Patent Application
20250233171
The present invention relates to fuel cell systems and particularly, although not exclusively, to cooling sub-systems within fuel cell systems such as hydrogen fuel cell systems.
Fuel Cell (FC) heat management can be conducted via a separate cooling circuit forming part of an FC system or via evaporative cooling.
Where a separate cooling circuit is used for FC heat management, liquid water, or another coolant, is circulated through a channel in the stack of FCs contained within the FC system such that heat generated in the FC stack is transferred to the coolant and this coolant subsequently flows out of the FC stack. The heat transferred to the coolant in the FC stack is rejected from the cooling circuit via a heat exchanger (HEX), for example the HEX acting as a radiator that rejects the heat to atmosphere. In such a system, an air feed to the FC used in the FC reaction is a separate circuit and flows into a separate channel of the FC stack.
When evaporative cooling is used for FC heat management, cooling water and the air feed for the FC reaction are fed into the same channel(s) of the FC stack. Cooling of the FC stack is achieved through transfer of heat energy from the FC stack to the water to effect evaporation. The ratio of water to air fed into the FC stack is such that the air exiting the FC stack is saturated with water vapour and contains entrained water droplets. The water vapour contained in the FC stack outlet is then condensed to separate out the water; for example, by feeding the FC stack outlet to a coolant-air HEX (i.e. a radiator).
With either approach to FC heat management, a substantial challenge is the need to reject low-quality heat from the coolant into the environment.
This challenge becomes even greater when using the FC system in an aviation setting. The heat generated by a FC stack is proportional to the operating current (and thus power) of the FC stack. The times at which the power demand placed on, and thus heat generation in, a FC stack being used in an aircraft are greatest are during take-off and initial climb. For example, at take-off when the aircraft is at maximum take-off weight (MTOW). As an aircraft gains altitude, the ambient air temperature the aircraft is exposed to falls; however, the times of high power demand generally coincide with when the aircraft is at lower altitudes than the cruising altitude of the aircraft; thus, the heat being generated by the FC stack is greatest when the ambient temperature is relatively high in comparison to the average temperature during the aircraft's flight. This is particularly the case when the aircraft is taking off when the ambient air temperatures on the ground are high (Hot Day conditions).
Typically, in a closed-loop cooling sub-system, the above challenge is addressed by providing a HEX with a large heat transfer area and thus a high heat duty to sufficiently cool the coolant, and/or providing a cooling sub-system with a large volume of coolant such that the hot coolant leaving the FC stack represents a small fraction of the thermal mass of the coolant sub-system.
The heat duty across a HEX is a strong function of the temperature difference between the fluids on either side of that HEX—the greater the temperature difference, the greater the heat duty. Accordingly, an aircraft FC system with a cooling sub-system that relies on a HEX transferring heat from the coolant to the environment (i.e. as a radiator) to reduce the temperature of the coolant will require the HEX and coolant volume to be sized based on Hot Day MTOW conditions in order to ensure the cooling sub-system can continue to provide sufficient cooling to the FC stack. This results in a substantially larger HEX and coolant volume than if the sizing conditions were, for example, MTOW but with the ambient temperature at its mean for the aircraft's usage, rather than Hot Day.
An aircraft FC system having a cooling sub-system with a large HEX is problematic, because such a HEX is heavy, expensive and generates substantial drag. Similarly, using large volumes of coolant evidently means the coolant occupies more space within the aircraft, potentially necessitating an increase in the aircraft's size, and increases the mass of the aircraft. These problems become greater as the power of the aircraft increases and accordingly the necessary HEX size and coolant volume increase.
Moreover, with evaporative-cooling-based systems, there is an additional challenge that the amount of water that can be evaporated within the FC stack per unit volume of air is capped based on the water saturation point of the air. In order to maximise the amount of water that can be evaporated, the entry-side air humidity and pressure are ideally set to be low. However, low air pressure is not desirable due to the resulting low reaction rates within the FC, which negatively impacts the FC system's efficiency and performance.
The present invention has been devised in light of the above considerations.
It is desired to provide an FC system having a cooling sub-system wherein the HEX of the cooling sub-system, which is used to reject heat transferred to the coolant into the atmosphere, is sized away from the conditions of peak ambient temperature and peak FC power (e.g. Hot Day MTOW).
Accordingly, in a first aspect there is provided an FC comprising:
This FC system, and in particular the cooling sub-system configuration, allows the coolant HEX to be sized at operating conditions away from Hot Day MTOW by having the exhaust line and the first multi-outlet valve arrangement that provides the possibility of the cooling system operating as a closed-loop system or an open-vented sub-system. Accordingly, at operating conditions such as Hot Day MTOW or similar, where the coolant HEX may be too small for the cooling sub-system to operate as a closed loop and still provide the required cooling to the FC stack, the cooling sub-system can be operated as an open-vented sub-system in which coolant exiting the FC stack is ejected from the cooling sub-system and no load is placed on the coolant HEX; at operating conditions away from Hot Day MTOW and similar, the coolant HEX size may be sufficient for the cooling sub-system to be operated as a closed-loop sub-system and still provide the cooling required by the FC stack, allowing the first multi-outlet valve arrangement to be set to recycle the coolant exiting the FC stack via the coolant HEX. Thus, the minimum heat transfer area of the coolant HEX needed to provide the required cooling to the FC stack to prevent the FC stack from overheating, is smaller than in a conventional cooling sub-system without the ability to operate as an open-vented cooling sub-system.
Some optional features of the present disclosure will now be set out. These are applicable singly or in any combination with an aspect of the present disclosure except where such a combination is clearly impermissible or expressly avoided.
Typically the controller of the cooling sub-system is further configured to switch first multi-outlet valve arrangement from the first state to the second state in response to an increase in the required heat duty of the cooling sub-system across the FC stack and/or a decrease in the achievable heat duty of the cooling sub-system across the coolant HEX. Furthermore, the controller is typically further configured to switch the first multi-outlet valve arrangement from the second state to the first state in response to a decrease in the required heat duty of the cooling system across the FC stack and/or an increase in the achievable heat duty of the cooling sub-system across the coolant HEX. A controller configured in this way helps the cooling sub-system to provide the required heat duty across the FC stack, whilst reducing the quantity of coolant ejected from the cooling sub-system via the exhaust by avoiding unnecessarily operating with the first multi-outlet valve arrangement in the second state.
The first multi-outlet valve arrangement may be configured to have a third state in which both the first valve outlet and the second valve outlet are open, providing a cooling sub-system in which a coolant path from the first multi-valve arrangement, through the coolant HEX to the coolant tank is open, and a coolant path from the first multi-valve arrangement to the coolant exhaust is open. Advantageously, the first multi-outlet valve arrangement having such a third state allows the amount of coolant ejected from the cooling sub-system during operation of the FC system to be reduced. This is because when transitioning from an open-vented cooling sub-system to a closed-loop cooling sub-system, the recycling of some of the coolant can be initiated prior to the point where the achievable heat duty across the coolant HEX is large enough for all of the coolant to be recycled whilst still meeting the required heat duty of the cooling sub-system across the FC stack. The controller may be further configured to be able to switch the first multi-outlet valve arrangement between all three of the first state, the second state and the third state depending on the balance between the required heat duty of the cooling sub-system across the FC stack and the achievable heat duty of the cooling sub-system across the coolant HEX. A controller configured in this way allows the amount of coolant ejected from the cooling sub-system during operation of the FC system to be reduced, as described above, and using the controller to set the first multi-outlet valve arrangement to the third state provides the cooling sub system with an additional control variable.
Typically, the cooling sub-system is configured to use water as the coolant. This is practical when the system is configured to eject coolant from the cooling sub-system into the surroundings via the exhaust.
The FC system may further comprise a cathode sub-system having an air feed line configured to feed air to the FC stack, and an air exhaust line configured to remove air from the FC stack, and an anode-side sub-system having a fuel feed line configured to feed fuel to the FC stack. Such a FC system can provide the FC stack with reactants for a FC reaction.
The cooling sub-system of the FC system may further comprise a water separation unit disposed on the air exhaust line to collect water from the air removed from the FC stack and a second recycle line extending from the water separation unit to the coolant tank. Such a FC system enables the separation of water from the air exhaust line and the recycling of this water into the cooling sub-system. This input of water may then allow the cooling sub-system to compensate for the water ejected from the system via the exhaust when operating with the first multi-outlet valve arrangement in the second state, allowing the coolant tank and the initial volume of coolant in the system to be made smaller than they would otherwise need to be.
Optionally, the FC system is configured such that the valve network further comprises: a second multi-outlet valve arrangement having a second valve inlet, a third valve outlet and a fourth valve outlet, the second valve inlet and fourth valve outlet being disposed on the stack feed line; and a first multi-inlet valve arrangement having a third valve inlet, a fourth valve inlet and a fifth valve outlet, the third valve inlet and the fifth valve outlet being disposed on the stack discharge line. Additionally, the cooling sub-system may further comprise a gas-pre-conditioning line extending from the third valve outlet to the fourth valve inlet. The controller may then be further configured to control the valve network to switch the second multi-outlet valve arrangement and the first multi-inlet valve arrangement between an open state in which the third valve outlet and the fourth valve inlet are open to open a coolant path through the gas-pre-conditioning line, and a closed state in which the third valve outlet and the fourth valve inlet are closed to close the coolant path through the gas-pre-conditioning line. The cathode-side sub-system may then further comprise a cathode-side HEX, a first side of the cathode-side HEX being disposed on the air feed line and a second side of the cathode-side HEX being disposed on the gas-pre-conditioning line between the third valve outlet and fourth valve inlet. Similarly, the anode-side sub-system may then further comprise an anode-side HEX, a first side of the anode-side HEX being disposed on the fuel feed line, and a second side of the anode-side HEX being disposed on the gas-pre-conditioning line between the third valve outlet and the fourth valve inlet. The controller may be further configured to open or close the gas-pre-conditioning line on the basis of a balance between two or more of: the required heat duty of the cooling sub-system (300) across the fuel cell stack; the achievable heat duty of the cooling sub-system (300) across the coolant heat exchanger; and the desired conditioning of the compressed air and/or the fuel stream. Conveniently, such an FC system allows the coolant sub-system to pre-cool air flowing into the FC stack via the air feed line and regulate the humidity of that air and/or to pre-condition the temperature of the fuel flowing into the FC stack via the fuel feed line, and thus improve the performance and control of the FC stack.
The cooling-sub system typically comprises a deionizer for the coolant. Such a deionizer may be disposed on the stack feed line. The deionizer can help to reduce the concentration of certain ions in the coolant that flows into the coolant channels of the FC stack, thereby limiting damage to the FC stack, for example, through minimising short circuiting and current leakage. It is preferable for the deionizer to be disposed on the stack feed line, especially when water is being provided into the cooling sub-system from the water separation unit, so that coolant is deionized just before entering the FC stack.
The cooling sub-system of the FC system may further comprise a HEX bypass line extending from the stack discharge line or the exhaust line to a position on the first recycle line downstream of the coolant HEX, and the controller may be further configured to open or close the HEX bypass line on the basis of a balance between the required heat duty of the cooling sub-system across the FC stack and the achievable heat duty of the cooling sub-system across the coolant HEX. Typically, the controller is further configured to close the HEX bypass line when the first multi-outlet valve arrangement is switched to the second state. Accordingly, an additional control variable of the cooling sub-system is provided by facilitating the bypassing of the coolant HEX, whilst still allowing the cooling sub-system to operate as a closed-loop cooling sub-system. Optionally, the controller may be further configured to be able to partially open the HEX bypass line, such that a coolant path through the coolant HEX and a coolant path through the HEX bypass line are open simultaneously. Such a configuration is useful in providing additional control over the FC system.
Optionally, the cooling sub-system further comprises an anti-icing coolant circuit extending from and returning to the first recycle line, the anti-icing coolant circuit being configured to carry coolant heated by the FC stack to ice protection systems of an aircraft, the heated coolant thereby losing heat to provide aircraft ice protection before returning to the first recycle line. Advantageously, this provides the cooling sub-system with another way in which to reject heat to the environment alongside the cooling HEX, and simultaneously reduces the amount of energy the aircraft may otherwise have to input into the anti-icing system, improving the vehicle's efficiency.
Typically, the anti-icing coolant circuit is connected to the first recycle line in parallel to the coolant HEX to provide an additional control variable of the cooling sub-system.
Typically, the coolant exhaust comprises an exhaust nozzle. This may assist the cooling sub-system in ensuring that coolant travelling down the exhaust line is ejected from the cooling sub-system.
The FC stack may comprise a plurality of proton-exchange membrane fuel cells (PEMFCs). Advantageously an FC stack comprising PEMFCs is lightweight and has a high energy density in comparison to FC stacks comprising other types of FC.
Typically, the FC system will comprise an FC stack that is a hydrogen FC stack. The FC system having an FC stack that uses hydrogen as a fuel source is advantageous in that the only chemical species produced by the reaction of the FC stack is water.
Commonly, the coolant HEX is an air-cooled HEX, a second side of the coolant HEX being exposed to an external airflow (e.g. an aircraft external airflow) which receives heat from the coolant. Thus, the cooling sub-system is simplified in comparison to using another form of HEX as the coolant HEX.
In a second aspect there is provided a propulsion device comprising the FC system of the first aspect and an electrically powered propulsor. In this case, the FC system further comprises a power sub-system which harvests electrical power generated by the FC stack and which is electrically connected to the propulsor to supply the propulsor with the generated electrical power. Advantageously, such a propulsion device can be made lighter and smaller than an FC-powered propulsion device without a cooling sub-system able to operate as an open-vented cooling sub-system. This is because the coolant HEX in the propulsion device of the second aspect can be made lighter and smaller.
Such a propulsion device can be an aircraft propulsion device.
Indeed, in a third aspect there is provided an aircraft comprising the propulsion device of the second aspect.
In a fourth aspect there is provided a method of operating the FC system of the first aspect. The method may comprise:
Optionally, the method may further comprise operating the cooling sub-system in a condition in which the coolant path from the first multi-valve arrangement to the coolant exhaust is open and the coolant path from the first multi-valve arrangement, through the coolant HEX and to the coolant tank is also open, by switching the first multi-outlet valve arrangement to the third state. Switching the first multi-outlet valve arrangement into and out of the third state is dependent on the required heat duty of the cooling sub-system across the FC stack and the achievable heat duty of the cooling sub-system across the coolant HEX. Advantageously, operating the cooling sub-system with the first multi-outlet valve arrangement in the third state allows the amount of coolant ejected from the cooling sub-system during operation of the FC system to be reduced. This is because when transitioning from an open-vented cooling sub-system to a closed-loop cooling sub-system, the recycling of some of the coolant can be initiated prior to the point where the achievable heat duty across the coolant HEX is large enough for all of the coolant to be recycled whilst still meeting the required heat duty of the cooling sub-system across the FC stack.
Embodiments and experiments illustrating the principles of the invention will now be discussed with reference to the accompanying figures in which:
Aspects and embodiments of the present invention will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.
The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.
The cathode-side sub-system 200 and the anode-side sub-system 400 interact with the cathode side 102 of the FC stack 100 and the anode side 104 of the FC stack 100, respectively. The cooling sub-system 300 is configured to manage heat generated in the FC stack 100 by the FC reaction. Specifically, the cooling sub-system 300 is configured to flow coolant through the FC stack 100, allowing heat to be exchanged from the FC stack 100 to the coolant, following which the coolant flows out of the FC stack 100. The power sub-system 500 is configured to provide a circuit connected to the cathode and anode of each of the FCs, thus allowing the voltage generated by the FC reaction to drive a current through said circuit for the harvesting of electrical power generated by the FC stack.
The FC system 1 is configured to conduct an FC reaction of a fuel, for example hydrogen, and oxygen. Accordingly, the cathode-side sub-system 200 is configured to deliver air to the cathode side 102 of the FC stack 100 for the FC reaction via an air feed line 216. Air coming into the cathode-side sub-system 200 first passes through a filter 205 to remove any debris within the incoming air, before then being compressed to a higher pressure in a compressor 210. Compressing the air prior to the FC stack 100 can improve the FC reaction kinetics and thus improve the efficiency and performance of the FC stack 100. Compressed air exiting the compressor 210 passes to a humidifier 215 prior to entering the cathode side 102 of the FC stack 100 via the air feed line 216. The humidifier 215 humidifies the compressed air travelling through the air feed line 216 prior to the compressed air entering the FC stack 100. A purge line is also provided from the humidifier 215.
An air stream leaving the cathode side 102 of the FC stack 100 in an air exhaust line 217 then also passes through the humidifier 215, which is disposed on the air exhaust line 217, so that water formed within the FC stack 100 can be used to humidify the compressed air in the air feed line 216, and then into a turbine 220 disposed on the air exhaust line 217. The air stream in the air exhaust line 217 is expanded in the turbine 220. Conveniently, the mechanical work provided by the expansion is used to, in part, power the compressor 210 via a turbocharger arrangement in which the turbine 220 is mechanically connected to the compressor 210. A motor 225 is also provided within the turbocharger arrangement to compensate for the difference in power provided by the turbine 220 and consumed by the compressor 210. The expanded air stream then exits the FC system 1 via the air exhaust line 217.
The humidifier typically comprises a small water circuit and/or a membrane that can transfer water across from the air exhaust line 217 into the air feed line 216.
The anode-side sub-system 400 is configured to deliver fuel to the anode side 104 of the FC stack 100 for the FC reaction. A fuel stream entering the FC system 1 via a fuel feed line 401 is passed to an ejector 405 before entering the anode side 104. The fuel stream flows through the anode side 104 and exits the FC stack 100 in an anode side exit stream. Typically, excess fuel is provided at the FC stack anode 104 to improve reaction performance over transient operations; as a consequence, the anode side exit stream, which comprises of a mixture of unreacted fuel and reaction products, is recirculated back into the anode inlet, allowing for optimal reactant distribution. FC reactions typically produce water (potentially alongside other reaction products). Thus, the anode side exit stream is passed to a water trap 410 to separate water from the rest of the contents of the fuel exit stream. The water trapped by the water trap 410, along with a portion of the anode side exit stream, is passed to a purge line, whilst the remaining portion of the anode side exit stream is recycled into the ejector 405 in a fuel recycle stream. Accordingly, it can be appreciated that the ejector 405 serves the purpose of pressure regulator for the fuel recycle stream and the fuel stream into the anode inlet.
The power sub-system 500 includes a direct-current-to-high-voltage-direct-current (HV DC/DC) converter 505 and a direct-current-to-low-voltage-direct-current (LV DC/DC) converter 510 to convert direct current generated in the power sub-system 500 by the FC reaction to high and low voltage direct currents, respectively. This allows the FC system 1 to provide both a high-voltage and low voltage DC power output.
Additionally, the power sub-system 500 further comprises a low voltage bus 515, and a DC/AC inverter 510 to convert the direct current generated in the power sub-system to an alternating current supply. This alternating current supply can then be provided from the inverter 510 to the motor 225 in the cathode-side sub-system 200 driving the compressor 210.
Heat is a by-product of the FC reaction, and accordingly the cooling sub-system 300 is configured to allow the heat generated in the FC stack 100 by the FC reaction to be managed. Specifically, the cooling sub-system 300 is configured to flow coolant through the FC stack 100, allowing heat to be exchanged from the FC stack 100 to the coolant, following which the coolant flows out of the FC stack 100. The cooling sub-system comprises a coolant tank 305 in which a reservoir of coolant, typically water, is stored. A stack feed line 340 extends from the coolant tank 305 to the FC stack 100. A pump 310 is disposed on the stack feed line 340 to pump coolant therethrough from the tank 305 to the FC stack 100. As illustrated in
The first multi-outlet valve arrangement 315 forms part of a valve network and comprises a first valve outlet 317 and a second valve outlet 318 in addition to the first valve inlet 316. Although the first multi-outlet valve arrangement 315 illustrated in
The coolant HEX 320 is used to reject low-quality heat transferred into the coolant within the FC stack 100 to the surroundings, such that the coolant flowing through the first recycle line 330 downstream of the coolant HEX 320 has a lower temperature than when it exited the FC stack 100 into the stack discharge line 345, allowing the coolant to be recycled around the closed loop and back into the FC stack 100 to transfer more heat out of the FC stack 100. Typically, the coolant HEX 320 is an air-cooled HEX, a second side of the coolant heat exchanger being exposed to an external airflow which receives heat from the coolant (i.e. the HEX is a radiator). Accordingly, ventilation may be provided to the FC system 1 to increase the achievable heat duty across the coolant HEX 320 by maintaining a large temperature difference between the air surrounding the coolant HEX 320 and the coolant flowing through the coolant HEX 320, and increasing the heat transfer coefficient of the coolant HEX 320.
The achievable heat duty across the coolant HEX 320 is a strong function of both the heat transfer area of the coolant HEX 320 and the temperature difference between the fluids on either side of the coolant HEX 320. In an aircraft context, and in a cooling sub-system that is only configured to operate as a closed loop cooling sub-system, the heat transfer area of the coolant HEX must be large enough to provide a heat duty across the coolant HEX that reduces the temperature of the coolant sufficiently to allow the cooling sub-system to provide the required cooling to the FC stack when the FC system is operating at Hot Day MTOW conditions. However, for most of the FC system's operational time, the FC stack will be operating away from these conditions. Accordingly, the coolant HEXs in conventional cooling sub-systems are typically much larger, heavier and more expensive than is necessary for the average operating conditions of the FC system they are part of.
In the present FC system 1, this problem of coolant HEX 320 sizing is addressed by providing a coolant exhaust 325 and an exhaust line 340 extending from the second valve outlet 318 to the coolant exhaust 325, allowing the cooling sub-system 300 to reject coolant out of the cooling sub-system 300 as exhaust fluid. Thus, in addition to the closed loop described above, the present cooling sub-system 300 is also provided with an open-vented configuration. In such a FC system 1, it is beneficial to use water as the coolant because ejection of water as an exhaust fluid is less environmentally damaging than the ejection of other possible coolants, such as petroleum-based fluids and fluorocarbons. The first multi-outlet valve arrangement 315 can be set in different states to control whether the cooling sub-system 300 operates as a purely closed-loop cooling sub-system, a purely open-vented cooling sub-system, or a combination of the two. The first multi-outlet valve arrangement 315 has a first state in which first valve outlet 317 is open, and the second valve outlet 318 is closed, providing a closed-loop cooling sub-system 300 in which a coolant path from the first multi-valve arrangement 315, through the coolant HEX 320 and to the coolant tank 305 is open and a coolant path from the first multi-valve arrangement 315 to the coolant exhaust 325 is closed. The first multi-outlet valve arrangement 315 also has a second state in which the first valve outlet 317 is closed, and the second valve outlet 318 is open, providing an open-vented cooling sub-system in which a coolant path from the first multi-valve arrangement 315 to the coolant exhaust 325 is open and a coolant path from the first multi-valve arrangement 315, through the coolant heat exchanger 320 and to the coolant tank 305 is closed.
As can be appreciated, operating the cooling sub-system 300 with the first multi-outlet valve arrangement 315 in the first state requires the achievable heat duty across the coolant HEX 320 to be large enough that the temperature reduction of the coolant across the coolant HEX 320 is adequate to allow the cooling sub-system 300 to provide the required heat duty to the FC stack 100. In contrast, operating the cooling sub-system 300 with the first multi-outlet valve arrangement 315 in the second state results in the coolant HEX 320 being bypassed, and the coolant exiting the FC stack 100 is not recycled to the coolant tank 305. Rather, the coolant exiting the FC stack 100 is ejected from the cooling sub-system 300 and there is no requirement to reject the low-grade heat such coolant absorbed from the FC stack 100 to the surroundings via the coolant HEX 320.
The cooling sub-system 300 further comprises a computer-based controller 395 configured to control the valve network to switch the first multi-outlet valve arrangement 315 between the first state and the second state. The controller 395 is configured to conduct such switching on the basis of a balance between a required heat duty of the cooling sub-system 300 across the FC stack 100 and an achievable heat duty of the cooling sub-system 300 across the coolant HEX 320.
The cooling sub-system 300 is therefore able to have a coolant HEX 320 sized away from Hot Day MTOW conditions and still provide the FC stack 100 with the cooling heat duty required at Hot Day MTOW conditions, or conditions approaching Hot Day MTOW conditions, by operating with the first multi-outlet valve arrangement in the second state, in which coolant exiting the FC stack 100 is ejected from the cooling system 300 via the coolant exhaust 325. When the conditions are such that the coolant HEX 320 is able to provide a heat duty across it that allows the cooling sub-system 300 to operate as a closed-loop cooling sub system (i.e. conditions are sufficiently far from Hot Day MTOW conditions, based on the achievable heat duty across the coolant HEX 320 and the required heat duty across the FC stack 100), the controller 395 can switch the first multi-outlet valve arrangement 315 to the first state and stop ejecting coolant from the cooling sub-system 300.
Switching the first multi-outlet valve arrangement 315 from the second state to the first state when the balance between the required heat duty of the cooling sub-system 300 across the FC stack 100 and the achievable heat duty across of the cooling sub-system 300 across the coolant HEX 320 allows is beneficial in reducing the amount of coolant ejected from the cooling sub-system 300. This may be particularly important in the case that the coolant volume within the coolant tank 305 cannot be readily topped up when the FC system 1 is in operation, and/or the coolant volume within the coolant tank 305 is only sufficient for operating the cooling sub-system 300 as an open-vented cooling sub-system for a certain amount of time before there is insufficient coolant within the cooling sub-system 300 for the cooling sub-system 300 to provide sufficient cooling heat duty to the FC stack 100.
The controller 395 is typically configured to switch the first multi-outlet valve arrangement 315 from the first state to the second state in response to an increase in the required heat duty of the cooling sub-system 300 across the FC stack 100 and/or a decrease in the achievable heat duty of the cooling sub-system 300 across the coolant heat exchanger 320. For example, if the power of the FC stack 100 is increased, if the ambient air temperature increases, or if the volume of air ventilating the FC system 1 decreases, the controller 395 may switch the first multi-outlet valve arrangement 315 from the first state to the second state. Similarly, the controller 395 is typically configured to switch the first multi-outlet valve arrangement 315 from the second state to the first state in response to a decrease in the required heat duty of the cooling sub-system 300 across the FC stack 100 and/or an increase in the achievable heat duty of the cooling sub-system 300 across the coolant heat exchanger 320. For example, if the power of the FC stack 100 is decreased, if the ambient air temperature decreases, or if the volume of air ventilating the FC system 1 increases, the controller 395 may switch the first multi-outlet valve arrangement 315 from the second state to the first state.
It can be appreciated that it may also be desirable to operate the cooling sub-system 300 under an operating condition wherein a portion of the coolant flowing into the first multi-outlet valve arrangement 315 is recycled to the coolant tank 305 in the first recycle line 330 via the coolant HEX 320 and the remaining portion of such coolant flows into the exhaust line 340 to be ejected from the cooling sub-system 300. Accordingly, the controller 395 may be configured to set the first multi-outlet valve arrangement 315 to a third state in which both the first valve outlet 317 and second valve outlet 318 are open. An ability to set the first multi-outlet valve arrangement 315 in this state may be desirable as it may allow the amount of coolant ejected from the cooling sub-system 300 to be reduced. This is because when transitioning from an open-vented cooling sub-system to a closed-loop cooling sub-system, the recycling of some of the coolant can be initiated prior to the point where the achievable heat duty across the coolant HEX 320 is large enough for all of the coolant to be recycled whilst still meeting the required heat duty of the cooling sub-system 300 across the FC stack 100.
Such an FC system 1 can thus comprise a coolant HEX 320 that is substantially smaller and lighter than would otherwise be required if the cooling sub-system 300 was not provided with the ability to switch between a closed-loop cooling sub-system and an open-vented cooling sub-system. The reduction in coolant HEX 320 size, weight and cost made possible is particularly beneficial when the FC system 1 forms part of a propulsion device where the power generated by the FC is used to supply electrical power generated by the FC stack 100 to an electrically powered propulsor 800, typically via the HV power output provided by the HV DC/DC converter 505. In this case the power-to-weight ratio and power-to-CdA ratio of a vehicle such a propulsion device is used can be increased, and thus its fuel efficiency can be improved. The increase in these ratios is particularly beneficial in the case of the propulsion device being used in an aircraft.
The cooling sub-system 300 of the FC system 1 in
Although the second multi-outlet valve arrangement 360 and the first multi-inlet valve arrangement 365 illustrated in
In order for the compressed air entering the FC stack 100 to be pre-cooled by coolant flowing through the gas-pre-conditioning line 370 line, a first side of a cathode-side HEX 230 is disposed on the air feed line 216, and a second side of the cathode-side HEX 230 is disposed on the gas-pre-conditioning line 370 between the third valve outlet 362 and the fourth valve inlet 367. Typically, the cathode-side HEX is positioned as illustrated in
Similarly, in order for the fuel stream entering the FC stack 100 to be pre-conditioned by coolant flowing through the gas-pre-conditioning line 370 line, a first side of an anode-side HEX 415 is disposed on the fuel feed line 401, and a second side of the anode-side HEX 415 is disposed on the gas-pre-condition line 370.
The controller 395 is configured to control the second multi-outlet valve arrangement 360 and the first multi-inlet valve arrangement 365 to switch the second multi-outlet valve arrangement 360 and the first multi-inlet valve arrangement 365 between an open state in which the third valve outlet 362 and the fourth valve inlet 367 are open to open a coolant path through the gas-pre-conditioning line 370, and a closed state in which the third valve outlet 362 and the fourth valve inlet (367) are closed to close the coolant path through the gas-pre-conditioning line 370.
The controller 395 may also be configured to control the degree to which the third valve outlet 362 and/or the fourth valve inlet 367 are opened, in turn altering the flowrate of coolant through the gas-pre-conditioning line 370 and thus the degree of pre-cooling of the compressed air and the fuel stream. The controller 395 is configured to change the state of the second multi-outlet valve arrangement 360 and the first multi-inlet valve arrangement 365 on the basis of a balance between two or more of:
Although both a cathode-side HEX 230 and an anode-side HEX 415 are present in
The cooling sub-system 300 in
Having the deionizer 390 disposed on the stack feed line 340 is beneficial in that the coolant will necessarily pass through the deionizer 390 prior to flowing into the FC stack 100, reducing the coolant's concentration of ions which have formed within the cooling sub-system 300 (through leaching, degradation corrosion, etc.) prior to the coolant entering the FC stack 100. It is desirable to deionize the coolant to reduce the risk of current leakage and short circuits within the FC stack 100.
The FC system 2 of
Firstly, the cooling sub-system 300 in
The water separation unit 355 is configured to collect water from the air removed from the fuel cell stack 100. A second recycle line 350 extends from the water separation unit 355 to the coolant tank 305 to send the collected water to the coolant tank 305. Advantageously, such a cooling sub-system 300 (ideally when using water as a coolant), can compensate for at least some of the volume of coolant ejected from the cooling sub-system 300 when the cooling sub-system operates as an open-vented cooling sub-system with the first multi-outlet valve arrangement in the second state by replenishing the coolant in the cooling sub-system 300 with water via the second recycle line 350. An ability to replenish the coolant whilst the FC system 2 is operating is beneficial when it is anticipated that the cooling sub-system 300 will need to be operated as an open-vented cooling sub-system. This is because the ability to replenish the coolant means that the volume of coolant contained within the cooling sub-system 300 when the FC system 2 begins operating can be smaller than it would otherwise need to be in order to cope with operating as an open-vented cooling sub-system. Accordingly, the coolant tank 305 can also be made smaller than it would otherwise need to be, because it does not need to store as great a volume of coolant. Accordingly, the cooling sub-system 300, and the FC system 2 as a whole, can be made smaller and lighter, and the size, mass and cost of the coolant tank 305 can be reduced.
The cooling sub-system 300 in
Another modification present in the cooling sub-system 300 in
In
In the arrangement illustrated in
In the case that the fifth valve inlet 376 and seventh valve outlet 378 are disposed on the exhaust line 340 such that the HEX bypass line 379 extends from the exhaust line 340, the bypass state may be provided by setting:
It can be appreciated that it may also be desirable to operate the cooling sub-system 300 such that a portion of the coolant flowing into the third multi-outlet valve arrangement 375 flows into the HEX bypass line 379 and the remaining portion of such coolant flows into the coolant HEX 320. Accordingly, the controller 395 may be configured to set the third multi-outlet valve arrangement 375 and second multi-inlet valve arrangement 380 such that both a coolant path through the HEX bypass line 379 and a coolant path through the coolant HEX 320 are open.
When the cooling sub-system is operating as an open-vented sub-system 300, the controller is configured to set the third multi-outlet valve arrangement 375 and the second multi-inlet valve arrangement 380 such that the bypass line 379 is closed and the exhaust line is open between the first multi-outlet valve arrangement 315 and the exhaust 325.
A further feature of the cooling sub-system 300 present in
An additional modification of the cooling sub-system 300 present in
Finally, the process flow diagram in
While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.
For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.
Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.
Throughout this specification, including the claims which follow, unless the context requires otherwise, the word “comprise” and “include”, and variations such as “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means for example +/−10%.
This application is based upon and claims the benefit of priority from United Kingdom of Great Britain & Northern Ireland Patent Application No. GB 2205780.6, filed on Apr. 21, 2022, the entire contents of which are incorporated herein by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2205780.6 | Apr 2022 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2023/057114 | 3/21/2023 | WO |
