Fuel Cell Air Intake System Final Report ME450: Winter 2009 Professor Hulbert Team 9 Timothy Diepenhorst Richard Lin Abubaker Mohammed Sedik Timothy Song Joshua Sotsky April 21, 2009 CONTENTS ABSTRACT ...............................................................................................................................1 EXECUTIVE SUMMARY .........................................................................................................2 PROBLEM DESCRIPTION .......................................................................................................3 INFORMATION SOURCES ......................................................................................................3 The Proton Exchange Membrane Fuel Cell ..............................................................................3 Airflow ....................................................................................................................................5 Humidity .................................................................................................................................6 Temperature ............................................................................................................................7 Pressure ...................................................................................................................................8 Purity..................................................................................................................................... 11 Noise ..................................................................................................................................... 12 Packaging .............................................................................................................................. 13 Customer Requirements ......................................................................................................... 14 ENGINEERING SPECIFICATIONS ........................................................................................ 14 Quality Function Deployment ................................................................................................ 15 Customer Requirement Weights ............................................................................................ 15 CONCEPT GENERATION ...................................................................................................... 15 Functional Decomposition ..................................................................................................... 16 Intake Inlet Scoop .................................................................................................................. 17 The “Whale Mouth” ........................................................................................................... 17 The idea of NACA Ducts ................................................................................................... 17 Although ground ducts and inlets ....................................................................................... 17 A Multi Scoop System ....................................................................................................... 17 A Variable Duct Opening ................................................................................................... 18 Compressed Oxygen Tanks ................................................................................................ 18 Filtration ................................................................................................................................ 18 Dust Filters ........................................................................................................................ 18 Membrane Filters ............................................................................................................... 18 Donaldson Chemical Filter ................................................................................................. 18 Active carbon filtration ...................................................................................................... 18 Compression .......................................................................................................................... 21 Scroll compressors ............................................................................................................. 21 Screw compressors ............................................................................................................. 22 Centrifugal compressors ..................................................................................................... 22 Lobe Compressors ............................................................................................................. 23 Humidification ...................................................................................................................... 23 Liquid Water Injection humidifiers .................................................................................... 23 Nafion® membrane humidifiers ......................................................................................... 23 Carbon Foam humidifiers ................................................................................................... 23 Temperature Controller.......................................................................................................... 24 Induction heating system .................................................................................................... 24 Air Conditioning Unit ........................................................................................................ 24 Intercoolers ........................................................................................................................ 24 CONCEPT SELECTION .......................................................................................................... 24 Intake Inlet Scoop .................................................................................................................. 24 “Whale Mouth” Design ...................................................................................................... 25 NACA Duct ....................................................................................................................... 25 Ground Duct ...................................................................................................................... 25 Multi-Scoop System ........................................................................................................... 25 Variable Intake ................................................................................................................... 25 Compressed Oxygen .......................................................................................................... 25 Filtration ................................................................................................................................ 25 Visteon Dust Filter ............................................................................................................. 26 Activated Carbon Filter ...................................................................................................... 26 Membrane Filter ................................................................................................................ 26 Donaldson Chemical Filter ................................................................................................. 26 Compression .......................................................................................................................... 26 Screw Compressor ............................................................................................................. 27 Scroll Compressor .............................................................................................................. 27 Centrifugal Compressor ..................................................................................................... 28 Lobe Compressor ............................................................................................................... 28 Humidifier ............................................................................................................................. 28 Liquid Water Injection ....................................................................................................... 28 Radial and Linear Nafion® Membrane Concepts ................................................................ 29 Carbon Foam Humidifier ................................................................................................... 29 Temperature Controller.......................................................................................................... 29 Intercooler.......................................................................................................................... 30 Air Conditioning Unit ........................................................................................................ 30 System Order ......................................................................................................................... 30 CONCEPT DESCRIPTION ...................................................................................................... 30 ENGINEERING DESIGN PARAMETER ANALYSIS ............................................................ 33 Thermodynamic Model of System 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