FUEL CELL POWER PLANT WITH INCREASED REACTANT PRESSURES

Abstract: The fuel cell power plant operates at higher reactant pressures, and thus higher power density (lower cost) and efficiency, by providing reactant reformer steam (42) from a separate steam boiler (42). Instead of supplying coolant steam to the reformer, the coolant is operated in a closed loop apart (10, 12) from the reformer (46), and the coolant steam is used to drive a steam generator (20, 22) to produce additional electricity. A portion of the raw fuel (40) is burned within the steam boiler and the remainder is passed through the reformer and thence to the fuel cells (2). Boiler exhaust (64) is used to drive a turocompressor (62) which pressurizes the air (30) used on the cathode side (6) of the fuel cells.

Description: Technical Field This invention relates to pressurized fuel cell power plants, and more particularly, to acid fuel cell power plants which are operated at higher than normal reactant pressures without unduly elevating the operating temperatures of the cells. Background Art As a general rule, acid type fuel cell power systems will operate more efficiently and with increased power density (lower cost) in a pressurized environment. Elevated steam pressures are generated in the fuel cell stacks of the system by heating water to elevated temperatures in the cooling system. The steam pressure will thus be proportional to the cell stack temperature. In an acid fuel cell system, the elevated pressure on the cathode or oxygen side of the system will be created by compressing air fed into the system by means of a turbocompressor which is operated with waste heat from the power plant. On the fuel side, raw hydrocarbon fuel will be elevated in pressure by an electrically driven pump or compressor and fed into a catalytic reformer vessel where the fuel is mixed with the heated steam at an elevated pressure. The raw fuel is thus catalytically converted to a hydrogen enriched fuel gas suitable for use in the electrochemical reaction in the fuel cells. This enriched fuel is fed to the anode side of the fuel cell power section of the plant from the reformer. This catalytic reforming of the fuel gas and the electrochemical reactions in the fuel cells proceed more vigorously at higher pressures and temperatures. In order to ensure proper fluid flow in the system, the reactant pressures cannot be higher than the steam pressure. In the prior art, the steam for the reformer has typically been provided by routing steam from the coolant, after the latter has cooled the cells, to the reformer. Such a system is shown in U.S. Patent No. 3,982,962 Bloomfield, granted September 28, 1976. When coolant steam is used in the reformer, the temperature and pressure of the steam in the reformer are limited by the operating temperatures of the cells in the power section which are being cooled by the coolant. In acid fuel cells, and particularly in phosphoric acid fuel cells, the material from which the cell components are made impose a maximum permissible operating temperature on the cells of about 232°C (450°F). If the operating temperatures of the cells exceed the maximum permissible operating temperatures, the cells will begin to fail. Acid fuel cell stacks are cooled by coolant passages which are interspersed throughout the stacks and which carry a coolant fluid, typically water. The coolant passages are preferably pipes which traverse the cell stack. These coolant pipes will typically be spaced apart in the stack so that each coolant pipe level will serve to cool about four or so cells on each side (above and below) the coolant pipe levels. A coolant system of this general type is disclosed in U.S. Patent No. 4,574,112, Breault et al., granted March 4, 1986. With this type of coolant system it will be appreciated that the coolant temperature will not reach the level of the temperature of the cells because the cooling is not performed one-on-one with the cells. For example, if one were to desire to operate the fuel gas reformer at a pressure of 310 N cm⁻² (450 psi) to feed hydrogen-rich gas to fuel cell stacks operating at about 276 N cm⁻² (400 psi), the pressure in the coolant tubes in the power section of the stack would have to be greater than 310 N cm⁻² (450 psi). In order to produce this 310 N cm⁻² (450 psi) coolant pressure, the temperature of the coolant steam would have to be greater than 238°C (460°F) in the coolant tubes. To achieve this 238°C (460°F) steam temperature in the coolant tubes, the cells would have to operate at temperatures greater than 260°C (500°F), which is above the maximum permissible extended operating cell temperature. It is thus apparent with the cooling and steam reforming systems of that prior art, one must not operate the fuel gas reformer at pressures in excess of about 121 N cm⁻² (175 psi), and that this pressure limit is the direct result of the maximum permissible power section fuel cell operating temperatures. This also places an upper limit of less than 121 N cm⁻² (175 psi) on the operating pressure in the cells. In JP-A-58 28176 a fuel cell power plant comprising a coolant system having two cycles is disclosed, i.e. a steam cycle cooling the cell stack and a low-boiling-point medium cycle, the two cycles being in contact by means of regenerators. US-A-3 972 731 shows a fuel cell power plant having a reformer which operates independently of the power section cooling system. The fuel cell power plant of JP-A-585974 also has an independently operating recirculating cooling system. Disclosure of Invention As previously noted, it is highly desirable to elevate the operating pressure of the fuel gas reformer and fuel cells to improve efficiency and power density. We have invented a fuel cell power plant system which can operate with an acid electrolyte, particularly phosphoric acid, wherein the fuel gas reformer and fuel cells can be operated at pressures in excess of 138 N cm⁻² (200 psi) and as high as about 276 N cm⁻² (400 psi) while the cell operating temperatures are maintained at safe levels of about 204°C (400°F). The benefits of our system include smaller, more efficient, less expensive reformers, fuel cells, heat exchangers, piping and controls, along with longer cell life. The power output of the system of our invention is equivalent to the prior art system per unit of operating fuel consumed, but the equipment size is smaller, improving cost per kilowatt of electricity produced. In the system of this invention, the fuel cell power section is cooled by water recirculated in a closed loop which loop does not extend to the reformer in the system. The two phase water-steam mixture produced by cooling the power section with water is cycled to a steam separator where the steam fraction is separated from the water fraction. The water fraction is returned to the cooling passages in the power section. The separated steam fraction is fed to a steam turbine generator which is operated by the coolant steam to generate electricity. About 20% of the electricity generated by the system thus is derived from the coolant steam. The exhaust from the steam turbine passes through a condenser whereupon the water condensate is fed into the water recycled from the steam separator to the coolant passages. Steam for operating the reformer is produced by a boiler into which water is fed and boiled to produce steam. The boiler is fired partly by a fraction of the raw hydrocarbon fuel which is used to operate the fuel cells. Steam is produced by the boiler at a temperature of about 238°C (460°F) and is fed to the reformer which is operating at a pressure of about 310 N cm⁻² (450 psi). The raw hydrocarbon fuel not used to fire the boiler is fed into the reformer for conversion to a hydrogen-enriched fuel suitable for fueling the fuel cells. The reformer is heated by burning anode and cathode exhaust gases in a burner associated with the reformer to maintain the reformer operating temperature. The exhaust from the reformer burner is fed to the boiler to help fuel the latter along with the raw fuel diverted for that purpose. The burner exhaust from the steam boiler is used to drive a turbocompressor which compresses the air fed to the cathode side of the power section of the system. It is therefore an object of this invention to provide a fuel cell power plant which can be operated at high reactant pressures for improved cost, size and efficiency. It is a further object of this invention to provide a power plant of the character described which utilizes an acid electrolyte and wherein the cells can be operated at optimum temperatures. It is another object of this invention to provide a power plant of the character described wherein reformer steam used to generate the reactant at higher pressures is produced by a steam boiler fired at least partially by raw fuel. It is an additional object of this invention to provide a power plant of the character described wherein the power section is cooled by a recycling water coolant loop with coolant steam being used to drive a steam powered electricity generator. It is yet another object of this invention to provide a power plant of the character described wherein the reformer steam system and the coolant steam system are completely separate from each other and operate independently of each other. These and other objects and advantages of the invention will become more readily apparent from the following detailed description of a preferred embodiment thereof when taken in conjunction with the accompanying drawing. Brief Description of the Drawing The drawing is a schematic representation of a power plant configured in accordance with the invention. Best Mode for Carrying Out the Invention Referring to the drawing, the electrochemical power section of the plant is denoted generally by the numeral 2, and includes an anode side 4, a cathode side 6 and a cooling portion 8. It will be appreciated that the power section 2 is actually a stack of rectangular fuel cells disposed one atop the other, with the anode side 4 being fueled with hydrogen rich fuel via a first manifold on one side of the stack with the anode exhaust gas being removed via a second manifold on the side of the stack opposite the first manifold. The cathode side is fed oxygen (air) in a direction transverse to the hydrogen gas flow via manifolds on the remaining two sides of the stack. Coolant water is admitted to the power section cooling portion 8 via inlet line 10 and the two-phase water-steam mixture formed as a result of the cooling operation leaves the cooling portion 8 through outlet line 12. The water-steam mixture is fed into a steam separator drum 14 wherein the water phase is separated from the steam phase. The water phase is returned to the inlet line 10 through line 15 by means of a pump 16. The steam phase leaves the separator 14 through a line 18 and is used to drive a turbine 20 which in turn operates a generator 22 to produce electricity. Exhaust from the turbine 20 passes to a condenser 24 through a line 26, and water condensed out of the turbine exhaust is returned to the coolant inlet 10 through lines 28 and 15. The temperature of the water in the line 10 is about 177°C (350°F), the temperature of the water-steam mixture in the line 12 is about 177°C (350°F), the temperature of the steam in the line 18 is about 177°C (350°F). At these temperatures, the pressure in the cooling portion 8 is about 93 N cm⁻² (135 psi) and the cells in the power section 2 will be operating at a maximum temperature of about 204°C (400°F). Air for the cathode side 6 enters the system through line 30 where it is compressed to a pressure of about 276 N cm⁻² (400 psi) by compressor 32 and fed to the cathode side 6 through cathode inlet line 34. Raw hydrocarbon fuel which has been compressed to a pressure of about 276 N cm⁻² (400 psi) by a pump 35 enters the system via line 36 where a control valve 38 diverts about 20% of the raw fuel into line 40 to be burned to fire a boiler 42 which produces high temperature, high pressure steam. Water from line 44 passes through the boiler 42 where it is converted to steam which is transported to a catalytic hydrocarbon fuel reformer 46 through line 48 and mixed with the raw hydrocarbon fuel in line 50 at the reformer inlet. The remaining 80% of the raw hydrocarbon fuel also is transported to the reformer 46 via line 50 from the valve 38. The steam in the line 48 and reformer 46 will be at a pressure of about 310 N cm⁻² (450 psi) and a temperature of about 238°C (460°F). The reformed hydrogen-rich fuel gas moves from the reformer 46 through an outlet line 52 to the inlet side of the anode 4. Exhaust from the anode side 4 is emitted to an outlet line 54 whereby it is transported to a burner 56 associated with the reformer 46. Exhaust from the cathode side 6 is transported to the reformer burner 56 by means of cathode outlet line. The anode and cathode exhausts which contain hydrogen and oxygen are burned in the burner 56 to maintain the reformer operating temperature at about 982°C (1800°F). Exhaust from the burner 56 still containing some oxygen is transported to the boiler 42 by line 60 for admixture with the raw fuel from line 40 and burned. Exhaust from the boiler 42 is fed to a turbine 62 through line 64, the turbine 62 being operable to drive the air compressor 32. It will be noted from the aforesaid description that the reformer, which is a conventional steam reformer, operates entirely independently of the power section coolant system. This invention thus enables one to operate the cell stack power section and coolant system at optimum pressures above 138 N cm⁻² (200 psi), and preferably at about 276 N cm⁻² (400 psi) but with low temperatures of about 204°C (400°F) which will ensure longer component and electrolyte life for the power plant. At the same time, the reformer can be operated at optimum pressures of about 310 N cm⁻² (450 psi) and temperatures of about 932°C (1800°F) so as to ensure optimum reforming of the fuel gas and extended catalyst life. These optimum conditions can be realized even though they would be mutually exclusive with the systems of the prior art which use coolant steam for the reforming process. Since a portion of the raw fuel is used to fuel the steam boiler, not all of the fuel consumed by the system will be used in the electrochemical production of electricity, thus the system will produce less electrochemical electricity per unit of fuel consumed than a prior art stack, however, the use of the coolant steam to drive the steam turbine electric generator provides additional electricity not electrochemically produced because of the fuel diversion. The total electrical power produced by the plant is thus equivalent per unit of fuel consumed, to that produced by a prior art conventional stack. A power system which embodies this invention can be made smaller and less expensively because increasing the system pressure improves cell performance and allows a reduction in the size of the fuel cells, fuel processing and thermal management reactors, piping and heat exchangers. An example of improved performance with increasing pressure is the behavior of the fuel cell. In current pressurized systems, cell stacks operate at 83 N cm⁻² (120 psi). That is, the air on the cathodes and the hydrogen rich fuel gas on the anodes are at 83 N cm⁻² (120 psi). The water in the cooling tubes is at about 110 N cm⁻² (160 psi) and 185°C (365°F). The cells operate at 2153 Am⁻² (200 amps per square foot (ASF)) and a voltage of 0.75 volts. Therefore, each cell generates about 1615 Wm⁻² (150 watts per square foot (WSF)). Using the format of this invention, the system could operate with the reactant gases at 276 N cm⁻² (400 psi) and the cells would generate a voltage of 0.82 volts at 2153 Am⁻² (200 ASF). This means the efficiency of the cells would be higher by 7 percentage points and the power density would be increased to 1765 Wm⁻² (164 WSF). If only higher power density were desired, the cells could be operated at the same voltage (0.75 volts) but at much higher current density of 5382 Am⁻² (500 ASF). This would increase the power density to 4037 Wm⁻² (375 WSF). If desired, an intermediate current density, between 2153 Am⁻² (200 ASF) and 5382 Am⁻² (500 ASF) could be picked as the operating point and a combination of higher efficiency and higher power density would result. As can be seen by these examples, significant improvements result with higher pressure operation made possible by this invention.

Claims: A fuel cell power plant system comprising: a) a power section (2) comprising a plurality of fuel cells forming a stack, each of said cells having an anode side (4) and a cathode side (6); b) means (8, 10, 12, 14, 15, 16) for cooling said stack with a water coolant, said means for cooling including a water circulating loop (10, 12, 15) and heat exchange means (8) in said stack through which the water coolant flows, said water circulating loop (10, 12, 15) including a steam separator (14) for separating coolant steam from a steam-water mixture exhausted from said heat exchange means (8); c) a turbogenerator (20, 22) operable by steam from said steam separator (14) for generating a portion of the electrical power produced by said power plant system; d) means (10, 15, 16) for recirculating water from said steam separator (14) back to said heat exchange means (8) in said stack; e) a reformer (46, 56) operable independently of said stack cooling means (8, 10, 12, 14, 15, 16) for catalytically converting raw hydrocarbon fuel to a hydrogen rich fuel gas suitable for fueling said anode side (4) of the fuel cells; f) a boiler (42) for producing steam having a temperature of at least about 204°C (400°F) by burning raw hydrocarbon fuel admitted to said system; g) means (48) for transporting steam from said boiler (42) at a pressure greater than about 138 N cm⁻² (200 psi) to said reformer (46, 56); h) means (35, 36, 38, 50, 48) for admitting raw hydrocarbon fuel to said system, said means for admitting including duct means (36,50 , 48) for transporting the raw hydrocarbon fuel to said reformer (46, 56) for admixture with said steam from said boiler (42) prior to entering said reformer (46, 56); i) means (52) for transferring hydrogen rich fuel gas from said reformer (46, 56) to said anode side (4) of said fuel cells at a pressure of at least about 138 N cm⁻² (200 psi); and j) means (30, 32, 34, 62) for supplying an oxidant gas at a pressure of at least about 138 N cm⁻² (200 psi) to said cathode side (6) of said fuel cells. The fuel cell power plant system of claim 1 wherein said means (8, 10, 12, 14, 15, 16) for cooling said stack (2) is operable to maintain said stack at an operating temperature of about 204°C (400°F). The fuel cell power plant system of claim 1 or 2 wherein said reformer (46) is operable at a pressure of about 276 N cm⁻² (400 psi). The fuel cell power plant system of anyone of claims 1 to 3 wherein said fuel cells are operable at a pressure of about 276 N cm⁻² (400 psi); said boiler (42) is operable to produce steam at a pressure of about 310 N cm⁻² (450 psi); and said means (8, 10, 12, 14, 15, 16) for cooling said stack (2) is operable at a pressure of about 93 N cm⁻² (135 psi). The fuel cell power plant system of any one of claims 1 to 4 wherein said boiler (42) is operable by burning raw hydrocarbon fuel and exhaust gas from the reformer burner (56). The fuel cell power plant system of any one of claims 1 to 5 wherein said means (30, 32, 34, 62) for supplying an oxidant gas comprises a turbocompressor (32, 62) operable by exhaust from said boiler means (42). The fuel cell power plant system of any one of claims 1 to 6 further comprising a condenser (24) operable to condense water out of the exhaust from said turbogenerator (20, 22), and means (28) operable to return the condensed water from said condenser (24) to said means (10, 15, 16) for recirculating water. The fuel cell power plant system of any one of claims 1 to 7, said fuel cells comprising an acid electrolyte, preferably a phosphoric acid electrolyte. A method of operating a fuel cell power plant, said method comprising the steps of: a) providing an oxidant gas at a pressure of at least 138 N cm⁻² (200 psi) to a cathode portion (6) of said fuel cell power plant; b) providing a supply of raw hydrocarbon fuel pressurized to a pressure of at least 138 N cm⁻² (200 psi); c) providing a supply of steam which is pressurized to a pressure greater than that of said raw hydrocarbon fuel by burning raw hydrocarbon fuel; d) mixing said raw hydrocarbon fuel and steam; e) catalytically converting said fuel and steam mixture into a hydrogen rich fuel; f) providing said hydrogen rich fuel at a pressure of at least 138 N cm⁻² (200 psi) to an anode portion (4) of said fuel cell power plant; g) cooling said fuel cell power plant with a closed loop water coolant system (8, 10, 12, 14, 15, 16) operating at an internal pressure of less than 138 N cm⁻² (200 psi) which loop is completely isolated from the system for converting raw hydrocarbon fuel and steam into hydrogen rich fuel; and h) separating steam from water in said closed loop (8, 10, 12, 14, 15, 16) and using the separated steam to drive an electric turbogenerator (20, 22) to produce additional electrical output. The method of claim 9 wherein the fuel cell stack (2) of said power plant is cooled to an operating temperature of about 204°C (400 °F). The method of claim 9 or 10 wherein said oxidant gas is provided at a pressure of about 276 N cm⁻² (400 psi), said raw hydrocarbon fuel is provided at a pressure of about 276 N cm⁻² (400 psi), said steam is provided at a pressure greater than about 276 N cm⁻² (400 psi), said hydrogen rich fuel is provided at a pressure of about 276 N cm⁻² (400 psi), and said coolant system (8, 10, 12, 14, 15, 16) operates at an internal pressure of about 93 N cm⁻² (135 psi). The method of any one of claims 9 to 11 wherein said steam is provided by burning raw hydrocarbon fuel and exhaust gas from said system for converting raw hydrocarbon fuel and steam into hydrogen rich fuel. The method of any one of claims 9 to 12 wherein said air is pressurized by a compressor (32) operated by exhaust from a boiler (42) providing said steam. The method of any one of claims 9 to 13 wherein water is condensed out of the exhaust from said turbogenerator (20, 22) and returned to said closed loop (8, 10, 12, 14, 15, 16) of said water coolant system. The method of any one of claims 9 to 14 wherein the fuel cells of said power plant operate with an acid electrolyte, preferably phosphoric acid electrolyte.

Inventors: BUSWELL, RICHARD F., COHEN, RONALD
Applicants: INTERNATIONAL FUEL CELLS CORPORATION
Application year: 1988
Main classification: H01M8
IPC codes: H01M8