Hydrogen Generator CO Sensor Self-Calibration via Combustor Control
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Solution Overview
Problem
Conventional fuel cell systems require calibration gas supply equipment for CO sensor operation checks, increasing system size and cost, and making frequent checks complex and impractical without this equipment.
Innovation Solution
A hydrogen generation apparatus that generates a predetermined concentration of carbon monoxide in flue gas by controlling the air-fuel ratio in the combustor, allowing the CO sensor to be checked for normal or abnormal state without calibration gas, using the raw material gas as combustion gas when the hydrogen generator temperature is below a certain threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If calibration gas supply equipment is added to perform CO sensor operation checks, then the CO sensor can be checked for normal or abnormal state, but the system size and cost increase
Solution Approach 1:
The system uses its own flue gas containing carbon monoxide as the calibration source for the CO sensor operation check, eliminating the need for external calibration gas supply equipment. The controller automatically controls the combustor to generate CO and directs it to the CO sensor for self-diagnosis
Solution Approach 2:
The flue gas from the combustor serves dual purposes: it is both the exhaust product of the hydrogen generation process and the calibration source for the CO sensor. This multi-functional use eliminates the need for separate calibration equipment
2Reliability
If calibration gas supply equipment is carried to installation location for CO sensor checks, then the CO sensor can be checked, but the calibration work becomes complex and cumbersome
Solution Approach 1:
The system performs self-diagnosis by generating its own calibration gas (carbon monoxide) through the combustor and using it to test the CO sensor, eliminating the need to transport and set up external calibration equipment at the installation location
Solution Approach 2:
The system prepares the calibration gas (carbon monoxide) in advance by controlling the combustor to generate it, so that the CO sensor can be checked immediately without requiring external equipment to be brought to the site
3Ease of operation
If air-fuel ratio is controlled to generate carbon monoxide in flue gas, then CO sensor operation check is simplified, but hydrogen generator temperature must be monitored to prevent carbon deposition
Solution Approach 1:
The controller monitors the hydrogen generator temperature and adjusts the air-fuel ratio accordingly, using feedback control to prevent carbon deposition while maintaining conditions suitable for CO generation during sensor calibration
Solution Approach 2:
The system dynamically adjusts the air-fuel ratio parameter based on temperature conditions, changing it to generate carbon monoxide when temperature is appropriate and preventing carbon deposition when temperature is too low
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
Enables straightforward operation checks of the CO sensor, reducing system complexity and cost by eliminating the need for calibration gas supply equipment and preventing carbon deposition on catalysts, thus maintaining hydrogen generator performance.
Implementation Method 1
a combustor (2), which combusts a combustion gas to heat the hydrogen generator (1)
Data Source
Figure 1
Figure 2
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AI summary
A hydrogen generation apparatus according to the present invention includes: a hydrogen generator (1); a combustor (2) configured to heat the hydrogen generator (1); a combustion gas supply device; an air supply device (8); a CO sensor (5) configured to detect carbon monoxide contained in a flue gas; and a controller (6). In a case where a temperature of the hydrogen generator (1) is lower than or equal to a first temperature set in advance, or in a case where a first period set in advance has elapsed after combustion by the combustor (2) has ended, the controller (6): causes the combustion gas supply device to supply a raw material gas as a combustion gas to the combustor (2); and controls an air-fuel ratio to be out of a predetermined range, the air-fuel ratio being a ratio between air and the combustion gas that are supplied to the combustor (2). In a case where the CO sensor (5) does not detect a predetermined carbon monoxide concentration, the controller (6): determines that the CO sensor (5) is in an abnormal state; gives a notification that the CO sensor (5) is in an abnormal state; or performs control to stop the hydrogen generation apparatus (101) from operating.