorptive media in the electrodes
within the CDI stack 803, and acts as a triggering device to
activate a control system (not shown) that controls regeneration of
the CDI stack 803. Accordingly, the regeneration process may be
initiated when the electrodes are fully saturated, or
alternatively, regeneration may be controlled to occur after every
fuel generation cycle. The sensor 824 may be a pH sensor, but other
devices may be used. For example, the sensor 813 may be a
conductivity sensor, an ion-selective sensor, a polarographic
sensor, an impedance sensor, an optical transmission sensor, or a
light scattering sensor. A suitable control system is disclosed in
U.S. Pat. Nos. 5,425,858 and 5,954,957 to Farmer, both of which are
incorporated by reference.
[0083] Still referring to FIG. 7, and turning now to the power
generation mode, the two-position valve 825 is positioned by
rotating the valve 825 in the direction "A" to establish a
recirculating water loop 853 that extends from the reservoir 815
through the pump 812 and into a humidification module 827 in the
PEMFC stack 802. The water leaving the PEMFC stack 802 is then
routed through a heat exchanger 850 before being routed to the
reservoir 815. The heat exchanger 850 removes heat from the water
that may be imparted by the electrochemical processes occurring
within the PEMFC stack 802. The heat exchanger 850 may be cooled by
water supplied from the source 702, or alternatively, the heat
exchanger 850 may be cooled by air, or other gases. Hydrogen from
the fuel storage system 706 is delivered to the PEMFC stack 802 by
a fuel delivery line 842 that is connected to the system 706. The
line 842 further includes a pressure regulator 854 to permit
delivery of the fuel to the PEMFC stack 802 at the proper
pressure.
[0084] Excess hydrogen is removed from the PEMFC stack 802 through
a hydrogen return line 843, and returned to the fuel storage system
706. An oxygen-containing oxidizer stream is delivered to the PEMFC
stack 802 through an oxidizer inlet line 851, with excess oxidizer
being removed from the PEMFC stack 802 through an oxidizer outlet
line 852. Electrodes 831 and 832 permit electrical current produced
by the PEMFC stack 802 to be transferred to an electrical converter
854 capable of converting the DC output of the stack 802 to other
voltages and modes as required by an electrical load 855. The
converter 854 may be comprised of transformers, rectifiers, or
other power conditioning apparatus as required to couple the
apparatus 70 to the electrical load 855. The electrical load 855
may be comprised of an electrical drive motor to provide motive
power to a regenerative fuel cell vehicle (RFCV). Alternatively,
the load 855 may be an electrical utility grid, an electrical
storage device, such as a plurality of interconnected storage
batteries, or other remote electrical power consumers.
[0085] The combination of a CDI stack with a PEME stack and a PEMFC
stack into an integrated system for use in an integrated power
generation apparatus advantageously allows energy requirements for
water deionization to be reduced by using electrical rather than
chemical methods, such as ion-exchange methods. Additionally, the
requirement for a unidirectional ion-exchange bed is eliminated by
replacing them with a bi-directional CDI stack, which occupies the
same space for deionization and regeneration functions, and thus
allows power generation systems to be more compact than systems
having competing deionization methods. Further, since the
regeneration process uses electrical means for regeneration, the
chemicals typically used in the regeneration of ion exchange beds
is eliminated. Therefore, the generation of secondary waste streams
produced during the regeneration of ion-exchange beds is also
eliminated. The CDI stack structure may also be easily integrated
into a PEME stack, since the structure of the CDI, PEME and PEMFC
stacks are similar. This similarity in structure may afford certain
cost savings to manufacturers.
[0086] The ability to supply electrical power, deionized water, and
to generate and store fuel may be very important in remote
locations, in isolated environments, or in space applications. In
mobile applications, for example, the combination of PEME and PEMFC
stacks with a CDI stack advantageously permits maintenance costs
and vehicular downtime to be reduced by removing the requirement
for periodic replacement of water deionization media. Further,
unlike conventional deionization methods, which offer different
levels of deionization performance at the beginning and end of
their maintenance periods, CDI stacks provide the same level of
performance over the lifetime of the vehicle. This is possible
because the CDI stacks can be regenerated to their initial
performance level without removal or replacement of the working
electrosorptive materials and components. Because CDI stacks may be
designed to consist of substantially open structures, the pressure
drop across a CDI stack is significantly smaller that the pressure
drop required for recirculation of a fluid through a bed of finely
divided, porous media. In a vehicle, such reduction is important
because parasitic loads such as pumps, fans, lights, and
compressors have a significant impact on overall vehicular
efficiency. In a fuel cell bus, for example, the parasitic load due
to the oxidizer compression system can be up to 20% of the total
power output from the PEMFC stack. Reducing the parasitic loads
means that more power can be devoted to vehicle propulsion or,
alternatively, that smaller vehicular power plants can be used.
[0087] FIG. 8 is a schematic diagram of an integrated power
generation apparatus 80 according to another embodiment of the
invention. The apparatus 80 is comprised of a URFC stack 901 that
functionally combines the PEME stack 801 and PEMFC stack 802
disclosed in the previous embodiment. The internal details and
operation of a URFC have been previously described. Thus, for the
sake of brevity, the URFC will not be described again. The URFC
stack 901 is further comprised of an active region 904 that may be
used to decompose water into hydrogen and water by electrolysis,
and also may be used to produce electricity by operating as a fuel
cell. Accordingly the apparatus 80 may be operated in a fuel
generation mode and a power generation mode. The active region 904
is positioned between an internal humidification module 902 to
condition the reactants entering the active region 904 when the
apparatus is operating in the power generation mode, and a CDI
stack 903 that delivers deionized water to the active region 904
when the apparatus is operating in the fuel generation mode.
[0088] With the apparatus 80 operating in the fuel generation mode,
water is delivered to the CDI stack 903 from an input source 702,
and is progressively deionized as it passes through the stack 903.
Once the water stream has reached a predetermined purity level, it
is delivered to the URFC stack 901. In order to decompose the
deionized water into hydrogen and oxygen, electrical current must
be applied to the URFC stack 901. The apparatus 80 therefore
receives electrical current from an external source 704. Since the
electrical current received from the external source 704 may not be
compatible with the electrical requirements of the URFC stack 901,
a power converter 910 is interposed between the source 704 and the
apparatus 80 to ensure electrical compatibility.
[0089] When operating in the fuel generation mode, two-phase
mixtures of hydrogen and water 805, and oxygen and water 806 are
generated by electrolysis in the stack 901, which are collected and
flow out of the URFC stack 901 through heat exchangers 813 and 814.
Check valves 807 and 808 receive the mixtures 805 and 806 from the
heat exchangers 813 and 814 to prevent the two-phase mixtures 805
and 806 from returning to the URFC stack 901. A water-hydrogen
phase separator 809, and a water-oxygen phase separator 810
separate the liquid and gaseous components in the two-phase
mixtures 805 and 806. The deionized water collected at the
water-oxygen phase separator 810 and the water-hydrogen phase
separator 809 may be deposited in a water level controller
reservoir 815 and stored for further use. A floating level sensor
816 may monitor the water level in the reservoir 815. Additionally,
a heat exchanger 844 may be used to remove residual water vapor in
the gas leaving the water-oxygen phase separator 810, and a similar
heat exchanger 845 may be used to remove residual water vapor in
the gas leaving the water-hydrogen phase separator 809.
[0090] The oxygen generated by the URFC stack 901 may be vented
through a leak valve 817 located in line 841, or accumulated in a
storage system (not shown) that may include a compressor that
receives the oxygen from the URFC stack 901 and transfers the
compressed oxygen to a plurality of storage vessels. The apparatus
80 may transfer the hydrogen fuel generated in the URFC stack 901
to a fuel storage system 706 through a fuel storage line 840. As
the total internal pressure within the fuel storage system 706
increases, a pressure sensor 818 in the line 840 may be used to
provide a signal to a control system (not shown) to indicate that
the maximum gas storage pressure within the system 706 has been
achieved. The control system may then interrupt the processes
within the URFC stack 901 by disconnecting the DC power supplied by
the converter 910 from the URFC stack 901. Once the fuel generation
is completed, the URFC stack 901 may be depressurized by closing a
valve 820 on the hydrogen supply line 840, and venting a small
amount of hydrogen fuel though a regulated leak valve 821 connected
to a hydrogen vent line 822. After each fuel generation, a sensor
824 may be used to determine the saturation level of the
electrosorptive media in the electrodes within the CDI stack 903 to
determine if regeneration is required.
[0091] In the power generation mode of operation of the apparatus
80, a recirculating water loop 853 extends from the reservoir 815
through a pump 812 and into a humidification module 902 in the URFC
stack 901 to provide deionized water to the module 902 for
humidification of the reactants. Excess water leaving the URFC
stack 901 may be routed through a heat exchanger 850 before being
returned to the reservoir 815. Hydrogen from the fuel storage
system 706 is delivered to the URFC stack 901 by a fuel delivery
line 842 that is connected to the system 706. The line 842 further
includes a pressure regulator 854 to permit delivery of the fuel to
the URFC stack 901 at the proper pressure.
[0092] Excess hydrogen may be removed from the URFC stack 901
through a hydrogen return line 843, and returned to the fuel
storage system 706. An oxygen-containing oxidizer stream is
delivered to the URFC stack 901 through an oxidizer inlet line 851,
with excess oxidizer being removed from the URFC stack 901 through
an oxidizer outlet line 852. Electrodes 911 and 912 permit
electrical current produced by the URFC stack 901 to be transferred
to the electrical converter 910 to convert the DC output of the
stack 901 to other voltages and modes as required by an electrical
load 855.
[0093] The combination of a CDI stack with a URFC stack in the
apparatus 80 allows an integrated power generation apparatus to be
formed that has fewer discrete components than the apparatus 70 as
shown in FIG. 7, since the functionality of the PEME stack and the
PEMFC stack have been combined in the URFC stack. Accordingly, the
present embodiment may have inherently less weight while
maintaining a power output that is comparable to the apparatus
70.
[0094] FIG. 9 is a partial, cross sectional view of an integrated
CDI apparatus 90 for water deionization and reactant conditioning
that may be utilized in the apparatus 70 of FIG. 7, and the
apparatus 80 of FIG. 8, according to one embodiment of the
invention. A plurality of plates 1002 having a plurality of
undulating (in cross section) and repetitively spaced channels 1015
each having an open side are positioned between a pair of fluid
impermeable sidewalls 1001. The plates 1002 are comprised of an
electrically conductive and fluid impermeable material, such as a
non-ferrous metal or metal alloy. The channels 1015 may be formed
by pressing, rolling, casting or machining the channels into the
plate 1002. Further, the channels 1015 may have different
cross-sectional areas, and may have either equal or unequal aspect
ratios. The channels 1015 may further vary in cross-sectional area
along the length of the channels 1015. The plates 1002 are arranged
within the apparatus 90 in repetitive groups 1016 that consist of a
pair of plates 1002 that have alternating pairs of channels 1015 in
each of the plates 1002 with the open sides substantially in
apposition, with the adjacent pair of channels 1015 having open
sides in opposition. Each of the groups 1016 further has a
centrally positioned membrane 1004 that is comprised of a suitable
water permeable and non-conductive material. Each respective group
1016 is separated from the other adjoining groups 1016 by a pair of
water impermeable and electrically non-conductive membranes 1003. A
power supply 1011 provides DC current to each of the groups 1016
through a bus 1014 that is coupled to one polarity of the supply
1011, and a bus 1015 that is coupled to the opposite polarity.
Although the groups 1016 are shown with a parallel electrical
interconnection to the supply 1011, a series electrical
interconnection may also be used. The power supply 1011 receives
electrical current from an electrical source 704. Each group 1016
is further comprised of a switch 1013 that permits the plates 1002
in the group to be electrically coupled when the switch 1013 is
moved to the closed position.
[0095] Still referring to FIG. 9, within each respective group
1016, the channels 1015 that have open sides in opposition have an
electrosorptive layer 1009 deposited on the walls of the channels
1015. The electrosorptive layer 1009 may be formed from the carbon
aerogel composite material described earlier, which is applied to
the walls of the channels 1015 by a conductive epoxy material.
Water is delivered to the channels 1015 that are lined with the
electrosorptive layer 1009 by manifolds (not shown) that are
coupled to each end of the apparatus 90 that direct water flow
through the channels 1015 in a direction normal to FIG. 9. However,
the channels 1015 may be arranged to follow a straight flow path, a
parallel flow path, a serpentine path, or any other pattern
suitable for the particular application. With current from the
power supply 1011 applied to the apparatus 90, and water traversing
the length of the channels 1015, the electrosorptive layers 1009 in
the channels 1015 attracts the charged ions to the layers 1009
disposed on the walls of the channels 1015, thus deionizing the
water passing through the channels 1015. When the layers 1009
approach an absorptive capacity, regeneration of the layers 1009
within the channels 1015 is achieved by decoupling the power supply
1011 from each group 1016, closing the switches 1013, and
circulating a flow of water in the apparatus 90 to flush the ions
from apparatus 20.
[0096] The conditioning of the gas reactants within the apparatus
90 is accomplished by directing the deionized water generated
within the apparatus 90 through one side of the apposed channels
1015 and directing the gas reactants through the other apposed
side. Since the fluid permeable membrane 1004 separates the
deionized water and the gas reactants, the deionized water may
migrate across the membrane 1004 to progressively humidify the gas
reactants as they flow through the apparatus 100. The flow pattern
for the gas reactants in the apparatus 90 may require redirection
within the apparatus 90 in a serpentine flow pattern to increase
the residence time of the reactants within the apparatus 90.
[0097] FIG. 10 is a partial, cross sectional view of an integrated
CDI apparatus 100 for water deionization and reactant conditioning
that may be used in the apparatus 70 as shown in FIG. 7, and in the
apparatus 80, as shown in FIG. 8, according to another embodiment
of the invention. A plurality of plates 1102 having a plurality of
undulating (in cross section) and repetitively spaced channels 1015
each having an open side and positioned between a pair of fluid
impermeable sidewalls 1001. The plates 1102 are comprised of an
electrically insulative and fluid impermeable material, such as a
thermoplastic or thermosetting resin, or other polymers. The
channels 1015 may be formed by casting, thermoforming, or machining
the channels into the plate 1102. The plates 1102 are arranged
within the apparatus 100 in repetitive groups 1116 that consist of
a pair of plates 1102 that have alternating pairs of channels 1015
in each of the plates 1102 having open sides substantially in
apposition, with the adjacent pair of channels 1015 having the open
sides in opposition. Each of the groups 1116 further has a
centrally positioned membrane 1104 that is comprised of a suitable
water permeable and nonconductive material. Each respective group
1016 is separated from the other adjoining groups 1016 by a pair of
water impermeable and electrosorptive layers 1105. The
electrosorptive layers 1105 may be comprised of a carbon aerogel
composite, although other alternatives exist. A planar electrode
1103 is interposed between each group 1016, so that each of the
planar electrodes 1103 electrically contacts the electrosorptive
layers 1105. A power supply 1011 provides DC current to each of the
groups 1016 through a bus 1014 that is coupled to one polarity of
the supply 1011, and a bus 1015 that is coupled to the opposite
polarity. Although the groups 1016 are shown with a parallel
electrical interconnection to the supply 1011, a series electrical
interconnection may also be used. The power supply 1011 receives
electrical current from an electrical source 704. Each group 1016
is further comprised of a switch 1013 that permits the plates 1102
in the group to be electrically coupled when the switch 1013 is
moved to the closed position.
[0098] In the apparatus 100, water is delivered to the channels
1015 that are in facial contact with the electrosorptive layers
1105 by manifolds (not shown) that are coupled to each end of the
apparatus 100 that direct water flow through the channels 1015 in a
direction normal to FIG. 10. The channels 1015 may be arranged to
follow a straight flow path, a parallel flow path, a serpentine
path, or any other pattern suitable for the particular application.
With current from the power supply 1011 applied to the apparatus
100, and water traversing the length of the channels 1015, the
portion of the electrosorptive layers 1105 that are exposed to the
water flowing in the channels 1015 attracts the charged ions from
the water to the layers 1105, thus deionizing the water passing
through the channels 1015. When the portions of the layers 1105
exposed to the water flow approach an absorptive capacity,
regeneration of the layers 1105 is achieved by decoupling the power
supply 1011 from each group 1016, closing the switches 1013, and
circulating a flow of water in the apparatus 100 to flush the ions
from apparatus 20.
[0099] The conditioning of the gas reactants within the apparatus
100 is accomplished by directing the deionized water generated
within the apparatus 100 through one side of the apposed channels
1015 and directing the gas reactants through the other apposed
side. Since the fluid permeable membrane 1104 separates the
deionized water and the gas reactants, the deionized water may
migrate across the membrane 1104 to progressively humidify the gas
reactants as they flow through the apparatus 100. The flow pattern
for the gas reactants in the apparatus 100 may require redirection
within the apparatus 100 in a serpentine flow pattern to increase
the residence time of the reactants within the apparatus 100.
[0100] The CDI apparatus 90 of FIG. 9 and the CDI apparatus of FIG.
10 combine the functionality of a CDI module with a humidification
module in a unitary device that may be used to provide deionized
water for fuel production while conditioning the reactant streams
through humidification. The functions thus combined may be
conducted simultaneously, or alternatively, at different times. The
CDI apparatus 90 and 100 thus permit an overall reduction in the
weight of the system by combining the CDI module and the
humidification module in a single unit.
[0101] FIG. 11 is a schematic diagram of an integrated power
generation apparatus 110 according to still another embodiment of
the invention. The apparatus 110 is comprised of a URFC stack 901
as disclosed in the embodiment described in connection with FIG. 8.
The internal details and operation of a URFC have been previously
described, and thus, for the sake of brevity, will not again be
described in detail. The URFC stack 901 is further comprised of an
active region 904 that may be used to decompose water into hydrogen
and water by electrolysis, and also may used to produce electricity
by operating as a fuel cell, as previously described. The active
region 904 is positioned adjacent to an integrated CDI assembly
1200 as disclosed in the embodiments described in connection with
FIGS. 9 and 10. The module 1200 may therefore generate deionized
water from a water source 702 for the electrolytic generation of
hydrogen and oxygen in the stack active region 904 when operating
in the fuel generation mode, and condition the reactants entering
the active region 904 by humidification of the reactants during the
power generation mode.
[0102] With the apparatus 110 operating in the fuel generation
mode, water is delivered to the integrated CDI assembly 1200 from
an input source 702, and is progressively deionized as it passes
through the assembly 1200. Once the water stream has reached a
predetermined purity level, it is delivered to the URFC stack 901.
Electrical current is applied to the URFC stack 901 from an
external source 704. Since the electrical current received from the
external source 704 may not be compatible with the electrical
requirements of the URFC stack 901, a power converter 910 is
interposed between the source 704 and the apparatus 110 to ensure
electrical compatibility.
[0103] With the apparatus 110 still operating in the fuel
generation mode, two-phase mixtures of hydrogen and water 805, and
oxygen and water 806 are generated by electrolysis in the stack
901, which are collected and flow out of the URFC stack 901 through
heat exchangers 813 and 814. Check valves 807 and 808 receive the
mixtures 805 and 806 from the beat exchangers 813 and 814 to
prevent the two-phase mixtures 805 and 806 from returning to the
URFC stack 901. A water-hydrogen phase separator 809, and a
water-oxygen phase separator 810 separate the liquid and gaseous
components in the two-phase mixtures 805 and 806. The deionized
water collected at the water-oxygen phase separator 810 and the
water-hydrogen phase separator 809 may be deposited in a water
level controller reservoir 815 and stored. A floating level sensor
816 may monitor the water level in the reservoir 815. Additionally,
a heat exchanger 844 may be used to remove residual water vapor in
the gas leaving the water-oxygen phase separator 810, and a similar
heat exchanger 845 may be used to remove residual water vapor in
the gas leaving the water-hydrogen phase separator 809.
[0104] The oxygen generated by the URFC stack 901 may be vented to
the atmosphere through a leak valve 817 located in line 841, or
accumulated in a storage system (not shown) that may include a
compressor that receives the oxygen from the URFC stack 901 and
transfers the compressed oxygen to a plurality of storage vessels.
The apparatus 110 may further transfer the hydrogen fuel generated
in the URFC stack 901 to a fuel storage system 706 through a fuel
storage line 840. Once the fuel generation is completed, the URFC
stack 901 may be depressurized by closing a valve 820 on the
hydrogen supply line 840, and venting a small amount of hydrogen
fuel though a regulated leak valve 821 connected to a hydrogen vent
line 822.
[0105] Turning now to the power generation mode, a recirculating
water loop 853 extends from the reservoir 815 through a pump 812
and into the integrated CDI assembly 1200 to provide deionized
water to the assembly 1200 for humidification of the reactants.
Excess water leaving the assembly 1200 may be routed through a heat
exchanger 850 before being returned to the reservoir 815. Hydrogen
from the fuel storage system 706 is delivered to the assembly 1200
by a fuel delivery line 842 that is connected to the system 706.
The line 842 further includes a pressure regulator 854 to permit
delivery of the fuel to the URFC stack 901 at the proper
pressure.
[0106] Excess hydrogen may be removed from the assembly 1200
through a hydrogen return line 843, and returned to the fuel
storage system 706. An oxygen-containing oxidizer stream is
delivered to the assembly 1200 through an oxidizer inlet line 851,
with excess oxidizer being removed from the assembly 1200 through
an oxidizer outlet line 852. Electrodes 911 and 912 permit
electrical current produced by the URFC stack 901 to be transferred
to the electrical converter 910 to convert the DC output of the
stack 901 to other voltages and modes as required by an electrical
load 855.
[0107] The combination of a URFC stack with the integrated water
deionizer and reactant humidification module additionally allows an
integrated power generation apparatus to be formed that has still
fewer discrete components, since the functionality of the
conditioning module has been combined in the CDI stack.
Accordingly, the present embodiment may have inherently less weight
and provide enhanced cooling to the URFC stack.
[0108] FIG. 12 is a partial cutaway, schematic diagram of an
integrated power generation apparatus 120 according to still
another embodiment of the invention. A URFC stack 1210 is comprised
of a plurality of electrically and fluidly interconnected modules
1220 that are positioned within an interior portion of the URFC
stack 1210. The modules 1220 are structured to combine the
functionality of a URFC stack with an integrated CDI module, as
previously described in connection with FIGS. 9 and 10.
Accordingly, each module 1220 may produce deionized water,
condition the reactants within the stack and produce fuel by
electrolysis in a fuel generation mode, and produce electricity in
a power generation mode.
[0109] With the apparatus 120 operating in the fuel generation
mode, water is delivered to the URFC stack 1210 from an input
source 702, and is progressively deionized as it passes through the
stack 1210. Electrical current is applied to the URFC stack 1210
from an external source 704. Since the electrical current received
from the external source 704 may not be compatible with the
electrical requirements of the URFC stack 1210, a power converter
910 is interposed between the source 704 and the apparatus 120 to
ensure electrical compatibility.
[0110] With the apparatus 120 still operating in the fuel
generation mode, two-phase mixtures of hydrogen and water 805, and
oxygen and water 806 are generated by electrolysis in the stack
901, which are collected and flow out of the URFC stack 1210
through heat exchangers 813 and 814. Check valves 807 and 808
receive the mixtures 805 and 806 from the heat exchangers 813 and
814 to prevent the two-phase mixtures 805 and 806 from returning to
the URFC stack 1210. A water-hydrogen phase separator 809, and a
water-oxygen phase separator 810 separate the liquid and gaseous
components in the two-phase mixtures 805 and 806. The deionized
water collected at the water-oxygen phase separator 810 and the
water-hydrogen phase separator 809 may be deposited in a water
level controller reservoir 815 and stored. A floating level sensor
816 may monitor the water level in the reservoir 815. Additionally,
a heat exchanger 844 may be used to remove residual water vapor in
the gas leaving the water-oxygen phase separator 810, and a similar
heat exchanger 845 may be used to remove residual water vapor in
the gas leaving the water-hydrogen phase separator 809.
[0111] The oxygen generated by the URFC stack 1210 may be vented to
the atmosphere through a leak valve 817 located in line 841, or
accumulated in a storage system (not shown) that may include a
compressor that receives the oxygen from the URFC stack 1210 and
transfers the compressed oxygen to a plurality of storage vessels.
The apparatus 120 may further transfer the hydrogen fuel generated
in the URFC stack 1210 to a fuel storage system 706 through a fuel
storage line 840. Once the fuel generation is completed, the URFC
stack 1210 may be depressurized by closing a valve 820 on the
hydrogen supply line 840, and venting a small amount of hydrogen
fuel though a regulated leak valve 821 connected to a hydrogen vent
line 822.
[0112] Turning now to the power generation mode, a recirculating
water loop 853 extends from the reservoir 815 through a pump 812
and into the stack 1210 to provide deionized water to the stack
1210 for humidification of the reactants. Excess water leaving the
stack 1210 may be routed through a heat exchanger 850 before being
returned to the reservoir 815. Hydrogen from the fuel storage
system 706 is delivered to the stack 1210 by a fuel delivery line
842 that is connected to the system 706. The line 842 further
includes a pressure regulator 854 to permit delivery of the fuel to
the URFC stack 1210 at the proper pressure.
[0113] Excess hydrogen may be removed from the assembly 1200
through a hydrogen return line 843, and returned to the fuel
storage system 706. An oxygen-containing oxidizer stream is
delivered to the URFC stack 1210 through an oxidizer inlet line
851, with excess oxidizer being removed from the stack 1210 through
an oxidizer outlet line 852. Electrodes 911 and 912 permit
electrical current to be transferred to a converter 910 so that
electrical current produced by the stack 1210 may be transferred to
a load 855. The electrodes 911 and 912 also receive electrical
current from a source 704 through the converter 910 for the
production of fuel by electrolysis.
[0114] Turning to FIG. 13, a cross sectional, schematic view of the
module 1220 is shown to describe the structural details of the
module 1220 in greater detail. A polymer membrane electrode 1320 in
interposed between electrode layers 1318 and 1322. Electrocatalyst
layers 1326 and 1328 are disposed on the electrode layers 1318 and
1322, and are substantially in facial contact with the polymer
membrane electrode 1320. The membrane electrode 1320, the electrode
layers 1318, and the electrocatalyst layers 1326 and 1328 thus form
a membrane electrode assembly (MEA) 1324 of a URFC cell. Flow field
plates 1308 comprised of a fluid impermeable material are
positioned on either side of the MEA 1324 and have a plurality of
fluid channels 1306 disposed therein. The channels 1306 project
through the flow field plates 1308 to define fluid surfaces 1307
and 1309 through which fluids may migrate. Water permeable
membranes 1312 are positioned on the flow field plates 1308, with
the membranes 1312 substantially overlapping the fluid surfaces
1309. A flow channel plate 1314 that is comprised of a water
impermeable material substantially abuts the membranes 1312. The
plates 1314 include a plurality of undulating corrugations that are
spaced apart so that when the plates 1314 is positioned on the
membranes 1312, the channels 1304 are defined, which will be in
substantial alignment with the channels 1306 of the flow field
plates 1308. An outer layer 1302 comprised of an electrosorptive
material, such as a carbon aerogel composite abuts the flow channel
plates 1314 and further defines flow channels 1308. Planar
electrodes 1300 substantially abut both outer layers.
[0115] Referring now to FIGS. 12 and 13, the operation of the
module 1220 will now be described. Water is received by the module
1220 from a water source 702. The water is routed through each of
the channels 1308, and is exposed to the outer layer 1302 that is
comprised of the electrosorptive material. When the plate
electrodes 1300 are electrically coupled to the power supply 910,
ions present in the water that is routed through the channels 1308
is progressively deionized. A suitable flow manifold (not shown)
routes water through the channels 1308, and also routes the
deionized water produced in the channels 1308 to the channels 1304
formed in the channel plates 1314. The deionized water in channels
1304 migrates across the membrane 1312 to humidify and further
condition the reactant gases that are routed through the channels
1306. The reactants thus conditioned may then migrate through the
MEA 1324, as previously described, to produce fuel when the module
1220 is operated in the fuel generation mode, or to produce
electricity when the module is operated in the power generation
mode.
[0116] Although planar electrodes are employed in the present
embodiment, other electrode configurations are possible, and within
the scope of the invention. For example, a conductive channel
plate, as described in connection with the embodiment disclosed in
FIG. 9 may also be used.
[0117] The apparatus 120 including the module 1220 allows the
previously described integrated CDI apparatus to be integrated into
a URFC device, thus allowing still further weight reductions.
Further, the combination of the integrated CDI with the URFC stack
provides for better thermal management of the stack since the
untreated and deionized water streams are available to transport
heat away from the interior portions of the stack.
[0118] The above description of illustrated embodiments of the
invention is not intended to be exhaustive or to limit the
invention to the precise form disclosed. While specific embodiments
of, and examples of, the invention are described in the foregoing
for illustrative purposes, various equivalent modifications are
possible within the scope of the invention, as those skilled in the
relevant art will recognize. For example, the disclosed
embodiments, or modifications thereof, may be used in mobile
applications, such as in a fuel cell powered vehicle, or in
stationary applications, such as a stationary power plant.
Additionally, the disclosed embodiments, or modifications thereof,
may be used in mobile applications where an individual person must
carry the embodiment. Moreover, the various embodiments described
above can be combined to provide further embodiments. Accordingly,
the invention is to be determined entirely by the following
claims.
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