Fuel-Cell Power System Waste Heat Recovery
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Solution Overview
Problem
Traditional fuel-cell power generation systems require dedicated cooling subsystems to manage heat generated by inverters, increasing system size, cost, and complexity.
Innovation Solution
The power generation system utilizes the heat generated by the power electronics subsystem to pre-heat a fuel stream, which is then supplied to the fuel-cell, reducing the need for additional cooling and simplifying the system by minimizing the heating requirements within the fuel-cell subsystem.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated cooling subsystems are used to manage heat generated by inverters, then the inverter can operate effectively, but the system size, cost, and complexity increase
Solution Approach 1:
The patent merges the cooling function with the fuel stream supply system. The fuel stream serves dual purposes: it is heated by the inverter (cooling the inverter) and then supplied to the fuel cell. This eliminates the need for separate cooling subsystems with fans, pipelines, and pumps, thereby reducing system complexity while maintaining effective inverter cooling
Solution Approach 2:
The patent converts the harmful heat generated by the inverter into a beneficial resource. Instead of treating the heat as waste that must be dissipated, the system uses it to pre-heat the fuel stream before it enters the fuel cell. This reduces the heating burden on the fuel cell subsystem and eliminates the need for dedicated cooling equipment
2Temperature
If dedicated cooling subsystems are used to dissipate inverter heat, then the inverter temperature is controlled, but the system cost increases due to additional components
Solution Approach 1:
The fuel stream is given multiple functions: it serves as both the cooling medium for the inverter and the fuel source for the fuel cell. The same fuel stream that would otherwise require separate heating equipment is instead heated by the inverter itself, making the system more cost-effective by eliminating redundant components
3Use of energy by moving object
If the fuel stream is pre-heated by the power electronics subsystem, then the heating requirements within the fuel-cell subsystem are reduced, but the power electronics subsystem must handle additional thermal management
Solution Approach 1:
The power electronics subsystem converts its waste heat, which would otherwise be a burden requiring active cooling, into a useful resource for pre-heating the fuel stream. This turns a thermal management problem into an energy recovery opportunity, reducing the overall energy requirements of the system
4Productivity
If waste heat from the power electronics subsystem is utilized for pre-heating fuel, then system efficiency improves, but the thermal management of the power electronics subsystem becomes more complex
Solution Approach 1:
The power electronics subsystem serves itself by using its own waste heat to pre-heat the fuel stream. This self-service approach improves overall system efficiency without requiring external thermal management systems, as the heat that would need to be removed is instead put to productive use
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 configuration reduces the size, cost, and complexity of the fuel-cell subsystem and improves efficiency by utilizing waste heat for pre-heating, thereby reducing the need for additional cooling systems and enhancing overall system performance.
Implementation Method 1
the power electronics subsystem is configured to heat the portion of the fuel stream to form a pre-heated fuel stream
Data Source
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AI summary
A power generation system 100 includes a fuel-cell subsystem 102 having a fuel-cell 110 configured to generate an electrical power. The power generation system 102 further includes a power electronics subsystem 104 electrically coupled to the fuel-cell subsystem and configured to process at least a portion of the electrical power generated by the fuel-cell subsystem 102. The power generation system 100 also includes a first conduit 106 fluidly coupled to the power electronics subsystem 104 and configured to supply at least a portion of a fuel stream to the power electronics subsystem 104. The power electronics subsystem 104 is configured to heat the portion of the fuel stream to form a pre-heated fuel stream 122. Moreover, power generation system 100 includes a second conduit 108 fluidly coupled to the power electronics subsystem 104 and the fuel-cell subsystem 102 and configured to supply the pre-heated fuel stream 122 to the fuel-cell subsystem 102. The fuel-cell 110 is configured to generate the electrical power using the pre-heated fuel stream 122.