Energy load management system

• US 10,547,071 B2
• Filed: 06/29/2017
• Issued: 01/28/2020
• Est. Priority Date: 10/16/2012
• Status: Active Grant

• Current Assignee: Bloom Energy Corporation
• Original Assignee: Bloom Energy Corporation
• Inventors: Higdon, David, Weingaertner, David, Zargari, Ali, Kusolasak, Suthitham
• Primary Examiner(s): Jelsma, Jonathan G
• Application Number:
  US15/637,268
• Publication Number:
  US 20170301934A1
• Time in Patent Office: 943 Days
• CPC Class Codes: H01M 2008/1293 Fuel cells with solid oxide electrolytes
• CPC Class Codes: H01M 4/9033 Complex oxides, optionally doped, of the type M1MeO3, M1 being an alkaline earth metal or a rare earth, Me being a metal, e.g. perovskites
• CPC Class Codes: H01M 4/9066 of metal-ceramic composites or mixtures, e.g. cermets
• CPC Class Codes: H01M 8/04014 Heat exchange using gaseous fluids; Heat exchange by combustion of reactants
• CPC Class Codes: H01M 8/04097 with recycling of the reactants H01M8/04119, H01M8/04104 take precedence
• CPC Class Codes: H01M 8/04373 of auxiliary devices, e.g. reformers, compressors, burners
• CPC Class Codes: H01M 8/04447 of anode reactants at the inlet or inside the fuel cell
• CPC Class Codes: H01M 8/04753 of fuel cell reactants
• CPC Class Codes: H01M 8/0491 of fuel cell stacks
• CPC Class Codes: H01M 8/0494 of fuel cell stacks
• CPC Class Codes: H01M 8/0618 Reforming processes, e.g. autothermal, partial oxidation or steam reforming
• CPC Class Codes: H01M 8/0662 Treatment of gaseous reactants or gaseous residues, e.g. cleaning
• CPC Class Codes: H01M 8/1253 the electrolyte containing zirconium oxide
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

A system and method for controlling a fuel cell system. An anode tail gas oxidizer (ATO) receives air and fuel exhaust streams from one or more fuel cell stacks of the fuel cell system. The one or more fuel cell stacks provide current to one or more loads. An ATO temperature signal is used to control at least one of a fuel inlet flow to the one or more fuel cell stacks or the current provided to the one or more loads.

Claims

1. A method for controlling a fuel cell system, wherein the fuel cell system comprises one or more fuel cell stacks, the method comprising:

receiving from a sensor an anode tail gas oxidizer (ATO) temperature signal indicative of a measured ATO temperature, wherein the ATO receives air and fuel exhaust streams from the one or more fuel cell stacks and wherein the one or more fuel cell stacks provide current to one or more loads;

determining an amount of fuel by which to adjust a fuel estimate or an additional amount of current that can be generated by the one or more fuel cell stacks based on a determined fuel utilization of the one or more fuel cell stacks by comparing the measured ATO temperature and an ATO set point temperature; and

controlling at least one of a fuel inlet flow to the one or more fuel cell stacks using the amount of fuel by which to adjust the fuel estimate or the current provided to the one or more loads using the additional amount of current that can be generated by the one or more fuel cell stacks.

2. The method of claim 1, wherein the step of controlling comprises:

determining by a controller from the ATO temperature signal whether the measured ATO temperature exceeds the ATO set point temperature by a predetermined value; and

varying a magnitude of least one of the fuel inlet flow to the one or more fuel cell stacks or the current provided to the one or more loads in response to the measured ATO temperature exceeding the ATO set point temperature by the predetermined value.

3. The method of claim 1, wherein:

the step of determining comprises determining from the ATO temperature signal whether excess fuel is present in the one or more fuel cell stacks; and

the step of controlling comprises at least one of increasing the current to the one or more loads or decreasing the fuel inlet flow rate to the one or more fuel cell stacks when excess fuel is present in the one or more fuel cell stacks.

4. The method of claim 1, wherein the step of controlling comprises controlling the fuel inlet flow to the one or more fuel cell stacks.

5. The method of claim 4, wherein the step of controlling comprises at least one of varying a fresh fuel inlet stream flow rate to the one or more fuel cell stacks or varying a recycling rate of a fuel cell stack anode exhaust stream into the one or more fuel cell stacks.

6. The method of claim 5, wherein the step of controlling comprises:

at least one of increasing the fresh fuel inlet stream flow rate to the one or more fuel cell stacks or increasing the recycling rate of the fuel cell stack anode exhaust stream into the one or more fuel cell stacks when the measured ATO temperature exceeds the ATO set point temperature by a first predetermined value; and

at least one of decreasing the fresh fuel inlet stream flow rate to the one or more fuel cell stacks or decreasing the recycling rate of the fuel cell stack anode exhaust stream into the one or more fuel cell stacks when the measured ATO temperature is less than the ATO set point temperature by a second predetermined value.

7. The method of claim 1, wherein the step of controlling comprises controlling the current provided to the one or more loads.

8. The method of claim 7, wherein the step of controlling comprises:

increasing the current when the measured ATO temperature exceeds the ATO set point temperature by a first predetermined value; and

decreasing the current when the measured ATO temperature is less than the ATO set point temperature by a second predetermined value.

9. The method of claim 1, further comprising:

receiving a current request from the one or more loads;

determining from the current request an estimate of a fuel flow ramp to be applied to the fuel inlet flow to meet the current request;

determining from the ATO temperature signal whether excess fuel is present in the one or more fuel cell stacks; and

decreasing the estimated fuel flow ramp by an amount of the excess fuel when excess fuel is present in the one or more fuel cell stacks.

10. The method of claim 1, wherein the ATO receives all of its incoming air from a fuel cell stack cathode exhaust stream and all of its incoming fuel from a fuel cell stack anode exhaust stream.

11. A system, comprising:

a fuel cell system, wherein the fuel cell system comprises one or more fuel cell stacks and an anode tail gas oxidizer (ATO), wherein the ATO receives air and fuel exhaust streams from the one or more fuel cell stacks and wherein the one or more fuel cell stacks provide current to one or more loads;

a temperature sensor configured to obtain an ATO temperature signal indicative of a measured ATO temperature; and

a controller configured to perform operations comprising;

receiving the ATO temperature signal from the sensor;

determining an amount of fuel by which to adjust a fuel estimate or an additional amount of current that can be generated by the one or more fuel cell stacks based on a determined fuel utilization of the one or more fuel cell stacks by comparing the measured ATO temperature and an ATO set point temperature; and

controlling at least one of a fuel inlet flow to the one or more fuel cell stacks using the amount of fuel by which to adjust the fuel estimate or the current provided to the one or more loads using the additional amount of current that can be generated by the one or more fuel cell stacks.

12. The system of claim 11, wherein the operation of controlling:

comprises determining from the ATO temperature signal whether the measured ATO temperature exceeds the ATO set point temperature by a predetermined value; and

varying a magnitude of least one of the fuel inlet flow to the one or more fuel cell stacks or the current provided to the one or more loads in response to the measured ATO temperature exceeding the ATO set point temperature by the predetermined value.

13. The system of claim 11, wherein:

the determining operation comprises determining from the ATO temperature signal whether excess fuel is present in the one or more fuel cell stacks; and

the controlling operation comprises at least one of increasing the current to the one or more loads or decreasing the fuel inlet flow rate to the one or more fuel cell stacks when excess fuel is present in the one or more fuel cell stacks.

14. The system of claim 11, wherein the controller is further configured to perform operations comprising:

receiving a current request from the one or more loads;

determining from the current request an estimate of a fuel flow ramp to be applied to the fuel inlet flow to meet the current request;

determining from the ATO temperature signal whether excess fuel is present in the one or more fuel cell stacks; and

decreasing the estimated fuel flow ramp by an amount of the excess fuel when excess fuel is present in the one or more fuel cell stacks.

15. The system of claim 11, wherein the ATO receives all of its incoming air from a fuel cell stack cathode exhaust stream and all of its incoming fuel from a fuel cell stack anode exhaust stream.

16. The system of claim 11, wherein the operation of controlling comprises controlling the fuel inlet flow to the one or more fuel cell stacks.

17. The system of claim 11, wherein the operation of controlling comprises controlling the current provided to the one or more loads.

18. The system of claim 11, wherein the operation of controlling comprises both controlling the fuel inlet flow to the one or more fuel cell stacks and controlling the current provided to the one or more loads.