Thermodynamic analysis, modelling and control of a novel hybrid propulsion system

Stringent emission regulations imposed by governments and depleting fossil fuel reserves have promoted the development of the automotive industry towards novel technologies. Various types of hybrid power plants for transport and stationary applications have emerged. The methodology of design and development of such power plants varies according to power producing components used in the systems. The practical feasibility of such power plants is a pre-requisite to any further development. This work presents thermodynamic analysis and modelling of such a novel power plant, assesses its feasibility and further discusses the development of a suitable control system. The proposed system consists of a hybrid configuration of a solid oxide fuel cell and IC engine as the main power producing components. A reformer supplies fuel gas to the fuel cell while the IC engine is supplied with a liquid fuel. The excess fuel from the fuel cell anode and the oxygen-depleted air from cathode of the fuel cell are also supplied to the engine. This gas mixture is aspirated into the engine with the balance of energy provided by the liquid fuel. The fuel cell exhaust streams are used to condition the fuel in the engine to ensure minimum pollutants and improved engine performance. Both, fuel cell and engine share the load on the system. The fuel cell operates on a base load while the engine handles majority of the transient load. This system is particularly suitable for a delivery truck or a bus cycle. Models of the system components reformer, solid oxide fuel cell, IC engine and turbocharger were developed to understand their steady state and dynamic behaviour. These models were validated against sources of literature and used to predict the effect of different operating conditions for each component. The main control parameters for each component were derived from these models. A first law analysis of the system at steady state was conducted to identify optimum operating region, verify feasibility and efficiency improvement of the system. The results suggested reduced engine fuel consumption and a 10 % improvement in system efficiency over the conventional diesel engines. Further, a second law analysis was conducted to determine the key areas of exergy losses and the rational efficiency of the system at full load operating conditions. The results indicate a rational efficiency of 25.4 % for the system. Sensitivity to changes in internal exergy losses on the system work potential was also determined. The exergy analysis indicates a potential for process optimisation as well as design improvements. This analysis provides a basis for the development of a novel control strategy based on exergy analysis and finite-time thermodynamics. A dynamic simulation of the control oriented system model identified the transient response and control parameters for the system. Based on these results, control systems were developed based on feedback control and model predictive control theories. These controllers mainly focus on air and fuel path management within the system and show an improved transient response for the system. In a hierarchical control structure for the system, the feedback controllers or the model predictive controller can perform local optimisation for the system, while a supervisory controller can perform global optimisation. The objective of the supervisory controller is to determining the load distribution between the fuel cell and the engine. A development strategy for such a top-level supervisory controller for the system is proposed. The hybrid power plant proposed in this thesis shows potential for application for transport and stationary power production with reduced emissions and fuel consumption. The first and second law of thermodynamics can both contribute to the development of a comprehensive control system. This work integrates research areas of powertrain design, thermodynamic analysis and control design. The development and design strategy followed for such a novel hybrid power plant can be useful to assess the potential of other hybrid systems as well

Automotive Powertrain Control — A Survey

This paper surveys recent and historical publications on automotive powertrain control. Control-oriented models of gasoline and diesel engines and their aftertreatment systems are reviewed, and challenging control problems for conventional engines, hybrid vehicles and fuel cell powertrains are discussed. Fundamentals are revisited and advancements are highlighted. A comprehensive list of references is provided.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/72023/1/j.1934-6093.2006.tb00275.x.pd

Modeling and control of an automotive fuel cell thermal system

This work develops an 8th order, non-linear thermal model of an automotive Proton Exchange Membrane (PEM) fuel cell system. Subsystem models were developed from first principals where ever possible and validated against data from a physical system. The entire model was then validated against system data from a General Motor\u27s 120kW fuel cell system. The system model was analyzed in both the time and frequency domain. Next, a reduced, 3rd order model was constructed from the full model and then linearized. The performances of all three models were compared and it was found that the 3rd order linear model provided an acceptable representation of the full non-linear model. Using the models developed in the first section, different control strategies were examined. A proportional-integral (PI) controller was developed as a baseline and compared to a full state feedback Linear Quadratic controller. This controller was augmented to include output variable feedback to improve the steady state performance of the controller. The state feedback controller was found to have faster response and less interaction between the controlled variables than the baseline controller. Because some of the states are unmeasured, an estimator was developed to determine the state values for the full state feedback controller

Investigating controller performance in hybrid SOFC systems in the presence of unknown nonlinearities

Solid oxide fuel cells (SOFCs) are energy conversion devices that offer many benefits over various other fuel cell types as a result of high operating temperatures (800-1000 °C). Unfortunately, SOFCs tend to possess poor load following capabilities due to delays along the fuel path and complex system dynamics. Maintaining safe operating conditions during changes in power demand is addressed using a controller designed to regulate the fuel cell current based on fuel flow measurement. In order to compensate for the resulting mismatch between demanded and delivered power, the SOFC system is hybridized with an energy storage device, such as an ultra-capacitor. Prior research at the HySES laboratory at RIT has led to control designs that guarantee robustness to uncertainties in system parameters such power electronics efficiencies. However, existing controllers for this system were developed under assumptions made about the unknown dynamics of the fuel supply system (FSS), such as exponential or bounded tracking. Retaining these controller designs, this thesis develops a general set of closed loop system equations in which the prior assumptions about the FSS are relaxed. The FSS behavior is treated as an unknown nonlinearity. Thereafter, concepts of absolute stability, Lyapunov stability and linear system approximation are used to evaluate the closed-loop system. The analysis leads to analytical conditions relating the controller gains and the local behavior of the FSS, predicting the onset of instability in the closed-loop system. The results are validated using simulations and using a hardware-in-the-loop test stand. Additionally, the problem of transient fuel utilization control of SOFCs is revisited and addressed by using a nonlinear observer design and an auxiliary hydrogen injection strategy. These approaches aim to compensate for fuel path delays and maintain desired operating conditions during transient loading conditions. Findings are validated using desktop simulations

Robust control strategies for hybrid solid oxide fuel cell systems

Solid Oxide Fuel Cell (SOFC) systems are electrochemical energy conversion devices characterized by the use of solid oxide as the electrolyte. They operate at high temperatures (between 800± ¡ 1000±C). Mitigating fuel starvation and improving load-following capability of SOFCs are conflicting control objectives. In this thesis, this issue is addressed using a hybrid SOFC ultra-capacitor configuration. The fuel cell is controlled by incorporating a steady-state property of fuel utilization into an input-shaping framework. Two comprehensive control strategies are developed. The first is a Lyapunov-based nonlinear control and the second is a standard H-infinity robust control. Both strategies additionally control the state of charge (SOC) of the ultra-capacitor that provides transient power compensation. A hardware-in-the-loop test-stand is developed where the proposed control strategies are verified. An investigation to improve the hybrid fuel cell system by incorporating a lithium-ion battery as an additional power source is conducted. Combining both battery and ultra-capacitor with a fuel cell is potentially a winning combination especially for high power applications. A novel SOC estimation method for lithium-ion battery is investigated. Based on the combined ultra-capacitor battery hybrid system, a lyapunov-Based nonlinear control strategy is designed

Thermal and water management of evaporatively cooled fuel cell vehicles

Proton Exchange Membrane Fuel Cells (PEMFCs) present a promising alternative to the conventional internal combustion engine for automotive applications because of zero harmful exhaust emissions, fast refuelling times and possibility to be powered by hydrogen generated through renewable energy. However, several issues need to be addressed before the widespread adoption of PEMFCs, one such problem is the removal of waste heat from the fuel cell electrochemical reaction at high ambient temperatures. Automotive scale fuel cells are most commonly liquid cooled, evaporative cooling is an alternative cooling method where liquid water is added directly into the fuel cell flow channels. The liquid water evaporates within the flow channel, both cooling and humidifying the cell. The evaporated water, along with some of the product water, is then condensed from the fuel cell exhaust, stored, and re-used in cooling the fuel cell. This work produces a system level model of an evaporatively cooled fuel cell vehicle suitable for the study of water balance and heat exchanger requirements across steady state operation and transient drive cycles. Modelling results demonstrate the ability of evaporatively cooled fuel cells to self regulate temperature within a narrow region (±2°C) across a wide operating range, provided humidity is maintained within the flow channels through sufficient liquid water addition. The heat exchanger requirements to maintain a self sufficient water supply are investigated, demonstrating that overall heat exchange area can be reduced up to 40% compared to a liquid cooled system due to the presence of phase change within the vehicle radiator improving heat transfer coefficients. For evaporative cooling to remain beneficial in terms of heat exchange area, over 90% of the condensed liquid water needs to be extracted from the exhaust stream. Experimental tests are conducted to investigate the condensation of water vapour from a saturated air stream in a compact plate heat exchanger with chevron flow enhancements. Thermocouples placed within the condensing flow allow the local heat transfer coefficient to be determined and an empirical correlation obtained. The corresponding correlation is used to produce a heat exchanger model and study the influence different heat exchanger layouts have on the overall required heat transfer area for an evaporatively cooled fuel cell vehicle. A one-dimensional, non-isothermal model is also developed to study the distribution of species, current density and temperature along the flow channel of an evaporatively cooled fuel cell using different methods of liquid water addition. Results show that good performance can be achieved with cathode inlet humidities as low as 20%, although some anode liquid water addition may be required at high current densities due to increased electro-osmotic drag. It is also demonstrated that both good membrane hydration and temperature regulation can be managed by uniform addition of liquid water across the cell to maintain a target exhaust relative humidity

Multivariable robust control of a simulated hybrid solid oxide fuel cell gas turbine plant

This work presents a systematic approach to the multivariable robust control of a hybrid fuel cell gas turbine plant. The hybrid configuration under investigation built by the National Energy Technology Laboratory comprises a physical simulation of a 300kW fuel cell coupled to a 120kW auxiliary power unit single spool gas turbine. The public facility provides for the testing and simulation of different fuel cell models that in turn help identify the key difficulties encountered in the transient operation of such systems. An empirical model of the built facility comprising a simulated fuel cell cathode volume and balance of plant components is derived via frequency response data. Through the modulation of various airflow bypass valves within the hybrid configuration, Bode plots are used to derive key input/output interactions in transfer function format. A multivariate system is then built from individual transfer functions, creating a matrix that serves as the nominal plant in an Hinfinity robust control algorithm. The controller\u27s main objective is to track and maintain hybrid operational constraints in the fuel cell\u27s cathode airflow, and the turbo machinery states of temperature and speed, under transient disturbances. This algorithm is then tested on a Simulink/MatLab platform for various perturbations of load and fuel cell heat effluence.;As a complementary tool to the aforementioned empirical plant, a nonlinear analytical model faithful to the existing process and instrumentation arrangement is evaluated and designed in the Simulink environment. This parallel task intends to serve as a building block to scalable hybrid configurations that might require a more detailed nonlinear representation for a wide variety of controller schemes and hardware implementations