Systems and methods for controlling hydrogen generation

• US 20060225350A1
• Filed: 01/27/2006
• Published: 10/12/2006
• Est. Priority Date: 01/28/2005
• Status: Abandoned Application

• Current Assignee: Millennium Cell Inc.
• Original Assignee: Millennium Cell Inc.
• Inventors: Molter, Robert, Fennimore, Keith A., Eason, Ian, Mohring, Richard M., Spallone, John, Berry, Grant
• Application Number:
  US11/340,506
• Publication Number:
  US 20060225350A1
• Time in Patent Office: Days
• US Class Current: 48/198.200
• CPC Class Codes: B01J 19/0006 Controlling or regulating processes controlling or regulating in general G05
• CPC Class Codes: B01J 2219/00063 of the reactants
• CPC Class Codes: B01J 2219/00065 Pressure measurement
• CPC Class Codes: B01J 2219/00164 controlling the flow
• CPC Class Codes: B01J 2219/002 inside the reactor
• CPC Class Codes: B01J 2219/0022 calculating difference
• CPC Class Codes: B01J 2219/00231 at the reactor inlet
• CPC Class Codes: B01J 7/02 by wet methods
• CPC Class Codes: C01B 2203/066 with fuel cells
• CPC Class Codes: C01B 2203/1619 Measuring the temperature
• CPC Class Codes: C01B 2203/1633 Measuring the pressure
• CPC Class Codes: C01B 2203/169 Controlling the feed
• CPC Class Codes: C01B 3/065 from a hydride
• CPC Class Codes: Y02E 60/36 Hydrogen production from non-carbon containing sources, e.g. by water electrolysis

Abstract

Systems and methods are disclosed for monitoring at least two system parameters (such as system temperature or pressure, or system pressure at two different locations) of a hydrogen generation system and controlling hydrogen generation from a fuel solution. The system comprises a hydrogen generator having a fuel chamber for a liquid fuel, a reactor chamber where the fuel undergoes a reaction to produce hydrogen, and at least two sensors in communication with the reactor chamber, the sensors measuring at least two system parameters of the hydrogen generator. The methods include control sequences for controlling the fuel flow rate to the reactor based on the sensed parameters.

Claims

1. A method for controlling hydrogen generation in a hydrogen generating system having a fuel chamber containing a fuel, and a reactor, comprising:

detecting at least one system parameter; and

controlling the flow of the fuel from the fuel chamber to the reactor based on the detected at least one system parameter,

wherein the at least one system parameter is system temperature, or at least two system parameters selected from the group consisting of a first pressure measured at a first location with respect to the reactor, a second pressure measured at a second location with respect to the reactor, and a |temperature within the system.|

2. The |Method of claim 1, wherein the at least one parameter is temperature.|

3. The method of claim 1 further comprising detecting a pressure at a location with respect to the reactor and detecting a temperature within the system.

4. The method of claim 1 further comprising detecting a first pressure at a first location with respect to the reactor and detecting a second pressure at a second location with respect to the reactor.

5. The method of claim 2 wherein the temperature is a temperature of the reactor.

6. The method of claim 1 further comprising:

|detecting a first pressure at a| first location with respect to the reactor;

comparing the first pressure to a predetermined pressure to determine a first fuel rate value;

|detecting a temperature within the system;

|

comparing the temperature to a predetermined temperature to determine a maximum fuel rate value;

comparing the first fuel rate value to the maximum fuel rate value to determine a system output value; and

controlling the flow rate of the fuel to the reactor based on the system output value.

7. The method of claim 6, wherein the temperature is a reactor temperature.

8. The method of claim 6, wherein the first pressure is hydrogen gas pressure.

9. The method of claim 6, wherein the first pressure is fluid pressure of the fuel at a location between the fuel chamber and the reactor.

10. The method of claim 6, wherein the first pressure is product pressure of a product at a location downstream of the reactor.

11. The method of claim 6 further comprising:

detecting a second pressure at a second location of the reactor;

comparing each of the first and second pressures to determine a first pressure differential;

comparing the first pressure differential to a predetermined pressure differential; and

interrupting the flow of fuel to the reactor if the first pressure differential is greater than the predetermined pressure differential.

12. The method of claim 6 further comprising:

providing at least one sensor adjacent the reactor to measure the at least one system parameter;

providing a controller for receiving input values from the at least one sensor;

providing an output value based on the input values; and

controlling the flow of the fuel based on the output value.

13. The method of claim 6, wherein determining the system output value comprises setting the system output value to the maximum fuel rate value if the maximum fuel rate value is less than the first fuel rate value.

14. The method of claim 13, wherein determining the system output value comprises setting the system output value to the first fuel rate value if the maximum fuel rate value is equal to or greater than the first fuel rate value.

15. The method of claim 14, further comprising periodically monitoring the at least one system parameter and resetting the system output value.

16. The method of claim 1, wherein the fuel is a reformable fuel.

17. The method of claim 1, wherein the hydrogen generating system is connected to a fuel cell.

18. A method of generating hydrogen, comprising:

providing a hydrogen generator having a fuel chamber for containing a fuel, a reactor, and a pump for conveying fuel to the reactor;

providing at least two sensors to independently measure at least two system parameters of the hydrogen generator;

providing a controller for receiving input values from the at least two sensors and for providing an output value based on the input values; and

controlling the pump speed based on the output value.

19. The method of claim 18, wherein one of the at least two system parameters is hydrogen gas pressure and another of the at least two system parameters is reactor temperature.

20. The method of claim 18, wherein the fuel is a reformable fuel.

21. The method of claim 18, wherein the fuel is selected from the group consisting of chemical hydrides and hydrocarbons.

22. The method of claim 18, wherein the fuel is a boron hydride.

23. The method of claim 18 further comprising:

measuring a first hydrogen gas pressure at a first location of the reactor;

comparing the first hydrogen gas pressure to a predetermined pressure to determine a first pump speed value;

detecting a first reactor temperature;

comparing the first reactor temperature to a predetermined temperature to determine a maximum pump speed value;

comparing the first pump speed value to the maximum pump speed value to determine a system output value; and

setting the pump speed based on the system output value.

24. The method of claim 23, wherein determining the system output value comprises setting the system output value to the maximum pump speed if the maximum pump speed is less than the first pump speed.

25. The method of claim 24, wherein determining the system output value comprises setting the system output value to the first pump speed if the maximum pump speed is equal to or greater than the first pump speed.

26. The method of claim 23, further comprising periodically monitoring the system parameters and resetting the system output value.

27. The method of claim 23 further comprising:

measuring a second hydrogen gas pressure at a second location of the reactor;

comparing each of the first and second hydrogen gas pressures determine a first pressure differential;

comparing the first pressure differential to a predetermined pressure differential, and setting the pump speed to zero if the first pressure differential is greater than the predetermined pressure differential.

28. The method of claim 18, wherein the pump is modulated via PWM modulation of a fixed speed pump.

29. A hydrogen generator, comprising:

a fuel storage chamber for a fuel solution;

a fuel regulating means for conveying at least part of the fuel solution from the fuel storage chamber to a reactor chamber;

at least two sensors configured to sense at least two system parameters, wherein the at least two system parameters are |independently selected from the group consisting of a first pressure measured at a first location with respect to the reactor, a second pressure measured at a second location with respect to the reactor;

|and a temperature within the system; and

a controller in communication with the at least two sensors and with the fuel regulating means.

30. The hydrogen generator of claim 29, wherein one of the first pressure and the second pressure is hydrogen gas pressure.

31. The hydrogen generator of claim 29, wherein one of the first pressure and the second pressure is fluid pressure.

32. The hydrogen generator of claim 29, wherein the fuel regulating means comprises a fuel pump.

33. The hydrogen generator of claim 29, wherein the fuel regulating means comprises a valve.

34. The hydrogen generator of claim 29, wherein the at least two sensors detect at least two different system parameters.

35. The hydrogen generator of claim 29, wherein at least one of the system parameters is hydrogen gas pressure.

36. The hydrogen generator of claim 29, wherein at least one of the system parameters is reactor chamber temperature.

37. The hydrogen generator of claim 29, wherein the controller is a microcontroller or a microprocessor.

38. The hydrogen generator of claim 29, wherein the fuel solution is a reformable fuel.

39. The hydrogen generator of claim 29, wherein the fuel solution comprises fuel selected from the group consisting of chemical hydrides and hydrocarbons.

40. The hydrogen generator of claim 29, wherein the fuel solution is a metal borohydride.

41. The hydrogen generator of claim 29, wherein the reactor chamber further comprises a reagent.

42. The hydrogen generator of claim 41, wherein the reagent is selected from the group consisting of a supported catalyst, an acidic solution, a transition metal salt solution and heat.

43. The hydrogen generator of claim 29, wherein hydrogen from the reactor chamber is delivered to a power module.

44. The hydrogen generator of claim 43, wherein the power module comprises a fuel cell.

45. The hydrogen generator of claim 29, wherein the controller is configured to compare a first pressure to a predetermined pressure to determine a first fuel rate value;

compare the reactor temperature to a predetermined temperature to determine a maximum fuel rate value;

compare the first fuel rate to the maximum fuel rate value to determine a system output value; and

control the flow rate of the fuel to the reactor based on the system output value.

46. The hydrogen generator of claim 45, wherein the controller is configured to compare each of a first and second pressure to determine a first pressure differential;

compare the first pressure differential to a predetermined pressure differential; and

interrupt the flow of fuel to the reactor if the first pressure differential is greater than the predetermined pressure differential.

47. The hydrogen generator of claim 46, wherein the controller is configured to set the system output value to the maximum fuel rate if the maximum fuel rate is less than the first fuel rate.

48. The hydrogen generator of claim 47, wherein the controller is configured to set the system output value to the first fuel rate if the maximum fuel rate is equal or greater to the first fuel rate.

49. The hydrogen generator of claim 47, wherein the controller is configured to periodically monitor the system parameters and reset the system output value.

50. The hydrogen generator of claim 29, wherein the fuel regulating means comprises a pump and the system output value is pump speed.

51. A method of generating hydrogen, comprising:

providing a hydrogen generator having a fuel chamber for containing a fuel, a reactor, and a valve for controlling flow of fuel to the reactor;

providing at least two sensors to independently measure at least two system parameters of the hydrogen generator;

providing a controller for receiving input values from the at least two sensors and for providing an output value based on the input values; and

controlling the valve speed based on the output value.

52. The method of claim 51, wherein one of the at least two system parameters is hydrogen gas pressure and another of the at least two system parameters is reactor temperature.

53. The method of claim 51, wherein the fuel is a reformable fuel.

54. The method of claim 51, wherein the fuel is selected from the group consisting of chemical hydrides and hydrocarbons.

55. The method of claim 51, wherein the fuel is a boron hydride.

56. The method of claim 51 further comprising:

measuring a first hydrogen gas pressure at a first location of the reactor;

comparing the first hydrogen gas pressure to a predetermined pressure to determine a first valve speed value;

detecting a first reactor temperature;

comparing the first reactor temperature to a predetermined temperature to determine a maximum valve speed value;

comparing the first valve speed value to the maximum valve speed value to determine a system output value; and

setting the valve speed of the system based on the system output value.

57. The method of claim 56, wherein determining a system output value comprises setting the system output value to the maximum valve speed if the maximum valve speed is less than the first valve speed.

58. The method of claim 57, wherein determining a system output value comprises setting the system output value to the first valve speed if the maximum valve speed is equal to or greater than the first valve speed.

59. The method of claim 56, further comprising periodically monitoring the system parameters and resetting the system output value.

60. The method of claim 56 further comprising:

measuring a second hydrogen gas pressure at a second location of the reactor;

comparing each of the first and second hydrogen gas pressures determine a first pressure differential;

comparing the first pressure differential to a predetermined pressure differential, and setting the valve speed to zero if the first pressure differential is greater than the predetermined pressure differential.