Modular Sorbent Bed Assembly for Fuel Cell Purification

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Solution Overview

Problem

Fuel cell systems, such as solid oxide fuel cell systems, face reliability issues due to undesirable constituents like moisture, oxygen, siloxanes, and sulfur in the fuel stream, which can cause irreversible damage and reduce efficiency, and existing sorbent bed systems have finite lifespans leading to underutilization and increased replacement costs.

Innovation Solution

A modular sorbent bed assembly with multiple beds connected in series, allowing for individual assembly replacement and utilization of different purification materials, along with detection systems to divert fuel flow and prevent damage, enabling 'hot swapping' and efficient use of sorbent beds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sorbent beds are replaced prior to exhaustion, then fuel cell stack is protected from damage, but cost of sorbent bed replacement increases due to underutilized portions

Engineering Contradiction:

Improvefuel cell stack protectionVSAvoidsorbent bed utilization

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The sorbent bed is divided into multiple segments (first sorbent bed, second sorbent bed, and at least one third sorbent bed) connected in series. This segmentation allows the fuel stream to pass through multiple sorbent beds sequentially, enabling better utilization of sorbent capacity while protecting the fuel cell stack. The segmented design allows for more precise monitoring and replacement strategies.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system includes detection means to detect when the sorbent bed is exhausted and control means to respond to the detection. This preliminary detection and response mechanism allows for timely replacement of sorbent beds before they cause damage to the fuel cell stack, optimizing both protection and utilization.

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If single sorbent bed is used, then system complexity is reduced, but service life and capacity of fuel processor is limited

Engineering Contradiction:

Improvesorbent bed configurationVSAvoidfuel processor service life

Core Design Contradiction:

Device complexityVSDuration of action of moving object

Solution Approach 1:

The fuel processor uses multiple sorbent beds (first, second, and at least one third sorbent bed) connected in series instead of a single sorbent bed. This segmentation increases the total service life and purification capacity of the fuel processor while maintaining manageable system complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multiple sorbent beds connected in series provide continuous purification action throughout the service life of the fuel processor. As fuel passes through each sorbent bed sequentially, the useful purification action is extended over a longer duration, increasing overall service life.

Inventive Principle:

Principle #20Continuity of useful action

3Device complexity

If sorbent beds are not monitored, then system complexity is reduced, but fuel cell stack may suffer irreversible damage

Engineering Contradiction:

Improvemonitoring systemVSAvoidfuel cell stack integrity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The system includes detection means to detect when the sorbent bed is exhausted and control means to respond to the detection. This feedback mechanism provides real-time monitoring of sorbent bed status and enables timely response to prevent fuel cell stack damage, ensuring reliability without excessive complexity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The detection and control means work together to monitor and respond to sorbent bed exhaustion automatically. This self-service approach allows the system to protect itself from damage without requiring constant external monitoring or intervention.

Inventive Principle:

Principle #25Self-service

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

The modular sorbent bed assembly increases the capacity and service life of fuel processors, reduces waste, and maintains system operation by isolating exhausted beds, thereby improving fuel cell stack efficiency and operational life.

Implementation Method 1

Passing fuel through desulfurizer sorbent beds is one way to remove sulfur and sulfur compounds from fuel prior to use in a fuel cell

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS10333163B2Sorbent bed assembly, fuel cell system including same, and systems and devices for loading and transporting same

Publication Date: 2019.06.25 BLOOM ENERGY CORP

AI summary

A sorbent bed assembly of a fuel cell system, including a first sorbent bed, a second sorbent bed and at least one third sorbent bed, the second sorbent bed disposed between the first sorbent bed and the at least one third sorbent bed, a cover plate on the plurality of sorbent beds and configured to connect the sorbent beds to one another, a fuel inlet connector on the cover plate and configured to receive a fuel, a manifold having a first fluid conduit configured to transport fuel between the first sorbent bed and at least one third sorbent bed, and a second fluid conduit configured to transport fuel between at least one third sorbent bed and the second sorbent bed, and a fuel outlet connector on the cover plate and configured to receive fuel that has passed through each of the sorbent beds.