Architecture design and performance analysis of a hybrid hydrogen fuel cell system for unmanned aerial vehicle

The flight endurance of UAV systems is an important issue that restricts the operational capabilities. Thus, different energy systems and alternative onboard energy generation systems have been tested for the UAVs. Within these systems, fuel cells provide high energy density that can increase flight endurance greatly. In this study, a PEM fuel cell – Li-Po battery hybrid system has been developed by evaluating three architecture models. In the guide of the experimental power demand data of a fixed-wing UAV, modeling and testing procedures were performed. Battery voltage and fuel cell current variations observed during the ground tests were evaluated. It has been observed that approximately 160–170 W of the 250 W power is met by the fuel cell since no preconditioning has been applied and the temperature values at which the fuel cell exhibits its optimum performance. In the case where the fuel cell could provide 7.8 An under conditions where the humidification effects were not included in the model, the required current was over 7.8 A between approximately 400-1200 s. The fuel cell and battery behavior in response to the sudden power changes and to the uncertainties corresponding to the changes in the motor power during the flight are also detailed.     

Influence of pressure losses on compressor performance in a pressurized fuel cell air supply system for airplane applications

Low ambient pressures at elevated flight altitudes lead to power losses in fuel cell powered aircrafts. As countermeasure ambient air can be pressurized with a suitable fuel cell air supply system. In this study the influence of low ambient pressures and pressure losses within the system on the performance of two turbo compressors and the resulting stack power are examined theoretically and the findings validated experimentally. Results show that decreasing ambient pressures and pressure losses in front and after the compressor reduce the maximum pressure from 2.4 to 1.6 bar(a) in the examined system. Air compression may require a significant share of the fuel cell stack power and the maximum system power is reduced from 54 to 41 kW. For air pressures higher than 1.8 bar(a) the fuel cell stack power gain due to pressurization is found to be cancelled out by the increasing power required for air compression.     

Design,fabrication and performance analysis of a 200 W PEM fuel cell short stack

A PEM fuel cell short stack of 200 W capacity, with an active area of 100 cm² has been designed and fabricated in-house. The status of unit cell performance was 0.55 W cm⁻². Based on the unit cell technology, a short stack has been developed. The proper design of uniform flow distribution, cooling plate and compressed end plate were important to achieve the best performance of the short stack. The performance of four cells stack was analyzed in static and dynamic modes. In the static mode of polarization curve, the stack has peak power density of 0.55 W cm⁻² (220 W) at 0.5 V per cell, when the voltage was scanning from low to high voltage (1.5–3.5 V), and resulted in minimum water flooding inside the stack. In this study a series of dynamic loadings were tested to simulate the vehicle acceleration. The fuel cell performances respond to dynamic loading influenced by the hydrogen/air stoichiometric, back pressure, and dynamic-loading time. It was needed high hydrogen stoichiometric and back pressure to maintain high dynamic performance. In the long-time stable power testing, the stack was difficult to maintain at high performance, due to the water flooding at high output power. An adjusting cathode back-pressure method for purging water was proposed to prevent the water flooding at flow channels and maintain the stable output power at 170 W (0.42 W cm⁻²).     

Water management of the DMFC passively fed with a high-concentration methanol solution

The methanol barrier layer adopted for high-concentration direct methanol fuel cells (HC-DMFCs) increases water transport resistance, and makes water management in HC-DMFCs more challenging and critical than that in the conventional direct methanol fuel cell (DMFC) without a methanol barrier layer. In the semi-passive HC-DMFC used in this work, oxygen was actively supplied to the cathode side while various concentrated methanol solutions, 4 M, 8 M, 16 M, and neat methanol, were passively supplied from the anode fuel reservoir. The effects of the cathode relative humidity, cathode pressure, and oxygen flow rate on the water crossover coefficient, fuel efficiency, and overall performance of the fuel cell were studied. Results showed that electrolyte membrane resistance, which was determined by its water content, was the predominant factor that determined the performance of a HC-DMFC, especially at a high current density. A negative water crossover coefficient, which indicated that water flowed back from the cathode through the electrolyte membrane to the anode, was measured when the methanol concentration was 8 M or higher. The back flow of water from the cathode is a very important water supply source to hydrate the electrolyte membrane. The water crossover coefficient was decreased by increasing the cathode relative humidity and back pressure. Water flooding at the cathode was not severe in the HC-DMFC, and a low oxygen flow rate was preferred to decrease water loss and yield a better performance. The peak power density generated from the HC-DMFC fed with 16 M methanol solution was 75.9 mW cm⁻² at 70 °C.     

Variability and comparability of testing procedures for PEMFC stacks and modules regarding performance aspects

Reliable and reproducible testing protocols are needed for fuel cell stacks, modules and subsystems in order to reach comparable results for example in performance measurements. A testing protocol was developed which aims at the performance measurement of fuel cell stacks and modules. Measurements for the reproducibility and comparability were performed on a low temperature polymer electrolyte membrane fuel cell stack and on a fuel cell subsystem. The resulting voltages at the different load steps show a difference in adaption to load changes form the stack and the subsystem. In most cases the stack adapted faster with a more stable voltage. The repeatability of the testing protocols was tested which resulted in a higher degradation of the fuel cell subsystem compared to the stack. The measurements in comparison between two laboratories showed a clear decrease in voltages at the second laboratory. The measurement of the test protocol influences the fuel cell stack with an increase in voltage whereas the voltages decrease for the fuel cell subsystem.     

Development of a lightweight fuel cell vehicle

This paper described the development of a fuel cell system and its integration into the lightweight vehicle known as the Mingdao hydrogen vehicle (MHV). The fuel cell system consists of a 5-kW proton exchange membrane fuel cell (PEMFC), a microcontroller and other supported components like a compressed hydrogen cylinder, blower, solenoid valve, pressure regulator, water pump, heat exchanger and sensors. The fuel cell not only propels the vehicle but also powers the supporting components. The MHV performs satisfactorily over a hundred-kilometer drive thus validating the concept of a fuel cell powered zero-emission vehicle. Measurements further show that the fuel cell system has an efficiency of over 30% at the power consumption for vehicle cruise, which is higher than that of a typical internal combustion engine. Tests to improve performance such as speed enhancement, acceleration and fuel efficiency will be conducted in the future work. Such tests will consist of hybridizing with a battery pack.     

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

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

Design and development of a fuel cell-powered small unmanned aircraft

The design, construction, and flight test of a fuel cell-powered small unmanned aircraft are described. A fuel cell system featuring a polymer electrolyte membrane fuel cell combined with a hydrogen generator, which serves as a new power source alternative to the existing batteries, is proposed. The hydrogen generator uses a catalytic hydrolysis reaction to extract hydrogen from an alkaline solution of sodium borohydride, and constructed with a reactor, pump, separator, and fuel cartridge. Considering the performance characteristics of the fuel cell, the hybrid power management of a fuel cell and a battery was contrived. The fuel cell stack, hydrogen generator, and power management system were evaluated at the various load conditions. A high efficiency unmanned aircraft was designed and fabricated to validate the possibility of the proposed fuel cell system, and a small flight control system was developed for a high endurance test flight. Wind-tunnel tests were conducted before the flight tests under actual flight conditions. The possibility for the utilization of a fuel cell in a small aircraft was validated through the fuel cell powered flight test. The fuel cell aircraft flew for 2 h without incidents in the fuel cell system.     

质子交换膜燃料电池参数敏感性分析

为分析质子交换膜燃料电池（PEMFC）的参数敏感性,采用COMSOL建立三维、两相、等温燃料电池单体模型,对其进行模拟计算。通过分析物质浓度分布、极化曲线及功率密度曲线得到不同的离聚物体积分数、背压对传质及电池性能的影响。计算结果表明：随着离聚物体积分数的增大,欧姆极化损失减小,从而使电池性能得到提升,且随着工作电压的减小,电流密度增幅增大;背压的增加使电流密度增大,改变阴极背压比改变阳极背压造成的影响更大。     

Modeling and parametric study of a 1 kWe HT-PEMFC-based residential micro-CHP system

A detailed thermodynamic, kinetic and geometric model of a micro-CHP (Combined-Heat-and-Power) residential system based on High Temperature-Proton Exchange Membrane Fuel Cell (HT-PEMFC) technology is developed, implemented and validated. HT-PEMFC technology is investigated as a possible candidate for fuel cell-based residential micro-CHP systems, since it can operate at higher temperature than Nafion-based fuel cells, and therefore can reach higher cogeneration efficiencies. The proposed system can provide electric power, hot water, and space heating for a typical Danish single-family household. A complete fuel processing subsystem, with all necessary balance-of-plant components, is modeled and coupled to the fuel cell stack subsystem. The micro-CHP system’s synthesis/design and operational pattern is analyzed by means of a parametric study. The parametric study is conducted to determine the most viable system/component design based on maximizing total system efficiency, without violating the requirements of the system. Four decision variables (steam-to-carbon ratio, fuel cell operating temperature, combustor temperature and hydrogen stoichiometry) were parameterized within feasible limits to provide insight on their effect on the overall performance of the proposed system under study and also to provide input on more efficient design in the future. The system is designed to provide maximum loads of 1 kW_e and 2 kW_th. A sensitivity analysis is applied to investigate the influence of the most important parameters on the simulated performance of the system.     

Integration of a fuel cell into the power system using an optimal controller based on disturbance accommodation control theory

In this paper, the integration of a fuel cell into the power system is treated as a load frequency control (LFC) problem with the fuel cell acting as a load disturbance source. The integration of a fuel cell into the power system results into a change in real power. But changes in real power affect the system frequency. Thus, the integration will result into a change of frequency of the synchronous machines. Hence, we need to design a control scheme for keeping the system in the steady state. An optimal controller based on the disturbance accommodation control (DAC) theory is proposed for this load frequency control problem. For demonstrating the effectiveness of the proposed controller, we have considered a two-area power system with the fuel cell introduced in area 1. The fuel cell is considered as an external disturbance to each subsystem. A mathematical model is derived for each subsystem and based upon these models controllers are designed for keeping each subsystem stable, which in turn stabilizes the overall system. So, the proposed controller is decentralized in nature. To account for the modeling uncertainties, an observer is designed to estimate each subsystem’s own and interfacing variables. The controller uses these estimates to optimize a given performance index and allocate generating unit outputs according to the requirements.     

Fuel cell system with sodium borohydride as hydrogen source for unmanned aerial vehicles

In this study, we design and fabricate a fuel cell system for application as a power source in unmanned aerial vehicles (UAVs). The fuel cell system consists of a fuel cell stack, hydrogen generator, and hybrid power management system. PEMFC stack with an output power of 100 W is prepared and tested to decide the efficient operating conditions; the stack must be operated in the dead-end mode with purge in order to ensure prolonged stack performance. A hydrogen generator is fabricated to supply gaseous hydrogen to the stack. Sodium borohydride (NaBH₄) is used as the hydrogen source in the present study. Co/Al₂O₃ catalyst is prepared for the hydrolysis of the alkaline NaBH₄ solution at room temperature. The fabricated Co catalyst is comparable to the Ru catalyst. The UAV consumes more power in the takeoff mode than in the cruising mode. A hybrid power management system using an auxiliary battery is developed and evaluated for efficient energy management. Hybrid power from both the fuel cell and battery powers takeoff and turning flight operations, while the fuel cell supplies steady power during the cruising flight. The capabilities of the fuel-cell UAVs for long endurance flights are validated by successful flight tests.     

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

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

Thermodynamic analysis and assessment of novel ORC- DEC integrated PEMFC system for liquid hydrogen fueled ship application

Proton-exchange membrane fuel cell (PEMFC) and liquid hydrogen are gaining attention as a power generation system and alternative fuel of ship. This study proposes a novel PEMFC system, integrated with the organic Rankine cycle–direct expansion cycle (ORC-DEC), which exploits cold exergy from liquid hydrogen and low temperature waste heat generated by the PEMFC for application in a liquid hydrogen fueled ship. A thermodynamic model of each subsystem was established and analyzed from the economic, energy, and exergy viewpoints. Moreover, parametric analysis was performed to identify the effects of certain key parameters, such as the working fluid in the ORC, pressure exerted by the fuel pump, cooling water temperature of the PEMFC, and the stack current density on the system performance. The results showed that the proposed system could generate 221 kW of additional power. The overall system achieved an exergy and energy efficiency of 43.52 and 40.45%, respectively. The PEMFC system had the largest exergy destruction, followed by the cryogenic heat exchanger. Propane showed the best performance among the several investigated ORC working fluids and the system performance improved with the increase in the cooling water temperature of the PEMFC. The economic analysis showed that the average payback time of ORC-DEC was 11.2 years and the average net present value (NPV) was $295,268 at liquid hydrogen costing $3 to $7, showing the potential viability of the system.     

Effects of PEMFC operating parameters on the performance of an integrated ethanol processor

In this paper the performance of a complete fuel cell system processing ethanol fuel has been analyzed as a function of the main fuel cell operating parameters. The fuel processor is based on the steam reforming process, followed by high- and low-temperature shift reactors, and carbon monoxide preferential oxidation reactor, which are coupled to a polymeric fuel cell (PEMFC). The goal was to analyze and improve the fuel cell system performance by simulation techniques. PEMFC operation has been analyzed using an available parametric model, which was implemented within HYSYS environment software. Pinch Analysis concepts were used to investigate the process energy integration and determine the maximum efficiency minimizing ethanol consumption. The system performance was analyzed for the SR-12 Modular PEM Generator, the Ballard Mark V fuel cell and the BCS 500 W stack. The net system efficiency is dependent on the required power demand. Efficiency values higher than 50% at low loads and less than 30% at high power demands are computed. In addition, the effect of fuel cell temperature, pressure and hydrogen utilization was analyzed. The trade-off between the reformer yield and the fuel cell performance defines the optimal operation pressure. The cell temperature determines operating zones where the water, involved in the reforming reactions, can be produced or demanded.     

Exergoeconomic analysis of a vehicular PEM fuel cell system

In this study, we deal with the exergoeconomic analysis of a proton exchange membrane (PEM) fuel cell power system for transportation applications. The PEM fuel cell performance model, that is the polarization curve, is previously developed by one of the authors by using the some derived and developed equations in literature. The exergoeconomic analysis includes the PEM fuel cell stack and system components as compressor, humidifiers, pressure regulator and the cooling system. A parametric study is also conducted to investigate the system performance and cost behaviour of the components, depending on the operating temperature, operating pressure, membrane thickness, anode stoichiometry and cathode stoichiometry. For the system performance, energy and exergy efficiencies and power output are investigated in detail. It is found that with an increase of temperature and pressure and a decrease of membrane thickness the system efficiency increases which leads to a decrease in the overall production cost. The minimization of the production costs is very crucial in commercialization of the fuel cells in transportation sector.     

Water and pressure effects on a single PEM fuel cell

A fuel cell is a promising energy conversion system that will eventually become the first-choice for producing power because of its clean or zero-emission nature. A steady-state, two-dimensional mathematical model with pressure and phase change effects for a single PEM fuel cell was developed to illustrate the inlet humidification and pressure effects on proton exchange membrane (PEM) fuel cell performance. This model considers the transport of species along the channel as well as water transfer through the membrane. It can be used to predict trends of the following parameters along the fuel cell channels: mole number of liquid water and water vapor, pressure, temperature, density, viscosity, velocity, saturation pressure, pressure drop, vapor mole fraction, volume flow rate, required pumping power and current density.     

Modeling and off-design performance of a 1 kWe HT-PEMFC (high temperature-proton exchange membrane fuel cell)-based residential micro-CHP (combined-heat-and-power) system for Danish single-family households

A novel proposal for the modeling and operation of a micro-CHP (combined-heat-and-power) residential system based on HT-PEMFC (High Temperature-Proton Exchange Membrane Fuel Cell) technology is described and analyzed to investigate its commercialization prospects. An HT-PEMFC operates at elevated temperatures, as compared to Nafion-based PEMFCs and therefore can be a significant candidate for cogeneration residential systems. The proposed system can provide electric power, hot water, and space heating for a typical Danish single-family household. A complete fuel processing subsystem, with all necessary BOP (balance-of-plant) components, is modeled and coupled to the fuel cell stack subsystem. The micro-CHP system is simulated in LabVIEW™ environment to provide the ability of Data Acquisition of actual components and thereby more realistic design in the future. A part-load study has been conducted to indicate performance characteristics at off-design conditions. The system is sized to provide realistic dimensioning of the actual system.     

Development of hybrid photovoltaic-fuel cell system for stand-alone application

In this paper we present firstly the different hybrid systems with fuel cell. Then, the study is given with a hybrid fuel cell–photovoltaic generator. The role of this system is the production of electricity without interruption in remote areas. It consists generally of a photovoltaic generator (PV), an alkaline water electrolyzer, a storage gas tank, a proton exchange membrane fuel cell (PEMFC), and power conditioning units (PCU) to manage the system operation of the hybrid system. Different topologies are competing for an optimal design of the hybrid photovoltaic–electrolyzer–fuel cell system. The studied system is proposed. PV subsystem work as a primary source, converting solar irradiation into electricity that is given to a DC bus. The second working subsystem is the electrolyzer which produces hydrogen and oxygen from water as a result of an electrochemical process. When there is an excess of solar generation available, the electrolyzer is turned on to begin producing hydrogen which is sent to a storage tank. The produced hydrogen is used by the third working subsystem (the fuel cell stack) which produces electrical energy to supply the DC bus. The modelisation of the global system is given and the obtained results are presented and discussed.     

水下工作柴油机排气降温系统设计及试验

排气背压对柴油机的动力性能和油耗有着重要的影响,排气背压过大会造成动力性能的损失和油耗的增加,因此,在为柴油机设计排气后处理装置时,要充分考虑排气背压的大小。本文针对水下工作的柴油机,设计了一套排气降温系统,可以使得该柴油机在水下工作时,其排气可以被冷却后直接排向大气,并且其动力性能不受影响,这就要求在设计过程中要使整个排气降温系统的流动阻力尽可能最小。通过试验结果表明:加装该排气降温系统后柴油机输出动力性能良好,无功率和转矩损失;特殊管壳式换热器换热效果良好,能使最高温度为503.4℃的高温烟气降低到39.4℃。本文研究的结果对小型水下动力装置排气降温系统的选择和设计有一定的参考价值。