Fuel cell system using external heat sources for maintaining internal temperature

• US 8,356,682 B2
• Filed: 12/27/2006
• Issued: 01/22/2013
• Est. Priority Date: 04/04/2005
• Status: Active Grant

• Current Assignee: Aptiv Technologies AG (Aptiv PLC)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Grieve, Malcolm James
• Primary Examiner(s): Shriver, II, J. Allen
• Assistant Examiner(s): AVERY, BRIDGET D
• Application Number:
  US11/645,849
• Publication Number:
  US 20070119638A1
• Time in Patent Office: 2,218 Days
• Field of Search: 180/65.1, 180/65.21, 180/65.225, 180/5.6, 180/6.5, 429/400, 429/433, 429/434
• US Class Current: 180/65.1
• CPC Class Codes: B60L 58/30 for monitoring or controlling fuel cells
• CPC Class Codes: B60L 58/31 for starting of fuel cells
• CPC Class Codes: B60L 58/33 by cooling
• CPC Class Codes: B60L 58/34 by heating
• CPC Class Codes: H01M 16/006 of fuel cells with rechargeable batteries
• 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 2250/402 Combination of fuel cell with other electric generators
• 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 8/04037 Electrical heating
• CPC Class Codes: H01M 8/04074 Heat exchange unit structures specially adapted for fuel cell
• CPC Class Codes: H01M 8/04268 Heating of fuel cells during the start-up of the fuel cells
• CPC Class Codes: H01M 8/2475 Enclosures, casings or containers of fuel cell stacks
• CPC Class Codes: H02J 2300/10 The dispersed energy generation being of fossil origin, e.g. diesel generators
• CPC Class Codes: H02J 2300/30 The power source being a fuel cell
• CPC Class Codes: H02J 3/381 Dispersed generators
• CPC Class Codes: H02J 7/1415 with a generator driven by a prime mover other than the motor of a vehicle
• CPC Class Codes: Y02B 90/10 Applications of fuel cells in buildings
• CPC Class Codes: Y02E 60/00 Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells
• CPC Class Codes: Y04S 10/126 : the energy generation units being or involving electric vehicles [EV] or hybrid vehicles [HEV], i.e. power aggregation of EV or HEV, vehicle to grid arrangements [V2G]

Abstract

A solid oxide fuel cell system including electric resistance elements for heating of space and components within the “hot zone” enclosure of the system, preferably in combination with means for using “waste” heat from other sources, to assist in warm-up from a cold start and/or to maintain a stand-by temperature of reformer and fuel cell elements within the system and/or to maintain optimum operating temperatures within the system during periods of very low electrical demand on the system. A method is included for using off-peak grid electricity, battery-stored onboard electricity, or vehicle-generated electricity to energize the resistance heaters, as well as utilizing gaseous waste heat sources such as vehicle exhaust gas to complement the resistance heating.

Claims

1. A fuel cell system having an enclosure containing components having an operating temperature sufficiently high to produce electricity, said fuel cell system comprising:

at least one electrical resistance heating element disposed within said enclosure for heating said components to a temperature near said operating temperature; and

a storage heater for storing thermal energy generated by said electrical resistance heating element when surplus electricity is available;

wherein said storage heater is disposed within said enclosure.

2. A fuel cell system in accordance with claim 1 comprising a plurality of said electrical resistance heating elements.

3. A fuel cell system in accordance with claim 1 wherein said electrical resistance heating element is energized by electricity from a source outside of said fuel cell system.

4. A fuel cell system in accordance with claim 1 further comprising a heat exchanger disposed outside said enclosure, wherein one of said components within said enclosure includes a fuel cell stack having at least one cathode and at least one anode, and wherein a hot side of said heat exchanger receives hot gas from a source outside of said fuel cell system to heat incoming air to said at least one cathode.

5. A fuel cell system in accordance with claim 1 wherein said operating temperature is above 550°

C.

6. A fuel cell system in accordance with claim 3 wherein said outside source is selected from the group consisting of a battery, an electric grid, an automotive generator, and a second power system.

7. A fuel cell system in accordance with claim 4 wherein said hot gas is selected from the group consisting of exhaust gas from an internal combustion engine, exhaust gas from a gas turbine engine, exhaust gas from a fuel cell power unit and exhaust gas from a space heater.

8. A fuel cell system in accordance with claim 5 wherein said fuel cell system is a solid oxide fuel cell system.

9. A fuel cell system having an enclosure containing components having an operating temperature sufficiently high to produce electricity, said fuel cell system comprising a heat exchanger disposed outside said enclosure for heating said components to a temperature near said operating temperature, wherein one of said components within said enclosure includes a fuel cell stack having at least one cathode and at least one anode, and wherein a hot side of said heat exchanger receives hot gas from a source outside of said fuel cell system to heat incoming air to said at least one cathode.

10. A fuel cell system in accordance with claim 9 wherein said hot gas is selected from the group consisting of exhaust gas from an internal combustion engine, exhaust gas from a gas turbine engine, exhaust gas from a fuel cell power unit and exhaust gas from a space heater.

11. A fuel cell system in accordance with claim 9 wherein said operating temperature is above 550°

C.

12. A fuel cell system in accordance with claim 9 wherein said fuel cell system requires a fueling rate sufficiently high to produce electricity and said heat exchanger heats said components to a temperature near said operating temperature when said fueling rate is not sufficiently high to produce electricity.

13. A fuel cell system in accordance with claim 11 wherein said fuel cell system is a solid oxide fuel cell system.

14. A fuel cell system having an enclosure containing components having an operating temperature sufficiently high to produce electricity, said fuel cell system comprising:

at least one electrical resistance heating element disposed within said enclosure for heating said components to a temperature near said operating temperature; and

a storage heater for storing thermal energy generated by said electrical resistance heating element when surplus electricity is available;

wherein said fuel cell system requires a fueling rate sufficiently high to produce electricity and said electrical resistance heating element heats said components to a temperature near said operating temperature when said fueling rate is not sufficiently high to produce electricity.

15. A fuel cell system in accordance with claim 14 wherein said electrical resistance heating element is energized by electricity from a source outside of said fuel cell system.

16. A fuel cell system in accordance with claim 14 further comprising a heat exchanger disposed outside said enclosure, wherein one of said components within said enclosure includes a fuel cell stack having at least one cathode and at least one anode, and wherein a hot side of said heat exchanger receives hot gas from a source outside of said fuel cell system to heat incoming air to said at least one cathode.

17. A fuel cell system in accordance with claim 16 wherein said hot gas is selected from the group consisting of exhaust gas from an internal combustion engine, exhaust gas from a gas turbine engine, exhaust gas from a fuel cell power unit and exhaust gas from a space heater.

18. A fuel cell system having an enclosure containing components having an operating temperature sufficiently high to produce electricity, said fuel cell system comprising:

at least one electrical resistance heating element disposed within said enclosure for heating said components to a temperature near said operating temperature; and

a storage heater for storing thermal energy generated by said electrical resistance heating element when surplus electricity is available;

wherein said storage heater is in thermal communication with said components for heating said components to a temperature near said operating temperature.

19. A fuel cell system in accordance with claim 18 wherein said electrical resistance heating element is energized by electricity from a source outside of said fuel cell system.

20. A fuel cell system in accordance with claim 18 further comprising a heat exchanger disposed outside said enclosure, wherein one of said components within said enclosure includes a fuel cell stack having at least one cathode and at least one anode, and wherein a hot side of said heat exchanger receives hot gas from a source outside of said fuel cell system to heat incoming air to said at least one cathode.

21. A fuel cell system in accordance with claim 20 wherein said hot gas is selected from the group consisting of exhaust gas from an internal combustion engine, exhaust gas from a gas turbine engine, exhaust gas from a fuel cell power unit and exhaust gas from a space heater.