5.

Fuel Cell Systems

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 1
 Main Parts of a Fuel Cell System

Usable
Heat

Heat
Recovery
Fuel Fuel DC-AC
Processing Cell Converter
(if necessary)
Fuel H2-Rich DC AC
Gas Gas Power Power

Exhaust
Air
Gas

Fuel Cell System

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 2
 Fuel Cell Systems: A more detailed View

(Fuel conversion is missing here!)

▶ There is much more to a FC-system than just a Fuel Cell!

Santarelli et al., Fuel Cells 10 (2010), 453-462

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 3
 Contents

5. Fuel Cell Systems

5.1 From Fuel to Electricity
5.2 Dynamic load management in FC systems
5.3 Examples of FC systems

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 4
 Examples of Fuel Processing:
Reforming and CO-removal
• Fuel: Gasoline, ethanol,
methanol
• Reforming and CO-
removal
• For use with PEMFC
• 1.3 g/s H2
• 76 l

Tail Gas Comb (unused H2)

Auto Therm Reform
High Temp Shift
Low Temp Shift
Pref Ox

Browers et al., Int. J. Hy. En. 32 (2007), 1437-1442

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 5
 Examples of Fuel Processing:
Anaerobic Digestion and Gas Conditioning

Onion processing plant at Anaerobic digestion and Electrochemical

“Gills Onions” gas clean up conversion in MCFCs

• 2x300kW el MCFCs from “Fuel Cell Energy”

• Project costs $ 10.8 million
• Provides heat & power for the production plant

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 6
 Examples of Fuel Processing:
Gas Cleaning Sequence

• Multiple units
• Frequent heat up / cool down necessary
• Challenging heat integration
• Additives may be necessary

Doyan et al., ECS Trans. 12 (2008), 385-389

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 7
 Examples of Heat Utilisation:
Combined Heat & Power for Households

• 5 kWel PEMFC system by Nuvera (not only HTFC!)

• 40 Cells at 500 cm² each
• 1.7 bar
• Two separate circuits Briguglio et al., Int. J. Hy. En. 36 (2011), 8023-8029

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 8
 Examples of Heat Utilisation:
Gas/Steam Turbine

• Concept for combined Fuel Cell / Cycle

process (bottoming cycle)
• High efficiency
• Heat recovered after afterburner

Doyan et al., ECS Trans. 12 (2008), 385-389

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 9
 Examples of Heat Utilisation:
Gas Turbine

• Siemens-Westinghouse, 300 kW, 1MW

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 10
 Examples of Heat Utilisation:
Gas Turbine with Intercooler and Re-heat Cycle

• Concept for combined Fuel Cell / Cycle process

• Complex heat integration concept
• Useful for plants of several MWel
Ghezel-Ayagh et al., J. Pow. S. 152 (2005), 219-225

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 11
 Examples of System Integration:
Heat Management & Control Loops

• Example of heat integration & control scheme for

combined FC / Gas Turbine system
Yang et al., IEEE Trans. 2008

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 12
 Examples of System Integration:
Heat Management in Fuel Cell Cars

Druckregler H2-Rückführung
Rezirkulationsgebläse

Brennstoffzelle Purgeventil
Luftversorgung
Anode
70 °C Kü
Kathode Kühlmedium

Thermostat
H2 O Befeuchter LA_

Kühler Kühlmittel-
Drossel-
Luftfilter Ladeluft- Pumpe
klappe
kühler

Schall-
M

dämpfer Lüfter
Verdichter M
=

©Volkswagen Aktiengesellschaft

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 13
 Example of System Scale Up:
Cascaded Fuel Cells

• Cascaded combination of two fuel cells

• Operated under different cell voltages
• Inter-feed at anode / cathode is possible
Ghezel-Ayagh et al., FC Sci & Tech 8 (2011), 031011

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 14
 Power Electronics

Classification based on voltage input and output:

• AC to AC: converter AC
AC

• AC to DC: rectifier
• DC to DC: converter
DC DC

• DC to AC: inverter

Fuel cell applications:

Fuel cell voltage System/load voltage
UFC≈0.8 V (DC) e.g. 24 V or 230 V or ...

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 15
 Power Electronics

Three types of DC-DC converter:

• Boost converter (step-up converter)

U U

t t

• Buck converter (step-down converter, chopper)

U U

t t

• Buck-Boost converter (inverting or combination)

U U
t

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 16
 Contents

5. Fuel Cell Systems

5.1 From Fuel to Electricity
5.2 Dynamic load management in FC systems
5.3 Examples of FC systems

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 17
 Dynamical Load Demand:
Drive Cycle Data

Ahmed et al., 2010 Am. Contr. Conf., FrC10.3

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 18
 Dynamical Load Demand:
System layout

• Fluctuating load demands are satisfied by different

sources / storage systems
• FC, battery, capacitor
• Dimensioning of storage systems depends on
assumed drive cycle
Ahmed et al., 2010 Am. Contr. Conf., FrC10.3

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 19
 Load management in Fuel Cell Cars
Traction, board grid

FC System H2 Tank

E-Engine
_
M
3~ ~
Inverter
Gear
Traction battery system
Battery

-
- -
- DC/DC
12 V Battery DC/DC

These components are also used in hybrid cars

(combustion engine / battery systems)

HyMotion 3; ©Volkswagen Aktiengesellschaft

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 20
 Load management in todays Hybrid Cars:
Modes of Operation
Velocity: low Velocity: high

Battery + E-engine Battery + 2 E-engines

Battery:
full

Generator + E-engine Generator + 2 E-engines

Battery:
low

Opel Ampera; ©Adam Opel AG

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 21
 Contents

5. Fuel Cell Systems

5.1 From Fuel to Electricity
5.2 Dynamic load management in FC systems
5.3 Examples of FC systems

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 22
 Stationary Power Supply Systems for Houses

Regelung
Interface

Zusatzbrenner
- Electrical power: 1 - 4,6 kWel
- Heating power: 1,5 - 7 kWth plus ca. 25-50 kWth
- Electric net efficiency > 35 %
- Total efficiency > 80 %
Brennstoffzellen- - Fuel: Natural gas
- System life-time: 15 years, 80 000 h
Stack - Maintenance interval: 2 years (Inspection each year)
- Supply and return temperature max. 70 / 55 °C
Wechselrichter

Reformer

Ref.: www.vaillant.com (2003)

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 23
 Stationary Power Supply Systems (Vaillant)
Elektr. Strom

Abgas Luft Abgas DC/AC

Wechselrichter

Filter
Regelung

Luft
Heizungssystem

Befeuchter
PEM -
Brennstoffzelle
PEM
Abgas H2O

Reformat
Hydr.
Weiche Primärkreislauf
H2O
Nachbrenner
Wasser-
H 2O
reinigung
Erdgas Reformer
“Energy Shift- CO-Reinigung
Manager” air
Heizungs- Converter
Regelung Filter
Entschwefelung
Bus System

Ref.: vailant, BZH_Si_Einfuehrung_Jan01.ppt / GK-B, (2001)

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 24
 Stationary Power Supply Systems
PEMFC 250 kW, Ballard

Process flow diagram for

Ref.: Larminie, J.: Fuel Cell Systems Explained, Wiley, Chichester (2000) Ballard 250 kW PEMFC plant
Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 25
 Modern Fuel Cell Car Systems:
HyMotion3, Volkswagen

• 80 kW PEMFC
• 3.2 kg H2, 700 bar
• 55 kW (peak 100 kW) E-engine
• 1,5 kWh battery capacity

HyMotion 3; ©Volkswagen Aktiengesellschaft

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 26
 Modern Fuel Cell Car Systems:
HyMotion3, Volkswagen

H2 Tanks
Li-ion Battery
Fuel Cell

• 80 kW PEMFC
• 3.2 kg H2, 700 bar
• 55 kW (peak 100 kW) E-engine
• 1,5 kWh battery capacity
E-engine
HyMotion 3; ©Volkswagen Aktiengesellschaft

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 27
 Modern Fuel Cell Car Systems:
Mercedes, BMW

• “B”-class model • Based on “1”-series of BMW

• Hybrid concept • Hybrid concept

© BMW Aktiengesellschaft
© Daimler Aktiengesellschaft

Lecture Fuel Cell Technology, Chair for Process Systems Engineering (Prof. K. Sundmacher) Winter Term 2019/20 28