This invention generally relates to detecting and controlling a fuel rich condition of a reactor in a fuel cell system.
A fuel cell is an electrochemical device that converts chemical energy directly into electrical energy. There are many different types of fuel cells, such as a solid oxide fuel cell (SOFC), a molten carbonate fuel cell, a phosphoric acid fuel cell, a methanol fuel cell and a proton exchange membrane (PEM) fuel cell.
As a more specific example, a PEM fuel cell includes a PEM membrane, which permits only protons to pass between an anode and a cathode of the fuel cell. At the anode of the PEM fuel cell, diatomic hydrogen (a fuel) ionizes to produce protons that pass through the PEM. The electrons produced by this reaction travel through circuitry that is external to the fuel cell to form an electrical current. At the cathode, oxygen is reduced and reacts with the protons to form water.
A typical fuel cell has a terminal voltage near one volt DC. For purposes of producing larger voltages, several fuel cells may be assembled together to form an arrangement called a fuel cell stack, an arrangement in which the fuel cells are electrically coupled together in series to form a larger DC voltage and to provide more power.
The fuel cell stack has an anode exhaust to output excess fuel (e.g., excess hydrogen or reformate). To prevent excess fuel from being exhausted into the environment, which is undesirable, a reactor, more specifically an anode tailgas oxidizer (ATO), is provided to oxidize the excess fuel. In addition, the thermal energy or heat generated from oxidizing the fuel in the ATO is used to generate steam for steam reforming for hydrogen or reformate production. To effectively oxidize the excess fuel and generate stable flow of steam with constant temperature, it is desirable to control the ATO's temperature within a predetermined range. However, the challenge associated with operation of the ATO is that it is difficult to control the proper amount of oxidant to achieve satisfactory ATO performance due to complicated ATO dynamics with long response time and strong coupling/interaction of ATO with other components (such as stack, steam circuit or reformer) in the fuel cell system.
In general, according to an embodiment, a fuel cell system includes a reactor to oxidize excess fuel, and a sensor associated with the reactor to provide an output indication. A controller detects a fuel-rich condition of the reactor based on the output indication from the sensor.
Advantages and other features will become apparent from the following description, drawings and claims.
In accordance with some embodiments, a fuel cell system has a reactor to oxidize excess fuel that is output from the exhaust of a fuel cell stack. In some embodiments, the reactor is referred to as an anode tailgas oxidizer (ATO). The ATO is supplied with an oxidant for burning the excess fuel to prevent exhausting the excess fuel into the environment. An issue associated with operation of the ATO is that the ATO may transition to a fuel-rich condition if too much fuel is input into the ATO and/or an insufficient amount of oxidant is provided to the ATO. An example fuel is hydrogen or hydrogen rich reformate, and an example oxidant is air (or oxygen). A sensor is associated with the ATO to provide an output indication. The output indication is received by a controller. The controller determines whether the ATO has entered into a fuel-rich condition based on the output indication of the sensor. Once the controller detects that the ATO has entered into a fuel-rich condition, then the controller takes corrective actions to bring the ATO back to a normal condition (a non-fuel-rich condition, also referred to as a “fuel-lean condition”).
One example of the sensor associated with the ATO is an oxidant sensor that is able to detect oxidant content (e.g., oxygen content) in the gas exhausted from the ATO. In some implementations, the oxidant content is expressed in terms of a relative amount (e.g., percentage) of the oxidant in the overall gas that is exhausted from the ATO. A percentage of oxidant content less than some predefined threshold (e.g., less than 1,000 ppm in the exhaust gas) is indicative of a fuel-rich condition of the ATO. Although the content of fuel (e.g., hydrogen) is not directly measured in the exhaust gas output, the fuel content can be inferred from the oxidant content, such that measured content less than the predefined threshold is indicative of a fuel-rich condition. In some implementations, the oxidant sensor outputs a logical “0” (to indicate fuel-lean condition) or a logical “1” (to indicate fuel-rich condition), or vice versa. In another implementation, the oxidant sensor outputs a value to indicate the relative amount of oxidant in the exhaust gas from the ATO. Note also that a fuel sensor can also optionally be provided to detect content of fuel (e.g., hydrogen) in the exhaust gas to aid in detecting a fuel-rich condition.
In an alternative embodiment, instead of using an oxidant sensor that detects oxidant content in exhaust gas from the ATO, a different sensor is a temperature probe provided inside the ATO (and particularly, at the catalyst of the ATO). The ATO temperature measured by the temperature probe can be used for determining whether the ATO has entered a fuel-rich condition.
The fuel cell stack 20 includes a cathode inlet 22, which receives the incoming oxidant flow to the stack 20 from a reactant conditioner 50. The incoming oxidant flow passes through the cathode chamber of the fuel cell stack 20, which represents the flow passageways through the cathodes of the fuel cells of the stack 20. The oxidant flow into the cathode inlet 22 produces a corresponding cathode exhaust, which exits the fuel cell stack 20 at a cathode outlet 24. As depicted in
From the junction 43, the cathode exhaust may be combined with a flow from another outlet of the three-way valve 44 to form an oxidant flow to the ATO 70. The oxidant flow to the ATO 70 is provided over a communication line 90. The fuel cell system 10 also includes a bypass line 80, which is connected to the junction 43 for purposes of communicating a flow from the junction 43 to an exhaust flow from the ATO 70. As depicted in
The fuel (e.g., hydrogen) for the fuel cell stack 20 is provided by a fuel source 60, which may be a reformer, hydrogen tank, and so forth, depending on the particular implementation. Thus, the fuel cell source 60 may provide a reformate flow, a pure hydrogen flow, etc., depending on the particular source of fuel for the fuel cell stack 20. The fuel flow that is provided by the fuel source 60 passes through a three-way valve 64 and through the reactant conditioner 50. From the reactant conditioner 50, the fuel flow is received into an anode inlet 26 of the fuel cell stack 20. The anode flow is communicated through the anode chamber of the fuel cell stack 20 for purposes of undergoing the electrochemical reactions inside the fuel cell stack 20. The fuel flow through the fuel cell stack 20 produces a corresponding anode exhaust, which exits the fuel cell stack 20 at an anode exhaust outlet 28. As depicted in
As a result of the oxidation inside the ATO 70, a relatively emission free exhaust flow is produced, which exits the ATO 70 at an outlet 72. As depicted in
The ATO 70 is also associated with a temperature sensor 71 to measure the temperature at the exhaust of the ATO 70. As explained further below, the measured temperature provided from the temperature sensor 71 allows the controller 100 to perform temperature feedback control of the oxidant blower 40.
The controller 100 may take on numerous forms, depending on the particular embodiment of the invention. In general, the controller 100 includes a processor 106, which may be formed from one or more microprocessors, microcontrollers, computers, or a combination of these components. In general, the processor 106 executes program instructions 104, which are stored in a memory 102. The memory 102 may be built into the controller 100 or external to the controller 100, depending on the particular embodiment of the invention. The program instructions 104, when executed by the processor 106, cause the controller 100 to perform one or more of the routines to control oxidant flow, which are set forth herein.
The controller 100 includes various input communication lines 120 for purposes of possibly receiving communications from other controllers, readings from sensors, current and voltage measurements, etc. Thus, through the communication lines 120, the controller 100 observes various states, operating conditions and measurements of the fuel cell system 10. Based on these measured parameters and communications, the controller 100 may control various components of the fuel cell system 10, such as the air blower 40, the three-way valves 44 and 64, the orifice 82 (when variable), the valve 27, electrical power conditioning circuitry (not depicted in
The arrangement of
Referring to
In the fast loop 150, the controller 100 controls the speed of the air blower 40 based on several input parameters, one of which may be the feedforward result from the O2 stoichiometry optimization routine 140. The parameters on which the control of the speed of the air blower 40 is based, may be combined together, as indicated by an adder 160, which provides the speed control signal for the air blower 40.
In addition to the results provided by the feedforward control routine 144, the controller 100 may also consider results provided by a feedback control routine 164, which considers feedback from the ATO 70. In this regard, the feedback control routine 164 generates a control input based on a difference between the ATO temperature (ATO T) 70 (measured by the temperature sensor 71 in
In accordance with some embodiments, note that the feedback routine 164 is used during a fuel-lean condition (or normal condition) of the ATO 70. In the fuel-lean condition, an increase in the oxidant flow to the ATO generally results in reduced temperature of the ATO, as measured by the temperature sensor 71 associated with the ATO 70. Because there is no excess fuel, the increase in oxidant flow (e.g., air flow) tends to cool the ATO 70. This effect is a negative feedback effect, in which increase in oxidant flow results in decreased temperature.
However, when the ATO 70 enters a fuel-rich condition, there is excessive fuel content at the ATO such that an increase in oxidant will actually lead to an increase in temperature, due to the fact that the increased oxidant flow will cause the fuel to oxidize right away. Consequently, during fuel-rich operation, the temperature of the ATO can go up relatively quickly if oxidant flow is not controlled properly. Thus, as discussed further below, the feedback control routine 164 is disabled when it is detected that the ATO 70 has entered into a fuel-rich condition.
The regulation of the air blower speed is also based on the result of a feedforward control routine 168 that generates an input to the adder 160 based on an estimated fuel (e.g., hydrogen) flow (represented as H2Flow2ATO) to the ATO 70. In this regard, an estimate is made as to the molar flow of hydrogen that exits the anode exhaust from the fuel cell stack 20 and is provided to the ATO 70.
The fast loop 150 also includes an oxidant switching control routine 170, which receives the estimated hydrogen flow (H2Flow2ATO) to the ATO 70 and a signal from the oxidant sensor 95 (see
Once the ATO 70 transitions back from the fuel-rich condition to the fuel-lean condition, the feedback control routine 164 is re-enabled. The output of the oxidant switching control routine 170 is provided as one of the inputs to the adder 160 for controlling the air blower 40 setting.
However, if the oxidant switching control routine 170 detects (at 304) that the ATO 70 has entered into a fuel-rich condition, then the oxidant switching control routine 170 turns off (at 306) the feedback control routine 164 (
The oxidant switching control routine 170 then waits (at 310) for a predefined time duration (e.g., 15 seconds) before checking (at 312) whether the ATO 70 has entered the fuel-lean condition. If not, control proceeds back and the tasks 306, 308, 310 are repeated. However, if the oxidant switching control routine 170 detects (at 312) that the ATO 70 has entered a fuel-lean condition, the oxidant switching control routine 170 turns on the feedback control routine 164 (at 314).
Next, the oxidant switching control routine 170 checks (at 316) to determine whether excursions into the fuel-rich condition are too frequent (e.g., a predetermined number, such as three, excursions in some predefined time interval, such as 10 minutes). If so, the fuel (e.g., hydrogen) stoichiometry is increased (at 318). Increasing the fuel stoichiometry refers to increasing the fuel flow to the fuel cell stack 20 (
Alternatively, instead of increasing fuel stoichiometry to increase oxidant flow to the ATO 70, the oxidant stoichiometry can be increased independently. This may require adjusting the three-way valve 44 in O2 stoic optimization 140. Or this may require a separate air blower (one for the fuel stack 20 and one of the ATO 70).
Instead of using the oxidant sensor 95 (
To use the temperature sensor 402 provided at the catalyst 400 of the ATO 70, a test is performed during operation of the fuel cell system to determine whether the ATO 70 is in a fuel-rich condition or fuel-lean condition. This test is referred to as a fuel-rich condition test, which is an on-line test in that the test is performed while the fuel cell system 10 is on-line and operational.
When performing the fuel-rich condition test, the feedback control routine 164 (
Instructions of software described above (including instructions 104 of
Data and instructions (of the software) are stored in respective storage devices, which are implemented as one or more computer-readable or computer-usable storage media. The storage media include different forms of memory including semiconductor memory devices such as dynamic or static random access memories (DRAMs or SRAMs), erasable and programmable read-only memories (EPROMs), electrically erasable and programmable read-only memories (EEPROMs) and flash memories; magnetic disks such as fixed, floppy and removable disks; other magnetic media including tape; and optical media such as compact disks (CDs) or digital video disks (DVDs).
While the invention has been disclosed with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of the invention.