Title of Invention

AN ELECTROCHEMICAL SYSTEM AND A METHOD OF OPERATING AN ELECTROCHEMICAL SYSTEM CONTAINING A REVERSIBLE FUEL CELL SYSTEM

Abstract An electrochemical system comprises a reversible fuel cell system which generates electrical energy and reactant product from fuel and oxidizer in a fuel cell mode and which generates the fuel and oxidant from the reactant product and the electrical energy in an electrolysis mode. The system also comprises a reactant product delivery device which is adapted to supply the reactant product to the reversible fuel cell system operating in the electrolysis mode, in addition to or instead of the reactant product generated by the reversible fuel cell system in the fuel cell mode, and a fuel removal device which is adapted to remove the fuel generated by the reversible fuel cell system operating in the electrolysis mode from the electrochemical system. Fig. 2
Full Text AN ELECTROCHEMICAL SYSTEM AND A METHOD
OF OPERATING AN ELECTROCHEMICAL SYSTEM
CONTAINING A REVERSIBLE FUEL CELL SYSTEM
BACKGROUND OF THE INVENTION
The present invention relates to an electrochemical system and a method
of operating an electrochemical system containing a reversible fuel cell system,
and generally directed to fuel cells and more specifically to reversible fuel cells
and their operation.
Fuel cells are electrochemical devices which can convert energy stored in
fuels to electrical energy with high efficiencies. There are classes of fuel cells
that also allow reversed operation, such that oxidized fuel can be reduced back
to unoxidized fuel using electrical energy as an input. The ability to generate
electricity and regenerate fuel makes these fuel cells suitable for electrical
energy storage.
BRIEF SUMMARY OF THE INVENTION
One preferred aspect cf the present invention provides an electrochemical
system which includes a reversible fuel cell system which generates electrical
energy and reactant product from fuel and oxidizer in a fuel cell mode and which
generates the fuel and oxidant from the reactant product and the electrical
energy in an electrolysis mode. The system also includes a reactant product
delivery device which is adapted to supply the reactant product to the reversible
fuel cell system operating in the electrolysis mode, in addition to or instead of the
reactant product generated by the reversible fuel cell system in the fuel cell
mode, and a fuel removal device which is adapted to remove the fuel generated
by the reversible fuel cell system operating in the electrolysis mode from the
electrochemical system.

Another preferred aspect of the present invention provides an
electrochemical system, comprising a first means for cyclically operating in a fuel
cell mode to generate electrical energy and reactant product from fuel and
oxidizer and in an electrolysis mode to generate the fuel and oxidant from the
reactant product and the electrical energy. The system also comprises a second
means for providing excess reactant product to the first means operating in the
electrolysis mode from outside the electrochemical system, in addition to or
instead of the reactant product generated by the first means in the fuel cell
mode, such that fuel in excess of fuel required to operate the first means in the
fuel cell mode is generated in the electrolysis mode over a predetermined
number of operating cycles, and a third means for removing the excess fuel
generated by the first means operating in the electrolysis mode from the
electrochemical system.
Another preferred aspect of the present invention provides a method of
operating an electrochemical system containing a reversible fuel cell system,
comprising cyclically operating the reversible fuel cell system in a fuel cell mode
to generate electrical energy and reactant product from fuel and oxidizer and in
an electrolysis mode to generate the fuel and oxidant from the reactant product
and the electrical energy. The method also comprises providing excess reactant
product to the reversible fuel cull system operating in the electrolysis mode from
outside the reversible fuel cell system, in addition to or instead of the reactant
product generated by the reversible fuel cell system in the fuel cell mode, such
that fuel in excess of fuel required to operate the reversible fuel cell system in
the fuel cell mode is generated in the electrolysis mode over a predetermined
number of operating cycles, and removing the excess fuel generated by the
reversible fuel cell system operating in the electrolysis mode from the
electrochemical system.


BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1 is a schematic of an electrical energy storage system.
Figure 2 is a schematic of an electrical energy storage system with a
reversible fuel cell system.
Figure 3 is a schematc of an electrical energy storage system with a
reversible fuel cell system, which can also generate fuel for use outside the
electrical energy storage system.
Figure 4 is a schematic cross section of a single SORFC operating in the
electrolysis mode according to a preferred embodiment of the present invention.
Figure 5 is a schematic cross section of a single SORFC operating in the
fuel cell mode according to a preferred embodiment of the present invention.
Figure 6 is a schematic side of view of a Sabatier reactor according to a
preferred embodiment of the present invention.
Figure 7 is a system schematic of the major SORFC components
operating in the fuel cell mode, according to a preferred embodiment of the
present invention.
Figure 8 is a system schematic of the major SORFC components
operating in the electrolysis mode, according to a preferred embodiment of the
present invention.


DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present inventor; have realized that regenerative or reversible
operation of fuel cells can be applied beyond mere energy storage to produce
fuel for uses outside the fuel cell system. A reversible fuel cell is used to
reversibly store electrical energy. When electrical energy is needed from the
storage system, the fuel cell Dperates in a fuel cell or discharge mode. In this
mode, fuel is oxidized in the fuel cell, electricity is generated, and part or all of
the reactant product is stored, if desired. The system is then recharged in an
electrolysis or charge mode. In this mode, the system is recharged by supplying
electrical power to the fuel cell, electrolyzing the stored and/or supplied reactant
product, thereby regenerating the fuel. The regenerated fuel and optionally the
regenerated oxidant are stored and available for energy generation in the fuel
cell mode. The system cyclically or alternatively switches operation between the
fuel cell and electrolysis mooes for any suitable number of cycles. If more
electrical energy and reactant product than needed to regenerate the fuel is
supplied to the reversible fuel cell over a predetermined number of operating
cycles, then excess or additional fuel can be generated during the electrolysis
mode during some or all of these cycles. In other words, more fuel is generated
when the system operates in the electrolysis mode than the fuel needed to
operate the system in the fuel cell mode. This excess fuel can be used outside
the energy storage system.
Figure 1 shows an energy source 100 connected via a conduit 110 to an
energy storage system 120. The energy storage system 120 is connected via
conduit 130 to the energy consumer 140. The energy storage system 120
supplies the required power to the energy consumer 140 at all times or at
predetermined times, if desired The energy supplied to the consumer comes
from the energy source 100, or from the energy storage system 120, or a
combination of the two. The system shown in Figure 1 decouples the amount of


power drawn by the energy consumer 140 from the amount of energy drawn
from the energy source 100.
Examples of the energy source 100 include, but are not limited to the
electrical grid, electrical generators and renewable energy sources. Preferred
renewable energy sources include photovoltaic sources, such as solar cell
arrays, wind power sources, such as wind turbines, tidal power sources in which
power is generated from forces of ocean, sea or lake tides, and geothermal
power sources in which power is generated from geothermal heat.
The energy storage system 120 is preferably a reversible or regenerative
fuel cell system, as will be described in more detail below with respect to Figure
2. Examples of the energy consumer 140 include, but are not limited to
residential households, commercial building, such as factories, hospitals and
office building, electrical subgrids, and remote transmitters.
The system 120 will draw more power from the energy source 100 than
what is supplied to the energy consumer 140 in the electrolysis mode and the
additional power is stored in the form of regenerated fuel. In the fuel cell mode
the system 120 provides electrical power or energy to the consumer 140 instead
of or in addition to the power provided to the consumer 140 from the energy
source 100. As used herein, the terms "electrical power" and "electrical energy"
refer to features of electricity provided by the energy source 100 and to features
of electricity provided to the consumer 140.
Figure 2 shows details cf the energy storage system 120. The system
120 is preferably an electrochemical system which contains a power
management system 160, a reversible fuel cell system 190, a fuel storage device
210 and an optional reactant product storage device 230. The system also
contains electrical connection conduits or wires 150, 170 and 180, as well as a
fuel conduit 200 and a reactant product conduit 220 which allow the fuel and


reactant product to pass between the reversible fuel cell system 190 and the fuel
storage 210 and product storage 230 devices, respectively.
The power management system 160 may be any suitable controller
device, such as a computer or microprocessor, and preferably contains logic
circuitry which decide how :o route the power streams. Energy from the
electrical energy source 10C can be directed fully to the electrical energy
consumer 140, fully to the reversible fuel cell system 190, or can be partitioned
between the electrical energy consumer 140 and the reversible fuel cell system
190. It is also possible to feed electrical energy back towards the electrical
energy source 100, which can be applied for example where the electrical
energy source 100 is the electrical grid. The power management system 160
also controls from where power is supplied to the electrical energy consumer
140. Power can be supplied from the electrical energy source 100, the
reversible fuel cell system 190, or a combination thereof.
The reversible fuel cell system 190 may comprise one or more reversible
fuel cells or one or more fuel cell/electrolyzer pairs. A reversible fuel cell is a
single electrochemical device which generates reactant product and electrical
energy or power in the fuel cell mode and which generates fuel from reactant
product and electrical energy in the electrolysis mode. A fuel cell/electrolyzer
pair includes two separate devices, where a non-reversible fuel cell device
generates energy, and the other electrolyzer device regenerates fuel.
Examples of the fuel cells, and electrolyzers include but are not limited to
high temperature fuel cells, such as solid oxide fuel cells (SOFC), and also
include proton exchange membrane fuel cells (PEM). Reversible or regenerative
SOFC's (SORFCs) are well suited to combine energy generation and fuel
regeneration in a single device. However, other fuel cells, such as molten
carbonate fuel cells, may also be used in the system 190. Preferably, the
system 190 contains at least one stack of reversible fuel cells or stacks of fuel


cell/electrolyzer pairs.
The fuel and reactant product storage devices 210 and 230 may comprise
any suitable gas, liquid or soiid storage devices. Preferably, these devices 210,
230 comprise gas or liquid tanks which are opened and closed with a valve.
The system 120 operates as follows. Power from the electrical energy
source 100 enters through conduit 110 and conduit 150 to the power
management system 160. When the reversible fuel cell system 190 operates in
the fuel cell mode and provides electrical energy, fuel is fed from the fuel storage
device 210 to the reversible fuel cell system 190 via the fuel conduit 200. In the
reversible fuel cell system 190, the chemical energy of the fuel is converted to
electrical energy, which is ther supplied to the power management system 160.
Optionally, all or part of the reactant product from the reversible fuel cell system
are transferred to the product storage device 230 via the reactant product
conduit 220. Products that are not stored are released.
When the reversible fuel cell system 190 operates in the electrolysis
mode, electrical energy from the power management system 160 is provided to
system 190 and the reactant pnduct from the product storage device 230 and/or
from outside the electrochemical energy storage system 120 is provided via the
reactant product conduit 220 to the system 190. The fuel is regenerated in the
reversible fuel cell system 190 and provided to the fuel storage 210 via the fuel
conduit 200.
Any suitable fuels, oxidizers and reactant product may be used. One
preferred example for the fuel is hydrogen which is reacted with oxygen from
ambient air to produce a water reactant product. However, other fuels and
oxidants can be used. For example, a hydrocarbon gas, such as methane, may
be used as a fuel to produce water and carbon dioxide reactant product. Other
hydrocarbon gases, such as natural gas propane, hexane, etc., may also be


used as fuel. Furthermore, these hydrocarbon materials may be reformed into a
carbon containing fuel, such as carbon monoxide, or previously supplied carbon
monoxide may also be used as fuel.
If surplus energy is available from the electrical energy source 100 and an
excess reactant product is supplied to the reversible fuel cell system 190, then
the system 190 can generate more fuel than what is needed by the system 190
in the fuel cell mode. This excess fuel may be removed from the system 120
and provided for any suitable end use outside the system 120.
Figure 3 illustrates the system 120 when the excess reactant product is
supplied to the system 120 and the excess fuel is removed from the system.
The system 120 is identical to the system 120 illustrated in Figure 2 with the
exception of the fuel remova device 240 and the reactant product delivery
device 250. Excess fuel is povided out of the system 120 through the fuel
removal device 240, while the excess reactant product is replenished through
reactant product delivery device 250. The devices 240 and 250 may comprise
any suitable devices which may deliver fuel and reactant product.
For example, the fuel removal device 240 may be a gas or liquid conduit
such as a pipe or hose which delivers fuel, such as hydrogen or methane, from
the reversible fuel cell system 190 and/or from the fuel storage device 210
outside the system 120. Alternatively, the device 240 may comprise a movable
gas or liquid storage container, such as a gas or liquid tank, which is physically
removed from the system 120 after the container is filled with fuel. If the device
240 comprises a container, then the device 240 may be used as both the fuel
storage device 210 while it remains in the system 120, and as a fuel removal
device 240, when it is removed from the system 120.
The reactant product delivery device 250 may be one or more gas or
liquid conduits which deliver reactant product, such as water and/or carbon


dioxide to the system 120. For example, the device may comprise a water pipe
or hose which delivers water to the product storage device 230 or directly to the
reversible fuel cell system 130. The device 250 may comprise two conduits
when the reactant product comprises two separate components, such as water
and carbon dioxide. Alternatively, the device 250 may comprise a movable gas
or liquid storage container, such as a gas or liquid tank, which is physically
delivered to the system 120 filled with reactant product. If the device 250
comprises a container, then the device 250 may be used as both the reactant
product storage device 230 whiIe it collects reactant product during the fuel cell
mode, and as a reactant product delivery device 250 when it provides reactant
products during the electrolysis mode.
The reactant product delivery device 250 is adapted to supply excess
reactant product to the reversible fuel cell system 190 operating in the
electrolysis mode, in addition tc or instead of the reactant product generated by
the reversible fuel cell system h the fuel cell mode. In other words, the device
250 supplies the reactant product 250 in excess of the amount generated by the
reversible fuel cell system 190 operating in the fuel cell mode. In one example, if
the reactant product is water, than the water generated by the system 190 in the
fuel cell mode is stored in the storage device 230 and the device 250 provides
additional water to the device 230. In another example, the water generated by
the system 190 in the fuel cell mode is discarded and the 250 provides water to
the device 230 and/or to the system 190 in excess of the amount produced by
the system 190 in the fuel cell mode.
In either example, the excess reactant product allows the system 190 to
generate an amount of fuel in the electrolysis mode in excess of the amount of
fuel required to operate the system 190 in the fuel cell mode over a
predetermined number of operating cycles. Thus, while anomalies, such as
breakdowns, early shut downs, etc., may occur during individual fuel cell mode
and electrolysis mode cycles, when the system 190 is operated cyclically over a


predetermined number of such cycles, such as over 10 cycles, for example over
100 to 1,000 cycles, the systen 190 produces the excess fuel.
The reversible fuel cell system 190 may generate more fuel in the
electrolysis mode than it consumes in the fuel cell mode over the predetermined
number of cycles under several conditions. In a first preferred embodiment of
the present invention, the reversible fuel cell system operates at a higher current
level in the electrolysis mode than in the fuel cell mode over the predetermined
number of cycles.
In a preferred aspect of the present invention, the reversible fuel cell
system 190 includes a SORFC stack. It is desirable for the energy storage
system 120 to operate at high round-trip efficiencies, which is the ratio of energy
provided to the electrical energy consumer 140 to the electrical energy from
source 100. In order to achieve high round-trip efficiencies, the SORFC is
preferably operated at comparably low current densities thereby minimizing
losses in the SORFC. Theoretically, the round-trip efficiency increases with
decreasing current density. However, the SORFC should be maintained at an
elevated operating temperature which typically ranges between 600°C and
1000X. The losses within the SORFC can be used to provide make-up heat to
keep the SORFC at the desirec temperature. If the current and thereby the
losses become too small, the desired operating temperature cannot be
maintained. Therefore, a practical low limit for the current density exists in the
electrolysis mode and in the fuel cell mode. This current density limit depends
on the thermal losses from the system and the heat generated at a specific
current.
Operation of a fuel cell at low current implies a fuel cell voltage close to
the open circuit voltage (OCV), which is the fuel cell voltage at zero current.
Operation below OCV implies power generation, while operation above OCV
implies fuel regeneration/electrolysis. When the fuel cell is operated in the


electrolysis mode, additional constraints on the minimum allowable current
density can exist. In the example of water electrolysis at high temperature,
operation of the fuel cell only slightly above OCV is an endothermic reaction.
There is a minimum voltage for electrolysis, termed the thermal neutral voltage at
which the electrolysis reaction is thermally neutral. In order to thermally sustain
the SORFC without the use of thermal storage during electrolysis, electrolysis
should be performed above the thermal neutral voltage. On the other hand,
power generation can be performed very close to OCV. As a result the desired
minimum current density for electrolysis is significantly larger than the desired
minimum current for power generation in the fuel cell mode. The difference
between the minimum currents depends on the thermal management system
and the choice of fuel and oxidizer. In a SORFC without additional fuel
generation, the current in power generation and electrolysis mode also should be
balanced with respect to the available time for power generation and
electrolysis. If, for example, energy is generated for 16 hours per day while fuel
is regenerated for 8 hours per day, the current during regeneration has to be
twice as large as the power generation current in order to balance fuel consumed
and regenerated.
The two constraints for current densities outlined above generally lead to
different values for the minimum current density in the fuel cell and electrolysis
modes. As a result of the higher current density in the electrolysis than in fuel
cell mode, the energy storage system 120 typically has additional/unused fuel
regeneration capacity. If additional or excess power or electrical energy and
reactant product is available during fuel regeneration in the electrolysis mode,
this excess fuel generation capacity can be utilized to generate additional fuel,
which can be used outside the electrical energy storage system.
Thus, the system 120 may be used as a regenerative power supply to
remote residences or comnercial operations or to residences or commercial
operations connected to the power grid. The electrical power generator has to


be sized to meet the peak load of the user. This sizing requirement allows a
surplus of fuel to be generated during charge times. Examples include, but are
not limited to systems sized to meet high electrical power peak demands which
occur during less than 100 percent of the system operation in the fuel cell mode
or systems with relatively low energy consumption (i.e., below the maximum
possible energy consumption) during the fuel cell mode.
Thus, in one preferred aspect of the first embodiment, the reversible fuel
system 190 is operated at a load lower than a peak load that the reversible fuel
cell system is capable of providing at least during a portion of a time that the
reversible fuel cell system operates in the fuel cell mode. Thus, the reversible
fuel system 190 is operated for at least a portion of its fuel cell mode at a current
density below its peak or maxirrum possible current density. In contrast, the
reversible fuel system 190 is operated at a higher current density, such as at a
peak current density, in the electrolysis mode to produce the excess fuel.
Since the systems 120, 190 are designed and sized for a desired energy
storage, the size of the fuel cell stack and the size of the balance of plant are
based on the desired energy storage. Thus, the size of the fuel cell stack is
based on the minimum number of fuel cells that operate in the fuel cell mode to
provide the desired peak power, rather than on the number of fuel cells or
electrolyzers that are required for the electrolysis mode. Thus, extra fuel cells or
stacks may be required ensure that the system 120 provides the desired peak
power in the fuel cell mode during a worst case scenario. However, the energy
generation capability of all of the fuel cells may not be used in the fuel cell mode
outside of the worst case scenario. In contrast, the fuel regeneration capability
of all fuel cells may be used during electrolysis mode to regenerate the fuel
needed for future fuel cell models) and to generate excess fuel for use outside
the system 120.
In another preferred aspect of the first embodiment, the reversible fuel


cell system 190 is electrically connected to an electrical energy source 100 which
comprises a photovoltaic energy generation system which provides electrical
energy to the reversible fuel cell system during daytime to generate and store
fuel. The photovoltaic energy generation system also provides electrical energy
to the consumer 140, as illustrated in Figure 1. The reversible fuel cell system
190 generates electrical energy during night time from the stored fuel and
provides this electrical energy to the consumer 140 during night time. Often, the
night time load on the reversible fuel cell system 190 is lower than a peak load
that the reversible fuel cell system is capable of providing, at least during a
portion of the night time period. Thus, the reversible fuel system 190 is operated
in the fuel cell mode during at least a portion of the night time period at a current
density below its peak current density. In contrast, the reversible fuel system
190 is operated at a higher current density, such as at a peak current density, in
the electrolysis mode during the day time period to produce the excess fuel.
In a second preferred embodiment, the reversible fuel cell system 190
operates for a longer duration in the electrolysis mode than in the fuel cell mode
over the predetermined number of cycles. This difference in operating time may
be used to produce the excess fuel. For example, the system 190 may operate
during one portion of the electrolysis mode to regenerate sufficient fuel for the
entire next fuel cell mode period, and then operate for the remainder of the
electrolysis mode period to produce the excess fuel.
Examples of the second embodiment include system 190 operation where
charging and discharging follows a day/night cycle. Such a system often
operates with a photovoltaic electrical energy source 100 described above. If the
night time discharge period is shorler than the day time charge period, a surplus
or excess fuel can be generated.
Another example is where the system 190 is used to provide emergency
backup power when the electrical energy source 100 is unable to provide


electrical energy to the consumer 140. For example, the system 190 may be
used as a backup power source for a time when an electrical grid energy source
100 stops providing electrical energy. In this example, the system 190 operates
at least 90 to 99 percent of the time in the electrolysis mode and occasionally
operates in the fuel cell mode when the source 100 does not provide electrical
energy. Thus, the system 190 is used as an electrolyzer which provides fuel for
non-system uses and as an emergency backup power generator. This mode of
operation reduces the cost of the emergency backup energy generation system.
If desired, the first and second embodiments may be combined, and the
system 190 may operate in the electrolysis mode for a longer time period and at
a higher current density than in the fuel cell mode.
In a third preferred embodiment, the reversible fuel cell system 190 is
electrically connected an electrical energy source 100 which comprises a
renewable energy source. Any suitable renewable energy source may be used.
An excess capacity of the renewable energy source is used to provide electrical
energy to the reversible fuel cell operating in the electrolysis mode to generate
the excess fuel. Different renewable energy sources have different types of
excess capacities.
In one example, the renewable energy source 100 may comprises a
photovoltaic system, such as a solar cell array. The photovoltaic system
contains extra capacity during a first portion, such as the first 95 to 99.9 percent,
of its designed lifespan. In other vords, the capacity of the photovoltaic system
decreases as the system ages during its life span. Thus, a photovoltaic system
is often designed to provide a desired amount of electrical energy based on the
remaining second portion of its expected lifespan, to prevent the photovoltaic
system from providing an insufficient amount of electrical energy in the second
portion of its expected life span, therefore, the photovoltaic system is designed
and sized to provide electrical enegy in excess of that required by the consumer


and that required by the reversible fuel cell system 190 to regenerate fuel for
operation in the fuel cell mode. The excess capacity of the photovoltaic system
during the first portion, such as the 95 to 99.9 percent, of its life span may be
used to provide electrical energy to the reversible fuel cell system 190 to
generate the excess fuel.
In another example, the photovoltaic system 100 is designed and sized to
provide a sufficient amount of electrical energy required by the consumer and
required by the reversible fuel cell system 190 to regenerate fuel for operation in
the fuel cell mode over a predetermined number of day and night cycles, even if
a large amount of days are cloudy. In other words, the photovoltaic system 100
is designed to provide a sufficient amount of electrical energy in a worst case
weather scenario, such as when a predetermined percent, X, of day time periods
are cloudy. However, the worst case weather scenario occurs occasionally.
Thus, when less than X percent of day time periods are cloudy, and the system
190 is fully recharged for operation in the next fuel cell mode period or periods,
the photovoltaic system 100 may be used to provide electrical energy to system
190 to generate excess fuel during the excess sunny portions of the day time
periods. For example, the photovoltaic system 100 is designed and sized to
provide a sufficient amount of electrical energy required by the consumer and
required by the reversible fuel cell system 190 in the winter, when the number of
sunny days is at a minimum and/or when the day length is shortest compared to
the night length. Thus, there is no sufficient sunlight during X percent of the time
during winter. The photovoltaic system 100 has excess capacity in the summer,
when there is no sufficient sunlight during only X-Y percent of the time. The
photovoltaic system 100 may be used to provide electrical energy to system 190
to generate excess fuel during Y percent of the time during the summer.
In another example, the renewable energy source 100 may comprise a
wind turbine system which is designed to provide a minimum amount of electrical
energy at a predetermined wind speed. Such systems often contain rotatable


blades coupled to a generator which generates electricity when the wind rotates
the blades. This system 100 contains extra capacity during periods when the
wind speed exceeds a predetermined wind speed.
The wind turbine system 100 is designed and sized to provide a sufficient
amount of electrical energy required by the consumer and required by the
reversible fuel cell system 190 to regenerate fuel for operation in the fuel cell
mode over a predetermined number of cycles, even if a there is no wind or the
wind speed is low during a large portion of a predetermined number of cycles. In
other words, the system 100 is designed to provide a sufficient amount of
electrical energy in a worst case weather scenario, such as when a
predetermined percent, X, of the lime there is no wind or the wind speed is lower
than desirable. However, the worst case weather scenario occurs occasionally.
Thus, when less than X percent of the time period has little or no wind and the
system 190 is fully recharged for operation in the next fuel cell mode period or
periods, the system 100 may be used to provide electrical energy to system 190
to generate excess fuel during the excess windy portions of the time period. For
example, if X-Y percent of the time period has no wind or insufficient wind, then
the system 100 may be used tc provide electrical energy to system 190 to
generate excess fuel during Y percent of time period.
In another example, the renewable energy source 100 may comprise a
tidal energy generation system which is designed to provide a minimum amount
of electrical energy at a predetermined tidal force. Such a system 100 contains
movable members, such as plates, located under a body of water, such as a
sea, ocean or lake. The movable members are connected to a generator. The
movable members are moved by the tides and the movement causes the
generator to generate electricity. This system contains extra capacity during
periods when the tidal force exceeds the predetermined tidal force.
The tidal energy generation system 100 is designed and sized to provide


a sufficient amount of electrical energy required by the consumer and required
by the reversible fuel cell system 190 to regenerate fuel for operation in the fuel
cell mode over a predetermined number of cycles, even if a there is no tide or
the tidal force is low during a large portion of a predetermined number of cycles.
In other words, the system 100 is designed to provide a sufficient amount of
electrical energy in a worst case tidal scenario, such as when a predetermined
percent, X, of the time the tidal force is lower than desirable. However, the worst
case tidal scenario occurs occasionally. Thus, when less than X percent of the
time period has insufficient tidal force and the system 190 is fully recharged for
operation in the next fuel cell mode period or periods, the system 100 may be
used to provide electrical energy to system 190 to generate excess fuel during
the excess high tidal force portions of the time period. For example, if X-Y
percent of the time period has insufficient tidal force, then the system 100 may
be used to provide electrical energy to system 190 to generate excess fuel
during Y percent of time period.
In another example, the enewable energy source 100 may comprise a
geothermal energy generation system which is designed to provide a minimum
amount of electrical energy at a predetermined geothermal energy. Such a
system 100 uses the heat and/of steam emitted from the earth and converts the
heat and/or steam into electrical energy. This system contains extra capacity
during periods when the geothermal energy exceeds a predetermined, worst
case thermal energy supply scenario. For example, ambient losses for the
geothermal energy differ between warm summer ambient temperatures and cold
winter ambient temperatures.
Thus, as described above, co-production of fuel in an energy storage
device using a fuel regenerating device can be realized in any situation where
the fuel consumed during discharge is less than the fuel regenerated during
charging periods, preferably over a predetermined number of charge and
discharge cycles. The system 90 generates fuel during the entire electrolysis


mode time period. From about to about 99 percent of the generated fuel, such
as about 10 to about 30 percent of the generated fuel is excess fuel which may
be used for non-system 120 uses, while the remaining fuel may be used to
operate the system 190 in the fuel cell mode.
It is preferred, but not recuired to use the system 120 with a renewable
energy source 100 in remote locations that are not connected to the power grid.
In this case, the reversible fuel cell system 190 of the electrical energy storage
system 120 may be used to generate fuel for air, land or water vehicles. A
vehicle fuel infrastructure is not required in this case and the system 120 may be
used to supply the necessary fuel to power the vehicles at the remote location.
For example, the vehicles may be powered by hydrogen, methane or other
hydrocarbon fuel. Furthermore, since the system 190 may be used to generate
electricity and an environmentally clean fuel, such as hydrogen, without emission
of greenhouse gases and carbon dioxide, the system 190 improves the
environment and reduces the emission of greenhouse gases for transportation
and other uses.
The excess generated fuel may be used for any suitable application
outside the system 120. For example, the excess fuel may be provided to power
an airborne vehicle, such as a rocket, airplane, helicopter or blimp, a water
based vehicle, such as a ship or submarine, a land based vehicle, such as a car,
truck, motorcycle, tank or train, a chemical reaction in a chemical manufacturing
process, such as a semiconductor manufacturing or chemical production
process, or a heating system of a building, such as a commercial building,
including office buildings, factories and hospitals and a residential building.
In another preferred embodiment of the present invention, the equilibrium
operating temperature of the reversible fuel cell system 190, such as a fuel cell
stack, in the electrolysis mode is selected independently from the equilibrium
operating temperature of the fuel cell stack in the fuel cell mode to optimize the


amount and/or cost of the fuel produced in the electrolysis mode. Thus, in this
embodiment, the equilibrium operating temperature of the fuel cell stack in the
electrolysis mode is preferably, but not necessarily different from the equilibrium
operating temperature of the fuel cell stack in the fuel cell mode.
In one preferred aspect, the equilibrium operating temperature of the fuel cell
stack in the electrolysis mode may be selected to optimize or maximize the
amount of fuel produced. In another preferred aspect, the equilibrium operating
temperature of the fuel cell stack in the electrolysis mode may be selected to
optimize or minimize the unit cost of the fuel produced. In this aspect, in certain
situations, depending on different fuel cell stack design and operating variables,
one or more minima may be observed on a curve of unit fuel cost versus amount
of fuel produced. The equilibrium operating temperature of the fuel cell stack in
the electrolysis mode may be optimized to operate at or near one of the minima
on this curve. In another preferred aspect, the equilibrium operating temperature
of the fuel cell stack in the electrolysis mode is selected to maximize the amount
of fuel produced during some time periods, such as during periods of high fuel
demand or price, and at other time periods it is selected to minimize the fuel unit
cost, such as during periods of low fuel price or demand. Thus, the equilibrium
operating temperature of the fuel cell stack in the electrolysis mode may be
higher or lower than that h the fuel cell mode depending on the desired
optimized condition, such as fuel amount or fuel unit cost.
Preferably, the equilibrium operating temperature of the fuel cell stack in
the electrolysis mode is obtained by adjusting the current density provided to the
fuel cell stack for a given reactant product flow rate. For example, the power
management system 160 may be used to control the current density provided to
the fuel cell stack (i.e., the reversible fuel cell system 190). As discussed above,
the system 160 may be any suitable control system, such as a computer or
microprocessor. Alternatively, the system 160 may comprise a manual current
density control system, such as a manually rotated knob, lever, dial or one or


more push buttons.
Alternatively, the equilibrium operating temperature of the fuel cell stack
may be adjusted by other methods. For example, the current density may be
held constant while the reac:ant product flow rate may be adjusted manually or
automatically by a controller, such as by a manual or automatic valve. If desired,
both the current density and the reactant product flow rate may be adjusted to
select the desired temperature.
The selection of an optimum equilibrium operating temperature of the fuel
cell stack in the electrolysis mode independent of the equilibrium operating
temperature of the fuel cell stack in the fuel cell mode provides an operational
advantage. As noted above, in order to thermally sustain the SORFC without the
use of thermal storage during electrolysis, electrolysis should be performed
above the thermal neutral voltage. Thus, the thermal losses keep the fuel cell
stack at a desired temperature. If the fuel cell stack is used to generate fuel for
use outside the system during electrolysis, the total amount of heat generated in
the electrolysis mode is the same. However, some of the heat is used to
generate the excess fuel rather than being lost, which reduces the thermal
losses and provides an operational cost advantage for the fuel cell stack that is
used to generate excess hydrogen.
As discussed above, the reversible fuel cell system 190 may comprise any
suitable system, such as a SORFC system, a PEM system or fuel
cell/electrolyzer pairs and may be used with any suitable electrical energy source
100 described above, such as a power grid or a renewable energy source. A
SORFC stack is the preferred reversible fuel cell system 190.
A single SORFC 10 operating in the electrolysis mode is shown in Fig. 4.
The SORFC contains an anode electrode 11, an electrolyte 13 and a cathode
electrode 12. An anode gas chamber 14 is formed between the electrolyte 13


and an anode side interconnect (not shown for simplicity). A cathode gas
chamber 15 is formed between the electrolyte 13 and a cathode side
interconnect (also not shown for simplicity).
A reaction product gas mixture 17 may contain primarily water if hydrogen
is used as a fuel. Alternatively, the reaction product gas mixture 17 may contain
primarily water vapor and carbon dioxide if a carbon containing gas or liquid is
used as a fuel. The reaction product gas mixture 17 is introduced into the
cathode gas chamber 15. A direct current power source (not shown) is
connected to the anode electrode 11 and the cathode electrode 12 in such a way
that when electrical current is. flowing, the anode electrode 11 takes on a positive
voltage charge and the cathode electrode 12 takes on a negative voltage
charge. When the electric current is flowing, the gas mixture 17 gives up oxygen
ions 16 to form cathode discharge mixture 19 consisting primarily of hydrogen
and optionally carbon monoxide if mixture 17 contained carbon dioxide. Oxygen
ions 16 transport across the electrolyte 13 under the electrical current. The
oxygen ions 16 are converted into the oxidant, such as oxygen gas 18 on the
anode electrode 11 under the influence of the electrical current. The oxygen gas
18 is discharged from the anode chamber 14, while the electrolysis product (e.g.,
hydrogen and optionally carbon monoxide) is collected from the cathode
chamber.
A single SORFC 20 operating in the fuel cell mode is shown in Fig. 5.
SORFC 20 is the same as SORFC 10, except that the cathode and anode
designations of its electrodes are reversed. Cathode electrode 21 is the same
electrode as that identified as the anode electrode 11 in Fig. 4 when operating in
the electrolysis mode. Anode electrode 22 is the same electrode as that
identified as the cathode electrode 12 in Fig. 4 when operating in the electrolysis
mode. Solid oxide electrolyte 23 is the same electrolyte as that identified as
electrolyte 13 in Fig. 4 when operating in the electrolysis mode. Cathode gas
chamber 24 is the same gas chamber as that identified as the anode gas


chamber 14 in Fig. 4 when operating in the electrolysis mode. Anode gas
chamber 25 is the same gas chamber as that identified as the cathode gas
chamber 15 in Fig. 4 when operating in the electrolysis mode.
A fuel gas 27 is introduced into the anode gas chamber 25. Oxygen gas
28 is introduced into the cathode chamber 24. The fuel may comprise hydrogen,
a hydrocarbon gas, such as methane, and/or carbon monoxide. Water may be
added to the fuel if desired. An electrical fuel cell load (not shown) is applied to
the SORFC 20 and the oxygen gas 28 forms oxygen ions 26 under the influence
of the electrical load. Oxygen ions 26 transport across the electrolyte 23 under
the influence of the electrical current. On the anode electrode 22, the oxygen
ions 26 combine with hydrogen and optionally carbon, if present, from gas
mixture 27 to form gas mixture 29 containing water vapor and optionally carbon
dioxide, if a carbon containing gas is present in the fuel 27. Gas mixture 29 is
discharged from the anode chamber and stored as the reaction product. In the
process described above, the SORFC 20 has made electrical energy or power,
which is output through its electrodes.
An optional Sabatier reactor subsystem 30 to be used when the fuel
comprises methane is shown in Fig. 6. The reactor tube 31 contains a catalyst,
such as a platinum family metal on an alumina support. Preferably, the catalyst
comprises ruthenium. A gas mixture 32 consisting primarily of hydrogen and
carbon monoxide is introduced into reactor tube 31 and contacts the catalyst
therein. The gas mixture 32 undergoes an immediate exothermic reaction and
produces gas mixture 33 consisting primarily of methane and water vapor. Gas
mixture 33 is then discharged from the reactor tube 31. When the Sabatier
reactor is used with the SORFC 10 operating in the electrolysis mode, the
hydrogen and carbon monoxide discharge mixture 19/32 is provided from the
SORFC into the Sabatier reactor 30.
Because the reaction within reactor tube 31 is highly exothermic, a heat


exchanger 34 located in or adjacent to tube 31 is used to capture the generated
heat. Gas mixture 35, consisting primarily of carbon dioxide and water, flows
through heat exchanger 34 to absorb the exothermic reaction heat. When the
Sabatier reactor is used with the SORFC 10 operating in the electrolysis mode,
the water vapor and carbon dioxide inlet mixture 17/35 is heated in the Sabatier
reactor by the reaction of the outlet or discharge mixture 19/32. The water vapor
and carbon dioxide inlet mixture 17/35 is then provided from the Sabatier reactor
into the SORFC 10.
The SORFC system 50 of a preferred embodiment operating in a fuel cell
mode is shown of Fig. 7 as a simplified schematic. The system 50 as shown
operates with methane as a fuel. However, if desired, a hydrogen fuel may be
used instead, as discussed above. A single SORFC 20 previously shown in Fig.
5 as a cross section operatng in the fuel cell mode is shown again in Fig. 7.
While a single SORFC is shown, it should be understood that the system 50
contains a plurality of SORFC stacks. A hydrogen recovery unit 51 transfers
hydrogen gas from within a first gas mixture stream into a second gas stream.
The hydrogen recovery unit 51 can be a device which recovers hydrogen based
on absorption/adsorption processes or based on an electrochemical proton
exchange process. The electrochemical exchange process is preferred.
An enthalpy recovery unit 52 transfers water vapor from first gas stream to
a second gas stream. The enthalpy recovery unit 52 can be a device which
transfers water vapor based on cyclic desiccant beds or a rotating desiccant
wheel. The desiccant wheel (i.e., "enthalpy wheel") is preferred. An optional
purge valve 53, such as a normally closed powered open solenoid valve may be
used if pure oxygen is used. A heat exchanger 54 is a counter flow gas-gas heat
exchanger. The SORFC power output, such as output electrode(s), is connected
to a power distribution sys:em. The oxidizer (i.e., oxygen or air) enters the
system 50 through the oxidizer inlet or conduit 55, while the fuel enters the
system through the fuel inlet or conduit arrangement 56/57. The fuel exhaust


exits through conduit arrangement 58/59.
A method of operating the system 50 in the fuel cell mode is now
described. Within the SORFC system 50 shown in Fig. 7, oxidizer, such as pure
oxygen reactant gas from an oxygen storage vessel, such as a liquid oxygen
tank, or air, is delivered to the cathode chamber of SORFC 20 through inlet
conduit 55. If oxygen reactant is highly pure, then it is normally dead headed
within the cathode chamber of SORFC 20. However, even the purest of gases
will include trace non reactant gas species. As a result the cathode chamber of
SORFC 20 should be occasionally purged of these non reactant species.
Oxygen purge valve 53 is used to accomplish this purging.
High purity hydrocarbon inlet stream, such as a methane stream, is
introduced into the SORFC system 50 from a hydrocarbon storage vessel, such
as a tank (not shown for clarity), through conduit 56 into the hydrogen recovery
unit 51. As noted above, a hydrogen fuel inlet stream may be used instead.
Within the hydrogen recovery unit 51, hydrogen gas is transferred from the fuel
exhaust outlet stream in conduit 58 into the methane stream. This hydrogen
supports a uniform methane reformation process within the anode chamber of
SORFC 20. The methane and hydrogen mixture next is introduced into the
enthalpy recovery unit 52, where a portion of the water vapor is transferred from
the fuel exhaust outlet stream in conduit 58 into the methane and hydrogen inlet
stream. Preferably, the enthaipy recovery unit also transfers heat from the outlet
stream to the inlet stream. From the enthalpy recovery unit 52, the methane,
hydrogen and water vapor mixture is introduced into the heat exchanger 54,
where the gas mixture temperature is increased near to the operational
temperature of 600C to 1000C using the high temperature waste heat from the
outlet stream in conduit 58 From heat exchanger 54, the hot mixture of
methane, hydrogen, and water vapor is delivered to the anode chamber of
SORFC 20 through conduit 157. Some steam reformation of the methane will
occur in the heat exchanger 54 and conduit 57 but the amount is suppressed by


the existence of the hydrogen The completion of the steam reforming of the
methane is accomplished in the anode chamber of the SORFC 20.
Within the anode chamber of the SORFC 20, the steam reforming of
methane and the oxidation of carbon and hydrogen in the fuel cell reactions
converts the discharged gas mixture (i.e., fuel exhaust) in conduit 58 to carbon
dioxide, additional water vapor and excess hydrogen. If hydrogen rather than
methane is used as a fuel, ther no carbon dioxide is produced. The discharged
gas mixture in conduit 58 passes through heat exchanger 54, releasing waste
heat, and then through the enthalpy recovery unit 52 to supply a portion of the
water vapor to support the input methane reformation. The discharged gas
mixture in conduit 58 is then directed to the hydrogen recovery unit 51 where
virtually all but trace quantities of the hydrogen is transferred to the inlet fuel
stream. Using the preferred electrochemical proton exchange process as the
hydrogen recovery unit 51, provides an exact measure of the hydrogen content
within the discharged gas mixture in conduit 58 which is used to adjust the input
methane flow rate. The outlet mixture in conduit 59 from hydrogen recovery unit
51 contains only carbon dioxide and water which are stored separately (not
shown).
The SORFC system 6C of a preferred embodiment operating in an
electrolysis mode is shown of Fig. 8 as a simplified schematic. A single SORFC
10 previously shown in Fig. 4 as a cross section operating in the electrolysis
mode is shown again in Fig. 8. The hydrogen recovery unit 51 transfers
hydrogen gas from within a first gas mixture stream into a second gas stream.
The hydrogen recovery unit 51 can be a device which recovers hydrogen based
on absorption/adsorption processes or based on an electrochemical proton
exchange process. The electrochemical exchange process is preferred.
If methane is used as a fuel, then the system 60 also includes the
Sabatier reactor subsystem 30, described with respect to Fig. 6, which converts


carbon monoxide and hydrogen into methane and water vapor. If methane is
used as a fuel, then the reactant product comprising carbon dioxide and water
enter the system 60 through inlet or conduit 61, which may be the same or
different than conduit 56, shown in Fig. 7. If hydrogen is used as a fuel, then
water is used as a reactant product. The generated oxygen exits through outlet
or conduit 65, while the methane and water exit through outlet or conduit
arrangement 63/64. Conduits 63/64 and 65, respectively, may be the same or
different conduits as conduits 38/59 and 55, respectively, shown in Fig. 7.
Thus, the system 60 operating in the electrolysis mode is the same
system as system 50 operating in the fuel cell mode, except that the inlet and
outlet streams are steered through the optional Sabatier reactor subsystem 30
instead of through the heat exchanger 54 and the enthalpy recovery unit 52,
which remains inactive in the electrolysis mode. The inlet and outlet streams
may be steered using valves and parallel conduits (not shown for clarity).
Furthermore, the electrode designations in the SORFC 10 of system 60 are
reversed compared to SORFC 20 of system 50, as explained in detail with
respect to Figs. 1 and 2 above.
A method of operating the system 60 in the electrolysis mode is now
described. If methane is used as a fuel, then carbon dioxide and water are
introduced into the SORFC system 60 through conduit 61 into hydrogen recovery
unit 51. Carbon dioxide may the introduced from a carbon dioxide storage vessel
or from a conduit. If hydrogen is used as a fuel, then the carbon dioxide is
omitted. Within the hydrogen recovery unit 51, hydrogen gas is transferred from
the outlet stream in conduit 63 into the carbon dioxide and water inlet stream.
This extra hydrogen eventually assures that all the carbon bearing gases are
converted into methane within the Sabatier reactor subsystem 30. The carbon
dioxide, water, and hydrogen inlet mixture next is introduced into the Sabatier
subsystem 30 heat exchanger where it is heated by the exothermic reaction.
From the Sabatier subsystem 30, the carbon dioxide, hydrogen and water vapor


mixture is delivered to the cathode chamber of SORFC 10 through conduit 62.
Within the cathode chamber of SORFC 10, the carbon dioxide and water vapor
are reduced by electrolysis 1o carbon monoxide and hydrogen. Excess water
and some unreacted carbon dioxide will be discharged from the cathode
chamber of SORFC 10 along with the carbon monoxide and hydrogen through
conduit 63.
The discharged gas mixture in conduit 63 passes through the Sabatier
subsystem 30 to convert all the carbon oxides to methane and water with the
excess hydrogen. If hydrogen is used as a fuel, then the Sabatier subsystem 30
is omitted and the discharged water vapor comprises the reactant product. The
discharged gas mixture in conduit 63 is then directed to the hydrogen recovery
unit 51 wherein virtually all but trace quantities of the hydrogen is transferred to
the inlet carbon dioxide and water stream. Using the preferred electrochemical
proton exchange process as the hydrogen recovery unit 51, provides an exact
measure of the hydrogen content within the discharged gas mixture in conduit 63
which is used to adjust the input carbon dioxide flow rate. The outlet mixture in
conduit 64 from hydrogen recovery unit 51 contains only methane and water
which are stored separately (not shown). If desired, the water may be
discharged and fresh water from a water pipe may be used for the SORFC
reactions.
In the meantime, pure oxygen gas is generated in the SORFC 10 anode
during the electrolysis process. The oxygen is discharged from the SORFC 10
anode through conduit 65 and on to discharge, direct metabolic use and/or to
liquefied storage (not shown).
The Sabatier reactor which generates methane is advantageous because
it operates at a temperature of about 400-900 °C degrees, which is a suitable
temperature for heating the inlet stream being provided into the SORFC to or
near to a desired SORFC operating temperature. However, other reactors which


generate hydrocarbon gases other than methane may be used instead of the
Sabatier reactor.
For example, reactors which convert an exhaust gas which contains
hydrogen and carbon oxides such as carbon monoxide and/or carbon dioxide,
and optionally water, to methanol may be used instead. The methanol reactors
typically, but not necessarily, contain a copper catalyst which converts hydrogen,
carbon oxides and/or water vapor to methanol. These reactors may be catalyst
bed type reactors, such as ARC reactors, quench converters, tube cooled
converters, isothermal reactors where a continuous catalyst bed surrounds a
spiral wound heat exchanger, and other suitable reactor types.
The following exothermic reactions are involved in the synthesis of
methanol: CO + 2H2 = CH3OH; CO2 + 3H2 = CH3OH and CO + H2O = CO2 +
H2. The use of a SORFC operating in the electrolysis mode to generate
methanol is advantageous because the SORFC exhaust gas contains a similar
composition to synthesis gas that is used as a source gas for methanol
production. The synthesis gas is usually specially prepared in a separate
catalytic steam reforming of natural gas in conventional methanol synthesis
process.
If desired, additional reactors may be present downstream of the Sabatier
or methanol reactors to further purify the methane or methanol if desired.
Alternatively, the additional reactors may be used to convert methane or
methanol to other hydrocarbon gases, such as ethane, propane, octane, formic
acid, formaldehyde and/or other suitable hydrocarbon gases. These
hydrocarbon gases may be used as a fuel for the SORFC in the fuel cell mode
and/or may be removed from the SORFC system for other use, sale or storage.
Thus, the SORFC system may be used to generate various hydrocarbon fuels
for storage or sale when the system is not generating power in the fuel cell
mode. Alternatively, suitable reactors may be used to convert the hydrogen and


carbon oxide containing SORFC electrolysis mode exhaust to the other
hydrocarbon gases, such as ethane, propane, octane, formic acid, formaldehyde
and/or other suitable hydrocarbon gases.
The SORFC systems described herein may have other embodiments and
configurations, as desired. Other components, such as fuel side exhaust stream
condensers, heat exchangers, heat-driven heat pumps, turbines, additional gas
separation devices, hydrogen separators which separate hydrogen from the fuel
exhaust and provide hydrogen for external use, fuel preprocessing subsystems,
fuel reformers and/or water-gas shift reactors, may be added if desired, as
described, for example, in L.S. Application Serial Number 10/300,021, filed on
November 20, 2002 (corresponding to Indian Patent Application No. 1093/
KOLNP/2004), in U.S. Provsional Application Serial Number 60/461,190, filed
on April 9, 2003 (corresponding to Indian Patent Application Nos. 2055/KOLNP/
2005 and 176/KOLNP/2007), and in U.S. Application Serial Number 10/446,704,
filed on May 29, 2003 (corresponding to Indian Patent Application Nos. 2055/
KOLNP/2005 and 176/KOLMP/2007) all incorporated herein by reference in their
entirety.
The foregoing description of the invention has been presented for
purposes of illustration and description. It is not intended to be exhaustive or to
limit the invention to the precise form disclosed, and modifications and variations
are possible in light of the above teachings or may be acquired from practice of
the invention. The description was chosen in order to explain the principles of the
invention and its practical application. It is intended that the scope of the
invention be defined by the claims appended hereto, and their equivalents.


WE CLAIM :
1. An electrochemical system, comprising:
a reversible fuel cell system which generates electrical energy and
reactant product from fuel ard oxidizer in a fuel cell mode, and which generates
the fuel and oxidant from the reactant product and the electrical energy in an
electrolysis mode;
a first means for providing excess reactant product to the reversible fuel
cell system operating in the electrolysis mode from outside the electrochemical
system, in addition to or instead of the reactant product generated by the
reversible fuel cell system in the fuel cell mode, such that fuel in excess of fuel
required to operate the reversible fuel cell system in the fuel cell mode is
generated in the electrolysis mode over a predetermined number of operating
cycles; and
a second means for removing the excess fuel generated by the reversible
fuel cell system operating n the electrolysis mode from the electrochemical
system.
2. The system as claimed in claim 1, comprising a renewable energy source
electrically connected to the reversible fuel cell system, such that an excess
capacity of the renewable energy source is used to provide electrical energy to
the reversible fuel cell system operating in the electrolysis mode to generate the
excess fuel to be provided to the third means.
3. The system as claimed in claim 1, wherein the reversible fuel cell system
is electrically connected to a third means for generating electrical energy from
sun light, for providing the electrical energy to the reversible fuel cell system
during daytime periods to generate fuel, and for allowing the reversible fuel cell
system to generate electrical energy during night time periods, wherein night
time periods are shorter thar day time periods.


4. The system as claimed in claim 1, wherein the reversible fuel cell system
is electrically connected to a fourth means for generating renewable electrical
energy and for using excess capacity to provide electrical energy to the
reversible fuel cell system operating in the electrolysis mode to generate the
excess fuel.
5. The system as claimed in claim 4, wherein the fourth means is a means
for generating electrical energy from sun light and for using the excess capacity
during a first half of its desigred lifespan.
6. The system as claimed in claim 4, wherein the fourth means is a means
for generating electrical energy from wind and for using the excess capacity
during periods when wind speed exceeds a predetermined wind speed required
to generate a desired amount of electrical energy.
7. The system as claimed in claim 4, wherein the fourth means is a means
for generating electrical energy from tidal force and for using the excess capacity
during periods when the tidal force exceeds a predetermined tidal force required
to generate a desired amount of electrical energy.
8. The system as claimed in claim 1, wherein the second means is a means
for providing the fuel removed from the reversible fuel cell system into an
airborne vehicle, a water based vehicle, a land based vehicle, a chemical
reaction in a chemical manufacturing process, or a heating system of a building
containing reversible fuel cell system.
9. A method of operating an electrochemical system containing a reversible
fuel cell system, comprising:


cyclically operating the reversible fuel cell system in a fuel cell mode to
generate electrical energy and reactant product from fuel and oxidizer and in an
electrolysis mode to generate the fuel and oxidant from the reactant product and
the electrical energy;
providing excess reactant product to the reversible fuel cell system
operating in the electrolysis mode from outside the reversible fuel cell system, in
addition to or instead of the reactant product generated by the reversible fuel cell
system in the fuel cell mode, such that fuel in excess of fuel required to operate
the reversible fuel cell system in the fuel cell mode is generated in the
electrolysis mode over a predetermined number of operating cycles; and
removing the excess fuel generated by the reversible fuel cell system
operating in the electrolysis mode from the electrochemical system.
10. The method as claimed in claim 9, wherein the reversible fuel cell system
generates more fuel in the dectrolysis mode than it consumes in the fuel cell
mode over the predetermined number of cycles.
11. The method as claimed in claim 10, wherein the reversible fuel cell system
operates at a higher current level in the electrolysis mode than in the fuel cell
mode over the predetermined number of cycles.
12. The method as claimed in claim 11, wherein:
the reversible fuel cell system is electrically connected to a photovoltaic
energy generation system which provides electrical energy to the reversible fuel
cell system during daytime to generate fuel;
the reversible fuel cell system generates electrical energy during night
time; and
the night time load on the reversible fuel cell system at least during a
portion of the night time period is lower than a peak load that the reversible fuel
cell system is capable of providing.


13. The method as claimed in claim 11, wherein the reversible fuel system is
operated at a load lower than a peak load that the reversible fuel cell system is
capable of providing at least during a portion of a time that the reversible fuel cell
system operates in the fuel cell mode.
14. The method as claimed in claim 10, wherein the reversible fuel cell system
operates for a longer duration in the electrolysis mode than in the fuel cell mode
over the predetermined number of cycles.
15. The method as claimed in claim 14, wherein:
the reversible fuel cell system is electrically connected to a photovoltaic
energy generation system which provides electrical energy to the reversible fuel
cell system during daytime to generate fuel;
the reversible fuel cell system generates electrical energy during night
time; and
night time periods are shorter than day time periods.
16. The method as claimed in claim 10, wherein the reversible fuel cell is
electrically connected to a renewable energy source, such that an excess
capacity of the renewable energy source is used to provide electrical energy to
the reversible fuel cell operating in the electrolysis mode to generate the excess
fuel.
17. The method as claimed in claim 16, wherein the renewable energy source
comprises a photovoltaic system which contains the excess capacity during a
first half of its designed lifespan.
18. The method as claimed in claim 16, wherein the renewable energy source
comprises a wind turbine system which is designed to provide a minimum
required amount of electrical energy at a predetermined minimum wind speed


and which contains the excess capacity during periods when the wind speed
exceeds the predetermined minimum wind speed.
19. The method as claimed in claim 16, wherein the renewable energy source
comprises a tidal energy generation system which is designed to provide a
minimum required amount of electrical energy at a predetermined minimum tidal
force and which contains the excess capacity during periods when the tidal force
exceeds the predetermined minimum tidal force.
20. The method as claimed in claim 9, wherein the step of providing the
excess reactant product comprises providing the excess reactant product to the
reversible fuel cell system operating in the electrolysis mode from outside the
electrochemical system in addition to a stored reactant product generated by the
reversible fuel cell system in the fuel cell mode.
21. The method as claimed in claim 9, wherein the step of providing the
excess reactant product comprises providing the excess reactant product to the
reversible fuel cell system operating in the electrolysis mode from outside the
electrochemical system instead of the reactant product generated by the
reversible fuel cell system in :he fuel cell mode.
22. The method as claimed in claim 9, comprising storing the fuel and the
reactant product produced by the reversible fuel cell system.
23. The method as claimed in claim 22, wherein:
at least a portion of the stored fuel is removed from the reversible fuel cell
system through a fuel conduit; and
at least a portion of the reactant product is provided to the reversible fuel
cell system from outside the electrochemical system through a reactant product
conduit.


24. The method as claimed in claim 22, wherein at least a portion of the
stored fuel is removed from the electrochemical system by removing a fuel
storage vessel from the electrochemical system.
25. The method as claimed in claim 9, wherein:
the reactant product comprises water; and
the fuel comprises hydrogen.
26. The method as claimed in claim 9, wherein:
the reactant product ccmprises water and carbon dioxide; and
the fuel comprises methane.
27. The method as claimed in claim 9, wherein:
the reversible fuel cell system comprises a stack of a plurality of reversible
fuel cells, which generate electrical energy in the fuel cell mode and which
generate fuel in the electrolysis mode; and
an equilibrium operating temperature of the fuel cell stack in the
electrolysis mode is selected independently from an equilibrium operating
temperature of the fuel cell stack in the fuel cell mode to optimize at least one of
an amount of fuel produced in the electrolysis mode and a unit cost of the fuel
produced in the electrolysis mode.
28. The method as claimed in claim 9, wherein the reversible fuel cell system
comprises a stack of solid oxide regenerative fuel cells.
29. The method as claimed in claim 9, wherein the reversible fuel cell system
comprises a plurality of PEM fuel cells.
30. The method as claimed in claim 9, wherein the reversible fuel cell system
comprises a fuel cell which generates electrical energy and an electrolyzer cell
which generates fuel.

31. The method as claimed in claim 9, comprising providing the fuel removed
from the electrochemical system into an airborne vehicle, a water based vehicle
or a land based vehicle.
32. The method as claimed in claim 9, comprising providing the fuel removed
from the electrochemical system into a chemical reaction in a chemical
manufacturing process.
33. The method as claimed in claim 9, comprising providing the fuel removed
from the electrochemical system into an heating system of a building containing
the reversible fuel cell system.
34. An electrochemical system, comprising:
a first means for cyclically operating in a fuel cell mode to generate
electrical energy and reactant product from fuel and oxidizer and in an
electrolysis mode to generate the fuel and oxidant from the reactant product and
the electrical energy;
a second means for providing excess reactant product to the first means
operating in the electrolysis mode from outside the electrochemical system, in
addition to or instead of the eactant product generated by the first means in the
fuel cell mode, such that fuel in excess of fuel required to operate the first means
in the fuel cell mode is generated in the electrolysis mode over a predetermined
number of operating cycles; and
a third means for removing the excess fuel generated by the first means
operating in the electrolysis mode from the electrochemical system.
35. The system as claimed in claim 34, wherein the first means generates
more fuel in the electrolysis mode than it consumes in the fuel cell mode over the
predetermined number of cycles.


36. The system as claimec in claim 35, wherein the first means is a means for
operating at a higher current level in the electrolysis mode than in the fuel cell
mode over the predetermined number of cycles.
37. The system as claimed in claim 36, wherein:
the first means is electrically connected to a fourth means for generating
electrical energy from sun light and for providing the generated electrical energy
to first means during daytime to generate fuel; and
the first means is a means for generating electrical energy during night
time, such that a night time oad on the first means at least during a portion of
the night period is lower than a peak load that the first means is capable of
providing.
38. The system as claimed in claim 36, wherein the first means is a means for
operating at a load lower than a peak load that the first means is capable of
providing at least during a portion of a time that the first means operates in the
fuel cell mode.
39. The system as claimed in claim 35, wherein the first means is a means for
operating for a longer duration in the electrolysis mode than in the fuel cell mode
over the predetermined number of cycles.
40. The system as claimed in claim 39, wherein:
the first means is electrically connected to a fourth means for generating
electrical energy from sun light and providing the electrical energy to the first
means during daytime periods to generate fuel;
the first means is a means for generating electrical energy during night
time periods, wherein night time periods are shorter than daytime periods.


41. The system as claimed in claim 34, wherein the first means is electrically
connected to a fifth means for generating renewable electrical energy and for
using excess capacity to provide electrical energy to the first means operating in
the electrolysis mode to generate the excess fuel.
42. The system as claimed in claim 41, wherein the fifth means is a means for
generating electrical energy from sun light and for using the excess capacity
during a first half of its designed lifespan.
43. The system as claimed in claim 41, wherein the fifth means is a means for
generating electrical energy from wind and for using the excess capacity during
periods when the wind speed exceeds a predetermined minimum wind speed
required to generate a desired amount of electrical energy.
44. The system as claimec in claim 41, wherein the fifth means is a means for
generating electrical energy From tidal force and for using the excess capacity
during periods when the tidal force exceeds a predetermined minimum tidal force
required to generate a desired amount of electrical energy.
45. The system as claimed in claim 34, wherein the second means for
providing excess reactant product comprises a means for providing excess
reactant product to the firs: means operating in the electrolysis mode from
outside the electrochemical system in addition to a stored reactant product
generated by the first means in the fuel cell mode.
46. The system as claimed in claim 34, wherein the second means for
providing excess reactant product comprises a means for providing excess
reactant product to the first means operating in the electrolysis mode from
outside the electrochemical system instead of the reactant product generated by
the first means in the fuel cell mode.


47. The system as claimed in claim 34, comprising a sixth means for storing
the fuel produced by the first means and a seventh means for storing the
reactant product produced by the first means.
48. The system as claimed in claim 34, wherein:
the reactant product comprises water; and
the fuel comprises hydrogen.
49. The system as claimed in claim 34, wherein:
the reactant product comprises water and carbon dioxide; and
the fuel comprises methane.
50. The system as claimed in claim 34, wherein the third means is a means
for providing the fuel removed from the first means into an airborne vehicle, a
water based vehicle, a land based vehicle, a chemical reaction in a chemical
manufacturing process, or a heating system of a building containing the first
means.
51. The system as claimed in claim 34, comprising an eighth means for
selecting an equilibrium operating temperature of the first means in the
electrolysis mode independently from an equilibrium operating temperature of
the first means in the fuel cell mode to optimize at least one of an amount of fuel
produced in the electrolysis mode and a unit cost of the fuel produced in the
electrolysis.

An electrochemical system comprises a reversible fuel cell system which
generates electrical energy and reactant product from fuel and oxidizer in a fuel
cell mode and which generates the fuel and oxidant from the reactant product
and the electrical energy in an electrolysis mode. The system also comprises a
reactant product delivery device which is adapted to supply the reactant product
to the reversible fuel cell system operating in the electrolysis mode, in addition to
or instead of the reactant product generated by the reversible fuel cell system in
the fuel cell mode, and a fuel removal device which is adapted to remove the fuel
generated by the reversible fuel cell system operating in the electrolysis mode
from the electrochemical system.
Fig. 2

Documents:

652-KOLNP-2006-CORRESPONDENCE.pdf

652-KOLNP-2006-FORM 27 1.1.pdf

652-KOLNP-2006-FORM 27.pdf

652-KOLNP-2006-FORM-27.pdf

652-kolnp-2006-granted-abstract.pdf

652-kolnp-2006-granted-assignment.pdf

652-kolnp-2006-granted-claims.pdf

652-kolnp-2006-granted-correspondence.pdf

652-kolnp-2006-granted-description (complete).pdf

652-kolnp-2006-granted-drawings.pdf

652-kolnp-2006-granted-examination report.pdf

652-kolnp-2006-granted-form 1.pdf

652-kolnp-2006-granted-form 13.pdf

652-kolnp-2006-granted-form 18.pdf

652-kolnp-2006-granted-form 3.pdf

652-kolnp-2006-granted-form 5.pdf

652-kolnp-2006-granted-pa.pdf

652-kolnp-2006-granted-reply to examination report.pdf

652-kolnp-2006-granted-specification.pdf


Patent Number 230333
Indian Patent Application Number 652/KOLNP/2006
PG Journal Number 09/2009
Publication Date 27-Feb-2009
Grant Date 25-Feb-2009
Date of Filing 21-Mar-2006
Name of Patentee BLOOM ENERGY CORPORATION
Applicant Address 1252, ORLEANS DRIVE, SUNNYVALE, CALIFORNIA
Inventors:
# Inventor's Name Inventor's Address
1 SRIDHAR K. R. 18351, OVERLOOK ROAD, LOS GATOS, CALIFORNIA 95030
2 GOTTMANN MATTHIAS 684 TORREYA AVENUE, SUNNYVALE, CALIFORNIA 94086
PCT International Classification Number H01M 8/18, 8/04
PCT International Application Number PCT/US2004/027347
PCT International Filing date 2004-08-24
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10/653,240 2003-09-03 U.S.A.