Large-scale fuel cell system and method for installing this system

Abstract

To provide a method of installing a large-scale fuel cell system.SOLUTION: A modular fuel cell subsystem (12) includes multiple rows, where each row includes a plurality of fuel cell power modules (12) and a power conditioning module (18) electrically connected to the fuel cell power modules (12). A single gas and water distribution module (WDM) is fluidly connected to multiple rows of the fuel cell power modules (12), and a single mini-power distribution module (MPDS) is electrically connected to each of the power conditioning module (18) in each row of modules. Each row of modules further includes a fuel processing module located on an opposite side of the plurality of fuel cell power modules (12) from the power conditioning module (18). Fuel and water connections enter each row from the side of the row containing the fuel processing module, and electrical connections enter each row from the side of the row containing the power conditioning module (18).SELECTED DRAWING: Figure 19C

Description

Technical Field

[0001] [Related Applications] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 227,836, filed Jul. 30, 2021; U.S. Provisional Application No. 63 / 301,399, filed Jan. 20, 2022; and U.S. Provisional Application No. 63 / 307,309, filed Feb. 7, 2022. The entire teachings of these applications are incorporated herein by reference.

[0002] The present disclosure generally relates to fuel cell systems, and more particularly to large-scale fuel cell systems and methods of installing such systems.

Background Art

[0003] Quick and inexpensive installation can help increase the popularity of fuel cell systems. Generally, the installation cost of a site-cast custom-designed concrete pad that requires trenching for piping and electrical wiring can be exorbitant. Since concrete pouring and trenching generally require one or more building permits and inspections by building inspectors, the installation time is also a problem at most sites.

[0004] Furthermore, fixed fuel cell systems may be installed in locations where the cost of real estate is quite high or the available space is limited (e.g., loading docks, narrow roads, or spaces between buildings, etc.). The installation of fuel cell systems should have a high utilization rate of the available space. If a significant amount of separated space is required to access the system through a door or the like, the installation cost of the real estate will increase significantly.

[0005] When the number of fuel cell systems installed on-site increases, generally one of the problems that occur is that separated space is required between these systems (to enable maintenance of one unit or the other unit). From the perspective of potential use by customers of fuel cell systems, the space between systems is lost.

[0006] In the design of some fuel cell systems, these problems are solved by increasing the overall capacity of the individual system design. However, this creates new challenges due to the increased size and weight of the required concrete pads. Therefore, this strategy tends to increase the installation time of the system. Furthermore, as the minimum size of the system increases, the fault tolerance of the design decreases.

[0007] The fuel cell stack or column of a fuel cell system is typically housed within a hot box (i.e., an insulated container). The hot boxes of existing large-scale fuel cell systems are housed within cabinets, housings, or enclosures. The terms cabinet, enclosure, and housing are used interchangeably herein. Cabinets are typically made of metal. The metal is coated with automotive or industrial powder coatings that are prone to scratching, denting, and corrosion. Most of these cabinets are similar to current industrial HVAC equipment cabinets. [Overview of the project]

[0008] In one embodiment, the modular fuel cell subsystem comprises multiple rows of modules, each row having a plurality of fuel cell power modules and a power adjustment module including a DC / AC inverter electrically connected to the fuel cell power modules; a single gas / water distribution module fluidly connected to the multiple rows of fuel cell power modules; and a single small power distribution module electrically connected to the power adjustment module within each row of the multiple rows of modules.

[0009] In one embodiment, the fuel cell system comprises a plurality of modular fuel cell subsystems, a system power distribution unit electrically connected to the plurality of modular fuel cell subsystems, and a plurality of precast concrete trenches housing pipes and wires that connect the plurality of modular fuel cell subsystems to utility fuel lines, utility water lines, and the system power distribution unit.

[0010] In another embodiment, the fuel cell power module comprises a base of aerated concrete, a non-aerated concrete pad positioned on the base and having a smaller area than the base, and a fuel cell power module positioned on the concrete base and including at least one fuel cell stack. In one embodiment, a precast concrete trench is provided for housing wires connecting the fuel cell power module to a power distribution unit.

[0011] In another embodiment, the system comprises a plurality of rows of fuel cell system modules, an electrical connection, and at least one piping connection, wherein each row of the fuel cell system module comprises a plurality of fuel cell power modules, a power adjustment module including a DC / AC inverter electrically connected to the power modules, and a fuel processing module including components for pre-treating fuel fluidly connected to the power modules, the power adjustment module being located on a first side of the plurality of fuel cell modules, the fuel processing module being located on a second side of each row of the plurality of fuel cell system modules opposite to the first side, the electrical connection being provided for the power adjustment module in each row located on the first side of each row, and the piping connection being provided for the fuel processing module in each row located on the second side of each row. [Brief explanation of the drawing]

[0012] [Figure 1] Figure 1 is a perspective view of a modular fuel cell system according to various embodiments of the present disclosure. [Figure 2] Figure 2 is a plan view of a modular fuel cell system according to various embodiments of the present disclosure. [Figure 3A] Figure 3A is a top view of the fuel cell system pad shown in Figure 2. [Figure 3B] Figure 3B is a perspective view of the fuel cell system pad shown in Figure 2. [Figure 3C] Figure 3C is a perspective view of the fuel cell system pad shown in Figure 2. [Figure 3D] Figure 3D is a perspective view of a modified version of the fuel cell system pad shown in Figure 2. [Figure 4A] Figure 4A is a perspective view of a modular fuel cell system according to various embodiments of the present disclosure. [Figure 4B] Figure 4B is a plan view of the system shown in Figure 4A. [Figure 4C] Figure 4C is a schematic diagram of the fuel cell system pad shown in Figure 4A. [Figure 5A] Figure 5A is a plan view of a modular fuel cell system according to various embodiments of the present disclosure. [Figure 5B] Figure 5B is a schematic diagram of the fuel cell system pad shown in Figure 5A. [Figure 5C] Figure 5C is a plan view of a modular fuel cell system according to various embodiments of the present disclosure. [Figure 5D] Figure 5D is a schematic diagram of the fuel cell system pad shown in Figure 5C. [Figure 6A] Figure 6A is a plan view of a modular fuel cell system according to various embodiments of the present disclosure. [Figure 6B] Figure 6B is a schematic diagram of the fuel cell system pad shown in Figure 6A. [Figure 7A] Figure 7A is a plan view of a modular fuel cell system according to various embodiments of the present disclosure. [Figure 7B] Figure 7B is a schematic diagram of the fuel cell system pad shown in Figure 7A. [Figure 8] Figure 8 is a perspective view of a modular pad section according to various embodiments of the present disclosure. [Figure 9A] Figure 9A is a perspective view of a modular pad according to various embodiments of the present disclosure. [Figure 9B] Figure 9B is a perspective view of a modular pad according to various embodiments of the present disclosure. [Figure 10]FIG. 10 is a perspective view of a modular pad according to various embodiments of the present disclosure. [Figure 11] FIG. 11 is a view showing a modular pad according to various embodiments of the present disclosure. [Figure 12] FIG. 12 is a view showing a modular pad according to various embodiments of the present disclosure. [Figure 13A] FIG. 13A is a perspective view of a pad according to various embodiments of the present disclosure. [Figure 13B] FIG. 13B is a perspective view of a pad according to various embodiments of the present disclosure. [Figure 14] FIG. 14 is a perspective view of a modular pad of a fuel cell system according to various embodiments of the present disclosure. [Figure 15] FIG. 15 is a perspective view of a modular pad of a fuel cell system according to various embodiments of the present disclosure. [Figure 16] FIG. 16 is a perspective view of a modular pad of a fuel cell system according to various embodiments of the present disclosure. [Figure 17] FIG. 17 is a perspective view of a pad section of a fuel cell system according to various embodiments of the present disclosure. [Figure 18A] FIG. 18A is a perspective view of a support frame of a fuel cell system. [Figure 18B] FIG. 18B is a view showing a module on the support frame of FIG. 18A. [Figure 19A] FIG. 19A is a top view of a large-scale fuel cell system before a precast concrete trench is filled with pipes and wiring according to an embodiment of the present disclosure. [Figure 19B] FIG. 19B is a top view of a large-scale fuel cell system after a precast concrete trench is filled with pipes and wiring according to an embodiment of the present disclosure. [Figure 19C] FIG. 19C is a perspective view of the large-scale fuel cell system of FIG. 19A. [Figure 19D] FIG. 19D is a perspective view of the large-scale fuel cell system of FIG. 19A. [Figure 19E]Figure 19E is a schematic side view of the components of the gas / water distribution module shown in Figure 19C. [Figure 19F] Figure 19F is a side cross-sectional view of the pad of the module of the large-scale fuel cell system shown in Figure 19D. [Figure 19G] Figure 19G is a schematic diagram illustrating the functionality of the system shown in Figure 19A. [Figure 19H] Figure 19H is a perspective view of the components of the system shown in Figures 19A and 19G. [Figure 19I] Figure 19I is a perspective view of the components of the system shown in Figures 19A and 19G. [Figure 19J] Figure 19J shows a fuel processing module equipped with a centralized desulfurizer. [Figure 19K] Figure 19K is a top view of the block of the large-scale fuel cell system shown in Figure 19A. [Figure 19L] Figure 19L is a top view of a large-scale fuel cell system according to an alternative embodiment of the present disclosure. [Figure 20A] Figure 20A is a perspective view of the steps in the method for installing the large-scale fuel cell system shown in Figures 19A to 19F. [Figure 20B] Figure 20B is a perspective view of the steps in the method for installing the large-scale fuel cell system shown in Figures 19A to 19F. [Figure 20C] Figure 20C is a perspective view of the steps in the method for installing the large-scale fuel cell system shown in Figures 19A to 19F. [Figure 20D] Figure 20D is a perspective view of the steps in the method for installing the large-scale fuel cell system shown in Figures 19A to 19F. [Figure 20E] Figure 20E is a perspective view of the steps in the method for installing the large-scale fuel cell system shown in Figures 19A to 19F. [Figure 20F] Figure 20F is a perspective view of the steps in the method for installing the large-scale fuel cell system shown in Figures 19A to 19F. [Figure 20G] Figure 20G is a perspective view of the steps in the method for installing the large-scale fuel cell system shown in Figures 19A to 19F. [Figure 20H] Figure 20H is a perspective view of the steps in the method for installing the large-scale fuel cell system shown in Figures 19A to 19F. [Figure 20I] Figure 20I is a perspective view of the steps in the method for installing the large-scale fuel cell system shown in Figures 19A to 19F. [Figure 20J] Figure 20J is a perspective view of the steps in the method for installing the large-scale fuel cell system shown in Figures 19A to 19F. [Figure 21] Figure 21 is a schematic top view of a subsystem according to one embodiment. [Figure 22A] Figure 22A is a schematic circuit diagram of the electrical components of the subsystem shown in Figure 21. [Figure 22B] Figure 22B is a schematic circuit diagram of the electrical components of the subsystem shown in Figure 21. [Figure 23] Figure 23 is a schematic circuit diagram of an electrical component according to one embodiment of the present disclosure. [Figure 24] Figure 24 is a photograph of a concrete curb and raceway that can be used when installing the system of the embodiment of this disclosure. [Figure 25A] Figure 25A is a photograph of a concrete curb and raceway that can be used when installing the system of the embodiment of this disclosure. [Figure 25B] Figure 25B is a photograph of a concrete curb and raceway that can be used when installing the system of the embodiment of this disclosure. [Figure 26A] Figure 26A is a top view of a large-scale fuel cell system according to another embodiment of the present disclosure. [Figure 26B] Figure 26B is a top view of the fuel cell system block shown in Figure 26A. [Figure 26C] Figure 26C is a top view of an alternative configuration of the fuel cell system block shown in Figure 26A, showing fuel and water conduits and electrical wiring according to one embodiment of the present disclosure. [Figure 26D]Figure 26D is a perspective view of the fuel cell system block of Figure 26A, showing the lateral entry of gas and water conduits at the first end of the row of power modules and the lateral entry of electrical wiring at the second end of the row of power modules. [Figure 26E] Figure 26E is a perspective view of a concrete trench in a block of a fuel cell power system according to various embodiments of the present disclosure, which houses electrical wiring extending between a row of power modules and a centralized system distribution unit. [Figure 27A] Figure 27A is a perspective view of the concrete pads and precast concrete trenches of the fuel cell power system block, as shown in Figures 26A to 26E. [Figure 27B] Figure 27B is a perspective view of a precast concrete trench housing an electrical connection section according to various embodiments of the present disclosure. [Figure 27C] Figure 27C is a top view of the precast concrete trench shown in Figure 27B. [Figure 28A] Figure 28A is a partial perspective view of a concrete pad supporting a fuel cell system module according to various embodiments of the present disclosure. [Figure 28B] Figure 28B is a partial perspective top view of the concrete pad shown in Figure 28A. [Figure 28C] Figure 28C is a top view of the concrete pad of Figure 28A, including an overlay structure attached to the top surface of the concrete pad according to various embodiments of the present disclosure. [Figure 28D] Figure 28D is a top view of a concrete pad supporting a component of a system power distribution unit according to various embodiments of the present disclosure. [Figure 29A] Figure 29A is a perspective view of a service relocation module positioned adjacent to the side of a cabinet in a fuel cell system module according to various embodiments of the present disclosure. [Figure 29B] Figure 29B is a perspective view of a service relocation module positioned adjacent to the side of a cabinet in a fuel cell system module according to various embodiments of the present disclosure. [Modes for carrying out the invention]

[0013] It should be understood that both the general description above and the detailed description below are merely illustrative and explanatory, and do not limit the scope of the present invention as claimed.

[0014] Referring to Figure 1, a modular fuel cell system 10 according to one exemplary embodiment is shown. The modular system 10 may include modules and components described in U.S. Patent Application No. 11 / 656,006, filed January 22, 2007, and U.S. Patent Application No. 14 / 208,190, filed March 13, 2014, which are incorporated herein by reference in their entirety. The modular design of the fuel cell system 10 provides flexible system installation and operation. Modules, in a single design set, enable scaling of power generation capacity, reliable power generation, flexible fuel handling, and flexibility in power output voltage and frequency. The modular design results in a "always-on" unit with extremely high availability and reliability. It also provides a simple means of scaling up and meeting the specific requirements of the customer's equipment. The modular design also allows for the use of available fuels, as well as the required voltage and frequency, which may vary by customer and / or geographical area.

[0015] The modular fuel cell system 10 comprises a housing 14 in which at least one (preferably two or more) power modules 12, one or more fuel processing modules 16, and one or more power adjustment (i.e., electrical output) modules 18 are disposed. In an embodiment, the power adjustment module 18 is configured to deliver direct current (DC). In an alternative embodiment, the power adjustment module 18 is configured to deliver alternating current (AC). In these embodiments, the power adjustment module 18 includes a mechanism to convert DC to AC, such as an inverter. For example, the system 10 may comprise any desired number of modules, for example, 2 to 30 power modules, for example, 3 to 12 power modules, for example, 6 to 12 modules.

[0016] The system 10 in Figure 1 comprises six power modules 12 (one row of six modules stacked side-by-side) on a pad 20, one fuel processing module 16, and one power adjustment module 18. The housing 14 may include cabinets to house each of the modules 12, 16, and 18. Alternatively, modules 16 and 18 may be housed in a single cabinet, as will be described in more detail later. Although one row of power modules 12 is shown, the system may have two or more rows of modules 12. For example, the system 10 may have two rows of power modules 18 arranged back-to-back / end-to-end.

[0017] Each power module 12 is configured to house one or more hot boxes 13. Each hot box contains one or more stacks or columns of fuel cells (not shown for clarity), for example, one or more stacks or columns of solid oxide fuel cells having ceramic oxide electrolytes separated by conductive interconnect plates. Other fuel cell types such as PEM, molten carbonate, and phosphoric acid may be used.

[0018] A fuel cell stack may include an externally and / or internally manifolded stack. For example, the stack may have fuel and air risers that penetrate openings in the interconnection plates between the fuel cell layers and / or fuel cells, and may be internally manifolded for fuel and air.

[0019] Alternatively, the fuel cell stack may be internally manifolded for fuel and externally manifolded for air, and only the fuel inlet and exhaust riser may penetrate openings in the interconnection plates between fuel cell layers and / or fuel cells, as described in U.S. Patent No. 7,713,649, which is entirely incorporated herein by reference. The fuel cell may have a cross-flow configuration (air and fuel flow substantially perpendicular to each other on opposing sides of the electrolyte in each fuel cell), a counter-flow parallel configuration (air and fuel flow substantially parallel to each other but in opposing directions on opposing sides of the electrolyte in each fuel cell), or a parallel-flow parallel configuration (air and fuel flow substantially parallel to each other in the same direction on opposing sides of the electrolyte in each fuel cell).

[0020] The modular fuel cell system 10 also includes at least one fuel processing module 16. The fuel processing module 16 includes components for pre-treating the fuel, such as an adsorption bed (e.g., a desulfurizer and / or other impurity adsorption bed). The fuel processing module 16 can be designed to process a specific type of fuel. For example, the system may include a diesel fuel processing module, a natural gas fuel processing module, and an ethanol fuel processing module, and these modules may be located in the same cabinet or in different cabinets. Different bed compositions tailored for a specific fuel may be provided within each module. The processing module(s) 16 may be configured to process at least one of the fuels selected from natural gas, compressed natural gas, methane, propane, liquefied petroleum gas, gasoline, diesel, household heating oil, kerosene, JP-5, JP-8, aviation fuel, hydrogen, ammonia, ethanol, methanol, synthesis gas, biogas, biodiesel, and other suitable hydrocarbon or hydrogen-containing fuels supplied from a pipeline. If desired, the fuel processing module 16 may include a reformer 17. Alternatively, if it is desirable to thermally integrate the reformer 17 into the fuel cell stack(s), a separate reformer 17 may be located in each hot box 13 within each power module 12. Furthermore, if an internally reformed fuel cell is used, the external reformer 17 can be omitted entirely.

[0021] The power adjustment module 18 includes components for converting DC power generated by the fuel cell stack to AC power (e.g., DC / DC converters and DC / AC converters as described in U.S. Patent No. 7,705,490, which is incorporated herein by reference in whole), electrical connectors for AC power output to the grid, circuits for managing electrical transients, and a system controller (e.g., a computer or dedicated control logic unit or circuit). The power adjustment module 18 can be designed to convert DC power from the fuel cell module to different AC voltages and frequencies. It may be designed to provide designs for 208V, 60Hz; 480V, 60Hz; 415V, 50Hz and other common voltages and frequencies.

[0022] The fuel processing module 16 and the power adjustment module 18 may be housed in a single cabinet of the housing 14. If a single input / output cabinet is provided, modules 16 and 18 may be arranged vertically within the cabinet (for example, with the components of the power adjustment module 18 above the desulfurizer canister / floor of the fuel processing module 16) or side by side.

[0023] As shown in one exemplary embodiment of Figure 1, one cabinet is provided for one row of six power modules 12, and the power modules 12 are arranged linearly in a side-by-side fashion on one side of the input / output modules. The row of modules can be positioned adjacent to the building from which the system will be powered (for example, with the back of the module cabinet facing the building wall). Although one row of power modules 12 is shown, the system may comprise two or more rows of modules 12. For example, as described above, the system may comprise two rows of power modules stacked back-to-back.

[0024] The linear array of power modules 12 can be easily expanded or contracted. For example, more or fewer power modules 12 may be provided depending on the power demand of the building or other facility served by the fuel cell system 10. The power modules 12 and input / output modules may be provided in other ratios. For example, in another exemplary embodiment, more or fewer power modules 12 may be provided adjacent to the input / output modules 16 / 18. Furthermore, support functions can be provided by two or more input / output modules 16 / 18 (for example, using separate fuel processing module 16 and power adjustment module 18 cabinets). In addition, in a preferred embodiment, the input / output modules 16 / 18 are located at the ends of the row of power modules 12, but may also be located in the middle of the row of power modules 12.

[0025] The modular fuel cell system 10 can be configured to facilitate inspection of its components. Components that require regular or frequent maintenance (such as consumable parts) may all be placed within a single module to reduce the time required by service personnel. For example, purge gas (optional) and desulfurizer materials for a natural gas-fueled system can be housed in a single module (e.g., fuel processing module 16 or a combined input / output module 16 / 18 cabinet). This would be the only module cabinet accessed during routine maintenance. Thus, each module 12, 16, and 18 can be inspected, repaired, or removed from the system without opening other module cabinets or inspecting, repairing, or removing other modules.

[0026] For example, as described above, system 10 may have multiple power modules 12. When at least one power module 12 goes offline (i.e., power is not generated by the stack in the hotbox 13 within the offline module 12), the remaining power modules 12, fuel processing module 16, and power adjustment module 18 (or merged input / output modules 16 / 18) do not go offline. Furthermore, the fuel cell system 10 may include two or more modules 12, 16, or 18 of each type. When at least one module of a particular type goes offline, the remaining modules of the same type do not go offline.

[0027] Therefore, in a system with multiple modules, each of modules 12, 16, or 18 can be electrically disconnected, removed from the fuel cell system 10, and / or inspected or repaired without stopping the operation of other modules in the system, allowing the fuel cell system to continue generating power. If one stack of fuel cells in one hot box 13 fails or is taken offline for inspection, it is not necessary to shut down the entire fuel cell system 10.

[0028] Figure 2 shows plan views of modular fuel cell systems 200 according to various embodiments of the present disclosure. Fuel cell system 200 is similar to fuel cell system 10 in Figure 1. Therefore, similar elements are referred to by the same reference numerals, and only the differences between the two are described in detail.

[0029] Referring to Figure 2, the system 200 comprises a power module 12, a power adjustment module 18, and a fuel processing module 16, which are disposed on the pad 210. The system 200 may be provided with doors 30 for accessing modules 12, 16, and 18. The system 200 may further be provided with a decorative door 30A.

[0030] The power modules 12 can be arranged in a back-to-back configuration. In particular, the power modules 12 may be arranged in parallel, and the fuel processing module 16 and the power adjustment module may be placed at the ends of the row. Thus, the system 200 has an overall rectangular configuration and may be shorter in length than other systems, such as system 10 in Figure 1. Therefore, system 200 can be installed in locations where space length is a concern. For example, system 200 can fit in a parking lot adjacent to a building that is supplied with power.

[0031] Although the system 200 is illustrated as comprising two rows of three power modules 12, the disclosure is not limited to any particular number of power modules 12. For example, in some embodiments, the system 200 may comprise two to thirty power modules 12, four to twelve power modules 12, or six to twelve power modules 12. In other words, the system 200 may comprise any desired number of power modules 12, which are arranged back-to-back. In addition, the positions of the fuel processing module 16 and the power adjustment module 18 may be reversed, and / or modules 16 and 18 may be located at one end of the system 200.

[0032] Figure 3A shows a schematic top view of the pad 210. Figure 3B shows a perspective view of the pad 210, and Figure 3C shows a perspective view of the pad 210 including the edge cover.

[0033] Referring to Figures 3A to 3C, the pad 210 comprises a base 212. The base 212 can be formed from concrete or a similar material. Alternatively, the base 212 can be made from any other suitable structural material, e.g., steel or another metal, and can be precast as a whole or partially cast. The base 212 may also be manufactured by casting the base material into a pattern mold, removing the cast base 212 from the mold, and then transporting the base 212 from the mold location (e.g., within a base manufacturing facility) to the operating site of the fuel cell system (i.e., where the fuel cell system is positioned to generate electricity). The base 212 can be configured as a single unit or may include multiple connecting sections.

[0034] The base 212 may have a first through hole 214 and a second through hole 216, a drain recess 218, a wiring recess 220, and a piping recess 222. The base 212 may also include a tie-down pocket 224, a tie-down insert 226, and a piping bracket 228.

[0035] The drainage recess 218 can extend along the center of the base 212 between rows of modules and can be configured, for example, to collect rainwater or debris collected on the base 212. Tie-down pockets 224 and tie-down inserts 226 can be configured to secure the corresponding modules to the base 212. The piping recess 222 can extend around the periphery of the base 212. In particular, the piping recess 222 can be formed along three or more edges of the base 212. The wiring recess 220 can extend from the first through-hole 214 to the second through-hole 216 and can be generally U-shaped.

[0036] The pad 210 may also include piping 230, wiring 232, and system electrical connections such as a busbar 234. In particular, the wiring 232 can be located within a wiring recess 220 and connected to one or more modules. For example, the wiring 232 can be connected to both the busbar 234 and the power module 12. The busbar 234 can be connected to a power adjustment module 18. The power adjustment module 18 can be connected to an external load through a second through-hole 216. The busbar 234 can be located on the edge of the through-hole 216 so that the wiring 232 does not extend across the through-hole 216. However, if such a location is necessary to meet system requirements, the busbar 234 may be located on opposite sides of the through-hole 216 so that the wiring 232 does not extend across the through-hole 216.

[0037] The piping 230 can be installed within the piping recess 222. The piping 230 may be connected to an external water source and / or fuel source via the first through-hole 214, or it may be attached to the piping bracket 228. In particular, the piping 230 may include a fuel pipe 230A connecting the fuel processing module 16 to the power module 12. The piping 230 may also include a water pipe 230B configured to supply water to the power module 12. The piping 230 may extend from the piping bracket 228 to the power module 12.

[0038] As shown in Figure 3C, the piping 230 can be covered by an edge cover 236. In particular, the edge cover 236 can be configured to cover the pipe recess 222. In some embodiments, the edge cover 236 may include multiple segments so that the edge cover 236 can be removed and / or installed in component units.

[0039] Figure 3D shows a perspective view of pad 211 according to various embodiments of this disclosure. Pad 211 is a replacement for pad 210, an alternative version of pad 210 in the fuel cell system of Figure 2. Therefore, only the differences between pads 210 and 211 will be described in detail.

[0040] Referring to Figure 3D, the pad 211 includes wiring 233 but does not include a busbar. In particular, the wiring 233 can be in the form of a cable configured to connect each power module 12 to the power adjustment module 18, and the system electrical connection can include a cable assembly input or output section 237.

[0041] Figure 4A shows perspective views of modular fuel cell systems according to various embodiments of the present disclosure. Figure 4B shows a plan view of system 400. Figure 4C shows a schematic diagram of pad 410 of Figure 4A. Fuel cell system 400 comprises components similar to those of fuel cell system 10 in Figure 1. Therefore, similar components are referred to by the same reference numerals, and only the differences between them are described in detail.

[0042] Referring to Figures 4A to 4C, the system 400 comprises a power module 12, a power adjustment module 18, and a fuel processing module 16, which are disposed on the pad 410. The system 400 may be provided with doors 30 for accessing modules 12, 16, and 18. The system 400 may further be provided with a decorative door 30A.

[0043] The power modules 12 can be arranged in a linear configuration. In particular, the power modules 12 may be arranged in a row, with the fuel processing module 16 and the power adjustment module 18 located at the ends of the row. According to some embodiments, the fuel processing module 16 and the power adjustment module 18 can be located in the center of the row. Thus, the system 400 has an overall linear configuration and may be housed in a location with a linear space but limited width. One example of such a location may be the back of a large retail store.

[0044] Although system 400 is illustrated as comprising a row of six power modules 12, this disclosure is not limited to any particular number of power modules 12. For example, in some embodiments, system 400 may comprise two to thirty power modules 12, four to twelve power modules 12, or six to twelve power modules 12. In other words, system 500 may comprise any desired number of power modules 12, where modules 12, 16, and 18 are arranged in a linear configuration.

[0045] The pad 410 comprises a base 412. The base 412 may have a first through hole 214 and a second through hole 216. The base 412 may also have wiring recesses and piping recesses, as described later with respect to Figure 10. The base 412 may be formed from concrete or a similar material. Alternatively, the base 412 may be made from any other suitable structural material, e.g., steel or another metal, and may be precast as a whole or partially cast. The base 412 may also be manufactured by casting the base material into a pattern mold, removing the cast base 412 from the mold, and then transporting the base 412 from the mold location (e.g., within a base manufacturing facility) to the fuel cell system location (i.e., the location where the fuel cell system is located to generate electricity).

[0046] The pad 410 may also comprise piping 230 (e.g., water pipe 230A and fuel pipe 230B), wiring 232, and a system busbar 234. In particular, the wiring 232 can be arranged in a substantially linear wiring recess and connected to one or more of the modules. For example, the wiring 232 can be connected to the busbar 234 and the power module 12, respectively. The busbar 234 can be connected to a power adjustment module 18. The power adjustment module 18 can be connected to an external load through a second through-hole 216. The busbar 234 can be positioned on the edge of the second through-hole 216 so that the wiring 232 does not extend across the second through-hole 216. However, if such a location is necessary to satisfy system requirements, the busbar 234 may be positioned on opposite sides of the second through-hole 216 so that the wiring 232 does not extend across the second through-hole 216.

[0047] According to some embodiments, the piping 230 and wiring 232 can be arranged adjacent to the door 30 to facilitate connection to modules 12, 16, and 18. In other words, the piping 230 and wiring 232 can be arranged adjacent to the edge of the base 412. According to some embodiments, the wiring 232 can be in the form of a cable, as shown in Figure 3D, and the busbar 234 can be omitted.

[0048] Figure 5A shows a plan view of a modular fuel cell system 500 according to various embodiments of the present disclosure. Figure 5B shows a schematic diagram of the pad 510 in Figure 5A. The fuel cell system 500 comprises components similar to those of the fuel cell system 200. Therefore, similar components are given the same reference numerals, and only the differences between them are described in detail.

[0049] Referring to Figures 5A and 5B, the system 500 comprises a power module 12, a power adjustment module 18, and a fuel processing module 16, which are disposed on the pad 510. The system 500 may be provided with doors 30 for accessing modules 12, 16, and 18. The system 500 may further be provided with a decorative door 30A.

[0050] The power modules 12 can be arranged in an L-shape. In particular, the power modules 12 may be arranged in a first row, and the fuel processing module 16, power adjustment module 18, and additional power modules 12 may be arranged in a second row substantially perpendicular to the first row. In particular, modules 16 and 18 can be arranged at the distal end of the second row. Thus, the system 500 may be configured to operate in a location with a straight space but limited width. One example of such a location may be the back of a large store.

[0051] Although the system 500 is illustrated as comprising six rows of power modules 12, the disclosure is not limited to any particular number of power modules 12. For example, in some embodiments, the system 500 may comprise two to thirty power modules 12, four to twelve power modules 12, or six to twelve power modules 12. In other words, the system 500 may comprise any desired number of power modules 12, with modules 12, 16, and 18 arranged in an orthogonal configuration.

[0052] The pad 510 comprises a base 512. The base 512 may have a first through hole 214 and a second through hole 216, a wiring recess, and a piping recess. The base 512 may be formed from concrete or a similar material. The base 512 may be precast as a whole or partially cast. For example, the base 512 may have a first section 512A and a second section 512B, both of which can be precast and then arranged adjacent to each other at the work site. The demarcation between section 512A and section 512B is indicated by a dotted line L. Modules of the first column may be arranged on the first section 512A, and modules of the second column may be arranged on the second section 512B.

[0053] The pad 510 may also include piping 230 (e.g., water piping 230A and fuel piping 230B), wiring 232, and a system busbar 234. In particular, the wiring 232 can be arranged in a wiring recess and connected to one or more of the modules. For example, the wiring 232 can be connected to both the busbar 234 and the power module 12. The busbar 234 can be connected to the power adjustment module 18. The power adjustment module 18 can be connected to an external load through a second through-hole 216.

[0054] According to some embodiments, the piping 230 and wiring 232 can be arranged adjacent to the door 30 to facilitate connection to modules 12, 16, and 18. In other words, the piping 230 and wiring 232 can be arranged adjacent to the edge of the base 512. According to some embodiments, the wiring 232 can be in the form of a cable, as shown in Figure 3D, and the busbar 234 can be omitted.

[0055] Figure 5C shows a plan view of a modular fuel cell system 550 according to various embodiments of the present disclosure. Figure 5D shows a schematic diagram of the pad 560 in Figure 5C. The fuel cell system 550 comprises components similar to those of the fuel cell system 500. Therefore, similar components are given the same reference numerals, and only the differences between them are described in detail.

[0056] Referring to Figures 5C and 5D, the system 550 comprises a power module 12, a power adjustment module 18, and a fuel processing module 16, which are arranged on the pad 560. The power module 12 may be arranged in a first row, and the fuel processing module 16 and the power adjustment module 18 may be arranged in a second row that is substantially perpendicular to the first row. Thus, the system 550 may be substantially L-shaped. The pad 560 may have a first section 560A and a second section 560B separated by a dotted line L. However, the pad 560 may be formed from a single piece of material. The modules of the first row may be arranged on the first section 560A, and the modules of the second row may be arranged on the second section 560B.

[0057] The pad 560 may also include piping 230 (e.g., water piping 230A and fuel piping 230B), wiring 232, a first through-hole 214, a second through-hole 216, and a system busbar 234. In particular, the wiring 232 can be arranged in a wiring recess and connected to one or more of the modules. For example, the wiring 232 can be connected to the busbar 234 and the power module 12, respectively. The busbar 234 can be connected to the power adjustment module 18. The power adjustment module 18 can be connected to an external load through the second through-hole 216.

[0058] According to some embodiments, the piping 230 and wiring 232 can be arranged adjacent to the door 30 to facilitate connection to modules 12, 16, and 18. In other words, the piping 230 and wiring 232 can be arranged adjacent to the edge of the pad 560. According to some embodiments, the wiring 232 can be in the form of a cable, as shown in Figure 3D, and the busbar 234 can be omitted.

[0059] Figure 6A shows a plan view of a modular fuel cell system 600 according to various embodiments of the present disclosure. Figure 6B shows a schematic diagram of the pad 610 of Figure 6A. The fuel cell system 600 comprises components similar to those of the fuel cell system 500. Therefore, similar components are given the same reference numerals, and only the differences between them are described in detail.

[0060] Referring to Figures 6A and 6B, the system 600 comprises a power module 12, a power adjustment module 18, and a fuel processing module 16, which are disposed on the pad 610. The system 600 may be provided with doors 30 for accessing modules 12, 16, and 18. The system 600 may further be provided with a decorative door 30A.

[0061] The power modules 12 can be arranged in an L-shape. In particular, the power modules 12 may be arranged in a first row, and the fuel processing module 16, power adjustment module 18, and additional power modules 12 may be arranged in a second row substantially orthogonal to the first row. In particular, modules 16 and 18 can be arranged at the distal end of the second row.

[0062] In contrast to system 500, system 600 has a dummy section 630 positioned between the first and second rows. The dummy section 630 may be a portion of the pad 610 that does not contain modules. Piping 230 and wiring 232 can pass through the dummy section 630 and may extend along the edge of the pad 610.

[0063] The pad 610 may have a first section 612A and a second section 612B separated by a dummy section 630. In some embodiments, the dummy section 630 may be a separate section of the pad 610 or may be part of either the first section 612A or the second section 612B. In some embodiments, an empty cabinet may be placed on the dummy section 630. Modules for the first row may be placed on the first section 612A, and modules for the second row may be placed on the second section 612B.

[0064] Figure 7A shows a plan view of a modular fuel cell system 700 according to various embodiments of the present disclosure. Figure 7B shows a schematic view of the pad 710 of Figure 7A. The fuel cell system 700 comprises components similar to those of the fuel cell system 500. Therefore, similar components are given the same reference numerals, and only the differences between them are described in detail.

[0065] Referring to Figures 7A and 7B, the system 700 comprises a power module 12, a power adjustment module 18, and a fuel processing module 16, which are disposed on the pad 710. The system 700 may be provided with doors 30 for accessing modules 12, 16, and 18. The system 700 may further be provided with a decorative door 30A.

[0066] The power modules 12 can be arranged in a stepped configuration. In particular, the power modules 12 can be arranged in a first row, a second row substantially orthogonal to the first row, and a third row substantially orthogonal to the second row. The fuel processing module 16 and the power adjustment module 18 can be arranged at the distal end of the third row. However, according to some embodiments, the fuel processing module 16 and the power adjustment module 18 can be arranged in the first row or the second row.

[0067] The system 700 has a dummy section 730 between the first row and the second row. The dummy section 730 may be a portion of the pad 710 that does not contain modules. In some embodiments, an empty cabinet may be placed on the dummy section 730. Piping 230 and wiring 232 may pass through the dummy section 730 and may extend along the edge of the pad 710.

[0068] The pad 710 may have a first section 712A, a second section 712B, and a third section 712C. The first section 712A and the second section 712B may be separated by a line L. The second section 712B and the third section 712C may be separated by a dummy section 730. In some embodiments, the dummy section 730 may be a separate segment of the pad 710 or a part of either the second section 712B or the third section 712C. Modules of the first column may be arranged on the first section 712A, modules of the second column may be arranged on the second section 712B, and modules of the third column may be arranged on the third section 712B. The pad 710 may also include a second system busbar 235 configured to connect the wiring 232 of the first section 712A and the second section 712B.

[0069] Figure 8 shows perspective views of modular pad section 800 according to various embodiments of the present disclosure. Referring to Figure 8, the pad section 800 can be used as any of the pad sections described above. The pad section 800 can be rectangular, and for example, the pad section 800 may have two substantially parallel long sides and two substantially parallel short sides extending between them.

[0070] The pad section 800 may have a first boss 802, a second boss 804, a third boss 806, a piping bracket 828, a wiring recess 820, a connection recess 822, and a piping recess 824, which may be formed on the upper surface of the pad section 800. The first boss 802 may be disposed between the second boss 804 and the third boss 806. The second boss 804 may have a larger surface area than the third boss 806. For example, the second boss 804 and the third boss 806 may have substantially the same width, but the second boss 804 may be longer than the third boss 806. The first boss 802 may have a larger surface area than the second boss 804 or the third boss 806. The portion 820A located between the third boss 806 of the wiring recess 820 and the adjacent piping bracket 828 may be enlarged, for example, the enlarged portion 820A may be wider than the rest of the wiring recess 820. According to some embodiments, a through hole 216 can be formed within the enlarged portion 820A.

[0071] The wiring recess 820 can be located between the bosses 802, 804, and 806 and the piping bracket 828. The bosses 802, 804, and 806 may have tie-down pockets 826 configured to secure modules located above them. The piping bracket 828 can be located in a first row, and the bosses 802, 804, and 806 can be located in a second row substantially parallel to the first row.

[0072] The piping recess 824 may be formed on two or three sides / edges of the pad section 800, depending on the shape of the pad constructed using the pad section. For example, if the pad section 800 is used in a fuel cell system having an L-shaped or linear configuration, the piping recess 824 may extend along the long side and one short side of the pad section 800. Alternatively, if the pad section 800 is used in a fuel cell system having a rectangular configuration, the piping recess 824 may extend along the long side and two short sides of the pad section 800.

[0073] The edge cover 832 may be placed in the pipe recess 822. The pad section 800 may be precast, delivered, and assembled on-site with one or more other pad sections 800.

[0074] Figures 9A and 9B show perspective views of modular pads 215 according to various embodiments of the present disclosure. Pads 215 can be used as pads 210 of a fuel cell system 200. Referring to Figures 9A and 9B, pad 215 has two of a pad section 800 that are arranged adjacent to each other. In particular, the pad sections 800 can be arranged on the same plane as each other and / or can be physically connected to each other.

[0075] In particular, each pad section 800 may be configured such that, when the sections 800 are assembled, the connecting recesses 822 and piping recesses 824 are aligned with each other, as shown in Figures 9A and 9C. In other words, when the pad sections 800 are aligned with each other, the connecting recesses 822 of adjacent pad sections 800 may form a continuous recess, and the piping recesses 824 of two adjacent pad sections 800 may form a continuous piping recess. In addition, the pad sections 800 may be aligned such that the second boss 804 is aligned with (in contact with) the third boss 806, and the first bosses 802 are aligned with (in contact with) each other. In other words, the long side of the first pad section 800 may be arranged in contact with the long side of the second pad section 800 (rotated 180 degrees relative to the same first pad section). One or more through holes 216 may be formed in the pad section 800 to allow piping and / or wiring to pass through. In particular, the through-hole 216 may be formed within the enlarged portion 820A of the wiring recess 820.

[0076] Figure 10 shows perspective views of modular pads 415 according to various embodiments of the present disclosure. Pad 415 may be a linear pad that can replace the linear pad 410 of Figures 4A and 4B. Referring to Figure 10, pad 415 has two pad sections 800 that are aligned longitudinally. In particular, the third boss 806 of one pad section 800 is positioned adjacent to the second boss 804 of the other pad section 800. In other words, one short side of one pad section 800 may be positioned in contact with the short side of the other pad section 800. Thus, the wiring recesses 820 and piping recesses 824 of the pad sections 800 may be aligned (continuously) with respect to each other. In particular, the wiring recesses 820 may be aligned to form a substantially continuous linear wiring recess.

[0077] Figure 11 shows a modular pad 615 according to various embodiments of the present disclosure. Pad 615 can replace pad 610 in Figure 6B.

[0078] Referring to Figure 11, the pad 615 has two pad sections 800 that are aligned orthogonally. In particular, the third boss 806 of one pad section 800 is positioned adjacent to the first boss 802 of the other pad section 800. Thus, the wiring recess 820 may be connected by one of the connecting recesses 822, and the piping recesses 824 of the pad sections 800 may be aligned (continuous) with respect to each other. In other words, the short side of one pad section 800 may be positioned in contact with the long side of the other pad section 800.

[0079] An additional pad section 800 may be aligned with one of the pad sections 800 so that stepped pads such as pad 710 in Figure 7B can be formed. In other words, each section 712A, 712B, and 712C can be formed using one of the pad sections 800.

[0080] Figure 12 shows a modular pad 415A according to various embodiments of the present disclosure. Pad 415A can replace pad 410 in Figures 4A and 4B.

[0081] Referring to Figure 12, the pad 415A has two modular pad sections 900. Since pad section 900 is similar to pad section 800, only the differences between them will be described in detail.

[0082] In particular, each pad section 900 has a first boss 802 and second bosses 808 disposed on both sides opposite to the first boss 804 on the upper surface of the pad section 900. The second bosses 808 may have the same size and shape. Therefore, although not applicable to pad section 800, since the pad section 800 has second bosses 804 and third bosses 806 of different sizes, the pad section 900 may be symmetrical in the width direction. As described above, the pad sections 900 may be aligned together with the pad section 800 in the pad section 415 in the same manner.

[0083] Figures 13A and 13B show perspective views of the pad 1000 of a fuel cell system according to various embodiments of the present disclosure.

[0084] Referring to Figures 13A and 13B, the pad 1000 can be incorporated into any of the fuel cell systems described above. The pad 1000 comprises a base 1010, a separator 1012, and a frame 1014. The base 1010 can be formed from concrete or a similar material, as described above. In particular, the base 1010 can be cast in site, or one or more sections can be precast and then assembled in site.

[0085] The separator 1012 can be mounted on the upper surface of the base 1010 and can be formed from sheet metal or other similar material. The separator 1012 may comprise rails 1017 mounted on opposing sides of the base 1010 and spacers 1016 mounted on the rails 1017. The rails 1017 may be a single piece or may have connected rail sections.

[0086] Frame 1014 can be attached to spacer 1016 using any suitable method, for example, by using bolts 1018, clamps, etc. Frame 1014 is configured to house modules such as power modules and fuel processing modules. Spacer 1012 may be configured to separate base 1010 and frame 1014, forming a space between them.

[0087] The pad 1000 may include piping 1020 disposed on the base 1010. The piping 1020 may extend from a through hole 1022 formed in the base 1010 and may be configured to supply water and / or fuel to a module disposed on the frame 1014. The pad 1000 may include a frame 1014A configured to house a power adjustment module. The pad 1000 may also include wiring (not shown) configured to connect the power module to the power adjustment module disposed on the frame 1014A. Alternatively, the wiring may pass through an opening 1015 formed in the frame 1014.

[0088] The separator 1012 is configured to separate the frame 1014 from the upper surface of the base 1010. Therefore, the piping 1020 may be laid directly on the upper surface of the base 1010. In other words, the upper surface of the base 1010 can be substantially flat and does not need to have recesses for the piping 1020 and / or wiring.

[0089] The configuration of pad 1000 offers advantages over conventional pads, such as the absence of the need to incorporate piping and / or wiring into the feature area that is cast into the base 1010, as it has a flat surface for the installation of the fuel cell system module. Therefore, pad 1000 can be manufactured at a lower cost because the base 1010 does not require a feature area that is cast into.

[0090] Figure 14 is a perspective view of a pad 1400 of a fuel cell system according to various embodiments of the present disclosure. Referring to Figure 14, the pad 1400 comprises a base 1410 and a replicator 1420 disposed on the base 1410. The base 1410 can be cast in site or precast and delivered to site. The base 1410 can be formed from concrete or a similar material.

[0091] The replicator 1420 can be attached to the base 1410 and can be formed from plastic or other non-corrosive material. The replicator 1420 can reproduce the features molded into the base in the preceding embodiments described above. For example, the replicator 1420 can have bosses formed so that wiring and / or piping channels or recesses are formed on the flat upper surface of the base 1410 between the replicators 1420. Thus, the replicator 1420 can create raised structures to support the modules 12, 16, and 18 of the fuel cell system, while the wiring and piping are formed on the flat upper surface of the concrete base 1410 within channels or recesses between the replicators. The replicator 1420 can also be used as a template for drilling features into the base 1410. The replicator 1420 can be attached to the base 1410 using any suitable attachment method, such as by joint attachment (e.g., snap fastening) and / or molding onto the upper surface of the base.

[0092] According to some embodiments, multiple pads 1400 may be attached to each other as pad sections to create a larger pad 1400. For example, the pads 1400 can be connected using "living hinges" on a pad piping cover that can be snap-locked into place. In other words, according to some embodiments, the pads 1400 can be considered as pad sections.

[0093] Figure 15 is a perspective view of a pad 1500 of a fuel cell system according to various embodiments of the present disclosure. Referring to Figure 15, the pad 1500 comprises a pad section 1510 and a tension cable 1520. Although one tension cable 1520 is shown, a plurality of tension cables 1520 may be included. The tension cable 1520 is configured to connect the pad section 1510. In particular, wedges 1530 may be provided on the tension cable 1520 to bias the pad section 1520 together. Although one wedge 1530 is shown, wedges may be provided on opposite sides of each tension cable 1520.

[0094] The pad section 1510 may further include alignment pins 1512 and alignment holes 1514. In particular, the alignment pins 1512 can be inserted into the alignment holes 1514 to align the pad sections 1520 with each other. According to some embodiments, to facilitate the alignment of the pad sections 1510, the alignment pins 1512 may be pyramidal in shape, and the alignment holes 1514 may have a corresponding shape.

[0095] Figure 16 is a perspective view of a pad 1600 of a fuel cell system according to various embodiments of the present disclosure. Referring to Figure 16, the pad 1600 has a pad section 1610 that is connected together. In particular, the pad section 1610 comprises a first bracket 1612 and a second bracket 1614 that interlock with each other and are locked together by a pin 1616 inserted between them. The pad section 1610 may have a recess or notch 1618 that can provide space for piping and / or wiring. Piping and / or wiring can be placed through the pad section 1610 into a hole 1620 formed inside. Depending on the configuration of the pad 1600, the pad 1600 may have a variety of shapes and / or sizes. In some embodiments, the pad section 1600 may be disposed on a relatively thin concrete pad.

[0096] Figure 17 shows a pad section 1700 of a fuel cell system according to various embodiments. Referring to Figure 17, the pad section 1700 includes a tie-down 1710 extending from its upper surface. The tie-down 1710 can be formed from forged or reinforced metal and may be inserted into the pad during or after manufacturing. The tie-down 1710 may be mushroom-shaped and may allow the module to be installed in the pad section 1700 without looking. Thus, since the tie-down 1710 is self-inducting, it allows the module to be easily attached to the pad section 1700.

[0097] Figure 18A shows a support frame 1800 of a fuel cell system according to various embodiments. The support frame may include water piping 1810, fuel piping 1812, and electrical wiring 1814, which may extend between a hole 1816 and a quick connect 1818 within the support frame 1800.

[0098] The support frame 1800 may be attached to the fuel cell system module 1820 at the manufacturing site, as shown in Figure 18B, with pre-wired connections, and then shipped to the site where the fuel cell system will generate electricity for assembly. The pre-attached frame 1800 may be similar to the frame 1014 shown in Figure 13A. Thus, the assembly of the fuel cell system can be simplified.

[0099] Figures 19A and 19B show top views of a large-scale fuel cell system of another embodiment, showing the system before and after the piping and wiring are buried in a precast concrete trench, respectively. Figures 19C and 19D are perspective views of the large-scale fuel cell system of Figures 19A and 19B. Figure 19E is a schematic side view of the components of the gas / water distribution module of Figure 19C. Figure 19F is a side cross-sectional view of the module pad of the large-scale fuel cell system of Figure 19D. Figure 19G is a schematic functional diagram of the system. All modules described later may be housed in separate housings from other modules. This system reduces the number of components, simplifies the installation of components, and therefore reduces the overall cost of the system.

[0100] A large-scale fuel cell system includes multiple rows of the power modules 12 (labeled PM5) described above. A single gas / water distribution module (GDM) is fluidly connected to multiple rows of power modules. For example, a single gas / water distribution module is fluidly connected to each of at least two rows of at least six power modules, for example, to each of four rows of seven power modules. As shown in Figure 19E, a single gas / water distribution module GDM may include connections between the water and fuel piping 230 described above and the power modules. The connections may include conduits (e.g., pipes) and valves 231F and 231W that deliver fuel and water from the central piping 230 to each power module. The fuel and water piping 230 may include the fuel pipe 230A labeled "UG" and the water pipe 230B labeled "UW". The gas and water piping 230 may be connected to a utility gas pipe and a utility water pipe, respectively. A single system-level fuel treatment module 16, which includes components for pre-treating the fuel, such as an adsorption bed (e.g., a desulfurizer and / or other impurity adsorption bed), can be connected to all gas lines 230A. Therefore, a single desulfurizer may be used to desulfurize the natural gas fuel supplied to all GDMs in the fuel cell system.

[0101] Optionally, one or more Water Distribution Modules (WDMs) may be included in the system. A WDM may comprise water treatment components (e.g., a water deionizer) and distribution pipes and valves connected to the local water supply pipes and individual modules within the system.

[0102] Each row of power module 12 is electrically connected to a single power regulating module 18 (marked AC5) described above, which may include a DC / AC inverter and other electrical components. A single miniature power distribution module (MPDS) is electrically connected to each of the power regulating modules 18 using the wire 232 described above, which is marked "UE". A single MPDS is electrically connected, for example, to each of at least two rows of at least six power modules 12, or to each of four rows of seven power modules, through each of the respective power regulating modules 18, for example four power regulating modules 18. The MPDS may include circuit breakers and electrical connections between the multiple power regulating modules 18 and one of the system power distribution modules PDS-1 or PDS-2.

[0103] One or more telemetry modules (TCs) may also be included in the system. A telemetry module may comprise a system controller and communication equipment that enables the system to communicate with a central controller and a system operator. Therefore, the four inverters and telemetry cables within the power adjustment module 18 may be connected to a single MPDS. The system also includes a system power distribution unit (i.e., a central power supply unit) that powers the safety systems within the GDM and also powers the telemetry Ethernet switch (4:1). This reduces the number of power and telemetry conduits to be installed by the on-site contractor from four to one. Alternatively, a single connection may be used for telemetry data transfer. A single CAT5 cable may be replaced with a wireless transceiver unit for data communication between the power adjustment module 18 and the telemetry module TC. This eliminates the need for data cable installation.

[0104] A set of multiple rows of power modules and their power regulation modules, each fluidly and electrically connected to the same GDM and the same MPDS, may be referred to as a subsystem. A fuel cell system can include multiple subsystems, for example, 2 to 10 subsystems. Figures 19A and 19B show four subsystems.

[0105] The fuel cell system may also include a system power distribution unit that is electrically connected to all subsystems of the fuel cell system using wire 232 (i.e., "UE"). The system power distribution unit may include at least one power distribution module, e.g., two modules PDS-1 and PDS-2, at least one transformer, e.g., two transformers (XFMR-1 and XFMR-2), and a disconnection switchgear (SWGR). Transformers XFMR-1 and XFMR-2 can be electrically connected to the PDS-1 module and the PDS-2 module, respectively, using wire 232. The switchgear may include a 15kV switchgear having an input section electrically connected to the transformer via wire 232 and an output section electrically connected to the electrical load / grid. An optional uninterruptible power subsystem (UPS) may also be included. Thus, power is supplied from the power modules to the grid and / or loads through the respective MPDS, PDS-1 or PDS-1, XFMR-1 or XFMR-2 and SWGR.

[0106] Figure 19K shows one block of a fuel cell system as shown in Figure 19A. One block comprises eight 300kW (6+1) power modules, eight power adjustment modules 18 (AC5), one TC, two WDMs, one 3000kVA transformer, two GDMs, and two MPDSs.

[0107] Figure 19L shows the layout of a system in an alternative embodiment. This system comprises eight blocks (one of which is a larger block with two additional rows of power modules). This system comprises 66 300kW (6+1) power modules, one centralized desulfurizer module system, 16 GDMs, 16 WDMs, 7 3000kVA transformers, one 4000kVA transformer, 15 2000-amp MPDSs, 2 2500-amp sub-MPDSs, and 8 TCs. The system in Figure 19L provides a compact layout of modules and reduces the length of electrical connections (e.g., copper wires) between modules. This reduces the cost of the system.

[0108] As shown in Figure 19G, a centralized desulfurization system (e.g., desulfurization module) 1600 replaces independent (separate) desulfurizers in each row of power modules. The centralized desulfurization module 1600 is fluidly connected to the GDM, which is fluidly connected to the power modules 12 and supplies fuel to the power modules 12. The power modules 12 are electrically connected to the MPDS, which is electrically connected to an electrical load (e.g., power grid or standalone load) 1901. The centralized desulfurization system (e.g., desulfurization module) 1600 is shown in Figure 19H. The centralized desulfurization system (e.g., desulfurization module) 1600 includes one or more containers 1602 (e.g., columns) filled with a sulfur-adsorbing material (e.g., sulfur-adsorbing bed). The GDM is shown in Figure 19I. The GDM distributes fuel to four rows of power modules (referred to as "stamps").

[0109] Figure 19J shows a flow diagram of a centralized desulfurizer system 1600. The system 1600 may comprise a filter at the fuel inlet and two parallel fuel passages (e.g., fuel lines, i.e., fuel conduits) for each row (i.e., “stamps”) of the power modules. Furthermore, two sets of two control valves 1603, such as mass flow control valves, may be located in the parallel fuel passages for each “stamp”. Pressure transducers (PRTs) may be located in various lines and can be used to monitor line pressure during system operation and take necessary actions. A gas sampling port 1604 may also be located in the main inlet line. In one embodiment, the system also comprises a separate sulfur breakthrough detection line 1606 (shown in a dotted box) used to detect sulfur breakthrough. The output of the detection line 1606 may be fluidly connected to a safety vent 1608. A sulfur detection sensor 1609 may be placed in the detection line 1606 to detect the presence of sulfur in the fuel output from the desulfurizer system 1600.

[0110] As shown in Figures 19B to 19D, piping 230 (e.g., fuel pipe 230A and water pipe 230B) can be provided from their respective utilities (e.g., gas pipe and water pipe) to their respective GDMs within each subsystem through precast concrete trenches 1902. Similarly, wire 232 can be provided between each MPDS and the system power distribution unit through the same precast concrete trenches 1902. The precast concrete trenches 1902 may have a "U" shape with two vertical side walls connected by a horizontal bottom wall or horizontal connecting bars. Openings may be provided in the horizontal bottom wall. The precast concrete trenches 1902 are located below the grade and covered with cover plates, dust, gravel and / or asphalt concrete pavement.

[0111] As shown in Figures 19D and 19F, each module of the system, for example, the power module 12 and / or the power adjustment module 18, can be mounted on a multilayer support. The multilayer support is formed on a compaction base 1910. The support comprises a base 1912 of aerated concrete (also known as concrete form), for example, a Confoam® aerated concrete base. A conventional (non-aerated) concrete pad 1914 is placed on the base 1912. The concrete pad 1914 has a smaller area than the base 1912. A U-shaped steel mesh formwork 1916, for example Novoform®, surrounding a metal reinforcing frame, is provided on the side of the concrete pad 1914. The base 1912 supports the bottom of the formwork 1916. The top of the concrete pad 1914 is located 1.5 to 2 inches above the finished grade, which may include gravel or asphalt concrete pavement 1918 located on top of the base 1912.

[0112] As shown in Figures 19A-19C, 19K, and 19L, each block of the fuel cell system may include at least one transformer. At least one transformer may be isolated (i.e., physically separated) from the row of power modules 12 and may be located on a separate pad from the power modules 12, the power adjustment module 18, and optionally, the GDM, WDM, TC units, and MPDS modules. At least one transformer may be located on a separate pad that includes other components of the system distribution unit, such as the system distribution module(s) (PDS-1 and PDS-2) and the disconnect switchgear (SWGR). Wire 232 (i.e., "UE") may extend through a trench such as a precast concrete trench 1902 from the separate pad containing at least one transformer and optionally other components of the system distribution unit to the respective pads containing the row of power modules 12, the power adjustment module 18, and optionally, the GDM, WDM, TC units, and MPDS modules. In various embodiments, at least one transformer (e.g., XFMR-1 and XFMR-2 in Figures 19A and 19B, and XFMR in Figures 19K and 19L) may be located in the center of the block, thereby allowing the rows of power modules 12 to be located on at least two opposing sides of the transformer (i.e., the rows of power modules 12 are not aligned in a row with the transformer on one side of the transformer). In some embodiments, at least one transformer may be located between at least two rows of power modules 12 in the block.

[0113] In the embodiments shown in Figures 19A and 19B, XFMR-1 may be electrically coupled to a plurality of power modules 12, including all of the power modules 12 located on the first side (i.e., left side) of the block, and XFMR-2 may be electrically coupled to a plurality of power modules 12, including all of the power modules 12 located on the second side (i.e., right side) of the block. In some embodiments, a third transformer (i.e., XFMR-3) may also be located in the center of the block, for example, on the same pad that includes the first transformer XFMR-1 and the second transformer XFMR-2. The first transformer XFMR-1 and the second transformer XFMR-2 may be configured to supply power to a third transformer XFMR-3, which may have a higher power rating than either of the first transformer XFMR-1 or the second transformer XFMR-2. For example, the first transformer XFMR-1 and the second transformer XFMR-2 may be 3000 kVA transformers, and the third transformer XFMR-3 may be a 5000 kVA transformer. The third transformer XFMR-3 may be configured to provide a single power output for the entire block.

[0114] In the embodiment shown in Figure 19L, each transformer XFMR may serve each block of the fuel cell system and may supply a single power output that can be transmitted via wires to a common switchgear (shown in the lower left of Figure 19L) which may be coupled to the grid and / or load.

[0115] By placing one or more transformers in the center of the block between each row of power modules 12, the total length of electrical connections (e.g., copper wires) that need to be extended within the fuel cell power system, both per block and as a whole, can be significantly reduced. This can greatly reduce the cost of the fuel cell system.

[0116] Figures 20A to 20J are perspective views of the steps in the method for installing the large-scale fuel cell system shown in Figures 19A to 19K.

[0117] As shown in Figures 20A and 20G, a trench is formed in the ground, then compacted using heavy machinery such as an excavator, and the frame is placed inside the trench. As shown in Figures 20B and 20H, a foamed concrete base 1912 is filled into the trench. The foamed concrete includes a fluid filler (e.g., foamed concrete such as Confoam filler 27) that is filled into the base 1912 from a pipe or hose and then solidifies.

[0118] As shown in Figures 20C and 20I, a U-shaped steel mesh formwork 1916 and reinforcing bars are placed on the base 1912. The formwork 1916 may include a polymer sheet covering the metal mesh. The reinforcing bars are located inside the formwork, as shown in Figure 20J. Next, a concrete pad 1914 is formed inside the boundary of the formwork 1916. Then, the module is placed on the concrete pad 1914.

[0119] As shown in Figures 20D and 20F, an additional trench is formed outside the base 1912. Then, the precast concrete trench 1902 is placed inside the additional trench.

[0120] Next, as shown in Figure 20E, the gas pipe 230A, water pipe 230B, and wire 232 are placed inside the precast concrete trench 1902 and connected to their respective GDM and power components such as MPDS, PDS-1, and PDS-2. The pipes and wires can be attached or clamped inside the precast concrete trench 1902 at different vertical heights (for example, using clamps 1903 and / or support bars). The precast concrete trench 1902 is then covered with cover plates, dust, gravel, and / or asphalt concrete pavement.

[0121] The methods shown in Figures 20A to 20J achieve 100% consolidation without mechanical vibration, thereby eliminating or reducing the need to support the wall during backfilling. Finally, it is easily excavable and may be removed with a shovel or cut with a hacksaw or hand saw.

[0122] Figure 21 is a schematic diagram of one subsystem of the system shown in Figures 19A to 19C. Each row of power module 12 may contain a 300kW Energy Server™ fuel cell generator from Bloom Energy Corporation, labeled "ES". Thus, the subsystem includes four rows of 300kW ES, totaling 1200kW of power. The entire system, including the four subsystems, can deliver 4800kW of power. The 1200kW ES configuration consists of 4 × 300kW ES, with all standard power, communication, water, and gas interconnects converged into a central section for common tie-in during the installation process.

[0123] The MPDS in Figures 22A and 22B utilizes two types of install proximity. Firstly, a single electrical connection to this module can be distributed to the power regulating module 18 by supplying interconnect cables as part of the field installation kit. This reduces the installation from four sets of conduits and trenches to one. This configuration also allows for the elimination of output circuit breakers and surge devices within each power regulating module 18, which would otherwise be removed from a total of four circuit breakers and four surge devices in a 1200kW system. An additional advantage is the inclusion of a WIFI transmitter within the MPDS module and its communication interconnecting to a separate ES. The WIFI system may service the entire facility, leading to the elimination of four sets of conduits and wires, thereby reducing installation costs and complexity. Thus, by consolidating separate units within the system, the system and installation can be reduced. By including the main circuit breaker within the system, the transformer can be placed closer to the rows of power modules, reducing installation costs and the amount of wiring required.

[0124] Figure 23 shows an alternative electronic component module according to another embodiment. The configuration in Figure 23 shows four separate cabinets (i.e., housings), each cabinet fully enclosed for a dedicated purpose. The first cabinet is the location for landing individual power modules from the four ESs, while paralleling the four ESs onto a common DC bus. This module includes bushings, fuse protection, and internal cable landing locations. This module can support both 50kW and 75kW rated power modules and may include a fully rated interconnect for the collected output DC as an optional means of extending the DC bus to an adjacent 1200kW system. The central modules 2 and 3 house only inverter units with large allowable current DC inputs and AC outputs. This embodiment can further reduce costs by eliminating smaller inverter units and fabricating a single standalone inverter for implementation within a centralized system distribution unit. The final module 4 provides further cost savings. This module houses the start-up and safety equipment for the fuel cell power module. This reduces the number of these items from four to one. This will further serve as the sole location for the collected output terminal for the system and for the external conduit entry.

[0125] In one embodiment, each subsystem comprises a 1200kW / 1200kVA or 1420kVA inverter. The subsystem still retains individual start and safety systems within the grid-connected inverter. This allows for individual safety shutdowns within a single 300kW ES (i.e., a row of power modules 12). A safety shutdown request from the GDM shuts down all four ESs within the subsystem. This results in reduced production costs if circuit breakers are eliminated within the four grid-parallel inverters. The protection provided by these circuit breakers may be moved to an integrated system PDS-1 or PDS-2. Thus, the four redundant surge protection devices and safety systems from each subsystem may be merged into a centralized system distribution unit.

[0126] Figures 24, 25A, and 25B are photographs of concrete curbs and raceways that can be used during the installation of the system of the embodiments of the present disclosure. Figure 24 shows concrete curbs that can be used instead of precast concrete pads. This allows subsystems to be jointly located in one area with a single electrical connection location. The curbs provide a passage beneath the module so that wires 232 and piping 230 can be installed on the grade rather than below it. This eliminates the need for trench excavation.

[0127] Furthermore, by using pre-fabricated concrete cable raceways as shown in Figures 25A and 25B, the amount of excavation and the use of separate conduits can be reduced or eliminated. The raceways may include the precast concrete trenches described above with respect to Figures 20D and 20J. These raceways can be installed on grades or in easily excavated trenches without the civil engineering work required for conduit burial. Finally, the fixed cable raceways and improved field design allow for the pre-determining of the actual conductor length, enabling the routing of pre-fabricated conductor assemblies for each cable run from the 1200kW subsystem to the central electrical gear (i.e., the system power distribution unit). This improves quality and reduces on-site waste and labor time. Overall, installation is improved by improving quality, reducing on-site construction time, and lowering labor costs (e.g., electrical and plumbing) while maintaining maintainability, reducing the overall height of the components and simplifying cable routing. Therefore, the open trenches shown in Figures 24-25B significantly reduce labor and material costs by avoiding trench compaction and closure with Class II / Engineered filler. Self-compacting slurry such as Confoam filler 27 (aerated concrete) is provided instead of subgrades and Class II AB trenches. This also results in better heat dissipation, eliminates RHO concrete, and simplifies maintenance and upkeep.

[0128] Figure 26A is a top view of a large-scale fuel cell system according to yet another embodiment of the present disclosure. Figure 26B is a top view of block 2603 of the fuel cell system of Figure 26A. Figure 26C is a top view of an alternative configuration of block 2603 of the fuel cell system of Figure 26A, showing fuel conduit 230A, water conduit 230B, and electrical wiring 232. Figure 26D is a perspective view of block 2603 of the fuel cell system of Figure 26A, showing the lateral entry of fuel conduit 230A and water conduit 230B into a fuel processing module 16 located at the first end of the row of power modules 12, and the lateral entry of electrical wiring 232 into a power adjustment module 18 located at the second end of the row of power modules 12. Thus, in this embodiment, the fuel processing module 16 and the power adjustment module 18 are located on opposite sides of the row of power modules 12. Figure 26E is a perspective view of a concrete trench 1902 for block 2603 of a fuel cell power system, which houses electrical wiring 232 extending between a row of power modules 12 and a centralized system distribution unit 2604. The fuel cell power systems shown in Figures 26A to 26E can reduce the number of components, including the total amount of electrical wiring, and simplify the installation of components, thereby reducing the overall cost of the system.

[0129] The large-scale fuel cell systems shown in Figures 26A to 26E may be similar to the systems described above with reference to Figures 19A to 19L. In particular, the system may comprise multiple rows (indicated as PM5) of power modules 12 arranged on a pad 2601a (e.g., a concrete pad), as shown in Figure 26D. Each row of power modules 12 is electrically connected to a single power adjustment module 18 (indicated as AC5) described above, which may include a DC / AC inverter and other electrical components. The fuel processing module 16 (indicated as FP5) and the power adjustment module 18 may be arranged on the same pad 2601a as the power modules 12. The system may be configured within multiple blocks 2603, each block 2603 comprising multiple rows of power modules 12 (as well as associated fuel processing modules 16 and power adjustment modules 18). The rows of power modules 12 are located on different sides of a centralized system power distribution unit 2604 in each block 2603. The system power distribution unit 2604 may comprise at least one transformer, for example, a first transformer XFMR-1 and a second transformer XFMR-2, which may be electrically connected to multiple rows of power modules 12 on each side of block 2603, respectively, and a third transformer XFMR-3, which may be electrically connected to the first transformer XFMR-1 and the second transformer XFMR-2 and supply a single power output to block 2603. The power output from each block 2603 may be supplied via electrical connections (e.g., copper wires) to a common switchgear 2605 that can couple the system to a grid and / or load.

[0130] The system distribution module (PDS) described above can be electrically connected to a plurality of power adjustment modules 18 in a row of power modules 12, and can also be electrically connected to the transformers (e.g., XFMR-1 or XFMR-2) of the system distribution unit 2604 within each block 2603. For example, each block 2603 may contain a pair of system distribution modules, such as the PDS-1 and PDS-2 described above, within the system distribution unit 2604, and each distribution module may be electrically connected to a power adjustment module 18 on each side (e.g., left and right) of the block 2603, and may supply power to either the first transformer XFMR-1 or the second transformer XFMR-2. In addition, each block 2603 of the system may optionally contain one or more of the water distribution modules (WDM) described above and one or more of the telemetry modules (TC) described above.

[0131] The system shown in Figure 26A comprises five blocks 2603, each containing multiple rows of power modules 12 and a system power distribution unit 2604. Each row contains seven power modules 12 and may form a 300 kW Energy Server® fuel cell generator (ES), as described above with reference to Figure 21. Four of the five blocks 2603 may contain 14 rows of power modules 12 and supply 4.2 MW of power. The fifth block 2603 (located on the right side in Figure 26A) contains 13 rows of power modules 12. Thus, the system as a whole can supply 20.7 MW of power. Various other configurations of the system, including variations in the number of blocks 2603 in the system, variations in the number of rows of power modules 12 per block 2603, variations in the number of power modules 12 per row, and variations in the layout (which may be more) of the blocks 2603 and the rows of power modules 12 within each block 2603, will be understood to be within the scope of this disclosure.

[0132] The systems shown in Figures 26A to 26E may differ from the systems described above with reference to Figures 19A to 19L in that the systems in Figures 26A to 26E do not necessarily have a centralized desulfurizer system, nor do they necessarily have a centralized gas / water distribution module (GDM) fluidly connected to the rows of power modules 12. Rather, the systems shown in Figures 26A to 26E may include a plurality of the above-described fuel treatment modules 16 (indicated as FP5) that include components for pre-treating the fuel, such as adsorption beds (e.g., desulfurizers and / or other impurity adsorption beds). Each row of power modules 12 may include a fuel treatment module 16 fluidly connected to each of the power modules 12 in the row. The fuel treatment modules 16 may be located on the same pad 2601a as the rows of power modules 12 and associated power adjustment modules 18.

[0133] Referring again to Figures 26A to 26E, in various embodiments, a fuel processing module 16 (i.e., FP5) may be located on the first side of the row of power modules 12 within each of the rows of power modules 12 of the system, and a power adjustment module 18 (i.e., AC5) may be located on the second side opposite the first side of the row of power modules 12. As shown in Figure 26B, fuel (indicated by an arrow labeled "F") and water (indicated by an arrow labeled "W") may enter the fuel processing module 16 via conduits 230A and 230B on one side of the row, and an external electrical connection (e.g., wire 232) to the power adjustment module 18 (indicated by an arrow labeled "E") may be located on the opposite side of the row. The underground fuel conduit (e.g., pipe) 230A and water conduit (e.g., pipe) 230B may supply fuel and water to the fuel processing modules 16 in each row, as shown in Figures 26C and 26D, respectively. In embodiments with at least one water distribution module (WDM), water from the municipal water supply may first be supplied to the WDM for treatment, as shown in Figure 26C, and the treated water may be supplied from the WDM to the fuel processing modules 16 in each row via water conduit 230B. The wire 232 described above may connect the power adjustment modules 18 in each row to the centralized system power distribution unit 2604 of each block 2603. In some embodiments, the wire 232 may be located within a precast concrete trench 1902, as described above with reference to Figures 19B-19D and Figures 20D and 20E. The precast concrete trenches 1902 can extend from the power adjustment modules 18 in each row to the centralized system power distribution units 2604 within each block 2603 of the fuel cell system. Alternatively, the wires 232 may be placed within concrete curbs or raceways, as shown in Figures 24, 25A, and 25B. In other embodiments, such as shown in Figure 26D, the wires 232 may optionally be placed within buried conduits that can be covered with a suitable material such as cement.

[0134] In various embodiments, separating the fuel processing module 16 and the power adjustment module 18 on opposite sides of the row of power modules 12 may eliminate the need to include utility connections (i.e., fuel conduits 230A and water conduits 230B, pipe connections) and electrical connections (e.g., copper wires) in the same trench. Placing the utility and electrical connections in the same trench may require a deeper trench (e.g., greater than 3 feet, e.g., up to 5 feet deep) to maintain sufficient vertical separation between the utility and electrical connections. Therefore, by placing the fuel conduits 230A and water conduits 230B in a separate trench from the electrical connections (e.g., wires 232), the trench does not need to be as deep, saving excavation time and costs.

[0135] In addition, the electrical connections may enter the side of the row closest to the centralized system power distribution unit 2604 within each block 2603. Therefore, the wire 232 connecting the row's power adjustment module 18 to the centralized power distribution unit 2604 in each block 2603 can traverse a shorter distance. As a result, less copper wiring can be used, and the trench (e.g., precast concrete trench 1902) housing the electrical connections can be made shorter, significantly reducing labor and material costs. Furthermore, the trench 1902 housing the electrical connections (e.g., wire 232) shown in Figure 26D can be relatively shallower compared to the trench 1902 shown in Figures 19B-19D and 20D and 20E, since it houses only electrical connections and not stacked electrical and utility (e.g., gas and water) connections.

[0136] Referring to Figures 26B to 26E, in various embodiments, electrical connections (e.g., wire 232) and utility connections (e.g., fuel conduit 230A and water conduit 230B) can enter the rows of power modules 12 from the side of the rows, rather than entering from below the rows, as in the embodiments described above with reference to Figures 3A to 3D, 4C, 5B, 5D, 6B, 7B, 8, 9B, 16, 17, 18A, 19A to 19D, 19K and 19L. In various embodiments, the service relocation module 2606a may be located on the outer surface of the cabinet of the fuel processing module 16 at the end of each row of power modules 12. The fuel conduit 230A and water conduit 230B may be installed to enter the service relocation module 2606a from below, or to enter the cabinet of the fuel processing module 16 from the side (e.g., on the finished grade). Additional service relocation modules 2606b may be located on the outer surface of the cabinet of the power adjustment module 18 at the opposite end of each row of power modules 12. Electrical connections (e.g., wire 232) may be installed to enter the service relocation module 2606b from below (e.g., from the precast concrete trench 1902), or to enter the cabinet of the power adjustment module 18 from the side (e.g., on the finished grade). In various embodiments, by providing lateral access for electrical connections and utility connections (pipe connections) to each row of power modules 12, the use of "notches" in the concrete pad 2601a (e.g., the aforementioned openings 214 and 216 passing through the concrete pad) can be avoided. This simplifies the design and installation of the concrete pad 2601a supporting the rows of power modules 12, and may also reduce labor costs by eliminating the need to extend trenches containing electrical and / or utility connections beneath the concrete pad to the locations of openings 214 and 216 (which may be multiple).

[0137] Figure 27A is a perspective view of the concrete pads 2601a, 2601b, and 2601c of block 2603 of the fuel cell power system as shown in Figures 26A to 26E, as well as the precast concrete trench 1902. Figure 27B is a perspective view of the precast concrete trench 1902 housing the electrical connections (i.e., wires 232). Figure 27C is a top view of the precast concrete trench 1902 in Figure 27B.

[0138] Referring to Figure 27A, the concrete pads 2601a and 2601c on which rows of power modules 12 are placed may be generally rectangular pads without internal "notches" or internal openings that penetrate the pads 2601a and 2601c, through which utility connections and electrical connections enter the respective rows. Rather, as described above, the utility connections (piping connections) and electrical connections can pass through the sides of the module cabinets on opposite sides of the rows. Therefore, the pads 2601a and 2601c do not have to include internal openings that penetrate the pads (i.e., openings that are surrounded on all sides by the pads 2601a and 2601b). The concrete pad 2601a may be positioned to support two rows of power modules 12 and the associated fuel processing modules 16 and power adjustment modules 18 located on either side of each row. The concrete pad 2601c may be positioned to support a single row of power modules 12 together with associated fuel processing modules 16 and power adjustment modules 18 located on either side of the row. Piping and electrical connections to and between the modules of the row may extend over the upper surfaces of the concrete pads 2601a and 2601c. In various embodiments described in more detail later, one or more overlay structures attached to the upper surfaces of the pads 2601a and 2601c may provide space or separation between the upper surfaces of the pads 2601a and 2601c and the lower surfaces of the fuel cell system modules 12, 16, and 18 supported on the pads 2601a and 2601c. Piping and electrical connections may be positioned to extend within the space between the upper surfaces of the pads 2601a and 2601c and the lower surfaces of the fuel cell system modules 12, 16, and 18. As in the embodiments described above with reference to Figures 13A, 13B and 14, the upper surface of the base 1010 may be substantially flat and does not need to include, for example, recesses or other features for piping and / or wiring and / or for the installation of fuel cell system modules 12, 16, 18.Therefore, concrete pads 2601a and 2601c can be manufactured at a lower cost because pads 2601a and 2601b do not require cast features. Alternatively, concrete pads 2601a and 2601c may include cast features for piping and / or wiring and / or for the installation of fuel cell system modules 12, 16, and 18.

[0139] The block 2603 shown in Figure 27A may also include a separate concrete pad 2601b on which various components of the system power distribution unit 2604 may be placed, such as the aforementioned power distribution modules (PDS-1, PDS-2) and transformers (XFMR-1, XFMR-2, XFMR-3). The precast concrete trench 1902 may extend between the concrete pad 2601b and the concrete pads 2601a and 2601b, respectively, which house the fuel cell system modules 12, 16, and 18.

[0140] In various embodiments, the fuel cell system modules 12, 16, 18 and the system power distribution unit 2604 can be supported on a multilayer support comprising a base 2607 and concrete pads 2601a, 2601b, 2601c disposed on the base 2607. The base 2607 may be an aerated concrete (also known as concrete foam) base 2607, for example, a Confoam® aerated concrete base which can be formed on a compacted base. The concrete pads 2601a, 2601b, and 2601c may be conventional (non-aerated) concrete pads. The concrete pads 2601a, 2601b, and 2601c may have a smaller area than the base 2607 on which the concrete pads 2601a, 2601b, and 2601c are placed. In some embodiments, the base 2607 may have a greater thickness than the concrete pads 2601a, 2601b, and 2601c. For example, the base 2607 may have a thickness greater than 12 inches, for example, 18 to 30 inches (e.g., about 24 inches). The concrete pads 2601a, 2601b, and 2601c may have a thickness less than 12 inches, for example, 6 to 12 inches (e.g., about 8 inches). In some embodiments, the precast concrete trench 1902 for housing the wire 232 may be placed on a portion of the base 2607.

[0141] Figure 28A is a partial perspective view of the concrete pad 2601a supporting modules 12, 16, and 18 of the fuel cell system. Figure 28B is a partial perspective top view of the concrete pad 2601a of Figure 28A. Figure 28C is a top view of the concrete pad 2601a of Figure 28A, including an overlay structure 2615 attached to the top surface of the concrete pad 2601a. ​​Figure 28D is a top view of the concrete pad 2601a supporting components of the system power distribution unit 2604.

[0142] Referring to Figures 28A and 28B, the concrete pad 2601a may be 6 to 10 inches, for example 8 inches thick, with a single reinforcing layer of reinforcing bars 2612. In some embodiments, the concrete pad 2601a may include a plurality of embedded struts 2613 that can be used to attach the overlay structure to the top surface of the concrete pad 2601a. ​​In other embodiments, other mounting mechanisms, such as anchor bolts, may be used to attach the overlay structure to the top surface of the concrete pad 2601a. ​​The concrete pad 2601a may have notches along the peripheral sides of the pad that may be adjacent to a portion of a precast concrete trench 1902 that accommodates electrical connections (e.g., wires 232) to a power adjustment module 18 located on the concrete pad. Figure 28C is a top view of the concrete pad 2601a with the overlay structure 2615 attached to the top surface of the concrete pad 2601a. In some embodiments, the overlay structure 2615 may comprise, for example, a frame 1014 and a separator 1012 as described above. As described above with reference to Figures 13A and 13B, the frame 1014 is configured to receive the power module 12, the fuel processing module 16 and / or the power adjustment module 18, and the separator 1012 is configured to separate the frame 1014 from the upper surface of the concrete pad 2601a. ​​Alternatively, or in addition, the overlay structure 2615 may comprise the replicator 1420 described above, which can form elevated structures supporting the power module 12, the fuel processing module 16 and / or the power adjustment module 18, as described above with reference to Figure 14. Other suitable overlay structures 2615 are also within the scope assumed in this disclosure.

[0143] Referring to Figure 28D, the concrete pad 2601b for the components of the system power distribution unit 2604 may have two reinforcing layers 2612. The concrete pad 2601b may have multiple notches 2614 along the peripheral side surface of the pad to adapt a portion of the precast concrete trench 1902 that accommodates electrical connections (e.g., wires 232) to the system power distribution unit 2604.

[0144] Figures 29A and 29B are perspective views of a service relocation module 2606 positioned adjacent to the side of the cabinet of the housing 14 of the fuel cell system module. As described above, the service relocation module 2606 may be configured to allow utility connections and / or electrical connections to enter the cabinet of the housing 14 of the fuel cell system module (e.g., fuel processing module 16 and / or power adjustment module 18) from the side. The service relocation module 2606 may comprise a housing 2620 having a removable cover 2621. Utility connections and / or electrical connections (e.g., gas conduits 230A and water conduits 230B in the case of utility connections, and wires 232 in the case of electrical connections) may enter the housing 2620 from below ground level through conduits (e.g., tubes) 2622. One or more openings 2623 on the side of the cabinet of the housing 14 allow the utility connections and / or electrical connections to enter the cabinet from the housing 2620. The embodiment in Figure 29A includes a plurality of lug connectors 2627 located inside the housing 2620 of the service relocation module 2606. The lug connectors 2627 connect a first plurality of underground utility and / or electrical connections to a second set of connections to the interior of the housing 14 cabinet. The embodiment in Figure 29B shows a “pull” type service relocation module 2620 in which the underground utility and / or electrical connections extend uninterrupted through the housing 2620 into the interior of the housing 14 cabinet.

[0145] The fuel cell systems of the embodiments of this disclosure are designed to reduce greenhouse gas emissions and have a positive impact on the climate.

[0146] The arrangements of fuel cell systems shown in various exemplary embodiments are for illustrative purposes only. While only a few embodiments are described in detail in this disclosure, 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, material use, color, orientation, etc.).

[0147] Some elements shown as being formed as a single unit can be constructed from multiple parts or elements, the arrangement of the elements can be reversed or changed in a different way, and the properties, number, or arrangement of individual elements can be altered or changed. Other substitutions, modifications, changes, and omissions may be made to the design, operating conditions, and arrangement of various exemplary embodiments without departing from the scope of this disclosure. Any one or more features of any embodiment can be used in any combination with any one or more other features of one or more other embodiments. [Note 7] The system comprises multiple rows of fuel cell system modules, electrical connections, and at least one piping connection. The plurality of rows of the fuel cell system module each comprises a plurality of fuel cell power modules, each including a stack or column of one or more fuel cells; a power adjustment module including a DC / AC inverter electrically connected to the power modules; and a fuel processing module including components for pre-treating fuel, which is fluidly connected to the power modules. The power adjustment module is located on the first side of the plurality of fuel cell modules. The fuel processing module is located in each of the multiple rows of the fuel cell system modules on the second side opposite to the first side of the multiple fuel cell modules. The electrical connection portion is provided for the power adjustment module of each row, which is located on the first side of each row. A fuel cell system in which the piping connection portion is provided for the fuel processing module of each row located on the second side of each of the rows. [Note 8] The fuel cell system according to Appendix 7, wherein the fuel cell system modules are arranged in a plurality of cabinets, and the electrical connections and at least one piping connection for each row are installed to enter through the sides of the cabinets located on both sides of the row. [Note 9] The system further comprises a first service relocation module and a second service relocation module. The first service relocation module is positioned adjacent to the side of the first cabinet containing the fuel processing module in each row. The first service relocation module is installed such that the fuel and water piping connections enter the housing of the first service relocation module from below and exit the housing through the opening on the side of the first cabinet. The second service relocation module is positioned adjacent to the side of the second cabinet containing the power adjustment module in each row. The fuel cell system according to Appendix 8, wherein the second service relocation module is configured such that at least one electrical connection enters the housing of the second service relocation module from below and exits the housing through the opening on the side of the second cabinet. [Note 10] The fuel cell system according to Appendix 7, further comprising a precast concrete trench extending between the first side of the row of fuel cell system modules and the system power distribution unit, the precast concrete trench housing wires connecting the power adjustment modules of each row to the system power distribution unit. [Note 11] The system comprises multiple rows of fuel cell system modules, electrical connections, at least one piping connection, and a precast concrete trench. Each of the multiple rows of the fuel cell system module comprises a plurality of fuel cell power modules, a power adjustment module including a DC / AC inverter electrically connected to the power modules, and a fuel processing module including components for pre-treating fuel, which is fluidly connected to the power modules. The power adjustment module is located on the first side of the plurality of fuel cell modules. The fuel processing module is located in each of the multiple rows of the fuel cell system modules on the second side opposite to the first side of the multiple fuel cell modules. The electrical connection portion is provided for the power adjustment module of each row, which is located on the first side of each row. The aforementioned piping connection is provided for the fuel processing module of each row, which is located on the second side of each of the aforementioned rows. The precast concrete trench extends between the first side of the row of fuel cell system modules and the system power distribution unit, and houses wires connecting the power adjustment modules of each row to the system power distribution unit. The aforementioned system distribution unit includes at least one transformer, Multiple rows of the fuel cell system module are arranged on at least two sides of the at least one transformer. The power adjustment module is located at the end of each row facing the system power distribution unit in the fuel cell system. [Note 12] The fuel cell system according to Appendix 11, wherein the system power distribution unit comprises a first transformer electrically connected to a first group of rows of fuel cell system modules, a second transformer electrically connected to a second group of rows of fuel cell system modules, and a third transformer electrically connected to the first and second transformers. [Note 13] The fuel cell system according to Appendix 7, wherein the row of fuel cell system modules is arranged on one or more pads, and the one or more pads do not have internal openings that penetrate each of the pads. [Note 14] The fuel cell system according to Appendix 13, wherein each of the one or more pads has a thickness of less than 12 inches.

Claims

1. Multiple rows of modules, each row comprising a plurality of fuel cell power modules, each including a stack or column of one or more fuel cells, and a power adjustment module, each row including a DC / AC inverter, electrically connected to the power modules, A single gas / water distribution module is fluidly connected to multiple rows of the aforementioned module, A single small power distribution module is electrically connected to the power adjustment module within each of the multiple rows of the module, A modular fuel cell subsystem equipped with the following features.

2. The module further comprises a single desulfurizer module that is fluidly connected to multiple rows of the aforementioned module, The modular fuel cell subsystem according to claim 1, wherein the single gas / water distribution module is located in a single cabinet installed on a pad.

3. Multiple rows of modules, each row comprising multiple fuel cell power modules and power adjustment modules including DC / AC inverters electrically connected to the power modules, A single gas / water distribution module is fluidically connected to multiple rows of power modules, A single small power distribution module is electrically connected to the power adjustment module within each of the multiple rows of the module, A single desulfurizer module is fluidly connected to multiple rows of the aforementioned module, A parallel fuel flow path line connects the fuel inlet line to each row of the power module, Control valves are arranged in each of the parallel fuel flow lines, An independent sulfur breakthrough detection line having an output fluid-connected to a safety vent, A sulfur detection sensor positioned in the sulfur breakthrough detection line, configured to detect the presence of sulfur in the fuel, A modular fuel cell subsystem equipped with the following features.

4. A plurality of modular fuel cell subsystems according to claim 1, A system power distribution unit electrically connected to the aforementioned plurality of modular fuel cell subsystems, Multiple precast concrete trenches housing pipes and wires that connect the multiple modular fuel cell subsystems to utility fuel lines, utility water lines, and the system power distribution unit, Equipped with, A fuel cell system in which the row of modules is arranged on one or more pads, and the one or more pads do not have internal openings that penetrate each of the pads.

5. Multiple modular fuel cell subsystems, A system power distribution unit electrically connected to the aforementioned plurality of modular fuel cell subsystems, Multiple modular fuel cell subsystems are connected to a utility fuel line, a utility water line, and a number of precast concrete trenches housing pipes and wires for connecting to the system power distribution unit. Equipped with, The aforementioned modular fuel cell subsystem is Multiple rows of modules, each row comprising multiple fuel cell power modules and power adjustment modules including DC / AC inverters electrically connected to the power modules, A single gas / water distribution module is fluidically connected to multiple rows of power modules, A single small power distribution module is electrically connected to the power adjustment module within each of the multiple rows of the module, Each is equipped with, A fuel cell system comprising a system power distribution unit comprising at least one transformer electrically connected to at least one miniature power distribution module of the plurality of modular fuel cell subsystems, wherein the plurality of modular fuel cell subsystems are arranged on at least two sides of the at least one transformer.

6. The system power distribution unit comprises a first transformer electrically connected to a first small power distribution module of a first modular fuel cell subsystem, a second transformer electrically connected to a second small power distribution module of a second modular fuel cell subsystem, and a third transformer electrically connected to the first and second transformers and supplying power output to the fuel cell system, wherein the first, second, and third transformers are each positioned between pairs of rows of modules of the fuel cell system. The fuel cell system according to claim 5, wherein the row of modules is arranged on one or more pads, and the one or more pads do not have internal openings that penetrate each of the pads.

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