Fuel Cell Heater Combustor Exhaust Control

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Solution Overview

Problem

Existing subterranean heaters using fuel cell stacks and combustors face limitations in utilizing all hydrogen from anode exhaust and oxygen from cathode exhaust, leading to inefficient heat production and dependency of combustor fuel flow on reformate flow to fuel cells, making independent control of thermal output challenging.

Innovation Solution

A heater design with a fuel cell stack assembly and a combustor within a housing, where an anode exhaust conduit allows selective communication of anode exhaust out of the housing, enabling independent operation of the combustor and utilizing remaining chemical energy in cathode exhaust, allowing for independent control of combustor thermal output.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the combustor is supplied with anode exhaust and cathode exhaust from the fuel cells to utilize remaining hydrogen and oxygen, then energy utilization efficiency is improved, but the combustor fuel flow becomes dependent on reformate flow to fuel cells, making independent control of thermal output difficult

Engineering Contradiction:

Improveenergy utilization efficiencyVSAvoidindependent control of thermal output

Core Design Contradiction:

Loss of energyVSEase of operation

Solution Approach 1:

The system segments the fuel supply paths by providing separate fuel inlets: a first fuel inlet for reformate to the fuel cells and a second fuel inlet for natural gas to the combustor. This segmentation allows independent control of combustor fuel flow while maintaining energy efficiency by capturing exhaust gases through dedicated conduits.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The anode exhaust conduit and cathode exhaust conduit act as intermediaries that transport exhaust gases from the fuel cells to the combustor. These conduits enable the combustor to receive and utilize remaining hydrogen and oxygen independently of the primary fuel supply to the fuel cells.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Power

If fuel cells operate at higher fuel utilization to produce more heat, then thermal output is improved, but fuel cell durability decreases

Engineering Contradiction:

Improvethermal outputVSAvoidfuel cell durability

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The system changes the operating parameters by maintaining fuel cells within the safe utilization range of 40-60% while using the combustor to burn remaining fuel. This parameter optimization ensures fuel cell durability is preserved while thermal output is maximized through the combined system of fuel cells and combustor.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system converts the harmful waste (unburned hydrogen and oxygen in exhaust gases) into a beneficial resource by directing these exhaust gases to the combustor. This transforms what would be energy loss into additional thermal output, allowing fuel cells to operate at optimal durability levels.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Temperature

If conventional heaters are used to heat subterranean formations, then heating effectiveness is achieved, but energy consumption is high

Engineering Contradiction:

Improveheating effectivenessVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The system merges fuel cell technology with combustor technology in a hybrid configuration. The fuel cells convert chemical energy to electrical energy and heat, while the combustor burns remaining fuel to generate additional heat. This combined system provides effective subterranean heating while significantly reducing energy consumption compared to conventional heaters by utilizing otherwise wasted chemical energy.

Inventive Principle:

Principle #5Merging (Combining)

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

This design enhances heat production efficiency by utilizing remaining hydrogen and oxygen, allowing for independent control of thermal output, reducing energy wastage and improving the overall heating process in subterranean geological formations.

Implementation Method 1

The fuel cells convert chemical energy from a fuel into heat and electricity through a chemical reaction with an oxidizing agent

Methodology Applied

Scientific EffectFuel cell chemical reaction: Fuel Cell

Implementation Method 2

a combustor for combusting a mixture of fuel and air, thereby functioning as an additional source of heat

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS9379394B2Heater with a fuel cell stack assembly and a combustor and method of operating

Publication Date: 2016.06.28 APTIV TECHNOLOGIES AG

AI summary

A heater includes a heater housing extending along a heater axis. A fuel cell stack assembly is disposed within the heater housing and includes a plurality of fuel cells which convert chemical energy from a fuel cell fuel into heat and electricity through a chemical reaction with a fuel cell oxidizing agent. A combustor disposed within the heater housing includes a combustor fuel inlet for introducing the combustor fuel into the combustor, a combustor oxidizing agent inlet for introducing a combustor oxidizing agent into the combustor, and combustor exhaust outlet for discharging a heated combustor exhaust from the combustor. An anode exhaust conduit is connected to the anode exhaust outlet and extends out of the heater housing for selectively communicating a first quantity of the anode exhaust out of the heater housing. The heater housing is heated by the fuel cell stack assembly and the heated combustor exhaust.