Remodeling of a commercial plug-in battery electric vehicle to a hybrid configuration with a PEM fuel cell

In the present research, a commercial battery-powered pure electric vehicle was suitably modified to convert it into a hybrid one integrating a PEMFC stack. The hydrogen supply system to the stack included a passive recirculation system based on a Ventury-type ejector. Besides, in order to achieve an optimum operation of the PEMFC stack, a discrete state machine model was considered in its control system. The inclusion of a rehabilitation operating mode prevented the stack from possible failures, increasing its lifetime. It was verified that for the rated operating point when supplying power to the vehicle (2.5 kW) the hydrogen consumption decreased, and the actual efficiency (47.9%) PEMFC was increased close to 1%. Field tests performed demonstrate that the range of the hybrid electric vehicle was increased by 78% when compared to the one of the original battery electric car. Also, under the tested experimental conditions in hybrid mode, 34% of the total energy demanded by the electric machine of the vehicle was supplied by the PEMFC stack.     

Experimental analysis of dynamic characteristics on the PEM fuel cell stack by using Taguchi approach with neural networks

This study determines the optimum operating parameters for a proton exchange membrane fuel cell (PEMFC) stack to obtain small variation and maximum electric power output using a robust parameter design (RPD). The operating parameters examined experimentally are operating temperatures, operating pressures, anode/cathode humidification temperatures, and reactant flow rates. First, the dynamic Taguchi method is used to obtain the maximum and stable power density against the different current densities, which are regarded as the systemic inputs considered a signal factor. The relationship between control factors and responses in the PEMFC stack is determined using a neural network. The discrete parameter levels in the dynamic Taguchi method can be divided into desired levels to acquire real optimum operating parameters. Based on these investigations, the PEMFC stack is operated at the current densities of 0.4–0.8 A/cm². Since the voltage shift is quite small (roughly 0.73–0.83 V for each single cell), the efficiency would be higher. In the range of operation, the operating pressure, the cathode humidification temperature and the interactions between operating temperature and operating pressure significantly impact PEMFC stack performance. As the operating pressure increasing, the increments of the electric power decrease, and power stability is enhanced because the variation in responses is reduced.     

A parametric comparison of three fuel recirculation system in the closed loop fuel supply system of PEM fuel cell

Anodic fuel recirculation system has a significant role on the parasitic power of proton exchange membrane fuel cell (PEMFC). In this paper, different fuel supply systems for a PEMFC including a mechanical compressor, an ejector and an electrochemical pump are evaluated. Furthermore, the performances of ejector and electrochemical pump are studied at different operating conditions including operating temperature of 333 K–353 K, operating pressure of 2 bar–4 bar, relative humidity of 20%–100%, stack cells number from 150 to 400 and PEMFC active area of 0.03 m²–0.1 m². The results reveal that higher temperature of PEMFC leads to lower power consumption of the electrochemical pump, because activation over-potential of electrochemical pump decreases at higher temperatures. Moreover, higher operating temperature and pressure of PEMFC leads to higher stoichiometric ratio and hydrogen recirculation ratio because the motive flow energy in ejector enhances. In addition, the recirculation ratio and hydrogen stoichiometric ratio increase, almost linearly, with increase of anodic relative humidity. Utilization of mechanical compressor leads to lower system efficiency than other fuel recirculating devices due to more power consumption. Utilization of electrochemical pump in anodic recirculation system is a promising alternative to ejector due to lower noise level, better controllability and wide range of operating conditions.     

Thermodynamic study of integrated proton exchange membrane fuel cell with vapour adsorption refrigeration system

With the rising usage of fossil fuels, there is an urgent need to develop new technologies specifically based on renewable energy sources to power the vehicles running on fuel. A fuel cell is an electrochemical cell that is used to convert the chemical energy of a fuel directly to electric power. Fuels cells possess advantages such as smaller size, high efficiency, silent operation, etc. However, there can be significant variations in the size and power output of the fuel cells depending upon the application. The focus of this paper is to estimate the performance of an integrated system comprising of Polymer Exchange Membrane Fuel cell (PEMFC) and vapour adsorption refrigeration system to produce electric output and cooling effect simultaneously. The adsorption system in this study is based on activated carbon and methanol combination. The effect of operating parameters such as the operating temperature, current density and evaporator temperature on the energy and exergy efficiency of the system is presented. The study shows a remarkable improvement in the performance of the integrated system compared to PEMFC alone. The results show that the system energy and exergy efficiency decrease as the current density value increases. Maximum system energy and exergy efficiency of 63.01% and 29.88% are achieved. In addition, a maximum energy efficiency of 65.39% was reported at an evaporator temperature of 5 °C and a current density of 0.8 A/cm².     

Experimental analysis of the performance of the air supply system in a 120 kW polymer electrolyte membrane fuel cell system

For analyzing the performance of 120 kW polymer electrolyte membrane fuel cell (PEMFC) system and its air supply system, an air system test bench was built, then applied on a 120 kW PEMFC system test bench composed of air supply subsystem, hydrogen supply subsystem, stack, cooling subsystem and electronic control subsystem. The strategy composed of feedforward table and Piecewise proportional integral (PI) feedback control strategy is employed to regulate the flow rate and pressure of air supply system. Firstly, the air compressor map and the mapping relationship between the speed of air compressor, opening of back-pressure valve and stack current are obtained by carrying out experiments on the PEMFC air system bench. Then, the max output performance, steady-state performance, the startup performance, the dynamic response abilities of PEMFC system are tested, respectively. During the experiments, performances under different test conditions were analyzed by comparing parameters such as voltage inconsistency, average voltage, minimum voltage, voltage range, net power of the PEMFC system, and stack power. The test results show that the air supply system can provide qualified flow rate and pressure for the PEMFC stack. The peak power of the stack is 120 kW and net power of the system is 97 kW when the current is 538 A. The response time from rated net power to idle net power is 12 s and from idle net power to rated net power is 23 s. The overshoot of average voltage and minimum voltage in the process of increasing load is both 0.01 V, which are 0.015 V and 0.02 V lower than that when the load is decreased, respectively. The dynamic response speed and stability of the PEMFC system in the process of decreasing the load are better than those in the process of increasing the load.     

A study of operation strategy of cooling module with dynamic fuel cell system model for transportation application

A fuel cell system model with detailed cooling module model was developed to evaluate the control algorithms of cooling module which is used for the thermal management of a proton exchange membrane fuel cell (PEMFC) system. The system model is composed of a dynamic fuel cell stack model and a detailed dynamic cooling module model. To extend modeling flexibility, the fuel cell stack model utilizes analytic approach to capture the transient behavior of the stack temperature corresponding to the change of the coolant temperature and the flow rate during load follow-up. The cooling module model integrated model of fan, water pump, coolant passage, and electric motors so that the model is capable of investigation of operating strategy of pump and fan.The fuel cell system model is applied to the investigation of the control logics of the cooling module. Since, it is necessary for the control of cooling module to define the reference conditions such as coolant temperature and fuel cell stack temperature, this study presents such thermal management criteria. Finally, two control algorithms were compared, a conventional control algorithm and a feedback control algorithm. As a consequence, the feedback control algorithm was found to be more suitable for the cooling module of the PEMFC stack, as they consume less parasitic power while producing more stack power compared to a conventionally controlled cooling module.     

Thermodynamic modeling and exergy analysis of proton exchange membrane fuel cell power system

The proton exchange membrane (PEM) fuel cell (PEMFC) is equipped with a series of auxiliary components which consume considerable amount of energy. It is necessary to investigate the design and operation of the PEMFC power system for better system performance. In this study, a typical PEMFC power system is developed, and a thermodynamic model of the system is established. Simulation is carried out, and the power distribution of each auxiliary component in the system, the net power and power efficiency of the system are obtained. This power system uses cooling water for preheating inlet gases, and its energy-saving effect is also verified by the simulation. On this basis, the exergy analysis is applied on the system, and the indexes of the system exergy loss, exergy efficiency and ecological function are proposed to evaluate the system performance. The results show that fuel cell stack and heat exchanger are the two components that cause the most exergy loss. Furthermore, the system performance under various stack inlet temperatures and current densities is also analyzed. It is found that the net power, energy efficiency and exergy efficiency of the system reach the maximum when the stack inlet temperature is about 348.15 K. The ecological function is maintained at a high level when the stack inlet temperature is around 338.15 K. Lower current density increases the system ecological function and the power and exergy efficiencies, and also helps decrease the system exergy loss, but it decreases the system net power.     

Fuel cell power conditioning unit for standalone application with real time validation

In recent era, fuel cells are emerging as better alternative to wind and solar based energy sources due to its reliability and high efficiency. Polymer Electrolyte Membrane Fuel Cell (PEMFC) is widely used in various applications due to low operating temperature and high energy density. On the other side low and unregulated stack voltage demands PEMFC integration with suitable power conditioning unit. However, the use of actual fuel cell power conditioning unit in design and testing for research is expensive. Any failure may lead to damage of source or power circuit. In this regard, the present work aims at developing a soft-computing model of PEMFC. Also, a DC-DC converter is designed to step-up the stack voltage. A classical PI controller is implemented to regulate the PEMFC fed power conditioning units for resistive loads. The proposed system is implemented is Hardware-In-the-Loop (HIL) using OPAL-RT's OP5600 Real Time Digital Simulator (RTDS).     

Performance evaluation of a fuel processing system based on membrane reactors technology integrated with a PEMFC stack

The development of fuel cells is promised to enable the distributed generation of electricity in the near future. However, the infrastructure for production and distribution of hydrogen, the fuel of choice for fuel cells, is currently lacking. Efficient production of hydrogen from fuels that have existing infrastructure (e.g., natural gas, gasoline or LPG) would remove a major drawback to use fuel cells for distributed power generation.The aim of this paper is to define the better operating conditions of an innovative hydrogen generation system (the fuel processing system, FP) based on LPG steam reforming, equipped with a membrane shift reactor, and integrated with a PEMFC (Proton Exchange Membrane Fuel Cell) stack of 5 kWel.With respect to the conventional hydrogen generation systems, the use of membrane reactors (MRs) technology allows to increase the hydrogen generation and to simplify the FP-PEMFC plant, because the CO removal system, needed to reduce the CO content at levels required by the PEMFC, is avoided.Therefore, in order to identify the optimal operating conditions of the FP-PEMFC system, a sensitivity analysis on the fuel processing system has been carried out by varying the main operating parameters of both the reforming reactor and the membrane water gas shift reactor. The sensitivity analysis has been performed by means of a thermochemical model properly developed.Results show that the thermal efficiency of the fuel processing system is maximize (82.4%, referred to the HHV of fuels) at a reforming temperature of 800 °C, a reforming pressure of 8 bar, and an S/C molar ratio equal to 6. In the nominal operating condition of the PEMFC stack, the FP-PEMFC system efficiency is 36.1% (39.0% respect to the LHV).     

Multi-stack coupled energy management strategy of a PEMFC based-CCHP system applied to data centers

Aiming at the power fluctuation and mismatch of the combined cooling, heating, and power (CCHP) system based on proton exchange membrane fuel cells (PEMFCs) and adsorption chiller, this study proposes a multi-stack coupled power supply strategy. The PEMFC stacks are divided into types Ⅰ, Ⅱ, and Ⅲ to meet the electric load and cooling load of the data center, and the heat requirements of the system. Meanwhile, economic analysis is conducted on the single-stack energy supply strategy and the multi-stack coupled energy supply strategy. The results show that with the multi-stack coupling power supply strategy, the cooling power and electric power almost completely match the load of the data center, without power fluctuations and overshoot. By smoothing the PID control results of the current of the stacks-Ⅲ, the heating power fluctuation is significantly reduced, and the maximum overshoot does not exceed 0.5 kW. Therefore, the strategy is conducive to the stable operation of the PEMFC stack and improves the lifetime of the system. Considering investment costs, maintenance costs, hydrogen costs, and electricity benefits, the multi-stack coupled energy supply strategy can save about 6.1 × 10⁵ $ per year. In summary, the multi-stack coupled energy supply strategy has advantages in system lifetime, operational stability, and economy.     

Simulation analysis of hydrogen recirculation rates of fuel cells and the efficiency of combined heat and power

The objective of this study was to simulate a proton-electrolyte membrane fuel cell (PEMFC) system, namely a PEMFC stack, an anode gas supply subsystem, an anode gas-recovery subsystem, a cathode gas supply subsystem, and a tail gas exhaustion subsystem. In addition, this paper presents an analysis of the efficiency of combined heat and power (CHP) systems. MATLAB and Simulink were employed for dynamic simulation and statistical analysis. The rates of active and the passive anode hydrogen recirculation were considered to elucidate the mechanism of hydrogen circulation. When recovery involved diverse recovery mechanisms, the recirculation rate was affected by the pressure at the hydrogen outlet of the PEMFC system. The greater the pressure was at that outlet, the higher the recovery rate was. In the hydrogen recovery system, when the temperature of the hydrogen supply end remained the same, increasing the temperature of the gas supply end increased the efficiency of the fuel cells; fixing the flow of the hydrogen supply end and increasing the temperature of the hydrogen supply end increased the efficiency of the PEMFC system. A calculation of the efficiency of the recovery system indicated that the thermal efficiency of the fuel cells exceeded 35%, the power generation efficiency exceeded 45%, and the efficiency of the CHP system exceeded 80%.     

Energetic and exergetic analysis of a biomass-fueled CCHP system integrated with proton exchange membrane fuel cell

As a high-efficiency and eco-friendly way of energy conversion, fuel cell has received much attention in recent years. A novel residential combined cooling, heating and power (CCHP) system, consisting of a biomass gasifier, a proton exchange membrane fuel cell (PEMFC) stack, an absorption chiller and auxiliary equipment, is proposed. Based on the established thermodynamic models, the effects of operating parameters, biomass materials type and moisture content on the system performance are closely investigated. Overall system performance is then compared under four different operating modes. From the viewpoints of energy utilization and CO₂ emissions, the CCHP mode has the best performance with corresponding energy efficiency of 57.41% and CO₂ emission index of 0.516 ton/MWh. Exergy analysis results suggest that the optimization and transformation on the gasifier and PEMFC stack should be encouraged. Energy and exergy assessments in this research provide pragmatic guidance to the performance improvement of the integrated CCHP systems with PEMFC. This research also achieves a reasonable combination of efficient cogeneration, green hydrogen production and full recovery of low grade waste heat.     

Efficiency improvement of a PEMFC system by applying a turbocharger

A novel proton exchange membrane fuel cell (PEMFC) system that employs a turbocharger to reuse waste energy is proposed. This study is focused on optimal placement of the PEMFC turbocharger, using either the hydrogen feed stream or the stack outlet as the motive force. A one-dimensional isothermal two-phase model for a PEMFC and an isenthalpic model for the turbocharger are developed for system analysis. To find a better energy source, the system efficiency, power generation, and interaction with the balance of plant (BOP) are considered. To evaluate the feasibility of both systems, an exergy analysis is also performed. The results show that the system efficiency is higher when the turbocharger is installed after the hydrogen tank and that the amount of power generation is also larger when the turbocharger is located in the stack outlet. For the exergy analysis, the case for the turbocharger installed after the hydrogen tank shows higher performance. Therefore, it is preferable to install the turbocharger after the hydrogen tank.     

Performance of a PEMFC system integrated with a biogas chemical looping reforming processor: A theoretical analysis and comparison with other fuel processors (steam reforming,partial oxidation and auto-thermal reforming)

In this work, the performance of a PEMFC (proton exchange membrane fuel cell) system integrated with a biogas chemical looping reforming processor is analyzed. The global efficiency is investigated by means of a thermodynamic study and the application of a generalized steady-state electrochemical model. The theoretical analysis is carried out for the commercial fuel cell BCS 500W stack. From literature, chemical looping reforming (CLR) is described as an attractive process only if the system operates at high pressure. However, the present research shows that advantages of the CLR process can be obtained at atmospheric pressure if this technology is integrated with a PEMFC system. The performance of a complete fuel cell system employing a fuel processor based on CLR technology is compared with those achieved when conventional fuel processors (steam reforming (SR), partial oxidation (PO) and auto-thermal reforming (ATR)) are used. In the first part of this paper, the Gibbs energy minimization method is applied to the unit comprising the fuel- and air-reactors in CLR or to the reformer (SR, PO, ATR). The goal is to investigate the characteristics of these different types of reforming process to generate hydrogen from clean model biogas and identify the optimized operating conditions for each process. Then, in the second part of this research, material and energy balances are solved for the complete fuel cell system processing biogas, taking into account the optimized conditions found in the first part. The overall efficiency of the PEMFC stack integrated with the fuel processor is found to be dependent on the required power demand. At low loads, efficiency is around 45%, whereas, at higher power demands, efficiencies around 25% are calculated for all the fuel processors. Simulation results show that, to generate the same molar flow-rate of H₂ to operate the PEMFC stack at a given current, the global process involving SR reactor is by far much more energy demanding than the other technologies. In this case, biogas is burnt in a catalytic combustor to supply the energy required, and there is a concern with respect to CO₂ emissions. The use of fuel processors based on CLR, PO or ATR results in an auto-thermal global process. If CLR based fuel processor is employed, CO₂ can be easily recovered, since air is not mixed with the reformate. In addition, the highest values of voltage and power are achieved when the PEMFC stack is fed on the stream coming from SR and CLR fuel processors. When a H₂ mixture is produced by reforming biogas through PO and ATR technologies, the relative anode overpotential of a single cell is about 55 mV, whereas, with the use of CLR and SR processes, this value is reduced to ∼37 and 24 mV, respectively. In this way, CLR can be seen as an advantageous reforming technology, since it allows that the global process can be operated under auto-thermal conditions and, at the same time, it allows the PEMFC stack to achieve values of voltage and power closer to those obtained when SR fuel processors are used. Thus, efforts on the development of fuel processors based on CLR technology operating at atmospheric pressure can be considered by future researchers. In the case of biogas, the CO₂ captured can produce additional economical benefits in a ‘carbon market’.     

Optimization of fuel cell system operating conditions for fuel cell vehicles

Proton exchange membrane fuel cell (PEMFC) technology for use in fuel cell vehicles and other applications has been intensively developed in recent decades. Besides the fuel cell stack, air and fuel control and thermal and water management are major challenges in the development of the fuel cell for vehicle applications. The air supply system can have a major impact on overall system efficiency. In this paper a fuel cell system model for optimizing system operating conditions was developed which includes the transient dynamics of the air system with varying back pressure. Compared to the conventional fixed back pressure operation, the optimal operation discussed in this paper can achieve higher system efficiency over the full load range. Finally, the model is applied as part of a dynamic forward-looking vehicle model of a load-following direct hydrogen fuel cell vehicle to explore the energy economy optimization potential of fuel cell vehicles.     

Theoretical and experimental investigations on thermal management of a PEMFC stack

In recent years micro-cogeneration systems (μ-CHPs), based on fuel cells technology, have received increasing attention because, by providing both useful electricity and heat with high efficiency, even at partial loads, they can have a strategic role in reduction of greenhouse gas emissions. For residential applications, the proton exchange membrane fuel cell (PEMFC), is considered the most promising, since it offers many advantages such as high power density, low operating temperature, and fast start-up and shutdown.In this paper the electrical and thermal behaviors of a PEMFC stack, suitable for μ-CHP applications, have been investigated through experimental and numerical activity.The experimental activity has been carried out in a test station in which several measurement instruments and controlling devices are installed to define the behavior of a water-cooled PEMFC stack. The test station is equipped by a National Instruments Compact DAQ real-time data acquisition and control system running Labview™ software.The numerical activity has been conducted by using a model, properly developed by the authors, based on both electrochemical and thermal analysis.The experimental data have been used to validate the numerical model, which can support and address the experimental activity and can allow to forecast the behavior and the performance of the stack when it is a component in a more complex energy conversion system.     

Road testing of a three-wheeler driven by a 5 kW PEM fuel cell in the absence and presence of batteries

The road testing and demonstration of a three-wheeler vehicle driven by a 5 kW proton exchange membrane fuel cell (PEMFC) was carried out in the absence and presence of lead acid batteries. Prior to integrating the PEMFC module and batteries in the three-wheeler, they were tested and demonstrated separately. The PEMFC module had a very fast response as the load was manually or, especially, automatically changed and it could supply a continuous power when the reactant was supplied continuously. In contrast, the 5 kW lead acid batteries alone could supply power for no longer than 300 s. In the presence of both the PEMFC module and batteries, when the drawing power was in the range of the PEMFC module capacity the propulsion motor gained its energy from the PEMFC module only, whilst the stack power output at all conditions was greater than the setting power of approximately 400 W. After integrating the PEMFC module and batteries into the three-wheeler, both energy sources were found to power the vehicle effectively. The motor power as well as the stack power changed as a linear proportion to the throttle. The motor consumed more power in case of high speed driving, take off or hill climbing, while it used only 0.354 kW in the absence of throttle. The hybrid system can achieve a maximum speed in this three-wheeler of around 24.9 km/h with a hydrogen consumption of 11 g H₂/km (71 g H₂/kWh) and an operating cost of 1.99 USD/km. The thermodynamic efficiency of the vehicle was 42.9%.     

Parameter design on the multi-objectives of PEM fuel cell stack using an adaptive neuro-fuzzy inference system and genetic algorithms

This work considers a design of a PEM fuel cell (PEMFC) stack that consists of 10 cells and expects to carry out an analysis of performance. In this work, PEMFC performance as affected by different combinations of control factors, such as the cathode and anode operating pressures, the humidification temperatures, and the stoichiometric flow ratio of reaction gas, is studied. On the PEMFC stack performance, the gas supply that is expected to be the minimum and the output power that is hoped to be the maximum are a result of the demand of the multi-objectives characteristics. Due to the Taguchi orthogonal array, the screen experiment is carried out by using a fractional factorial design in order to determine main factors and interaction effects first, and then the robust design is conducted. The intelligent parameter design is developed via an Adaptive Neuro-Fuzzy Inference System combined with the definition of percentage reduction of quality loss (PRQL) in order to supply a fitness function to the genetic algorithms (GA). The best parameter design is proposed after an analysis and comparison is conducted. Finally, the adaptability of prediction for the model created by this approach is confirmed by the confirmation experiment. This work shows that the PEMFC performance is improved by 35.8% via the average PRQL.     

Water management in a novel proton exchange membrane fuel cell stack with moisture coil cooling

Water flooding causes severe degradation of the performance and lifetime of proton exchange membrane fuel cell (PEMFC). In this study, a novel PEMFC stack with in-built moisture coil cooling was designed and the effects of moisture coil cooling on water management in the new PEMFC stack under various operating conditions were investigated. The result showed that the performance of the PEMFC stack was significantly improved due to the moisture condensation under high current density, high operating temperature, high relative humidity and high operating pressure. The output power was increases by 21.62% (525.71 W) at 1600·mA cm⁻² while the increased parasitic power was no more than 35W. Moreover, degradation of the cathode catalyst layer after 100 h operation was also reduced by using moisture coil cooling. Compared with the situation without moisture condensation, the maximum decay rate of the cathode catalyst layer thickness after 100 h operation was reduced by 13.01%. Accordingly, the novel design is valuable and can be widely used in the future design of PEMFC.