DESC:FIELD
The present disclosure relates to the technical field of membranes. Particularly the present disclosure relates to electrolytic membranes, more particularly polymer electrolyte membranes (PEMs), fuel cells made thereof, and still more particularly fuel cell systems. Still, more particularly, a fuel cell system having polymer electrolyte membranes (PEMs) fuel cells, a method for the assembly/ integration of the fuel cell system, and a method for the operation of the fuel of a fuel cell system, an air circulation unit for fuel cell systems and a method for its operation, hydrogen circulation unit for the fuel cell system and a method for its operation, a thermal management unit for the fuel cell unit and a method for its operation, a fuel cell control unit and a method for its operation, power conditioning unit for the fuel cells and a method for its operation.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicate otherwise.
The term ‘polymer electrolyte membrane (PEM)’ or ‘proton exchange membrane’ refers to semipermeable membranes generally made from ionomers and designed to conduct protons while acting as an electronic insulator and reactant barrier, e.g. to oxygen and hydrogen gas, i.e. protons are conducted through the membrane but the membranes are reasonably impermeable to the gases.
The term ‘polymer electrolyte membrane fuel cells (PEMFCs)’ refers to fuel cells comprising a cathode, an anode and a polymer electrolyte membrane (PEM), wherein the PEM membrane conducts protons from the anode to the cathode, acts as a separating barrier between the contents of the anode and the cathode compartments and prevents the flow of electrons from the anode compartment to the cathode compartment. Hydrogen or low molecular weight hydrocarbons such as methanol are used as the fuel at the anode and oxygen/air as the oxidizer at the cathode.
The term ‘polymer electrolyte membrane (PEM) Fuel Cells using hydrogen as fuel’ refers to a fuel cell comprising a cathode, an anode and a polymer electrolyte membrane (PEM), wherein hydrogen is oxidized at the anode and the oxygen is reduced at the cathode, the protons are transported from the anode to the cathode through the electrolytic membrane and the electrons are carried over an external circuit load. On the cathode, oxygen reacts with protons and electrons producing heat and forming water as a by-product.
The term ‘BALANCE OF PLANT (BOP)’ refers to all the auxiliary systems and infrastructure necessary to support the operation of a power plant, industrial facility. BOP typically includes systems such as water treatment, cooling, fuel handling, storage, electrical infrastructure (excluding the actual power generation components), and other support systems needed for the main plant or facility to function efficiently and reliably.
These definitions are in addition to those expressed in the art.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Membrane technology is eminently used in various industrial processes such as the desalination of saline water, separation of ionic materials from non-ionic materials, recovery of acid and alkali from different solutions, electrolysis and the like. Another major application of membranes is in fuel cells. Fuel cells are generally classified based on the electrolytes they employ. There are several types of fuel cells such as alkaline fuel cells (AFC), phosphoric acid fuel cells (PAFC), proton exchange membrane (PEMFC), molten carbonate fuel cells (MCFC), solid oxide fuel cells (SOFC) and the like with a wide range of applications such as stationary power plants, off-grid power supply, and portable/micro power source in various applications.
In recent years, energy storage devices such as battery packs are alternately used in various existing systems such as vehicles to transmit power to a motor to drive the vehicles. Further, systems such as solar panel unit, a regenerative braking unit, a thin air ion-capturing unit, a glass window pane unit, a wind turbine driven unit, and the like are also used for charging the energy storage devices. However, such systems are associated with drawbacks such as intermittent supply, high upfront costs, storage capacities, geographical limitations, lower efficiencies and space constraints. Furthermore, some of the sources contribute to the emissions of greenhouse gases that lead to the potential impact on the environment. In such conditions, fuel cells are a promising alternative.
In a conventional fuel cell system, custom-made connectors/ parts are required for the integration of the fuel cell stack with the air filter unit, hydrogen sub-system and powertrain. Further, in the conventional fuel cell system, the control unit is placed inside the body of the system, making it a tedious process for servicing and replaceability in case of any malfunction. Conventional fuel cell systems are associated with the drawbacks such as inferior quality of hydrogen and air feed, purging of the hydrogen in high explosive limits, and lack of pressure, flow and temperature control, leading to inefficient power generation. Further, conventional fuel cell systems are not adapted to operate at lower ambient temperatures.
Furthermore, the architecture/design to integrate the fuel cell stack with the aforementioned subsystem mainly lacks conductivity monitoring and control mechanism for the thermal management unit in a conventional fuel cell system so that any corrective action can be taken in a due course of time which results in unwanted and adverse effects.
There is, therefore, felt a need for polymer electrolyte membranes (PEMs), fuel cells made therefrom and fuel cell system, having polymer electrolyte membranes (PEMs) fuel cells, a method for the assembly/ integration of the fuel cell system, and a method for the operation of the fuel of a fuel cell system, an air circulation unit for fuel cell systems and a method for its operation, hydrogen circulation unit for the fuel cell system and a method for its operation, a thermal management unit for the fuel cell unit and a method for its operation, a fuel cell control unit and a method for its operation, power conditioning unit for the fuel cells and a method for its operation, that overcome the above-mentioned limitations or at least provide a useful alternative.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure is to ameliorate one or more problems of the background or to at least provide a useful alternative.
Another object of the present disclosure is to provide polymer electrolyte membrane (PEMs) .
Still another object of the present disclosure is to provide polymer electrolyte membrane (PEMs) for fuel cells.
Yet another object of the present disclosure is to provide durable polymer electrolyte membrane (PEMs) for fuel cells.
Still another object of the present disclosure is to provide an inexpensive polymer electrolyte membrane (PEMs) for fuel cells.
Yet another object of the present disclosure is to provide polymer electrolyte membrane (PEMs) for fuel cells having an excellent mechanical strength.
Still another object of the present disclosure is to provide fuel cells made using the polymer electrolyte membrane (PEMs).
Yet another object of the present disclosure is to provide simple and efficient fuel cells.
Still another object of the present disclosure is to provide fuel cells with maximum utilization of hydrogen as a fuel.
Yet another object of the present disclosure is to provide a method for the assembly of fuel cells.
Still another object of the present disclosure is to provide an air circulation unit for fuel cell systems.
Yet another object of the present disclosure is to provide a method for the operation of an air circulation unit for fuel cell systems.
Still another object of the present disclosure is to provide hydrogen circulation unit for fuel cell systems.
Yet another object of the present disclosure is to provide a method for the operation of a hydrogen circulation unit for fuel cell systems.
Still another object of the present disclosure is to provide a thermal management unit for fuel cell systems.
Yet another object of the present disclosure is to provide a method for the operation of a thermal management unit for fuel cell systems.
Still another object of the present disclosure is to provide a fuel cell control unit.
Yet another object of the present disclosure is to provide a method for the operation of fuel cell control unit.
Still another object of the present disclosure is to provide a power conditioning unit for fuel cell systems.
Yet another object of the present disclosure is to provide a method for the operation of a power conditioning unit for fuel cell systems.
Still another object of the present disclosure is to provide a fuel cell system.
Yet another object of the present disclosure is to provide a fuel cell system that provides electro chemical power source.
Still another object of the present disclosure is to provide a fuel cell system that can be used in various applications.
Yet another object of the present disclosure is to provide a fuel cell system that is efficient.
Still another object of the present disclosure is to provide a fuel cell system that has increased safety.
Yet another object of the present disclosure is to provide a fuel cell system with minimum loss of hydrogen fuel.
Still another object of the present disclosure is to provide a fuel cell system that can also effectively operate at lower ambient temperatures.
Yet another object of the present disclosure is to provide a fuel cell system that is highly efficient.
Still another object of the present disclosure is to provide a fuel cell system that is adapted for remote monitoring and controlling.
Yet another object of the present disclosure is to provide a fuel cell system that has minimal maintenance.
Still another object of the present disclosure is to provide a fuel cell system that does not require custom-made parts for integration into various existing systems.
Yet another object of the present disclosure is to provide a fuel cell system that can operate at a wide range of temperatures.
Still another object of the present disclosure is to provide a fuel cell system having easy servicing and replaceability.
Still another object of the present disclosure is to provide a method for the assembly/ integration of the fuel cell system in various existing systems.
Yet another object of the present disclosure is to provide a method for the operation of a fuel cell system in various existing systems.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a fuel cell system. The fuel cell system comprises at least one cathode feed and at least one anode feed. The fuel cell system further comprises: an air circulation unit 104 configured to take in air from the ambient and further configured to humidify the air to a predetermined pressure and temperature to facilitate the supply of air containing oxidants to the cathode feed of the fuel cell; a hydrogen circulation unit 106 configured to be in communication with a Hydrogen storage tank and further configured to facilitate supply of Hydrogen to the required anode feed at a desired pressure; a thermal management unit, configured with at least one coolant pump and further configured to maintain the temperature of the fuel cell stack within a desired temperature range; a fuel cell control unit 132, provided with a programmed electronic controller the fuel cell control unit the air circulation unit 104, the hydrogen circulation unit and the thermal management unit, and the control unit configured to control the balance of plant (BOP) components of the fuel cell; a power conditioning unit configured with at least one bidirectional DC-DC convertor configured to convert the stack electrical power to stable DC power; and a ventilation unit configured to circulate air over the balance of plant components and the fuel cell feed, and further configured to vent residual air, H2, or other gasses from the fuel cell.
In an embodiment, the fuel cell is configured with a plurality of polymer electrolyte membranes (PEMs) electrode assemblies.
Further, the air circulation unit includes an air purification means, a flow measurement device, an Air Compressor or blower, a Heat exchanger, a humidifier, Cathode Isolation devices , Cathode bypass devices and Humidifier bypass devices, a Water separation unit and Compressor integrated turbo, configured to humidify the take in air and is further configured to facilitate the supply of the take-in air containing oxidants to the cathode feed of the fuel cell.
In an embodiment, the air purification means is configured to filter particulate more than 25microns and to adsorb toxic molecules from the take in air.
In an embodiment, the water separation unit is configured to extract water from moisture saturated air leaving the outlet of the fuel cell.
Further, the Hydrogen circulation unit is configured with at least one micron filter, at least one hydrogen quality sensor, at least one pressure control valve and at least one flow controller, at least one isolation valve, at least one coolant circulation assembly, at least one hydrogen quality sensor, a fuel preheater, an isolation valves, a pressure controller, and a mass flow controller, and is further configured to feed desired hydrogen fuel quality at a required pressure.
In an embodiment, the micron filter is configured to restrict the inrush of any dust particle or other debris to the anode feed of the fuel cell.
Further, the thermal management unit includes at least one temperature sensor, flow control valves, at least one flow diverter, a de-ionizer, a coolant heater, the coolant pump and intercooler for the compressed air.
In an embodiment, the coolant pump drives the coolant through the close loop consisting the fuel cell and the air intercooler towards the radiator where the coolant exchanges the heat from the ambient.
In an embodiment, the thermal management unit is configured to provide a coolant for cooling the compressed air coming out of the air circulation unit, maintain the conductivity of the coolant less than the pre-determined conductivity value of the coolant and a quick heat up of the coolant as required.
In an embodiment, the fuel cell control unit includes sensors, alarms monitoring system and wired communication, control unit accessories.
In an embodiment, the BOP components include coolant pump, air compressor and hydrogen recirculation blowers
In an embodiment, the fuel cell system includes at least one invertor, configured to control the RPM of the air compressor 118, an anode recirculation blower and the coolant pump.
In another embodiment, the fuel cell system includes at least one hydrogen sensor, positioned at the outlet of the fuel cell, to detect the leakage of the hydrogen from the fuel cell.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The fuel cell system, of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a block diagram of an integrated PEM fuel cell system comprising hydrogen circulation unit, thermal management unit and power conditioning unit, in accordance with an embodiment of the present disclosure;
Figure 2 illustrates a block diagram of the PEM fuel cell system connected to a cathode air circulation unit with isolation cathode mechanism, in accordance with an embodiment of the present disclosure; and
Figure 3 illustrates a block diagram of the PEM fuel cell system connected to an anode feed or hydrogen circulation unit, in accordance with an embodiment of the present disclosure.
Figure 4 illustrates a schematic of a hydrogen circulation unit, in accordance with an embodiment of the present disclosure.
Figure 5 illustrates a schematic of a thermal management unit, in accordance with an embodiment of the present disclosure.
Figure 6 illustrates a schematic of a power conditioning unit, in accordance with an embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS
100 – System
102 – Polymer Electrolyte Membrane (PEM) Fuel Cell stack
104 – Air circulation unit
106 – Hydrogen circulation unit
108 – Radiator
110 – Coolant pump unit
112 – Anode water separator unit
112A – Cathode water separator unit
114 – DC to DC converter
116 – Humidifier / air humidification system
118 – Air Compressor
118A – Air Turbo
120 – Heat Exchanger
122 – Mass flow Controller (MFC)
124 – Pressure Control Valve /Dome Loaded Pressure Regulator
126 – Cathode Inlet Isolation Valve
128 – Cathode Outlet Isolation Valve
130 – Hydrogen Isolation Valve
132 – Fuel cell control unit
134 – Thermal management system/ unit
136 – flow control valve
138 – Power conditioning unit
140 – coolant heater
142 – mass flow sensors or temperature sensors
144 – filter
146 – coolant tank
148 – hydrogen recirculation blower
150 – anode recirculation flow meter
152 – deionizer
154 – cathode sub system
156 – anode sub system
158 – Fuel cell control unit (FCCU)
160 – vehicle control unit (VCU)
162 – Hydrogen storage tank
164 – invertor
166 – Anode drain and Purge system
DETAILED DESCRIPTION
The present disclosure relates to membranes. Particularly the present disclosure relates to electrolytic membranes, more particularly polymer electrolyte membranes (PEMs). In particular fuel cells made thereof and assembly of fuel cells. Still, more particularly, fuel cell system having polymer electrolyte membranes (PEMs) fuel cells, a method for the assembly/ integration of the fuel cell system, and a method for the operation of the fuel of a fuel cell system, an air circulation unit for fuel cell systems and a method for its operation, hydrogen circulation unit for the fuel cell system and a method for its operation, a thermal management unit for the fuel cell unit and a method for its operation, a fuel cell control unit and a method for its operation, power conditioning unit for the fuel cells and a method for its operation.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, specific processes specific apparatus structures, and unique techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises”, “comprising”, “including” and “having” are open-ended transitional phrases and therefore specify the presence of stated features, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being “mounted on”, “engaged to”, “connected to” or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.
Terms such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Membrane technology is eminently used in various industrial processes such as the desalination of saline water, separation of ionic materials from non-ionic materials, recovery of acid and alkali from different solutions, electrolysis and the like. Another major application of membranes is in fuel cells. Fuel cells are generally classified based on the electrolytes they employ. There are several types of fuel cells such as alkaline fuel cells (AFC), phosphoric acid fuel cells (PAFC), proton exchange membrane (PEMFC), molten carbonate fuel cells (MCFC), solid oxide fuel cells (SOFC) and the like with a wide range of applications such as stationary power plants, off-grid power supply, portable/micro power source in various applications and the like.
Membrane technology is eminently used in various industrial processes such as the desalination of saline water, separation of ionic materials from non-ionic materials, recovery of acid and alkali from different solutions, electrolysis and the like. Another major application of membranes is in fuel cells. Fuel cells are generally classified based on the electrolytes they employ. There are several types of fuel cells such as alkaline fuel cells (AFC), phosphoric acid fuel cells (PAFC), proton exchange membrane (PEMFC), molten carbonate fuel cells (MCFC), solid oxide fuel cells (SOFC) and the like with a wide range of applications such as stationary power plants, off-grid power supply, and portable/micro power source in various applications.
In recent years, energy storage devices such as battery packs are alternately used in various existing systems such as vehicles to transmit power to a motor to drive the vehicles. Further, systems such as a solar panel unit, a regenerative braking unit, a thin air ion-capturing unit, a glass window pane unit, a wind turbine-driven unit, and the like are also used for charging energy storage devices. However, such systems are associated with drawbacks such as intermittent supply, high upfront costs, storage capacities, geographical limitations, lower efficiencies and space constraints. Furthermore, some of the sources contribute to the emissions of greenhouse gases that lead to the potential impact on the environment. In such conditions, fuel cells are a promising alternative.
In a conventional fuel cell system, custom-made connectors/ parts are required for the integration of the fuel cell stack with the air filter unit, hydrogen sub-system and powertrain. Further, in the conventional fuel cell system, the control unit is placed inside the body of the various existing systems, making it a tedious process for servicing and replaceability in case of any malfunction. Conventional fuel cell systems are associated with the drawbacks such as inferior quality of hydrogen and air feed, purging of the hydrogen in high explosive limits, and lack of pressure, flow and temperature control, leading to inefficient power generation. Further, conventional fuel cell systems are not adapted to operate at lower ambient temperatures.
Furthermore, the architecture/design to integrate the fuel cell stack with the aforementioned subsystem of the various existing systems mainly lacks conductivity monitoring and control mechanism for the thermal management unit in a conventional fuel cell system so that any corrective action can be taken in a due course of time which results in unwanted and adverse effects.
Therefore, the present disclosure envisages a fuel cell system. The system comprises at least one cathode feed and at least one anode feed. The different embodiment of the present disclosure is explained with reference to the Figure 1 through Figure 6.
In accordance with the present disclosure, the fuel cell system further comprises an air circulation unit 104, a hydrogen circulation unit 106, a thermal management unit 134, a fuel cell control unit 132, a power conditioning unit 138, and a ventilation unit, operatively connected to each other to efficiently control the operation of the fuel cell. The air circulation unit 104 is configured to take in air from the ambient and is further configured to humidify the air to a predetermined pressure and temperature to facilitate the supply of air containing oxidants to the cathode feed of the fuel cell. The hydrogen circulation unit 106 is configured to be in communication with a Hydrogen storage tank and is further configured to facilitate supply of Hydrogen to the required anode feed at a desired pressure. The thermal management unit is configured with at least one coolant pump in communication to the coolant tank and further configured to maintain the temperature of the fuel cell stack within a desired temperature range. The fuel cell control unit 132 is provided with a programmed electronic controller the fuel cell control unit the air circulation unit 104. The hydrogen circulation unit and the thermal management unit, and the control unit are configured to control the balance of plant (BOP) components of the fuel cell. The power conditioning unit is configured with at least one bidirectional DC-DC convertor, configured to convert the stack electrical power to stable DC power. The ventilation unit is configured to circulate air over the balance of plant components and the fuel cell feed, and is further configured to vent residual air, H2, or other gasses from the fuel cell. The different components of each units are explained below in detail.
In addition, the present disclosure envisages polymer electrolyte membranes (PEMs), fuel cells made therefrom, assembly of fuel cells, a fuel cell system having polymer electrolyte membranes (PEMs) fuel cells, a method for the assembly/ integration of the fuel cell system, and a method for the operation of the fuel of a fuel cell system, an air circulation unit for fuel cell systems and a method for its operation, hydrogen circulation unit for the fuel cell system and a method for its operation, a thermal management unit (134) for the fuel cell unit and a method for its operation, a fuel cell control unit and a method for its operation, power conditioning unit (138) for the fuel cells and a method for its operation, a method for the assembly/ integration of the fuel cell system in various existing systems, and a method for the operation of the fuel of a fuel cell system in various existing systems.
In accordance with one aspect, the present disclosure envisages polymer electrolyte membranes (PEMs).
In accordance with one embodiment of the present disclosure, the polymer electrolyte membranes (PEMs) may include aromatic hydrocarbon electrolyte membrane. Other suitable membranes and membrane materials can also be used.
The polymer electrolyte membranes (PEMs) of the present disclosure are inexpensive, have a comparatively higher mechanical strength, and are durable.
In another aspect, the present disclosure envisages a fuel cell prepared using the polymer electrolyte membranes (PEMs) of the present disclosure.
In accordance with one embodiment of the present disclosure, the fuel cell can include, but is not limited to at least one anode compartment, at least one cathode compartment, at least one polymer electrolyte membranes (PEMs), at least one anode inlet, at least one anode outlet, at least one cathode inlet, at least one cathode outlet. Other suitable materials and components can also be used.
In another embodiment of the present disclosure, the fuel cell can comprise a plurality of such membrane electrode assemblies.
The fuel cells of the present disclosure are inexpensive, easy to manufacture, and have lower maintenance.
In yet another aspect, the present disclosure envisages a method for the assembly of fuel cells to obtain a fuel cell stack.
The method for the assembly of fuel cells to obtain a fuel cell stack of the present disclosure is easy to perform and economical.
In another aspect, the present disclosure envisages a method for the operation of the fuel cell and fuel cell stack.
The method for the operation of the fuel cell and fuel cell stack of the present disclosure is simple and cost-effective.
In yet another aspect, the present disclosure envisages an air circulation unit for fuel cell systems.
In accordance with the present disclosure, the air circulation unit can include, but is not limited to at least one air flow measurement device, at least one air flow control device, at least one air quality measurement device, at least one cathode feed humidity control device, at least one valve.
In accordance with the present disclosure, the air circulation unit 104 can include special valves for fuel cell cathode isolation. The air circulation unit can also comprise bypass connections including, but not limited to cathode bypass and humidifier bypass. Such bypass connections enhances the safety and life of the fuel cell.
The air circulation unit 104 may also include a liquid water separation unit having a liquid water separation capability configured for water reusability for further use.
The air circulation unit 104 may also include a turbo compressor mechanism to absorb the kinetic energy of the cathode exhaust there by reduces the parasitic loss of the system by reducing the electrical load of the air compressor.
The air circulation unit 104 for fuel cell system of the present disclosure is simple, compact in design and easy to operate.
In yet another aspect, the present disclosure envisages a method for the operation of air circulation unit 104 for fuel cell system.
The method for the operation of air circulation unit for fuel cell system is easy to perform and environment friendly. The method is also cost effective.
In yet another aspect, the present disclosure envisages a hydrogen circulation unit for the fuel cells.
In accordance with the present disclosure, the hydrogen circulation unit can include, but is not limited to at least one micron filter, at least one hydrogen quality sensor, at least one pressure control valve and at least one flow controller. Other suitable accessories may also be used.
In accordance with the present disclosure, the hydrogen circulation unit can further include at least one isolation valve, and at least one coolant circulation assembly.
The hydrogen circulation unit of the present disclosure can be easily integrated in the various existing systems. The hydrogen circulation unit can also be integrated with the existing air circulation unit of various existing systems.
The hydrogen circulation unit of the present disclosure is safe, compact, easy to operate, and scalable.
In still another aspect, the present disclosure envisages a thermal management unit (134) for the fuel cells.
The thermal management unit (134) of the present disclosure can include, but is not limited to temperature sensors, mass flow sensors 142, coolant tank 146, radiator 108 and flow control valves 136. Other suitable devices, instrumentation and accessories can also be used.
The thermal management unit (134) of the present disclosure can be equipped with flow diverters like but not limited to three-way valves to divert the low temperature coolant flow through fuel cell stack 102, deionizer 152, coolant heater, DI filter and intercooler for compressed air by means of a coolant pump 110.
The thermal management unit (134) of the present disclosure makes it possible for the invention to maintain the temperature of the fuel cell stack 102 and temperature of cathode feed by minimizing the actuator usages existing products uses multiple valves to achieve the same.
The thermal management unit (134) of the present disclosure can assists the fuel cell system to start at low ambient temperature condition due to integrated temperature control heater, making the fuel cell system operate efficiently at a variety of geographical locations.
In yet another aspect, the present disclosure envisages a method for the operation of a thermal management unit (134) for fuel cell systems.
In accordance with the present disclosure, the method is easy to perform, and environment friendly.
In yet another aspect, the present disclosure envisages a fuel cell control unit for the fuel cells.
The fuel cell control unit of the present disclosure can include, but is not limited to sensors, alarms monitoring system and wired communication. Other suitable instruments, control unit accessories can also be used.
The fuel cell control unit (FCCU) 158 of the present disclosure can be installed within the system or outside the system for remote operation.
The fuel cell control unit 158 of the present disclosure provides an alarm in case the conductivity of the coolant goes out of specification, this alarm can further be used to take corrective action like but not limited to controlled shutdown.
The fuel cell control unit of the present disclosure is easy to operate, requires minimal wiring communication and is thus compact.
In still another aspect, the present disclosure envisages a method for the operation of fuel cell control unit of the present disclosure.
The method for the operation of fuel cell control unit is easy to perform, and cost-effective.
In still another aspect, the present disclosure envisages a power conditioning unit (138) for the fuel cells.
The power conditioning of the present disclosure is compact in design and easy to operate.
In yet another aspect, the present disclosure envisages a method for the operation of power conditioning unit (138).
The method for the operation of power conditioning unit (138) in accordance with the present disclosure is simple and eco-friendly.
In yet another aspect, the present disclosure envisages a method for the assembly/ integration of the fuel cell system.
The method for the assembly/ integration of the fuel cell system is simple to perform, does not require highly skilled labour, comparatively less time consuming and economical.
In still another aspect, the present disclosure envisages a method for the operation of the fuel of a fuel cell system.
The method for the operation of the fuel of a fuel cell system is simple and cost effective.
In still another aspect, the present disclosure envisages fuel cell system having polymer electrolyte membranes (PEMs) fuel cells. The system comprises an air circulation unit 104, a hydrogen circulation unit 106, a thermal management unit (134), a fuel cell control unit 132, a power conditioning unit (138) and a ventilation unit.
Figure 1 illustrates a block diagram of an integrated polymer electrolyte membrane (PEM) fuel cell system 100 (hereinafter referred to as “system 100”) in. The system 100 may include PEM Fuel Cell stack 102 that is integrated with an air circulation unit 104, a hydrogen circulation unit 106, a thermal management unit (134), a fuel cell control unit 132, a power conditioning unit (138) and a ventilation unit to provide an electro chemical power source.
The air circulation unit 104 and the hydrogen circulation unit 106 are configured to provide a required cathode feed and an anode feed, respectively, to the PEM fuel cell stack 102 to perform an electrochemical reaction. In an embodiment, the PEM fuel cell stack 102 includes a plurality of PEM fuel cells.
For this, the cathode feed of the PEM fuel cell stack 102 is in communication with the air circulation unit 104 such that the cathode feed of the PEM cells receives oxygen molecules from the air circulation unit 104.
For this, the system 100 may include at least one air purification device. The air purification device may be configured to provide particulate filtration for particles that are more than 25 micron along with toxic gas adsorption capability. In accordance with an embodiment of the present disclosure, the air can have following equivalent gas composition which is provided in the TABLE 1.
Gas Specification
Oxygen 20.9% or greater
Hydrocarbons Less than 50 ppm
Carbon monoxide Less than 35 ppm
Carbon dioxide Less than 1%
Ozone Less than 1 PPM
Sulphur compounds Less than 0.3 ppm
Hydrogen Sulphide Less the 1 ppm
NOX Less than 10 ppb
SOX Less than 1 ppb
NH3 Less than 3 ppb
Liquid Water Less than 0.5% with less than 5uS/cm
Inorganics (including salts) Less than 20 ug/cm

In detail, the cathode feed may be equipped with a membrane humidifier. The membrane humidifier is adapted to humidify the incoming cathode feed of the PEM fuel cell stack 102. The membrane humidifier is configured to transfer the humidity from a cathode outlet to a cathode inlet of the PEM fuel cell stack 102 based on the temperature difference between the humidifier inlet and the outlet feed.
In an embodiment, the system 100 may include measurement devices to measure the humidifier outlet temperature, pressure, and humidity. In another embodiment, the measurement devices is selected from, but is not limited to, the group consisting of temperature sensors, pressure sensors and humidity sensors.
With reference to Figure 2, the cathode feed may include at least a single cathode inlet isolation valve 126 and at least a single cathode outlet isolation valve 128 attached to the PEM fuel cell stack 102. The cathode outlet of the PEM fuel cell passes through a humidifier 116. A cathode water separator unit 112A connected to an air turbo 118a, and an air compressor 118 is attached to an air heat exchanger 120 for increasing the efficiency of the system 100. The system 100 may include at least one air flow meter. The at least one air flow meter is configured to measure air flows and air temperatures of the air present in the air compressors. The at least one air flow meter may be connected with an inverter controlled air compressor to provide enough flow and pressure to move the air through the PEM fuel cell stack. The compressed hot air coming out of the air compressor 118 passes through at least one air heat exchanger 120/intercooler. In an embodiment, the air heat exchanger 120/intercooler can be an air cooled heat exchanger or a liquid cool heat exchanger for cooling the compressed air coming out from the air compressor 118 so that the downstream humidifier 116 and the PEM fuel cell stack 102 is at regulated temperature. The anode feed of the PEM fuel cell stack 102 is in communication with the hydrogen circulation unit 106 such that the anode feed of the fuel cell stack 102 receives hydrogen molecules from the hydrogen circulation unit 106.
With reference to Figure 3, an anode inlet of the PEM fuel cell stack 102 may include at least one 10 micron Hydrogen particulate filter, at least one hydrogen isolation valve 130 with the anode inlet pressure and temperature measurement capability. The system 100 includes a coolant to a hydrogen heat exchanger which is configured to heat up the incoming hydrogen and further exchange the heat with the coolant coming out from the PEM fuel cell stack 102. The system 100 may be equipped with at least a pressure control valve 124. In an embodiment, the pressure control valve can be a Dome Loaded Pressure Regulator. The pressure control valve 124 may be configured to regulate the tank Hydrogen pressure to a pre-determined pressure of the PEM fuel cell stack 102 and/or a mass flow controller 122. In an embodiment, the pressure control valve 124 and the mass flow controller 122 are positioned in a series arrangement to supply of Hydrogen to the PEM Fuel cell stack. In another embodiment, the pressure control valve 124 and the mass flow controller 122 are positioned in a parallel arrangement to supply of Hydrogen to the PEM Fuel cell stack. In still another embodiment, the pressure control valve 124 and the mass flow controller 122 can be positioned individually also to supply of Hydrogen to the PEM Fuel cell stack.
An anode outlet of the PEM fuel cell stack 102 is in a communication with an anode water separator unit 112 via at least a drain valve. The drain valve is configured to remove the water from the system 100. The anode outlet may also include at least a purge solenoid valve configured to remove diffused Nitrogen from the anode feed. At the downstream of the water separate unit, the system 100 may include anode outlet pressure and temperature measuring devices configured to measure the pressure and the temperature of the anode outlet of the PEM fuel cell stack.
Further, in order to recirculate the flow of the unused hydrogen, the system 100 may include an anode recirculation blower which is controlled via a variable frequency drive, and at least one pressure relief safety device. The at least one pressure relief safety device safeguards the PEM fuel cell stack 102 and an anode plumbing to avoid the condition of the over pressurization of the PEM fuel cell stack. The outlet of the purge solenoid valve and the outlet of pressure relief safety device are connected to a stream of the turbo outlet attached to the air compressor 118.
The system 100 may also include a fuel cell thermal management unit (134). The fuel cell thermal management unit (134) may be configured to maintain the temperature of the PEM fuel cell stack 102. In detail, the fuel cell thermal management unit (134) may be configured to provide a coolant for cooling the compressed air coming out of the air compressor 118, maintain the conductivity of the coolant less than the pre-determined conductivity value of the coolant, and a quick heat up of the coolant.
In detail, the thermal management unit (134) of the present system is equipped with flow diverters. In an embodiment, the flow diverters can be selected from the group consisting of, but not limited to, three-way valves to divert the low temperature coolant flow through the PEM Fuel cell stack 102, De-ionizer 152, a coolant heater 140 and an Intercooler 118A for the compressed air. This unique design of the thermal management unit (134) is configured to maintain the temperature of the PEM fuel cell stack 102 and temperature of the cathode feed by minimizing the actuator usages, whereas the conventional systems uses multiple valves to achieve the same. Due to this, the thermal management unit (134) provides the capability to the system 100 to start at a low ambient temperature condition due to the integrated temperature control heater.
For this, the PEM fuel cell stack 102 is connected with a radiator 108 and a coolant pump unit 110 via a non-ion leaching plumbing. The system 100 may include at least one three-way valve to divide and divert a certain portion of the coolant flow towards the air compressor 118 or intercooler. The system 100 may also include a conductivity meter configured to monitor the fuel cell coolant conductivity and may further control the conductivity of the coolant. In an embodiment, the conductivity meter is configured to monitor the conductivity of the coolant at a pre-determined value of 5 micro Siemens. The system 100 may also include a coolant heater which is configured to heat up the coolant for low ambient temperature operations.
The ventilation unit provides required ventilation air over the balance of plant component and PEM stack. In an embodiment, the system 100 may include a hydrogen sensor, positioned at enclosure of the PEM fuel cell stack, to detect the leakage of the hydrogen. In the event of the detection of the hydrogen leaks, the ventilation air carries away the hydrogen leaks coming out of the balance of plant plumbing and PEM fuel cell stack. For this, at least one 300 CFM fan is adapted to carry away the leaked Hydrogen.
In an embodiment, the power conditioning unit (138) may include at least one DC-DC converter 114 configured to convert the stack electrical power to a stable DC power. The thermal management system 134, a cathode sub system 154, and an anode subsystem 156 are being configured to be in communication with the Fuel cell control unit (FCCU) 158 and the PEM fuel cell stack 102 to control the operation and is further configured to be powered by the bi-directional DCDC converter 114 and inverter 164 of the power contioning unit. The bi-directional DCDC converter 114 generates usable DC power and the invertor generates usable AC power as shown in figure 6. In an embodiment, the power conditioning unit 138 is configured to be in bi-directional communication with vehicle control unit (VCU) 160 and in communication with the PEM fuel cell stack 102.
In an embodiment, the thermal management system 134 includes the radiator 108, the deionizer 152, the heater 120, and and the coolant pump 110. In another embodiment, the cathode sub-system 154 includes air flow control system and air compressor 118, and air humidification system 116. In another embodiment, the anode system 156 includes hydrogen flow control in communication with the hydrogen recirculation system 148 and Hydrogen storage tank 162 and the anode drain and purge system 166.
In another embodiment, the system 100 may also include at least one invertor 164 where each invertor is configured to control the RPM of the air compressor 118, an anode recirculation blower and the coolant pump. In still another embodiment, the system 100 may also include a heater control unit configured to control the coolant heater power. In yet another embodiment, the system 100 may also include a control unit in communication with the control unit to control the various operation of the system 100.
The PEM fuel cell stack 102 of the present disclosure generates an electro chemical power source along with energy storage devices to operate as a fuel cell system.
The architecture described in the present system 100 makes it possible for any user of the system 100 to integrate it with an air filter unit, a hydrogen circulation unit 106, a powertrain using standard mechanical and electrical connector. The present system 100 is integrated with a fuel cell control unit 132 (outside the system 100) for easy servicing and replaceability in case of any malfunction.
The air circulation unit 104 of the present system 100 is capable of air flow measurement, air flow control, air quality measurement, cathode feed humidity control. The air circulation unit 104 is also equipped with special valves for Fuel cell cathode isolation, a cathode bypass and a humidifier bypass which enhances the safety and life of the PEM fuel cells. The air circulation unit 104 also has the liquid water separation capability for water reusability for further use in the various existing systems and is also equipped with a turbo compressor mechanism to absorb the kinetic energy of the cathode exhaust, thereby reducing the parasitic loss of the present system 100 by reducing the electrical load of the air compressor 118. The cathode exhaust of the PEM Fuel cell stack 102 is integrated with the Hydrogen purge unit to safely vent it in the atmosphere making sure the present system 100 is always purging the hydrogen within a low explosive limits,
In addition to, the hydrogen circulation unit 106 of the present system 100 may be equipped with micron filter to avoid the inrush of any dust particle or other debris to the anode side of the PEM fuel cell stack 102. The Hydrogen unit 106 of the PEM fuel cell stack 102 has at least one single isolation valve which can be used to conduct Hydrogen Isolation in case of any emergency. The system 100 may include a sensor such as Hydrogen quality sensor, soke sensor configured to make sure that the Anode is feed with right fuel quality. The Hydrogen circulation unit 106 of the present system 100 may include a coolant to a fuel pre heater, the pressure control valves 124 and a mass flow controllers (MFC) 122 either arrange in series or in parallel or individually as well. This configuration of having Hydrogen quality sensor connected with isolation valves, pressure controller 124 and mass flow controller 122 provides a unique advantage of isolating the hydrogen circulation unit 106 in case of an undesired fuel quality, unregulated pressure or undesired flow of hydrogen. The hydrogen circulation unit 106 provides an anode recirculation flow measurement which can be a dual phase flow.
In an embodiment, the Hydrogen circulation unit 106 includes the filter such as hydrogen filter 144 in communication to the hydrogen isolation valve.
In an embodiment, the Hydrogen circulation unit 106 includes a hydrogen recirculation blower and a anode recirculation flow meter. The hydrogen recirculation blower is configured to be in fluid communication with the fuel cell stack to receive the receive the Hydrogen from the cell stack and to regulate the flow rate of hydrogen, the recirculation flow meter is installed within the passage. The fuel cell stack is also provided with a vent out passage with a valve such as purge valve and bypass valve fitted thereon to control the flow rate.
The present system 100 may include at least one anode recirculation actuator device which is not limited to an electric blower or an ejector. In an embodiment, the present system 100 may include the electric blower and the ejector either individually or in series or in parallel configuration or each other.
The present system 100 may include in-built conductivity monitoring and control mechanism of the thermal management unit (134) of the system 100 which provides a user and various existing systems with alerting devices (like an alarm). The alerting devices may be activated in the condition where the conductivity of the coolant is not within the prescribed ranges/values. After providing the alert to the user by the alerting device, corrective courses of action (like, but not limited to, controlled shutdown) can be taken in due course of time. Such a kind of safety and coolant quality feature is not present in any conventional systems that are available in the market. Further to this, the mechanical design of the coolant filter is in a manner such that it can be easily removed without disintegrating.
In yet another aspect, the present disclosure envisages a method for the assembly/ integration of the fuel cell system in various existing systems.
The method for the assembly/ integration of the fuel cell system in a various existing systems is simple, comparatively less time-consuming, and requires minimal modifications in various existing systems.
In still another aspect, the present disclosure envisages a method for the operation of the fuel of a fuel cell system in various existing systems.
The method for the operation of the fuel of a fuel cell system in various existing systems is simple and cost-effective.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of
the fuel cell system that:
• are inexpensive;
• have a comparatively higher mechanical strength; and
• are durable,
fuel cells prepared using the polymer electrolyte membranes (PEMs) that are:
• cost effective;
• environment friendly; and
• having a lower maintenance,
a method for the assembly of fuel cells to obtain a fuel cell stack, that
• is simple and economic,
an air circulation unit for fuel cell systems, that is:
• easy to operate; and
• compact in design,
a method for the operation of an air circulation unit for fuel cell systems, that is:
• simple and cost effective,
a hydrogen circulation unit for the fuel cells, that
• is safe to operate; and
• environment friendly,
a thermal management unit for the fuel cells, that
• is efficient;
• improves the functioning of the fuel cell system; and
• easy to operate,
a method for the operation of the thermal management unit for the fuel cell system, that is:
• easy to perform; and
• environment friendly.
a fuel cell control unit, that
• enhances the durability of fuel cell system;
• increases the safety of operation of the fuel cell system,
a method for the operation of the fuel cell control unit, that
• is simple to perform,
a power conditioning unit for the fuel cells, that
• is compact and easy to operate,
a method for the operation of a power control unit for fuel cells, that
• is simple; and
• environment friendly,
a fuel cell system having polymer electrolyte membranes (PEMs) fuel cells for various existing systems, that:
• provides an electrochemical power source in various existing systems;
• has membrane humidification capability;
• provides an anode recirculation flow measurement and a thermal management unit;
• effectively maintains the temperature of the PEM fuel cell stack;
• operates at lower ambient temperatures;
• where a hydrogen sub-system can be isolated in case of an undesired fuel (hydrogen) quality/unregulated pressures/undesired flow;
• where a coolant filter can be easily removed without disintegrating;
• is highly efficient when compared to conventional fuel cell systems;
• alerts about safety and coolant quality features to a user;
• does not require any custom-made connectors for integration; and
• is integrated with the control unit of various existing systems for remote monitoring and controlling.
a method for the assembly/ integration of the fuel cell system in various existing systems, that
• simple to perform;
• is comparatively less time-consuming; and
• requires minimal modifications in various existing systems,
and
a method for the operation of the fuel cell system in various existing systems, that
• is easy; and
• environment friendly.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
,CLAIMS:WE CLAIM:
1. A fuel cell system (100), said system (100) comprising at least one cathode feed and at least one anode feed, said fuel cell system (100) further comprising:
• an air circulation unit (104) configured to take in air from the ambient and further configured to humidify said air to a predetermined pressure and temperature to facilitate the supply of air containing oxidants to the cathode feed of the fuel cell;
• a hydrogen circulation unit (106) configured to be in communication with a Hydrogen storage tank and further configured to facilitate supply of Hydrogen to the required anode feed at a desired pressure;
• a thermal management unit (134), configured with at least one coolant pump and further configured to maintain the temperature of the fuel cell stack within a desired temperature range;
• a fuel cell control unit (132), provided with a programmed electronic controller said fuel cell control unit (132) said air circulation unit (104) 104, said hydrogen circulation unit (106) and said thermal management unit (134), and said control unit configured to control the balance of plant (BOP) components of the fuel cell;
• a power conditioning unit (138) configured with at least one bidirectional DC-DC convertor (114) configured to convert the stack electrical power to stable DC power; and
• a ventilation unit configured to circulate air over the balance of plant components and the fuel cell feed, and further configured to vent residual air, H2, or other gasses from the fuel cell.
2. The fuel cell system (100) as claimed in claim 1, wherein the fuel cell is configured with a plurality of polymer electrolyte membranes (PEMs) electrode assemblies.
3. The fuel cell system (100) as claimed in claim 1, wherein said air circulation unit (104) includes an air purification means, a flow measurement device, an Air Compressor or blower, a Heat exchanger, a Humidifier (116), Cathode Isolation devices , Cathode bypass devices and Humidifier (116) bypass devices, a Water separation unit and Compressor integrated turbo, configured to humidify the take in air and further configured to facilitate the supply of said take in air containing oxidants to the cathode feed of the fuel cell.
4. The fuel cell system (100) as claimed in claim 3, said air purification means configured to filter particulate more than 25microns and to adsorb toxic molecules from the take in air.
5. The fuel cell system (100) as claimed in claim 3, said water separation unit configured to extract water from moisture saturated air leaving the outlet of the fuel cell.
6. The fuel cell system (100) as claimed in claim 1, said Hydrogen circulation unit (106) configured with at least one micron filter, at least one hydrogen quality sensor, at least one pressure control valve and at least one flow controller, at least one isolation valve, at least one coolant circulation assembly, at least one hydrogen quality sensor, a fuel preheater, an isolation valves, a pressure controller, and a mass flow controller, and is further configured to feed desired hydrogen fuel quality at a required pressure.
7. The fuel cell system (100) as claimed in claim 6, said micron filter configured to restrict the inrush of any dust particle or other debris to the anode feed of the fuel cell.
8. The fuel cell system (100) as claimed in claim 1, wherein said thermal management unit (134) includes at least one temperature sensor, flow control valves, at least one flow diverter, a de-ionizer, a coolant heater, the coolant pump and intercooler for the compressed air.
9. The fuel cell system (100) as claimed in claim 8, wherein the coolant pump drives the coolant through the close loop consisting the fuel cell and the air intercooler towards the radiator (108) where the coolant exchanges the heat from the ambient.
10. The fuel cell system (100) as claimed in claim 8, wherein said thermal management unit (134) is configured to provide a coolant for cooling the compressed air coming out of said air circulation unit (104), maintain the conductivity of the coolant less than the pre-determined conductivity value of the coolant and a quick heat up of the coolant as required.
11. The fuel cell system (100) as claimed in claim 1, wherein said fuel cell control unit (132) includes sensors, alarms monitoring system (100) and wired communication, control unit accessories.
12. The fuel cell system (100) as claimed in claim 1, wherein the BOP components include coolant pump, air compressor and hydrogen recirculation blowers
13. The fuel cell system (100) as claimed in claim 3, includes at least one invertor, configured to control the RPM of the air compressor 118, an anode recirculation blower and the coolant pump.
14. The fuel cell system (100) as claimed in claim 1, includes at least one hydrogen sensor, positioned at the outlet of the fuel cell, to detect the leakage of the hydrogen from the fuel cell.
Dated this 03th Day of June, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K. DEWAN & CO.
Authorized Agent of Applicant