CASCADING STACK ELECTROCHEMICAL FUEL CELL

Abstract

A fuel cell comprising a series of cascaded cell stacks comprising at least one humidifier-degasser coupled to the cell stacks proximate a stack inlet; the at least one humidifier-degasser comprising at least one degasification section fluidly coupled upstream of at least one humidifier section; and at least one inert concentrator cell coupled downstream from the cell stacks proximate a stack vent.

Claims

1. A fuel cell comprising: a series of cascaded cells comprising: at least one humidifier-degasser coupled to said cell stacks proximate a stack inlet; said at least one humidifier-degasser comprising at least one degasification section coupled via an MEA material to a reactant and a product water upstream of at least one humidifier section; and at least one inert concentrator cell coupled downstream from said cell stacks proximate a stack vent.

2. The fuel cell according to claim 1, wherein said series of cascaded cells flow reactants serially.

3. The fuel cell according to claim 1, wherein said at least one humidifier section comprises a first catalyzed water transport membrane and second catalyzed water transport membrane separated by a product water flow passage; an oxidant flow passage coupled to said first catalyzed water transport membrane opposite said product water flow passage; a fuel flow passage coupled to said second catalyzed water transport membrane opposite said product water passage; and a hydrogen rate controller electrically coupled to said second catalyzed water transport membrane.

4. The fuel cell according to claim 1, wherein said degasification section comprises a membrane electrode assembly between a product water flow passage and a fuel flow passage; and an electrical potential being applied across said membrane electrode.

5. The fuel cell according to claim 1, wherein said at least one inert concentrator cell comprises a hydrogen pump; said hydrogen pump comprising a membrane electrode assembly disposed between an input chamber and an output chamber configured to accept hydrogen flow through a fuel flow passage from at least one cell in said cascaded cells and said output chamber to a fuel inlet manifold of said at least one cell.

6. The fuel cell according to claim 5, wherein said inert concentrator cell is configured to concentrate contaminant gases in said input chamber and pass hydrogen gas across said membrane electrode assembly into said fuel inlet manifold.

7. The fuel cell according to claim 3, wherein said at least one catalyst is coupled to a surface of said first catalyzed water transport membrane and said second catalyzed water transport membrane.

8. A fuel cell comprising: a hydrogen removal cell coupled to a fuel inlet, an oxidant inlet and a product water inlet, said hydrogen removal cell comprising a membrane electrode assembly between a product water flow passage and a fuel flow passage, an electrical potential being applied across said membrane electrode; an oxidant flow passage coupled to said first catalyzed water transport membrane opposite said product water flow passage; a fuel flow passage coupled to said second catalyzed water transport membrane opposite said product water passage; a hydrogen rate controller electrically coupled to said second catalyzed water transport membrane; and at least one inert concentrator cell coupled to at least one cell in a cascaded cell stack, said inert concentrator coupled to a stack vent and configured to discharge contaminants from said fuel cell.

9. The fuel cell according to claim 8, wherein said at least one inert concentrator cell comprises a hydrogen pump; said hydrogen pump comprising a membrane electrode assembly with an input chamber coupled to an anode chamber configured as a fuel flow passage from at least one cell in said cascaded cell stack and said membrane electrode assembly having an output coupled to a fuel inlet manifold of said at least one cell.

10. The fuel cell according to claim 9, wherein said inert concentrator cell is configured to concentrate contaminant gases in said input chamber and pass hydrogen gas across said membrane electrode assembly into said fuel inlet manifold.

11. The fuel cell according to claim 8, wherein said series of cascaded cell stacks flow reactants serially.

12. The fuel cell according to claim 11, wherein said reactants comprise a gaseous fuel and a gaseous oxidant.

13. The fuel cell according to claim 12, further comprising: a humidifier cell coupled downstream of said hydrogen removal cell, said humidifier cell comprising a first catalyzed water transport membrane and second catalyzed water transport membrane separated by a product water flow passage, wherein said humidifier is configured to add moisture to said oxidant and to add moisture to said fuel responsive to an electrical current controlled by said hydrogen rate controller.

14. A process comprising: flowing reactants through a cascaded fuel cell stack, the reactants comprising a fuel and an oxidant; degasifying a product water by use of a hydrogen removal cell coupled in series to said cascaded fuel cell stack proximate a stack inlet for said reactants; humidifying said fuel and said oxidant with a portion of said product water by use of a humidifier cell coupled to said reactants and said product water proximate said hydrogen removal cell; concentrating contaminants from said reactants in an inert concentrator cell coupled to said cascaded fuel cell stack proximate a stack vent; and recirculating a portion of said fuel from said inert concentrator cell to at least one cell of said cascaded fuel cell stack.

15. The process of claim 14, wherein said degasifying said product water further comprises: electrochemically reacting oxygen with hydrogen in the product water.

16. The process of claim 15, further comprising: electrochemically pumping hydrogen from a low partial pressure in the product water to a reactant pressure in the fuel being supplied to the at least one cell of said cascaded fuel cell stack.

17. The process of claim 15, further comprising: electrochemically injecting said hydrogen to said product water; reacting said dissolved hydrogen and dissolved oxygen in said product water.

18. The process of claim 15, wherein a rate of hydrogen addition into the product water is controlled by a hydrogen rate controller, said hydrogen rate controller comprises a variable resistance potentiometer shunted across a membrane electrode assembly.

19. The process of claim 14, further comprising: venting said contaminants from said inert concentrator cell.

20. The process of claim 19, wherein said humidifying said fuel and said oxidant further comprises: flowing said product water across a water transport membrane; evaporating said product water into said reactants from a surface of said water transport membrane said reactants contact.

21. A fuel cell comprising: a series of cascaded cell stacks comprising: at least one inert concentrator cell coupled downstream from said cell stacks proximate a stack vent.

22. A fuel cell comprising: a series of cascaded cell stacks comprising: at least one humidifier-degasser coupled to said cell stacks proximate a stack inlet; said at least one humidifier-degasser comprising at least one hydrogen removal section coupled via an MEA material to a reactant and a product water upstream of at least one humidifier section.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] FIG. 1 is a prior art schematic diagram of an alkaline power plant.

[0045] FIG. 2 is an illustration of a prior art active PEM power plant.

[0046] FIG. 3 is a schematic of an advanced product water removal PEM power plant.

[0047] FIG. 4 is a schematic of an exemplary fuel cell cascading stack and an inert concentrator cell element and a humidifier-degasser cell element.

[0048] FIG. 5 is a schematic of the first stage of an exemplary humidifier-oxygen removal cell section of an exemplary fuel cell stack shown without a hydrogen injection circuit.

[0049] FIG. 6 is a schematic of the second stage of the same exemplary humidifier-degasser section of an exemplary fuel cell stack.

[0050] FIG. 7 is a schematic of an exemplary humidifier-degasser portion of a fuel cell stack comprised of stage 1 and stage 2.

[0051] FIG. 8 is a schematic of an exemplary humidifier-degasser cell section of a fuel cell stack comprised of the humidifier oxygen removal cell section and the humidifier hydrogen removal cell section.

DETAILED DESCRIPTION

[0052] Referring now to FIG. 4, there is illustrated a fuel cell 10 having a fuel cell stack 12. The fuel cell stack 12 includes a humidifier-oxygen removal cell(s) 14, and utilizes a fluid management method that combines a stack cascade(s) 16 of cells with at least one hydrogen pump/inert concentrator 18. The fuel cell stack 12 is a non-flow though device that allows input of dry reactant gasses 20 into a stack inlet(s) 21, humidifies the reactants 20 utilizing fuel cell product water, then removes dissolved and gaseous reactants from the product water issuing from the stack so this product water can be easily managed even in zero gravity. After being humidified at 14, the fuel reactant 20 flows through a fuel cascade 16 as shown in FIG. 4. This cascade 16 allows a continuous flow of reactants at a 2:1 H2:O2 stoichiometric ratio from cell N to cell 1 (venting cell) 22 improving reactant distribution and utilization within each cell.

[0053] Cell 1 (and possibly more cells) 22 are coupled to an inert concentrator cell (hydrogen pump cell) 24. Reactant 20 in cell 1 22 flows through the anode chamber of cell 1 then into a manifold 26 that directs the reactant 20 flow into an input chamber 28 of the hydrogen pump cell 24. The hydrogen fuel 30 is then pumped across the ICC MEA back into an inlet manifold 32 of cell 1 22. In this manner, a flow is established within cell 1 22 and inert elements are concentrated in the inlet side of the Inert Concentrator Cell (ICC) 24.

[0054] Because of the very high efficiency of the H2 electrode, high concentrations of inert elements can be achieved (in order to later vent/purify) and the inert concentrator cell 24 can continue to operate. As these inerts reach a predetermined level the ICC voltage or current or both are used to create a signal to commence venting of the ICC 24 and cell 1 22. This venting process is repeated as often as necessary to maintain proper operation of cell 1 22 and the ICC 24. The venting is accomplished by use of a stack vent 33. The venting process can be based on an inert concentrator voltage/current, a shunt current bypass, a cell 1 voltage, and the like.

[0055] Referring also to FIG. 5, an exemplary humidifier-oxygen removal cell (H-ORC) 14 is shown. The humidifier-oxygen removal cell 14 primarily performs two functions. The humidifier-oxygen removal cell 14 humidifies incoming reactants 20 and removes oxygen from the product water. FIG. 5 shows the humidifier-oxygen removal cell 14 cross section in detail showing the arrangement and the processes carried out in the humidifier-oxygen removal cell 14. In the humidifier-oxygen removal cell 14, reactants 20 and product water 34 are separated by two catalyzed Nafion water transport membranes 36 (36a and 36b). In addition to Nafion other suitable proton conducting membranes include: (1) perfluorinated membranes other than Nafion, (2) partially fluorinated membranes, (3) non-fluorinated membranes, (4) nonfluorinated and composite membranes and the like. Some of the product water 34 flowing through the cell 14 migrates through the membranes 36 and evaporates from the membrane surfaces into the reactant 20 streams oxidant/oxygen 38, fuel/hydrogen 40, humidifying the reactants 20 (from FIG. 4).

[0056] At the same time that water 34 evaporates into the reactant streams, 38, 40, reactants 38, 40 are diffusing through the membranes and dissolving in the product water 34. The humidifier-oxygen removal cell 14 concept takes advantage of this characteristic to react oxygen in the product water with the diffusing hydrogen reducing the amount of oxygen 38 being carried from the humidifier-oxygen removal cell 14 dissolved in the product water 34: The surfaces of the water transport membranes 36 are catalyzed to promote reaction of the dissolved hydrogen 40 and oxygen 38 to water 34.

[0057] The diffusion rates of hydrogen 40 and oxygen 38 are proportional to their partial pressure differentials across their respective membranes 36. Consequently more hydrogen 40 transports to the product water 34, which is devoid of hydrogen 40, than oxygen 38 with which the product water 34 is saturated. The catalyst 42, on the surfaces of the membranes 36, promotes reaction of the dissolved gases to water 34. The result is that some of the dissolved hydrogen 40 and oxygen 38 are reacted and the product water 34 is partially degasified. However the ratio is not exact and the proportion of gases varies constantly depending upon operating point of the power plant and as a result of small but possible leaks of reactant 20 into the water stream 34.

[0058] The solution is the electrochemical reaction of excess hydrogen 40 in addition to hydrogen that diffuses to the product water stream 34 to assure that all oxygen 38 is consumed. The additional hydrogen 40 that is required is drawn electrochemically into the water 34. This is done by connecting a load across the catalyzed membrane 36b disposed between the product water 34 and the hydrogen reactant stream, completing an electrochemical circuit enabling this catalyzed membrane to function as a fuel cell membrane electrode assembly (MEA).

[0059] The MEA 46 has a hydrogen source 50 on the reactant stream side 52. On the surface 56 of the MEA, hydrogen 50 is ionized to protons and electrons by a catalytic reaction. The result is that when an external circuit 48 is connected, protons will flow through the MEA 36b from the higher energy state to the lower energy state while electrons flow through the external circuit 48 and the protons and electrons then combine with oxygen to form water 34 at the lower pressure (water side) electrode 54. The rate of hydrogen 50 flow, or addition, is limited by the current which is allowed to flow. The current, or hydrogen addition rate, is controlled by a hydrogen rate controller 58. In an exemplary embodiment, the hydrogen rate controller 58 can be a variable resistance potentiometer 58 shunted across the MEA 36b. This device 44 generates minute quantities of power and is able to acquire reactants to generate this power directly from the flow of fluids from the stack 12. The power generated is dissipated in the potentiometer 58.

[0060] At low resistance, hydrogen flow 50 is larger than at high resistance. Thus by controlling current flow hydrogen 40 addition-rate to the product water 34 is controlled. Using this controller 58 sufficient hydrogen 50 can be added to always consume all oxygen 38 present in the product water stream 34. The result is a stream 34 devoid of oxygen 38 but containing dissolved hydrogen 40.

[0061] Referring also to FIG. 6 and FIG. 7, the product water 34, devoid of oxygen 38 but possibly containing some residual hydrogen 40, flows from the H-ORC 44 to a humidification-hydrogen removal cell (H-HRC) 60. Both illustrations in FIG. 5 and FIG. 6 illustrate capability to conduct humidification and degasification, albeit with differing gasses in each cell 60. This can be known as reactant removal cells 14/60.

[0062] Referring to FIG. 6, the humidification-hydrogen removal cell 60 performs two functions. The humidification-hydrogen removal cell 60 removes residual hydrogen 40 from the product water 34 and provides a control signal that may feed back to the humidifier-oxygen removal cell 44 injector circuit 48 that adjusts the rate of hydrogen 40 addition to the water in the humidifier-oxygen removal cell 44. Residual dissolved hydrogen 40 is removed electrochemically from the product water stream 34. The hydrogen 40 is electrochemically pumped from a low partial pressure in the water 34 to reactant pressure in the fuel stream 40 to the cell stack 12. FIG. 6 shows the humidification-hydrogen removal cell 60 and the hydrogen removal process.

[0063] The humidification-hydrogen removal cell 60 consists of a product water chamber 62 separated from the reactant hydrogen 40 by the MEA 46. Application of a small potential 64 to the MEA 46 causes the MEA 46 to scavenge dissolved hydrogen 40 from the product water stream 34 and electrochemically pump the hydrogen 40 back to the to the gaseous hydrogen reactant stream 40 flowing to the cell stack 12. Controlling the applied potential 64 and monitoring the resultant current, which is directly proportional to hydrogen pumping rate, controls the hydrogen content of the water leaving the humidification-hydrogen removal cell 60. The humidification-hydrogen removal cell 60 current may be used to bias the resistance of the MEA circuit 48 of the humidifier-oxygen removal cell 44. The overall result is an essentially gas-free product water stream 34 with minimal addition of hydrogen 40 to the product water 34 in the humidification cell 44. The control signal and circuit assure only enough hydrogen 40 is added to the product water 34 in the humidifier-oxygen removal cell 44 to completely remove oxygen 38 from the water 34. The humidification-hydrogen removal cell 60 leaves only a small, controlled quantity of hydrogen 40 in the product water 34. As currently configured, the controller 58 limits the residual dissolved hydrogen 40 to a level below the concentration that will cause hydrogen evolution when the product water stream 34 is depressurized. If desired, the computer code managing the rate controller 58 can be adjusted to completely remove hydrogen gas from the product water stream 34.

[0064] The proposed innovation includes the cascaded fuel cell stack with its humidifier-degasification section and ICC section provides a technological advance that contributes to system simplicity and improved reliability through (1) innovative, integrated system-level design concepts and (2) passive ancillary components. More specifically: all gas mechanical re-circulation is eliminated and motorized ancillary components are reduced; power plant weight, volume complexity and cost are reduced. Power plant reliability and efficiency are improved. Power plant and PEM membrane durability are both improved. Performance and efficiency of individual PEM cells are improved. Parasite power requirements are reduced. Control and monitoring requirements are reduced. Vehicle-power plant interface connections are simplified.

[0065] The fuel cell stack 12 is a non-flow though device that allows input of dry reactant gasses, humidifies the reactants utilizing fuel cell product water, then removes dissolved and gaseous reactants from the product water issuing from the stack so this product water can be easily managed even in zero gravity.

[0066] The benefits of the innovative design include allowing all cells within the stack maintain a desired stoic ratio, and concentrating contaminants in the ICC cell so a minimal amount of venting is required. Minimal venting can provide a significant improvement in reactant utilization that is crucial especially in remote space missions.

[0067] When the inert concentrator is vented the concentrated nature of the accumulated elements allows for a venting to occur which removes primarily waste as opposed to a waste/hydrogen combination. Illustrated by reference numeral 33 in FIG. 4.

[0068] The cascade/ICC combination allows for significantly greater efficiency than either a situation where hydrogen is mechanically pumped or one where hydrogen is expelled along with waste gas at a higher ratio.

[0069] The current invention performs electrochemical circulation through as few as just one cell by combining the benefits of a cascade with the benefits of the electrochemical hydrogen pump.

[0070] The current invention provides for in-stack degasification of fuel cell product water.

[0071] The proposed innovation; the cascaded fuel cell stack with its H-D section and ICC section provides a technological advance that contributes to system simplicity and improved reliability through (1) innovative, integrated system-level design concepts and (2) passive ancillary components. All gas mechanical re-circulation is eliminated and motorized ancillary components are reduced. Power plant weight, volume complexity and cost are reduced. Power plant reliability and efficiency are improved. Power plant and PEM membrane durability are both improved. Performance and efficiency of individual PEM cells is improved. Parasite power requirements are reduced. Control and monitoring requirements are reduced. Vehicle power plant interface connections are simplified.

[0072] There has been provided a non-flow through fuel cell. While the non-flow through fuel cell has been described in the context of specific embodiments thereof, other unforeseen alternatives, modifications, and variations may become apparent to those skilled in the art having read the foregoing description. Accordingly, it is intended to embrace those alternatives, modifications, and variations which fall within the broad scope of the appended claims.