DESC:FIELD OF THE INVENTION

[0001] The present invention generally relates to a fuel cell, and more particularly the present disclosure relates to a system of recovering a condensate from a Proton-Exchange Membrane (PEM) fuel cell.
BACKGROUND

[0002] With the growing requirement for clean energy, fuel cells have been a clean, efficient, reliable, and quiet source of power. In addition, the fuel cells do not require any periodic recharge like the batteries, but instead, continue to produce electricity as long as a fuel source is supplied to the fuel cells. A proton-exchange membrane (PEM) fuel cell may even produce a net electricity of 30 kW while consuming hydrogen and oxygen and producing water and electricity as a by-product/exhaust gasses. However, the water extracted from the reaction in the form of moisture mixed with nitrogen remains unused.

[0003] Accordingly, there is a need for a system for using biproducts/exhaust gasses such as water and nitrogen in useful products.

SUMMARY

[0004] This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention nor is it intended for determining the scope of the invention.

[0005] The present disclosure discloses an energy recovery system for a fuel cell unit. The energy recovery system includes an inlet fluidically coupled with a gas outlet of the fuel cell unit, a condenser fluidically coupled with the inlet and disposed downstream to the inlet. The condenser includes a shell defining an enclosure to facilitate the resting of condensate fluid. The shell is adapted to be partially filled with the condensate fluid. The condenser includes a sparger fluidically coupled with the inlet and disposed inside the shell and adapted to be submerged in the condenser fluid. The condenser includes a mesh disposed inside the shell and fluidically coupled with the inlet. The exhaust gases exiting the inlet are adapted to pass through the mesh to facilitate the absorption of the moisture from the exhaust gases and the exhaust gasses is ejected in the condensate fluid through the sparger.

[0006] In an embodiment, the present disclosure relates to a fuel cell unit having an inlet for providing feed to the fuel cell, a gas outlet to eject the exhaust gases with the moisture, and an energy recovery system coupled with the gas outlet. The energy recovery system includes an inlet fluidically coupled with a gas outlet of the fuel cell unit, a condenser fluidically coupled with the inlet and disposed downstream to the inlet. The condenser includes a shell defining an enclosure to facilitate the resting of a condensate fluid.

[0007] The shell is adapted to be partially filled with the condensate fluid. The condenser includes a sparger fluidically coupled with the inlet and disposed inside the shell and adapted to be submerged in the condenser fluid. The condenser includes a mesh disposed inside the shell and fluidically coupled with the inlet. The exhaust gases exiting the inlet are adapted to pass through the mesh to facilitate the absorption of the moisture from the exhaust gases and the exhaust gasses is ejected in the condensate fluid through the sparger.

[0008] The energy recovery system is commercially feasible with the fuel cell. The energy recovery system requires low to almost no energy to operate. In an embodiment, of forced convection very low energy is required. The energy recovery system helps convert the purged-out material into a useful product and facilitates the recovery of the purged product from the fuel of the fuel cell. In addition, the cost of the overall equipment is also low. In addition, the energy recovery system is an environmentally friendly solution to collect the water from the PEM fuel cell.

[0009] To further clarify the advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0011] Figure 1 illustrates a circuit diagram of a fuel cell unit integrated with an energy recovery system, according to an embodiment of the present disclosure;
[0012] Figure 2 illustrates a fuel cell of the fuel cell unit, according to an embodiment of the present disclosure;
[0013] Figure 3 illustrates a condenser of the energy recovery system having natural convection, according to an embodiment of the present disclosure;
[0014] Figure 4 illustrates the condenser of the energy recovery system having a forced convection, according to an embodiment of the present disclosure;
[0015] Figure 5 illustrates a sparger of the condenser of the fuel cell unit , in accordance with the embodiment of the present disclosure;
[0016] Figure 6 illustrates different perspective views of an embodiment the condenser, according to an embodiment of the present disclosure; and
[0017] Figure 7 illustrates different perspective views of a developed prototype of the condenser of the energy recovery system, according to an embodiment of the present disclosure.

[0018] Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION
[0019] For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the various embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

[0020] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the invention and are not intended to be restrictive thereof.
[0021] Reference throughout this specification to “an aspect”, “another aspect” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrase “in an embodiment”, “in another embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0022] The terms “comprise”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by “comprises... a” does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.

[0023] Referring to Figure 1, a circuit diagram of a fuel cell unit 100 integrated with an energy recovery system 102 is shown, in accordance with the embodiment of the present disclosure. Figure 2 illustrates a fuel cell 101 of the fuel cell unit 100, in accordance with the embodiment of the present disclosure.

[0024] As shown in Figure 1 and Figure 2, the fuel cell unit 100 includes a fuel cell 101 adapted to generate electric energy through the reaction between a hydrogen (or a hydrogen-rich fuel source) and oxygen. In an embodiment, the fuel cell unit 101 may include a fuel cell 101 of a Proton Exchange Membrane (PEM) fuel cell. In an embodiment, the PEM fuel cell 101 has high efficiencies relative to traditional combustion engines and low emissions, producing only heat and water as a by-product.

[0025] As shown, the circuit diagram of the fuel cell unit 100 includes the fuel cell 100 to facilitate the generation of electricity, a fuel source defining a source of oxygen and hydrogen, a first outlet 104 of the fuel cell 100 to facilitate the output of the electricity, and a gas outlet 106 to facilitate the output/ejection of the exhaust gasses having steam along with the nitrogen. In addition, the fuel cell unit 100 may include a power distribution module 107 coupled with the first outlet 104 of the fuel cell 101 to facilitate the distribution of the power generated from the fuel cell 101.

[0026] In an embodiment the energy recovery system 102 includes a condenser 108 fluidly coupled with the gas outlet 106 of the fuel cell 101 to facilitate the extraction of the moisture and the nitrogen from the fuel cell 100. In addition, the fuel cell unit 100 may include an electrolyser 109 fluidically coupled with the condenser 108 to intake a feed of the water from the condenser 108 without departing from the scope of the present disclosure.

[0027] Referring to Figure 3 and Figure 4, the condenser 108 is shown. Specifically, Figure 3, illustrates the condenser 108 of the energy recovery system 102 having a natural convection. Figure 4 illustrates the condenser 108 of the energy recovery system 102 having a forced convection. As shown in Figure 3, the condenser 108 includes a first inlet 110 fluidly coupled with the gas outlet 106 of the fuel cell 100 such that the by-products from the fuel cell 100 are adapted to enter into the condenser 108.

[0028] In an embodiment, the by-products of the condenser 108 include a nitrogen gas mixed with steam or moisture. In an example, the mass flow rate of the by-products/exhaust gasses entering the condenser 108 is 20 kilograms per hour. In another example, the first inlet 110 defines a conduit shape configuration having an outer diameter of 74 millimeters and an inner diameter of 64 millimeters.

[0029] As shown, the condenser 108 includes a shell 120 having a base 122, one or more sidewalls 124 extending upwardly from the base 122, and a roof 126 adapted to rest on the sidewall 124 and disposed opposite to the base 122. In addition, the shell 120 includes a first opening 128 to facilitate the entry of the first inlet 110 into the shell 120, a second opening 130 disposed spaced apart from the first opening 128 and extending in the roof 126 to facilitate the exit/ejection of the gasses from the shell 120, and a third opening 132 extending along the base 122 to facilitate the exit of the condensate such as water from the shell 120.

[0030] In an embodiment, the first inlet 110 includes a mesh 134 to facilitate the absorption of the moisture ejected from the exhaust gases of fuel cell 100. In an embodiment, the mesh 134 is a demister pad mesh to facilitate the absorption of the moisture from the exhaust gases of the fuel cell 100. In an embodiment, the mesh 134 is disposed inside the shell 120 and fluidically coupled with the inlet 110. In an embodiment, the exhaust gasses exiting the inlet 110 are adapted to pass through the mesh 134 to facilitate the absorption of the moisture from the exhaust gasses, and the exhaust gasses is ejected in the condensate fluid.

[0031] In addition, the shell 120 includes the condensate fluid such as water adapted to rest inside the shell 120 and partially fill the shell 120. In addition, the sidewall 124 includes a plurality of fins 136 disposed on an outer surface and adapted to absorb the heat extracted from the output of the fuel cell 100 while the moisture is being injected into the condensate fluid. In an embodiment, the condenser 108 includes a fan 140 or a forced convention system having a fan 140 to facilitate the blowing of the wind on the fins 136 to facilitate the cooling of the fins 136 and transferring the heat to the atmosphere from the fins 136.

[0032] Further, the first inlet 110 is fluidically coupled with a sparger 142. In an embodiment, the sparger 142 disposed inside the shell 120 and adapted to be submerged in the condenser fluid.

[0033] Referring to Figure 5, the sparger 142 of the condenser 108 of the fuel cell unit 100, in accordance with the embodiment of the present disclosure. As shown, the sparger 142 includes a first end 142a fluidically coupled with the inlet 110 and a pair of ends 142b disposed orthogonally with the first end 142a defining a T-shaped configuration.

[0034] In an embodiment, the portion extending between the two ends 142b includes a plurality of holes 142c to facilitate the exit of the by-products/exhaust gasses from the sparger 142 into the condensate fluid. The output from the fuel cell 101 is fed into the condenser 108 via the sparger 142 and the output is fed into the liquid, the liquid absorbs the water and the heat, and all the gasses is converted into the liquid.

[0035] In an embodiment, while the exhaust gasses are passed through the sparger 142 while being passed through the mesh 134 the moisture is already absorbed. So the exhaust gasses makes bubbles inside the condensate fluid and the gasses rises above the condensate fluid towards the roof 126 of the shell 120. The rising of the exhaust gasses mainly nitrogen towards the roof 126 of the shell 120 facilitates the collection of the exhaust gasses such as nitrogen proximate to the second opening 130. The second opening 130 facilitates the exit of the exhaust gasses such as nitrogen via the second opening 130.

[0036] In addition, the condenser 108 includes an exit conduit 146 extending outwardly from the base 122 of the condenser 108 to facilitate the exit of the condensate water from the condenser 108 to facilitate the extraction/recovery of the condensate water from the condenser 108. In an embodiment, the exit conduit may be coupled with the electrolyser 109 fluidically coupled with the condenser 108 to intake a feed of the water from the condenser 108 without departing from the scope of the present disclosure.

[0037] Referring to Figure 6, different perspective views of an embodiment the condenser 108 are shown, without departing from the scope of the present disclosure. As shown, Figure 6 includes the dimensions of an embodiment of the condenser 108. In an example, the condenser 108 as shown in Figure 6 may not include the sparger 142 to facilitate the cooling of the exhaust gasses from the fuel cell 101 without departing from the scope of the present disclosure.

[0038] Referring to Figure 7, different perspective views of a developed prototype of the condenser 108 of the energy recovery system 102 are shown, in accordance with the embodiment of the present disclosure. In an embodiment, the prototype of the condenser 108 may be made of aluminum, however, galvanized steel, galvanized iron, copper, mild steel, and stainless steel, of varying size, dimensions, and thickness may be used without departing from the scope of the invention.

[0039] In an exemplary embodiment of the energy recovery system, 102 for the PEM fuel cell 100 is disclosed. The PEM fuel cell 100 may produce a net electricity of 30 kW. Typically, the PEM fuel cell 100 may consume hydrogen and oxygen to produce water and electricity. Collecting electricity is the major target for every fuel cell producer and user. Water and produce may be used and collected. In an example, the PEM fuel cell 100 of 30 kW consumes about 3.36 kg/hr H2 and 26.88 kg/hr O2 to produce 30.24 kg/hr H2O. In an example, the sparger 142 may generate/save about 47.41 kilowatt (kW) of power without departing from the scope of the present disclosure.

[0040] In an embodiment, the water typically comes out in the form of moisture along with nitrogen from the PEM fuel cell 100 via the gas outlet 106 to the first inlet 110. The exhaust gas ejecting/exiting via the first inlet 110 is passed into the pool of liquid through the sparger 142. Then the heat is transferred from the sparger 142 to the liquid pool and the heat will be transferred to atmosphere through the fins 136 equipped at the condenser 108 or at the surface of the condenser 108.

[0041] The advantages of the present disclosure are now explained. The energy recovery system 102 is commercially feasible. The energy recovery system 102 requires low to almost no energy to operate. In an embodiment, of forced convection very low energy is required. The energy recovery system 102 helps convert the purge-out material into useful products and facilitates the recovery of the purged product from the fuel of the fuel cell 100. In addition, the cost of the overall equipment is also low. In addition, the energy recovery system 102 is an environment-friendly solution to collect the water from the PEM fuel cell 100.

[0042] While specific language has been used to describe the present subject matter, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.
,CLAIMS:1. An energy recovery system (102) for a fuel cell unit (100), the energy recovery system (102) comprising:
an inlet (110) fluidically coupled with a gas outlet of the fuel cell unit (100); and
a condenser (108) fluidically coupled with the inlet (110) and disposed downstream to the inlet (110), the condenser (108) comprises:
a shell (120) defining an enclosure to facilitate the resting of a condensate fluid, wherein the shell (120) is adapted to be partially filled with the condensate fluid;
a sparger (142) fluidically coupled with the inlet (110) and disposed inside the shell (120) and adapted to be submerged in the condenser fluid; and
a mesh (134) disposed inside the shell (120) and fluidically coupled with the inlet (110), wherein the exhaust gasses exiting the inlet (110) are adapted to pass through the mesh (134) to facilitate the absorption of the moisture from the exhaust gasses and the exhaust gasses is ejected in the condensate fluid through the sparger (142).

2. The energy recovery system (102) as claimed in claim 1, wherein the sparger (142) includes a first end (142a) fluidically coupled with the inlet (110) and a pair of ends (142b) disposed orthogonally with the first end defining a T-shaped configuration, wherein the portion extending between the two ends (142b) includes a plurality of holes (142c) to facilitate the exit of the gasses from the sparger (142).

3. The energy recovery system (102) as claimed in claim 1, wherein the fuel cell unit includes a Proton Exchange Membrane (PEM) fuel cell and the condensate fluid is a water.

4. The energy recovery system (102) as claimed in claim 1, wherein the shell (120) comprises:
a base (122);
one or more sidewalls (124) extending upwardly from the base (122); and
a roof (126) adapted to rest on the sidewall (124) and disposed opposite to the base (122).

5. The energy recovery system (102) as claimed in claim 4, wherein the roof (126) includes a first opening (128) to facilitate the entry of the first inlet (110) into the shell (120), and a second opening (130) disposed spaced apart from the first opening (128) to facilitate the exit/ejection of the gasses from the shell (120).

6. The energy recovery system (102) as claimed in claim 4, wherein the base (122) includes a third opening (132) to facilitate the exit of the condensate fluid from the shell (120).

7. The energy recovery system (102) as claimed in claim 1, wherein the mesh (134) is a demister pad mesh to facilitate the absorption of the moisture from the output gasses of the fuel cell unit (100).

8. The energy recovery system (102) as claimed in claim 1, wherein the sidewall (124) includes a plurality of fins (136) disposed on an outer surface and adapted to absorb the heat extracted from the exhaust gasses of the fuel cell unit (100).

9. The energy recovery system (102) as claimed in claim 8, comprising a forced convention system having a fan (140).

10. A fuel cell unit (100) comprising:
an inlet for providing a feed to the fuel cell (101);
a gas outlet (106) to eject the exhaust gasses with the moisture; and
an energy recovery system (102) coupled with the gas outlet (106), the energy recovery system (102) comprising:
an inlet (110) fluidically coupled with a gas outlet of the fuel cell unit (100);
a condenser (108) fluidically coupled with the inlet (110) and disposed downstream to the inlet (110), the condenser (108) comprises:
a shell (120) defining an enclosure to facilitate the resting of a condensate fluid, wherein the shell (120) is adapted to be partially filled with the condensate fluid;
a sparger (142) fluidically coupled with inlet (110) and disposed inside the shell (120) and adapted to be submerged in the condenser fluid; and
a mesh (134) disposed inside the shell (120) and fluidically coupled with the inlet (110), wherein the exhaust gasses exiting the inlet (110) are adapted to pass through the mesh (134) to facilitate the absorption of the moisture from the exhaust gasses and the exhaust gasses is ejected in the condensate fluid through the sparger (142).