Power generation system and method

• US 6,915,869 B2
• Filed: 03/12/2003
• Issued: 07/12/2005
• 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: Grieve, Malcolm James, Miller, Carl Elmer, Botti, Jean Joseph
• Primary Examiner(s): FISCHMANN, BRYAN R
• Application Number:
  US10/387,663
• Publication Number:
  US 20030168263A1
• Time in Patent Office: 853 Days
• Field of Search: 180/65.1, 180/65.2, 180/65.3, 180/65.4, 180/53.1, 180/53.5, 180/309, 429/12, 429/13, 429/26, 429/30, 429/22, 602/72, 602/73, 602/96, 603/81, 602/85, 605/93, 605/95, 605/96, 606/052, 123/3, 123/DIG.12
• 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 and method 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 solid oxide fuel cell having an air intake in fluid communication with an air supply, a fuel intake in fluid communication with the engine exhaust, a solid oxide fuel cell 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 recovery. 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 solid oxide fuel cell oxygen separator and a ceramic membrane oxygen separator.

Claims

1. A method for operating a power generation system, comprising:

(a) supplying at least a first portion of fuel and a first portion of air to an engine, wherein said engine is configured to produce a hydrogen rich engine exhaust;

(b) reacting said first portion of fuel and said first portion of air in said engine to produce a hydrogen rich engine exhaust;

(c) introducing said hydrogen rich engine exhaust to a fuel intake of an SOFC, said SOFC having an air side having an air intake;

(d) introducing a second portion of air to said air intake of said SOFC; and

(e) ionizing oxygen in the second portion of air such that the ionized oxygen migrates from the air side to the fuel side of the SOFC where it reacts with said hydrogen rich engine exhaust produce to produce an SOFC effluent.

2. The method for operating a power generation system as in claim 1, further comprising:

directing said SOFC effluent through a catalytic converter having a converter exhaust.

3. The method for operating a power generation system as in claim 2, wherein said converter exhaust comprises negligible quantities of hydrocarbons, nitric oxide, carbon monoxide and particulates.

4. The method for operating a power generation system as in claim 1, further comprising:

using said SOFC effluent to heat said second portion of air prior to introduction into said air intake.

5. The method for operating a power generation system as in claim 1, further comprising:

introducing a second portion of fuel to the fuel intake.

6. The method for operating a power generation system as in claim 1, further comprising:

introducing said SOFC effluent to a turbine disposed in fluid communication with said SOFC effluent and recovering energy from said SOFC effluent therein; and

optionally, after recovering energy from said SOFC effluent in said turbine, passing said SOFC effluent through a catalytic converter.

7. The method for operating a power generation system as in claim 1, further comprising:

compressing said first portion of air and said second portion of air.

8. The method for operating a power generation system as in claim 1, further comprising:

operating said engine to produce a hydrogen rich exhaust having a combined concentration of hydrogen and carbon monoxide greater than about 30% by volume, based on the total volume of said hydrogen rich exhaust.

9. The method for operating a power generation system as in claim 8, wherein said engine is a free piston gas generator having a rich homogenous charge compression ignition.

10. The method for operating a power generation system as in claim 8, wherein said engine is configured with an oxygen separator, a rich internal combustion engine cylinder system in at least part of said engine, a an optional rich homogenous charge compression ignition, and an optional dilute cylinder system in part of said engine.

11. The method for operating a power generation system as in claim 8, wherein said engine is a turbo-generator system.

12. The method for operating a power generation system as in claim 11, 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.

13. The method for operating a power generation system as in claim 1, further comprising:

operating said system to produce a hydrogen rich exhaust having a combined concentration of hydrogen and carbon monoxide greater than about 70% by volume, based on the total volume of said hydrogen rich exhaust.

14. The method for operating a power generation system as in claim 1, further comprising:

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

15. The method for operating a power generation system as in claim 1, further comprising:

generating a stream of oxygen rich effluent;

supplying at least a portion of said oxygen rich effluent to said engine; and

reacting said oxygen rich effluent with a portion of fuel to produce a hydrogen rich engine exhaust.

16. The method for operating a power generation system as in claim 15, wherein said generating is with a member of the group consisting of pressure swing absorption oxygen separators, SOFC oxygen separators, ceramic membrane oxygen separators, and combinations thereof.

17. A method for operating a power generation system comprising:

supplying at least a first portion of fuel and a first portion of air to an engine configured to produce a hydrogen rich engine exhaust;

reacting said first portion of fuel and said first portion of air in said engine to produce a hydrogen rich engine exhaust;

introducing said hydrogen rich engine exhaust, an alternate SOFC fuel, or a combination thereof, to a fuel intake of a SOFC, said SOFC having an air side having an air intake;

introducing a second portion of air to said air intake of said SOFC;

ionizing oxygen in the second portion of air such that the ionized oxygen migrates from the air side to the fuel side of said SOFC where it reacts with said hydrogen rich engine exhaust, said alternate SOFC fuel, or a combination thereof, to product an SOFC effluent, an oxygen depleted air stream, and electricity;

utilizing said SOFC electricity to operate a base load of electrical accessories, provide traction power, recharge electrical sources, or a combination thereof, while said engine provides limited traction power.

18. A method for operating a power generation system as in claim 17 further comprising:

shutting down said engine; and

supplying all of a vehicle'"'"'s traction power, accessory power, or a combination thereof, from electricity produced by said SOFC.

19. A method for operating a power generation system as in claim 18, further comprising:

operating said system in a high power mode for providing high traction power, high accessory power, or a combination thereof, using electricity produced by said SOFC, 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 engine operation, using electricity produced by said SOFC in combination with a battery, or a combination thereof.