Combined fuel cell aircraft auxiliary power unit and environmental control system

• US 8,016,228 B2
• Filed: 04/21/2008
• Issued: 09/13/2011
• Est. Priority Date: 04/21/2005
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Fucke, Lars, Daggett, David L.
• Primary Examiner(s): Collins; Timothy D
• Assistant Examiner(s): Sanderson; Joseph W
• Application Number:
  US12/106,799
• Publication Number:
  US 20090305092A1
• Time in Patent Office: 1,240 Days
• Field of Search: 244/58, 244/53.R, 244/118.5, 429/12, 429/19, 429/20, 429/26, 607/28, 60/395.11
• US Class Current: 244/58
• CPC Class Codes: B64D 13/06 the air being conditioned pressurising B64D13/02
• CPC Class Codes: B64D 2013/0611 combined with auxiliary power units (APU's)
• CPC Class Codes: B64D 2041/005 Fuel cells
• CPC Class Codes: B64D 41/00 Power installations for auxiliary purposes
• 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 2250/407 Combination of fuel cells with mechanical energy generators
• CPC Class Codes: H01M 8/04014 Heat exchange using gaseous fluids; Heat exchange by combustion of reactants
• CPC Class Codes: H01M 8/04111 using a compressor turbine assembly
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y02T 50/50 On board measures aiming to increase energy efficiency
• CPC Class Codes: Y02T 90/40 Application of hydrogen technology to transportation, e.g. using fuel cells
• CPC Class Codes: Y10S 429/901 Fuel cell including means for utilization of heat for unrelated application, e.g. heating a building

Abstract

Combined aircraft hybrid fuel cell auxiliary power unit and environmental control system and methods are disclosed. In one embodiment, a method includes chemically converting a portion of combustible fuel into electrical energy. An unutilized portion of fuel emitted by the chemical conversion of combustible fuel is combusted to thermal power. The heated gas is used to drive a power recovery turbine connected to a drive shaft. A source of input oxidizing gas is compressed and is used to help chemically convert the combustible fuel into electrical energy. The heated gas is used to mechanically drive the power recovery turbine which is coupled to a generator to produce electrical energy.

Claims

1. A method of combining a fuel cell and a power recovery turbine to generate electrical power in an aircraft, the method comprising:

chemically converting a portion of combustible fuel into electrical energy using the fuel cell coupled to a pressurized flow of air to generate direct current and alternating current;

combusting an unutilized portion of fuel emitted by the chemical conversion of combustible fuel to electrical power to generate heated gas;

using the heated gas to drive the power recovery turbine connected to a drive shaft;

compressing a source of input oxidizing gas using a compressor mounted on the drive shaft;

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

using the heated gas to drive the power recovery turbine which is coupled to a generator to produce electrical energy; and

recovering exhaust energy from the chemical conversion of combustible fuel into mechanical power;

providing, via a first compressor powered by the mechanical power, pressurized source of conditioned cabin air

providing, via a second compressor powered by the mechanical power, the pressurized flow of air for the fuel cell; and

using a recovered exhaust waste to produce a water supply.

2. A method of generating electrical power, comprising:

chemically converting a portion of combustible fuel into electrical energy;

combusting an unutilized portion of fuel emitted by the chemical conversion of combustible fuel to electrical power to generate heated gas;

transferring heat, using a heat exchanger, from the heated gas to a second pressurized flow of air that is used at least in part to provide breathable airflow into an interior compartment;

using the heated gas to drive a power recovery turbine connected to a drive shaft;

compressing a source of input oxidizing gas using a compressor mounted on the drive shaft;

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

using the heated gas to drive the power recovery turbine which is coupled to a generator to produce electrical energy.

3. The method of claim 2, further comprising recovering exhaust energy from the chemical conversion of combustible fuel into mechanical power.

4. The method of claim 3, further comprising using the recovered exhaust energy to provide the pressurized source of conditioned cabin air.

5. The method of claim 3, further comprising using a recovered exhaust waste to produce a water supply.

6. The method of claim 2, wherein the chemically converting a portion of combustible fuel into electrical enerqy includes generating direct current and alternating current.

7. The method of claim 2, further comprising chemically producing reactants in the conversion of combustible fuel, including at least one of hydrogen and carbon monoxide.

8. The method of claim 2, further comprising pressurizing the source of input gas to accelerate the chemical reactions.

9. A method, comprising:

compressing a source of input oxidizing gas with a first compressor coupled to a drive shaft to create compressed oxidizing gas;

converting a portion of combustible fuel into electrical energy using the compressed oxidizing gas in a fuel cell;

combusting an unutilized portion of fuel emitted by the fuel cell to generate heated gas; and

directing the heated gas through a power recovery turbine coupled to the first compressor and a second compressor by the drive shaft; and

providing a pressurized flow of air suitable for human consumption from the second compressor into a compartment of passengers.

10. The method of claim 9, further comprising driving the power recovery turbine to produce electrical energy using the heated gas.

11. The method of claim 9, further comprising collecting hot exhaust discharged from the fuel cell using a condenser to harvest water.

12. A method of generating auxiliary power, the method comprising:

driving a power recovery turbine using heated gas exhausted from a fuel cell, the power recovery turbine to drive a first compressor to provide a first pressurized flow of air being suitable to provide a breathable airflow into a compartment and to drive a second compressor to provide a second pressurized flow of air for use by the fuel cell;

converting combustible fuel into electrical energy with the second pressurized flow of air using the fuel cell; and

combusting an unutilized portion of fuel emitted by the fuel cell to generate the heated gas.

13. The method of claim 12, further comprising transferring heat from the heated gas to the first pressurized flow of air to heat the breathable airflow that is provided into the compartment.

14. A method generating electrical power in an aircraft using a fuel cell and a power recover turbine, comprising:

compressing a source of input oxidizing gas with a first compressor coupled to a drive shaft to create compressed oxidizing gas;

converting a portion of combustible fuel into electrical energy using the compressed oxidizing gas in the fuel cell;

combusting an unutilized portion of fuel emitted by the fuel cell to generate heated gas;

directing the heated gas through the power recovery turbine coupled to the first compressor by the drive shaft;

driving the power recovery turbine to produce electrical energy using the heated gas; and

providing a pressurized flow of air from a second compressor coupled to the drive shaft and directed to a passenger compartment, the pressurized flow of air being suitable to provide a breathable airflow into the passenger compartment.