Fuel Cell Power Generation Using Shift Reactor Hydrogen Recovery

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Solution Overview

Problem

Aircraft electrical systems rely on engine-driven power generation, which is inefficient and heavy, and lack a sustainable method for generating electricity and cooling using onboard resources.

Innovation Solution

A vehicle system integrating a shift reactor to process carbon monoxide into hydrogen and a fuel cell to produce electricity, with a plasma fuel reformer and water-gas shift reaction, along with a cooling system utilizing water as a coolant, where the fuel cell's by-product water is used for cooling and hydrogen is recovered from jet fuel, reducing carbon monoxide content and emissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If engine-driven power generation is used, then electrical power can be generated on the aircraft, but the system becomes heavy and inefficient

Engineering Contradiction:

Improveelectrical power generationVSAvoidpower generation system weight

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

The patent replaces the conventional mechanical engine-driven generator system with a chemical fuel cell system. The fuel cell converts chemical energy from hydrogen directly into electrical energy through electrochemical reactions, eliminating the need for mechanical conversion components and reducing system weight while improving efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses onboard jet fuel as the hydrogen source, eliminating the need for separate hydrogen storage tanks. The fuel reformer converts jet fuel into hydrogen on-demand, and the water-gas shift reactor optimizes the hydrogen content, creating a self-sufficient system that uses existing aircraft resources.

Inventive Principle:

Principle #25Self-service

2Quantity of substance

If jet fuel is used as hydrogen source, then additional hydrogen storage is eliminated, but carbon monoxide content must be reduced

Engineering Contradiction:

Improvehydrogen availabilityVSAvoidcarbon monoxide content

Core Design Contradiction:

Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful carbon monoxide byproduct of jet fuel reforming into useful hydrogen through the water-gas shift reaction. The shift reactor uses steam to convert CO into additional hydrogen and carbon dioxide, thereby eliminating the harmful effect while increasing the beneficial hydrogen output for the fuel cell.

Inventive Principle:

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

Solution Approach 2:

The system changes the chemical composition parameters of the reformate gas by controlling the water-gas shift reaction conditions (temperature, pressure, steam-to-carbon ratio) to optimize hydrogen content and reduce carbon monoxide levels to acceptable ranges for fuel cell operation.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If water is used as coolant, then cooling system becomes simpler, but water must be managed as a fuel cell by-product

Engineering Contradiction:

Improvecooling system complexityVSAvoidwater management

Core Design Contradiction:

Device complexityVSLoss of substance

Solution Approach 1:

Instead of discarding the water produced by the fuel cell, the system recovers and utilizes it as coolant in the cooling system. This closes the water loop, eliminating the need for separate water storage and reducing waste, while simplifying the overall system architecture by using a byproduct for a necessary function.

Inventive Principle:

Principle #34Discarding and recovering

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 system efficiently generates electricity and provides cooling using hydrogen and water produced from jet fuel, reducing the need for additional power sources and coolants, enhancing fuel efficiency, reducing aircraft weight, and improving fuel cell longevity.

Implementation Method 1

a shift reactor configured to receive carbon monoxide produced by the vehicle, and process the received carbon monoxide to produce an output comprising hydrogen

Methodology Applied

Scientific EffectWater-gas shift reaction: Chemical Transport Reactions

Implementation Method 2

a fuel cell coupled to the shift reactor and configured to receive the hydrogen from the shift reactor, and produce, using the received hydrogen, electricity for use on the vehicle

Methodology Applied

Scientific EffectFuel cell electrochemical reaction: Fuel Cell

Implementation Method 3

The cooling system may be configured to provide the water as a coolant to the fuel cell, thereby cooling the fuel cell

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS11505328B2Electrical power generation on a vehicle

Publication Date: 2022.11.22 BAE SYSTEMS PLC

AI summary

A vehicle comprising: a shift reactor (110) configured to: receive carbon monoxide produced by the vehicle; and process the received carbon monoxide to produce an output comprising hydrogen; and a fuel cell (112) coupled to the shift reactor (110) and configured to: receive the hydrogen from the shift reactor (110); and produce, using the received hydrogen, electricity for use on the vehicle.