System and method for controlling the operation of a fuel processsing system

• US 20080176118A1
• Filed: 04/19/2007
• Published: 07/24/2008
• Est. Priority Date: 10/06/1999
• Status: Active Grant

• Current Assignee: DCNS SA (Government of France)
• Original Assignee: IdaTech LLC (IdaTech Ltd.)
• Inventors: Herron, Thomas G., Edlund, David J., Pledger, William A.
• Granted Patent: US 7,771,882 B2
• Time in Patent Office: Days
• US Class Current: 429/17
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 1/06 using only one supply
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 2250/12 by confirmation, e.g. of the input
• CPC Class Codes: B60L 2250/16 by display
• CPC Class Codes: B60L 3/0053 relating to fuel cells
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 50/72 Constructional details of fuel cells specially adapted for electric vehicles
• CPC Class Codes: B60L 58/31 for starting of fuel cells
• CPC Class Codes: B60L 58/34 by heating
• CPC Class Codes: B60L 58/40 for controlling a combination of batteries and fuel cells
• CPC Class Codes: H01M 8/04089 of gaseous reactants
• CPC Class Codes: H01M 8/0612 from carbon-containing material
• CPC Class Codes: Y02E 60/32 Hydrogen storage
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y02T 90/40 Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

A control system and method for a fuel processing system. The control system automates the operation of a fuel processing system by monitoring operating parameters and automatically controlling the operation of the system responsive to the monitored parameters, predefined subroutines and/or user inputs.

Claims

1. A method for controlling the operation of a hydrogen-producing fuel processing system, which system comprises a fuel processor which in use in a running state of the fuel processing system receives a feed stream and produces hydrogen gas therefrom, a feed assembly which in use in the running state of the fuel processing system delivers the feed stream to the fuel processor, a fuel cell stack which in use in the running state of the fuel processing system receives at least a portion of the hydrogen gas, and control means which in use in the running state of the fuel processing system automates the operation of the fuel processing system, and in which method the control means:

receives inputs of selected operating parameters of the fuel processing system;

determines whether a measured value of a selected operating parameter is above or below a determined threshold value or value range and thereby outside normal operating parameters of the system, and, if so;

selects in accordance with said determination whether the fuel processing system is to be transitioned to a selected operating state available to the fuel processing system; and

sends command signals to transition the fuel processing system from its running state to the selected state, wherein the selected operating state is selected from a plurality of operating states that comprises at least;

i) a standby state in which the control means achieves and maintains determined operating temperatures and pressures within the fuel processor but in which hydrogen gas is not being generated in more than a nominal amount by the fuel processing system; and

ii) a faulted state in which the flow of feedstock to the fuel processor is stopped and in which the control means awaits an input for a duration of time before automatically attempting to transition the system to another operating state of the plurality of operating states.

2. The method of claim 1, in which the fuel processing system further comprises a hydrogen storage device which in use is adapted to store at least a portion of the hydrogen gas produced by the fuel processor, and further in which, in the standby state, little if any hydrogen gas is delivered to the fuel cell stack or the hydrogen storage device.

3. The method of claim 1, wherein upon detection of a malfunction in the running state, the control means automatically transitions the fuel processing system to the faulted state.

4. The method of claim 3, wherein upon detection of a malfunction in the standby state, the control means automatically transitions the fuel processing system to the faulted state.

5. The method of claim 1, wherein, in the running state, upon receipt by the control means of an input directing it to shutdown the fuel processing system, the control means is adapted to direct the fuel processing system to transition to the standby state and then to an off state.

6. The method of claim 1, wherein the selected operating parameters include one or more of the flow rate of fluid in a feed stream to the fuel processor, the temperature of a hydrogen producing region of the fuel processor, and the pressure in the hydrogen producing region.

7. The method of claim 1, wherein the control means automatically transitions the fuel processing system from an off state to the standby state responsive to an input signal.

8. The method of claim 7, wherein the input signal is selected from a group consisting of a user input, a load being applied to the fuel cell stack, and a timed input from the control means.

9. The method of claim 7, wherein, if the standby state is successfully achieved, the control means directs the fuel processing system to attain the running state or to await the input of a signal to transition the fuel processing system to the running state.

10. The method of claim 1, wherein, from the faulted state, the control means either directs a transition of the fuel processing system to an off state if no reset signal is achieved, or attempts to direct a transition of the fuel processing system to the standby state.

11. The method of claim 1, wherein, if an input directing the control means to shut down the fuel processing system is received while the fuel processing system is in the running state, the control means transitions the fuel processing system first to the standby state and then to the off state.

12. The method of claim 1, wherein the control means comprises a computerized controller which is included in an automated control system and the control system further comprises a sensor assembly which in use monitors the selected operating parameters of the fuel processor and the feed assembly and communicates inputs to the controller corresponding to the selected operating parameters, and wherein the controller transitions the fuel processing system between the running state and the plurality of operating states based at least in part on the inputs.

13. The method of claim 12, wherein the controller utilizes a plurality of programmed subroutines to switch the fuel processing system between the plurality of operating states.

14. The method of claim 1, wherein the control means automatically shuts down the fuel processing system if the value of a selected operating parameter exceeds a corresponding threshold value.

15. The method of claim 1, wherein the control means controls the operation of the fuel processing system to maintain the value of the selected operating parameters at determined values or within ranges bounded by threshold values.

16. The method of claim 1, wherein in the standby state, the fuel processor is maintained at an operating temperature and an operating pressure for producing hydrogen gas from the feed stream, but no more of the hydrogen gas is delivered to the fuel cell stack than is required to operate the fuel processing system in the standby state.

17. The method of claim 1, wherein in the standby state, none of the hydrogen gas is delivered to the fuel cell stack.

18. The method of claim 1, wherein in the standby state, at least a substantial portion of the hydrogen gas is delivered to a heating assembly that is adapted to combust the portion of the hydrogen gas to produce heat.

19. The method of claim 1, wherein the fuel processing system includes a user interface in communication with the control means, which interface displays information indicative of the performance of the fuel processing system.

20. The method of claim 1, wherein the fuel processor includes a steam reformer.

21. The method of claim 1, wherein the fuel cell stack includes at least one proton exchange membrane fuel cell.