Cost targets for domestic fuel cell CHP

Fuel cells have the potential to reduce domestic energy bills by providing both heat and power at the point of use, generating high value electricity from a low cost fuel. However, the cost of installing the fuel cell must be sufficiently low to be recovered by the savings made over its lifetime. A computer simulation is used to estimate the savings and cost targets for fuel cell CHP systems.     

A natural-gas fuel processor for a residential fuel cell system

A system model was used to develop an autothermal reforming fuel processor to meet the targets of 80% efficiency (higher heating value) and start-up energy consumption of less than 500 kJ when operated as part of a 1-kWe natural-gas fueled fuel cell system for cogeneration of heat and power. The key catalytic reactors of the fuel processor – namely the autothermal reformer, a two-stage water gas shift reactor and a preferential oxidation reactor – were configured and tested in a breadboard apparatus. Experimental results demonstrated a reformate containing ∼48% hydrogen (on a dry basis and with pure methane as fuel) and less than 5 ppm CO. The effects of steam-to-carbon and part load operations were explored.     

Optimal economic-emission performance of fuel cell/CHP/storage based microgrid

In this paper, optimal heat and power dispatch of the fuel cell (FC) and combined heat and power (CHP) based microgrid (MG) in grid-connected mode is studied in the presence of demand response program (DRP). Considering cost and emission minimization has turned this study to a multi-objective problem. Multiple generating and storing units such as FC, CHP, power-only unit, boiler, battery storage system, and heat buffer tank are considered in investigated MG. Also, demand response program has been modeled, and the effects of such programs on the load profile have been discussed. The DRP transfers some amount of load from peak periods to other periods which flats the load curve and minimizes total cost and emission of the MG. To solve the multi-objective optimization problem, the Pareto solutions are generated by using the compromising programming, then, optimal solution is chosen by implementing the fuzzy satisfying approach. In comparison with other methods, the proposed method has reduced the set of efficient solutions to a more reasonable size without demanding any information about the decision making parameters. Finally, the problem is solved in two cases as with and without DRP to clarify the impact of DRP on MG scheduling.     

Demonstration and development of a polymer electrolyte fuel cell system for residential use

Fuel cell systems, especially those fed with hydrogen, have reached considerable performance targets in laboratory conditions with constant loads and conservative environmental conditions. However, a check of the potential of such systems in real conditions is necessary, particularly in terms of varying electrical and thermal loads and of more severe climatic conditions.To determine the state of the art of such technology and to develop systems capable of supporting future national energy scenarios within the PNR-FISR project, “Polymeric electrolytes and ceramic fuel cells: demonstration of systems and development of new materials,” the development of fuel cell systems ranging from 1 to 5 kW of power and based on either solid polymer (PEMFC) or solid oxide (SOFC) technology are in progress. In this paper, the demonstration of a pre-commercial PEMFC system fed with hydrogen and developed in cooperation with NUVERA is described. The system has been developed in order to determine its limits and capacity in relation to start-up time, response time, consumption, efficiency, reliability, etc. It has currently reached 1000 working hours of continuous performance with variable loads that simulate those of a typical residential dwelling.     

Effects of fuel processing methods on industrial scale biogas-fuelled solid oxide fuel cell system for operating in wastewater treatment plants

The performance of three solid oxide fuel cell (SOFC) systems, fuelled by biogas produced through anaerobic digestion (AD) process, for heat and electricity generation in wastewater treatment plants (WWTPs) is studied. Each system has a different fuel processing method to prevent carbon deposition over the anode catalyst under biogas fuelling. Anode gas recirculation (AGR), steam reforming (SR), and partial oxidation (POX) are the methods employed in systems I-III, respectively. A planar SOFC stack used in these systems is based on the anode-supported cells with Ni-YSZ anode, YSZ electrolyte and YSZ-LSM cathode, operated at 800 °C. A computer code has been developed for the simulation of the planar SOFC in cell, stack and system levels and applied for the performance prediction of the SOFC systems. The key operational parameters affecting the performance of the SOFC systems are identified. The effect of these parameters on the electrical and CHP efficiencies, the generated electricity and heat, the total exergy destruction, and the number of cells in SOFC stack of the systems are studied. The results show that among the SOFC systems investigated in this study, the AGR and SR fuel processor-based systems with electrical efficiency of 45.1% and 43%, respectively, are suitable to be applied in WWTPs. If the entire biogas produced in a WWTP is used in the AGR or SR fuel processor-based SOFC system, the electricity and heat required to operate the WWTP can be completely self-supplied and the extra electricity generated can be sold to the electrical grid.     

Numerical modeling of an automotive derivative polymer electrolyte membrane fuel cell cogeneration system with selective membranes

Cogeneration power plants based on fuel cells are a promising technology to produce electric and thermal energy with reduced costs and environmental impact. The most mature fuel cell technology for this kind of applications are polymer electrolyte membrane fuel cells, which require high-purity hydrogen.The most common and least expensive way to produce hydrogen within today's energy infrastructure is steam reforming of natural gas. Such a process produces a syngas rich in hydrogen that has to be purified to be properly used in low temperature fuel cells. However, the hydrogen production and purification processes strongly affect the performance, the cost, and the complexity of the energy system.Purification is usually performed through pressure swing adsorption, which is a semi-batch process that increases the plant complexity and incorporates a substantial efficiency penalty. A promising alternative option for hydrogen purification is the use of selective metal membranes that can be integrated in the reactors of the fuel processing plant. Such a membrane separation may improve the thermo-chemical performance of the energy system, while reducing the power plant complexity, and potentially its cost. Herein, we perform a technical analysis, through thermo-chemical models, to evaluate the integration of Pd-based H₂-selective membranes in different sections of the fuel processing plant: (i) steam reforming reactor, (ii) water gas shift reactor, (iii) at the outlet of the fuel processor as a separator device. The results show that a drastic fuel processing plant simplification is achievable by integrating the Pd-membranes in the water gas shift and reforming reactors. Moreover, the natural gas reforming membrane reactor yields significant efficiency improvements.     

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.     

Flooding of the diffusion layer in a polymer electrolyte fuel cell: Experimental and modelling analysis

Water management is widely investigated because it affects both the performance and the lifetime of polymer electrolyte fuel cells. Membrane hydration is necessary to ensure the high proton conductivity, but too much water can cause flooding and pore obstruction within the cathode gas diffusion layer and the electrode. Experimental studies prove that the characteristics of the diffusion layer have great influence on water transport; the introduction of a micro-porous layer between the gas diffusion layer and the electrode reduces flooding and stabilizes the performance of the fuel cell, although the reason is not fully explained. A quantitative method to characterize water transport through the diffusion layers was proposed in our previous work, and the present work aims to further understand the flooding phenomenon and the role of the micro-porous layer. The improved experimental setup and methodology allow an accurate and reliable evaluation of water transport through the diffusion layer in a wide range of operating conditions. The proposed 1D + 1D model faithfully reproduces the experimental data adopting effective diffusivity values in agreement with literature. The presented experimental and modelling analysis allows us to evaluate the influence of pore obstruction on the effective diffusivity, the overall transport coefficient and water flow through the diffusion layer, elucidating the effect of the micro-porous layer on fuel cell performance and operation stability.     

Key performance indicators evaluation of a domestic hydrogen fuel cell CHP

The project H2home – decentralised energy supply by hydrogen fuel cells – is part of the HYPOS initiative (Hydrogen Power Storage & Solutions East German) and has the aim to develop an embedded system suitable for the highly efficient use of electrical, thermal and cooling energy provided by green hydrogen in domestic applications. This system is characterized by a hydrogen CHP plant based on a low temperature PEM fuel cell and a hydrogen-based heat generator module with the application of condensation technology as well as an integrated solution for the use of electrical energy in an AC and DC grid through power electronic components. The electric efficiency of the CHP is nearly 50% and the total efficiency higher than 95%.To evaluate the performance of the proposed technology the first step was to model a reference case using the simulation tool TRNSYS^®. Therefore, a multi-family house with 16 residential units was chosen. Within the next step different technologies for the energy supply in complex buildings were identified and evaluated. For this purpose, various Key Performance Indicators (KPI's) have been defined and summarized in three main groups allowing a technical, ecological and economical comparison of the selected technologies. The method as well as the main results of the KPI investigations will be explained in the present paper.     

Part two: Control of a novel HTPEM-based micro combined heat and power fuel cell system

A novel micro combined heat and power system and a dynamic model thereof were presented in part one of the publication. In the following, the control system and dynamic performance of the system are presented. The model is subjected to a measured consumption pattern of 25 Danish single family houses with measurements of heat, power and hot water consumption every 15th minute during one year.     

Experimental investigation on a methane fuel processor for polymer electrolyte fuel cells

This study presents experimental study on a novel methane fuel processing system for hydrogen (H₂) production. The unit includes into a single package the autothermal reformer, the CO shift converter, the preferential oxidation reactor and the internal heat exchangers. Effects of operative conditions, related to the H₂ productivity, on the performances, were investigated experimentally, in order to evaluate the integration of the fuel processor with a Polymer Electrolyte Fuel Cell (PEFC) system for residential applications. The sensitivity analysis showed that the overall performance is strongly dependent upon the operative conditions considered.     

Evaluation of a platinum leasing program for fuel cell vehicles

This paper evaluates the feasibility of a platinum leasing program for future fuel-cell vehicles (FCVs) in the United States. By internalizing the residual value of platinum in the vehicle's upfront cost, a platinum lease may offer cost savings to the consumer. Several leasing scenarios were evaluated to estimate potential cash savings.     

Experimental investigation of parameters influencing the freeze start ability of a fuel cell system

To improve the freeze start ability of a fuel cell system some significant influencing parameters are defined and investigated. Experiments with a fuel cell test system are carried out in a climate chamber at various conditions. The time interval until fuel cell stack power equals 50% of its maximum power is defined as an indicator for a successful freeze start as well as a value for comparison and evaluation of the results. The target of this work is the minimization of this freeze start time by avoiding the freezing of process water on the catalyst layer of the Membrane Electrode Assembly (MEA), since this leads to temporary performance losses.The shut down strategy of the fuel cell system is identified to be one of the main parameters influencing the freeze start. It is found that a higher degree of dryness in the stack leads to a significant improvement in the freeze start performance, since the water absorbing capacity of the membrane increases and therefore also the time until its saturation. If this saturation takes place after the temperature of the MEA reached 0 °C, no significant ice-formation occurs. It is shown that by improving the shut down strategy of the fuel cell system at T_Start = −6 °C a start without performance loss can be realized. At temperatures lower than that temporary performance losses occur.Even if a lower voltage leads to a higher current and therefore to a higher water production rate, its effect on the freeze start due to the increased heat of reaction is positive. Further investigated parameters, for example the volume of the coolant loop, also affect the freeze start ability, but it can be concluded that the shut down strategy is of main importance.     

Simulated start-stop as a rapid aging tool for polymer electrolyte fuel cell electrodes

The corrosion stability of supported catalysts as employed in state of the art intermediate temperature polymer electrolyte fuel cells has been studied by means of simulated start-stop cycling (150 cycles). The carbon dioxide formation from the air electrode has been monitored during repeated cycling runs and the loss of catalyst support has been correlated with performance drops. Degradation effects have been studied at different current densities in order to differentiate between kinetic and mass transport effects. Finally, correlations of this accelerated aging tool with a more realistic durability test over 4000 h and 157 start-stop cycles have been made and the good agreement between simulated and realistic approaches has been confirmed, demonstrating the high value of the experimental approach and analysis.     

Performance comparison between partial oxidation and methane steam reforming processes for solid oxide fuel cell (SOFC) micro combined heat and power (CHP) system

The aim of this research work is to describe in qualitative and quantitative form the performance of a micro Combined Heat and Power system for residential application based on Solid Oxide Fuel Cell fueled by natural gas with two different types of pre-reforming systems, namely Steam Reforming and Partial Oxidation and recirculation of anode and cathode gas.The comparative analysis among the different configurations will lead us to conclude that maximum efficiency is achieved when cathode and anode gas recirculation are used along with steam methane reforming. Further Steam Methane Reforming process produces a higher electrical system efficiency compared to Partial oxidation reforming process.Efficiency is affected when running the system in part load mode mainly due to heat loss, additional natural gas supplied to the burner to satisfy the required heat demand inside the system, and ejector efficiency drop in the recirculation system. Due to high temperature of operation heat loss strongly affects the system efficiency especially at part load operation.     

Air mass flow and pressure optimisation of a PEM fuel cell range extender system

In order to eliminate the local CO₂ emissions from vehicles and to combat the associated climate change, the classic internal combustion engine can be replaced by an electric motor. The two most advantageous variants for the necessary electrical energy storage in the vehicle are currently the purely electrochemical storage in batteries and the chemical storage in hydrogen with subsequent conversion into electrical energy by means of a fuel cell stack. The two variants can also be combined in a battery electric vehicle with a fuel cell range extender, so that the vehicle can be refuelled either purely electrically or using hydrogen. The air compressor, a key component of a PEM fuel cell system, can be operated at different air excess and pressure ratios, which influence the stack as well as the system efficiency. To asses the steady state behaviour of a PEM fuel cell range extender system, a system test bench utilising a commercially available 30 kW stack (96 cells, 409 cm² cell area) was developed. The influences of the operating parameters (air excess ratio 1.3 to 1.7, stack temperature 20 °C–60 °C, air compressor pressure ratio up to 1.67, load point 122 mA/cm² to 978 mA/cm²) on the fuel cell stack voltage level (constant ambient relative humidity of 45%) and the corresponding system efficiency were measured by utilising current, voltage, mass flow, temperature and pressure sensors. A fuel cell stack model was presented, which correlates closely with the experimental data (0.861% relative error). The air supply components were modelled utilising a surface fit. Subsequently, the system efficiency of the validated model was optimised by varying the air mass flow and air pressure. It is shown that higher air pressures and lower air excess ratios increase the system efficiency at high loads. The maximum achieved system efficiency is 55.21% at the lowest continuous load point and 43.74% at the highest continuous load point. Future work can utilise the test bench or the validated model for component design studies to further improve the system efficiency.     

Premixed hydrogen-air combustion system for fuel cell systems

The advance of efficient hydrogen-air combustion systems has increasingly become of interest in the framework of the development of fuel cell systems, especially for the automotive sector. Therefore, compact modulating systems are required, with the additional demand of low emissions, to be integrated in a fuel cell system. A modulating combustion system based on combustion within inert porous media and an integrated heat exchanger has been developed and investigated. The system is able to handle premixed combustion of lean H₂/air mixtures at a surface load range of 1075 kW/m²-2150 kW/m², and a global equivalence ratio of ?=0.5. The special hydrogen-air mixing concept eliminates the risk of flame flashback and enables operation with very low NO_x emissions.     

Fuel cell power conditioning system design for residential application

This paper presents a design of a high performance proton exchange membrane fuel cell (PEMFC) power conditioning system (PCS) for residential application. Firstly, a high efficiency PCS topology is described which can improve the PCS maximum efficiency up to 92.9%. Furthermore, a novel PCS controller is presented, which succeeds in suppressing the low frequency current ripple, controlling the dc link voltage and inverter output current. The controller also achieves reliable power grid integration. The experimental results show that a residential fuel cell PCS with high performance can be achieved.     

Design of a PEM fuel cell system for residential application

Fuel cells are energy transformation technologies and they are clean, don't damage to environment, have high efficiency and provide uninterruptible energy generation. Research and development studies about fuel cells have been done increasingly. In the recent years, fuel cell technologies have performed in some sectors such as military, industrial, space, portable, residential, transportation and trading.     

Advanced control of grid-connected inverters for proton exchange membrane fuel cell system

Voltage support is one of the most important issues for operating grid-connected inverters under grid faults. Many control strategies have been addressed in literature, but most of them focus on the voltage support control without considering issues of power quality due to voltage harmonics. In order to sort out the drawback, a novel advanced control strategy is presented in this paper. It is able to provide the voltage support function. Meanwhile, the power quality is improved by regulating the control coefficients. The time-domain simulation and experimental results are provided to evaluate the conventional and proposed control strategies. The results show that the total harmonic distortion of PCC voltage can be reduced from 9.35% to 2.88% with the proposed solution. Meanwhile, the voltage support is also achieved, which verify the effectiveness of the proposed solution.