Fuel cell module assembly and system using same

Abstract

To provide: a fuel cell module assembly that can receive and output lower temperature process gases; and systems that enable replacement of fuel cell stacks with minimal disruption to the remaining fuel cell stacks in a power plant.SOLUTION: A module assembly 100 with a first end A comprises a heat exchanger 102 configured to supply a process gas from an external source to a fuel cell stack assembly 101 with heat exchange of an exhaust gas from the fuel cell stack assembly. By providing the first end A with fluid communication such as a cathode input port 120 and a cathode output port 121, the module assembly can be taken out of a power generating facility of a racking structure.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present application relates generally to the field of fuel cell module assemblies and systems using those module assemblies, and more particularly to fuel cell module assemblies with integrated thermal components that can be grouped into clusters and systems and systems using those clusters. [Background technology]

[0002] A fuel cell is a device that converts chemical energy stored in a fuel, such as hydrogen or methane, into electrical energy using an electrochemical reaction. Generally, a fuel cell includes an anode for catalytically reacting with a fuel and a cathode in fluid communication with an oxidant, such as air or a fuel gas output from a combustion source.

[0003] Fuel cells are typically arranged in a stacked relationship. One fuel cell stack configuration includes an external manifold stack, in which the fuel cell stack remains open on its sides and fluids, such as fuel or oxidant, are supplied by sealed manifolds around the periphery of each side of the fuel cell stack. The manifolds thus provide sealed passages for delivering fuel and oxidant gases to the fuel cells and directing the flow of such gases within the stack, thereby preventing leakage of those gases to the environment or to other manifolds. Such manifolds are typically used in molten carbonate fuel cells (MCFCs), which operate at approximately 650°C.

[0004] In a fuel cell stack, multiple fuel cell stacks are electrically and fluidically connected to increase power output without unduly increasing the size (i.e., surface area) of each individual fuel cell or the number of individual fuel cells. For large modular enclosure concepts containing many fuel cell stacks (potentially constructed and serviced at a different location from the final power plant site), transporting the modules can be difficult or impossible due to size and cost considerations. A power plant may contain several of these large modular enclosures, which presents at least two challenges. First, appropriate ducting (e.g., stainless steel, insulated pipes) is required to deliver hot process gases (~650 °C) to the modules. Second, during repair or replacement of an individual fuel cell stack within a large modular enclosure, all fuel cell stacks must be taken offline (i.e., shut down) because opening the "hot zone" containing the fuel cell stacks will cause that zone to cool. As a result, the remaining fuel cell stacks likely will not be capable of operating at low temperatures.

[0005] It would be advantageous to provide a fuel cell module assembly that can receive and output cooler process gases and to provide a system that allows fuel cell stacks to be replaced with minimal disruption to the remaining fuel cell stacks in the power plant. Summary of the Invention

[0006] According to one embodiment of the present invention, there is provided a fuel cell module assembly including a fuel cell stack assembly, a heat exchanger, and a housing enclosing the fuel cell stack assembly and the heat exchanger. The fuel cell stack assembly has a fuel cell stack configured to receive and output a first process gas, a first manifold configured to supply the first process gas to the fuel cell stack, and a second manifold configured to receive the first process gas output from the fuel cell stack. The heat exchanger is configured to receive the first process gas from an external source and output the first process gas to the first manifold, and to receive the first process gas from the second manifold and output the first process gas.

[0007] According to one embodiment of the present invention, there is provided a fuel cell power plant system including a module assembly having a first end and housing a fuel cell stack, a racking structure configured to hold the module assembly during an installation mode, a balance of plant equipment, and a duct configured to provide fluid communication between the balance of plant equipment and the first end of the module assembly during the installation mode. The module assembly and racking structure are configured such that during a removal mode, the module assembly can be removed from the racking structure in a direction away from the first end of the fuel cell module. [Brief explanation of the drawings]

[0008] FIG. 1 is a perspective view of a fuel cell module assembly according to one embodiment of the present invention.

[0009] FIG. 2 is a perspective view of a module cluster according to an embodiment.

[0010] FIG. 3 is a perspective view of a cluster group including multiple racking structures according to an embodiment.

[0011] FIG. 4 is a perspective view of a power plant system including multiple clusters according to an embodiment.

[0012] FIG. 5 is a perspective view of a fuel cell module assembly and racking structure during removal or installation mode according to an embodiment.

[0013] FIG. 6 is a close-up perspective view of a fuel cell module assembly coupled to a duct, according to an embodiment.

[0014] FIG. 7 is a cutaway side elevation view of the power plant system of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0015] The present invention provides fuel cell module assemblies that may be stacked relative to other fuel cell module assemblies, for example, in a rack configuration, and extracted (or installed) horizontally, resulting in a plant with a higher power density (e.g., MW / acre) compared to conventional fuel cell power plants. The fuel cell module assemblies of the present invention enable modularization of power plants, which may increase the flexibility of the power generation capacity of the power plant while reducing the time, cost, and size of the power plant construction. The fuel cell module assemblies of the present invention may also include heat exchangers (or heat condensers, etc.), which may allow the fuel cell modules of the present invention to receive and output cooler process gases compared to conventional fuel cell modules, thereby enabling the construction of power plants with smaller and less expensive ducts (e.g., smaller diameter ducts, less expensive duct materials) compared to conventional fuel cell power plants. The fuel cell module assemblies of the present invention may be used in controllable units of module assemblies (e.g., module clusters). A power plant with multiple controllable units can remain operational (i.e., generate power) when a particular module assembly is serviced because only the controllable units of that particular module assembly need be taken offline, while the remaining controllable units can remain online and available to generate power.

[0016] The present invention provides a fuel cell module assembly including one or more fuel cell stacks and one or more heat exchangers. The fuel cell module assembly may include an exterior housing enclosing the one or more fuel cell stacks and the one or more heat exchangers. One embodiment of the present invention, depicted in FIG. 1, is described below. However, it will be understood that the present invention is not limited to the particular depiction of FIG. 1.

[0017] FIG. 1 shows a perspective view of a fuel cell module assembly 100 according to one embodiment of the present invention. The module assembly 100 may include multiple fuel cell stack assemblies (stack assemblies) 101, a heat exchanger 102, a first containment wall 103, and a second containment wall 104. In one embodiment, an outer longitudinal containment wall (not shown) connects the first and second containment walls to form a sealed enclosure for the module assembly 100 (e.g., a housing). In another embodiment, the outer longitudinal containment wall (not shown) forms a housing around the components and assemblies included within the module assembly 100. The housing may have any shape suitable for enclosing subassemblies of a fuel cell module assembly and / or for enabling installation or removal or disassembly of fuel cell modules from a rack structure configured to hold one or more fuel cell module assemblies. For example, the housing may have a square, rectangular, or circular footprint, or may have a cubic or cylindrical shape. While the first and second containment walls 103, 104 shown in FIG. 1 have circular perimeters, the invention is not so limited. The perimeters of the first and second containment walls 103, 104 may have square, rectangular, or other shapes and may be the same or different from one another. The module assembly 100 may also have multiple longitudinal containment walls, as opposed to a single cylindrical wall in the case of a cylindrical or tubular housing. For example, the module assembly 100 may have a rectangular, cubic, or other shape.

[0018] The first containment wall 103, located at the first end A (also referred to as the "process end") of the module assembly 100, may include openings or conduits (e.g., ports, piping, ducts) for receiving and outputting process gases, such as a fuel supply gas, a fuel exhaust, an oxidant supply gas, and an oxidant exhaust. Process gases may also refer to gas streams that enter the fuel cell system, are processed within the fuel cell system, and are exhausted from the fuel cell system. For example, an anode process gas enters the fuel cell system as an anode feed gas, is electrochemically processed at the anode of the fuel cell, and is exhausted from the fuel cell system as an anode exhaust. Similarly, a cathode process gas enters the fuel cell system as a cathode feed gas, is electrochemically processed at the cathode of the fuel cell, and is exhausted from the fuel cell system as a cathode exhaust. As shown in FIG. 1, the first containment wall 103 includes an anode input port 110 for receiving an anode process gas (feed), an anode output port 111 for outputting an anode process gas (exhaust), a cathode input port 120 for receiving a cathode process gas (feed), and a cathode output port 121 for outputting a cathode process gas (exhaust).

[0019] The second containment wall 104, located at the second end B (also referred to as the “electrical end” or “extraction end”) of the module assembly 100, may include electrical connections for receiving / outputting control signals to the components and subassemblies included within the module assembly 100 and / or for outputting electrical power generated by the fuel cell stack subassembly 101. The electrical connections may include contacts, connectors, ports, plugs, etc., that electrically connect to other electrical components, a control center, and / or other assemblies within the power plant supporting the module assembly 100. In another embodiment, the electrical connections may be located at the process end (e.g., on or near the first containment wall 103) of the module assembly 100. As described below, when installed within a rack structure, the module assembly 100 may be extracted from the rack structure by, for example, using a crane, pulley system, etc. to pull the second end of the module assembly 100 away from the rack structure. In one embodiment, the second containment wall 104 may include hooks, protrusions, or other structural features suitable for connecting to (or coupling with) an extraction mechanism (e.g., a crane, pulley system, etc.).

[0020] As shown in FIG. 1 , the module assembly 100 includes four stack assemblies 101. However, the present invention is not so limited. The module assembly 100 may include a fewer or greater number of stack assemblies 101. In the embodiment of FIG. 1 , the stack assemblies 101 are oriented horizontally, and the fuel cell stack contained within the stack assembly 101 has a plurality of fuel cells (each cell having an anode, a matrix, and a cathode) stacked horizontally. A manifold extends laterally along the side of each stack assembly 101. The manifold carries process gas to and from the anodes and cathodes of the fuel cells within the stack assembly 101. In certain embodiments, during operation, the manifold functions as a duct configured to transport hot process gas to the fuel cells contained within the stack assembly 101. In embodiments, the plurality of manifolds includes a first manifold and a second manifold, where the first manifold is configured to supply process gas to the fuel cell stack and the second manifold is configured to receive the process gas output from the fuel cell stack.

[0021] As shown in FIG. 1 , the module assembly 100 includes two heat exchangers 102, which are positioned between the first containment wall 103 and the stack assembly 101. However, the present invention is not so limited. The module assembly 100 may include fewer or more heat exchangers 102. In another embodiment, the heat exchangers 102 may span the length of the stack assembly 101. For example, multiple heat exchangers 102 may be positioned below, above, or along the longitudinal axis of the stack assembly 101. In this embodiment, a given unit of heat exchanger(s) 102 may be appropriately sized for a given size or power density of the stack assembly 101. In such an embodiment, a higher percentage of the lateral space within the module assembly 100 may be used for power generation (i.e., using fuel cells). In an embodiment, the heat exchanger is configured to receive process gas from an external source and output the process gas to the fuel cell stack (via a first manifold), and to receive process gas from the fuel cell stack (via a second manifold) and output the process gas as a module exhaust stream (e.g., as a vent exhaust from the module assembly 101 to the ambient environment toward an aftertreatment device).

[0022] As mentioned above, fuel cells such as MCFCs operate at approximately 570°C to 670°C. In a conventional MCFC power plant, the process gas entering a conventional MCFC module should be approximately 650°C, and the ducts entering those modules must be capable of carrying process gas at that temperature (and must accommodate a corresponding volume of that gas). To withstand such temperatures, the ducts may require expensive materials such as stainless steel and insulation. By integrating a heat exchanger (or heat condenser, etc.) into the fuel cell module assembly of the present invention, a lower temperature process gas can be supplied to the module itself during operation. For example, the cathode input (oxidant feed gas) to the modules of the present invention may be near ambient temperature or 85% to 95% below the operating temperature (e.g., about 20°C to 65°C); the cathode output (oxidant exhaust) from the modules may be 70% to 80% below the operating temperature (e.g., about 100°C to 150°C); the anode input (fuel feed gas) to the modules may be 75% to 85% below the operating temperature (e.g., about 110°C to 150°C); and the anode output (fuel exhaust) from the modules may be 70% to 80% below the operating temperature (e.g., about 150°C to 200°C). In embodiments, a heat exchanger integrated into the module assembly is configured to receive a feed gas and output an exhaust gas at a temperature below the operating temperature of the fuel cell but above the condensation temperature of the process gas, and to output the feed gas and receive an exhaust gas at or near the operating temperature of the fuel cell. In one embodiment, during operation, in the heat exchanger, the process gas exiting the fuel cell may heat the process gas entering the module assembly, and the process gas exiting the module assembly may be cooled by the process gas entering the module assembly.

[0023] Furthermore, the low process gas temperature allows for the use of less expensive materials for the ducts (e.g., uninsulated pipe, galvanized steel). Furthermore, the size of the ducts to this module can be reduced compared to conventional modules (with the same process gas demand). For example, the ducts installed in a plant using this module can be two to three times smaller in volume than the ducts installed in a plant using conventional modules (with the same process gas demand). The piping and insulation in a process plant occupy a significant portion of the overall plant volume and footprint, especially in very large systems. This inventive design allows for lower process temperatures and smaller piping and ducts, significantly reducing the overall plant footprint.

[0024] FIG. 2 is a perspective view of a module cluster 200 according to one embodiment of the present invention. The module cluster 200 may include a rack structure 201 configured to hold a plurality of module assemblies 100 (shown together with a housing enclosing the stack assembly 101 and the heat exchanger 102), a balance of plant equipment 202, and a duct 301 (shown in FIGS. 3 and 4 ). The rack structure 201 and the module assemblies 100 may operate together in an installed mode, a removal mode, or an installation mode. In the installed mode, the duct 301 is configured to provide fluid communication between the balance of plant equipment 202 and a first end A of the module assemblies 100. In the removal mode, the module assemblies 100 are removable from the rack structure 201 in a direction away from the first end A of the module assemblies 100 (e.g., toward a second end B of the module assemblies 100). In the installation mode, the module assemblies 100 are installed in the rack structure 201 in a direction toward the first end A of the module assemblies 100.

[0025] The rack structure 201 may have a first end A' and an opposite second end B'. During installation, the first end A of the module assembly 100 may be adjacent to the first end A' of the rack structure 201. During removal, the module assembly 100 may be removed from the second end B' of the rack structure 201.

[0026] As shown in Figure 2, the rack structure 201 holds four module assemblies 100. However, the present invention is not so limited. The rack structure 201 may hold a fewer or greater number of module assemblies 100. In the embodiment of Figure 2, the rack structure 201 may hold multiple module assemblies 100 and balance of plant equipment 202 in a stacked arrangement, and the rack structure 201 and module assemblies 100 are configured such that during removal, the module assemblies 100 are removable from the rack structure 201 in the same direction (e.g., from the second end B' of the rack structure 201).

[0027] 3 is a perspective view of a cluster group 300 according to one embodiment of the present invention. The cluster group 300 may include multiple module clusters 200 (including ducts 301). The cluster group 300 may have a first end A'' and a second end B''. The ducts 301 of each module cluster 200 may be proximate the first end A'' of the cluster group 300. In one embodiment, the module assemblies held in each cluster group 200 may be removed in the same direction (e.g., from the second end B'' of the cluster group 300).

[0028] 3, the cluster group 300 includes four module clusters 200 arranged side by side. However, the present invention is not limited thereto. The cluster group 300 may include a smaller number of module clusters 200 or a larger number of module clusters 200.

[0029] During removal mode, a single module cluster 200 within the cluster group 300 may be electrically and / or fluidically isolated from the other module clusters 200. When removing a module assembly 100 from a module cluster 200, the affected module cluster 200 may be "offline" or electrically isolated from the remaining module clusters 200 within the cluster group 300, and process gases may be diverted away from the affected module cluster 200. The remaining module clusters 200 may remain "online" or available to receive / output process gases and generate power.

[0030] 4 is a perspective view of a power plant 400 in accordance with one embodiment of the present invention. The power plant 400 may include a plurality of clusters 300, a crane assembly 402 (or similar device) configured to raise / lower a module assembly 100, and install / remove the module assembly 100 from the clusters 300. The crane assembly 402 may include a carriage assembly 401 configured to hold the module assembly 100 as the crane assembly 402 raises / lowers the module assembly 100 and installs / removes the module assembly 100.

[0031] As shown in FIG. 4 , the power plant 400 may include an anode feed gas duct 410, an anode exhaust duct 411, a cathode feed gas duct 420, and a cathode exhaust duct 421. The external source of the cathode feed gas may be ambient air, a combustion source, or another source that emits carbon dioxide. For example, the cathode feed gas duct 420 may be fluidly connected to an exhaust gas source (e.g., a power generation facility or an industrial facility). The cathode process gas may be exhausted to the environment via the cathode exhaust duct 421. The external source of the anode feed gas may be any hydrocarbon source (e.g., a natural gas pipeline, an anaerobic digester, etc.). It is understood that such anode feed gas may pass through one or more gas processing / treatment assemblies. Such processing / treatment assemblies may be part of the balance of plant equipment. From the module assembly 100, the processed anode gas (anode exhaust) may be sent to a post-treatment assembly (e.g., for carbon capture, etc.). The balance of plant equipment may include assemblies configured to prepare process gases for introduction into the fuel cell and assemblies configured to treat exhaust gases (e.g., for carbon capture, etc.).

[0032] 5 is a perspective view of a module assembly 100 and cluster group 300 (to be removed or installed) during a removal mode or an installation mode, according to one embodiment. In this embodiment, during installation mode, in cooperation with a crane or other lifting mechanism, a carriage assembly 401 may secure the module assembly 100 from a transport mechanism (e.g., a rail car, a trailer bed, etc.) or a staging area and move (e.g., lift, rotate, position, etc.) the module assembly 100 toward the second end B'' of the cluster group 300 (and the second end B' of the rack structure 201). The carriage assembly 401 may position the module assembly 100 so that it can be installed (by sliding, pushing, pulling, translating, etc.) into the open rack structure level 501. The process described above may be reversed during removal mode.

[0033] The rack structure level 501 and / or the module assemblies 100 may include rails, tracks, grooves, sliding surfaces, rollers, etc. to allow the module assemblies 100 to be moved in and out of the rack structure 201 .

[0034] The carriage assembly 401 may be any such assembly known in the art capable of lifting heavy industrial components or equipment (e.g., large heat exchangers) and translating such components or equipment onto a raised structure. The carriage assembly 401 may be configured to accommodate a center of gravity that shifts when the module assembly 100 is displaced from the carriage assembly 401. For example, the carriage assembly 401 may include a carriage structure 502 and a carriage platform 503 configured to move laterally relative to one another such that the carriage structure 502 may maintain a position proximate to the center of gravity of the carriage assembly 401 when a weight load is transferred onto or from the carriage platform 503.

[0035] FIG. 6 shows a close-up perspective view of a module assembly 100 connected to a duct near a first end A″ of the cluster group 300 (or a first end A′ of the racking structure 200) according to one embodiment of the present invention. As shown in FIG. 6 , ports located at the first end A of the module assembly 100 communicate with ducts located near the first end A″ of the cluster group 300 (or the first end A′ of the racking structure 200). During the installed mode, the anode input port 110 communicates with the anode feed gas duct 410, the anode output port 111 communicates with the anode exhaust duct 411, the cathode input port 120 communicates with the cathode feed gas duct 420, and the cathode output port 121 communicates with the cathode exhaust duct 421. Communication between the ports on the module assembly 100 and the ducts may be by any means or method known in the art. The communication between the module assembly port and the duct may be releasable (e.g., bolts, screws, clamps, electrostatic forces, etc.) or non-releasable (e.g., welding). In a preferred embodiment, the communication between the module assembly port and the module cluster duct is releasable. It should be understood that any communication creates a fluid connection between the module assembly port and the module cluster duct that is sealed from the surrounding environment. Seals, gaskets, etc. may be used to form a sealed connection between the module assembly port and the module cluster duct.

[0036] In some embodiments, communication between the module assembly port and the module cluster duct may be maintained by gravity or other electrostatic forces. For example, the weight of the module assembly 100 may secure the connection between the module assembly port and the module cluster duct. In another example, the module assembly 100 may be pushed toward the module cluster duct so that the module assembly port is pressed into the receiving end of the cluster duct. An electrostatic force may be applied to the module assembly 100 to maintain a sealed connection between the module assembly port and the receiving end of the cluster duct.

[0037] 7 shows a cutaway side elevation view of a power plant 400 according to an embodiment of the present invention. The two cluster groups 300 may be oriented so that the second ends B" of the cluster groups 300 face each other to form a staging area 701 between the second ends B", which may be appropriately sized to accommodate receiving a module assembly 100 from an off-site location, securing the module assembly 100 (e.g., by a carriage assembly 401), and orienting the module assembly 100 for installation into one or the other of the two cluster groups 300 (e.g., by rotating the module assembly 100 so that the first end A of the module assembly 100 faces the cluster group 300 into which the module assembly 100 is to be installed). The crane assembly 402 may be configured to translate along the face of the second end B" of the cluster group 300 so that the crane assembly 402 may position the carriage assembly 401 adjacent to any rack structure 200 included in the cluster group 300. The crane assembly 402 may be configured to raise (or lower) the carriage assembly 401 adjacent to any rack structure level 501 within the cluster group 300. The carriage assembly 401 and crane assembly 402 may be configured to rotate the module assembly 100 for installation into or removal from the cluster group 300.

[0038] Further Aspects Aspect 1. A fuel cell module assembly comprising a fuel cell stack assembly, a heat exchanger, and a housing containing the fuel cell stack assembly and the heat exchanger, wherein: the fuel cell stack assembly comprises a fuel cell stack, the fuel cell stack configured to receive and output a first process gas; the plurality of manifolds comprises a first manifold and a second manifold, the first manifold configured to supply the first process gas to the fuel cell stack, the second manifold configured to receive the process gas output from the first fuel cell stack; the heat exchanger configured to receive the first process gas from an external source and output the first process gas to the first manifold, and configured to receive the first process gas from the second manifold and output the first process gas; and the housing encloses the fuel cell stack assembly and the heat exchanger.

[0039] Aspect 2. The fuel cell module assembly of Aspect 1, wherein the fuel cell stack is further configured to receive and output a second process gas, the plurality of manifolds include a third manifold and a fourth manifold, the third manifold configured to supply the second process gas to the fuel cell stack, and the fourth manifold configured to receive the process gas output from the second fuel cell stack, and the heat exchanger is further configured to receive the second process gas from a second external source and output the second process gas to the third manifold, and configured to receive the second process gas from the fourth manifold and output the second process gas.

[0040] Aspect 3. The fuel cell module assembly of Aspect 2, wherein the housing includes a plurality of ports located at a first end of the housing, the plurality of ports fluidly connecting to the heat exchanger and including a first port, a second port, a third port, and a fourth port, wherein the first port is configured to receive a first process gas from an external source, the second port is configured to output the first process gas from the housing, the third port is configured to receive a second process gas from a second external source, and the fourth port is configured to output the second process gas from the housing.

[0041] Embodiment 4. The fuel cell module assembly of embodiment 2 or 3, wherein the heat exchanger is further configured to receive a first process gas from an external source at a first temperature and output the first process gas to the fuel cell stack assembly at a second temperature, the first temperature being about 85% to about 95% cooler than the second temperature.

[0042] Aspect 5. The fuel cell module assembly of aspect 4, wherein the heat exchanger is further configured to receive the first process gas from the fuel cell stack assembly at a third temperature and output the first process gas at a fourth temperature, the fourth temperature being about 70% to about 80% lower than the third temperature.

[0043] Embodiment 6. The fuel cell module assembly of embodiment 5, wherein the heat exchanger is further configured to receive a second process gas from a second external source at a fifth temperature and output the second process gas to the fuel cell stack assembly at a sixth temperature, the fifth temperature being about 75% to about 85% lower than the sixth temperature.

[0044] Embodiment 7. The fuel cell module assembly of embodiment 6, wherein the heat exchanger is further configured to receive the second process gas at a seventh temperature from the fuel cell stack assembly and to output the second process gas at an eighth temperature, the eighth temperature being about 70% to about 80% higher than the seventh temperature.

[0045] Aspect 8. A fuel cell power plant system comprising: a module assembly having a first end and including a fuel cell stack; a rack structure configured to hold the module assembly; a balance of plant equipment; and a duct configured to provide fluid communication between the balance of plant equipment and the first end of the module assembly during an installed mode, wherein the module assembly and the rack structure are configured such that the module assembly is removable from the rack structure in a direction away from the first end of the module assembly during a removal mode.

[0046] Aspect 9. The fuel cell power plant system of aspect 8, wherein the rack structure has a first end and a second end opposite the first end, at least a portion of the duct is proximate to the first end of the rack structure, and during the installed mode, the first end of the module assembly is proximate to the first end of the rack structure.

[0047] Aspect 10. The fuel cell power plant system of aspect 9, wherein the module assembly and rack structure are configured such that during the removal mode, the module assembly is removable from the second end of the rack structure.

[0048] Aspect 11. A fuel cell power plant system described in any one of aspects 8 to 10, wherein the fuel cell stack is configured to receive and output process gas, and the module assembly further includes: a plurality of manifolds including a first manifold and a second manifold, the first manifold configured to supply the process gas to the fuel cell stack, and the second manifold configured to receive the process gas output from the fuel cell stack, and the heat exchanger configured to receive process gas at a first temperature from an external source and output process gas at a second temperature to the first manifold, and configured to receive process gas at a third temperature from the second manifold and output process gas at a fourth temperature.

[0049] Aspect 12. The fuel cell power plant system of aspect 11, wherein the first temperature is about 75% to about 95% lower than the second temperature, and the fourth temperature is about 75% to about 95% lower than the third temperature.

[0050] Aspect 13. A fuel cell power plant system as described in any one of aspects 8 to 12, further comprising a plurality of module assemblies, wherein the rack structure is configured to hold the plurality of module assemblies in a stacked arrangement, and wherein the rack structure and each of the plurality of module assemblies are configured such that during a removal mode, the module assemblies can remove the rack structure in the same direction.

[0051] Aspect 14. The fuel cell power plant system of aspect 10, further comprising a plurality of module assemblies; and wherein the rack structure is configured to hold the plurality of module assemblies in a stacked arrangement.

[0052] Aspect 15. The fuel cell power plant system of aspect 14, wherein the rack structure is configured to balance the plant equipment in a stacked arrangement relative to the plurality of module assemblies.

[0053] Aspect 16. A fuel cell power plant system as described in Aspect 15, characterized in that the duct includes a body portion configured to be proximate a first end of the rack structure and extend away from the balance of the plant equipment toward the plurality of module assemblies, and a plurality of branches extending away from the body portion including a first branch portion configured to communicate with the plurality of branch module assemblies.

[0054] Aspect 17. The fuel cell power plant system according to any one of aspects 14 to 16, wherein a plurality of module assemblies, rack structures, balance of plant equipment, and ducts form a module cluster.

[0055] Aspect 18. The fuel cell power plant system of aspect 17, further comprising a plurality of module clusters, including the module cluster.

[0056] Aspect 19. The fuel cell power plant system of aspect 18, wherein during the removal mode, the module cluster is configured to be electrically and / or fluidically isolated from other module clusters among the plurality of module clusters.

[0057] Aspect 20. A fuel cell power plant system as described in aspect 18 or 19, characterized in that a plurality of module clusters are arranged side by side to form a cluster group, the cluster group having a first end, and the first end of each rack structure among the plurality of module clusters is at the first end of the cluster group.

[0058] Aspect 21. The fuel cell power plant system of aspect 20, further comprising a plurality of clusters, the clusters comprising the clusters.

[0059] As used herein, the terms "approximately," "about," "substantially," and similar terms are intended to have a broad meaning consistent with common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of ordinary skill in the art who review this disclosure that these terms are intended to enable description of the particular features described and claimed without limiting the scope of those features to the precise numerical ranges provided. Accordingly, these terms should be interpreted to indicate that insubstantial or insignificant modifications or variations of the subject matter described and claimed are considered to be within the scope of the present disclosure as set forth in the appended claims.

[0060] It should be noted that the term "exemplary" as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and / or illustrations (and such term does not necessarily imply that such embodiments are particular or top-tier examples).

[0061] As used herein, the terms "coupled," "connected," and the like mean that two members are joined directly or indirectly to one another. Such joining may be fixed (e.g., permanent) or movable (e.g., removable or releasable). Such joining may be achieved when the two members, or the two members and any additional intermediate members, are integrally formed with one another as a single unit, or when the two members, or the two members and any additional intermediate members, are attached to one another.

[0062] References herein to the location of elements (e.g., "top," "bottom," "upper," "lower," etc.) are merely used to describe the orientation of the various elements in the figures. It should be noted that the orientation of the various elements may differ according to other exemplary embodiments, and such variations are intended to be encompassed by the present disclosure.

[0063] While the present invention has been described in terms of its preferred embodiments, those skilled in the art will understand that various other embodiments and modifications may occur that are within the scope and spirit of the invention, and that such other embodiments and modifications are intended to be covered by the corresponding claims. Those skilled in the art will readily appreciate that many modifications are possible without substantially departing from the novel teachings and advantages of the subject matter described herein (e.g., variations in the size, dimensions, structure, shape, and proportions of various elements, parameter values, mounting arrangements, use of materials, color, orientation, manufacturing processes, etc.). For example, the order or sequence of any process or method steps may be changed or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangements of the various exemplary embodiments without departing from the scope of the present disclosure.

Claims

1. 1. A fuel cell module assembly including a housing enclosing a heat exchanger and a fuel cell stack assembly, The fuel cell stack assembly includes a plurality of fuel cell stacks; the housing having a first containment wall at a first end, a second containment wall at a second end, and at least one outer longitudinal containment wall configured to connect the first and second containment walls, wherein the housing has a shape that allows the fuel cell stack to be installed or removed horizontally in the direction of the longitudinal containment walls; a heat exchanger disposed at the first end of the housing and fluidly connected to a first supply conduit for a first process gas through a first opening in the first containment wall at the first end of the housing, and the heat exchanger fluidly connected to a second supply conduit for a second process gas through a second opening in the first containment wall at the first end of the housing; The fuel cell stack assembly includes a fuel cell stack and a plurality of manifolds, the fuel cell stack including a plurality of fuel cells configured to receive and output a first process gas, the plurality of manifolds including a first manifold and a second manifold, the first manifold configured to supply the first process gas to the fuel cell stack, the second manifold configured to receive the first process gas output from the fuel cell stack, the heat exchanger configured to receive the first process gas from an external source and output the first process gas to the first manifold, and configured to receive the first process gas from the second manifold and output the first process gas, a heat exchanger configured to receive the second process gas from a second external supply source and output the second process gas to the third manifold, and to receive the second process gas from the fourth manifold and output the second process gas to the third manifold; and a heat exchanger configured to receive the second process gas from the fourth manifold and output the second process gas to the third manifold.

2. 2. The fuel cell module assembly of claim 1, wherein the housing includes a plurality of ports located in the first containment wall at the first end of the housing, the plurality of ports fluidly connecting to the heat exchanger and including a first port, a second port, a third port, and a fourth port, the first port configured to receive a first process gas from an external source, the second port configured to output the first process gas from the housing, the third port configured to receive a second process gas from a second external source, and the fourth port configured to output the second process gas from the housing.

3. 10. The fuel cell module assembly of claim 1, wherein the heat exchanger is further configured to receive a first process gas from an external source at a first temperature and output the first process gas to the fuel cell stack assembly at a second temperature, the first temperature being about 85% to about 95% lower than the second temperature, and the heat exchanger is further configured to receive the first process gas from the fuel cell stack assembly at a third temperature and output the first process gas at a fourth temperature, the fourth temperature being about 70% to about 80% lower than the third temperature.

4. 4. The fuel cell module assembly of claim 3, wherein the heat exchanger is further configured to receive the second process gas from the second external source at a fifth temperature and output the second process gas to the fuel cell stack assembly at a sixth temperature, the fifth temperature being about 75% to about 85% lower than the sixth temperature, and wherein the heat exchanger is further configured to receive the second process gas from the fuel cell stack assembly at a seventh temperature and output the second process gas at an eighth temperature, the eighth temperature being about 70% to about 80% lower than the seventh temperature.

Images