PASSIVE ELECTRODE BLANKETING IN A FUEL CELL

- Hydrogenics Corporation

When a conventional fuel cell module is shutdown the conditions within the fuel cell stack change. The conditions change because elements that support and regulate the operation of the fuel cell stack switch to their respective shutdown states. For example, the input and output valves are closed, which cuts off the supply inflows and exhaust outflows. Moreover, when an element such as a flow control device switches to a shutdown state internal conditions, such as for example, the pressure within the anode electrodes change. When the internal conditions of the fuel cell stack change the reactants (e.g. hydrogen and oxygen) remaining in the fuel cell stack and the feed lines (between the fuel cell stack and the closed valves) are substantially consumed in combustion reactions as opposed to being consumed in electrochemical reactions yielding a useful form of energy.

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Description

This application is a continuation of prior U.S. application Ser. No. 10/875,288 filed Jun. 25, 2004, which claims the benefit of Provisional Applications 60/482,010 and 60/495,091 filed Jun. 25, 2003 and Aug. 15, 2003, respectively, claims the benefit of Provisional Application No. 60/771,018, filed Feb. 8, 2006, each of which is incorporated herein by reference.

FIELD

The invention relates to fuel cells, and, in particular to reducing the rate of wear and degradation experienced by some components of a fuel cell during shutdown and restarting periods.

BACKGROUND

The following paragraphs are not an admission that anything discussed in them is prior art or part of the knowledge of persons skilled in the art.

A fuel cell converts chemical energy stored in a fuel into a useful form of energy, such as for example, electricity. One example of a particular type of fuel cell is a Proton Exchange Membrane (PEM) fuel cell that is operable to produce electricity.

A typical PEM fuel cell includes an electrolyte membrane arranged between an anode electrode and a cathode electrode. Hydrogen fuel is supplied to the anode electrode and an oxidant is supplied to the cathode electrode. Within the PEM fuel cell the hydrogen fuel and the oxidant are employed as reactants in a set of complementary electrochemical reactions that yield electricity, heat and water.

A number of factors cause other undesired reactions to occur that increase the rate of wear and degradation experienced by some components of a PEM fuel cell. For example, small amounts of hydrogen fuel and oxidant remaining inside a PEM fuel cell, after respective supplies of these reactants are closed off, are known to combust during shutdown and restarting processes. Combustion within a PEM fuel cell causes the deterioration of various components including the electrolyte membrane and catalyst layers deposited on the electrodes. The cumulative deterioration of various components significantly reduces the efficiency of the PEM fuel cell and may lead to failure of the PEM fuel cell.

More specifically, combustion as opposed to electrochemical consumption of the hydrogen and oxygen occurs because the conditions within a PEM fuel cell module start to change as support systems operable during the normal operation (i.e. the “on” state) of the PEM fuel cell module are switched to an “off” state. As the internal conditions change, some hydrogen molecules diffuse to the cathode side of the membrane and burn in the presence of the oxygen. Similarly, some oxygen molecules diffuse across the membrane and react with the hydrogen fuel on the anode side of the membrane. The diffusion of hydrogen across the membrane is actually more common (in the absence of a driving differential pressure across the membrane) since hydrogen molecules are smaller than oxygen molecules, and, thus more readily diffuse through the membrane.

Another undesired reaction that may occur is the electrochemical corrosion of at least one catalyst layer within a PEM fuel cell. This further deteriorates the performance of a PEM fuel cell.

INTRODUCTION

The following introduction is intended to introduce the reader to this specification but not to define any invention. One or more inventions may reside in a combination or sub-combination of the apparatus elements or process steps described below or in other parts of this document. The inventor does not waive or disclaim his rights to any invention or inventions disclosed in this specification merely by not describing such other invention or inventions in the claims.

One aspect of a fuel cell module described in the specification includes a first reactant holding tank, which is pressurized by a pump during normal operation of the fuel cell module so that a pre-determined mass of first reactant is present in the holding tank. During shutdown of the fuel cell power module, the first reactant supply is closed to the fuel cell module and the first reactant from the holding tank is provided instead to a first reactant inlet of the fuel cell module. This system is useful when the first reactant supply pressure is low (e.g. a low pressure fuel cell module construction is used) and the use of a non-pressurized holding tank would necessitate a very large volume holding tank. Since the pressure in the first reactant holding tank is built up in this embodiment of the invention, the volume of the holding tank can be small but the provided mass of first reactant from the holding tank will still be sufficient to perform a blanketing shutdown as described above.

Another aspect of a fuel cell module described in the specification relates to a fuel cell stack including at least one fuel cell, each fuel cell including an anode electrode, a cathode electrode and an electrolyte medium arranged between the anode electrode and the cathode electrode. During normal operation the anode electrode is provided with a first reactant and the cathode electrode is provided with a first mixture containing a second reactant and a non-reactive agent. The fuel cell module further comprises a parasitic load that is connectable across the anode and the cathode electrodes. The fuel cell module further comprises a first reactant supply, fluidly connectable to the anode electrode, for supplying the first reactant to the anode electrode. The fuel cell module further comprises a side stream, optionally connected in parallel to, and fluidly connectable to the first reactant supply and the anode electrode. The fuel cell module further comprises a reactant reservoir, fluidly connectable to the side stream, for storing an amount of the first reactant suitable for a shutdown process of the fuel cell module. When the fuel cell module is shutdown, the stored amount of the first reactant is drawn from the reactant reservoir and electrochemically reacts with an amount of the second reactant remaining in the fuel cell module, to electrochemically consume all of the amounts of the first and second reactants, thereby leaving a second mixture that substantially comprises the non-reactive agent. The fuel cell module further comprises a pressure generating device, fluidly connectable to the side stream and positioned upstream of the reactant reservoir, for pressurizing and delivering the first reactant from the first reactant supply to the reactant reservoir.

Another aspect of a fuel cell module described in the specification relates to a fuel cell including a first electrode, a second electrode and an electrolyte medium arranged between the first and second electrodes. During normal operation the first electrode is provided with a first reactant and the second electrode is provided with a first mixture containing a second reactant and a non-reactive agent. The fuel cell module further comprises a parasitic load that is connectable across the first and second electrodes. The fuel cell module further comprises a first reactant supply, fluidly connectable to the anode electrode, for supplying first reactant to the anode electrode. The fuel cell module further comprises a side stream, optionally connected in parallel to, and fluidly connectable to the first reactant supply and the anode electrode. The fuel cell module further comprises a reactant reservoir, fluidly connectable to the side stream, for storing an amount of the first reactant suitable for a shutdown process of the fuel cell module. When the fuel cell module is shutdown, the stored amount of the first reactant is drawn from the reactant reservoir and electrochemically reacts with an amount of the second reactant remaining in the fuel cell module, to electrochemically consume all of the amounts of the first and second reactants, thereby leaving a second mixture that substantially comprises the non-reactive agent. The fuel cell module further comprises a pressure generating device, fluidly connectable to the side stream and positioned upstream of the reactant reservoir, for pressurizing and delivering the first reactant from the first reactant supply to the reactant reservoir.

Another aspect of a process for shutting down a fuel cell described in the specification relates to a fuel cell including a first electrode, a second electrode and an electrolyte membrane arranged between the first and second electrodes. During normal operation the process comprises the step of providing the first electrode with a first reactant and the second electrode with a first mixture containing a second reactant and a non-reactive agent. The operation process further comprises the step of pressurizing a portion of the first reactant and storing the first reactant in a reactant reservoir. During shutdown of the fuel cell the process further comprises the step of stopping an inflow of the first reactant into the first electrode. The shutdown process further comprises the step of cutting-off power to supporting balance of plant elements. The shutdown process further comprises the step of drawing current through a parasitic load connectable across the first and second electrodes. The shutdown process further comprises the step of permitting the stored first reactant to flow to the first electrode for the electrochemical consumption of a remaining amount of a second reactant. The first reactant electrochemically reacts with the remaining amount of the second reactant, thereby leaving a second mixture that substantially comprises the non-reactive agent.

Additional features, advantages, and embodiments of one or more inventions may be set forth or apparent from consideration of the following detailed description, drawings and claims. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description provide examples or further explanation without limiting the scope of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified schematic diagram of a fuel cell module;

FIG. 2 is a schematic diagram illustrating a first arrangement of a fuel cell module according to aspects of an embodiment of the invention;

FIG. 3 is a chart illustrating the composition of gases present in cathode electrodes of the fuel cell module shown in FIG. 2 during sequential stages of a shutdown process;

FIG. 4 is a schematic diagram illustrating a second arrangement of a fuel cell module according to aspects of another embodiment of the invention;

FIG. 5 is a schematic diagram illustrating a third arrangement of a fuel cell module according to aspects of another embodiment of the invention;

FIG. 6 is a schematic diagram illustrating a fourth arrangement of a fuel cell module according to aspects of another embodiment of the invention;

FIGS. 7a, 7b and 7c are schematic diagrams illustrating fourth, fifth and sixth arrangements of a fuel cell module according to aspects of another embodiment of the invention; and

FIG. 8 is a schematic diagram illustrating a seventh arrangement of a fuel cell module according to another embodiment of the present invention.

DETAILED DESCRIPTION

Various apparatuses or processes will be described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover processes or apparatuses that are not described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an embodiment of any claimed invention. The applicants, inventors and owners reserve all rights in any invention disclosed in an apparatus or process described below that is not claimed in this document and do not abandon, disclaim or dedicate to the public any such invention by its disclosure in this document.

A fuel cell module is typically made up of a number of fuel cells connected in series to form a fuel cell stack. The fuel cell module also includes a suitable combination of associated structural elements, mechanical systems, hardware, firmware and software that is employed to support the function and operation of the fuel cell module. Such items include, without limitation, piping, sensors, regulators, current collectors, seals and insulators.

Referring to FIG. 1, shown is a simplified schematic diagram of a Proton Exchange Membrane (PEM) fuel cell module, simply referred to as fuel cell module 100 hereinafter, that is described herein to illustrate some general considerations relating to the operation of fuel cell modules. It is to be understood that the present invention is applicable to various configurations of fuel cell modules that each include one or more fuel cells.

There are a number of different fuel cell technologies, and in general, this invention is expected to be applicable to all types of fuel cells. Very specific example embodiments of the invention have been developed for use with Proton Exchange Membrane (PEM) fuel cells. Other types of fuel cells include, without limitation, Alkaline Fuel Cells (AFC), Direct Methanol Fuel Cells (DMFC), Molten Carbonate Fuel Cells (MCFC), Phosphoric Acid Fuel Cells (PAFC), Solid Oxide Fuel Cells (SOFC) and Regenerative Fuel Cells (RFC).

Aspects of some example embodiments of the invention are described herein with respect to PEM fuel cell modules that employ hydrogen as a fuel and air as a source for an oxidant. Those skilled in the art will appreciate that air is approximately 80% nitrogen (N2) and 20% oxygen (O2) and is thus a suitable source of the oxidant. Moreover, these percentages have been approximated ignoring the presence of other gases in the atmosphere (e.g. CO2, CO, SO2, PbS, etc.).

The invention is generally applicable to any fuel cell that uses a gaseous fuel. Thus, the invention is applicable to fuel cells fueled from a reformer, which generates a gaseous stream including hydrogen and other components.

The fuel cell module 100 includes an anode electrode 21 and a cathode electrode 41. The anode electrode 21 includes a gas input port 22 and a gas output port 24. Similarly, the cathode electrode 41 includes a gas input port 42 and a gas output port 44. An electrolyte membrane 30 is arranged between the anode electrode 21 and the cathode electrode 41.

The fuel cell module 100 also includes a first catalyst layer 23 between the anode electrode 21 and the electrolyte membrane 30, and a second catalyst layer 43 between the cathode electrode 41 and the electrolyte membrane 30. In some embodiments the first and second catalyst layers 23, 43 are deposited on the anode and cathode electrodes 21,41, respectively.

A load 115 is coupled between the anode electrode 21 and the cathode electrode 41.

In operation, hydrogen fuel is introduced into the anode electrode 21 via the gas input port 22 under some predetermined conditions. Examples of the predetermined conditions include, without limitation, factors such as flow rate, temperature, pressure, relative humidity and a mixture of the hydrogen with other gases. The hydrogen reacts electrochemically according to reaction (1), given below, in the presence of the electrolyte membrane 30 and the first catalyst layer 23.
H2→2H++2e−  (1)

The chemical products of reaction (1) are hydrogen ions (i.e. cations) and electrons. The hydrogen ions pass through the electrolyte membrane 30 to the cathode electrode 41 while the electrons are drawn through the load 115. Excess hydrogen (sometimes in combination with other gases and/or fluids) is drawn out through the gas output port 24.

Simultaneously an oxidant, such as oxygen in the air, is introduced into the cathode electrode 41 via the gas input port 42 under some predetermined conditions. Examples of the predetermined conditions include, without limitation, factors such as flow rate, temperature, pressure, relative humidity and a mixture of the oxidant with other gases. The excess gases, including un-reacted oxidant and the generated water are drawn out of the cathode electrode 41 through the gas output port 44.

The oxidant reacts electrochemically according to reaction (2), given below, in the presence of the electrolyte membrane 30 and the second catalyst layer 43.
1/2O2+2H++2e−→H2O  (2)
The chemical product of reaction (2) is water. The electrons and the ionized hydrogen atoms, produced by reaction (1) in the anode electrode 21, are electrochemically consumed in reaction (2) in the cathode electrode 41. The electrochemical reactions (1) and (2) are complementary to one another and show that for each oxygen molecule (O2) that is electrochemically consumed two hydrogen molecules (H2) are electrochemically consumed.

Continuously supplying a fuel cell module (e.g. the fuel cell module 100 illustrated in FIG. 1) with hydrogen fuel and oxidant to drive electrochemical reactions (1) and (2) is wasteful and is unnecessary in many situations, such as, for example, where there is a fluctuating or intermittent load. However, in some instances shutting down a fuel cell module initiates one or more undesired reactions that degrade some components of the fuel cell module. Thus, it is desirable to be able to reliably turn-off (i.e. shutdown) and re-start a fuel cell module without causing excessive degradation to some components of the fuel cell module. In some embodiments of the invention there is provided a modification to a fuel cell module that reduces the rate of wear and degradation experienced by some components of the fuel cell module during shutdown and re-starting periods. In some embodiments the modification is further adapted to passively reduce the rate of wear and degradation, whereas in other embodiments active mechanisms are employed to support passive reduction in the rate of wear and degradation. In particular, in some embodiments of the invention the rate of wear and degradation is reduced by reducing the amount of combustion of the remaining reactants while increasing the electrochemical consumption of those reactants during a shutdown process.

Referring to FIG. 2, shown is a schematic diagram illustrating a fuel cell module 300 arranged according to aspects of an embodiment of the invention. Those skilled in the art will appreciate that a fuel cell module includes a suitable combination of supporting elements, commonly referred to as ‘balance of plant’, and that the fuel cell module 300 is illustrated showing only those elements necessary to describe aspects of this embodiment of the invention.

The fuel cell module 300 includes a fuel cell stack 200 that is made up of one of more PEM fuel cells. Each PEM fuel cell (not shown) includes an electrolyte membrane arranged between an anode electrode and a cathode electrode as schematically illustrated in FIG. 1. The fuel cell stack 200 has a cathode inlet port 202, a cathode outlet port 203, an anode inlet port 204 and an anode outlet port 205. The cathode inlet and outlet ports 202,203 are fluidly connected to each of the respective cathode electrodes included in the fuel cell stack 200. Similarly, the anode inlet and outlet ports 204,205 are fluidly connected to each of the respective anode electrodes included in the fuel cell stack 200.

The fuel cell stack 200 also includes electrical connections 18a,b across which a load (e.g., an electric motor) is connectable. A relatively small parasitic load 17 is optionally connected across the electrical connections 18a,b of the fuel cell stack 200. The small parasitic load 17 helps to limit the voltage response during a shutdown process, which is described in more detail below.

The value of the parasitic load 17 is preferably chosen to be relatively small compared to an actual load (e.g. the electric motor) that the fuel cell module 300 supplies power too, so that the amount of power dissipated by the parasitic load 17 during normal operation is relatively small compared to the amount of power dissipated through the actual load. In a very specific example, the parasitic load 17 is chosen such that it dissipates less than 0.03% the amount of power dissipated by the actual load during normal operation.

In some embodiments, as shown in FIG. 2, the small parasitic load 17 is permanently coupled across the electrical connections 18a,b; and thus, power is dissipated by the small parasitic load 17 during normal operation. In other embodiments the small parasitic load 17 is arranged so that it is coupled across the electrical connections 18a,b of the fuel cell stack 200 immediately before or after the fuel cell module 300 is shutdown and is decoupled from the fuel cell stack 200 during normal operation.

In some other alternative embodiments the parasitic load 17 is made-up of internal impedances within the fuel cell stack 200. In particular, in some embodiments the membrane(s) included in the fuel cell stack 200 provide enough of an internal resistance to serve as an adequate parasitic resistance during a shutdown process for limiting the voltage response of the fuel cell stack 200.

The fuel cell module 300 includes input valves 10 and 12 that are controllable to cut-off the inflow of reactant gases to the cathode inlet port 202 and the anode inlet port 204, respectively. Similarly, output valves 11 and 13 are provided to controllably cut-off the outflow of exhaust gases from the cathode outlet port 203 and the anode outlet port 205, respectively.

The input valve 10 is connected in series between the cathode inlet port 202 and a blower 60. The blower. 60 is any device (e.g., a motorized fan, a compressor, etc.) suitable to force air into the cathode inlet port 202 when the valve 10 is open. Optionally, the blower 60 also serves to passively deter, but not necessarily stop, the free flow of air into the cathode inlet port 202 when power is cut-off from the blower 60. This is described in more detail below with reference to FIGS. 3, 4 and 6.

The input valve 12 is connected in series between a fuel supply port 107 and the anode inlet port 204. The fuel supply port 107 is further connectable to a hydrogen fuel supply vessel (not shown) or some other hydrogen fuel delivery system (not shown). A fuel reservoir 19 and a flow control device 14 are connected respectively in series between the input valve 12 and the anode inlet port 204.

The output valve 11 is connected in series between the cathode outlet port 203 and a first exhaust port 108. Similarly, the output valve 13 is connected in series between the anode outlet port 205 and a second exhaust port 109. The exhaust ports 108 and 109 are each optionally connectable to other devices, such as for example, an exhaust system including an electrolyzer for re-cycling exhaust gases or liquids from the fuel cell module 300.

A check valve 15 is connected between an air supply port 106 to the ambient environment (not illustrated) and the cathode inlet port 202, such that the check valve 15 is in parallel with the input valve 10. In some embodiments, the check valve 15 is a pressure sensitive mechanism that opens when the pressure at the cathode inlet port 202 drops below the air pressure of the ambient environment by a pre-set amount, known as a cracking pressure. In some embodiments the cracking pressure is specifically set to correspond to a predetermined pressure differential between the air pressure in the ambient environment and the pressure inside of the cathode inlet port 202. In related embodiments the predetermined pressure differential corresponds to a total volume of a mixture of gases in the cathode electrodes in the fuel cell stack 200 and, in particular, to an amount of oxygen in the cathode electrodes relative to other gases, such as for example nitrogen from the air. This is described in further detail below with reference to FIG. 3.

The hydrogen reservoir 19 is provided to store a fixed amount of hydrogen that is employed during a shutdown process of the fuel cell module 300 that is described in further detail below with reference to FIG. 3. In some embodiments, the hydrogen reservoir 19 is a vessel that is appropriately sized to store enough hydrogen fuel to substantially electrochemically consume the oxygen remaining in the fuel cell module 300 when the valves 10, 11,12 and 13 are closed and the forced inflow of air from the blower 60 is terminated. In other embodiments, the hydrogen reservoir 19 is made-up of a predetermined length of hose or tubing (possibly coiled) for storing enough hydrogen for the same purpose. Alternatively, in other embodiments, the hydrogen reservoir 19 is smaller than required but the amount of hydrogen fuel in the hydrogen reservoir 19 is replenished as required during a shutdown process so that enough hydrogen fuel is provided to substantially electrochemically consume the remaining oxygen. Moreover, those skilled in the art would appreciate that the amount of hydrogen (or reactant of interest) remaining in a fuel cell stack after shutdown is to be taken into consideration when sizing a hydrogen (reactant) reservoir.

The flow control device 14 is provided to regulate the supply of hydrogen fuel delivered to the anode inlet port 204 by, for example, setting the pressure of the hydrogen fuel delivered to the anode inlet port 204. In some embodiments the flow control device 14 is specifically a forward pressure regulator that is dome loaded using air pressure in combination with a bias spring. The forward pressure regulator sets the pressure at the anode inlet port 204 relative to the pressure at the cathode inlet port 202 by some amount. In one very specific example the pressure at the anode inlet port 204 is regulated to be higher than the pressure at the cathode inlet port 202 by a predetermined fixed amount. In some embodiments a flow control device requires a power supply for operation, whereas in other embodiments a flow control device is a passive element, such as for example, a passive forward pressure regulator.

The fuel cell module 300 optionally includes a hydrogen recirculation pump 16 connecting the anode outlet port 205 to the anode inlet port 204. During normal operation of the fuel cell module 300 the hydrogen recirculation pump 16 is operable to re-circulate some portion of the unused hydrogen expelled through the anode outlet port 205 back to the anode inlet port 204.

Examples of the types of valves that are usable for the valves 10, 11, 12 and 13 include, without limitation, normally closed valves, normally open valves and latching valves. Those skilled in the art would appreciate that various other types of valves may be suitably employed.

In some embodiments some of the valves 10, 11, 12 and 13 are normally closed valves. A normally closed valve is opened, thus permitting free flow of gases (or liquids), only when a control signal (or some electromotive force) is continuously supplied to the particular valve. That is, when power is not supplied to a particular normally closed valve, the valve remains closed, thus preventing the free flow of gases (or liquids) through the valve.

In some embodiments some of the valves 10,11, 12 and 13 are normally open valves. A normally open valve is closed, thus stopping the free flow of gases (or liquids), only when a control signal (or some electromotive force) is continuously supplied to the particular valve. That is, when power is not supplied to a particular normally open valve, the valve remains open, thus allowing the free flow of gases (or liquids) through the valve.

In some embodiments some of the valves 10, 11, 12 and 13 are latching valves. A latching valve requires a control signal pulse to switch between “open” and “closed” positions. In the absence of a control signal pulse (or another electromotive pulse) a latching valve remains in the position it is in without change.

During normal (i.e. energy producing or an “on” state) operation of the fuel cell module 300 the valves 10, 11, 12 and 13 are open permitting the free flow of gases (and liquids) to/from the respective ports 202, 203, 204 and 205. Moreover, power is supplied to the blower 60, the flow control device 14 and the hydrogen re-circulation pump 16 to regulate the inflows of reactant gases into the fuel cell stack 200. Those skilled in the art will appreciate that other supporting elements are supplied with power accordingly and that energy produced by the fuel cell module 300 is coupled from the electrical connections 18a,b.

Oxidant for the cathode electrodes in the fuel cell stack 200 is obtained from air, which, again, is made up of approximately 20% oxygen. The blower 60 forces air into the cathode inlet port 202 via the open input valve 10. Once inside the cathode electrodes some of the oxygen from the air is employed in the electrochemical reaction (2) described above.

Hydrogen fuel travels through the fuel supply port 107 into the anode inlet port 204 via the hydrogen reservoir 19 and the flow control device 14. The hydrogen recirculation pump 16 also contributes to the hydrogen fuel supply delivered to the anode inlet port 204, as it operates to force some portion of the unused hydrogen, that is expelled from the anode outlet port 205 back into the anode inlet port 204. Once inside the anode electrodes some of the hydrogen is employed in electrochemical reaction (1) described above.

Excess exhaust gases and liquids from the cathode outlet port 203 and the anode outlet port 205 flow through the corresponding output valves 11 and 13 and out of the fuel cell module 300 through exhaust ports 108 and 109, respectively.

The check valve 15 remains closed during normal operation since the pressure in the cathode inlet port 203 is equal to or greater than the air pressure of the ambient environment.

When a conventional fuel cell module is shutdown the conditions within the fuel cell stack change. The conditions change because elements that support and regulate the operation of the fuel cell stack switch to their respective shutdown states. For example, the input and output valves are closed, which cuts off the supply inflows and exhaust outflows. Moreover, when an element such as a flow control device switches to a shutdown state internal conditions, such as for example, the pressure within the anode electrodes change. When the internal conditions of the fuel cell stack change the hydrogen and oxygen remaining in the fuel cell stack and the feed lines (between the fuel cell stack and the closed valves) are often substantially consumed in combustion reactions as opposed to being consumed in the electrochemical reactions (1) and (2), as described above.

The fuel cell module 300 illustrated in FIG. 2 is not a conventional fuel cell module, as the components of the fuel cell module 300 are configured to passively reduce the overall amount of combustion of hydrogen and oxygen within the fuel cell stack 200 during a shutdown process. This is accomplished by passively inducing an increase in the electrochemical consumption of hydrogen and oxygen that is left inside the fuel cell module 300 relative to what would normally occur during a shutdown process in a conventional fuel cell module.

In particular, the hydrogen reservoir 19 serves as a source for a sufficient amount of additional hydrogen fuel for the fuel cell stack 200 after the input valve 12 has been closed. Briefly, the additional hydrogen fuel drawn from the hydrogen reservoir 19, in combination with other parts of the fuel cell module 300, induces the electrochemical consumption of the oxygen remaining inside the fuel cell stack 200. Also, since the source of the oxygen is air (which is approximately 80% nitrogen), once the oxygen is consumed, the electrodes within the fuel cell stack 200 are passively blanketed with nitrogen. A high concentration of nitrogen reduces the amount of combustion that occurs subsequently within the fuel cell stack 200. The passive blanketing process is a function of the change in pressures within the fuel cell module 300 and specifically within the fuel cell stack 200. The blanketing process that occurs during a shutdown process is described in detail below with reference to FIG. 3 and continued reference to FIG. 2.

FIG. 3 shows a chart illustrating an approximate and simplified breakdown of the mixture of gases present in the cathode electrodes of the fuel cell stack 200 shown in FIG. 2 during sequential stages of a shutdown period. FIG. 3 is provided only as an aid for the visualization of a substantially continuous and fluid process and it is in no way intended to limit the scope of the invention as claimed in the following section.

When the fuel cell module 300 is shutdown the inflows of reactant gases (hydrogen fuel and oxygen carried in the air) are cutoff so that the fuel cell stack 200 is effectively starved of the reactant gases that are needed to continue the electrochemical reactions (1) and (2). In order to do this, the valves 10, 11, 12 and 13 are closed and the power supplied to the blower 60, the flow control device 14 and the hydrogen recirculation pump 16 is cut-off. Closing the output valves 11 and 13 reduces the amount of gases that leak into the cathode and anode electrodes, respectively, via the corresponding outlets 203 and 205, when the fuel cell module 300 is shut down.

The role of the parasitic load 17, whether it is connected permanently or not, is to limit the voltage of the fuel cell stack 200 (i.e. the stack voltage) when the fuel cell module 300 is shutdown and/or de-coupled from the actual load. If the parasitic load 17 is not connected permanently, the parasitic load 17 is coupled across the electrical connections 18a,b immediately before or after a shutdown process is initiated. Preventing the output voltage of the fuel cell stack 200 from reaching a very high level helps to limit an electrochemical corrosion mechanism that can be triggered by a high stack voltage. The presence of the parasitic load 17 further induces the electrochemical consumption of the hydrogen and oxygen remaining within the fuel cell module 300 when a shutdown process is initiated.

Specifically, the parasitic load 17 passively induces the electrochemical consumption of the remaining reactant gases by providing a path for current and voltage to be discharged from the fuel cell stack 200. As the concentration of the reactant gases is reduced on either one or both of the anode or cathode electrodes, the electrochemical potential of the constituent fuel cells (measured as voltage) of the fuel cell stack 200 decreases. If the parasitic load 17 is a simple resistor, as the fuel cell voltage decreases, the corresponding current flowing through the resistor also decreases. This coupling between the gradual decrease in fuel cell voltage potential and the resulting decrease in current dissipation from a static resistor results in a gradual decrease in fuel cell voltage without the danger of fuel cells going negative within the fuel cell stack, as would be the case if a larger current draw was occurring without sufficient supply of reactant gases.

Referring now to 3-1 in FIG. 3, immediately after a shutdown process is initiated the cathode electrodes within the fuel cell stack 200 contain a mixture of gases that roughly corresponds to the composition of air (on earth). That is, each cathode electrode in the fuel cell stack 200 contains a mixture of gases that are approximately 80% nitrogen and 20% oxygen (ignoring traces of other gases). The pressure in each cathode electrode is approximately the same as the air pressure in the ambient environment (e.g. about 1 atm).

As the conditions within the fuel cell stack change (for reasons discussed above) the oxygen in the cathode electrodes of the fuel cell stack 200 is primarily electrochemically consumed according to electrochemical reactions (1) and (2). The required hydrogen fuel used to sustain the electrochemical reactions (1) and (2) is supplied from the hydrogen reservoir 19. As the oxygen is consumed the volume of the gas mixture in the cathode electrodes drops significantly causing a corresponding drop in internal pressure within the cathode electrodes. Illustrated at 3-2 of FIG. 3 is an example of the breakdown of a mixture of gases within the cathode electrodes after the oxygen has been substantially consumed. Nitrogen makes up approximately 98% of the gases present in the cathode electrodes and the pressure within the cathode electrodes is approximately 0.8 atm.

With continued reference to FIG. 2, since the internal pressure within the cathode electrodes of the fuel cell stack 200 falls below the air pressure of the ambient environment the check valve 15 opens, presuming that the cracking pressure has been exceeded. Additional air flows into the fuel cell module 300 via the air supply port 106 and the open check valve 15 leading to a new mixture of gases in the cathode electrodes. The check valve 15 closes when the pressure within the cathode electrodes rises to a level sufficient to close the check valve (taking into consideration the tolerances of the check valve used), which will happen after a sufficient amount of air enters the cathode electrodes. When a conventional check valve is used a spring will force the valve to close once the pressure within the cathode electrodes has risen enough that a delta pressure is below the check valve cracking pressure.

Assuming that the check valve were to remain open until the pressure with the cathode electrode was approximately equivalent to that of the ambient environment, the breakdown of the new mixture of gases is illustrated at 3-3 of FIG. 3. The new mixture of gases consists of 80% nitrogen from the original mixture of gases illustrated at 3-1, and 20% of newly added air. Taking into consideration that air is about 80% nitrogen, the equivalent breakdown of the new mixture of gases shown at 3-3 is illustrated at 3-4 of FIG. 3. The total amount of nitrogen present in the cathode electrodes is about 96% and the pressure is about the same as the air pressure of the ambient environment (e.g. 1 atm). This process is repeated, with the oxygen present in the cathode electrode (being approximately 4% of the cathode electrode volume) being electrochemically consumed with hydrogen provided from the hydrogen reservoir 19. In turn, the void created in the cathode electrodes by the oxygen consumption would be filled with air from the ambient environment (once again composed of approximately 80% nitrogen and 20% oxygen). Consequently, the cathode electrodes of the fuel cell stack 200 are blanketed with predominantly nitrogen gas by this substantially continuous process.

Furthermore, the arrangement of the fuel cell module 300 illustrated in FIG. 2 also induces passive nitrogen blanketing of the anode electrodes in the fuel cell stack 200. As the hydrogen fuel from the hydrogen reservoir 19 is consumed, the volume of the gas mixture present in the anode electrodes drops, which, subsequently results in a corresponding pressure drop within the anode electrodes. The pressure drop within the anode electrodes induces a pressure gradient to be established across the respective membranes from the cathode to the anode side of each membrane in the fuel cell stack 200. This pressure gradient will passively draw nitrogen across the membranes from the respective cathode electrodes to the anode electrodes, thus, causing the anode electrodes to be blanketed with nitrogen as well.

Those skilled in the art will appreciate that the blanketing of the cathode and the anode electrodes occurs in concert in a continuous and fluid manner and it is thus difficult to illustrate this process in discrete steps. Thus, the description provided above is not intended to limit the scope of the invention to a specific sequence of discrete events or processes.

In accordance with aspects of some embodiments of the invention described herein, it will be understood that, in order to achieve effective blanketing of the anode and cathode electrodes with nitrogen of atmospheric pressure, it is necessary to provide sufficient access to additional air to leave a high concentration of nitrogen remaining after the oxygen has been almost completely consumed. This in turn requires a near stoichiometric amount of hydrogen to be supplied to the anode electrodes of a fuel cell stack to facilitate the electrochemical consumption of the oxygen. More generally, at least one reactant supplied to a fuel cell must be provided with a non-reactive agent that remains within the fuel cell after the reactants have been almost completely electrochemically consumed by one another.

Referring to FIG. 4, shown is a schematic diagram illustrating a fuel cell module 302 according to aspects of another embodiment of the invention. Those skilled in the art will appreciate that a fuel cell module includes a suitable combination of supporting elements and that the fuel cell module 302 is illustrated showing only those elements necessary to describe aspects of an embodiment of the invention.

The fuel cell module 302 illustrated in FIG. 4 is similar to the fuel cell module 300 illustrated in FIG. 2. Accordingly, elements common to both fuel cell modules 300 and 302 share common reference indicia. The differences between the two fuel cell modules 300 and 302 are that the fuel cell module 302 does not include input valve 10, output valve 11, check valve 15 and air supply port 106.

The blower 60, illustrated in FIG. 4 is coupled to the cathode inlet port 202 without a valve (e.g. input valve 10) arranged there between. The blower 60 is any device (e.g., a motorized fan, a compressor, etc.) that serves to force air into the cathode inlet port 202. The blower 60 also serves to passively deter, but not necessarily stop, the free flow of air into the cathode inlet port 202 when power is cut-off from the blower 60.

During normal operation, the fuel cell module 302 operates in a substantially identical manner to fuel cell module 300 described above.

During a shutdown process the operation of the fuel cell module 302 is similar to the operation of the fuel cell module 300; however, as already noted, there is no check valve to deter and permit free air flow into the cathode inlet port 202. Instead, the flow of air into the cathode inlet port 202 is slowed down enough by the path through the blower 60 that the oxygen remaining in the cathode electrodes of the fuel cell stack 200 (when the fuel cell module 300 is shutdown) is substantially electrochemically consumed before additional air flows into the cathode electrodes to replace the lost volume of the consumed oxygen. That is, with further reference to FIG. 3, the breakdown of the mixture of gases in the cathode electrodes is similar to what is shown at 3-2 before additional air is passively drawn into the cathode electrodes by the relative drop in pressure. Once additional air makes its way through the blower 60 into the cathode electrodes of the fuel cell stack 200 the breakdown in the mixture of gases in the cathode electrodes is similar to what is shown in 3-3 (and, equivalently 3-4).

In other words, the partial restriction of the air flow through the blower 60 prevents the continuous, rapid replenishment of the electrochemically consumed oxygen on the cathode electrode which would prevent the formation of a predominately nitrogen rich gas composition on the cathode electrode. Thus a gradual depletion of oxygen concentration on the cathode electrode follows a similar process as described above with respect to FIG. 2, with the exception that no large measurable vacuum is created in the cathode electrodes. Rather the electrochemical depletion of oxygen creates a volumetric void and a localized depleted oxygen concentration in the cathode electrodes that draws additional air to the electrode surface (through a combination of pressure and concentration differential driving forces).

Moreover, since there is no output valve (e.g. output valve 11) to block the path from the cathode outlet port 203 to the first exhaust port 108, some air flows into the cathode electrodes via the cathode outlet port 203 and the first exhaust port 108. Also, as described above with respect to FIG. 2, as hydrogen is consumed, in the fuel cell module 302 (of FIG. 4), the pressure in the anode electrodes drops causing nitrogen to be drawn across the respective membranes.

It should also be noted that since valves 10 and 11 from FIG. 2 are not included in system 302, air will continue to diffuse into the cathode electrode. Over time this will cause the gas composition in the cathode electrodes to equalize to approximately that of the surrounding atmosphere. This in turn will gradually result in a change in concentration in the anode electrode gas composition, such that over an extended period of time it can be assumed that both the anode and cathode electrode gas compositions will be approximately that of the surrounding atmosphere. In such embodiments slightly higher levels of degradation are expected compared to the previous examples described above.

It has also been found that while an arrangement with no valves on the cathode side can be used, this does leave the nitrogen blanket of the cathode vulnerable to disturbance and displacement. At least to ensure that the nitrogen blanket is stable for some considerable period, at least one side of the cathode should be closed off by a valve to prevent disturbance of the nitrogen blanket by a draft, for example. This valve can be placed in the inlet and activated after the blanket has formed and substantially all the oxygen has been consumed, or it could be in the outlet. These alternatives are described in relation to FIGS. 5 and 6.

Again, those skilled in the art will appreciate that the blanketing of the cathode and the anode electrodes occurs in concert in a continuous and fluid manner and it is thus difficult to illustrate this process in discrete steps. Thus, the description provided above is not intended to limit the scope of the invention to a specific sequence of discrete events or processes.

Referring to FIG. 5, shown is a schematic diagram illustrating a fuel cell module 304 according to aspects of another embodiment of the invention. Those skilled in the art will appreciate that a fuel cell module includes a suitable combination of supporting elements and that the fuel cell module 304 is illustrated showing only those elements necessary to describe aspects of an embodiment of the invention.

The fuel cell module 304 illustrated in FIG. 5 is similar to the fuel cell module 300 illustrated in FIG. 2. Accordingly, elements common to both fuel cell modules 300 and 304 share common reference indicia. The differences between the two fuel cell modules 300 and 304 are that the fuel cell module 304 does not include output valve 11, check valve 15 and air supply port 106.

During normal operation the fuel cell module 304 operates in a substantially identical manner to fuel cell module 300, described above.

During a shutdown process the operation of the fuel cell module 304 is similar to the operation of the fuel cell module 302 described above. Again, there is no check valve to deter and permit free air flow into the cathode inlet port 202. Moreover, the input valve 10 is arranged between the blower 60 and the cathode inlet port 202, so additional air cannot flow into the cathode electrodes of the fuel cell stack 200 via the blower 60 during a shutdown process since the input valve 10 is closed. Instead, the flow of air into the cathode electrodes comes through the cathode outlet port 203 via the first exhaust port 108. In such an embodiment it is desirable to size and/or shape the first exhaust port 108 such that the flow of air in the reverse direction is slowed down enough by the reverse path through the first exhaust port 108 so that the oxygen remaining in the cathode electrodes of the fuel cell stack 200 (when the fuel cell module 300 is shutdown) is substantially electrochemically consumed before additional air flows into the cathode electrodes to replace the lost volume of the consumed oxygen. That is, with further reference to FIG. 3, the breakdown of the mixture of gases in the cathode electrodes is similar to what is shown at 3-2 before additional air is passively drawn into the cathode electrodes by the relative drop in pressure. Once additional air makes its way through the blower 60 into the cathode electrodes of the fuel cell stack 200 the breakdown in the mixture of gases in the cathode electrodes is similar to what is shown in 3-3 (and, equivalently 3-4). Also, as described above with respect to FIG. 2, as hydrogen is consumed, in the fuel cell module 304 (of FIG. 5), the pressure in the anode electrodes drops causing nitrogen to be drawn across the respective membranes.

Again, those skilled in the art will appreciate that the blanketing of the cathode and the anode electrodes occurs in concert in a continuous and fluid manner and it is thus difficult to illustrate this process in discrete steps. Thus, the description provided above is not intended to limit the scope of the invention to a specific sequence of discrete events or processes.

Referring to FIG. 6, shown is a schematic diagram illustrating a fuel cell module 306 according to aspects of another embodiment of the invention. Those skilled in the art will appreciate that a fuel cell module includes a suitable combination of supporting elements and that the fuel cell module 306 is illustrated showing only those elements necessary to describe aspects of an embodiment of the invention.

The fuel cell module 306 illustrated in FIG. 6 is similar to the fuel cell module 300 illustrated in FIG. 2. Accordingly, elements common to both fuel cell modules 300 and 306 share common reference indicia. The differences between the two fuel cell modules 300 and 306 are that the fuel cell module 306 does not include input valve 10, check valve 15 and air supply port 106.

As in FIG. 4, the blower 60 illustrated in FIG. 6 is coupled to the cathode inlet port 202 without a valve (e.g. input valve 10) arranged there between. The blower 60 is any device (e.g., a motorized fan, a compressor, etc.) that serves to force air into the cathode inlet port 202. The blower 60 also serves to passively deter, but not necessarily stop, the free flow of air into the cathode inlet port 202 when power is cut-off from the blower 60.

During normal operation the fuel cell module 306 operates in a substantially identical manner to fuel cell module 300, described above.

During a shutdown process the operation of the fuel cell module 306 is similar to the operation of the fuel cell modules 300 and 302; however, as already noted, there is no check valve to deter and permit free air flow into the cathode inlet port 202. Instead, the flow of air into the cathode inlet port 202 is slowed down enough by the path through the blower 60 that the oxygen remaining in the cathode electrodes of the fuel cell stack 200 (when the fuel cell module 300 is shutdown) is substantially electrochemically consumed before additional air flows into the cathode electrodes to replace the lost volume of the consumed oxygen. That is, with further reference to FIG. 3, the breakdown of the mixture of gases in the cathode electrodes is similar to what is shown at 3-2 before additional air is passively drawn into the cathode electrodes by the relative drop in pressure. Once additional air makes its way through the blower 60 into the cathode electrodes of the fuel cell stack 200 the breakdown in the mixture of gases in the cathode electrodes is similar to what is shown in 3-3 (and, equivalently 3-4).

Moreover, since the fuel cell module 306 includes the output valve 11, additional air is prevented from entering the cathode outlet port 203 during a shutdown process since the output valve 11 is closed during the shutdown process. Also, as described above with respect to FIG. 2, as hydrogen is consumed, in the fuel cell module 306 (of FIG. 6), the pressure in the anode electrodes drops causing nitrogen to be drawn across the respective membranes.

Again, those skilled in the art will appreciate that the blanketing of the cathode and the anode electrodes occurs in concert in a continuous and fluid manner and it is thus difficult to illustrate this process in discrete steps. Thus, the description provided above is not intended to limit the scope of the invention to a specific sequence of discrete events or processes.

With reference to FIGS. 2, 4, 5 and 6, as an alternative an optional second check valve (not illustrated) can be coupled between the anode inlet port 204 and the cathode inlet port 202. The second check valve is configured to open when there is a pre-determined pressure differential between the pressure in the anode electrode(s) and the cathode electrode(s) during a shutdown process permitting flow from only the cathode electrodes(s) to the anode electrode(s); and, during normal operation the second check valve is configured to remain closed.

The second check valve is used to ensure that nitrogen from the cathode electrodes is passed to the anode electrodes when a sufficient portion of the hydrogen fuel from the hydrogen reservoir 19 is consumed electrochemically, which will result in a corresponding pressure drop as described above. This is to supplement and/or replace the need for nitrogen diffusion across the respective membranes in the fuel cell stack 200, as a means for blanketing the anode electrode(s).

In all of the aforementioned embodiments shown in FIGS. 2, 4, 5 and 6, the flow control device 14 is provided to regulate the supply of hydrogen fuel delivered to the anode inlet port 204 by, for example, setting the pressure of the hydrogen fuel delivered to the anode inlet port 204. The pressure of the hydrogen fuel is typically set in a range of between about 65 psi to about 85 psi. Accordingly, the hydrogen fuel supply (not shown) is capable of supplying the hydrogen fuel at these pressures.

In those instances when it is desirable to use a low pressure hydrogen gas source (first reactant) to supply the fuel cell module, the use of a hydrogen reservoir as described earlier would result in a large volume reservoir relative to the fuel cell module. This may not be efficient or cost effective. Examples of low pressure hydrogen supplies include, but are not limited to, metal hydride storage vessels and a hydrogen reformer coupled with a palladium membrane.

According to a further embodiment of the invention, as shown in FIG. 7a, there is provided a fuel cell module (essentially as described above) having a fuel cell stack 200 and a first reactant holding tank 190, which is pressurized by a pressure generating device, such as, for example, a positive displacement pump 195 during normal operation of the fuel cell module so that a pre-determined amount of first reactant is present in the holding tank under a higher pressure than when the first reactant is fed to the fuel cell stack. Examples of positive style displacement pumps, include, but are not limited to, piston pumps, diaphragm pumps, and rotary screw pumps. Other examples of pressure generating devices can include, but are not limited to, a blower, a motorized fan, and a compressor.

The pump 195 and the first reactant holding tank 190 are provided in a side stream, the ends of which are connected, in a parallel arrangement, to the line between the valve 12 and the anode inlet port 204. It will be understood that the other anode and cathode ports, as shown in the earlier figures, are still present in the fuel cell stack 200, but for simplicity are not shown in FIGS. 7a, b and c. Further, while the holding tank is shown with one connection to the side stream, it is possible that it could be provided with an inlet port connected to the pump 195 and a separate outlet port connected to a flow control device 14′, detailed below, so as to form a series configuration.

During shutdown of the fuel cell power module, the first reactant supply is closed to the fuel cell stack via input valve 12 (as described earlier). During shutdown, the first reactant from the holding tank 190 is provided to the anode inlet port 204 of the fuel cell stack, via a flow control device 14′, such as a forward pressure regulator (FPR), which in function corresponds to the earlier mentioned flow control device 14, to perform the blanketing shutdown process as described in conjunction with earlier embodiments.

Further embodiments of the invention may include a pressure feedback sensor 192 to allow at least limited automated control of the pump 195 as shown in FIG. 7b. The pressure sensor 192 can be programmed with a preset pressure value. When the pressure in the holding tank 190 exceeds the preset value, the pressure sensor sends an electronic signal to shut off the power to the pump 195. When the pressure in the holding tank 190 falls below the preset value, the pressure sensor sends an electronic signal to turn back on the power to the pump 195. A person skilled in the art will appreciate that the preset pressure value will be selected taking into account the volume of the holding tank and its maximum working pressure.

In still a further embodiment, shown in FIG. 7c, a solenoid valve 196 can be arranged between the pump 195 and the flow control device 14′ to prevent hydrogen from leaking through the flow control device since this leakage could cause unnecessary start/stop cycles for the pump.

The pump 195 may be any device which can pressurize the first reactant in the first reactant holding tank 190. The pump acts as a “solenoid valve” (i.e. a back-flow valve) to prevent reverse flow of the high pressure stored gas in the first reactant holding tank 190 into the low pressure system gas feed to the stack, or if the pump does not form a complete seal, an additional solenoid valve (not shown), similar to solenoid valve 196, may be added to prevent this reverse flow.

The low pressure system of the embodiment as shown in FIGS. 7a to 7c is useful when the first reactant supply pressure is low (typically 1 to 3 psi as opposed to high pressure supply of around 65 to 85 psi). Since the pressure in the first reactant holding tank is built up during normal operation, the volume of the holding tank can be small but the provided mass of first reactant from the holding tank will still be sufficient to perform a blanketing shutdown as described above. It should be noted that FIGS. 7a to 7c only show those features which are particularly relevant to the low pressure system. Further features of the fuel cell module are essentially identical to what has been shown for previous embodiments of the invention.

Referring now to FIG. 8, this shows an alternative arrangement. Instead of the parallel arrangement shown in FIGS. 7a, b and c. Here, a first reactant holding tank 190′ is shown at the end of a side branch having a single connection to the line supplying the first reactant to the anode inlet port 204. In this side branch, there is also the pump, here designated 195′, and optionally a valve indicated schematically at 196′.

The pump 195′ is preferably a pump that when turned off or inoperative permits backflow through the pump. Then, in use, the pump in normally operated to establish and maintain a desired pressure in the first reactant holding tank 190′. At shutdown, the pump 195′ is turned off, and the stored first reactant is permitted to flow back through the pump 195′ to the anode of the fuel cell stack 200 as described above.

If the pump 195′ is a positive displacement pump that does not permit backflow when inoperative, then a bypass line around the pump and controlled by a valve can be provided (not shown).

The valve 196′ can be provided as required. Thus, if the configuration is such that the pump 195′ is only operated until a desired pressure is established in the holding tank 190′ and then turned off, it may be necessary to have a valve 196′ that is open during operation of the pump 195′, and then closed to retain and hold the first reactant in the holding tank 190′ until required.

A further reason for providing a valve 196′ would be to control outflow of the first reactant during the shutdown procedure. The valve 196′ can be any suitable type of valve, including any valve as detailed above.

What has been described is merely illustrative of the application of the principles of the invention. Those skilled in the art would appreciate that other arrangements are possible without departing from the scope of the present invention. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.

Claims

1. A fuel cell module, comprising:

a fuel cell stack including at least one fuel cell, each fuel cell including an anode electrode, a cathode electrode and an electrolyte medium arranged between the anode electrode and the cathode electrode, wherein during normal operation the anode electrode is provided with a first reactant and the cathode electrode is provided with a first mixture containing a second reactant and a non-reactive agent;
a parasitic load that is connectable across the anode and the cathode electrodes;
a first reactant supply port, fluidly connectable to the anode electrode, for supplying the first reactant to the anode electrode;
a side stream fluidly connectable to the first reactant supply and the anode electrode;
a reactant reservoir, fluidly connectable to the side stream, for storing an amount of the first reactant suitable for a shutdown process of the fuel cell module, whereby, in use when the fuel cell module is shutdown, the stored amount of the first reactant is drawn from the reactant reservoir and electrochemically reacts with the second reactant in the fuel cell module, to electrochemically consume the first and second reactants, thereby leaving a second mixture that substantially comprises the non-reactive agent; and
a pressure generating device, fluidly connectable to the side stream and positioned upstream of the reactant reservoir, for pressurizing and delivering the first reactant from the first reactant supply to the reactant reservoir.

2. A fuel cell module according to claim 1, further comprising a flow control device which is fluidly connectable to the side stream and positioned downstream of the reactant reservoir, the flow control device regulating a flow of the first reactant from the reactant reservoir to the anode electrode when the fuel cell module is shutdown.

3. A fuel cell module according to claim 2, further comprising a pressure sensor which is fluidly connectable with one of the reactant reservoir and the side stream, downstream of the reactant reservoir, and electrically connectable to the pressure generating device for sensing the pressure in the reactant reservoir and controlling the pressure generating device during regular operation of the fuel cell module.

4. A fuel cell module according to claim 3, further comprising a solenoid valve which is fluidly connectable to the side stream and positioned intermediate the pressure generating device and the flow control device for preventing backflow of the first reactant from the flow control device.

5. A fuel cell module as claimed in claim 2, 3 or 4, wherein a supply line is fluidly connectable between the first reactant supply port and the anode electrode, and wherein the side stream is connected in parallel to the supply line.

6. A fuel cell module as claimed in claim 2, wherein a supply line is fluidly connectable between the first reactant supply port and the anode electrode, and wherein the side stream comprises a branch line connected at one end to the supply line, with both the pressure generating device and the flow control device located between said one end and the reactant reservoir, whereby in use, the pressure generating device and the flow control device are upstream of the reactant reservoir during pressurization thereof and downstream thereof when the first reactant is drawn from the reactant reservoir.

7. A fuel cell module as claimed in claim 6, further including a pressure sensor connected to one of the reactant reservoir and the branch line between the reactant reservoir and the pressure generating device, and electrically connectable to the pressure generating device for sensing pressure in the reactant reservoir and controlling the pressure generating device during regular operation of the fuel cell module.

8. A fuel cell module according to claim 1, wherein the reactant reservoir is a pressurized vessel.

9. A fuel cell module according to claim 1, wherein the pressure generating device is a positive displacement pump.

10. A fuel cell module according to claim 1, wherein the fuel cell stack comprises:

a cathode inlet port for supplying the first mixture to the cathode electrodes;
a cathode outlet port for evacuating un-reacted amounts of the second reactant, amounts of the non-reactive agent and exhaust products from the cathode electrodes;
an anode inlet port, fluidly connectable to the reactant reservoir, and for supplying the first reactant to the anode electrodes; and,
an anode outlet port for evacuating un-reacted amounts of the first reactant and exhaust products from the anode electrodes.

11. A fuel cell module according to claim 10, wherein the electrolyte medium is a Proton Exchange Membrane (PEM).

12. A fuel cell module according to claim 11, including at least one Proton Exchange Membrane that permits the non-reactant agent to cross over from the cathode to the anode and a valve permitting gas to flow from the cathode to the anode during the shutdown process.

13. A fuel cell module according to claim 11, wherein the first reactant is hydrogen, the second reactant is oxygen carried in the air and the non-reactive agent is nitrogen carried in the air.

14. A fuel cell module according to claim 13, further comprising:

a hydrogen supply port; and,
an anode input valve, connectable between the hydrogen supply port and the reactant reservoir, for cutting-off a flow of hydrogen from the hydrogen supply port to the anode inlet port during the shutdown process.

15. A fuel cell module as claimed in claim 1, wherein the cathode electrode include a cathode inlet port and a cathode outlet port, and wherein at least one of a valve for the cathode inlet port and a valve for the cathode outlet port is provided to reduce disturbance of the second mixture present at the cathode after the shutdown process.

16. A fuel cell module, comprising:

a fuel cell including a first electrode, a second electrode and an electrolyte medium arranged between the first and second electrodes, wherein during normal operation the first electrode is provided with a first reactant and the second electrode is provided with a first mixture containing a second reactant and a non-reactive agent;
a parasitic load that is connectable across the first and second electrodes;
a first reactant supply, fluidly connectable to the anode electrode, for supplying first reactant to the anode electrode;
a side stream fluidly connectable to the first reactant supply and the anode electrode;
a reactant reservoir, fluidly connectable to the side stream, for storing an amount of the first reactant suitable for a shutdown process of the fuel cell module, whereby, in use when the fuel cell module is shutdown, the stored amount of the first reactant is drawn from the reactant reservoir and electrochemically reacts with an amount of the second reactant remaining in the fuel cell module, to electrochemically consume the first and second reactants, thereby leaving a second mixture that substantially comprises the non-reactive agent; and
a pressure generating device, fluidly connectable to the side stream and positioned upstream of the reactant reservoir, for pressurizing and delivering the first reactant from the first reactant supply to the reactant reservoir.

17. A reactant supply system for a fuel cell stack, having an anode inlet, an anode outlet, a cathode inlet and a cathode outlet, the reactant supply system comprising:

a first reactant supply port connectable in use to the anode inlet of the fuel cell stack;
a second reactant supply port connectable in use to the cathode inlet, for supply of a mixture comprising the second reactant and a non-reactant agent;
a parasitic load that is connectable across the anode and cathode electrodes of the fuel cell stack;
a side stream fluidly connectable to the first reactant supply line;
a reactant reservoir, fluidly connectable to the side stream, for storing an amount to the first reactant suitable for a shutdown process of the fuel cell stack, whereby, in use, when the fuel cell stack is shutdown, the stored amount of the first reactant is drawn from the reactant reservoir and electrochemically reacts with the secondary reactant in the fuel cell module, to electrochemically consume the first and second reactants, thereby leaving a second mixture that substantially comprises the non-reactive agent; and
a pressure generating device, fluidly connectable to the side stream for pressurizing delivering the first reactant to the reactant reservoir.

18. A process for shutting down a fuel cell, the fuel cell including a first electrode, a second electrode and an electrolyte membrane arranged between the first and second electrodes, the process comprising during normal operation:

providing the first electrode with a first reactant and the second electrode with a first mixture containing a second reactant and a non-reactive agent, and;
pressurizing a portion of the first reactant and storing the first reactant in a reactant reservoir; and
the process further comprising at shutdown:
stopping an inflow of the first reactant into the first electrode;
cutting-off power to supporting balance of plant elements;
drawing current through a parasitic load connectable across the first and second electrodes;
permitting the stored first reactant to flow to the first electrode for the electrochemical consumption of a remaining amount of a second reactant;
wherein the first reactant electrochemically reacts with the remaining amount of the second reactant, thereby leaving a second mixture that substantially comprises the non-reactive agent.

19. A process as claimed in claim 18, the process including storing a near stoichiometric amount of the first reactant for consumption of the remaining amount of the second reactant.

20. A process as claimed in claim 19, including controlling the flow of the first reactant from the reactant reservoir with a flow control device.

21. A process as claimed in claim 20, including, in normal operation, controlling the supply of the reactant to the first reservoir in dependence of the pressure in the first reservoir.

22. A process as claimed in claim 21, including preventing backflow of the first reactant out of the first reservoir with a valve.

23. A process as claimed in claim 18, including permitting the non- reactive agent to cross over from the second electrode to the first electrode at shutdown, whereby both the first and second electrodes are blanketed with the non-reactive gas at shutdown.

24. A process as claimed in claim 23, including providing one of an electrolyte membrane that permits cross over of the non-reactive gas at shutdown and a valve permitting flow of gas from the second electrode to the first electrode at shutdown.

Patent History
Publication number: 20070166598
Type: Application
Filed: Feb 8, 2007
Publication Date: Jul 19, 2007
Applicant: Hydrogenics Corporation (Mississauga)
Inventors: Nathaniel Joos (Toronto), Stephen Burany (Mississauga)
Application Number: 11/672,772
Classifications
Current U.S. Class: 429/38.000; 429/22.000; 429/32.000; 429/13.000
International Classification: H01M 8/24 (20060101); H01M 8/04 (20060101); H01M 8/10 (20060101);