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Modeling and Design of Hybrid PEM Fuel Cell Systems for Lift Trucks

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Modeling and Design of Hybrid PEM Fuel Cell Systems for Lift Trucks Downloaded from orbit.dtu.dk on: Oct 10, 2021 Modeling and Design of Hybrid PEM Fuel Cell Systems for Lift Trucks Hosseinzadeh, Elham Publication date: 2012 Document Version Publisher's PDF, also known as Version of record Link back to DTU Orbit Citation (APA): Hosseinzadeh, E. (2012). Modeling and Design of Hybrid PEM Fuel Cell Systems for Lift Trucks. DTU Mechanical Engineering. General rights Copyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright owners and it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights. Users may download and print one copy of any publication from the public portal for the purpose of private study or research. You may not further distribute the material or use it for any profit-making activity or commercial gain You may freely distribute the URL identifying the publication in the public portal If you believe that this document breaches copyright please contact us providing details, and we will remove access to the work immediately and investigate your claim. Modeling and Design of Hybrid PEM Fuel Cell Systems for Lift Trucks by Elham Hosseinzadeh Ph.D. Thesis Department of Mechanical Engineering Technical University of Denmark 2012 Preface This thesis is submitted as a partial fulfillment of the requirements for the Ph.D. degree at the Technical University of Denmark. The work has been prepared from October 2009 to December 2012 at the Section of Thermal Energy Systems, Department of Mechanical Engineering, Technical University of Denmark (DTU) under the supervision of Associate Professor Masoud Rokni. An external research stay was conducted from September 2011 to December 2011 at the University of Delaware under the supervision of Associate Professor Ajay K. Prasad, Director of the UD Center for Fuel Cell Research and with the co-supervision of Professor Suresh G. Advani, Chair of the Mechanical Engineering Department. This Ph.D. project was a part of a larger project called HyLift_C3, which was mainly financed by Højteknologifonden (approximately 2/3 of the funding). It consists of three work packages and DTU–MEK led WP3. This project was in cooperation between DTU and the H2Logic company which is an innovative company mainly working on fuel cell motive power, hydrogen production and hydrogen refueling. The thesis is written as a monograph, but a number of papers have been published based on the work in this research study. Elham Hosseinzadeh Kgs. Lyngby, December 2012 i Acknowledgments Completing a Ph.D. was a challenging job, and I would not have been able to complete this journey without the aid and support of countless people over the past three years. I must first express my gratitude towards my advisor, Associate Professor Masoud Rokni. His leadership, support, attention to details and hard work have set an example I hope to match some day. Special acknowledgments go out to Henrik H. Mortensen from the H2Logic Company for his useful advice and collaboration throughout the research project. I would like to acknowledge Højteknologifonden, Technical University of Denmark and the H2Logic Company for funding this project. I would also like to thank Associate Professor and Head of Section Brian Elmegaard, and my old colleague Christian Bang-Møller for showing their support whenever needed. Special thanks to Ph.D. student; Raja Abid Rabbani for our collaboration and useful discussions from time to time. I extend my deepest gratitude to all my colleagues at the TES Section for creating such a nice environment for a workplace. I was fortunate enough to spend my external stay at the University of Delaware, Center for Fuel Cell Research. I would like to express my deepest gratitude to Associate Professor Ajay K. Prasad and Professor Suresh G. Advani for their hospitality, inspiring discussions and their contributions to this research study. I would like to extend my appreciation especially to Ph.D. student Jingliang Zhang for his help with the project during my stay there. I am grateful to the Otto Mønsted Foundation for their generous financial support during my stay at the University of Delaware. I am deeply and forever indebted to my parents for their love, support and encour- agement throughout my entire life. Finally, I would like to express my deepest appreciations to my beloved husband, Masoud for his understanding, support, patience and endless love through the duration ii of this study. iii Abstract Reducing CO2 emissions is getting more attention because of global warming. The transport sector which is responsible for a significant amount of emissions must reduce them due to new and upcoming regulations. Using fuel cells may be one way to help to reduce the emissions from this sector. Battery driven lift trucks are being used more and more in different companies to reduce their emissions. However, battery driven lift trucks need a long time to recharge and thus may be out of work for a long time. Fuel cell driven lift trucks diminish this problem and are therefore getting more attention. The most common type of fuel cell used for automotive applications is the PEM fuel cell. They are known for their high efficiency, low emissions and high reliability. However, the biggest obstacles to introducing fuel cell vehicles are the lack of a hydrogen infrastructure, cost and durability of the stack. The overall aim of this research is to study different fuel cell systems and find out which system has the highest efficiency and least complexity. This will be achieved by modelling and optimizing the fuel cell system followed by some experimental tests. Efficiency of the stack is about 50%. But efficiency of the whole system is less than this value, because some part of the electricity produced by the stack would run the auxiliary components. This work deals with the development of a steady state model of necessary components in the fuel cell system (humidifier, fuel cell stack and ejector), studying different system configurations and optimizing the operating conditions in order to achieve the maximum system efficiency. A zero-dimensional component model of a PEMFC has been developed based on polynomial equations which have been derived from stack data. The component model has been implemented at a system level to study four system configurations (single and serial stack design, with/without anode recirculation loop). System design evaluations reveal that the single stack with a recirculation loop has the best performance in terms of electrical efficiency and simplicity. To further develop the selected system configuration, the experimental PEMFC iv model is replaced by a zero-dimensional model based on electrochemical reactions. The model is calibrated against available stack data and gives the possibility of running the system under the operating conditions for which experimental data is not available. This model can be used as a guideline for optimal PEMFC operation with respect to electrical efficiency and net power production. In addition to the optimal operation, investigation of different coolants and operating conditions provides some recommendations for water and thermal management of the system. After theoretically analyzing the system, theremore attempts to improve the anode recirculation loop, basically by using an ejector instead of a recirculation pump. The CFD technique has been used to design and analyze a 2-D model of an ejector for the anode recirculation of the PEMFC system applied in a fork-lift truck. In order for the ejector to operate in the largest possible range of load, different approaches (with fixed nozzle and variable nozzle ejectors) have been investigated. Different geometries have been studied in order to optimize the ejector. The optimization is carried out not only by considering the best performance of the ejector at maximum load with prioritizing operation in the larger range, but also by catching the design point at maximum load even though it does not have the best efficiency at such point. Finally, a hybrid drive train simulation tool called LFM is applied to optimize a virtual fork-lift system. This investigation examines important performance metrics, such as hydrogen consumption and battery SOC as a function of the fuel cell and battery size, control strategy, drive cycle, and load variation for a fork-lift truck system. This study can be used as a benchmark for choosing the combination of battery and fuel cell. v List of publications Journal papers: 1. E. Hosseinzadeh, M. Rokni, “Development and validation of a simple analytical model of the Proton Exchange Membrane Fuel Cell (PEMFC) in a fork-lift truck power system”. International Journal of Green Energy, In press, Available online 14 May 2012. 2. E. Hosseinzadeh, M. Rokni, A. Rabbani, H. Mortensen“Thermal and water man- agement of Low Temperature Proton Exchange Membrane Fuel Cell in fork-lift truck power system”, Accepted in the Journal of Applied Energy, 2012, In press. 3. E. Hosseinzadeh, S. G. Advani, A. K. Prasad, M. Rokni, “Performance simulation and analysis of a fuel cell/battery hybrid forklift truck”, Submitted to the Journal of Hydrogen Energy, 2012. 4. E. Hosseinzadeh, M. Rokni, M. Jabbari, H. Mortensen “Numerical Analysis of Transport Phenomena for Design of the Ejector in a PEM Fuel Cell system”. Submitted to the Journal of Heat and Mass Transfer, 2012. Peer reviewed conference paper: 1. E. Hosseinzadeh, M. Rokni, “Proton Exchange Membrane Fuel Cells Applied for Transport Sector”, 5th International Ege Energy Symposium and Exhibition, IEESE, 2010, Denizli, Turkey. Peer reviewed abstract: 1. E. Hosseinzadeh, M. Rokni, “Application of Proton Exchange Membrane Fuel Cell for Lift Trucks”, 15th EUROPEAN FUEL CELL FORUM, June 2011, Luzern, Switzerland. vi Contents 1 Introduction 1 1.1 Motivation . .1 1.2 Literature review . .3 1.3 Objectives .
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