Power generation system and method

• US 6,609,582 B1
• Filed: 04/19/1999
• Issued: 08/26/2003
• Est. Priority Date: 04/19/1999
• Status: Expired due to Fees

• Current Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Botti, Jean Joseph, Grieve, Malcolm James, Miller, Carl Elmer
• Primary Examiner(s): Rice, Kenneth R.
• Assistant Examiner(s): McClellan, James S.
• Application Number:
  US09/294,679
• Time in Patent Office: 1,590 Days
• Field of Search: 180/65.1, 180/65.2, 180/65.3, 180/65.4, 180/309, 429/13, 429/22, 605/95, 605/96, 606/052, 602/76, 290/4.R, 290/4.C
• US Class Current: 180/65.245
• CPC Class Codes: B60K 6/24 characterised by the combustion engines
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/32 characterised by the fuel cells
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60W 2710/06 Combustion engines, Gas turbines
• 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: H01M 2008/1293 Fuel cells with solid oxide electrolytes
• CPC Class Codes: H01M 2250/20 Fuel cells in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 2300/0074 Ion conductive at high temperature
• CPC Class Codes: H01M 8/04022 Heating by combustion
• CPC Class Codes: H01M 8/04089 of gaseous reactants
• CPC Class Codes: H01M 8/0612 from carbon-containing material
• CPC Class Codes: H01M 8/1231 with both reactants being gaseous or vaporised
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 90/40 Application of hydrogen technology to transportation, e.g. using fuel cells
• CPC Class Codes: Y10S 123/12 Hydrogen
• CPC Class Codes: Y10S 903/905 Combustion engine
• CPC Class Codes: Y10S 903/906 Motor or generator
• CPC Class Codes: Y10S 903/908 : Fuel cell
• CPC Class Codes: Y10S 903/944 : Characterized by control of fuel cell

Abstract

A power generation system providing an engine configured to produce hydrogen rich reformate to feed a solid oxide fuel cell includes an engine having an intake and an exhaust; an air supply in fluid communication with the engine intake; a fuel supply in fluid communication with the engine intake; at least one SOFC having an air intake in fluid communication with an air supply, a fuel intake in fluid communication with the of, engine exhaust, a SOFC effluent and an air effluent. Engines include a free piston gas generator with rich homogenous charge compression, a rich internal combustion engine cylinder system with an oxygen generator, and a rich inlet turbo-generator system with exhaust heat recover. Oxygen enrichment devices to enhance production of hydrogen rich engine exhaust include pressure swing absorption with oxygen selective materials, and oxygen separators such as an SOFC oxygen separator and a ceramic membrane oxygen separator.

Claims

1. A power generation system comprising:

(a) an engine having an intake and an exhaust, wherein said engine is configured to produce a hydrogen rich engine exhaust;

(b) an air supply in fluid communication with said engine intake;

(c) a fuel supply in fluid communication with said engine intake;

(d) at least one SOFC having an air intake in fluid communication with an air supply, a fuel intake in fluid communication with said hyrdrogen rich engine exhaust, a SOFC effluent and an air effluent.

2. The power generation system as in claim 1, wherein said engine is configured to produce a hydrogen rich exhaust having a combined concentration of hydrogen and carbon monoxide greater than about 30% by volume.

3. The power generation system as in claim 1, wherein said system is configured to produce a hydrogen rich exhaust having a combined concentration of hydrogen and carbon monoxide greater than about 50% by volume.

4. The power generation system as in claim 1, further comprising:

at least one water shift device having an intake in fluid communication with said hydrogen rich engine exhaust and an effluent in fluid communication with said SOFC fuel intake.

5. The power generation system as in claim 1, wherein said engine comprises a free piston gas generator.

6. The power generation system as in claim 5, further comprising a rich homogenous charge compression ignition.

7. The power generation system as in claim 1, wherein said engine further comprises an oxygen separator, a rich internal combustion engine cylinder system in at least part of said engine, a rich homogenous charge compression ignition, an optional dilute cylinder system in part of said engine, and combinations thereof.

8. The power generation system as in claim 1, wherein said engine comprises a turbo-generator system.

9. The power generation system as in claim 8, wherein said turbo-generator system is selected from the group consisting of a turbo-generator system having a two stage combustor and a turbo-generator system having a single stage combustor.

10. The power generation system as in claim 1, further comprising:

an oxygen separator having an oxygen stream effluent in fluid communication with said engine intake.

11. The power generation system as in claim 10, wherein said system is configured to produce a hydrogen rich exhaust having a combined concentration of hydrogen and carbon monoxide greater than about 70% by volume.

12. The power generation system as in claim 10, wherein said oxygen separator is selected from the group consisting of pressure swing absorption oxygen separators, SOFC oxygen separators, ceramic membrane oxygen separators, and combinations thereof.

13. The power generation system as in claim 7, further comprising:

an oxygen separator having an oxygen stream effluent in fluid communication with said engine intake.

14. The power generation system as in claim 13, wherein said oxygen separator is selected from the group consisting of pressure swing absorption oxygen separators, SOFC oxygen separators, ceramic membrane oxygen separators, and combinations thereof.

15. The power generation system as in claim 1, further comprising a turbine in fluid communication with said SOFC effluent.

16. The power generation system as in claim 15, wherein said turbine is further in fluid communication with said air effluent.

17. The power generation system as in claim 1, wherein said SOFC fuel intake is further in fluid communication with said fuel supply.

18. The power generation system as in claim 17, wherein said SOFC fuel intake is further in fluid communication with said air supply.

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

20. The power generation system as in claim 1, further comprising a fast start-up reformer having an intake in fluid communication with a fuel supply and an effluent in fluid communication with said SOFC fuel intake.

21. The power generation system as in claim 20, wherein said fast start-up reformer is selected from the group consisting of a burner, heat exchanger, plasmatron, vaporizer, fuel reformer, catalytic reformer, rich burner and combinations thereof.

22. The power generation system as in claim 1, further comprising a catalytic converter having an inlet, wherein said inlet is in fluid communication with said SOFC effluent.

23. The power generation system as in claim 1, further comprising at least one heat exchanger having an intake in fluid communication with said engine exhaust and an air effluent in fluid communication with said SOFC air intake.

24. The power generation system as in claim 1, further comprising:

said SOFC fuel intake further in fluid communication with an alternate fuel supply, said hydrogen rich engine exhaust, or a combination thereof;

wherein

electricity produced by said SOFC operates a base load of electrical accessories, provides traction power, recharges electrical sources, or a combination thereof, while said engine provides limited traction power.

25. The power generation system as in claim 1, further comprising:

said SOFC fuel intake further in fluid communication with an alternate fuel supply, said hydrogen rich engine exhaust, or a combination thereof;

wherein

electricity produced by said SOFC supplies all of a vehicle'"'"'s traction power, operates electrical accessories, or a combination thereof.

26. The power generation system as in claim 1, further comprising:

said SOFC fuel intake further in fluid communication with an alternate fuel supply, said hydrogen rich engine exhaust, or a combination thereof;

said engine operating at less than full capacity or shut down; and

wherein;

a high power mode for providing high traction power, high accessory power, or a combination thereof, is provided using electricity produced by said SOFC in combination with a fast start-up reformer, using electricity produced by said SOFC in combination with turning on said engine for short cycles of operation, using electricity produced by said SOFC in combination with a battery, or a combination thereof.

27. A power generation system comprising:

(a) a rich homogenous charge compression ignition free piston engine having an intake and an exhaust, wherein said engine is configured to produce a hydrogen rich engine exhaust;

(b) an air supply in fluid communication with said engine intake;

(c) a fuel supply in fluid communication with said engine intake;

(d) at least one SOFC having an air intake in fluid communication with an air supply, a fuel intake in fluid communication with said hydrogen rich engine exhaust, a SOFC effluent and an air effluent.

28. The power generation system as in claim 27, further comprising:

an oxygen enrichment device having an oxygen stream effluent in fluid communication with said engine intake for providing oxygen enriched air to said engine.

29. The power generation system as in claim 27, further comprising:

an oxygen enrichment device having an oxygen stream effluent in fluid communication with said engine intake for providing oxygen enriched air to said engine;

wherein said oxygen enrichment device is an oxygen separator, a pressure swing absorption oxygen separator, a SOFC oxygen separator, a ceramic membrane oxygen separator, or a combination thereof.

30. The power generation system as in claim 27, further comprising:

at least one water shift device having an intake in fluid communication with said hydrogen rich engine exhaust and an effluent in fluid communication with said SOFC fuel intake.

31. The power generation system as in claim 27 wherein said SOFC fuel intake is further in fluid communication with said fuel supply.

32. The power generation system as in claim 27, wherein said SOFC fuel intake is further in fluid communication with said air supply.

33. The power generation system as in claim 27, further comprising at least one compressor in fluid communication with said air supply and said SOFC.

34. The power generation system as in claim 27, further comprising a fast start-up reformer having an intake in fluid communication with a fuel supply and an effluent in fluid communication with said SOFC fuel intake.

35. The power generation system as in claim 34, wherein said fast start-up reformer is selected from the group consisting of a burner, heat exchanger, plasmatron, vaporizer, fuel reformer, catalytic reformer, rich burner, and combinations thereof.

36. The power generation system as in claim 27, further comprising a catalytic converter having an inlet, wherein said inlet is in fluid communication with said SOFC effluent.

37. The power generation system as in claim 27, further comprising at least one heat exchanger having an intake in fluid communication with said engine exhaust and an air effluent in fluid communication with said SOFC air intake.

38. A power generation system comprising:

(a) a rich internal combustion engine having an intake and an exhaust, wherein said engine is configured to produce a hydrogen rich engine exhaust;

(b) an air supply in fluid communication with said engine intake;

(c) a fuel supply in fluid communication with said engine intake;

(d) at least one SOFC having an air intake in fluid communication with an air supply, a fuel intake in fluid communication with said hydrogen rich engine exhaust, a SOFC effluent and an air effluent.

39. The power generation system as in claim 38, further comprising:

a homogenous charge compression ignition.

40. The power generation system as in claim 38, further comprising:

an oxygen enrichment device having an oxygen stream effluent in fluid communication with said engine intake for providing oxygen enriched air to said engine.

41. The power generation system as in claim 38, further comprising:

an oxygen enrichment device having an oxygen stream effluent in fluid communication with said engine intake for providing oxygen enriched air to said engine;

wherein said oxygen enrichment device is an oxygen separator, a pressure swing absorption oxygen separator, a SOFC oxygen separator, a ceramic membrane oxygen separator, or a combination thereof.

42. The power generation system as in claim 38, further comprising:

at least one water shift device having an intake in fluid communication with said hydrogen rich engine exhaust and an effluent in fluid communication with said SOFC fuel intake.

43. The power generation system as in claim 38, wherein said engine comprises a dilute cylinder system in part of said engine.

44. The power generation system as in claim 38, wherein said SOFC fuel intake is further in fluid communication with said fuel supply.

45. The power generation system as in claim 38, wherein said SOFC fuel intake is further in fluid communication with said air supply.

46. The power generation system as in claim 38, further comprising at least one compressor in fluid communication with said air supply and said SOFC.

47. The power generation system as in claim 38, further comprising a fast start-up reformer having an intake in fluid communication with a fuel supply and an effluent in fluid communication with said SOFC fuel intake.

48. The power generation system as in claim 47, wherein said fast start-up reformer is selected from the group consisting of a burner, heat exchanger, plasmatron, vaporizer, fuel reformer, catalytic reformer, rich burner, and combinations thereof.

49. The power generation system as in claim 38, further comprising a catalytic converter having an inlet, wherein said inlet is in fluid communication with said SOFC effluent.

50. The power generation system as in claim 38, further comprising at least one heat exchanger having an intake in fluid communication with said engine exhaust and an air effluent in fluid communication with said SOFC air intake.

51. A power generation system comprising:

(a) a spark ignition internal combustion engine having an intake and an exhaust, and an oxygen enrichment device having an oxygen stream effluent in fluid communication with said engine intake for providing oxygen enriched air to said engine, wherein said engine is configured to produce a hydrogen rich engine exhaust;

(b) an air supply in fluid communication with said engine intake;

(c) a fuel supply in fluid communication with said engine intake;

(d) at least one SOFC having an air intake in fluid communication with an air supply, a fuel intake in fluid communication with said hydrogen rich engine exhaust, a SOFC effluent and an air effluent.

52. The power generation system as in claim 51, wherein said oxygen enrichment device is an oxygen separator, a pressure swing absorption oxygen separator, a SOFC oxygen separator, a ceramic membrane oxygen separator, or a combination thereof.

53. The power generation system as in claim 51, further comprising:

at least one water shift device having an intake in fluid communication with said hydrogen rich engine exhaust and an effluent in fluid communication with said SOFC fuel intake.

54. The power generation system as in claim 51, wherein said SOFC fuel intake is further in fluid communication with said fuel supply.

55. The power generation system as in claim 51, wherein said SOFC fuel intake is further in fluid communication with said air supply.

56. The power generation system as in claim 51, further comprising at least one compressor in fluid communication with said air supply and said SOFC.

57. The power generation system as in claim 51, further comprising a fast start-up reformer having an intake in fluid communication with a fuel supply and an effluent in fluid communication with said SOFC fuel intake.

58. The power generation system as in claim 51, wherein said fast start-up reformer is selected from the group consisting of a burner, heat exchanger, plasmatron, vaporizer, fuel reformer, catalytic reformer, rich burner, and combinations thereof.

59. The power generation system as in claim 51, further comprising a catalytic converter having an inlet, wherein said inlet is in fluid communication with said SOFC effluent.

60. The power generation system as in claim 51, further comprising at least one heat exchanger having an intake in fluid communication with said engine exhaust and an air effluent in fluid communication with said SOFC air intake.

61. A power generation system comprising:

(a) a compression ignition internal combustion engine having an intake and an exhaust, and an oxygen enrichment device having an oxygen stream effluent in fluid communication with said engine intake for providing oxygen enriched air to said engine, wherein said engine is configured to produce a hydrogen rich engine exhaust;

(b) an air supply in fluid communication with said engine intake;

(c) a fuel supply in fluid communication with said engine intake;

(d) at least one SOFC having an air intake in fluid communication with an air supply, a fuel intake in fluid communication with said hydrogen rich engine exhaust, a SOFC effluent and an air effluent.

62. The power generation system as in claim 61, wherein said oxygen enrichment device is an oxygen separator, a pressure swing absorption oxygen separator, a SOFC oxygen separator, a ceramic membrane oxygen separator, or a combination thereof.

63. The power generation system as in claim 61, further comprising:

at least one water shift device having an intake in fluid communication with said hydrogen rich engine exhaust and an effluent in fluid communication with said SOFC fuel intake.

64. The power generation system as in claim 61, wherein said SOFC fuel intake is further in fluid communication with said fuel supply.

65. The power generation system as in claim 61, wherein said SOFC fuel intake is further in fluid communication with said air supply.

66. The power generation system as in claim 61, further comprising at least one compressor in fluid communication with said air supply and said SOFC.

67. The power generation system as in claim 61, further comprising a fast start-up reformer having an intake in fluid communication with a fuel supply and an effluent in fluid communication with said SOFC fuel intake.

68. The power generation system as in claim 61, wherein said fast start-up reformer is selected from the group consisting of a burner, heat exchanger, plasmatron, vaporizer, fuel reformer, catalytic reformer, rich burner, and combinations thereof.

69. The power generation system as in claim 61, further comprising a catalytic converter having an inlet, wherein said inlet is in fluid communication with said SOFC effluent.

70. The power generation system as in claim 61, further comprising at least one heat exchanger having an intake in fluid communication with said engine exhaust and an air effluent in fluid communication with said SOFC air intake.

71. A power generation system comprising:

(a) a rich combustor turbo-generator system having an intake and an exhaust, wherein said rich combustor turbo-generator system is configured to produce a hydrogen rich engine exhaust;

(b) an air supply in fluid communication with said engine intake;

(c) a fuel supply in fluid communication with said engine intake;

(d) at least one SOFC having an air intake in fluid communication with an air supply, a fuel intake in fluid communication with said hydrogen rich engine exhaust, a SOFC effluent and an air effluent.

72. The power generation system of claim 71, wherein said rich combustor turbo-generator system is selected from the group consisting of a turbo-generator system having a two stage combustor and a turbo-generator system having a single stage combustor.

73. The power generation system as in claim 71, further comprising:

an oxygen enrichment device having an oxygen stream effluent in fluid communication with said engine intake for providing oxygen enriched air to said engine.

74. The power generation system of claim 73, wherein said oxygen enrichment device is an oxygen separator, a pressure swing absorption oxygen separator, a SOFC oxygen separator, a ceramic membrane oxygen separator, or a combination thereof.

75. The power generation system as in claim 71, further comprising:

at least one water shift device having an intake in fluid communication with said hydrogen rich engine exhaust and an effluent in fluid communication with said SOFC fuel intake.

76. The power generation system as in claim 71, wherein said SOFC fuel intake is further in fluid communication with said fuel supply.

77. The power generation system as in claim 71, wherein said SOFC fuel intake is further in fluid communication with said air supply.

78. The power generation system as in claim 71, further comprising at least one compressor in fluid communication with said air supply and said SOFC.

79. The power generation system as in claim 71, further comprising a fast start-up reformer having an intake in fluid communication with a fuel supply and an effluent in fluid communication with said SOFC fuel intake.

80. The power generation system as in claim 71, wherein said fast start-up reformer is selected from the group consisting of a burner, heat exchanger, plasmatron, vaporizer, fuel reformer, catalytic reformer, rich burner, and combinations thereof.

81. The power generation system as in claim 71, further comprising a catalytic converter having an inlet, wherein said inlet is in fluid communication with said SOFC effluent.

82. The power generation system as in claim 71, further comprising at least one heat exchanger having an intake in fluid communication with said engine exhaust and an air effluent in fluid communication with said SOFC air intake.

83. A power generation system comprising:

(a) a engine having an intake and an exhaust, wherein said engine is configured to run in an extended rich mode to produce a substantially continuous hydrogen rich engine exhaust;

(b) an air supply in fluid communication with said engine intake;

(c) a fuel supply in fluid communication with said engine intake;

(d) at least one energy conversion device having an air intake in fluid communication with an air supply, a fuel intake in fluid communication with said hydrogen rich engine exhaust, a fuel effluent and an air effluent.

84. The power generation system as in claim 83, further comprising:

an oxygen enrichment device having an oxygen stream effluent in fluid communication with said engine intake for providing oxygen enriched air to said engine.

85. The power generation system as in claim 83, further comprising:

an oxygen enrichment device having an oxygen stream effluent in fluid communication with said engine intake for providing oxygen enriched air to said engine;

wherein said oxygen enrichment device is an oxygen separator, a pressure swing absorption oxygen separator, a SOFC oxygen separator, a ceramic membrane oxygen separator, or a combination thereof.

86. The power generation system as in claim 83, further comprising:

at least one water shift device having an intake in fluid communication with said hydrogen rich engine exhaust and an effluent in fluid communication with said energy conversion device fuel intake.

87. The power generation system as in claim 83, wherein said energy conversion device fuel intake is further in fluid communication with said fuel supply.

88. The power generation system as in claim 83, wherein said energy conversion device fuel intake is further in fluid communication with said air supply.

89. The power generation system as in claim 83, further comprising at least one compressor in fluid communication with said air supply and said energy conversion device.

90. The power generation system as in claim 83, further comprising a fast start-up reformer having an intake in fluid communication with a fuel supply and an effluent in fluid communication with said energy conversion device fuel intake.

91. The power generation system as in claim 90, wherein said fast start-up reformer is selected from the group consisting of a burner, heat exchanger, plasmatron, vaporizer, fuel reformer, catalytic reformer, rich burner, and combinations thereof.

92. The power generation system as in claim 83, further comprising a catalytic converter having an inlet, wherein said inlet is in fluid communication with said energy conversion device fuel effluent.

93. The power generation system as in claim 83, further comprising at least one heat exchanger having an intake in fluid communication with said engine exhaust and an air effluent in fluid communication with said energy conversion device air intake.

94. The power generation system as in claim 83, wherein said engine is a rich homogenous charge compression ignition engine, a rich internal combustion engine, a spark ignition internal combustion engine having an oxygen enrichment device, a compression ignition internal combustion engine having an oxygen enrichment device, or a rich combustor turbogenerator system having an optional oxygen enrichment device and a combustor selected from a two stage combustor or single stage combustor.

95. The power generation system as in claim 83, wherein said energy conversion device is a fuel cell, a SOFC, a gas turbine, a spark ignited engine, a compression ignited engine, or a combination thereof.