This invention relates generally to fuel cell systems and more specifically to catalytically combusting an anode exhaust of a fuel cell, for example a Proton Exchange Membrane (PEM) fuel cell, to provide the heat to release hydrogen from a liquid storage material.
Fuel cells, for example PEM fuel cells, are touted as the future of the automotive industry. Fuel cells electrochemically react a fuel, such as hydrogen, with an oxidant, such as air, to produce electricity and water. PEM fuel cells are ideally suited for use in automobiles or for in-home applications and for many other applications.
In order for fuel cells to become practical for use within automobiles, a storage solution must be demonstrated that will provide the necessary quantities of hydrogen to the fuel cell. One of the fuel cell and storage combinations is a PEM fuel cell with a liquid storage medium. In this system, a hydrogen-charged liquid is pumped into a reactor that houses a catalyst. Alternatively, a homogenous catalyst is mixed with the liquid. The liquid and the catalyst are heated in the reactor such that at least part of the stored hydrogen within the liquid is released to the PEM fuel cell for electricity generation. Even with the assistance of a catalyst, a hydrogen-charged liquid must reach a certain temperature before it can release hydrogen. Typically, after hydrogen release, the hydrogen-depleted material is pumped back to a holding tank until it is adequately recharged with hydrogen either on-board or off-board. One concept for recharge involves pumping the hydrogen-depleted liquid out (at a refill station or the like) and pumping a new hydrogen-charged liquid into the system. In this concept, the hydrogen-depleted liquid can be regenerated as a hydrogen-charged liquid by reacting it with hydrogen in the presence of a catalyst off-board. This off-board concept has several advantages such as ease-of-use, safety, adaptability to existing gas station infrastructure, and it can be utilized without the use of a high-pressure tank or a cryogenic storage tank. These features are very attractive to on-board vehicular storage. Alternatively, the hydrogen-depleted liquid can be regenerated on-board a vehicle by re-charging with hydrogen in the presence of a catalyst. This concept is especially suited with a homogenous catalyst mixed into the liquid. It has the disadvantage of requiring heat removal during hydrogen charging, but has the advantage of re-charging on-board at a refill station without transporting the hydrogen depleted liquid into an off-site chemical plant.
Today's modern PEM fuel cells operate at relatively low temperatures, typically at about 80° C. Typically, the excess heat from the fuel cell is used to release the hydrogen from the hydrogen storage tank. Accordingly, it is widely assumed that the most practical applications would require the hydrogen storage tank to release hydrogen at about the same temperature that the fuel cell operates at, for example with PEM fuel cells, this temperature range would be from about 60° C. to about 80° C., and widely assumed to be less than 100° C. It is widely believed that the energy efficiency of the system will be lower, and the system will be more complex, if extra heat must be independently generated to release hydrogen from the tank.
One of the challenges for a PEM fuel cell system with a liquid carrier of hydrogen is that the PEM fuel cell exhaust temperature is too low to release hydrogen from most liquid carriers of hydrogen.
Another challenge of a PEM fuel cell system with a liquid carrier of hydrogen is the difficulty in starting the system under cold weather conditions. It is necessary for people in cold climates with temperatures as low as −20° C. to start the PEM fuel cell and hydrogen desorption. For the most part, no effective solution has been developed to solve the cold start problem.
Accordingly, there is a need to develop an improved fuel cell system that enables utilization of liquid carrier storage of hydrogen without requiring independent heat generation to release the hydrogen from the storage tanks. There is also a need to enable cold start of a PEM fuel cell and a hydrogen storage system.
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:
A fuel cell system 10 comprising a fuel cell 12, a liquid storage tank 14 and a catalyst reactor 16 is shown in
As discussed above, a significant challenge associated with implementing fuel cell system 10 into an automobile is the temperature required to dehydrogenate hydrogen 20 from the hydrogen-charged liquid 22. Accordingly, a significant amount of research is currently being conducted around identifying more effective catalysts to dehydrogenate hydrogen faster and at lower temperatures. Even with these research efforts, essentially all liquid media of hydrogen storage require temperatures higher than about 150° C. to effectively release hydrogen at an acceptable rate to feed into the fuel cells. This temperature of about 150° C. or higher is incompatible with the operating temperatures of the fuel cells. PEM fuel cells operate at about 80° C. There are two factors that limit PEM fuel cells from operating at higher temperatures: 1) the current PEM devices cannot withstand higher operating temperatures without system degradation; and 2) the PEM fuel cells need to be kept at a temperature below the boiling point of water to ensure the system is adequately hydrated. Accordingly, the current operating temperature limit of an ambient pressure PEM system is about 80° C. There are certain advantages to operate at higher temperatures, and for this reason, there are many efforts to develop higher temperature PEM systems. Future advancements of the PEM fuel cell might permit operating temperatures to push upwards to about 100° C. Even if the operating temperature of PEM fuel cells rises to 100° C., it is still not high enough to release most of the hydrogen stored in the hydrogen-charged liquid 22.
In accordance with one embodiment of the instant invention, a fuel cell system 50 is shown in
The anode exhaust 60 from the fuel cell 52 is mixed with a fraction of the cathode exhaust 62 and combusted in catalytic combustor 54 to produce an offgas 64 with a temperature greater than about 150° C., and typically greater than 200° C. The higher temperature offgas 64 is used to raise the temperature of the hydrogen-charged liquid 66 and the catalyst in reactor 56 to release the hydrogen from the liquid 66. The higher temperature offgas 64 enables a variety of hydrogen-charged liquids 66, some existing, some yet to be developed, to be used effectively with PEM fuel cells.
Fuel cell 52, is typically a PEM fuel cell but can include a variety of other fuel cell types including but not limited to a phosphoric acid fuel cell, a solid oxide fuel cell or an alkali fuel cell. PEM fuel cells are typically associated with onboard or automotive applications, so many discussions within this application will focus on PEM fuel cells. While certain embodiments of this invention may primarily be discussed with reference to PEM fuel cells, this is not a limitation of this invention. An oxidant 68, typically air, and hydrogen (H2) 70, are introduced into fuel cell 52 and electrochemically react to produce electricity 72, cathode exhaust 62 and anode exhaust 60 comprising water (H2O) and small quantities of unutilized H2, for example less than about 15% by volume of the anode exhaust 60, and typically less than about 10% by volume. Typical H2 utilization efficiency in a PEM fuel cell is less than about 90%, so there is always some percentage of H2 that cannot be converted inside the PEM fuel cell that is released via the anode exhaust 60. Anode exhaust 60 is typically so dilute in H2, and contains such large quantities of steam, that homogeneous combustion cannot efficiently be utilized to recover heat from the anode exhaust 60 to take advantage of this otherwise wasted energy. Instead, the anode exhaust 60 is typically used directly, at its existing temperature, around 80° C., to heat the hydrogen storage system to release the hydrogen.
In the instant invention, however, anode exhaust 60 is directed into catalytic combustor 54. The anode exhaust 60 is catalytically reacted to produce an offgas 64 having an elevated temperature, for example greater than about 150° C. and typically greater than 200° C. In some embodiments of the invention, the temperature of the offgas 64 is between about 200° C. to about 900° C. In other embodiments of the invention, the temperature of the offgas 64 is between about 200° C. to about 500° C.
In catalytic combustor 54, part of the cathode exhaust 60 is mixed with the anode exhaust 62 at a predetermined ratio and is fed to a combustion catalyst such as Pt/Al2O3, Pt—Pd/Al2O3, Pt—Rh/Al2O3, Pt—Ru/Al2O3, or Pt—Ir/Al2O3. Once the constituents begin to catalytically react, the small amount of H2 in the anode exhaust 60 will react with the O2 in the cathode exhaust 62 to generate heat. Depending on the H2 concentration of the anode exhaust 60, and the ratio of O2 to H2 or cathode exhaust to anode exhaust feeding into the catalytic combustor 54, the temperature of the catalyst (typically a catalyst bed), and correspondingly the temperature of the offgas 64, can be controlled over a wide temperature range, for example from about 150° C. to about 900° C.
A partial list of the liquid carrier materials for storing hydrogen in tank 58 is shown in TABLE 1. The term hydrogen-charged liquid includes only partially charged liquid. Similarly, the hydrogen-depleted liquid also includes the hydrogen partially depleted liquid.
For instance, decalin can be dehydrogenated to form naphthalene and releases about 7.3-weight percent hydrogen. With a catalyst of about 5% platinum and rhenium on a carbon support, the conversion rate from decalin to naphthalene at 210° C., 240° C., and 280° C. is about 50%, 80% and 100% respectively. The hydrogenation speed is also much faster at higher temperatures. For instance, at 210° C. for 2.5 hours, only about 50% decalin converts to naphthalene; whereas at 280° C. only about 0.5 hour is needed to reach the same conversion amount. The higher the temperature, the faster and the more complete the dehydrogenation process. In addition, only at temperatures higher than 210° C., does the dehydrogenation rate become reasonable to provide hydrogen to fuel cells. This temperature is incompatible with the existing fuel cell system, but it can readily provided by the instant invention.
Another embodiment of the instant invention is shown in
In yet another embodiment of the instant invention shown in
In yet another embodiment of the instant invention shown in
In yet another embodiment of the instant invention, the fuel cell system 50 comprises a plurality of heat exchangers to optimize the thermal management of the entire system. The heat exchangers take advantage of the excess heat from the hydrogen-depleted liquid 102, the hydrogen 70, and the exhaust vent 302 to: 1) raise the temperature of the feeding air or other oxidant into the fuel cell 52, 2) heat the anode exhaust 60 and the cathode exhaust 62 feeding to the catalytic combustor 54, 3) heat other parts of a larger system outside the fuel cell system 50 such as a vehicle that uses the fuel cell system 50, or 4) generate electricity using a thermoelectric material.
Depending on the heat of desorption (ΔH) of the hydrogen-charged liquid 66 and the available residual hydrogen in the anode exhaust 60, one embodiment of the instant invention is shown in
One embodiment of the instant invention is to enable easy cold start of the fuel cell and the dehydrogenation reaction in the reactor 56. This embodiment is schematically shown in
When it is time for re-filling at a gas station, the hydrogen-depleted liquid 102 is pumped out and new hydrogen-charged liquid 66 is refilled. The hydrogen-depleted liquid 102 is regenerated to hydrogen-charged liquid 66 by reacting it with hydrogen at the presence of a catalyst. The re-hydrogenation is typically performed off-board of a vehicle at a gas station or at a place away from the gas station in a central chemical plant. The advantage of such a process is easy re-fueling, easy adoption to existing gas station infrastructure, and minimum re-fueling time. Alternatively, the hydrogen-depleted liquid 102 may be regenerated on-board a vehicle by re-charging with hydrogen in the presence of a catalyst. This embodiment of the instant invention is schematically shown in
When the fuel cell 52 is running during re-fueling, the high temperature exhaust 64 from the catalytic combustor should preferably be ducted temporarily away from the reactor 56 if the heat of re-hydrogenation is very high. A coolant can be optionally introduced to remove excess heat from the reactor 56. If the re-hydrogenation heat is low, a fraction of the catalytic combustor exhaust 64 can be introduced to maintain the reactor 56 at a desired temperature. Thermal management, balance, and control should be apparent to those skilled in the art.
In the case that a homogenous catalyst is mixed with the hydrogen-charged liquid and the hydrogen-depleted liquid, the hydrogen may be directly introduced into the storage tank 58 to convert the at least partially hydrogen-depleted liquid into the at least partially hydrogen-charged liquid. If the excess heat is high, cooling mechanisms may be introduced into the storage tank 58 to remove part of the heat in order to maintain the storage tank 58 at a desired hydrogenation temperature.
Again in the case that a homogenous catalyst is mixed with the hydrogen-charged liquid and the hydrogen-depleted liquid, it may be possible to combine the reactor 56 with the storage tank 58. Heat exchanger mechanisms are introduced into the tank to heat the liquids and the catalyst to the desired temperature for hydrogenation and dehydrogenation.
Depending on the properties of the hydrogen-charged liquids 66, some of them may have a high vapor pressure such that the gas (predominately hydrogen) coming out of the reactor 56 may have small amounts of evaporated gas of the hydrogen-charged liquid materials in addition to desorbed hydrogen. In this case, a condenser may be introduced to remove the evaporated materials thus producing high purity hydrogen to the fuel cell. In other cases, the dehydrogenation process produced multiple gases. In this situation, hydrogen membranes known in the art can be used to filter high-purity hydrogen to feed into the fuel cell. A known hydrogen membrane material is pure Palladium (Pd).
While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
This application is related to co-pending U.S. patent application Ser. No. 11/193,970, having docket number 183593-1 and entitled “Fuel Cell System,” U.S. patent application Ser. No. 11/292,583, having docket number 183593-2 and entitled “Fuel Cell System,” U.S. patent application Ser. No. 11/292,584, having docket number 183593-3 and entitled “Fuel Cell System,” each of which are herein incorporated by reference.