Power generation system and method

• US 6,230,494 B1
• Filed: 02/01/1999
• Issued: 05/15/2001
• Est. Priority Date: 02/01/1999
• Status: Expired due to Term

• Current Assignee: Aptiv Technologies Limited (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Grieve, Malcolm James, Miller, Carl Elmer, Botti, Jean Joseph
• Primary Examiner(s): Nguyen, Hoang
• Application Number:
  US09/241,171
• Time in Patent Office: 834 Days
• Field of Search: 606/43, 606/45, 606/49, 607/34, 607/37, 60/340.2
• US Class Current: 60/649
• CPC Class Codes: B60L 50/70 using power supplied by fuel cells in combination with batteries B60L50/75
• CPC Class Codes: F01K 25/00 Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for
• CPC Class Codes: F02B 1/12 with compression ignition with fuel-air charge ignited by compression ignition of an additional fuel F02B7/00
• CPC Class Codes: F02C 6/00 Plural gas-turbine plants; Combinations of gas-turbine plants with other apparatus; Adaptations of gas-turbine plants for special use
• CPC Class Codes: H01M 8/04 Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
• CPC Class Codes: H01M 8/06 Combination of fuel cells with means for production of reactants or for treatment of residues regenerative fuel cells H01M8/18
• CPC Class Codes: Y02E 20/14 Combined heat and power generation [CHP]
• CPC Class Codes: Y02E 60/50 Fuel cells
• 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

The power generation system and method of the present invention employ a solid oxide fuel cell which reforms fuel to a degree which is controlled by the amount of fuel introduced to the solid oxide fuel cell. The effluent is directed preferably through a heat exchanger and then into an engine. This hybrid system more efficiently produces energy, both mechanical and electrical, over conventional systems.

Claims

1. A power generation system, comprising:

(a) at least one SOFC capable of reforming fuel, said SOFC having a fuel side and an air side;

(b) a preheating device in fluid communication with said fuel side and said air side of said SOFC;

(c) an air supply in fluid communication with said preheating device such that air can be heated in said preheating device and then introduced to said air side of said SOFC;

(d) a fuel supply in fluid communication with said preheating device such that fuel can be burned, vaporized, atomized, or a combination thereof and then introduced to said fuel side of said SOFC; and

(e) at least one energy conversion device in fluid communication with an SOFC effluent from said fuel side of said SOFC.

2. A power generation system as in claim 1, wherein said energy conversion device is an engine, turbine, or a combination thereof.

3. A power generation system as in claim 1, wherein said energy conversion device is an engine in fluid communication with said SOFC effluent and said air supply, said engine having an engine effluent in fluid communication with a turbine.

4. A power generation system as in claim 3, further comprising a second SOFC having a second fuel side and a second air side and a second SOFC effluent, wherein said second fuel side is in fluid communication with said engine effluent, said second air side in fluid communication with said air supply, and said second SOFC effluent is in fluid communication with said turbine.

5. A power generation system as in claim 4, wherein said engine is further in fluid communication with said fuel supply.

6. A power generation system as in claim 3, wherein said engine is further in fluid communication with said fuel supply.

7. A power generation system as in claim 3, further comprising a catalytic converter having an inlet, wherein said inlet is in fluid communication with said energy conversion device.

8. A power generation system as in claim 1, further comprising at least one heat exchanger in fluid communication with said SOFC effluent and said air supply such that air can pass through said heat exchanger prior to introduction to said air side of said SOFC, and said SOFC effluent can pass through said heat exchanger prior to introduction to said energy conversion device.

9. A power generation system as in claim 1, further comprising at least one compressor in fluid communication with said air supply and said SOFC.

10. A power generation system as in claim 1, wherein said preheating device is a burner, plasmatron, vaporizer, reformer, heat exchanger, or combination thereof.

11. A power generation system as in claim 1, further comprising a catalytic converter in fluid communication with said energy conversion device.

12. A power generation system, comprising:

(a) at least one SOFC capable of reforming fuel, said SOFC having an intake fuel side, an intake air side, an effluent fuel side and an effluent air side;

(b) a preheating device in fluid communication with said intake fuel side and said intake air side of said SOFC;

(c) an air supply in fluid communication with said preheating device such that air can be heated in said preheating device and then introduced to said air side of said SOFC;

(d) a fuel supply in fluid communication with said preheating device such that fuel can be burned, vaporized, atomized, or a combination thereof and then introduced to said fuel side of said SOFC; and

(e) at least one combustor in fluid communication with said effluent fuel side and said effluent air side.

13. A power generation system as in claim 12, wherein said combustor is a catalytic combustor, plasmatron, or a combination thereof.

14. A power generation system as in claim 12, wherein said combustor has a combustor effluent in fluid communication with a turbine.

15. A power generation system as in claim 14, further comprising a catalytic converter in fluid communication with said turbine.

16. A power generation system as in claim 12, further comprising a catalytic converter in fluid communication with said combustor.

17. A power generation system as in claim 12, wherein said combustor has a combustor effluent in fluid communication with a heat exchanger, said heat exchanger in fluid communication with an air supply such that said air supply can be heated in said heat exchanger to form a heated air stream.

18. A power generation system as in claim 12, further comprising at least one compressor in fluid communication with an air supply and said preheating device.

19. A power generation system as in claim 18, further comprising at least one compressor in fluid communication with said heated air stream and said preheating device.

20. A power generation system as in claim 12, wherein said preheating device is a burner, plasmatron, vaporizer, reformer, heat exchanger, or combination thereof.

21. A method for operating a power generation system, comprising the steps of:

(a) compressing an air stream to a first pressure;

(b) introducing fuel and said first compressed air to a preheating device;

(c) burning at least a first portion of said fuel in said preheating device to form a preheater effluent and a heated air stream;

(d) introducing said preheater effluent to a fuel side of a SOFC, said SOFC having an SOFC fuel effluent; and

(e) introducing said heated air stream to an air side of said SOFC, said SOFC having an SOFC air effluent.

22. A method for operating a power generation system as in claim 21, further comprising heating said air stream with said SOFC fuel effluent.

23. A method for operating a power generation system as in claim 22, further comprising heating said air stream with said SOFC air effluent.

24. A method for operating a power generation system as in claim 23, further comprising vaporizing or atomizing a second portion of said fuel;

and directing said SOFC fuel effluent and said SOFC air effluent through a turbine.

25. A method for operating a power generation system as in claim 24, further comprising directing a turbine effluent through a catalytic converter.

26. A method for operating a power generation system as in claim 25, further comprising heating said air stream with catalytic converter effluent.

27. A method for operating a power generation system as in claim 24, further comprising heating said air stream with turbine effluent.

28. A method for operating a power generation system as in claim 24, further comprising compressing a portion of said air stream to a second pressure and introducing said second compressed air to said air side of said SOFC.

29. A method for operating a power generation system as in claim 23, further comprising:

vaporizing or atomizing a second portion of said fuel;

burning said SOFC fuel effluent with said SOFC air effluent in an engine; and

directing engine effluent through a turbine.

30. A method for operating a power generation system as in claim 29, further comprising introducing at least a portion of said fuel to said engine.

31. A method for operating a power generation system as in claim 30, further comprising compressing a portion of said air stream to a second pressure and introducing said second compressed air to said fuel side of said SOFC.

32. A method for operating a power generation system as in claim 31, further comprising compressing a portion of said air stream to a second pressure and introducing a portion of said second compressed air to said air side of said SOFC.

33. A method for operating a power generation system as in claim 30, further comprising compressing a portion of said air stream to a second pressure and introducing said second compressed air to said air side of said SOFC.

34. A method for operating a power generation system as in claim 21, further comprising introducing said SOFC fuel effluent and said SOFC air effluent to a heat exchanger to heat a coolant.

35. A method for operating a power generation system as in claim 34, further comprising heating an environment with said heated coolant, wherein said environment is a passenger compartment, building or engine.

36. A method for operating a power generation system as in claim 21, further comprising introducing said preheater effluent to a heat exchanger to heat a coolant.

37. A method for operating a power generation system as in claim 36, further comprising heating an environment with said heated coolant, wherein said environment is a passenger compartment, building or engine.

38. A method for operating a power generation system as in claim 21, further comprising introducing an oxygen stream to said air side of said SOFC.

39. A method for operating a power generation system, comprising the steps of:

(a) compressing a heated air stream to a first pressure;

(b) vaporizing or atomizing a first portion of fuel in a preheating device to produce a preheater effluent;

(c) introducing preheater effluent to a fuel side of a an SOFC, said SOFC having an SOFC fuel effluent;

(d) introducing said first compressed air to an air side of said SOFC, said SOFC having an SOFC air effluent;

(e) heating said heated air with said SOFC fuel effluent;

(f) introducing said SOFC fuel effluent, said SOFC air effluent, and a second portion of fuel to an engine to produce an engine effluent; and

(g) introducing said engine effluent to a turbine.

40. A method for operating a power generation system as in claim 39, further comprising compressing air;

and introducing said compressed air to said engine.

41. A method for operating a power generation system as in claim 40, further comprising heating said heated air with said SOFC air effluent.

42. A method for operating a power generation system as in claim 40, further comprising recycling at least a portion of said engine effluent through said engine.

43. A method for operating a power generation system as in claim 42, further comprising introducing turbine effluent to a catalytic converter.

44. A method for operating a power generation system as in claim 43, further comprising heating said heated air with catalytic converter effluent.

45. A method for operating a power generation system as in claim 40, further comprising introducing turbine effluent to a catalytic converter.

46. A method for operating a power generation system as in claim 40, further comprising burning at least a portion of said first portion of fuel.

47. A method for operating a power generation system as in claim 39, further comprising burning at least a portion of said first portion of fuel.

48. A method for operating a power generation system as in claim 39, further comprising heating said first compressed air in said preheating device.

49. A method for operating a power generation system as in claim 39, further comprising introducing said SOFC fuel effluent and said SOFC air effluent to a heat exchanger to heat a coolant.

50. A method for operating a power generation system as in claim 49, further comprising heating an environment with said heated coolant, wherein said environment is a passenger compartment, building or engine.

51. A method for operating a power generation system as in claim 39, further comprising introducing said preheater effluent to a heat exchanger to heat a coolant.

52. A method for operating a power generation system as in claim 51, further comprising heating an environment with said heated coolant, wherein said environment is a passenger compartment, building or engine.

53. A method for operating a power generation system as in claim 39, further comprising introducing an oxygen stream to said air side of said SOFC.

54. A method for regenerating a catalytic converter, comprising the steps of:

(a) compressing a heated air stream;

(b) vaporizing or atomizing fuel;

(c) introducing said fuel to a fuel side of an SOFC;

(d) applying a reverse potential to said SOFC such that the potential on the fuel side of said SOFC is negative;

(e) forming oxygen ions on said fuel side of said SOFC;

(f) migrating said oxygen ions from said fuel side to said air side of said SOFC to form an oxygen stream; and

(g) regenerating said catalytic converter by introducing said oxygen stream to said catalytic converter.

55. A method for regenerating a catalytic converter as in claim 54, further comprising compressing said oxygen stream prior to regenerating said catalytic converter.

56. A method for operating a power generation system, comprising the steps of:

(a) compressing a heated air stream;

(b) combining said compressed heated air stream with fuel to form a combined stream;

(c) introducing said combined stream to a fuel side of an SOFC;

(d) applying a reverse potential to said SOFC such that the potential on said fuel side of said SOFC is negative;

(e) forming oxygen ions on said fuel side of said SOFC;

(f) migrating said oxygen ions from said fuel side to said air side of said SOFC to form an oxygen stream; and

(g) heating said heated air stream with said oxygen stream and a SOFC fuel effluent stream from said fuel side of said SOFC;

(h) introducing a second portion of fuel, a second compressed air stream, and said oxygen stream to an engine to form an engine effluent; and

(i) introducing the engine effluent and the SOFC fuel effluent to a turbine to form a turbine effluent.

57. A method for operating a power generation system as in claim 56, further comprising directing the turbine effluent through a catalytic converter.

58. A method for operating a power generation system as in claim 56, further comprising heating said heated air stream with said SOFC fuel effluent and said oxygen stream.

59. A method for operating a power generation system, comprising the steps of:

(a) compressing a heated air stream to a first pressure;

(b) vaporizing or atomizing a first portion of fuel in a preheating device to produce a preheater effluent;

(c) introducing preheater effluent to a fuel side of a an SOFC, said SOFC having an SOFC fuel effluent;

(d) introducing said first compressed air to an air side of said SOFC, said SOFC having an SOFC air effluent;

(e) introducing said SOFC fuel effluent and said SOFC air effluent to a combustor to form a combustor effluent; and

(f) introducing said combustor effluent to a turbine.

60. A method for operating a power generation system as in claim 59, further comprising introducing turbine effluent to a catalytic converter.

61. A method for operating a power generation system as in claim 60, further comprising heating said heated air stream with catalytic converter effluent.

62. A power generation system comprising:

(a) at least one SOFC capable of reforming fuel, said SOFC having a fuel side and an air side;

(b) a preheating device in fluid communication with said fuel side and said air side of said SOFC;

(c) an air supply in fluid communication with said preheating device such that air can be heated in said preheating device and introduced to said air side of said SOFC;

(d) a fuel supply in fluid communication with said preheating device such that fuel can be burned, vaporized, atomized, or a combination thereof and introduced to said fuel side of said SOFC;

wherein

electricity produced by said SOFC is used to operate a powertrain, operate vehicle accessories, or a combination thereof.

63. A power generation system as in claim 62, wherein electricity produced by said SOFC supplies all of a vehicle'"'"'s tractive power.

64. A method for operating a power generation system comprising:

(a) introducing fuel and air to a preheating device;

(b) burning at least a first portion of said fuel in said preheating device to form a preheater effluent and a heated air stream;

(c) introducing said preheater effluent to a fuel side of a SOFC;

(d) introducing said heated air stream to an air side of said SOFC; and

(e) using electricity produced by said SOFC to operate a powertrain, operate vehicle accessories, or a combination thereof.

65. A method for operating a power generation system as in claim 64, comprising:

using electricity produced by said SOFC to supply all of a vehicle'"'"'s tractive power.