An experimental study of a PEM fuel cell power train for urban bus application

An experimental study was carried out on a fuel cell propulsion system for minibus application with the aim to investigate the main issues of energy management within the system in dynamic conditions. The fuel cell system (FCS), based on a 20 kW PEM stack, was integrated into the power train comprising DC–DC converter, Pb batteries as energy storage systems and asynchronous electric drive of 30 kW. As reference vehicle a minibus for public transportation in historical centres was adopted. A preliminary experimental analysis was conducted on the FCS connected to a resistive load through a DC–DC converter, in order to verify the stack dynamic performance varying its power acceleration from 0.5 kW s⁻¹ to about 4 kW s⁻¹. The experiments on the power train were conducted on a test bench able to simulate the vehicle parameters and road characteristics on specific driving cycles, in particular the European R40 cycle was adopted as reference. The “soft hybrid” configuration, which permitted the utilization of a minimum size energy storage system and implied the use of FCS mainly in dynamic operation, was compared with the “hard hybrid” solution, characterized by FCS operation at limited power in stationary conditions. Different control strategies of power flows between fuel cells, electric energy storage system and electric drive were adopted in order to verify the two above hybrid approaches during the vehicle mission, in terms of efficiencies of individual components and of the overall power train.     

Lithium polymer batteries and proton exchange membrane fuel cells as energy sources in hydrogen electric vehicles

This paper deals with the application of lithium ion polymer batteries as electric energy storage systems for hydrogen fuel cell power trains. The experimental study was firstly effected in steady state conditions, to evidence the basic features of these systems in view of their application in the automotive field, in particular charge-discharge experiments were carried at different rates (varying the current between 8 and 100 A). A comparison with conventional lead acid batteries evidenced the superior features of lithium systems in terms of both higher discharge rate capability and minor resistance in charge mode. Dynamic experiments were carried out on the overall power train equipped with PEM fuel cell stack (2 kW) and lithium batteries (47.5 V, 40 Ah) on the European R47 driving cycle. The usage of lithium ion polymer batteries permitted to follow the high dynamic requirement of this cycle in hard hybrid configuration, with a hydrogen consumption reduction of about 6% with respect to the same power train equipped with lead acid batteries.     

Experimental study of a fuel cell power train for road transport application

The development of fuel cell electric vehicles requires the on-board integration of fuel cell systems and electric energy storage devices, with an appropriate energy management system. The optimization of performance and efficiency needs an experimental analysis of the power train, which has to be effected in both stationary and transient conditions (including standard driving cycles).In this paper experimental results concerning the performance of a fuel cell power train are reported and discussed. In particular characterization results for a small sized fuel cell system (FCS), based on a 2.5 kW PEM stack, alone and coupled to an electric propulsion chain of 3.7 kW are presented and discussed. The control unit of the FCS allowed the main stack operative parameters (stoichiometric ratio, hydrogen and air pressure, temperature) to be varied and regulated in order to obtain optimized polarization and efficiency curves. Experimental runs effected on the power train during standard driving cycles have allowed the performance and efficiency of the individual components (fuel cell stack and auxiliaries, dc–dc converter, traction batteries, electric engine) to be evaluated, evidencing the role of output current and voltage of the dc–dc converter in directing the energy flows within the propulsion system.     

Performance and cost of automotive fuel cell systems with ultra-low platinum loadings

An automotive polymer-electrolyte fuel cell (PEFC) system with ultra-low platinum loading (0.15 mg-Pt cm⁻²) has been analyzed to determine the relationship between its design-point efficiency and the system efficiency at part loads, efficiency over drive cycles, stack and system costs, and heat rejection. The membrane electrode assemblies in the reference PEFC stack use nanostructured, thin-film ternary catalysts supported on organic whiskers and a modified perfluorosulfonic acid membrane. The analyses show that the stack Pt content can be reduced by 50% and the projected high-volume manufacturing cost by >45% for the stack and by 25% for the system, if the design-point system efficiency is lowered from 50% to 40%. The resulting penalties in performance are a <1% reduction in the system peak efficiency; a 2-4% decrease in the system efficiency on the urban, highway, and LA92 drive cycles; and a 6.3% decrease in the fuel economy of the modeled hybrid fuel-cell vehicle on the combined cycle used by EPA for emission and fuel economy certification. The stack heat load, however, increases by 50% at full power (80 kW_e) but by only 23% at the continuous power (61.5 kW_e) needed to propel the vehicle on a 6.5% grade at 55 mph. The reduced platinum and system cost advantages of further lowering the design-point efficiency from 40% to 35% are marginal. The analyses indicate that thermal management in the lower efficiency systems is very challenging and that the radiator becomes bulky if the stack temperature cannot be allowed to increase to 90-95 °C under driving conditions where heat rejection is difficult.     

Experimental assessment of fuel cell/supercapacitor hybrid system for scooters

This paper presents an experimental assessment of fuel cell hybrid propulsion systems for scooters based on a modular 1.2 kW PEM fuel cell. The tests of the hybrid system are carried out using a programmable electronic load. Different configurations of the fuel cell/battery and the fuel cell/supercapacitor hybrid systems are explored. Both systems demonstrate their ability to deliver the requested load satisfactorily. The distributions of the fuel cell power delivery, although different between the two systems, are within the region where the fuel cell efficiency is approximately constant. As a result, the rates of fuel consumption show no discernable difference between the two systems for all three driving cycles considered. In addition to the fuel consumption, considerations including bus voltage, cost and packaging issues suggest that the supercapacitor has advantages over the battery for the use as secondary energy storage in fuel cell hybrid propulsion system for scooters.     

Thermo-economic modeling of an indirectly coupled solid oxide fuel cell/gas turbine hybrid power plant

Power generation using gas turbine (GT) power plants operating on the Brayton cycle suffers from low efficiencies, resulting in poor fuel to power conversion. A solid oxide fuel cell (SOFC) is proposed for integration into a 10 MW gas turbine power plant, operating at 30% efficiency, in order to improve system efficiencies and economics. The SOFC system is indirectly coupled to the gas turbine power plant, paying careful attention to minimize the disruption to the GT operation. A thermo-economic model is developed for the hybrid power plant, and predicts an optimized power output of 20.6 MW at 49.9% efficiency. The model also predicts a break-even per-unit energy cost of USD 4.65 ¢ kWh⁻¹ for the hybrid system based on futuristic mass generation SOFC costs. This shows that SOFCs may be indirectly integrated into existing GT power systems to improve their thermodynamic and economic performance.     

Thermo-economic modeling of a solid oxide fuel cell/gas turbine power plant with semi-direct coupling and anode recycling

Power generation using gas turbine (GT) power plants operating on the Brayton cycle suffers from low efficiencies, resulting in poor fuel to power conversion. A solid oxide fuel cell (SOFC) is proposed for integration into a 10 MW gas turbine power plant, operating at 30% efficiency in order to improve system efficiencies and economics. The SOFC system is semi-directly coupled to the gas turbine power plant, with careful attention paid to minimize the disruption to the GT operation. A thermo-economic model is developed for the hybrid power plant, and predicts an optimized power output of 21.6 MW at 49.2% efficiency. The model also predicts a breakeven per-unit energy cost of USD 4.70 ¢/kWh for the hybrid system based on futuristic mass generation SOFC costs. Results show that SOFCs can be semi-directly integrated into existing GT power systems to improve their thermodynamic and economic performance.     

Thermo-economic optimization of an indirectly coupled solid oxide fuel cell/gas turbine hybrid power plant

Power generation using gas turbine (GT) power plants operating on the Brayton cycle suffers from low efficiencies, resulting in poor fuel to power conversion. A solid oxide fuel cell (SOFC) is proposed for integration into a 10-MW GT power plant, operating at 30% efficiency, in order to improve system efficiencies and economics. The SOFC system is indirectly coupled to the GT, in order to minimize the disruption to the GT operation. A thermo-economic model is developed to simulate the hybrid power plant and to optimize its performance using the method of Lagrange Multipliers. It predicts an optimized power output of 18.9 MW at 48.5% efficiency, and a breakeven per-unit energy cost of USD 4.54 ¢ kW h⁻¹ for the hybrid system based on futuristic mass generation SOFC costs.     

Dynamic behaviour of Li batteries in hydrogen fuel cell power trains

A Li ion polymer battery pack for road vehicles (48 V, 20 Ah) was tested by charging/discharging tests at different current values, in order to evaluate its performance in comparison with a conventional Pb acid battery pack. The comparative analysis was also performed integrating the two storage systems in a hydrogen fuel cell power train for moped applications. The propulsion system comprised a fuel cell generator based on a 2.5 kW polymeric electrolyte membrane (PEM) stack, fuelled with compressed hydrogen, an electric drive of 1.8 kW as nominal power, of the same typology of that installed on commercial electric scooters (brushless electric machine and controlled bidirectional inverter). The power train was characterized making use of a test bench able to simulate the vehicle behaviour and road characteristics on driving cycles with different acceleration/deceleration rates and lengths. The power flows between fuel cell system, electric energy storage system and electric drive during the different cycles were analyzed, evidencing the effect of high battery currents on the vehicle driving range. The use of Li batteries in the fuel cell power train, adopting a range extender configuration, determined a hydrogen consumption lower than the correspondent Pb battery/fuel cell hybrid vehicle, with a major flexibility in the power management.     

Energy management of a fuel cell hybrid ultra-energy efficient vehicle

This paper focuses on energy management in an ultra-energy efficient vehicle powered by a hydrogen fuel cell with rated power of 1 kW. The vehicle is especially developed for the student competition Shell Eco-marathon in the Urban Concept category. In order to minimize the driving energy consumption a simulation model of the vehicle and the electric propulsion is developed. The model is based on vehicle dynamics and real motor efficiency as constant DC/DC, motor controllers and transmission efficiency were considered. Based on that model five propulsion schemes and driving strategies were evaluated. The fuel cell output parameters were experimentally determined. Then, the driving energy demand and hydrogen consumption was estimated for each of the propulsion schemes. Finally, an experimental study on fuel cell output power and hydrogen consumption was conducted for two propulsion schemes in case of hybrid and non-hybrid power source. In the hybrid propulsion scheme, supercapacitors were used as energy storage as they were charged from the fuel cell with constant current of 10 A.     

Fuel processor-battery-fuel cell hybrid drivetrain for extended range operation of passenger vehicles

Power required to run auxiliary systems on a passenger car, such as those for air conditioning and advanced vehicle control, reduces the driving range of a vehicle equipped with a hybrid drive train. Under practical driving conditions, a significant amount of additional energy is required at low power levels compared to the rated power of the drive unit. In the present study, we consider a fuel cell-battery drive train augmented by an on-board fuel (ethanol) processor to provide the motoring power requirements of a car. Using systematic driving cycle simulations that take account of power-to-weight, energy-to-weight and power-to-efficiency factors of on-board power sources under simulated load conditions, we show that a combination of steadily-operated compact ethanol reformer, a low-power battery continuously charged by excess reformer capacity and a high-power fuel cell powered by conservatively-used hydrogen from cylinder can increase the range of hybrid fuel cell drivetrains to about 750 km. Although the overall energy consumption of the three-way hybrid is more than that of fuel cell-battery hybrid, lesser use of stored hydrogen improves the fuel economy of the hybrid drivetrain. While the system complexity is increased, long-range distressed mode operation becomes feasible with the added fuel processor.     

Development of integrated fuel cell hybrid power source for electric forklift

A hybrid drivetrain comprising a 16 kW polymer electrolyte membrane fuel cell system, ultracapacitor modules and a lead-acid battery was constructed and experimentally tested in a real counterweight forklift application. A scaled-down version of the hybrid system was assembled and tested in a controlled laboratory environment using a controllable resistive load. The control loops were operating in an in-house developed embedded system. The software is designed for building generic control applications, and the source code has been released as open source and made available on the internet. The hybrid drivetrain supplied the required 50 kW peak power in a typical forklift work cycle consisting of both loaded and unloaded driving, and lifting of a 2.4 tonne load. Load variations seen by the fuel cell were a fraction of the total current drawn by the forklift, with the average fuel cell power being 55% of nominal rating. A simple fuel cell hybrid model was also developed to further study the effects of energy storage dimensioning. Simulation results indicate that while a battery alone significantly reduces the load variations of the fuel cell, an ultracapacitor reduces them even further. Furthermore, a relatively small ultracapacitor is enough to achieve most of the potential benefit.     

An integrated power generation system combining solid oxide fuel cell and oxy-fuel combustion for high performance and CO2 capture

An integrated power generation system combining solid oxide fuel cell (SOFC) and oxy-fuel combustion technology is proposed. The system is revised from a pressurized SOFC-gas turbine hybrid system to capture CO₂ almost completely while maintaining high efficiency. The system consists of SOFC, gas turbine, oxy-combustion bottoming cycle, and CO₂ capture and compression process. An ion transport membrane (ITM) is used to separate oxygen from the cathode exit air. The fuel cell operates at an elevated pressure to facilitate the use of the ITM, which requires high pressure and temperature. The remaining fuel at the SOFC anode exit is completely burned with oxygen at the oxy-combustor. Almost all of the CO₂ generated during the reforming process of the SOFC and at the oxy-fuel combustor is extracted from the condenser of the oxy-combustion cycle. The oxygen-depleted high pressure air from the SOFC cathode expands at the gas turbine. Therefore, the expander of the oxy-combustion cycle and the gas turbine provides additional power output. The two major design variables (steam expander inlet temperature and condenser pressure) of the oxy-fuel combustion system are determined through parametric analysis. There exists an optimal condenser pressure (below atmospheric pressure) in terms of global energy efficiency considering both the system power output and CO₂ compression power consumption. It was shown that the integrated system can be designed to have almost equivalent system efficiency as the simple SOFC-gas turbine hybrid system. With the voltage of 0.752 V at the SOFC operating at 900 °C and 8 bar, system efficiency over 69.2% is predicted. Efficiency penalty due to the CO₂ capture and compression up to 150 bar is around 6.1%.     

Analysis of fuel cell hybrid locomotives

Led by Vehicle Projects LLC, an international industry–government consortium is developing a 109 t, 1.2 MW road-switcher locomotive for commercial and military railway applications. As part of the feasibility and conceptual-design analysis, a study has been made of the potential benefits of a hybrid power plant in which fuel cells comprise the prime mover and a battery or flywheel provides auxiliary power. The potential benefits of a hybrid power plant are: (i) enhancement of transient power and hence tractive effort; (ii) regenerative braking; (iii) reduction of capital cost.Generally, the tractive effort of a locomotive at low speed is limited by wheel adhesion and not by available power. Enhanced transient power is therefore unlikely to benefit a switcher locomotive, but could assist applications that require high acceleration, e.g. subway trains with all axles powered.In most cases, the value of regeneration in locomotives is minimal. For low-speed applications such as switchers, the available kinetic energy and the effectiveness of traction motors as generators are both minimal. For high-speed heavy applications such as freight, the ability of the auxiliary power device to absorb a significant portion of the available kinetic energy is low. Moreover, the hybrid power plant suffers a double efficiency penalty, namely, losses occur in both absorbing and then releasing energy from the auxiliary device, which result in a net storage efficiency of no more than 50% for present battery technology.Capital cost in some applications may be reduced. Based on an observed locomotive duty cycle, a cost model shows that a hybrid power plant for a switcher may indeed reduce capital cost. Offsetting this potential benefit are the increased complexity, weight and volume of the power plant, as well as 20–40% increased fuel consumption that results from lower efficiency.Based on this analysis, the consortium has decided to develop a pure fuel cell road-switcher locomotive, that is, not a hybrid.     

高温燃料电池_燃气轮机混合发电系统性能分析

针对 高温燃料电池系统的高效率、环保性以及排气废热的巨大利用潜能,将其与燃气轮机组成混合装置进行发电是未来分布式发电的一种极有前景的方案。文中对高温燃料电池及混合循环系统作了简介,并对两种典型的高温燃料电池－燃气轮机混合循环发电系统进行了性能分析,这将为我国高温燃料电池－燃气轮机混合循环系统的研制提供参考。     

A numerical investigation of a diffusion-absorption refrigeration cycle based on R124-DMAC mixture for solar cooling

Research on new working fluid for uses in absorption systems has been continued. The feasibility of a solar driven DAR using the mixture R124/DMAC as working fluid is investigated by numerical simulation. The cycle is simulated for two cooling medium temperatures, 27 °C and 35 °C, and four driving heat temperatures in the range [90 °C–180 °C]. The performance characteristics of this system is analyzed parametrically by computer simulation for a design cooling capacity of 1 kW. The results show that the system performance and the lowest (minimum) evaporation temperature reached are largely dependent upon the absorber efficiency and the driving temperature. It is shown that for solar applications this fluid mixture has a higher COP and may constitute an alternative to the conventional ammonia–water system.     

Hybrid polymer electrolyte membrane fuel cell–lithium‐ion battery powertrain testing platform – hybrid fuel cell electric vehicle emulator

A testing and validation platform for hybrid fuel cell (FC)–lithium‐ion battery (LIB) powertrain systems is investigated. The hybrid FC electric vehicle emulator enables testing of hybrid system components and complete hybrid power modules up to 25 kW for application in electric light‐duty vehicles, light electric vehicles and so forth. A hybrid system comprising a 10‐kW_el low‐temperature polymer electrolyte membrane FC stack and an 11.5‐kWh LIB pack is installed. The system supplies power to a 20‐kW permanent magnet synchronous motor and a 25‐kW alternating current asynchronous, electrically programmable dynamometer is used to simulate the vehicle load during testing at dynamic drive cycle. The steady‐state performance tests of the direct current (DC) motor, DC/DC converter, low‐temperature polymer electrolyte membrane FC stack and LIB are performed as well as dynamic tests of the complete hybrid system. The Economic Commission for Europe driving cycle is selected as a reference cycle to validate the investigated hybrid FC–LIB powertrain. An efficiency of 83% and 95% is measured for electric motor and DC/DC converter, respectively. An average stack efficiency of 50% is achieved. An average hydrogen consumption of 3.9 g * km^?1 is reached during the Economic Commission for Europe driving cycle test. Copyright © 2017 John Wiley & Sons, Ltd.     

Techno-economic comparison of series hybrid, plug-in hybrid, fuel cell and regular cars

We examine the competitiveness of series hybrid compared to fuel cell, parallel hybrid, and regular cars. We use public domain data to determine efficiency, fuel consumption, total costs of ownership and greenhouse gas emissions resulting from drivetrain choices. The series hybrid drivetrain can be seen both as an alternative to petrol, diesel and parallel hybrid cars, as well as an intermediate stage towards fully electric or fuel cell cars.We calculate the fuel consumption and costs of four diesel-fuelled series hybrid, four plug-in hybrid and four fuel cell car configurations, and compared these to three reference cars. We find that series hybrid cars may reduce fuel consumption by 34-47%, but cost €5000-12,000 more. Well-to-wheel greenhouse gas emissions may be reduced to 89-103 g CO₂ km⁻¹ compared to reference petrol (163 g km⁻¹) and diesel cars (156 g km⁻¹). Series hybrid cars with wheel motors have lower weight and 7-21% lower fuel consumption than those with central electric motors.The fuel cell car remains uncompetitive even if production costs of fuel cells come down by 90%. Plug-in hybrid cars are competitive when driving large distances on electricity, and/or if cost of batteries come down substantially. Well-to-wheel greenhouse gas emissions may be reduced to 60-69 g CO₂ km⁻¹.     

高温燃料电池/燃气轮机混合循环发电技术

高温燃料电池／燃气轮机混合循环系统以其效率高、排放低的特点,在未来分布式发电和集中式大规模发电中占有重要地位。本文首先简介了高温燃料电池和先进燃气轮机的结构特点及其分类,在此基础上阐述了高温燃料电池与先进燃气轮机混合系统的基本模式,然后对适用于分布式发电和集中式发电的几种典型混合循环系统的结构和相应的流程及特点进行了详细的描述,最后给出了高温燃料电池和燃气轮机混合循环发电系统中的一些主要代表性技术以及目前研究的进展、挑战和目标。     

Optimal sizing of a fuel processor for auxiliary power applications of a fuel cell-powered passenger car

The present study considers the optimal sizing of a three-way hybrid powertrain consisting of a compact reformer, a compact battery and a low temperature PEM fuel cell stack serving as the main power unit. A simulation model consisting of the relevant characteristic parameters of the three power sources has been developed and has been used to study the fuel utilization features of the hybrid powertrain while going through the NEDC driving cycle with a given auxiliary power requirement. The optimality is based on minimizing fuel cost while having an assured range of 500 km under practical driving conditions and a further 100 km under reduced auxiliary power usage. It is shown that for performance characteristics of Toyota Mirai and for average auxiliary power consumption of 5 kW, a smaller NiMH battery size of 1.3 kWh together with a fuel processor of 5.6 kW constant output would be optimal with a further requirement of 25% more hydrogen and 33 kg of ethanol to be carried on-board. Substantial reductions in vehicle mass and fuel load can be achieved for more modest performance characteristics and auxiliary power consumption.