Oxygen excess ratio control for proton exchange membrane fuel cell using model reference adaptive control

Optimized robust oxygen excess ratio (OER) control for proton exchange membrane fuel cells (PEMFCs) is now a critical issue for improving their economic efficiency and performance. In general, it is very difficult to control the OER due to modeling errors, parameter uncertainties, and disturbances. To address these issues, we propose a control system based on model reference adaptive control (MRAC) various difficulties inherent air supply systems.We utilize an adaptive law to address uncertainties implementation of the MRAC and nominal feedback controllers on a nonlinear model of fuel cell system is presented for illustration of the proposed system's robustness with various operating conditions. In addition, the control performance of MRAC is compared with nominal feedback control. The results show that the presented MRAC strategy performs better than the nominal feedback control method with less wear and less control effort on the compressor. The proposed MRAC algorithm can increase the compressor efficiency by using the adaptive law even with uncertainties.     

A nonlinear control strategy for fuel delivery in PEM fuel cells considering nitrogen permeation

Hydrogen energy shows its great potential to be one of the future sustainable energies with abundant storage and high energy content. Proton exchange membrane (PEM) fuel cells, as a hydrogen energy conversation plant with high efficiency, becomes a hot topic of many researches. This paper proposes a multi-input-multi-output (MIMO) nonlinear control strategy for fuel delivery in PEM fuel cell systems. Specifically, a control oriented dynamic model is developed for the fuel delivery system (FDS) with anode recirculation and anode bleeding. Based on the model, a MIMO nonlinear state feedback controller is proposed to maintain adequate hydrogen supply and suitable anode hydrogen concentration. Moreover, an optimized output feedback controller is proposed to improve the state feedback controller, where the unknown hydrogen partial pressures utilized are estimated by developed observers. Lyapunov based stability analysis is carried out to analyze the proposed output feedback controller and the observers. Simulation results show the effectiveness of the proposed controller under various current demands.     

Design of control systems for portable PEM fuel cells

The current evolution in the design of fuel cell systems, together with the considerable development of integrated control techniques in microprocessor systems allows the development of portable fuel cell applications in which optimized control of the fuel cells performance is possible. Control, in the strict sense, implies a thorough knowledge of both the static and dynamic behaviour of the system comprising the stack, manifold and the compressor that enables oxygen supply. The objective of this control, far from being simply to maintain the stack free from oxygen and hydrogen shortages, is to achieve the necessary values of these gases, minimizing compressor consumption, which is the cause of the greatest inefficiency of fuel cells. This objective is essential when fuel cell systems are involved in situations where the net power of the stack is reduced and any unnecessary consumption lowers the total power available to the user. The design of an efficient control system requires the following steps: (1) modeling of the stack, compressor and other pneumatic elements involved in the system. (2) Calculation of the control equations and simulation of the entire system (including control). (3) Emulation of the stack and other pneumatic elements and simulation utilizing the designed control system. (4) Physical realization of the control system and testing within the fuel cell system. The design of a control system for fuel cell systems is introduced to manage PEMFC stacks. The control system will guarantee the correct performance of the stack around its optimal operation point, in which the net power is maximized. This means that both, the air flow and the stack temperature are controlled to a correct value.     

Nonlinear controller design based on cascade adaptive sliding mode control for PEM fuel cell air supply systems

Optimized robust control for proton exchange membrane (PEM) fuel cell air supply systems is now a hot topic in improving the performance of oxygen excess ratio (OER) and the net power. In this paper, a cascade adaptive sliding mode control method is proposed to regulate oxygen excess ratio (OER) for proton exchange membrane (PEM) fuel cell air supply systems. Based on a simplified sixth-order nonlinear dynamic model, which takes parametric uncertainties, external disturbances and measurement noises into consideration, the nonlinear controller based on cascade adaptive sliding mode (NC-ASM) control is proposed. The method combines the nonlinear terms of super twisting algorithm and two added linear terms, and the modified second order sliding mode (SOSM) algorithm based on an observer is employed to form a cascade structure. Besides, an adaptive law is also utilized to regulate the parameters of the NC-ASM controller online. The performance of the controller is implemented on a real-time emulator. The results show that the proposed strategy performs better than the conventional constant sliding mode (CSM) control and PID method. Though during large range of load current and in the presence of various uncertainties, disturbances and noises, the NC-ASM controller can always converge rapidly, the feasibility and effectiveness are validated.     

Thermal analysis of air-cooled PEM fuel cells

Air-cooled proton exchange membrane fuel cells (PEMFCs), having combined air cooling and oxidant supply channels, offer significantly reduced bill of materials and system complexity compared to conventional, water-cooled fuel cells. Thermal management of air-cooled fuel cells is however a major challenge. In the present study, a 3D numerical thermal model is presented to analyze the heat transfer and predict the temperature distribution in air-cooled PEMFCs. Conservation equations of mass, momentum, species, and energy are solved in the oxidant channel, while energy equation is solved in the entire domain, including the membrane electrode assembly (MEA) and bipolar plates. The model is validated with experiments and can reasonably predict the maximum temperature and main temperature gradients in the stack. Large temperature variations are found between the cool incoming air flow and the hot bipolar plates and MEA, and in contrast to water-cooled fuel cells, significant temperature gradients are detected in the flow direction. Furthermore, the air velocity and in-plane thermal conductivity of the plate are found to play an important role in the thermal performance of the stack.     

Evaluation method of oxygen excess ratio control under typical control laws for proton exchange membrane fuel cells

For real-used proton exchange membrane fuel cells (PEMFC), it is critical to design an effective controller and evaluate its performance. Current evaluations of controllers are often empirical or qualitative, and quantitative evaluation methods are lacking. In this paper, the quantifiable objective evaluation method is proposed for assessing the controller performance, including optimal control, adaptive control, variable structure control, and model-based control, aiming at the oxygen excess ratio. In the method, the anti-starvation, transient-state, steady-state, and multiple load-changing performances are comprehensively considered through weighting, rating, and especially the introduction of negative scores through the integration of four independent indexes. The importance and effectiveness of evaluation method are verified through the specific analysis of four controllers and the internal states of PEMFC. Besides, the evaluation method can be extended appropriately, such as considering the robustness, optimal output power, and other practical problems, which is significant for the development of PEMFC system controller.     

Ultralow Pt loading on CVD graphene for acid electrolytes and PEM fuel cells

Continuous-phase, porous graphene was produced by CVD process and tested for suitability as catalyst and catalyst support for polymer electrolyte membrane (PEM) fuel cells. N-doping of CVD graphene was carried by NH₃ gas flown over graphene for a given time. Ultralow Pt was sputter deposited onto porous, continuous phase N-doped graphene. Oxygen reduction reaction (ORR) activity by Rotating Disc Electrode (RDE) in 0,1 M HClO₄ electrolyte and PEM fuel cell performance were measured. N-doping and thicker Pt sputtering increases reduction current in RDE measurements. Sputter deposition of 1 nm and 10 nm Pt on CVD graphene (2.1 and 21.45 μgPt/cm² loading) has shown orders of magnitude increase in current compare to only-graphene samples. In fuel cell testing, sputter deposited Pt layer of 10 nm has provided 2.5 A/mgPt at 0.5 V polarization while 1 nm samples shows 15 A/mgPt performance at the same voltage.     

Study of nonlinear control schemes for an automotive traction PEM fuel cell system

To be practical in automotive traction applications, fuel cell systems must provide power output levels of performance that rival that of typical internal combustion engines. In so doing, transient behavior is one of the keys for success of fuel cell systems in vehicles. The focus of this paper is on the air/fuel supply subsystem in tracking an optimum variable pressurization and air flow for maximum system efficiency during load transients. The control-oriented model developed for this study considers electrochemistry, thermodynamics, and fluid flow principles for a 13-state, nonlinear model of a pressurized fuel cell system. For control purposes, a model reduction is performed, and several multi-variable control designs are examined. The first technique uses an observer-based linear optimum control which combines a feed-forward approach based on the steady-state plant inverse response, coupled to a multi-variable LQR feedback control. An extension of that approach, for control in the full nonlinear range of operation, leads to the second technique, nonlinear gain-scheduled control. Some enhancements were applied to overcome the fast variations in the scheduling variable. Finally, a rule-based, output feedback control, implemented with fuzzy logic, is coupled with a nonlinear feed-forward approach, and is examined under the same conditions applied to the first two techniques. The control designs developed are compared in simulation studies to investigate robustness to disturbance, time delay, and actuator limitations.     

Enhancement of efficiency and power output of hydrogen fuelled proton exchange membrane (PEM) fuel cell using oxygen enriched air

This paper deals with the effects of the oxygen-enriched air (up to 50% oxygen by mass) along with other operating parameters (hydrogen flow rate, temperature, and relative humidity) on the performance of hydrogen-fuelled proton exchange membrane (PEM) fuel cell. The active area of a fuel cell considered was 50 cm² with three cells in series connections. The air was supplied with O₂ enriched from 23% to 50% at the cathode. The voltage obtained with the respective enriched air was 2.52 and 2.80 V respectively. The optimum oxygen enrichment was found as 45%. The stack temperature plays a significant role on performance improvement and the optimum temperature was found as 50 °C. The voltage efficiency and power output were improved by 9% and 33% with 45% oxygen-enriched air. Electrochemical impedance spectroscopy was used to analyze the impedance behavior of the fuel cell with the variable current demand. The bode plot indicates current dominates voltage at low oxygen-enriched air (25%) and vice-versa at high-enriched air. The inductive effect was dominating at the low frequency and overtaken by the capacitive effects at the higher frequency. These results would be useful to develop a dedicated fuel cell with the oxygen-enriched air.     

The dynamics analysis and controller design for the PEM fuel cell under gas flowrate constraints

This paper is on the dynamics analysis and controller design for the PEM fuel cell under the flowrate constraints of the supplied hydrogen and oxygen. By linearization around the equilibrium trajectories defined by the quantities of hydrogen and oxygen input flowrate, the nonlinear dynamics of the PEM fuel cell can be expressed as a linear parameter varying system with the output current and temperature as the system parameters. The state-feedback controller design is performed based on the linear time-invariant model obtained from the derived linear parameter varying system evaluated at the half load operation condition. The control objective is to achieve a maximized relative stability or equivalently the maximum decay rate under the specified magnitude constraints on the input flowrate of hydrogen and oxygen. The convex linear matrix inequality algorithm is utilized for numerical construction of the state-feedback control law. Under the fixed load resistance corresponding to the half load condition, the time response simulations are conducted for both the cases of initial condition regulation and external command tracking. For the simulation of regulation, the initial deviation of state variables diminishes quickly that agrees with the obtained large delay rate during controller design. In the case of command tracking for the same amount of state variables, the controlled system can follow the issued command in the right direction but leave large tracking error, which is due to the weak controllability of the gas flowrates on the activation overvoltage for the PEM fuel cell system dynamics.     

Air mass flow and pressure optimisation of a PEM fuel cell range extender system

In order to eliminate the local CO₂ emissions from vehicles and to combat the associated climate change, the classic internal combustion engine can be replaced by an electric motor. The two most advantageous variants for the necessary electrical energy storage in the vehicle are currently the purely electrochemical storage in batteries and the chemical storage in hydrogen with subsequent conversion into electrical energy by means of a fuel cell stack. The two variants can also be combined in a battery electric vehicle with a fuel cell range extender, so that the vehicle can be refuelled either purely electrically or using hydrogen. The air compressor, a key component of a PEM fuel cell system, can be operated at different air excess and pressure ratios, which influence the stack as well as the system efficiency. To asses the steady state behaviour of a PEM fuel cell range extender system, a system test bench utilising a commercially available 30 kW stack (96 cells, 409 cm² cell area) was developed. The influences of the operating parameters (air excess ratio 1.3 to 1.7, stack temperature 20 °C–60 °C, air compressor pressure ratio up to 1.67, load point 122 mA/cm² to 978 mA/cm²) on the fuel cell stack voltage level (constant ambient relative humidity of 45%) and the corresponding system efficiency were measured by utilising current, voltage, mass flow, temperature and pressure sensors. A fuel cell stack model was presented, which correlates closely with the experimental data (0.861% relative error). The air supply components were modelled utilising a surface fit. Subsequently, the system efficiency of the validated model was optimised by varying the air mass flow and air pressure. It is shown that higher air pressures and lower air excess ratios increase the system efficiency at high loads. The maximum achieved system efficiency is 55.21% at the lowest continuous load point and 43.74% at the highest continuous load point. Future work can utilise the test bench or the validated model for component design studies to further improve the system efficiency.     

Cold pre-compression of membrane electrode assembly for PEM fuel cells

Direct compression from the land structure of bipolar plate in a PEM fuel cell is considered as an important factor for the higher performance under the land than under the channel areas. Therefore the objective of this study is to determine if a cold pre-compression treatment on the whole membrane electrode assembly (MEA) area may have a significant positive effect on the overall performance of the cell. Five different levels of cold pre-compression have been applied and the experimental results show that the overall performance of the cell first increases with the level of compression to a maximum, and then decreases. These results clearly show that cold pre-compression of the MEA can significantly enhance the performance of the entire cell and there exists an optimal level of compression. Results of electrochemical impedance spectroscopy (EIS) show that the cold pre-compression results in a significant reduction in charge transfer resistance, especially in the high current density region. Further study by the cyclic voltammetry (CV) shows that the electro-chemical area (ECA) is changed with the different cold pre-compressed MEAs and there exists an optimal compression that results in the maximum ECA.     

Model-based control of cathode pressure and oxygen excess ratio of a PEM fuel cell system

For PEM fuel cells supplied with air, pressure and flow control is a key requirement for an efficient and dynamic operation because fuel cells are in risk of starvation when the partial pressure of oxygen at the cathode falls below a critical level. To avoid oxygen starvation and, at the same time, to allow for a dynamic operation of the fuel cell system, both excess ratio of oxygen and cathode pressure need to be adjusted rapidly.     

The potential of PEM fuel cell for a new drinking water source

The worldwide water scarcity, especially in the developing countries and arid regions, forces people to rely on unsafe sources of drinking water. There is a pressing need for these regions to develop decentralized, small-scale water utilities. However, more than 50% of the total operating costs associated with such small-scale, water-utility operations are the cost of providing electricity to run water pumps. We think that advances in a variety of renewable and sustainable energy technologies offer considerable promise for reducing the energy required for the production and distribution of water by small-scale water utilities. This paper provides a comprehensive review of the potential for using proton exchange membrane (PEM) fuel cells to provide an alternative supply of drinking water. This system can eliminate the excessive energy requirements that are currently associated with water production. Such alternative water production processes are designed to increase the production rate of drinking water by reducing the amount of water required to humidify the reactant gases during stable cell performance. The principal operational components of PEM fuel cells are reviewed and evaluated, including air stoichiometry, pressure, and cell temperature. Hydrogen-fed fuel cell systems provide sufficient water to meet the potable water needs of a typical household. Furthermore, it is concluded that PEM fuel cells have great promise for decentralized, small-scale, water-production applications, because they are capable of generating sufficient quantities of potable water by operating at maximum power and by increasing the number of polymer membranes.     

Dynamic behaviors of PEM fuel cells under load changes

In this study, a one-dimensional isothermal single-phase transient model considering the finite-rate water absorption/desorption of membrane was established to study the dynamic behaviors of polymer electrolyte membrane (PEM) fuel cells under different cathode inlet humidity conditions in the presence of voltage step changes. Both the overshoot and undershoot phenomena were observed. Moreover, the distributions of water inside the electrolyte and the influence of that on the response current density of fuel cells were analyzed. When voltage stepped up/down, the water content in anode generally increased/decreased, and the water content in cathode is reversed. If the cathode intake is fully humidified, the water vapor in cathode is always over-saturated causing the change of ionic resistance is determined by that of the water content in anode. If the cathode intake is partially humidified, the change of ionic resistance could maintain within a small range owing to the change of water content in anode can be balanced by that of the water content in cathode.     

Electrochemical characterization of sulfonated PEEK-WC membranes for PEM fuel cells

Sulfonated PEEK-WC polymer was obtained according to chloro-sulfonic acid procedure making possible the preparation of different membrane samples with a sulfonation degree from 48 to 90%. Dense membranes were prepared from casting solutions of S-PEEK-WC dissolved in DMF. Proton conductivity measurements were performed on such S-PEEK-WC membranes in a range of temperature from 30 to 120 °C and 100% of relative humidity, reaching 2.5 × 10⁻² S cm⁻¹ as the best value at 100 °C and with a sulfonation degree of 90%. In the meanwhile, the open circuit voltage of this S-PEEK-WC membrane (DS = 90%) varied from 0.963 V at 60 °C to 0.802 V at 100 °C, demonstrating that an increase of temperature negatively affects the membrane performance due to the mechanical properties degradation. In this work, a wide experimental campaign was carried out to investigate the electrochemical performances in terms of polarization curves, open circuit voltage and proton conductivity of S-PEEK-WC membranes as well as the fuel crossover and water uptake.     

Prediction performance of PEM fuel cells by gene expression programming

In the present study, gene expression programming has been utilized to evaluate the output voltage of different PEM fuel cells as the performance symbol of these structures. A total number of 843 data were collected from the literature, randomly divided into 682 and 161 sets, and then trained and tested, respectively by different models. The used data as input parameters were consisted of current density, fuel cell temperature, anode humidification temperature, cathode humidification temperature, operating pressures, fuel cell type, O₂ flow rate, air flow rate and active surface area of the PEM fuel cells. According to these input parameters, in the gene expression programming models, the voltage of each PEM fuel cell in different conditions was predicted. The training and testing results in the gene expression programming model have shown an acceptable potential for predicting voltage values of the PEM fuel cells in the considered range.     

Fast start-up of a diesel fuel processor for PEM fuel cells

Fuel cell systems based on liquid fuels are particularly suitable for auxiliary power generation due to the high energy density of the fuel and its easy storage. Together with industrial partners, Oel-Waerme-Institut is developing a 3 kW_el PEM fuel cell system based on diesel steam reforming to be applied as an APU for caravans and yachts. The start-up time of a fuel cell APU is of crucial importance since a buffer battery has to supply electric power until the system is ready to take over. Therefore, the start-up time directly affects the battery capacity and consequently the system size, weight, and cost.     

Design and implementation of LQR/LQG strategies for oxygen stoichiometry control in PEM fuel cells based systems

This paper presents the oxygen stoichiometry control problem of proton exchange membrane (PEM) fuel cells and introduces a solution through an optimal control methodology. Based on the study of a non-linear dynamical model of a laboratory PEM fuel cell system and its associated components (air compressor, humidifiers, line heaters, valves, etc.), a control strategy for the oxygen stoichiometry regulation in the cathode line is designed and tested. From a linearised model of the system, an LQR/LQG controller is designed to give a solution to the stated control problem. Experimental results show the effectiveness of the proposed controllers design.     

Output-feedback voltage tracking control for input-constrained PEM fuel cell systems

An output-feedback voltage control system for nonlinear PEM fuel cells is presented. For voltage tracking around equilibrium operating points, the controller design minimizes the energy ratio between tracking error and normalized command while hydrogen and oxygen flowrates satisfy specified magnitude constraints and closed-loop poles meet desired placement constraints. Time response simulations based on Ballard 5 kW PEM fuel cell system parameters verify the design. Simulated controllers constructed numerically via the linear matrix inequality algorithm elaborate relationships between designed input flowrate and voltage tracking error. With controller design based on the same nominal input flowrate constraints, the achieved voltage tracking capability is comparable to our published state-feedback design study. To reduce voltage tracking error under fixed external resistance, gas flowrate magnitude constraints must be relaxed, requiring more fuel energy to manipulate the system variables for operation away from equilibrium conditions. Whereas state-feedback designs depend on internal state variables which are not always measurable, output-feedback control using only voltage tracking error as measurement simplifies practical implementation.