Proton Exchange Membrane Fuel Cell System Identification and Control: Part II — H-Infinity Based Robust Control

This paper applies robust control strategies to a PEM fuel-cell system. In Part I of this work [17], a PEM fuel cell was described as a two-input-two-output system with the inputs of hydrogen and air flow rates, and the outputs of cell voltage and current. From the responses, system identification techniques were adopted to model the system transfer function matrix. Then adaptive control methods were applied to control the system with encouraging results. In this paper, the H∞ robust control strategy is proposed due to the highly nonlinear and time-varying characteristics of the system. From the results, it is illustrated to be an efficient control method for the fuel cell systems.

Methanol Reforming Over PT Catalysts for Polymer Electrolyte Membrane Fuel Cells

An experimental investigation on hydrogen generation from methanol using Pt catalysts is presented in this paper. Methanol has the advantages of high energy density, high reforming activity and low CO selectivity at low temperatures. At present Cu-based catalysts are widely used for methanol reforming. But they are pyrophoric and thermally unstable, which causes issues in operating a real system. Pt catalysts dispersed on cerium oxides were tested for methanol reforming to resolve the problems. Steam reforming over Pt/cerium oxides showed the low conversion ratio less than 90% and the high CO concentration of about 15% at 400 °C. Autothermal reforming by adding O2 rapidly promoted the conversion of methanol and reduced the concentration of CO at lower temperature. Increasing the amount of dispersed Pt, the range of 0.5–3.0 wt%, shifted the reforming trends towards lower temperature and decreased the concentration of CO. To achieve more production rate within a given catalyst bed, catalysts coated monolithic honeycomb is prepared. It showed very high conversion at space velocities of up to 60,000/h.

Partial Validation of a Proposed Rating Methodology for Residential Fuel Cell Systems

The National Institute of Standards and Technology (NIST), in conjunction with Virginia Tech, has developed a rating methodology for residential-scale stationary fuel cell systems. The methodology predicts the cumulative electrical production, thermal energy delivery, and fuel consumption on an annual basis. The annual performance is estimated by representing the entire year of climate and load data into representative winter, spring/fall, and summer days for six different U.S. climatic zones. It prescribes a minimal number of steady state and simulated use tests, which provide the necessary performance data for the calculation procedure that predicts the annual performance. The procedure accounts for the changes in performance resulting from changes in ambient temperature, electrical load, and, if the unit provides thermal as well as electrical power, thermal load. The rating methodology addresses four different types of fuel cell systems: grid-independent electrical load following, grid-connected constant power, grid-connected thermal load following, and grid-connected water heating. This paper will describe a partial validation of the rating methodology for a grid-connected thermal load following fuel cell system. The rating methodology was validated using measured data from tests that subjected the fuel cell system to domestic hot water and space heating thermal loads for each of the three representative days. The simplification of a full year’s load and climate data into three representative days was then validated by comparing the rating methodology predictions with the prediction of each hour over the full year in each of the six cities.

Design of Hydrogen Fuel Cell Autorickshaw

In Asia there are less private cars, but there is a high proportion of 2-stroke engines in scooters, motorcycles, auto-rickshaws (Tuk-Tuks), all running on petrol-oil mixtures with levels of hydrocarbon emissions (from partially burnt fuel and oil) well in excess of levels permitted in the USA and Europe. Worldwide Rickshaw/scooter/motorcycle type engine production is estimated at 17 million per year. According to National Transport Research Center (NTRC), the total population of registered (all types) motor vehicles in Pakistan in year 2000 was 4.224 million, out of which more than half of the population is (2.206 million) two wheelers or three wheelers (motorcycle/scooter/auto rickshaw). Almost all auto rickshaws have two stroke power packs and also 60% of motorcycle/scooters are of the same category. Pakistan is a very densely populated developing country, with very loose environment protection rules, which are practically unregulated due to large financial implications. This scenario leads to adverse air quality conditions especially in large cities of the country where the main contributory factors are vehicular traffic, that too, two stroke vehicles Industry, diesel-powered vehicles, and the omnipresent three-wheeled, two-stroke rickshaws all contribute to the extremely dirty air. Taxi/car use is increasing, but rickshaws have the advantage of being able to swarm through the congested car traffic in cities. This explains the over .6 million motorcycles/scooters/rickshaws currently in Pakistan, of which approximately 20% are two stroke Auto-rickshaws of 175 cc. Pakistan’s vehicle fleet has a growth rate of 8.0% (1990–99). The purpose of this study is to examine a particular application of fuel cell technology “The Auto Rickshaws”. They are small three-wheeled vehicles that can carry three people. Due to their small size and low price, rickshaws have traditionally been powered by high power density two-stroke internal combustion engines. Two-stroke engines produce a great deal of pollution and are an object of concern in many Asian countries. Severe pollution from two-stroke engines is a significant driver for cleaner technology. Thus, the target of this study is the Asian urban commuter, since a rickshaw is largely used in many Asian cities and contributes directly to air pollution in major crowded cities of Pakistan also. Countries like China, India, Bangladesh, Taiwan and Pakistan [1] are facing dramatic growth rates in two-stroke vehicle population as bicycle rickshaws are being replaced, so, low-powered but clean rickshaws would be a major step in providing mobility without compromising urban air quality.

Robust Design Techniques for Evaluating Fuel Cell Thermal Performance

The National Renewable Energy Laboratory (NREL) and Plug Power Inc. have been working together to develop fuel cell modeling processes to rapidly assess critical design parameters and evaluate the effects of variation on performance. This paper describes a methodology for investigating key design parameters affecting the thermal performance of a high temperature, polybenzimidazole (PBI)-based fuel cell stack. Nonuniform temperature distributions within the fuel cell stack may cause degraded performance, induce thermo-mechanical stresses, and be a source of reduced stack durability. The three-dimensional (3-D) model developed for this project includes coupled thermal/flow finite element analysis (FEA) of a multi-cell stack integrated with an electrochemical model to determine internal heat generation rates. Sensitivity and optimization algorithms were used to examine the design and derive the best choice of the design parameters. Initial results showed how classic design-of-experiment (DOE) techniques integrated with the model were used to define a response surface and perform sensitivity studies on heat generation rates, fluid flow, bipolar plate channel geometry, fluid properties, and plate thermal material properties. Probabilistic design methods were used to assess the robustness of the design in response to variations in load conditions. The thermal model was also used to develop an alternative coolant flow-path design that yields improved thermal performance. Results from this analysis were recently incorporated into the latest Plug Power coolant flow-path design. This paper presents an evaluation of the effect of variation on key design parameters such as coolant and gas flow rates and addresses uncertainty in material thermal properties.

Micromachined Methanol Steam Reforming System Integrated With Catalytic Combustor Using Carbon Nanotubes as Catalyst Supports

In this paper we have successfully demonstrated a new micromachined fuel processing system including vaporizer, catalytic combustor and methanol steam reformer. This fuel processing system utilizes the thermal energy generated from the catalytic hydrogen combustion to heat up the entire system. For the first time, we have used carbon nanotubes as a supporting structure of Pt catalyst for combustion. The catalytic combustor could supply the energy to heat the reformer and maintain its working temperature. We have also developed a new coating method of reforming catalyst (Cu/ZnO/Al2O3) and observed that adequate amount of hydrogen can be generated for PEMFC. We have successfully reported the feasibility of the proposed fuel processing system in each assembled component.

Dynamic Behavior and In-Situ Diagnostics of PEFCs

During fuel cell operation the electrochemical activity often is not homogenous over the electrode area. This may be caused by an non-uniform water content in the membrane, an inhomogeneous temperature distribution, and reactant gradients in the cell. Consequently a variation of the current density over the cell area occurs which tends to result in inferior performance. For in situ measurements of the current density distribution in fuel cell stacks a segmented bipolar plate was developed. The segmented bipolar plate was first tested in single cells with stack endplates to verify the function of all components. The tests showed that the measurement tool works very reliable and accurate. The insight in an operating fuel cell stack via current density distribution measurement is very helpful to investigate interactions between cells. Results can be used to validate models and to optimise stack components, e.g. flow field and manifold design, as well as to detect the best stack operating conditions. By applying segmented bipolar plates as sensor plates for stack system controls an improved performance, safe operation and longer life cycles can be achieved. The developed segmented bipolar plates with integrated current sensors were used to assemble a short stack consisting of 3 cells; each of them having an active area of 25cm2 divided into 49 segments. The design of the bipolar plate proofed very suitable for easy assembling of single cells and stacks. First measurement results show that different current distributions can appear in the cells and these can vary from cell to cell, depending on the operating conditions of the stack. Electrical coupling between the cells was investigated and found to be only marginal for the assembly used.

Component Failure Analysis From the U.S. Army ERDC-CERL Residential Proton Exchange Membrane Fuel Cells Demonstration

Background: The U.S. Army Engineer Research and Development Center, Construction Engineering Research Laboratory (ERDC-CERL) continues to manage The Department of Defense (DoD) Residential Proton Exchange Membrane (PEM) Fuel Cell Demonstration Project. This project was funded by the United States Congress for fiscal years 2001 through 2004. A fleet of 91 residential-scale PEM fuel cells, ranging in size from 1 to 5 kW, has been demonstrated at various U.S. DoD facilities around the world. Approach: The performance of the fuel cells has been monitored over a 12-month field demonstration period. A detailed analysis has been performed cataloging the component failures, investigating the mean time of the failures, and the mean time between failures. A discussion of the lifespan and failure modes of selected fuel cell components, based on component type, age, and usage will be provided. This analysis also addresses fuel cell stack life for both primary and back-up power systems. Several fuels were used throughout the demonstration, including natural gas, propane, and hydrogen. A distinction will be made on any variances in performance based on the input fuel stock. Summary: This analysis will provide an overview of the ERDC-CERL PEM demonstration fuel cell applications and the corresponding data from the field demonstrations. Special emphasis will be placed on the components, fuel cell stack life, and input fuel characteristics of the systems demonstrated.

Three-Dimensional Based Model of a Planar SOFC Fuelled by Biomass Gas

Efficient and low polluting production of electricity and heat is an issue which cannot be postponed. Fuel cells, which convert the chemical energy stored in a fuel into electrical and thermal energy, are an efficient solution for such a problem. These devices rely on the combination of hydrogen and oxygen into water: oxygen is extracted from the air while hydrogen can be obtained from either fossil fuels or renewable sources. The use of biomass as hydrogen source in connection with fuel cells is an argument of particular interest, since high temperature gasification processes are actually utilized. Solid Oxide Fuel Cells (SOFC), working at high temperatures, have become therefore an interesting candidate to realize the internal reforming of the feed gas from a gasifier. The reforming reaction occurs at the anode of the SOFC, upstream and separated from the fuel cell reaction. The section of the anode where reforming occurs is adjacent to the section where electrochemical reaction occurs. So, heat produced by the electrochemical reaction can be transferred internally with minimal losses. Simulation models of the performance of SOFC stacks and biomass gasifiers are useful to visualize temperature, current and concentration distributions, which are difficult to measure by experimental techniques, allowing the definition of optimal choices in terms of geometries and operating conditions. In this work, an analysis of a SOFC coupled with a biomass gasifier is performed. The objective of this study is the identification of the main effects of the operating conditions on the fuel cell performance in terms of efficiency, and the distribution of the main electro-thermal-fluid-dynamics variables, namely current and temperature. A gasifier model has been implemented to calculate the equilibrium compositions using the Gibbs free energy minimization method. The obtained results are directly used to estimate the inlet gas composition for the SOFC. The SOFC has been modelled by a 3D approach (FLUENT), which solves the energy and mass transport and the internal reforming, coupled with a 0D electrolyte model which, starting from the local information in terms of gas composition, temperature and pressure, is able to predict the fuel cell performance in terms of electrical response and mass-energy fluxes. The whole model has been applied to the analysis of an integrated SOFC-gasifier system to address a planar SOFC response by varying the gasifier operating conditions and the global system performance.

Proton Exchange Membrane Fuel Cell System Identification and Control: Part I — System Dynamics, Modeling and Identification

This paper consists of two parts to address a systematic method of system identification and control of a proton exchange membrane (PEM) fuel cell. This fuel cell is used for communication devices of small power, involving complex electrochemical reactions of nonlinear and time-varying dynamic properties. From a system point of view, the dynamic model of PEM fuel cell is reduced to a configuration of two inputs, hydrogen and air flow rates, and two outputs, cell voltage and current. The corresponding transfer functions describe linearized subsystem dynamics with finite orders and time-varying parameters, which are expressed as discrete-time auto-regression moving-average with auxiliary input models for system identification by the recursive least square algorithm. In experiments, a pseudo random binary sequence of hydrogen or air flow rate is fed to a single fuel cell device to excite its dynamics. By measuring the corresponding output signals, each subsystem transfer function of reduced order is identified, while the unmodeled, higher-order dynamics and disturbances are described by the auxiliary input term. This provides a basis of adaptive control strategy to improve the fuel cell performance in terms of efficiency, transient and steady state specifications. Simulation shows the adaptive controller is robust to the variation of fuel cell system dynamics.