Optimal unit sizing of cogeneration systems under the toleration for shortage of energy supply

The paper investigates the influence of tolerating the shortage of energy supplies on the economy of cogeneration systems in consideration of energy demands as random variables. To make a reasonable investigation into the influence, an optimal unit sizing method proposed by the authors is adopted after it is extended to this case so that it enables probability distributions of energy demands to be considered. In the method, equipment capacities and maximum contract demands of utilities such as electricity and natural gas are determined so as to minimize the expected value of the annual total cost in consideration of operational strategies for all the estimated energy demands under the toleration for the shortage of energy supplies. Numerical studies are carried out on cogeneration systems installed in a hotel or an office building with changing shortage rates of energy supplies as parameters. Through the studies, it is found that the expected systems' economy is improved even if the shortage rates of energy supplies are very small, and that the improvement for the office building is larger than that for the hotel. Copyright © 2000 John Wiley & Sons, Ltd.     

Implementation of a heat recovery unit in a proton exchange membrane fuel cell system

A heat recovery unit (HRU) has been developed and implemented in a proton exchange membrane (PEM) fuel cell cogeneration system that generates electricity and hot water efficiently. It consists of a stack coolant circuit, a heat exchanger, and a heat recovery circuit. An intelligent thermal control algorism is proposed as well to manage the cogeneration system. The HRU together with the control scheme has managed the fuel cell cogeneration system properly and efficiently. The stack coolant inlet temperature (SCIT) is well controlled at the preset temperatures (55 °C and 59 °C) under different external loads (0–3 kW). Results also show that the dynamics of the SCIT is closely related to the actions of the secondary fluid pump. Up to 50% fuel energy can be recovered thermally in the present cogeneration system. Examination of the external-load effects reveals that increasing external loads increases the electrical efficiency but decreases the heat recovery efficiency slightly. The maximum efficiency as a combination of heat and power is 82% based on hydrogen's lower heating value.     

Experimental analysis of a degraded open-cathode PEM fuel cell stack

The well-known challenges to overcome in PEM fuel cell research are their relatively low durability and the high costs for the platinum catalysts. This work focuses on degradation mechanisms that are present in open-cathode PEM fuel cell systems and their links to the decaying fuel cell performance. Therefore a degraded, open-cathode, 20 cell, PEM fuel cell stack was analyzed by means of in-situ and ex-situ techniques. Voltage transients during external perturbations, such as changing temperature, humidity and stoichiometry show that degradation affects individual cells quite differently towards the end of life of the stack. Cells located close to the endplates of the stack show the biggest performance decay. Electrochemical impedance spectroscopy (EIS) data present non-reversible catalyst layer degradation but negligible membrane degradation of several cells. Post-mortem, ex-situ experiments, such as cyclic voltammetry (CV), X-ray photoelectron spectroscopy (XPS) and X-ray diffraction (XRD) show a significant active area loss of the first cells within the stack due to Pt dissolution, oxidation and agglomeration. Scanning electron microscope (SEM) images of the degraded cells in comparison with the normally working cells in the stack show severe carbon corrosion of the cathode catalyst layers.     

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.     

Optimal sizing of a heat pump/thermal storage system based on the linear programming method

An optimal planning method is proposed for a heat pump/thermal storage system that utilizes time-of-use pricing of the electrical utility. Equipment capacities are determined so as to minimize the annual total cost in consideration of system's operational strategies for energy demand requirements. This optimal planning problem is solved by the linear programming method. Through a numerical study on a heat pump/thermal storage system for a commercial building, the effect of thermal storage tank is investigated on the long-term economics of the system. A parametric study is also performed with respect to the initial capital unit cost of thermal storage tank. The relation is clarified among the optimal capacities of thermal storage tank and other pieces of equipment. It is ascertained that this optimal planning method is a useful tool for evaluating the economic properties of heat pump/thermal storage systems.     

Dynamic electrochemical model of an alkaline fuel cell stack

The Institute for Energy and Environment (IEE) at the University of Strathclyde has developed various fuel cell (FC) systems for stationary and vehicular applications. In particular the author is involved in the development of alkaline fuel cell (AFC) systems. To understand the dynamic behaviour of the system's key element, the alkaline fuel cell stack, a dynamic model was developed allowing the characterisation of the electrochemical parameters. The model is used to forecast the behaviour of the fuel cell stack under various dynamic operating conditions. The so-called Nernst potential, which describes the open circuit voltage of the stack, is calculated using thermodynamic theory. Electrochemistry theory has been used to model the sources of the electric losses within the FC, such as activation, ohmic and concentration losses. The achievable value of this paper is the first publication of a detailed dynamic AFC based on mass balance, thermodynamics and electrochemical theory. The effects of the load changes on various fuel cell parameters, such as electrolyte concentration and concentrations of dissolved hydrogen and oxygen were covered in this investigation using the author's model. The model allows a detailed understanding of the dynamic effects within the AFC during load change events, which lead to the experienced electric response of the overall FC stack.     

Influence of current densities in SOFC and PEFC stacks on a SOFC–PEFC combined system

A solid oxide fuel cell (SOFC)–polymer electrolyte fuel cell (PEFC) combined system was investigated by numerical simulation. Here, the effect of the current densities in the SOFC and the PEFC stacks on the system's performance is evaluated under a constant fuel utilization condition. It is shown that the SOFC–PEFC system has an optimal combination of current densities, for which the electrical efficiency is highest. The optimal combination exists because the cell voltage in one stack increases and that of the other stack decreases when the current densities are changed. It is clarified that there is an optimal size of the PEFC stack in the parallel-fuel-feeding-type SOFC–PEFC system from the viewpoint of efficiency, although a larger PEFC stack always leads to higher electrical efficiency in the series-fuel-feeding-type SOFC–PEFC system. The 40 kW-class PEFC stack is suitable for the 110 kW-class SOFC stack in the parallel-fuel-feeding type SOFC–PEFC system.     

Performance analysis of a 5 kW PEMFC with a natural gas reformer

Power systems based on fuel cells have been considered for residential and commercial applications in energy Distributed Generation (DG) markets. In this work we present an experimental analysis of a power generation system formed by a 5 kW proton exchange membrane fuel cell (PEMFC) unit and a natural gas reformer (fuel processor) for hydrogen production. The performance analysis developed simultaneously the energy and economic viewpoints and enabled the determination of the best technical and economic conditions of this energy generation power plant, and the best operating strategies, enabling the optimization of the overall performance of the stationary cogeneration fuel cell unit. It was determined the electrical performance of the cogeneration system in function of the design and operational power plant parameters. Additionally, it was verified the influence of the activation conditions of the fuel cell electrocatalytic system on the system performance. It also appeared that the use of hydrogen produced from the natural gas catalytic reforming provided the system operation in excellent electrothermal stability conditions resulting in increase of the energy conversion efficiency and of the economicity of the cogeneration power plant.     

Measuring method for flow rate distribution between cells in a polymer electrolyte fuel cell stack

The fuel cell transmogrified from a single cell that was the research object to stack is used in various fields such as cars, portable power sources, and fuel-cell cogeneration systems. It is preferable in the stack for the flow rate distribution between cells to be uniform because of the performance gain in power generation efficiency and longevity. As for the flow rate distribution between cells, the method for measuring using smoke in the measuring method and making visible the heat distribution in the stack is reported. However, a research stack was used with these measures, not a stack for practical use. In this report, a method for measuring the flow rate distribution between cells which can also be used for a cell that uses hydrogen limiting current in practical use was examined.     

The durability investigation of a 10‐cell metal bipolar plate proton exchange membrane fuel cell stack

The metal bipolar plates (BPs) have replaced the graphite BPs in vehicle‐used proton exchange membrane fuel cell (PEMFC) stack because of their high volume power density. To investigate the durability of metal BP stack, this paper performed a durability test of 2000 hours on a 10‐cell metal BP fuel cell stack. The degradations of the average voltage and individual cell voltage in fuel cell stack were analyzed. To investigate the degradation mechanism, the stack was disassembled and the morphologies and compositions of no. 1, no. 5, and no. 10 cells after 2000 hours were characterized by SEM, TEM, and ASS. The results indicated that at 800 mA/cm², the voltage decay rate is 42.303 μV/hour and the voltage decay percentage of the stack is 14.34% after 2000 hours according to the linearly fitting result. According to the US Department of Energy (DOE) definition of fuel cell stack life, only the voltage decay rate of OCV and the tenth cell is lower than the maximum voltage degradation rates of 10 000 hours. The decreases of homogeneity of stack were the main reason for its performance degradation. Especially for the tenth cell, its performance has almost no drop. The main failure reason of this metal BP stack is structural design rather than metal corrosion. The losses of Pt catalyst and C supporting are the main reason of performance degradation.     

Modelling,simulation and control of a proton exchange membrane fuel cell (PEMFC) power system

Fuel cell power systems are emerging as promising means of electrical power generation on account of the associated clean electricity generation process, as well as their suitability for use in a wide range of applications. During the design stage, the development of a computer model for simulating the behaviour of a system under development can facilitate the experimentation and testing of that system's performance. Since the electrical power output of a fuel cell stack is seldom at a suitable fixed voltage, conditioning circuits and their associated controllers must be incorporated in the design of the fuel cell power system. This paper presents a MATLAB/Simulink model that simulates the behaviour of a Proton Exchange Membrane Fuel Cell (PEMFC), conditioning circuits and their controllers. The computer modelling of the PEMFC was based on adopted mathematical models that describe the fuel cell's operational voltage, while accounting for the irreversibilities associated with the fuel cell stack. The conditioning circuits that are included in the Simulink model are a DC–DC converter and DC–AC inverter circuits. These circuits are the commonly utilized power electronics circuits for regulating and conditioning the output voltage from a fuel cell stack. The modelling of the circuits is based on relationships that govern the output voltage behaviour with respect to their input voltages, switching duty cycle and efficiency. In addition, this paper describes a Fuzzy Logic Controller (FLC) design that is aimed at regulating the conditioning circuits to provide and maintain suitable electrical power for a wide range of applications. The model presented demonstrates the use of the FLC in conjunction with the PEMFC Simulink model and that it is the basis for more in-depth analytical models.     

Experimental study on vibration-induced clamping force reduction in fuel cell structures

When applied to transportation systems, fuel cell structures are exposed to external mechanical disturbance including shocks and harmonic excitations from operating components. To minimize performance degradation from machine operations, the fuel cell structure needs to be examined via vibration reliability tests. In this study, the reduction in the clamping force of the stack by random vibrations was investigated by experiments. The stack mass and gasket were clamped with bolts for vibration tests. The vibration induced shear movements between clamped stacks. To estimate the vibration input magnitudes, the Dirlik method was used. The reduction in the stack clamping force was estimated using the Basquin's power law. The clamping force decreased by the shear vibration input to the stack structure. The degree of clamping force reduction was larger for the heavier stack. When the stacks were separated by the gasket the reduction became smaller. Through the Dirlik method, the vibration reliability of the stack was evaluated. This information provides severity of the external vibration on the stack functionality.     

Fuel cell micro-CHP techno-economics: Part 2 – Model application to consider the economic and environmental impact of stack degradation

This article presents a literature review regarding the mechanisms of fuel cell degradation, accompanied by the reported range of observed degradation rates in experimental, demonstration and early commercial systems. It then synthesises and exploits this information to investigate the influence of degradation on the economic and environmental credentials of fuel cell micro-combined heat and power (micro-CHP) for the UK residential sector. The investigation applies a techno-economic model developed in the companion article designed to demarcate the key characteristics of commercially successful systems. Two distinct modes of degradation are examined; one proportional to power density in the stack, and the other proportional to thermal-cycling rate of the stack. It is found that limiting the power-density related degradation rate is very important from economic and environmental viewpoints, but thermal-cycling related degradation is less important when thermal energy storage is available because cycling can be avoided. Furthermore it is noted that techno-economic studies that ignore degradation can overestimate the marginal value of a micro-CHP system with respect to the conventional alternative by up to 45% and the CO₂ emissions reduction potential by up to 57%, for performance degradation rates of 2% per MW_eh output. This conclusion is noteworthy because most techno-economic analyses of fuel cells ignore degradation, potentially providing misleading results. Finally it is concluded that existing commercial degradation targets, such as the SECA targets, are appropriate for achieving marketable systems.     

Kinetic studies of cathode degradation on PEM fuel cell short stack level undergoing freeze startups with different states of residual water and current draws

One of the biggest challenges for a wide spread introduction of polymer electrolyte membrane fuel cells in automotive applications is the freeze start at subzero temperatures as this poses a severe threat to fuel cell performance and overall lifetime. Therefore, the impact of current draw during stack freeze startup at various rest water contents and current densities was investigated applying state of the art in-situ testing as quasi cyclic voltammetry.The results indicate a clear dependency between number of freeze startups and performance loss, whereas higher initial water content within the stack reduced its destructive impacts.In our earlier work we were able to show the dependency between residual water and degradation for non-freeze-startup-capable systems at the unit cell level [31]. With this work we confirm that the same physical relationship also applies to freeze-startup-capable systems on the short stack level.Furthermore, reversible performance losses that were encountered during this study can be assigned to oxidizable fuel contaminants, which are believed to be CO, and an easy cleansing procedure is being suggested.     

Energy,exergy, and environmental (3E) assessments of an integrated molten carbonate fuel cell (MCFC), Stirling engine and organic Rankine cycle (ORC) cogeneration system fed by a biomass-fueled gasifier

In this paper, a novel syngas-fed combined cogeneration plant, integrating a biomass gasifier, a molten carbonate fuel cell (MCFC), a heat recovery steam generator (HRSG) unit, a Stirling engine, and an organic Rankine cycle (ORC), is introduced and thermodynamically analyzed to recognize its potentials compared to the previous solo/combined systems. For the proposed system, energetic, exergetic as well as environmental evaluations are performed. Based on the results, the gasifier and the fuel cell have a significant contribution to the exergy destruction of the system. Through a parametric study, the current density and the stack temperature difference are known as the main effective factors on the plant performance. Meanwhile, dividing the whole system into three sub-models, i.e., model (1): power production plant including the gasifier and MCFC without including Stirling engine, HRSG, and ORC unit, model (2): the cogeneration system without ORC unit, and model (3): the whole cogeneration system, an environmental impact assessment is carried out regarding CO₂ emission. Considering paper as biomass revealed that maximum value of exergy efficiency is 50.18% with CO₂ emissions of 28.9 × 10⁻² t.MWh⁻¹ which compared to the solo MCFC system indicates 28.40% increase and 13.3 × 10⁻² t.MWh⁻¹ decrease in exergy efficiency and CO₂ emission, respectively.     

High-performance gas–electricity cogeneration using a direct carbon solid oxide fuel cell fueled by biochar derived from camellia oleifera shells

Direct carbon solid oxide fuel cells (DC-SOFCs) are promising for generating electricity cleanly and efficiently from solid carbon fuel. Biochar from Camellia oleifera shells is used in a tubular electrolyte-supported 2-cell DC-SOFC stack with a yttrium-stabilized zirconia (YSZ) electrolyte and silver–gadolinium-doped ceria (Ag-GDC) as symmetrical electrodes. The DC-SOFC exhibits comparable electrical performance to the same cell operated on hydrogen fuel and can cogenerate CO and electricity when fueled by biochar. The gas–electricity cogeneration performance of the DC-SOFC is tested under constant-current discharge in terms of electrical power output, CO output rate and purity, electrical conversion efficiency, and gas–electrical cogeneration conversion efficiency. The purity of the output CO can reach more than 80%. Considering the chemical energy of CO a part of the output power, the energy conversion efficiency of >70% is attained. Furthermore, the gas–electricity cogeneration performance is relatively stable before the biochar fuel is exhausted.     

Proton exchange membrane fuel cell degradation prediction based on Adaptive Neuro-Fuzzy Inference Systems

This paper studies the prediction of the output voltage reduction caused by degradation during nominal operating condition of a PEM fuel cell stack. It proposes a methodology based on Adaptive Neuro-Fuzzy Inference Systems (ANFIS) which use as input the measures of the fuel cell output voltage during operation. The paper presents the architecture of the ANFIS and studies the selection of its parameters. As the output voltage cannot be represented as a periodical signal, the paper proposes to predict its temporal variation which is then used to construct the prediction of the output voltage. The paper also proposes to split this signal in two components: normal operation and external perturbations. The second component cannot be predicted and then it is not used to train the ANFIS. The performance of the prediction is evaluated on the output voltage of two fuel cells during a long term operation (1000 h). Validation results suggest that the proposed technique is well adapted to predict degradation in fuel cell systems.     

Thermal and electrical energy management in a PEMFC stack – An analytical approach

An analytical method has been developed to differentiate the electrical and thermal resistance of the PEM fuel cell assembly in the fuel cell operating conditions. The usefulness of this method lies in the determination of the electrical resistance based on the polarization curve and the thermal resistance from the mass balance. This method also paves way for the evaluation of cogeneration from a PEMFC power plant. Based on this approach, the increase in current and resistance due to unit change in temperature at a particular current density has been evaluated. It was observed that the internal resistance of the cell is dependent on the electrode fabrication process, which also play a major role in the thermal management of the fuel cell stack.     

Optimization of powerplant component size on board a fuel cell/battery hybrid bus for fuel economy and system durability

The size of the individual powerplant components on board a fuel cell/battery hybrid vehicle affects the power management strategy which determines both the fuel economy and the durability of the fuel cell and the battery, and thus the average lifetime cost of the vehicle. Cost is one of the major barriers to the commercialization of fuel cell vehicles, therefore it is important to study how the sizing configuration affects overall vehicle cost. In this paper, degradation models for the fuel cell and the battery on board a fuel cell/battery hybrid bus are incorporated into the power management system to extend their lifetimes. Different sizing configurations were studied and the results reveal that the optimal size with highest lifetime and lowest average cost is highly dependent on the drive cycle. The vehicle equipped with a small fuel cell stack serving as a range extender will fail earlier and consume more fuel under drive cycles with high average power demand resulting in higher overall cost. However, the same configuration gives optimal results under a standard bus cycle with lower average power demand. At the other end of the spectrum, a fuel cell-dominant bus does not guarantee longer lifetime since the fuel cell operates mostly under low-load conditions which correspond to higher potentials reducing lifetime. Such a configuration also incurs a higher initial capital cost of the fuel cell stack resulting in a high average cost. The best configuration is a battery-dominated system with moderately-sized fuel cell stack which achieves the longest lifetime combined with the lowest average running cost throughout the lifetime of the vehicle.     

A thermodynamic investigation of the potential for cogeneration for fuel cells

The cogeneration potential of several types of fuel cell systems (phosphoric acid, alkaline, solid polymer electrolyte, molten carbonate, and solid oxide) is examined using energy and exergy analyses. In the analysis, each fuel cell system is modelled as a device for which the inputs are fuel and air, and the outputs are electrical- and thermal-energy products and material and thermal-energy wastes. Energy and exergy efficiencies, for cogeneration and non-generation modes of operation, are presented for each fuel cell system. The results indicate that exergy analyses evaluate performance on a rational and meaningful basis (mainly because they consider the “equivalent work potentials” of the thermal- and electrical-energy products), and that energy analyses often present misleadingly optimistic views of performance. It is concluded that exergy analyses should be used when examining the cogeneration potential of fuel cell systems.