Fuel cell system comprising modular design features

Abstract

There is described a fuel cell power system including a fuel processor subsystem, a fuel cell subsystem, and a power conditioning subsystem. The fuel processor subsystem comprises a main module for producing hydrogen rich streams from a hydrocarbon fuel, a balance of plant module for auxiliary components, and a control and electronic module for monitoring and controlling the fuel processor subsystem. The fuel cell subsystem comprises a main module for generation of electric power and thermal energy from hydrogen rich streams produced by the fuel processor module and air, a balance of plant module for auxiliary components, and a control and electronic module for monitoring and controlling the fuel cell subsystem. Each module has individual components attached thereto, the modules being designed and manufactured separately and assembled together to form the respective subsystems.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application is related to commonly assigned pending U.S. patent application entitled “Integrated Fuel Cell Power Module”, filed on Sep. 24, 2004 and bearing Ser. No. 10 / 948,794, the content of which is hereby incorporated by reference.TECHNICAL FIELD [0002] The present invention relates to devices which produce an electrical current by means of a chemical reaction or change in physical state, and more specifically, electrochemical fuel cell power generation systems comprising multiple subsystems including fuel processing, fuel cell stack, power conditioning, electronics and controls as well as the components of balance of plant. BACKGROUND OF THE INVENTION [0003] Fuel Cells (FC's) are electrochemical devices that directly convert the chemical energy of a fuel into electricity. In contrast to energy storage batteries, fuel cells operate continuously as long as they are provided with reactant gases. In the case of hydrogen / oxy...

AI Technical Summary

Benefits of technology

[0007] According to the present invention, the fuel cell system will be suitable as a stand-alone product for hydrogen production, pure hydrogen based transportation and backup power systems and fossil fuel residential applications as a result of disclosed modular design features. The functionally grouped and mechanically integrated modules can be separately manufactured, and serviced. Once manufactured, these modules can be easily installed and integrated to form a fuel processor, a fuel cell backup power system, or a residential fuel cell combined heat and power system. It provides the great degree of flexibility in manufacturing, assembly, and service. Each module can be easily replaced once it fails without sacrificing the entire system.

[0009] The present invention discloses a fuel cell system that is comprised of functionally grouped and mechanically integrated modules at all levels of system, subsystem and components, with the objective to increase the manufacturability, assembling ability and serviceability. Another objective is to increase the simplicity, and compactness of fuel cell systems. Yet another objective is to reduce the costs associated with fuel cell manufacturing, assembly, maintenance and service. Still another objective is to provide a method that allows quick development of various fuel cell products, e.g. fossil fuel residential or stationary CHP units, direct hydrogen fueled backup power units, and hydrogen production fuel processor.

[0010] The fuel cell power generation system is an integrated package from some or all of four major subsystems including fuel process subsystem, fuel cell subsystem, power conditioning subsystem and heat recovery subsystem. Furthermore, the fuel processor subsystem consists of three modules: fuel processor module, balance of plant module and electronics and controls module. Similarly, the fuel cell subsystem is made of three modules: fuel cell module, balance of plant module and electronics and controls module. The fuel processor module and fuel cell module each contain several separately manufactured and serviceable component modules, which are appropriately integrated. Linkage between the modules can be flexible and / or quick-connectable type. All the modules from component, subsystem to system are designed and constructed separately, and once manufactured they are linked or somehow stacked together according to the flow scheme to form an integrated compact device. The modular design feature as presented in this invention allows ease of manufacturing, leak testing, assembling and maintenance. It also allows repairing or replacing individual modules easily and cost effectively, once a failure has been detected.

Problems solved by technology

The products developed and manufactured in such cases cannot be transferable, i.e. each product requires a separate, lengthy and costly process of development, manufacturing and assembly.

Still, one of the most important issues impeding the commercialization of fuel cells is the cost.

Besides the material, the complexity in the present designs shares a significant portion of the high cost.

However, this feature has led to poor manufacturability, poor accessibility for assembling and poor serviceability.

Images