Abstract: A fuel cell APU system comprising a plurality of fuel cell modules connected in parallel. Each module includes a local controller connected to a master controller that coordinates the modules to achieve a desired power output at any given time. Each module is operated within an output range to maximize efficiency of the system. When load demand on a first module exceeds the desired output range of the module, an additional module is brought online in parallel with the first. As the load increases further, additional modules are brought online in cascade fashion to permit all modules to be operated efficiently. If a module is disabled, it is automatically switched out of service and replaced by a standby module. The master controller keeps track of the total operating time of each module and varies the sequence in which different modules are brought into service to balance deterioration among the modules.

Abstract: A fuel cell APU system comprising a plurality of fuel cell modules connected in parallel. Each module includes a local controller connected to a master controller that coordinates the modules to achieve a desired power output at any given time. Each module is operated within an output range to maximize efficiency of the system. When load demand on a first module exceeds the desired output range of the module, an additional module is brought online in parallel with the first. As the load increases further, additional modules are brought online in cascade fashion to permit all modules to be operated efficiently. If a module is disabled, it is automatically switched out of service and replaced by a standby module. The master controller keeps track of the total operating time of each module and varies the sequence in which different modules are brought into service to balance deterioration among the modules.

Abstract: In a solid-oxide fuel cell system, the fuel cell stacks, the fuel reformer, tail gas combuster, heat exchangers, and fuel/air manifold, are contained in a “hot zone” within a thermal enclosure. A separate and larger structural enclosure surrounds the thermal enclosure, defining a “cool zone” outside the thermal enclosure for incorporation of “cool” components such as the air supply system and the electronic control system. To prevent unwanted temperature rise in the cool zone during shutdown, from residual heat escaping from the hot zone through the thermal enclosure, the structural enclosure is provided with vents through the lower and upper walls thereof to permit thermal convective circulation of air through the enclosure. The vents are baffled to prevent entry of splash and other contaminants, and the lower vent is provided with a float valve to prevent flooding of the enclosure in event of immersion of the SOFC system.

Abstract: A Combined Heat and Power System (“CHPS”) includes a solid oxide fuel cell system and a vapor compression cycle heat pump. The CHPS improves the overall efficiency of a CHP system with respect to conversion of fuel energy to usable heat and electrical energy without need for an accessory burner-heat exchanger system. The compressor motor of the heat pump is powered by a portion of the electricity generated by the SOFC, and the thermal output of the heat pump is increased by abstraction of heat from the SOFC exhaust. This integration allows for novel and complementary operation of each type of system, with the benefits of improved overall fuel efficiency for the improved CHP system.

Abstract: In a fuel cell assembly, nickel-based anodes are readily oxidized when exposed to oxygen as may happen through atmospheric invasion of the assembly during cool-down following shutdown of the assembly. Repeated anode oxidation and reduction can be destructive of the anodes, leading to cracking and failure. To prevent such oxygen migration, oxygen getter devices containing oxygen-gettering material such as metallic nickel are provided in the fuel passageways leading to and from the anodes. Oxidation of the oxygen-gettering material is readily reversed through reduction by fuel when the assembly is restarted.

Abstract: A load frame with mechanical springs for providing compression to a fuel cell stack during assembly and operation of a fuel cell assembly. The stack assembly load frame includes a base plate for supporting the stack, a moveable spring holder above the stack, a retaining plate above the spring holder, and tubular supports or rods retaining the post-sintered spacing established by the applied load defining the spacing of the base plate from the retaining plate. A spring for maintaining compression in each stack is positioned between the spring holder and the retaining plate. The invention further comprises a method for assembling a fuel cell assembly to provide an adequate compressive load to the stack during assembly and operation.

Abstract: A solid-oxide fuel cell system having “hot” components, e.g., the fuel cell stacks, the fuel reformer, tail gas combuster, heat exchangers, and fuel/air manifold, contained in a “hot zone” within a thermal enclosure intended specifically for minimizing heat transfer to its exterior and having no significant structural or protective function for its contents. A two-part clamshell arrangement allows all piping and leads which must pass through the enclosure to do so at the join line between the parts, thus eliminating need for ports and fittings in the thermal enclosure. A separate and larger structural enclosure surrounds the thermal enclosure, defining a “cool zone” outside the thermal enclosure for incorporation of “cool” components, e.g., the air supply system and the electronic control system, and providing structural protection for all components of the fuel cell system.

Abstract: A solid-oxide fuel cell system including an integrated reforming unit comprising a hydrocarbon fuel reformer; an integral tail gas and cathode air combustor and reformer heat exchanger; a fuel pre-heater and fuel injector cooler; a fuel injector and fuel/air mixer and vaporizer; a reforming air pre-heating heat exchanger; a reforming air temperature control valve and means; and a pre-reformer start-up combustor. The integration of a plate reformer, tail gas combustor, and combustor gas heat exchanger allows for efficient operation modes of the reformer, both endothermic and exothermic as desired. The combustor gas heat exchanger aids in temperature regulation of the reformer and reduces significant thermal gradients in the unit.

Abstract: A fuel cell system is disclosed. A fuel cell stack is in fluid communication with a reformer. An air conditioning system is in fluid communication with the reformer. Methods of making and using a fuel cell system are also disclosed.

Abstract: In a fuel cell assembly, nickel-based anodes are readily oxidized when exposed to oxygen as may happen through atmospheric invasion of the assembly during cool-down following shutdown of the assembly. Repeated anode oxidation and reduction can be destructive of the anodes, leading to cracking and failure. To prevent such oxygen migration, check valves and oxygen getter devices containing oxygen-scavenging material such as metallic nickel are provided in the reformate passageways leading to and from the anodes. The check valves preferably are closed by gravity. Oxidation of the oxygen-gettering material is readily reversed through reduction by reformate when the assembly is restarted.

Abstract: In a solid-oxide fuel cell system, the fuel cell stacks, the fuel reformer, tail gas combuster, heat exchangers, and fuel/air manifold, are contained in a “hot zone” within a thermal enclosure. A separate and larger structural enclosure surrounds the thermal enclosure, defining a “cool zone” outside the thermal enclosure for incorporation of “cool” components such as the air supply system and the electronic control system. To prevent unwanted temperature rise in the cool zone during shutdown, from residual heat escaping from the hot zone through the thermal enclosure, the structural enclosure is provided with vents through the lower and upper walls thereof to permit thermal convective circulation of air through the enclosure. The vents are baffled to prevent entry of splash and other contaminants, and the lower vent is provided with a float valve to prevent flooding of the enclosure in event of immersion of the SOFC system.

Abstract: A load frame with mechanical springs for providing compression to a fuel cell stack during assembly and operation of a fuel cell assembly. The stack assembly load frame includes a base plate for supporting the stack, a moveable spring holder above the stack, a retaining plate above the spring holder, and tubular supports or rods retaining the post-sintered spacing established by the applied load defining the spacing of the base plate from the retaining plate. A spring for maintaining compression in each stack is positioned between the spring holder and the retaining plate. The invention further comprises a method for assembling a fuel cell assembly to provide an adequate compressive load to the stack during assembly and operation.

Abstract: A non-contact fuel vaporizer adds heat to the injected fuel by combining the fuel with heated air in a vaporization chamber downstream of air supply inlets. The fuel is metered axially through a conventional fuel injector. The heated air is metered through an air director plate that introduces the air in a helical trajectory concentrically around the injector spray. When the hot swirling air comes in contact with the atomized fuel, substantially all of the fuel is vaporized before coming into contact with a wall of the vaporization chamber.

Abstract: In a fuel cell assembly, nickel-based anodes are readily oxidized when exposed to oxygen as may happen through atmospheric invasion of the assembly during cool-down following shutdown of the assembly. Repeated anode oxidation and reduction can be destructive of the anodes, leading to cracking and failure. To prevent such oxygen migration, check valves and oxygen getter devices containing oxygen-scavenging material such as metallic nickel are provided in the reformate passageways leading to and from the anodes. The check valves preferably are closed by gravity. Oxidation of the oxygen-gettering material is readily reversed through reduction by reformate when the assembly is restarted.

Abstract: A solid-oxide fuel cell system having “hot” components, e.g., the fuel cell stacks, the fuel reformer, tail gas combuster, heat exchangers, and fuel/air manifold, contained in a “hot zone” within a thermal enclosure intended specifically for minimizing heat transfer to its exterior and having no significant structural or protective function for its contents. A two-part clamshell arrangement allows all piping and leads which must pass through the enclosure to do so at the join line between the parts, thus eliminating need for ports and fittings in the thermal enclosure. A separate and larger structural enclosure surrounds the thermal enclosure, defining a “cool zone” outside the thermal enclosure for incorporation of “cool” components, e.g., the air supply system and the electronic control system, and providing structural protection for all components of the fuel cell system.

Abstract: In a fuel cell assembly, nickel-based anodes are readily oxidized when exposed to oxygen as may happen through atmospheric invasion of the assembly during cool-down following shutdown of the assembly. Repeated anode oxidation and reduction can be destructive of the anodes, leading to cracking and failure. To prevent such oxygen migration, oxygen getter devices containing oxygen-gettering material such as metallic nickel are provided in the fuel passageways leading to and from the anodes. Oxidation of the oxygen-gettering material is readily reversed through reduction by fuel when the assembly is restarted.

Abstract: A solid-oxide fuel cell system including an integrated reforming unit comprising a hydrocarbon fuel reformer; an integral tail gas and cathode air combustor and reformer heat exchanger; a fuel pre-heater and fuel injector cooler; a fuel injector and fuel/air mixer and vaporizer; a reforming air pre-heating heat exchanger; a reforming air temperature control valve and means; and a pre-reformer start-up combustor. The integration of a plate reformer, tail gas combustor, and combustor gas heat exchanger allows for efficient operation modes of the reformer, both endothermic and exothermic as desired. The combustor gas heat exchanger aids in temperature regulation of the reformer and reduces significant thermal gradients in the unit.

Abstract: A method of starting a solid oxide fuel cell system is disclosed. The method comprises pressurizing a main plenum to a first pressure. The main plenum comprises a first supply of fuel, blowers, and air control valves. The first supply of fuel and a first supply of air are directed to a preheated micro-reformer. A heated pre-reformate is created in the micro-reformer and discharged from the micro-reformer to a main reformer. The main reformer is preheated with the heated pre-reformate. A second supply of fuel and a second supply of air are introduced to the main reformer. A heated main reformate is created in the main reformer and directed to a waste energy recovery assembly. A cathode supply is heated in the waste energy recovery system and then directed to a solid oxide fuel cell stack in order to heat the solid oxide fuel cell stack. Methods of transitioning, operating, shutting down, and maintaining in standby mode are also disclosed.

Abstract: A fuel cell system is disclosed. A fuel cell stack is in fluid communication with a reformer. An air conditioning system is in fluid communication with the reformer. Methods of making and using a fuel cell system are also disclosed.

Abstract: A method of starting a solid oxide fuel cell system is disclosed. The method comprises pressurizing a main plenum to a first pressure. The main plenum comprises a first supply of fuel, blowers, and air control valves. The first supply of fuel and a first supply of air are directed to a preheated micro-reformer. A heated pre-reformate is created in the micro-reformer and discharged from the micro-reformer to a main reformer. The main reformer is preheated with the heated pre-reformate. A second supply of fuel and a second supply of air are introduced to the main reformer. A heated main reformate is created in the main reformer and directed to a waste energy recovery assembly. A cathode supply is heated in the waste energy recovery system and then directed to a solid oxide fuel cell stack in order to heat the solid oxide fuel cell stack. Methods of transitioning, operating, shutting down, and maintaining in standby mode are also disclosed.