Fuel Cell Startup Controller Power Failure Recovery
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Solution Overview
Problem
Fuel cell systems face challenges during startup operations, particularly when a power failure occurs, as they require a time-consuming temperature rise and loading process, and existing methods do not adequately address power failures during this phase, leading to system stops and increased startup times.
Innovation Solution
A fuel cell system with a reformer, solid oxide fuel cells, and a startup controller that gradually increases raw fuel supply in stages, along with a heater and exhaust gas combustor, to stabilize output and maintain temperature, while also providing auxiliary power during power failures by switching to fuel cell power and using an uninterruptible power system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuel cell system uses a time-consuming startup operation to raise temperatures and gradually increase loading, then the fuel cells achieve stable operation and avoid excessive temperature increases in the combustor, but the system requires extended startup time and cannot respond quickly to power failures during startup
Solution Approach 1:
The patent applies preliminary action by pre-heating the fuel cells using a heater before startup operation begins. This preliminary heating reduces the time required during actual startup while maintaining the gradual loading protocol to prevent excessive combustor temperature increases. The heater prepares the system in advance, so when startup is initiated, the fuel cells are already at a higher temperature, shortening the overall startup duration without compromising stability.
2Strength
If the system gradually increases fuel gas and oxidant gas supply in stages during loading, then the fuel cells maintain durability and avoid excessive combustor temperature, but the output from the fuel cells increases slowly over a long period
Solution Approach 1:
The patent applies preliminary action by pre-heating the fuel cells to high temperature before the gradual loading process begins. This allows the system to start the staged fuel gas and oxidant gas supply at a higher baseline temperature, which accelerates the output increase rate during each stage while still maintaining the careful progressive approach needed to protect fuel cell durability and prevent combustor overheating.
3Ease of operation
If the system stops and restarts after a power failure during startup operation, then the auxiliary machinery can be reset, but the fuel cell system must repeat the entire time-consuming startup operation
Solution Approach 1:
The patent applies preliminary action by using a heater to pre-heat the fuel cells before startup operation begins. This way, if a power failure occurs during startup, the fuel cells retain higher temperature and the system can resume operation more quickly after power restoration, avoiding the need to repeat the entire cold startup process from room temperature.
Solution Approach 2:
The patent applies continuity of useful action by maintaining the heater operation or thermal energy in the fuel cells even during power failures. The thermal energy is preserved in the fuel cell stack, and when power is restored, the startup process can continue from the existing temperature state rather than restarting from cold, thus maintaining continuous progress toward operational temperature.
4Reliability
If the system supplies sufficient power to auxiliary machinery during power failure, then the fuel cell system can maintain operation, but the fuel cells must operate at higher output levels during startup
Solution Approach 1:
The patent applies preliminary action by pre-heating the fuel cells before startup operation. This preliminary heating reduces the time and power required during the actual startup and loading phases. When a power failure occurs, the fuel cells can reach higher output levels more quickly because they are already warm, allowing sufficient power to be supplied to auxiliary machinery without requiring excessively high output during the entire startup process.
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 solution enables the fuel cell system to maintain operation during power failures by providing necessary power to auxiliary machinery and preventing excessive temperature increases, thus reducing startup time and fuel consumption, and ensuring continuous operation.
Implementation Method 1
a reformer 22 that reforms raw fuel to generate fuel gas
Implementation Method 2
a solid oxide fuel cell 23 that generates electric power by using the fuel gas and oxidant gas
Implementation Method 3
an exhaust gas combustor 73 that burns unutilized fuel gas discharged in an unutilized state from the fuel cell
Implementation Method 4
a heater 61 that heats an interior of the housing during the startup operation
Data Source
AI summary
In a fuel cell system, the output from a plurality of fuel cells can reach an output greater than or equal to auxiliary driving power in a short time because the initial supply amount of raw fuel supplied from a raw fuel supply part is greater than or equal to a first supply amount that is a raw fuel supply amount corresponding to the auxiliary driving power. Thus, even if the raw fuel is supplied at the initial supply amount when a power failure has occurred in an electric power system during a startup operation of the fuel cell system, it is possible to supply electric power from the fuel cells to the auxiliary machinery and continue to drive the auxiliary machinery under the control of a startup controller. This suppresses the stop of the fuel cell system under the startup operation.