U.S. patent application number 11/891005 was filed with the patent office on 2007-11-29 for fuel cell thermal management system.
Invention is credited to Eric T. White.
Application Number | 20070275281 11/891005 |
Document ID | / |
Family ID | 26950903 |
Filed Date | 2007-11-29 |
United States Patent
Application |
20070275281 |
Kind Code |
A1 |
White; Eric T. |
November 29, 2007 |
Fuel cell thermal management system
Abstract
The invention provides fuel cell systems and methods of
operation where a fuel cell system is used as a backup power supply
in a cold environment where the system must be maintained at a
suitable temperature to allow the fuel cell to operate when needed.
In one embodiment, the invention provides a thermal protection
system for a fuel cell backup power generator. An enclosure houses
a fuel cell and a coolant circuit. The coolant circuit is coupled
to the fuel cell. A temperature sensor is provided that is adapted
to indicate a system temperature. A heater is provided to increase
the system temperature when actuated. For example, the heater can
be an electric resistive heater or a burner coupled to a
combustible fuel supply such as a propane tank. The heater can be
located in the interior of the enclosure, in the coolant circuit,
etc. A control circuit is provided that is adapted to actuate the
heater when the system temperature is below a predetermined
threshold.
Inventors: |
White; Eric T.; (Altamont,
NY) |
Correspondence
Address: |
TROP PRUNER & HU, PC
1616 S. VOSS ROAD, SUITE 750
HOUSTON
TX
77057-2631
US
|
Family ID: |
26950903 |
Appl. No.: |
11/891005 |
Filed: |
August 8, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10265025 |
Oct 4, 2002 |
7264895 |
|
|
11891005 |
Aug 8, 2007 |
|
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60336447 |
Oct 31, 2001 |
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Current U.S.
Class: |
429/430 ;
429/437; 429/442; 429/901 |
Current CPC
Class: |
H01M 8/04947 20130101;
H01M 2220/10 20130101; Y02B 90/10 20130101; H01M 8/04014 20130101;
Y02E 60/50 20130101; H01M 8/04037 20130101; Y02E 60/10 20130101;
H01M 8/04365 20130101; H01M 8/04731 20130101; H01M 2008/1095
20130101; H01M 8/04358 20130101 |
Class at
Publication: |
429/024 ;
429/013; 429/026 |
International
Class: |
H01M 8/04 20060101
H01M008/04 |
Claims
1. A method of regulating the temperature of a dormant fuel cell
backup power supply, comprising: coupling a fuel cell system to a
load and a primary power supply, wherein the fuel cell system is
adapted to supply power to the load upon a failure of the primary
power supply; measuring a temperature of the fuel cell system to
generate a temperature signal; communicating the temperature signal
to a control circuit; determining whether the temperature is below
a predetermined threshold; and actuating a heater when the
temperature is below the predetermined threshold.
2. The method of claim 1, further comprising: actuating a pump to
circulate a heat transfer fluid through the fuel cell system when
the temperature is below the predetermined threshold.
3. The method of claim 1, wherein a temperature sensor located in
an atmosphere of the fuel cell system is used to generate the
temperature signal.
4. The method of claim 1, wherein a temperature sensor located in a
coolant circuit of the fuel cell system is used to generate the
temperature signal.
5. The method of claim 1, wherein the predetermined threshold is in
the range of 0 to 15.degree. C.
6. The method of claim 1, wherein the heater is located in an
atmosphere of the fuel cell system.
7. The method of claim 1, wherein the heater is an electric
resistive heater powered by the primary power supply.
8. The method of claim 1, wherein the heater is a burner coupled to
a combustible fuel supply.
9. The method of claim 1, wherein the heater is a flow of heat
transfer fluid circulated from a source external to the backup
power supply.
10. The method of claim 1, wherein the source is a hot water tank
in a building.
11. A method of regulating the temperature of a dormant fuel cell
backup power supply, comprising: coupling a fuel cell system to a
load and a primary power supply, wherein the fuel cell system is
adapted to supply power to the load upon a failure of the primary
power supply; measuring a temperature of the fuel cell system to
generate a temperature signal; communicating the temperature signal
to a control circuit; determining whether the temperature is below
a predetermined threshold; and flowing a heat transfer fluid
through a portion of the system to raise the temperature when the
temperature is below the predetermined threshold, wherein the
backup power supply is located outside a building, wherein the heat
transfer fluid is circulated between the building and the backup
power supply.
Description
[0001] This application is a divisional of U.S. patent application
Ser. No. 10/265,025, entitled "FUEL CELL THERMAL MANAGEMENT," which
was filed on Oct. 4, 2002, and claims priority under 35 USC 119(e)
to U.S. Provisional Application No. 60/336,447, entitled, "FUEL
CELL THERMAL MANAGEMENT SYSTEM," which was filed on Oct. 31, 2001,
application Ser. Nos. 10/265,025 and 60/336,447 are each hereby
incorporated by reference in its entirety.
BACKGROUND
[0002] The invention relates to systems and associated method of
operation relating to thermally protected fuel cell backup power
supplies.
[0003] A fuel cell is an electrochemical device that converts
chemical energy produced by a reaction directly into electrical
energy. For example, one type of fuel cell includes a polymer
electrolyte membrane (PEM), often called a proton exchange
membrane, that permits only protons to pass between an anode and a
cathode of the fuel cell. At the anode, diatomic hydrogen (a fuel)
is reacted to produce protons that pass through the PEM. The
electrons produced by this reaction travel through circuitry that
is external to the fuel cell to form an electrical current. At the
cathode, oxygen is reduced and reacts with the protons to form
water. The anodic and cathodic reactions are described by the
following equations: H.sub.2.fwdarw.2H.sup.++2e.sup.- at the anode
of the cell, and O.sub.2+4H.sup.++4e.sup.-.fwdarw.2H.sub.2O at the
cathode of the cell.
[0004] A typical fuel cell has a terminal voltage of up to about
one volt DC. For purposes of producing much larger voltages,
multiple fuel cells may be assembled together to form an
arrangement called a fuel cell stack, an arrangement in which the
fuel cells are electrically coupled together in series to form a
larger DC voltage (a voltage near 100 volts DC, for example) and to
provide more power.
[0005] The fuel cell stack may include flow field plates (graphite
composite or metal plates, as examples) that are stacked one on top
of the other. The plates may include various surface flow field
channels and orifices to, as examples, route the reactants and
products through the fuel cell stack. A PEM is sandwiched between
each anode and cathode flow field plate. Electrically conductive
gas diffusion layers (GDLs) may be located on each side of each PEM
to act as a gas diffusion media and in some cases to provide a
support for the fuel cell catalysts. In this manner, reactant gases
from each side of the PEM may pass along the flow field channels
and diffuse through the GDLs to reach the PEM. The PEM and its
adjacent pair of catalyst layers are often referred to as a
membrane electrode assembly (MEA). An MEA sandwiched by adjacent
GDL layers is often referred to as a membrane electrode unit
(MEU).
[0006] Suitable fuel cell components are well known in the art. As
examples, common membrane materials include Nafion.TM., Gore
Select.TM., sulphonated fluorocarbon polymers, and other materials
such as polybenzimidazole and polyether ether ketone. Various
suitable catalyst formulations are also known in the art, and are
generally platinum-based. The GDL's generally comprise either a
paper or cloth based on carbon fibers. The flow field plates are
generally molded, stamped or machined from materials including
carbon composites, plastics and metal alloys. The plates may
include various surface flow channels and orifices to, as examples,
route the reactants and products through the fuel cell stack.
Reactant gases from each side of the PEM may pass along the flow
channels and diffuse through the GDLs to reach the PEM.
[0007] Some fuel cell systems may be characterized as "dead
headed". Operation of a dead headed hydrogen fuel cell has
typically occurred as follows: Hydrogen is input to the stack at
the anode inlet. The anode outlet is dead-ended with a purge valve.
During operation, hydrogen enters the anode side of the fuel cell,
passes through the membrane as load is applied, and reacts with
oxygen on the cathode side, forming water. Some amount of water may
back diffuse from the cathode side to the anode side. Nitrogen may
also diffuse to the anode side. Factors such as the increased
amount of nitrogen and water diffusion eventually cause cell
performance to drop, and when this occurs a purge valve is
triggered to open and close.
[0008] A fuel cell system may include a fuel processor that
converts a hydrocarbon (natural gas or propane, as examples) into a
fuel flow for the fuel cell stack. For a given output power of the
fuel cell stack, the fuel flow to the stack must satisfy the
appropriate stoichiometric ratios governed by the equations listed
above. Thus, a controller of the fuel cell system may monitor the
output power of the stack and based on the monitored output power,
estimate the fuel flow to satisfy the appropriate stoichiometric
ratios. In this manner, the controller regulates the fuel processor
to produce this flow, and in response to the controller detecting a
change in the output power, the controller estimates a new rate of
fuel flow and controls the fuel processor accordingly. One "stoich"
of fuel flow is defined as the amount theoretically needed to
satisfy a given load on the fuel cell, assuming all of the reactant
is reacted in the fuel cell.
[0009] The fuel cell system may provide power to a load, such as a
load that is formed from residential appliances and electrical
devices that may be selectively turned on and off, causing the
power that is demanded by the load to vary. Thus, the load may not
be constant, but rather the power that is consumed by the load may
vary over time and abruptly change in steps. For example, if the
fuel cell system provides power to a house, different
appliances/electrical devices of the house may be turned on and off
at different times to cause the load to vary in a stepwise fashion
over time. Fuel cell systems adapted to accommodate variable loads
are sometimes referred to as "load following" systems.
[0010] Fuel cells generally operate at temperatures much higher
than ambient (e.g., 50-80.degree. C. or 120-180.degree. C.), and
the fuel and air streams circulated through the fuel cells
typically include water vapor. For example, reactants associated
with sulphonated fluorocarbon polymer membranes must generally be
humidified to ensure the membranes remain moist during operation.
In such a system, water may condense out of a process stream where
the stream is cooled below its dew point. For example, if the anode
and cathode exhaust streams are saturated with water vapor at the
stack operating temperature, water will tend to condense from these
streams as they cool after leaving the stack. Similarly, the
humidity and temperature conditions of other process streams may
also produce condensation. It may be desirable to remove condensate
from a process stream in a fuel cell system process stream. As
examples, such condensate can interfere with the flow of process
streams, can potentially build to levels that can flood portions of
the system, and can also cause problems if allowed to freeze (e.g.,
in an outdoor unit that is not in service).
[0011] There is a continuing need for fuel cell systems and
associated methods of operating fuel cell systems to achieve new
and approved applications while accommodating design considerations
including the forgoing in a robust, cost-effective manner.
SUMMARY
[0012] The invention provides fuel cell systems and methods of
operation where a fuel cell system is used as a backup power supply
in a cold environment where the system must be maintained at a
suitable temperature to allow the fuel cell to operate when needed.
Such systems are sometimes referred to as thermally protected
systems.
[0013] In one aspect, the invention provides a thermal protection
system for a fuel cell backup power generator. An enclosure houses
a fuel cell and a coolant circuit. The coolant circuit is coupled
to the fuel cell. A temperature sensor is provided that is adapted
to indicate a system temperature. As examples, the system
temperature can refer to the temperature of a component in the
system such as the interior atmosphere of the enclosure, the fuel
cell assembly, etc. A heater is provided to increase the system
temperature when actuated. For example, the heater can be an
electric resistive heater or a burner coupled to a combustible fuel
supply such as a propane tank. As examples, the heater can be
located in the interior of the enclosure, in the coolant circuit,
etc. A control circuit is provided that is adapted to actuate the
heater when the system temperature is below a predetermined
threshold (e.g., 0-15.degree. C.).
[0014] The fuel cell is preferably a PEM fuel cell, though other
types of fuel cells needing thermal protection can also be used.
The coolant is generally a dielectric fluid having a freezing
temperature below the freezing temperature of water. However, water
can also be used (e.g., de-ionized water). In some embodiments, the
primary power supply that the fuel cell system is backing up is
used to power a resistive heater in the system to keep the system
ready for operation. As an example, the primary power supply can be
a utility power grid.
[0015] In some embodiments, the control circuit can be a simple
thermostat, whereas in other embodiments, the controller can
include more sophisticated circuitry such as a programmable circuit
coupled to a network of sensors, PID controllers, etc. Generally, a
portion of the control circuitry used to operate the fuel cell
system is used to operate the thermal protection system of the
present invention while the system is in the dormant state (e.g.,
not supplying current to the electrical load being supplied by the
primary power supply).
[0016] In some embodiments, a pump is also used during the dormant
state to circulate coolant through the system to keep the system at
a suitable temperature to allow the system to operate when needed.
In some cases, the pump can be powered by the primary power
supply.
[0017] In another aspect, a method is provided for regulating the
temperature of a dormant fuel cell backup power supply, including
the following steps: (1) coupling a fuel cell system to a load and
a primary power supply, wherein the fuel cell system is adapted to
supply power to the load upon a failure of the primary power
supply; (2) measuring a temperature of the fuel cell system to
generate a temperature signal; (3) communicating the temperature
signal to a control circuit; (4) determining whether the
temperature is below a predetermined threshold; and (5) actuating a
heater when the temperature is below the predetermined threshold
(e.g., 0 to 15.degree. C.). In some embodiments, an alternate step
(5) may be used that includes flowing a heat transfer fluid through
a portion of the system to raise the temperature when the
temperature is below the predetermined threshold, wherein the
backup power supply is located outside a building, and wherein the
heat transfer fluid is circulated between the building and the
backup power supply. For example, the system can be used to provide
backup power to a building, and hot water from a hot water tank in
the building can be circulated through the system when needed to
keep it warm.
[0018] Some embodiments may further include actuating a pump to
circulate a heat transfer fluid through the fuel cell system when
the temperature is below the predetermined threshold. In some
embodiments, a temperature sensor located in an atmosphere of the
fuel cell system is used to generate the temperature signal. In
other embodiments, a temperature sensor located in a coolant
circuit of the fuel cell system is used to generate the temperature
signal.
[0019] Additional embodiments of the invention can also include any
of the other features or techniques described herein, either alone
or in combination. Advantages and other features of the invention
will become apparent from the following description, drawings and
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic diagram of an embodiment of a system
including a fuel cell.
[0021] FIG. 2 is a schematic diagram of an embodiment of a system
including a fuel cell.
[0022] FIG. 3 is a schematic diagram of an embodiment of a system
including a fuel cell.
[0023] FIG. 4 is a schematic diagram of an embodiment of a system
including a fuel cell.
[0024] FIG. 5 is a flowchart of a logic set for performing one
aspect of the present invention.
DETAILED DESCRIPTION
[0025] A fuel cell system is contemplated which provides backup
power to a load, which has lost its primary power source (i.e. the
grid). In some cases the fuel cell system may be located in remote
locations having widely varying temperatures. Such a back up power
system would require the fuel cell portion of the system to start
up and provide power in a timely manner. In locations which
experience low temperatures at or below freezing, start up time may
be increased due to the time it takes the fuel cell system to "warm
up" or come up to the operating temperature.
[0026] The present invention contemplates a back up power system
having a fuel cell as the power generation source, which utilizes
power from the primary power source (e.g. the grid) to power a
thermal regulation system which maintains the fuel cell system at
an acceptable temperature. As shown in FIG. 1, the primary power
source 10 supplies power to a load 20 via power line 30. Primary
power source 10 may be an electrical power grid or another power
generation device such as a generator and may supply either AC or
DC power to load 20. Power line 40 connects primary power source 10
to thermal regulating system 50 to maintain a desired temperature
with fuel cell system 60. In some cases the primary and/or backup
power source may provide AC power, and the load and/or thermal
regulating system may require DC power. In such cases an AC to DC
converter may be utilized where necessary to provide the required
type of power. Similarly the primary and/or backup power source may
provide DC power where AC power is required, in such cases a DC to
AC power converter may be utilized.
[0027] As shown in FIG. 2 power line 40 energizes controller 70,
which provides available power for thermal system 50 and allows
communication with a master controller (not shown). A sensor 80 is
located within cabinet 90 and monitors the internal temperature of
the cabinet and relays that information to controller 70.
Alternatively sensor 80 may be placed on or in fuel cell system 60
to monitor the temperature of various components and/or fluid
streams. When the temperature falls below a predetermined
threshold, controller 70 sends a signal to thermal system 50
thereby enabling the system to provide heat into the cabinet via
heater 100 or directly to fuel cell system 60 as described herein.
Heater 100 may be a resistive heater located within a coolant
supply loop that circulates throughout cabinet 90. Preferably an
immersion heater is located directly within the coolant line and
provides the heat necessary to raise the temperature level of the
system to the predetermined level. Alternatively, heater 100 may be
an electrical heater located within cabinet 90 adapted to heat the
atmosphere within the cabinet or any type of heater capable of
raising and maintaining the interior temperature of cabinet 90.
[0028] FIG. 3 illustrates an alternate embodiment, whereby
controller 70 activates thermal system 50 when temperature sensor
80 indicates that the temperature of the coolant return has fallen
outside a predetermined threshold. In this embodiment, heated
coolant (such as glycol, Therminol.TM., de-ionized water, or other
commonly used coolants) is circulated from thermal system 50
through fuel cell system 60. Sensor 80 monitors the temperature of
the coolant return and signals controller 70 when the temperature
has exceeded the predetermined limits. Controller 70 shuts off
thermal system 50 when the temperature is warm enough, and starts
up the system when the temperature drops below the limits.
[0029] One embodiment of thermal system 50 is shown in FIG. 4.
Thermal system 50 may comprise a heater 110, a heat exchanger 120,
a radiator 130, and a coolant pump 140. Each of these devices may
have a bypass loop which allows the system to bypass any of these
elements based on sensor (not shown) readings taken during
operation. Heat exchange between thermal system 50 and fuel cell
system 60 may take place using various methods. One embodiment, as
shown in FIG. 4, utilizes a second coolant loop interfacing with
heat exchanger 120 and fuel cell system 60. A coolant pump 150
moves the cooling fluid through the second coolant loop.
Alternatively, a single coolant loop may be used, with the coolant
flowing from heater 110 into fuel cell system 60.
[0030] FIG. 5 depicts a flowchart containing one set of logic
steps, which enables the performance of the thermal management
system described herein. The logic may be contained on controller
70, and embody at least one program storage device readable by a
machine, tangibly embodying at least one program of instructions
executable by the machine to perform a method of managing the
thermal system of a fuel cell system.
[0031] Step 500 comprises obtaining a sensor reading (such as
sensor 80 in FIG. 2), and providing that information to controller
70. In step 510 the controller determines if the temperature below
a predetermined threshold. Examples of such a threshold may be a
low-end temperature of between 3-15 degrees Celsius with a
preferred range of 5-8 degrees and a high-end temperature of 15-20
degrees Celsius. Temperatures within this range will keep the
system above the freezing point, while minimizing the energy draw
from the primary power source. It may also be desired to maintain
the system at operating temperature, which may be in the range of
50-75 degrees Celsius (for a PEM system) to minimize start-up
time.
[0032] If it is determined that the temperature is below the
threshold then the controller turns on the coolant pump(s) and
coolant heater, as shown in step 520. This begins the circulation
of heated coolant throughout the system. If it is determined that
the temperature is not below the predetermined threshold, then the
process begins again at step 500. Once heated coolant begins
circulating the sensor relays new temperature information as shown
in step 530. If it is determined in step 540 that the temperature
is below the high-end threshold than the system continues to
operate (step 550). However if the temperature is above the
high-end threshold then a signal is sent from controller 70 to turn
off the coolant pump(s) and heater (step 560), and the process
begins again from step 500.
[0033] While the invention has been disclosed with respect to a
limited number of embodiments, those skilled in the art, having the
benefit of this disclosure, will appreciate numerous modifications
and variations therefrom. It is intended that the invention covers
all such modifications and variations as fall within the true
spirit and scope of the invention.
* * * * *