Hybrid solid oxide fuel cell aircraft auxiliary power unit

• US 6,834,831 B2
• Filed: 12/31/2002
• Issued: 12/28/2004
• Est. Priority Date: 12/31/2002
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Daggett, David
• Primary Examiner(s): BAREFOOT, GALEN L
• Application Number:
  US10/334,480
• Publication Number:
  US 20040124308A1
• Time in Patent Office: 728 Days
• Field of Search: 244/53.R, 244/58, 244/59, 244/60, 244/61, 244/118.5, 60/390.7, 429/16, 429/19, 429/20, 429/26, 429/30, 429/31, 204/241, 204/269
• US Class Current: 244/58
• CPC Class Codes: B64D 2041/005 Fuel cells
• CPC Class Codes: B64D 41/00 Power installations for auxiliary purposes
• CPC Class Codes: F02C 6/10 supplying working fluid to a user, e.g. a chemical process, which returns working fluid to a turbine of the plant
• CPC Class Codes: H01M 2250/405 Cogeneration of heat or hot water
• CPC Class Codes: H01M 2250/407 Combination of fuel cells with mechanical energy generators
• CPC Class Codes: H01M 8/04089 of gaseous reactants
• CPC Class Codes: Y02B 90/10 Applications of fuel cells in buildings
• CPC Class Codes: Y02E 20/16 Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02T 90/40 Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

An apparatus and method for improving the efficiency and energy output of a power unit are disclosed. The power unit employs a fuel cell configured to chemically convert combustible fuel into electrical energy. A waste fuel burner is configured to receive uncombusted fuel emitted by the fuel cell, and the waste burner combusts the uncombusted fuel to generate heated gas. A turbine is configured to receive and be driven by the heated gas. The turbine is further configured to drive a drive shaft which is coupled to a compressor. The compressor is configured to compress a pressurized source of oxidizing gas for supplying compressed oxidizing gas to the fuel cell such that efficiency of the fuel cell is improved. A generator also may be coupled to the drive shaft, and the generator is configured to generate electrical power from the drive shaft being turned by the turbine.

Claims

1. A power unit comprising:

a fuel cell configured to convert combustible fuel into electrical energy;

a waste fuel burner configured to receive uncombusted fuel emitted by the fuel cell and combusting the uncombusted fuel to generate heated gas;

a turbine configured to receive the heated gas and be driven by the heated gas, the turbine being further configured to drive a drive shaft;

a compressor coupled to the drive shaft, the compressor being configured to further compress a pressurized source of oxidizing gas for supplying compressed oxidizing gas to the fuel cell; and

a generator coupled to the drive shaft, the generator being configured such that the driving of the drive shaft by the turbine generates electrical energy, wherein the pressurized source of oxidizing gas is enriched with water vapor and includes cabin air from a pressurized aircraft.

2. The apparatus of claim 1, wherein the fuel cell includes a solid oxide fuel cell and the combustible fuel includes jet fuel.

3. The apparatus of claim 1, further comprising a reformer configured to receive waste heat emitted by the fuel cell and the combustible fuel, the reformer being further configured to assist in converting the combustible fuel into reactants used by the fuel cell.

4. The apparatus of claim 3, wherein the reformer is one of a steam reformer, a catalytic partial oxidation reformer, or an autothermal reformer.

5. The apparatus of claim 3, further comprising a water source configured to supply water to the reformer, the reformer using water from the water source to convert the combustible fuel into the reactants.

6. The apparatus of claim 3, wherein the water source includes a water separator coupled to receive exhaust gas from the turbine, the water separator being configured to extract water from the exhaust gas received from the turbine.

7. The apparatus of claim 6, wherein water produced by the water separator is used by other than the reformer.

8. The apparatus of claim 3, wherein the reactants converted from the combustible fuel by the reformer include hydrogen and carbon monoxide.

9. The apparatus of claim 1, further comprising at least one heat exchanger configured to receive waste heat generated by the fuel cell and return that waste heat to the fuel cell to enhance chemical reactions taking place therein and reduce thermal gradients taking place across a fuel cell stack.

10. The apparatus of claim 1, wherein the generator further comprises a starter coupled with the drive shaft, the starter being configured such that the starter drives the compressor when the turbine is not driving the drive shaft.

11. An aircraft auxiliary power unit comprising:

a fuel cell configured to convert jet fuel into electrical energy;

a waste fuel burner configured to receive uncombusted fuel emitted by the fuel cell and combusting the uncombusted fuel to generate heated gas;

a turbine configured to receive the heated gas and be driven by the heated gas, the turbine being further configured to drive a drive shaft;

a compressor coupled to the drive shaft being configured to further compress pressurized aircraft cabin air received at a compressor input for supplying compressed pressurized aircraft cabin air to the fuel cell; and

a generator coupled to the drive shaft, the generator being configured such that the driving of the drive shaft by the turbine generates electrical energy.

12. The apparatus of claim 11, wherein the fuel cell includes a solid oxide fuel cell.

13. The apparatus of claim 11, further comprising a reformer configured to receive waste heat emitted by the fuel cell, the reformer being further configured to assist in converting the jet fuel into reactants used by the fuel cell.

14. The apparatus of claim 13, wherein the reformer is one of a steam reformer, a catalytic partial oxidation reformer, or an autothermal reformer.

15. The apparatus of claim 13, further comprising a water source configured to supply water to the reformer, the reformer using water from the water source to convert the jet fuel into the reactants.

16. The apparatus of claim 13, wherein the water source includes a water separator coupled to receive exhaust gas from the turbine, the water separator being configured to extract water from the exhaust gas received from the turbine.

17. The apparatus of claim 16, wherein water produced by the water separator is used by other than the reformer.

18. The apparatus of claim 13, wherein the reactants converted from the jet fuel by the reformer include hydrogen and carbon monoxide.

19. The apparatus of claim 11, further comprising at least one heat exchanger configured to receive waste heat generated by the fuel cell and return that waste heat to the fuel cell to enhance chemical reactions taking place therein and reduce thermal gradients taking place across a fuel cell stack.

20. The apparatus of claim 11, wherein the generator further comprises a starter coupled with the drive shaft, the starter being configured such that the starter drives the compressor when the turbine is not driving the drive shaft.

21. A method for supplying electrical power, the method comprising:

chemically converting combustible fuel into electrical energy;

combusting uncombusted fuel emitted by the chemical conversion of combustible fuel to generate heated gas;

using the heated gas to mechanically further compress a pressurized source of input oxidizing gas;

using the compressed oxidizing gas to chemically convert the combustible fuel into electrical energy; and

using the heated gas to mechanically drive a generator to produce electrical energy, wherein the source of pressurized input oxidizing gas includes cabin air from a pressurized aircraft.

22. The method of claim 21, wherein a fuel cell chemically converts the combustible fuel.

23. The method of claim 22, wherein the fuel cell includes a solid oxide fuel cell and the combustible fuel is jet fuel.

24. The method of claim 21, further comprising reforming waste heat emitted by chemically converting of the combustible fuel into reactants used in the chemically converting of the combustible fuel.

25. The method of claim 24, wherein the reforming is performed by one of a steam reformer, a catalytic partial oxidation reformer, or an autothermal reformer.

26. The method of claim 21, further comprising supplying water for use in the reforming of the waste heat.

27. The method of claim 21, wherein the supplying of water results from extracting water from the exhaust gas after the exhaust gas has been used to mechanically further compress the pressurized source of input oxidizing gas.

28. The method of claim 24, wherein the reforming results in reactants including hydrogen and carbon monoxide.

29. The method of claim 21, wherein the source of pressurized input oxidizing gas is enriched with water vapor.

30. The method of claim 21, further comprising using at least one heat exchanger to return waste heat generated by the fuel cell and to the fuel cell to enhance chemical reactions taking place therein and reduce thermal gradients taking place across a fuel cell stack.

31. The method of claim 21, further comprising using a starter motor to mechanically further compress the pressurized source of input oxidizing gas when there is no heated gas to mechanically further compress the pressurized source of input oxidizing gas.