Fuel cell power system having a plurality of rack fuel cell power modules

• US 7,166,985 B1
• Filed: 07/21/2005
• Issued: 01/23/2007
• Est. Priority Date: 03/05/2002
• Status: Expired due to Fees

• Current Assignee: Intelligent Energy Limited (Lb-shell Plc)
• Original Assignee: Jadoo Power Systems, Inc.
• Inventors: Arikara, Muralidharan P., Bawden, Jr., Lawrence R., Berger, William Jackson, Van Fleet, Barbara H.
• Primary Examiner(s): Tso, Edward H.
• Application Number:
  US11/186,327
• Time in Patent Office: 551 Days
• Field of Search: 320/101, 320/116, 429/12, 429/19, 429/22, 361/600, 361/611, 361/613, 361/730
• US Class Current: 320/101
• CPC Class Codes: H01M 2250/10 Fuel cells in stationary systems, e.g. emergency power source in plant
• CPC Class Codes: H01M 8/04089 of gaseous reactants
• CPC Class Codes: H01M 8/04679 of fuel cell stacks
• CPC Class Codes: H01M 8/0488 of fuel cell stacks
• CPC Class Codes: Y02B 90/10 Applications of fuel cells in buildings
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

A fuel cell power module is provided. The module comprises (a) power production unit, (b) a power conditioning and protection unit, and (c) a control unit, each unit being modules and integrated into a module for independent removal. Multiple modules are networked so that each module is connected to a master controller so that if one module is removed from operation, the other is able to continue operation.

Claims

1. A fuel cell power system comprising:

a plurality of fuel cell power modules, coupled to one or more power busses, to provide electrical power on the one or more power busses, wherein each fuel cell power module includes;

a fuel cell stack;

a voltage conditioning device, coupled to the fuel cell stack, to output power on the one or more power busses; and

a control unit;

one or more hydrogen storage sources, coupled to each fuel cell power module of the plurality of fuel cell power modules; and

a master controller, electrically coupled to the control unit of each fuel cell power module, to control or manage operation of the plurality of fuel cell power modules.

2. The fuel cell power system of claim 1 wherein the voltage conditioning device of each fuel cell power module is a DC—

DC converter or a DC-AC inverter.

3. The fuel cell power system of claim 1 further including a back plane, wherein the back plane includes connections to communicate with at least one of the plurality of fuel cell power modules.

4. The fuel cell power system of claim 3 wherein the back plane includes one or more of a fluid, data and power interfaces that connect to an associated fluid, data and power interface of at least one of the plurality of fuel cell power modules.

5. The fuel cell power system of claim 3 wherein the back plane is a module.

6. The fuel cell power system of claim 3 wherein the back plane includes two or more of a fluid, data and power interfaces that connect to an associated fluid, data and power interface of at least one of the plurality of fuel cell power modules.

7. The fuel cell power system of claim 1 wherein each fuel cell power module is a rack fuel cell power module.

8. The fuel cell power system of claim 1 wherein the master controller, in response to a failure, removal or cessation of operation of one or more of the fuel cell power modules, adjusts the operation of the fuel cell power system.

9. The fuel cell power system of claim 1 wherein the fuel cell stack, the voltage conditioning device, and the control unit of each fuel cell power module are independently removable during operation of the fuel cell power system.

10. The fuel cell power system of claim 1 wherein the one or more hydrogen storage sources include a local hydrogen storage source coupled to the fuel cell stack of an associated fuel cell power module.

11. The fuel cell power system of claim 1 wherein the one or more hydrogen storage sources include a common hydrogen storage source coupled to the fuel cell stacks of a plurality of fuel cell power modules.

12. The fuel cell power system of claim 1 wherein the one or more hydrogen storage sources include:

a local hydrogen storage source coupled to the fuel cell stack of an associated fuel cell power module; and

a common hydrogen storage source coupled to the fuel cell stacks of a plurality of fuel cell power modules.

13. The fuel cell power system of claim 12 wherein the local hydrogen storage source and/or the common hydrogen storage source (i) contains hydrogen, in gas or liquid form, and/or (ii) derives hydrogen from any hydrogen containing compound.

14. The fuel cell power system of claim 1 wherein, in response to a failure of a fuel cell power module, at least one of the other fuel cell power modules of the plurality of fuel cell power modules automatically adjust its output power.

15. The fuel cell power system of claim 1 wherein the master controller adjusts the output power of one or more fuel cell power modules in response to a failure, removal or cessation of operation of one or more of the fuel cell power modules.

16. The fuel cell power system of claim 1 wherein the one or more hydrogen storage sources include a common hydrogen storage source, coupled to the fuel cell stacks of a plurality of fuel cell power modules, and wherein the fuel cell power system further includes:

a dual feed hydrogen supply manifold to connect the common hydrogen storage source to the plurality of fuel cell power modules; and

a first set of valves, disposed within the supply manifold, to segment the supply manifold, wherein the first set of valves, in response to control signals, isolates one or more sections of the supply manifold.

17. The fuel cell power system of claim 16 further including:

a dual hydrogen exhaust manifold; and

a second set of valves, disposed within the exhaust manifold, to segment the exhaust manifold, wherein the second set of valves, in response to control signals, isolates one or more sections of the exhaust manifold while allowing one or more of the fuel cell power modules to purge hydrogen.

18. The fuel cell power system of claim 1 wherein the one or more hydrogen storage sources include a common hydrogen storage source, coupled to the fuel cell stacks of a plurality of fuel cell power modules, and wherein the fuel cell power system further includes:

a dual feed hydrogen supply manifold to connect the common hydrogen storage source to the plurality of fuel cell power modules;

a first set of valves, disposed within the supply manifold, to segment the supply manifold, wherein the first set of valves, in response to control signals, isolates individual sections of the supply manifold;

a dual hydrogen exhaust manifold; and

a second set of valves, disposed within the exhaust manifold, to segment the exhaust manifold, wherein the second set of valves, in response to control signals, isolates one or more sections of the exhaust manifold.

19. The fuel cell power system of claim 1 further including:

dual coolant pumps; and

dual feed inlet and outlet manifolds, coupled to the plurality of fuel cell power modules;

wherein the dual coolant pumps supply coolant to dual feed inlet and outlet manifolds.

38. The fuel cell power system of claim 1 wherein the master controller allows monitoring of the operability of one or more fuel cell power modules.

20. A fuel cell power system comprising:

a plurality of fuel cell power modules, coupled to one or more power busses, to provide electrical power on the one or more power busses, wherein each fuel cell power module includes;

a fuel cell stack;

a voltage conditioning device, coupled to the fuel cell stack, to output power on the one or more power busses; and

a control unit; and

one or more hydrogen storage sources, coupled to each fuel cell power module of the plurality of fuel cell power modules;

a master controller, electrically coupled to the control unit of each fuel cell power module, to control or manage operation of the plurality of fuel cell power modules; and

wherein the plurality of fuel cell power modules are connected to form a fault-tolerant power network.

21. The fuel cell power system of claim 20 wherein the voltage conditioning device of each fuel cell power module is a DC—

DC converter or a DC-AC inverter.

22. The fuel cell power system of claim 20 further including a back plane, wherein the back plane includes connections to communicate with at least one of the plurality of fuel cell power modules.

23. The fuel cell power system of claim 22 wherein the back plane includes fluid and power interfaces that connect to fluid and power interfaces of a fuel cell power module.

24. The fuel cell power system of claim 22 wherein the back plane is a module.

25. The fuel cell power system of claim 22 wherein the back plane includes data and power interfaces that connect to data and power interfaces of a fuel cell power module.

26. The fuel cell power system of claim 20 wherein each fuel cell power module is a rack fuel cell power module.

27. The fuel cell power system of claim 20 wherein the master controller, in response to a failure, removal or cessation of operation of one or more of the fuel cell power modules, adjusts the operation of the other fuel cell power modules.

28. The fuel cell power system of claim 20 wherein the one or more hydrogen storage sources include a local hydrogen storage source, coupled to the fuel cell stack of an associated fuel cell power module.

29. The fuel cell power system of claim 20 wherein the one or more hydrogen storage sources include a common hydrogen storage source coupled to the fuel cell stacks of a plurality of fuel cell power modules.

30. The fuel cell power system of claim 20 wherein the one or more hydrogen storage sources include:

a local hydrogen storage source coupled to the fuel cell stack of an associated fuel cell power module; and

a common hydrogen storage source coupled to the fuel cell stacks of a plurality of fuel cell power modules.

31. The fuel cell power system of claim 30 wherein the local hydrogen storage source and/or the common hydrogen storage source (i) contains hydrogen, in gas or liquid form, and/or (ii) derives hydrogen from any hydrogen containing compound.

32. The fuel cell power system of claim 20 wherein the master controller adjusts the output power of one or more fuel cell power modules in response to a failure, removal or cessation of operation of one or more of the fuel cell power modules.

33. The fuel cell power system of claim 20 wherein the one or more hydrogen storage sources include a common hydrogen storage source, coupled to the fuel cell stacks of a plurality of fuel cell power modules, and wherein the fuel cell power system further includes:

a dual feed hydrogen supply manifold to connect the common hydrogen storage source to the plurality of fuel cell power modules; and

a first set of valves, disposed within the supply manifold, to segment the supply manifold, wherein the first set of valves, in response to control signals, isolates one or more sections of the supply manifold.

34. The fuel cell power system of claim 33 further including;

a dual hydrogen exhaust manifold; and

a second set of valves, disposed within the exhaust manifold, to segment the exhaust manifold, wherein the second set of valves, in response to control signals, isolates one or more sections of the exhaust manifold while allowing one or more of the fuel cell power modules to purge hydrogen.

35. The fuel cell power system of claim 20 wherein the one or more hydrogen storage sources include a common hydrogen storage source, coupled to the fuel cell stacks of a plurality of fuel cell power modules, and wherein the fuel cell power system further includes:

a dual feed hydrogen supply manifold to connect the common hydrogen storage source to the plurality of fuel cell power modules;

a first set of valves, disposed within the supply manifold, to segment the supply manifold, wherein the first set of valves, in response to control signals, isolates individual sections of the supply manifold;

a dual hydrogen exhaust manifold; and

a second set of valves, disposed within the exhaust manifold, to segment the exhaust manifold, wherein the second set of valves, in response to control signals, isolates one or more sections of the exhaust manifold.

36. The fuel cell power system of claim 20 further including:

dual coolant pumps; and

dual feed inlet and outlet manifolds, coupled to the plurality of fuel cell power modules;

wherein the dual coolant pumps supply coolant to dual feed inlet and outlet manifolds.

37. The fuel cell power system of claim 20 wherein the master controller allows monitoring of the operability of one or more fuel cell power modules.

39. A fuel cell power system comprising:

a first fuel cell power device including;

a first fuel cell stack;

a first voltage conditioning device, coupled to the first fuel cell stack, to output power on one or more power busses; and

a first control unit;

a second fuel cell power device including;

a second fuel cell stack;

a second voltage conditioning device, coupled to the second fuel cell stack,

to output power on the one or more power busses; and

a second control unit;

one or more hydrogen storage sources coupled to first and second fuel cell power devices; and

a master controller, electrically coupled to the first and second control units, to control or manage operation of the first and second fuel cell power devices.

40. The fuel cell power system of claim 39 wherein the first and second voltage conditioning devices each include a DC—

DC converter or a DC-AC inverter.

41. The fuel cell power system of claim 39 further including a plurality of back planes, wherein each back plane includes connections to communicate with at least one of the first and second fuel cell power devices.

42. The fuel cell power system of claim 41 wherein each back plane includes one or more of a fluid, data and power interfaces that connect to an associated fluid, data and power interface of at least one of the first and second fuel cell power devices.

43. The fuel cell power system of claim 41 wherein each back plane is a module.

44. The fuel cell power system of claim 41 wherein each back plane includes two or more of a fluid, data and power interfaces that connect to an associated fluid, data and power interface of at least one of the first and second fuel cell power devices.

45. The fuel cell power system of claim 39 wherein the first and second fuel cell power devices are rack fuel cell power modules.

46. The fuel cell power system of claim 39 wherein the master controller, in response to a failure, removal or cessation of operation of the first fuel cell power device, adjusts the operation of the second fuel cell power device.

47. The fuel cell power system of claim 39 wherein the first fuel cell stack, the first voltage conditioning device, and the first control unit of the first fuel cell power device are independently removable during operation of the fuel cell power system.

48. The fuel cell power system of claim 39 wherein the one or more hydrogen storage sources include a first local hydrogen storage source coupled to the first fuel cell stack and a second local hydrogen storage source coupled to the second fuel cell stack.

49. The fuel cell power system of claim 39 wherein the one or more hydrogen storage sources include a common hydrogen storage source coupled to the first and second fuel cell stacks.

50. The fuel cell power system of claim 39 wherein the one or more hydrogen storage sources include;

a first local hydrogen storage source coupled to first fuel cell stack;

a second local hydrogen storage source coupled to second fuel cell stack; and

a common hydrogen storage source coupled to the first and second fuel cell stacks.

51. The fuel cell power system of claim 39 wherein, in response to a failure of the first fuel cell power device, the second fuel cell power device automatically adjusts its output power.

52. The fuel cell power system of claim 39 wherein the master controller, in response to a failure, removal or cessation of operation of the first fuel cell power device, adjusts the output power of the second fuel cell power device.

53. The fuel cell power system of claim 39 wherein the master controller allows monitoring of the operability of at least the first fuel cell power device.

54. The fuel cell power system of claim 39 wherein the one or more hydrogen storage sources (i) contains hydrogen, in gas or liquid form, and/or (ii) derives hydrogen from any hydrogen containing compound.