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8.1 System Processes The design of a fuel cell system involves more than the optimizing of the fuel cell section with respect to efficiency or economics. It involves minimizing the cost of electricity (or heat and electric products as in a cogeneration system) within the constraints of the desired application. For most applications, this requires that the fundamental processes be integrated into an efficient plant with low capital cost. Often these objectives are conflicting, so compromises, or design decisions, must be made. In addition, project-specific objectives, such as desired fuel, emission levels, potential uses of rejected heat (electricity, steam, or heat), desired output levels, volume or weight criteria (volume/kW or weight/kW), and tolerance for risk all influence the design of the fuel cell power system. 8.1.1 FuelProcessing Fuel processing is defined in this Handbook as the conversion of a commercially available gas, liquid, or solid fuel to a fuel gas reformate suitable for the fuel cell anode reaction. Fuel processing encompasses the cleaning and removal of harmful species in the fuel, the conversion of the fuel to the fuel gas reformate, and downstream processing to alter the fuel gas reformate according to specific fuel cell requirements. Examples of these processes are: • Fuel Cleaning – Removal of sulfur, halides, and ammonia to prevent fuel processor and fuel cell catalyst degradation. • Fuel Conversion – Converting a fuel (primarily hydrocarbons) to a hydrogen-rich gas reformate. • Reformate Gas Alteration – Converting carbon monoxide (CO) and water (H2O) in the fuel gas reformate to hydrogen (H2) and carbon dioxide (CO2) via the water-gas shift reaction; selective oxidation to reduce CO to a few ppm, or removal of water by condensing to increase the H2 concentration. A fuel processor is an integrated unit consisting of one or more of the above processes, as needed for the fuel cell requirements37 and the fuel, that function together to be cost effective for the application. Design considerations may include high thermal efficiency, high hydrogen yield (for some fuel cells hydrogen plus carbon monoxide yield), multi-cycling, compactness, low weight, and quick starting capability, depending on the application. Figure 8-2 depicts the Processing steps needed for a low temperature cell.38 Most fuel processors make use of the chemical and heat energy left in the fuel cell effluent to provide heat for fuel processing thus enhancing system efficiency. 37. Primarily determined by the cell’s operating temperature. 38. Requires relatively complex fuel processing. 8-2PDF Image | Fuel Cell Handbook (Seventh Edition)
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