Fuel Cell Cooling Network with Integrated Thermal Hydraulic Engine
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Solution Overview
Problem
Fuel cell power plants face challenges in efficient temperature management, which affects the degradation of components and power generation efficiency, and existing systems require complex ancillary coolant loops and separate heat exchangers.
Innovation Solution
Integration of a thermal hydraulic engine within a coolant network that absorbs heat from the fuel cell power plant, utilizing a single or multiple cooling stations to manage temperature and direct heated fluid for secondary power generation, eliminating the need for a separate low grade heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a traditional ancillary coolant loop with separate heat rejection heat exchangers and low grade heat exchangers is used, then thermal management function is achieved, but device complexity increases
Solution Approach 1:
The patent combines the heat rejection heat exchanger and low grade heat exchanger into a single integrated heat exchanger unit. The coolant loop is reconfigured so that coolant flows directly from the fuel cell stack through the integrated heat exchanger, eliminating the need for separate heat rejection and low grade heat exchange components. This merging reduces device complexity while maintaining effective thermal management.
Solution Approach 2:
The integrated heat exchanger performs multiple functions simultaneously: it acts as both a heat rejection device and a low grade heat exchange device. By designing a single heat exchanger that can handle both heat rejection and heat recovery functions, the system achieves multi-functionality, reducing the number of components needed while maintaining comprehensive thermal management capability.
2Temperature
If multiple separate heat exchangers are used for heat rejection and heat recovery, then thermal management efficiency is improved, but manufacturing costs increase
Solution Approach 1:
The patent merges multiple separate heat exchanger components into a single integrated heat exchanger assembly. This consolidation reduces the total number of parts that need to be manufactured, assembled, and maintained, thereby reducing manufacturing costs. The integrated design maintains the thermal management efficiency of having both heat rejection and heat recovery functions by incorporating both capabilities within a single unified component.
3Power
If heat from the fuel cell power plant is fully utilized for power generation, then electrical power output increases, but temperature control becomes more difficult
Solution Approach 1:
The patent implements a continuous coolant flow path that maintains constant heat extraction from the fuel cell stack. The coolant continuously circulates through the integrated heat exchanger, ensuring steady-state heat removal that prevents temperature buildup. This continuous action allows maximum heat utilization for power generation while maintaining stable temperature control through uninterrupted heat exchange.
Solution Approach 2:
The system incorporates temperature sensing and control mechanisms that monitor the coolant temperature and adjust the coolant flow rate or heat exchanger operation accordingly. This feedback control ensures that as heat is extracted for power generation, the temperature remains within optimal operating ranges, balancing power extraction with temperature management.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances electrical power generation while simplifying thermal management, reducing component costs, and providing supplemental power through efficient heat utilization, thereby improving system economies and temperature control within the fuel cell power plant.
Implementation Method 1
fluid in the coolant network can become heated fluid by absorbing heat from the fuel cell power plant
Implementation Method 2
Thermal hydraulic engines typically utilize heat to cause fluid expansion. A mechanical component, such as a piston, moves as a result of the fluid expansion
Implementation Method 3
a cooling station configured to reduce a temperature of fluid provided to the cooling station
Data Source
AI summary
An illustrative example electrical power generating system includes a fuel cell power plant that is configured to generate electrical power. The fuel cell power plant includes a cell stack assembly including a plurality of fuel cells that are configured to generate electrical power based on a chemical reaction. A coolant network is configured to carry fluid toward the cell stack assembly where fluid in the coolant network can become heated by absorbing heat from the fuel cell power plant. The coolant network includes a thermal hydraulic engine that is configured to generate electrical power. The coolant network is configured to carry the heated fluid to the thermal hydraulic engine where the heated fluid can be used for generating electrical power. The coolant network is configured to carry a reduced temperature fluid from the thermal hydraulic engine back toward the cell stack assembly.