A 75-kW methanol reforming fuel cell system

A 75-kW methanol reforming fuel cell system, which consists of a fuel cell system and a methanol auto-thermal reforming fuel processor has been developed at Dalian Institute of Chemical Physics, Chinese Academy of Sciences (CAS). The core of the fuel cell system is a group of CO tolerant PEMFC stacks with a double layer composite structured anode. The fuel cell stacks show good CO tolerance even though 140 ppm CO was present in the reformate stream during transients. The auto-thermal reforming (ATR) fuel cell processor could adiabatically produce a suitable reformate without external energy consumption. The output of hydrogen-rich reformate was approximately 120 N m³ h⁻¹ with a H₂ content near 53% and the CO concentrations generally were under 30 ppm. The fuel cell system was integrated with the methanol reforming fuel processor and the peak power output of the fuel cell system exceeded 75 kW in testing. The hydrogen utilization approached 70% in the fuel cell system.     

Testing of a small-scale stand-alone power system based on solar energy and hydrogen

An experimental small-scale stand-alone power system based on hydrogen and solar energy has been tested. The system performance and operational experience are reported. Future expansion of the test-facility is taken into consideration using solutions with wide working ranges. The test-facility is designed for testing of individual components, for subsystems, and for complete power system operation. The complete power system in this study consists of a 4.8 kW programmable power supply, 1.5 kW electrolyser, a hydrogen purification unit (99.999% H₂ quality), a 14 Nm³ H₂ metal hydride storage, a 0.5 kW fuel cell, a 300 Ah lead-acid battery, and a 0.6 kW programmable load. Possible applications for such small-scale power systems are mountain cabins, remote islands, and telecommunication stations, among others. The basic idea in this particular power system configuration was to make it as simple as possible; the fuel cell and the metal hydride unit were air-cooled, and the components were connected in parallel without DC/DC converters. The only control action possible in the power system (presented in this study) was to switch the components either ON or OFF. However, connecting the components electrically in parallel without DC/DC converters gives no degrees of freedom regarding the ability to regulate power and voltage levels of the different components. Air-cooled metal hydrides might fail to deliver hydrogen due to poor heat transfer.     

Simulation of a low temperature water gas shift reactor using the heterogeneous model/application to a pem fuel cell

In the last few years, a renewed interest in the water gas shift (WGS) reaction at low temperature has arisen due to its application to fuel cells.In this work, a simulation of a fixed bed reactor for this reaction, which forms part of a hydrogen production–purification train for a 10 kW PEM fuel cell using ethanol as the raw material, was carried out. A commercial Cu/Zn/Ba/Al₂O₃ catalyst was employed and a one-dimensional heterogeneous model was applied for the simulation. The catalyst deactivation due to thermal factors (sintering) was taken into account in the model. Isothermal and adiabatic regimes were analyzed as well.Results of the simulation indicate that the pellet can be considered isothermal but temperature gradients in the film cannot be disregarded. On the other hand, concentration gradients in the film can be ignored but CO profiles are established inside the pellet. Adiabatic operation can be recommended because of its simplicity of operation and construction. The reactor volume is strongly sensitive to the CO outlet concentration at CO levels lower than 6000 ppm. For a 10 kW PEM fuel cell, using adequate pellet size and taking into account the catalyst deactivation, a reactor volume of 0.64 l would be enough to obtain an outlet CO concentration of about 7160 ppm. This concentration value can be handled by the next purification stage, COPROX.     

Fuel cell operation on landfill gas at Penrose Power Station

This demonstration test successfully demonstrated the operation of a commercial phosphoric acid fuel cell (FC) on landfill gas (LG) at the Penrose Power Station in Sun Valley, CA. Demonstration output included operation up to 137 kW; 37.1% efficiency at 120 kW; exceptionally low secondary emissions (dry gas, 15% O₂) of 0.77 ppmV CO, 0.12 ppmV NO_x, and undetectable SO₂; no forced outages with an adjusted availability of 98.5%; and a total of 707 h of operation on LG. The LG pretreatment unit (GPU) operated for a total of 2297 h, including the 707 h with the FC, and documented total sulfur and halide removal to much lower than the specified <3 ppmV for the FC. The GPU flare safely disposed of the removed LG contaminants by achieving destruction efficiencies greater than 99%.     

Experimentation on a cogenerative system based on a microturbine

The paper reports on experimental results of an energetic characterization of a cogenerative plant. The generator is a microturbine Turbec T100-CHP integrated in a heat recovery system. For operation in standard conditions the maximum electrical and thermal power generated are, respectively, 105 and 167 kW. Experimental tests were run by varying the electrical power produced between 50 and 110 kW with 10 kW stepping. For each step the set-point of the water temperature at the outlet of the recuperator was varied in the range 60–80 °C with 5 °C stepping. In every operating condition the measurement system allows the real-time calculation of the quantities needed for the energetic characterization of the plant, such as efficiency indices and PES (primary energy saving index). It is seen that performances remain essentially constant in the range 80–110 kW. A moderate decrease is then observed until about 60 kW, while a further reduction of the electrical power implies a clear worsening (PES decreases from about 30% to 16% in the tested range). Furthermore, environmental impact has been investigated with respect to gaseous and acoustic emissions. In particular the concentration of pollutants in exhaust gases, except for NO_x and CO₂, strongly increases by reducing the electrical power output.     

Development of a 1 kW polymer electrolyte fuel cell power source

This paper reports on the development of key components, specifications, configuration and operating characteristics of a hydrogen-fueled portable power source with polymer electrolyte fuel cell (PEFC). A 1 kW class fuel cell module operating on an exclusive method of internal humidification was developed for the power source. A dc–ac inverter, in which a general-purpose integrated power module (IPM) was used as a switching device for microprocessor-based power conversion control, was developed to save the cost of generating dc power output from the cell module. The power source supplies full power within 2 min from start-up, and is capable of generating rated 1 kW power for about 3 h and even longer if the cylinders are replaced. This power source has been confirmed to offer a high power generation efficiency of 30% or higher in overall output range, yielding good-quality power with little noise.     

Development of portable fuel cell arrays with printed-circuit technology

Portable hydrogen/oxygen fuel cell power sources were constructed using printed-circuit board (PCB) technology. Multiple iterations of miniature planar fuel cell devices were prototyped, demonstrating fast cycle innovation and dramatic power density improvements in <1 year of development. Several novel flow structure and gas routing designs were explored. Electrical interconnections for configurable voltage were wired on board by printed-circuit traces and vias. Fuel cell device voltages ranging from 1 V single cells to 16 V planar arrays were demonstrated, with power output ranging from <1 to >200 W. The lightweight laminate PCB technology allows the best prototypes to achieve >700 mW/cm² area power density and >400 mW/cm³ volumetric power density. PCB technology offers an intriguing platform for portable fuel cell development below 1 kW. Possibilities for on board diagnostics/control and further power density improvements are envisioned.     

Experimental evaluation of a low-power direct air-cooled double-effect LiBr–H2O absorption prototype

This paper describes a new small air-cooled double-effect LiBr–H₂O absorption prototype directly powered by fuel and discusses the experimental findings for some tests carried out in Madrid in 2007, with natural gas as energy source. The prototype, which has been designed to supply 7 kW of cooling power, was able to chill water up to 7–18 °C under extreme outdoor temperatures. A new flat-sheet adiabatic absorber was used allowing it to operate at outdoor temperatures about 45 °C without any sign of crystallization. A mean daily coefficient of performance (COP) of about 1.05 was obtained. Since this absorption machine does not need cooling tower, there is neither water consumption nor Legionella pollution. Moreover, it is a quite compact unit. The ratio of cooling power over volume is about 6.0 kW/m³, while for the only air-cooled absorption chiller, Rotartica 045v, in the marked until 2009 this ratio is 4 kW/m³. When comparing with electric chillers presently on the market, this prototype was found to have a cooling cost approximately 15.9% higher and an environmental impact 16.7% lower. The absorption prototype is a more environmentally friendly solution as it does not emit fluorinated refrigerants.     

Ecological efficiency in thermoelectric power plants

This work evaluates the environmental impact resulting from the natural gas and diesel combustion in thermoelectric power plants that utilize the combined cycle technology (CC), as regarding to Brazilian conditions according to Thermopower Priority Plan (TPP). In the regions where there are not natural gas the option has been the utilization of diesel and consequentily there are more emission of pollutants. The ecological efficiency concept, which evaluates by and large the environmental impact, caused by CO₂, SO₂, NO_x and particulate matter (PM) emissions. The combustion gases of the thermoelectric power plants working with natural gas (less pollutant) and diesel (more pollutant) cause problems to the environment, for their components harm the human being life, animals and directly the plants. The resulting pollution from natural gas and diesel combustion is analyzed, considering separately the CO₂, SO₂, NO_x and particulate matter gas emission and comparing them with the in use international standards regarding the air quality. It can be concluded that it is possible to calculate thermoelectric power plant quantitative and qualitative environment factor, and on the ecological standpoint, for plant with total power of 41 441 kW, being 27 170 kW for the gas turbine and 14271 kW for the steam turbine. The natural gas used as fuel is better than the diesel, presenting ecological efficiency of 0.944 versus 0.914 for the latter, considering a thermal efficiency of 54% for the combined cycle.     

Experimental studying of a small combined cold and power system driven by a micro gas turbine

A small combined cold and power (SCCP) system is presented. An experimental study of the performance of the SCCP system is described. The gas fuelled SCCP system uses a micro gas turbine generator set and an absorption chiller. The test facility designed and built is also described. The rated electricity power of the micro gas turbine generator is about 24.5 kW at the experimental conditions. When exhaust gas from the micro gas turbine is used to drive the absorption chiller, the rated cooling capacity is 52.7 kW without supplying fuel to burn in the absorption chiller and 136.2 kW with supplying about 78.9 kW LPG fuel to burn in the absorption chiller, respectively. Primary energy rate (PER) and comparative saving of primary energy demand are used to evaluate the performance of the SCCP system. PER of the SCCP system decreases rapidly with the decrease of electric power output when the electric power output is less than 10 kW. The calculated results also show that comparative saving of primary energy demand of the SCCP system decreases with the decrease of electric power output and the SCCP system do not save primary energy comparing to conventional energy system when the electric power output is less than 10 kW.     

System design of a large fuel cell hybrid locomotive

Fuel cell power for locomotives combines the environmental benefits of a catenary-electric locomotive with the higher overall energy efficiency and lower infrastructure costs of a diesel-electric. A North American consortium, a public–private partnership, is developing a prototype hydrogen-fueled fuel cell-battery hybrid switcher locomotive for urban and military-base rail applications. Switcher locomotives are used in rail yards for assembling and disassembling trains and moving trains from one point to another. At 127 tonnes (280,000 lb), continuous power of 250 kW from its (proton exchange membrane) PEM fuel cell prime mover, and transient power well in excess of 1 MW, the hybrid locomotive will be the heaviest and most powerful fuel cell land vehicle yet. This fast-paced project calls for completion of the vehicle itself near the end of 2007. Several technical challenges not found in the development of smaller vehicles arise when designing and developing such a large fuel cell vehicle. Weight, center of gravity, packaging, and safety were design factors leading to, among other features, the roof location of the lightweight 350 bar compressed hydrogen storage system. Harsh operating conditions, especially shock loads during coupling to railcars, require component mounting systems capable of absorbing high energy. Vehicle scale-up by increasing mass, density, or power presents new challenges primarily related to issues of system layout, hydrogen storage, heat transfer, and shock loads.     

Development of a miniaturized polymer electrolyte membrane fuel cell with silicon separators

The fabrication process and electrochemical characterization of a miniaturized PEM fuel cell with silicon separators were investigated. Silicon separators were fabricated with silicon fabrication technologies such as by photolithography, anisotropic wet etching, anodic bonding and physical vapor deposition (PVD). A 400 μm × 230 μm flow channel was made with KOH wet etching on the front side of a silicon separator, and then a 550 nm gold current collector and 350 nm TiN_x thin film heater were respectively formed on the front side and the opposite side by PVD. Two separators were assembled with the membrane electrode assembly (MEA) having a 4 cm² active area for the single cell. With pure hydrogen and oxygen under atmospheric pressure without humidification, the performance of the single fuel cell was measured. A single cell operation led to generation of 203 mW cm⁻² at 0.6 V at room temperature, which corresponded to 360 mW cm⁻³ in terms of volumetric fuel cell power density, with 20 ccm of gas flow rate of hydrogen and oxygen at the inlet.     

Electrocatalysis of oxygen reduction on carbon supported Ru-based catalysts in a polymer electrolyte fuel cell

Powder of nanosized particles of Ru-based (Ru_x, Ru_xSe_y and Ru_xFe_ySe_z) clusters were prepared as catalysts for oxygen reduction in 0.5 M H₂SO₄ and for fuel cells prepared by pyrolysis in organic solvent. These electrocatalysts show a high uniformity of agglomerated nanometric particles. The reaction kinetics were studied using rotating disk electrodes and an enhanced catalytic activity for the powders containing selenium and iron was observed. The Ru-based electrocatalysts were used as the cathode in a single prototype PEM fuel cell, which was prepared by spray deposition of the catalyst on the surface of Nafion^® 117 membranes. The electrochemical performance of each single fuel cell was compared to that of a platinum/platinum conventional membrane electrode assembly (MEA), using hydrogen and oxygen feed streams. A maximum power density of 140 mW cm⁻², at 80 °C with 460 mA cm⁻² was obtained for the Ru_xFe_ySe_z catalysts; approximately 55% lower power density than that obtained with platinum.     

Direct oxidation of jet fuels and Pennsylvania crude oil in a solid oxide fuel cell

A Cu-ceria solid oxide fuel cell (SOFC) is shown to generate electric power using jet fuels and Pennsylvania crude oil through direct oxidation of the fuels. The liquid fuels contained up to 910 ppm of sulfur and were injected into the anode compartment either with or without N₂ dilution. The performance of the fuel cell was stable over 30 h for jet fuels and Pennsylvania crude oil without N₂ dilution whereas N₂ dilution prolonged the stable power generation up to 100 h for jet fuel and up to 80 h for Pennsylvania crude oil. The generated power density was about 0.1 W cm⁻² for both fuels.     

Diesterol: An environment-friendly IC engine fuel

Diesterol is a new specific term which denotes a mixture of fossil diesel fuel (D), vegetable oil methyl ester called biodiesel (B) and plant derived ethanol (E). In the context of the present paper, this term refers specifically to the combination of diesel fuel, bioethanol produced from potato waste, dehydrated in a vapor phase using 3A Zeolite, and sunflower methyl ester produced through transesterification. The mixture of DBE, i.e. diesterol, was patented under the Iranian patent No. 39407, dated 12-3-2007. The main purpose of this research work was to reduce engine exhaust NO_x, CO, HC and smoke emissions due to application of biofuel and the increase of fuel oxygen content. It was needed to prepare suitable low cost and renewable additives. The diesterol properties such as pour point, viscosity, flash point, copper strip corrosion, ash content, sulfur content and cetane number were determined experimentally. The optimum ratio of bioethanol and biodiesel was found to be 40/60 considering fuel oxygen content, fuel price and mixture properties. Bioethanol was added to enhance the oxygenated component in the fuel, while the sunflower methyl ester was added to maintain the fuel stability at low temperatures. The parameters considered for investigation are the engine power, torque, specific fuel consumption and exhaust emissions for various mixture proportions. The experimental results showed that bioethanol plays an important role in determining the flash point of the blends. By adding 3% bioethanol to diesel and sunflower methyl ester, the flash point was reduced by 16 °C. The viscosity of the blend was also reduced by increasing the amount of bioethanol. The sulfur content of bioethanol and sunflower methyl ester is very low compared to diesel fuel. The sulfur content of diesel is 500 ppm whereas that of bioethanol and sunflower methyl ester is 0 and 15 ppm, respectively. This lower sulfur content is another factor enhancing the use of fuel blends in diesel engines. The bioethanol and sunflower methyl ester combination has sulfur content less than 20 ppm. The maximum power and torque using diesel fuel were 17.75 kW and 64.2 Nm at 3600 and 2400 rpm, respectively. Adding oxygenated compounds to the new blend seems to slightly reduce the engine power and torque and increased the average sfc for various speeds. The experimental measurement and observation of smoke concentration, NO_x, CO and HC concentration indicated that both of these pollutants reduced by increasing the biofuel composition of diesterol throughout the engine operating range.     

Development of 10 kW-scale hydrogen generator using chemical hydride

We have developed a hydrogen generator that generates high purity hydrogen gas from the aqueous solution of sodium borohydride, NaBH₄. This paper discussed the performance testing of the hydrogen generator using a Pt-LiCoO₂-coated honeycomb monolith. The NaBH₄ solution hydrolyzed to generate H₂ and sodium metaborate when it contacted the monolith. The gravimetric and the volumetric H₂ densities of the system were 2 wt.% and 1.5 kg H₂/100 l, respectively. The volumetric density was similar to that of the compressed H₂ at 25 MPa. The hydrogen generator successfully provided a maximum H₂ generation rate of 120 nl/min. Assuming a standard PEM (polymer electrolyte fuel cell, PEFC) fuel cell operated at 0.7 V, generating 120 nl/min was equivalent to12 kW.     

Analysis of stationary fuel cell dynamic ramping capabilities and ultra capacitor energy storage using high resolution demand data

Current high temperature fuel cell (HTFC) systems used for stationary power applications (in the 200–300 kW size range) have very limited dynamic load following capability or are simply base load devices. Considering the economics of existing electric utility rate structures, there is little incentive to increase HTFC ramping capability beyond 1 kWs⁻¹ (0.4% s⁻¹). However, in order to ease concerns about grid instabilities from utility companies and increase market adoption, HTFC systems will have to increase their ramping abilities, and will likely have to incorporate electrical energy storage (EES). Because batteries have low power densities and limited lifetimes in highly cyclic applications, ultra capacitors may be the EES medium of choice. The current analyses show that, because ultra capacitors have a very low energy storage density, their integration with HTFC systems may not be feasible unless the fuel cell has a ramp rate approaching 10 kWs⁻¹ (4% s⁻¹) when using a worst-case design analysis. This requirement for fast dynamic load response characteristics can be reduced to 1 kWs⁻¹ by utilizing high resolution demand data to properly size ultra capacitor systems and through demand management techniques that reduce load volatility.     

Performance and ageing of an anode-supported SOFC operated in single-chamber conditions

Anode-supported cells made of conventional materials were tested in single-chamber conditions under various CH₄/air gas mixtures. Methane-to-oxygen ratio (R_MIX) and nominal temperature between 600 and 800 °C both affect the performance of the cell. At a flow rate of 350 sccm, maximum values of power density (260 mW cm⁻²) and cell voltage (1.05 V) were obtained for R_MIX = 2 at 800 °C. However, short term ageing experiments show that the stability of the cells depends on R_MIX as well as the flow of current. Scanning electron micrographs (SEM) reveal some important changes in anode microstructure close to the fuel inlet that may be, assign to the volatilization of the nickel contained in the Ni–YSZ cermet.     

Effects of slip boundaries on thermal convection in 2D box using lattice Boltzmann method

This work studied the thermal convection under various slip boundary conditions in a 2D box with aspect ratio equal to two. The slip parameter is the normalized tangential momentum accommodation coefficient (TMAC, 0 ? σ ? 1). The results show that the slip boundary conditions of vertical side walls (σ_v) and horizontal plates (σ_h) will affect the pattern selections of the flow and temperature fields. When σ_h < 0.02, the pattern is the one-roll mode for all σ_v. When σ_h ? 0.02 and σ_v ? 0.1, the fluids prefer the two-roll mode where two rolls make the fluids to move upwards in the middle of the box. While σ_h ? 0.02 and σ_v ? 0.2, the fluids prefer the other two-roll mode which makes the fluid to move downwards in the middle of the box.