US20220376284A1

US20220376284A1 - Systems, devices, and methods for hydrogen energy production and storage

Info

Publication number: US20220376284A1
Application number: US17/664,062
Authority: US
Inventors: Evan JOHNSON; Dylan COOK; Paul YOLLIN; Eli Adler; Taiga MIGITA
Original assignee: Nabors Energy Transition Solutions LLC
Current assignee: Nabors Energy Transition Solutions LLC
Priority date: 2021-05-20
Filing date: 2022-05-19
Publication date: 2022-11-24
Also published as: CA3219018A1; WO2022246440A1; WO2022246441A1; US11761375B2; GB202317438D0; US20220372909A1; GB2621075A; CA3219023A1; GB2621074A; US20230392541A1; GB202317440D0

Abstract

Systems, devices, and methods for producing and storing hydrogen energy are described. Hydrogen energy may be produced and distributed according to a tiered consumption system, such that consumption requirements of a first tier are prioritized over a second tier and third tier, respectively. Energy and hydrogen for this system may be produced by one or more fuel cell/electrolyzers, and produced hydrogen may be stored in one or more hydride storage tanks.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This Application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/191,273, entitled “SYSTEMS AND METHODS FOR HYDROGEN ENERGY PRODUCTION AND STORAGE,” by Evan Johnson et al., filed May 20, 2021, and claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/191,215, entitled “SYSTEMS AND METHODS HYDROGEN ENERGY FUEL CELL AND ELECTROLYZER,” by Evan Johnson et al., filed May 20, 2021, and claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/191,279, entitled “SYSTEMS AND METHODS FOR A HYDROGEN ENERGY STORAGE HYDRIDE TANK,” by Evan Johnson et al., filed May 20, 2021, and claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/191,270, entitled “SYSTEMS AND METHODS FOR A HYDROGEN ZERO EMISSIONS VEHICLE,” by Evan Johnson et al., filed May 20, 2021, and claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/219,554, entitled “SYSTEMS AND METHODS FOR HYDROGEN ENERGY PRODUCTION AND STORAGE,” by Evan Johnson et al., filed Jul. 8, 2021, all of which are assigned to the current assignee hereof and incorporated herein by reference in their entireties.

FIELD OF THE DISCLOSURE

The disclosure herein relates to systems, devices, and methods for producing hydrogen via one or more fuel cells/electrolyzers and storing hydrogen energy.

BACKGROUND

Hydrogen fuel cells are a growing solution to meet the power demands of homes, businesses, and vehicles. This rise in popularity is due to emerging technologies for producing and storing hydrogen that increase the use of these systems in new settings, as well as the underlying benefits of the technology, which include energy production without moving parts with minimal environmental impacts. However, current hydrogen energy storage solutions continue to pose high costs and are often too inefficient, inconsistent, and unreliable for use in many applications, including smaller residential applications.
One popular solution for hydrogen energy systems is proton-exchange membrane (PEM) technology. Most units based on this technology use membranes sandwiched in between conductive flow fields in large stacks, which can cause electrical resistance to build up across the unit. This resistance is known to cause excess waste heat and poor energy efficiency, and such large stacks make it difficult to repair or replace components.
Current solutions for storing produced hydrogen also suffer from a number of problems. For example, many systems rely on prohibitively large tanks to store produced hydrogen, and hydrogen tank fatigue is a major problem that limits the useful life of storage tanks.
Accordingly, systems and methods for more efficient, scalable hydrogen production and storage systems are needed.

SUMMARY

In a first aspect of the disclosure, the present invention encompasses an energy control system that includes: an energy production system including an electrolyzer/fuel cell configured to produce hydrogen gas and/or electricity; a hydride storage tank fluidically connected to the energy production system and configured to receive and store the produced hydrogen gas; and a power control module configured to control the production of hydrogen gas by the energy production system and the storage of produced hydrogen gas in the hydride storage tank, the power control module further configured to implement a consumption system including a first energy tier and a second energy tier, wherein power consumption by the first energy tier using energy produced by the electrolyzer/fuel cell is prioritized over power consumption by the second energy tier such that energy produced in excess of the power consumption by the first energy tier is stored by the hydride storage tank for the second energy tier.
In a second aspect of the disclosure, the invention encompasses an energy production system, including: an electrolyzer/fuel cell configured to produce hydrogen gas and/or electricity; and a hydride storage tank connected to the fuel cell and configured to receive and store the produced hydrogen gas, wherein the hydride storage tank includes a heat exchanger disposed in association with the electrolyzer/fuel cell, wherein waste heat emitted from the electrolyzer/fuel cell is received by the heat exchanger and used to facilitate release of the produced hydrogen gas from the hydride storage tank.
In a third aspect of the disclosure, the invention encompasses a method of producing and storing energy, including: producing electricity and hydrogen with an electrolyzer/fuel cell; storing the produced hydrogen in a hydride storage tank fluidically connected to the electrolyzer/fuel cell; controlling the production of hydrogen gas with a power control module; and implementing a consumption system with the power control module, the consumption system including a first energy tier and a second energy tier, wherein power consumption by the first energy tier using energy produced by the fuel cell is prioritized over power consumption by the second energy tier such that energy produced in excess of the power consumption by the first energy tier is stored in the hydride storage tank for the second energy tier.
In various embodiments, each of which relates to each of the aspects of the disclosure set forth above and herein, the hydride storage tank includes a heat exchanger, wherein waste heat from the fuel cell is used by the heat exchanger. In preferred embodiments, the hydride storage tank includes a doped graphene hydride material. In yet other preferred embodiments, the hydride storage tank includes one or more alanate (IH4) materials configured to releasably store gas containing hydrogen.
In other embodiments, the electrolyzer/fuel cell includes a conductive graphene membrane. In further embodiments, the electrolyzer/fuel cell includes a membrane with an anode side and a cathode side opposite the anode side. In preferred embodiments, the electrolyzer/fuel cell includes a direct electrical contact on both the anode side and the cathode side. In other preferred embodiments, the electrolyzer/fuel cell includes a plurality of cell portions each with flow field tubing with non-conductive flow fields, such that current from the direct electrical contact is evenly distributed across each of the plurality of cell portions.
In further embodiments, the first energy tier is a residential or industrial electricity consumer and the second energy tier is a storage system. In other embodiments, the consumption system includes a third energy tier such that power consumption for the first and second energy tiers is prioritized over the third energy tier.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

FIG. 1 is a diagram of a Hydrogen Energy Production and Storage (HEPS) system, according to one or more aspects of the present disclosure.

FIG. 2 is a schematic diagram of a first portion of the HEPS system of FIG. 1 including a Power Distribution Center, according to one or more aspects of the present disclosure.

FIG. 3 is a schematic diagram of a second portion of the HEPS system of FIG. 1 including an Energy Management Module, according to one or more aspects of the present disclosure.

FIG. 4 is a schematic diagram of a third portion of the HEPS system of FIG. 1 including an Energy Management Module, according to one or more aspects of the present disclosure.

FIG. 5 is a schematic diagram of a fuel cell/electrolyzer, according to one or more aspects of the present disclosure.

FIG. 6 is a schematic diagram of a modular stack of the fuel cell/electrolyzer of FIG. 5, according to one or more aspects of the present disclosure.

FIG. 7A is a top view of the flow field on the cathode touching side of the fuel cell/electrolyzer of FIG. 5, according to one or more aspects of the present disclosure.

FIG. 7B is a top view of the flow field on the anode touching side of the fuel cell/electrolyzer of FIG. 5, according to one or more aspects of the present disclosure.

FIG. 8 is a schematic diagram of a hydride storage tank, according to one or more aspects of the present disclosure.

FIG. 9 is a flowchart diagram of a method of producing and storing hydrogen and energy, according to one or more aspects of the present disclosure.

DETAILED DESCRIPTION

It is to be understood that the present disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact.
The system, devices, and methods disclosed herein illustrate hydrogen energy production and storage.
Referring to FIG. 1, illustrated is Hydrogen Energy Production and Storage (HEPS) system 100. This system 100 is configured to efficiently produce and store energy and hydrogen for residential, commercial, industrial, and vehicle applications. The HEPS system 100 may include a power distribution center 102, an energy management module 104, and a group 110 of energy production and storage components which may include one or more of the following components: an oxygen storage tank 112, a fuel cell 114, and electrolyzer 116, a water reservoir, a water tank 120, a hydrogen buffer tank 122, a hydride storage tank 124, and heat exchanger 126. In some implementations, the group 110 of energy production and storage components includes multiples of one or more of the above components, such as a set of fuel cells 114 or a set of hydride storage tanks 124. The HEPS system 100 is scalable, and allows for adding or removing components to the group 110 to scale with energy and storage demands. The components in the group 110 of energy production and storage components are preferably modular, and may be interconnected as shown further in FIG. 4, such that various components send and receive electrical signals, water, oxygen, hydrogen, and other materials from other components in the group 110. The energy management module 104 may be directly connected to each component of the group 110 of energy production and storage components, a shown further in FIG. 4.
In some implementations, the energy production sources 150 include the supply of power from sources such as wind, solar, and geothermal power, as well as other external sources of power. The energy production sources 150 may be connected to the DC shunt 223A via two wires. If the energy production sources 150 outputs AC power, it will be converted to DC power before going through the DC shunt 223A. The DC shunt 223A may measure the amperage and produced power from the energy production sources 150 and connects the energy production sources 150 and the power controller 202 of the power distribution center 102 through connector 232. The DC shunt 223A may be connected to the 5 pin external analog to digital converter 304 of the energy management module 104 (shown in FIG. 3) via three wires to connector 260.
The local power grid 130 may be an electrical power grid that extra power may be sold to. The power grid 130 may be connected to an AC shunt 222A via two wires, which is connected to connector 230 of the power distribution center 102 (via three wires) and to connector 260 of the energy management module 104 (via two wires). The AC shunt 222A may measure the AC power output and amperage to the local power grid 130.
The application 140 may represent the primary consumer of energy produced by the HEPS system and may include residential, commercial, industrial, and vehicle applications. In some implementations, multiple applications 140 may be connected to the HEPS system 100. The application 140 may be connected to an AC shunt 222B via two wires, which is connected to connector 230 of the power distribution center 102 (via three wires) and to connector 260 of the energy management module 104 (via two wires). The AC shunt 222B may measure the AC power output and amperage to the application 140.
The HEPS system 100 may be configured to carry out a tiered power consumption system. In that regard, the power distribution center 102 may monitor power production of the group 110 of energy production and storage components as well as other energy production sources 150 and power consumption by various applications 140. The power distribution center 102 may be configured to direct the energy management module 104 to direct power to various applications 140 according to a tiered system of priorities. For example, the applications 140 may include a home system with set power consumption priorities. The first priority may be power consumption to light or heat the home or to operate home electronics and/or appliances. Any remaining power is then sent to a second consumption tier to hydrogen production sources (which may include hydrogen production through electrolysis), followed by production sources such as such as a fuel cell 114 and electrolyzer 116, and storage by hydride storage tanks 124, and if any remains, to a further consumption tier such as the local power grid 130. In this case, the power distribution center 102 may communicate with the power grid 130 and release excess power when it is useful for the energy company for a specific area of the local power grid 130. The HEPS system 100 is fully scalable and may be increased in size to service industrial operations, commercial buildings, and residential buildings. Thus, in another embodiment, the applications 140 may include an industrial site with primary power consumption priorities. The first priority may be power consumption to operate drilling equipment, or to light or heat an industrial building supporting the equipment. Any remaining power is then sent to a second consumption tier to hydrogen production sources (which may include hydrogen production through electrolysis), followed by production sources such as such as a fuel cell 114 and electrolyzer 116, and storage by hydride storage tanks 124, and if any remains, to a further consumption tier such as the local power grid 130.
A further improvement contemplated by the HEPS system 100 is the efficient use of waste heat. In particular, waste heat from the fuel cell 114 may be recycled to the heat exchangers 126 of the hydride storage tanks 124. This heat may be used to facilitate the release of hydrogen gas from the hydride storage tanks 124. The heat exchanger 126 may also be used to remove heat from the hydride storage tanks during filling of the hydride tanks 124 to reduce fill times and increase the storage capacity of the storage tanks 124. Waste heat may also be used for other purposes, such as to heat a residential, commercial, or industrial building, or drilling equipment such as a doghouse. Additionally, when the hydride storage tanks 124 are refueled, the waste heat produced may be used to heat buildings, enclosed structures, or to heat water in various components of the group 110 of energy production and storage components, such as the water reservoir 118 or water tank 120.
FIG. 2 is a schematic diagram of a first portion of the HEPS system of FIG. 1 including a power distribution center 102. In some implementations, the power distribution center 102 includes a power controller 202, a buffer capacitor, and a DC to AC converter 206, as well as connectors 230, 232, 234, and 250. Connector 250 may be linked to connector 270 of the energy management module 104 as shown in FIG. 3.
The power distribution center 102 may be used to control the distribution of produced power throughout the HEPS system 100. In particular, high power and high amperage parts of the HEPS system 100 may be routed through the power distribution center 102. The DC to AC converter 206 within the power distribution center 102 may receive DC power produced by the energy production sources 150 and the fuel cell 114 and convert the power to AC power for use in the HEPS system 100. The DC to AC converter 206 may be connected to the buffer capacitor 204 with two wires and to the local power grid 130 and the application 140 through connector 230.
The power distribution center 102 may include a buffer capacitor 204 that is configured to take an energy load spike in order to give the fuel cell 114 additional power if needed to carry out energy production. The buffer capacitor 204 may be connected to the DC to AC converter 206 and the power controller 202.
The power controller 202 of the power distribution center 102 may be the central hub through which high amperage and high power lines are routed. Inputs to the power controller 202 are from the energy production sources 150 through the DC shunt 223A and connector 232 and the fuel cell 114 through the DC shunt 223B and connector 234. The power controller 202 has outputs to the buffer capacitor 204, energy management module 104 through connector 250, and electrolyzer 116 through connector 234 and DC shunt 223C.
A fuel cell relay 224 may be included to control the flow of power from the fuel cell 114. The logic side of the fuel cell relay 224 may be connected to the controller 302 in the energy management module 104 (shown in FIG. 3) through connector 260 using two wires. The controller side of the fuel cell relay 224 may be connected to the power controller 202 in the power distribution center 102 through the connector 234.
An electrolyzer production relay 226 may be included to control the flow of power to the electrolyzer 116. The logic side of the electrolyzer production relay 226 may be connected to the controller 302 in the energy management module 104 (shown in FIG. 3) through connector 260 using two wires. The controller side of the electrolyzer production relay 236 may be connected to the power controller 202 in the power distribution center 102 through the connector 234.
FIG. 3 is a schematic diagram of a second portion of the HEPS system of FIG. 1 including an energy management module 104. In some implementations, the energy management module 104 houses a logical interface of the HEPS system 100. The energy management module 104 may be encased in a weather resistance case to protect the electronics inside. These electronics may include a controller 302, and in an exemplary embodiment a 5 pin external analog to digital converter 304, a 13 pin external analog to digital converter 306, a power distributor 310, and a 12V to 5V converter 312.
The controller 302 may monitor the other components of the energy management module 104 and HEPS system 100 generally, and may turn on and off components as needed in order to run the system as efficiently as possible. The controller 302 may have built in data logging and IoT implementation to allow users to monitor the HEPS system's 100 functionality and may be configured send warnings if there are any malfunctions. These warnings may be sent as notifications via computer systems, text, phone, or through other channels. In some implementations, the various HEPS systems for controlling power production and storage may be automated, such that consumption and performance levels are monitored and changed automatically, preferably based on preset parameters.
Inputs to the controller 302 are all routed through the 5 pin external analog to digital converter 304 or the 13 pin external analog to digital converter 306. These inputs may include the AC shunt 222A which may inform the controller 302 of the power output to the local power grid 130, the AC shunt 222B which may inform the controller 302 of the power output to the one or more applications 140, the DC shunt 223A which may inform the controller 302 of the power output from the energy production sources 150, the DC shunt 223B which may inform the controller 302 of the power output from the fuel cell 114, and the DC shunt 223C which may inform the controller 302 of the power output to the electrolyzer 116.
Other inputs to the controller 302 may be shown in FIG. 4, including pressure sensors 402 which may inform the controller 302 of the pressure within the oxygen storage tank 112, fuel cell 114, water tank 120, and hydrogen buffer tank 122, thermometers 404 which may inform the controller 302 of temperature levels within the fuel cell 114, water reservoir 118, water tank 120, hydride storage tank 124, and electrolyzer 116, and level sensors 406 which may inform the controller 302 of levels of liquids and gas within the water reservoir 118, water tank 120, and hydride storage tank 124.
Outputs of the controller 302 may include the fuel cell relay 224, which may control the connection from the fuel cell 114 to the power controller 202, and electrolyzer production relay 226, which may control the connection from the power controller 202 to the electrolyzer 116 as shown in FIG. 2. Other outputs of the controller 302 are shown in FIG. 4 and may include a hydrogen gas feedback line pump 412, which may regulate the rate at which hydrogen gas is fed back into the intake line to maintain peak efficiency, water pump 410A, which may control the transfer of water from the water tank 120 to the heat exchanger 126 for heating and cooling, water pump 410B, which may control the transfer of water from the water reservoir 118 to the water tank 120 to ensure that the water level inside the water tank 120 does not fall below operable levels, water pump 410C, which may control the transfer of water from the water tank 120 to the fuel cell 114 to ensure the proper temperature and adequate water supply, water pump 410D, which may control the transfer of water from the water tank 120 to the hydride storage tank 124 to regulate the temperature of the hydride storage tank 124, and water pump 410E, which may control the transfer of water from the water tank 120 to the electrolyzer 116 to regulate the supply of water and the temperature of the electrolyzer 116.
Returning to FIG. 3, the energy management module 104 may include a power distributor 310 that is configured to receive 12V power from the power distribution center 102 (through connector 270) and allow the power of various components within the energy management module 104. The power distributor 310 outputs to the 12V to 5V converter 312, the driver 308 and the power components on the right side of the energy management module 104.
The 12V to 5V converter 312 may convert 12V power from the power distributor 310 to 5V power for the controller 302. The connection between the power distributor 310 and 12V to 5V converter 312 may include a 12V wire and a ground/0V wire. The connection between the 12V to 5V converter 312 and the controller 302 may include a 5V reference wire and a ground/0V wire.
The 13 pin external analog to digital converter 306 may convert analog sensor input to usable digital values for the controller 302 to read. The digital converter 306 may be connected to all analog sensors on the right side of the energy management module 104 in the diagram of FIG. 3. The 13 pin external analog to digital converter 306 may also output a ground reference and a 5V reference along with individual analog wires. The 13 pin external analog to digital converter 306 may be connected to the controller 302 using four wires.
The 5 pin external analog to digital converter 304 may convert analog sensor input to usable digital values for the controller 302 to read. It may be connected to all analog shunts on the top side of the energy management module 104 in the diagram of FIG. 3. The 5 pin external analog to digital converter 304 may output a ground reference and a 5V reference along with individual analog wires. It may be connected to the controller 302 using four wires.
The driver 308 may take 5V digital signals from the controller 302 to control the ground side of the 12V circuits. The driver 308 may be connected to the controller 302, ground from the power distributor 310, and connected to the various components it powers.
FIG. 4 is a schematic diagram of a third portion of the HEPS system of FIG. 1 including a number of components for hydrogen energy production and storage. These components may include an oxygen storage tank 112, fuel cell 114, electrolyzer 116, water reservoir 118, water tank 120, hydrogen buffer tank 122, hydride storage tank 124, and heat exchanger 126.
The oxygen storage tank 112 may be used to contain excess oxygen used in the fuel cell 114. Two oxygen gas lines may be included between the oxygen storage tank 112 and the fuel cell 114 (passing oxygen in opposite directions), each including a flash arrestor 408. These flash arrestors 408 may serve as a directional safety measure to prevent an explosion in either the oxygen storage tank 112 or the fuel cell 114 from reaching the other component. A pressure sensor 402 may be used to inform the controller 302 of the current pressure inside the oxygen storage tank 112 and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires.
The fuel cell 114 may be used to produce energy for the power distribution center 102. The fuel cell 114 may be connected to the oxygen storage tank 112 using two oxygen gas lines, to the water tank 120 using two water lines, and to the hydrogen buffer tank 122 using a hydrogen gas line. More details of the fuel cell are discussed with reference to FIGS. 5-7.
A pressure sensor 402 may be used to inform the controller 302 of the current pressure inside the fuel cell 114, and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires. A thermometer may be used to inform the controller 302 of the current pressure inside the fuel cell 114, and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires. A hydrogen gas feedback line pump 412 may take a hydrogen feedback line and pumps hydrogen into the hydrogen intake line in order to keep a constant flow of hydrogen inside the fuel cell 114, thus increasing the efficiency of the fuel cell 114. A DC shunt 223B may be used to measure DC power outage and amperage to the power distribution center 102, and may connect to the fuel cell 114 and the power controller 202 in the power distribution center 102 through connector 234. The DC shunt 223B may be connected to the 5 pin external analog to digital converter 304 through connector 260 using three wires.
The water reservoir 118 may be used to store distilled water that can be added to various components of the HEPS system 100 to ensure they do not run dry. The water reservoir 118 may be connected to the water tank 120 through water pump 410B and water filter 413. A level sensor 406 may be connected to the water reservoir 118 and may inform the controller 302 of the current water level inside the water reservoir 118, and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires. A thermometer 404 may also be connected to the water reservoir 118 and may be used to inform the controller 302 of the current water temperature of the water inside the water reservoir 118, and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires.
The heat exchanger 126 may be used to cool down water that is heated during the various heat generating processes, as well as to assist with hydrogen storage in the hydride storage tank 124. In some implementations, two separate heat exchangers 126 are included in the components, one to cool down water passing through components, and one to assist in hydrogen storage in the hydride storage tank 124. The heat exchanger 126 may be connected to the water tank 120 through two water lines. A thermometer 404 may be used to inform the controller 302 of the current water temperature inside the heat exchanger 126, and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires. A fan 414 may be used to assist in the cooling of water that passes through the heat exchanger 126. The fan 414 may be connected to the power distributor 310 and driver 308 through connector 290. In some implementations, the heat exchanger includes coiled metal tubing (such as stainless steel) inside the hydride storage tank 124. Coolant may be run through this tubing to absorb or transfer the heat.
The water tank 120 may hold and distribute water to other components in the HEPS system 100. A pressure sensor 402 may be used to inform the controller 302 of the current pressure inside the water tank 120, and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires. A thermometer 404 may be used to inform the controller 302 of the current water temperature of the water inside the water tank 120, and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires.
A level sensor 406 may be used to inform the controller 302 of the current water level inside the water tank 120, and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires.
The water tank 120 may be connected to water lines with a number of water pumps 410 to transport water to various components of the HEPS system 100. Water pump 410A may be used to control water temperature by passing water through the heat exchanger 126, and may be connected to the power distributor 310 and driver 308 of the energy management module 104 using two wires that pass through connector 208. Water pump 410B may be used to control when to pump water from the water reservoir 118 to the water tank 120 to ensure that the water level inside the water tank 120 does not fall below operable levels, and may be connected to the power distributor 310 and driver 308 of the energy management module 104 using two wires that pass through connector 208. Filter 413 may be used to filter out any particulates that are detrimental to the various processes of the HEPS system 100, and may be connected inline between water pump 410B and the water tank 120. Water pump 410C may control when to pump water from the water tank 120 to the fuel cell 114 to ensure the proper temperature and adequate water supply, and may be connected to the power distributor 310 and driver 308 of the energy management module 104 using two wires that pass through connector 208. Water pump 410D may control when to pump water from the water tank 120 to the hydride storage tank 124 to regulate the temperature of the hydride storage tank 124, and may be connected to the power distributor 310 and driver 308 of the energy management module 104 using two wires that pass through connector 208. Water pump 410E may control when to pump water from the water tank 120 to the electrolyzer 116 to regulate the supply of water and the temperature of the electrolyzer 116, and may be connected to the power distributor 310 and driver 308 of the energy management module 104 using two wires that pass through connector 208.
The hydrogen buffer tank 122 may be used to store and dispense hydrogen for use in various components of the HEPS system 100. A pressure sensor 402 may inform the controller 302 of the current temperature inside the hydrogen buffer tank 122, and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires.
One or more hydride storage tanks 124 may be included in the HEPS system, and may be used to store produced hydrogen gas. Further details of the hydride storage tanks are discussed in reference to FIG. 8. A thermometer 404 may inform the controller 302 of the current temperature inside the hydride storage tank 124, and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires. A level sensor 406 may inform the controller 302 of the current level of hydrogen inside the hydride storage tank 124, and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires.
The electrolyzer 116 may be used to produce hydrogen gas for use in the fuel cell 114 and storage in the hydride storage tank 124. A thermometer 404 may inform the controller 302 of the current temperature inside electrolyzer 116, and may be connected to the 13 pin external analog to digital converter 306 of the energy management module 104 through connector 280 using three wires. A DC shunt 223C may be used to measure the DC power output and amperage from the power distribution center 102, and may connect the electrolyzer 116 and power controller 202 in the power distribution center 102 through connector 234. The DC shunt 223C may be connected to the 5 pin external analog to digital converter through the connector, using three wires.
FIG. 5 is a schematic diagram of a fuel cell/electrolyzer 500, according to one or more aspects of the present disclosure. In some implementations, the fuel cell/electrolyzer 500 may include the fuel cell 114 and electrolyzer 116 depicted above in FIGS. 1, 2 and 4. In some implementations, the fuel cell 114 and electrolyzer 116 are integrated together within a single housing, and may even share flow fields. In other implementations, the fuel cell 114 and electrolyzer have separate housings and are connected together. The fuel cell/electrolyzer 500 may be a modular system with varying numbers of stacks 600 (show in more detail in FIG. 6) which may be brought online to match demand for incoming power. This may result in increased efficiency of the fuel cell/electrolyzer 500 as compared to existing systems, many of which have a defined and unchangeable number of fuel cells. Another feature of the fuel cell/electrolyzer 500 is a layout that allows current to essentially jump between contacts on the cells, which avoids resistance typically found in the flow fields of existing fuel cells, greatly increases efficiency.
The fuel cell/electrolyzer 500 may include a body 502 with a number of membrane units 504 connected to a water tube in 506 and a water and oxygen tube out 508 by a number of nozzles 505. Water in a heat exchanger 530 may be input into the water tube in 506. Hydrogen may be generated with an electrolyzer portion of the fuel cell/electrolyzer 500 and passed into tube 510. Hydrogen that is not used for the generation of energy in the fuel cell/electrolyzer 500 flows out 512 and passes through a hydrogen purity spectroscoper 514 as pure hydrogen 516. A power controller 520 is connected to a positive electrode 522 and a negative electrode 524 which pass through the membrane units 504. A thermometer 532 may be used to monitor the temperature within water in the heat exchanger 530 and water and oxygen flowing out of the fuel cell/electrolyzer 500. A legend 550 shows the various liquids, gases, and solids in the fuel cell/electrolyzer 500.
FIG. 6 is a schematic diagram of a portion 1-1 of the fuel cell/electrolyzer of FIG. 5 and depicts aspects of a stack 600. An outside structure 602 may hold a number of membrane units 504 which may form cells 606 within the stack 600. In some implementations, each stack 600 includes about 5-10 cells each and form 12V-24V stacks 600. In other implementations, each stack may include approximately 1-20 cells each. The number of these membrane units 504 may be adjustable to match the use of the fuel cell/electrolyzer 500. In some implementations, the membrane units 504 are formed from materials such as Nafion coated with a graphene membrane. The membrane units 504 may be formed from other materials, such as other polymers and graphene combinations. Metal contacts 618 may be included on the anode side of each membrane unit 504, which may plug into metal contacts 616 on the cathode side. This may allow the cells 606 to be connected in series, thus allowing for easy modularity. Plugs 630 in the outside structure 602 may be used to connect stacks 600 in a modular format. In some implementations, stacks 600 may be plugged into a servo-type frame such that the total cell stack voltage may be adjusted easily, e.g., while maintaining a suitably consistent current. Input and output tubes 506, 508, 510 may include quick connects, so that when cells 606 are stacked, tubes 506, 508, 510 can connect together easily.
The flow fields 620, 622 in the fuel cell/electrolyzer 500 are not conductive. In particular, cathode flow fields 620 of hydrogen gas flow in direction A and anode flow fields 622 are double sided, such that a water input 624 is on an opposite side of the flow field 620 from a water output 626. A top view 700 of the cathode flow field 620 is shown in FIG. 7A, showing hydrogen extraction through tube 510. A top view 750 of the anode flow field 622 is shown in FIG. 7B with a back and forth path. Positive and negative direct contacts 612, 614 on both the anode and cathode sides of the membrane units 504 allows the input voltage to split between cells 606 such that the current is essentially the same for all cells 606. By allowing the current to, in essence, jump from the contact of one cell 606 to the next, resistance (high amounts of which is typically produced by the flow fields of existing fuel cells) is minimized, thus greatly increasing efficiency. In some implementations, each stack 600 operates at a temperature range of 35 to 44 degrees Celsius for optimum efficiency with minimal resistance.
FIG. 8 is a schematic diagram of a hydride storage tank 800 as included in the HEPS system 100. The hydride storage tank 800 may be the hydride storage tank 124 depicted in FIGS. 1 and 4 above. More than one hydride storage tank 800 may be used in the HEPS system, as the demand for hydrogen storage scales for larger systems. The hydride storage tank 800 may have a standardized shape and size for use in vehicles, homes, businesses, and refueling stations. This may provide a scalable infrastructure that allows for easy tank substitution and/or replacement, refueling both at home and while traveling, and an overall decrease in cost, both for consumers as well as in manufacturing.
The hydride storage tank 800 may include an outer tank 802, an inner tank 804, and insulation 806 between the outer tank 802 and inner tank 804. Hydrogen may pass in through a valve 811 from a hydrogen source 822 such as fuel cell/electrolyzer 500 and may pass out through the valve 811 for transfer and consumption. The hydride storage tank 800 may also be connected to a heat exchanger 850 that facilitates the storage and release of the proper amount of hydrogen by altering the pressure of the hydride storage tank 800 using a change in temperature. This may be accomplished through the use of one or more water baths within the hydride storage tank, which help to keep the temperature consistent as well as keeping a constant ambient pressure, which aids in the efficient production hydrogen.
In some implementations, the heat exchanger 850 may be the heat exchanger 126 depicted in FIGS. 1 and 4. The heat exchanger 850 may include a DC power source 820 with positive and negative connections 821, 823 which may be used to heat coils 810 within the inner tank 804. Coolant for heating and cooling 826 may pass through a valve 813 into and out of the hydride storage tank 800. System management 824 may be responsible for monitoring coolant levels and opening and closing the valve 813 as well as monitoring and switching the DC power source 820 and monitoring and switching open and closed the valve 811. Heat from other sources 830 may also be used in in the heat exchanger 850. For example, waste heat from the fuel cell 500 depicted in FIGS. 5-7 (and fuel cell 114 in FIGS. 1, 2, and 4) may be used, as well as exhaust heat from engines or other processes.
In some implementations, the hydride storage tank 800 may utilize a combination of metal alloys that allows for greater volume storage and efficient recharging and discharging compared to existing hydrogen storage systems. Metal hydrides are specific metallic compounds and alloys that may act like sponges to both absorb and release hydrogen at consistent pressures. Different alloys or metallic compounds have different pressure and temperature release properties, resulting in different absorption and release times. There are eight categories of metal hydrides: AB5; AB2; AB; A2B; complex compounds; Mg alloys; miscellaneous other intermetallic compounds; and solid solution alloys. The hydride storage tank 800 may include one type of compound or complex compounds, and in particular, complex metal hydrides such as alanate (IH4) materials. In some implementations, alanates have the potential for higher gravimetric hydrogen capacities in the operational window than simple metal hydrides. Furthermore, alanates can store and release hydrogen reversibly when catalyzed with titanium dopants, according to the following two-step displacive reaction for sodium alanate: NaAIH4=⅓ Na3AIH6+⅔ AI+H2 Na3AIH6=3 NaH+ 3/2 H2. In some implementations, the hydride storage tank 800 utilizes sodium alanate as a hydride material. The hydride material may be formed in a bed within the hydride storage tank 800. In some implementations, the hydride material forms a lining on a portion of the inner wall(s) of the inner tank 804. In other implementations, the hydride material forms a core in a central area of the hydride storage tank, or is disposed at regular intervals such as in the form of alternating-path trays in a distillation column. Heat exchange conduits may be placed within or around the hydride material to facilitate heating and cooling by the heat exchanger 850. The hydride material may be included in stainless steel, aluminum, or carbon fiber materials, including graphene reinforced materials.
Furthermore, the hydride storage tank 800 may include graphene as a hydride material. This may include doped graphene. For example, enhanced doped graphene powders may allow for a weak bond with hydrogen molecules and can be bonded at room temperature with 200 psi of pressure. Hydrogen may be released with a drop in pressure and application of heat from the heat exchanger 850 (as well as from the fuel cell 500 or from other sources such as a combustion engine). In some implementations, hydride materials in the hydride storage tank 800 may be recycled at the end of their lifespan and reused.
In addition to the unique combination of metal allowing for increase storage and efficiency, the hydride storage tank 800 may include features to minimize hydride tank fatigue caused by repeated hydride bonding. Hydride bonding may occur due to hydrogen bonds within metallic compounds and alloys in hydrogen tanks. The subsequent release of hydrogen from the metallic compounds may cause strain in the tank walls. Hydride tank fatigue may be minimized in the hydride storage tank 800 through the use of a custom alloy suspension liquid that allows for contractions and expansions of the hydride materials, which thereby minimizes hydride tank fatigue. The alloy suspension liquid may allow for essentially 100% charge and discharge ability while extending the life of the tanks, in some implementations to 25 years or more.
FIG. 9 is a flow chart showing an exemplary method 900 of producing and distributing hydrogen and energy. It is understood that additional steps can be provided before, during, and after the steps of method 900, and that some of the steps described can be replaced or eliminated for other implementations of the method 900. In particular, the various components of the HEPS system 100, including the fuel cell 114, electrolyzer 116, hydride storage tank 124, and heat exchanger 126 the figures above may be used to carry out various steps of the method 900.
At step 902, the method 900 may include establishing a tiered energy consumption system with a plurality of tiers. In some implementations, first, second, and third energy tiers are included. In other implementations, more or less tiers may be included. The tiers may be based on energy consumption priorities. For example, a first consumption tier may include the energy consumption needs of an industrial or residential consumer, such as heating, cooling, and powering drilling equipment or appliances, as applicable. A second consumption tier may include a hydrogen production and storage system such as the fuel cell 114, electrolyzer 116, hydride storage tank 124, and heat exchanger 126 as discussed above. A third consumption tier may be an electrical power grid.
At step 904, the method 900 may include producing energy with an energy source, such as energy production sources 150 discussed in reference to FIGS. 1-2 above. At step 906, the method 900 may include sending the produced energy to the first consumption tier. This energy may be used to light and heat industrial or residential buildings, and to operate drilling equipment and/or home electronics and/or appliances, respectively.
At step 908, the method 900 may include determining if the first tier priorities have been met. If not, energy production continues until these priorities are met, before energy is transferred to other tiers. If the first tier priorities are met, energy is sent to second tier consumers, such as a hydrogen and energy production and storage system.
At step 912, the method 900 may include using the supplied energy from step 910 to produce hydrogen and energy with one or more fuel cells, such as fuel cell 114 and electrolyzer 116 as discussed in FIGS. 1, 2, and 4-6.
At step 916, the method 900 may include storing hydrogen with a storage system. In some implementations, the storage system includes one or more hydride storage tanks 124 with heat exchangers 126 as discussed in reference to FIGS. 1, 4, and 8. These hydride storage tanks 124 may be configured to receive energy produced by the fuel cell 114 and electrolyzer 116 and dispense hydrogen when directed by an energy management system.
An optional step 914 may be included in method 900, in which waste heat from the one or more fuel cells is transferred to the storage system, where it may be used by the one or more heat exchangers 126. Waste heat may also be transferred directly to energy consumers, such as being used to heat industrial, residential or commercial buildings, or associated equipment as described herein.
At step 918, the method 900 may include determining if the second tier priorities have been met. If not, energy production continues until these priorities are met, before energy is transferred to later tiers. If the second tier priorities are met, energy is sent to third tier consumers in step 920, which may include the local power grid. In some implementations, when power is sent to the energy grid, the HEPS system is configured to communicate with the grid control system and release excess power when it is useful for the energy company running the grid as well as particular energy consumers. The HEPS system may be scalable and can be increased in size to produce energy sufficient to other numbers of tiers, including large commercial buildings.
The foregoing outlines features of several implementations so that a person of ordinary skill in the art may better understand the aspects of the present disclosure. Such features may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed herein. One of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the implementations introduced herein. One of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure.
The Abstract at the end of this disclosure is provided to comply with 37 C.F.R. § 1.72(b) to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments as listed below.
Embodiment 1. An energy control system, comprising: an energy production system comprising an electrolyzer/fuel cell configured to produce hydrogen gas and/or electricity; a hydride storage tank fluidically connected to the energy production system and configured to receive and store the produced hydrogen gas; and a power control module configured to control the production of hydrogen gas by the energy production system and the storage of produced hydrogen gas in the hydride storage tank, the power control module further configured to implement a consumption system comprising a first energy tier and a second energy tier, wherein power consumption by the first energy tier using energy produced by the electrolyzer/fuel cell is prioritized over power consumption by the second energy tier such that energy produced in excess of the power consumption by the first energy tier is stored by the hydride storage tank for the second energy tier.
Embodiment 2. The energy control system of embodiment 1, wherein the hydride storage tank comprises a heat exchanger, wherein waste heat from the fuel cell is used by the heat exchanger.
Embodiment 3. The energy control system of embodiment 2, wherein the hydride storage tank comprises a doped graphene hydride material.
Embodiment 4. The energy control system of embodiment 2, wherein the hydride storage tank comprises one or more alanate (IH4) materials configured to releasably store gas containing hydrogen.
Embodiment 5. The energy control system of embodiment 1, wherein the electrolyzer/fuel cell comprises a conductive graphene membrane.
Embodiment 6. The energy control system of embodiment 1, wherein the electrolyzer/fuel cell includes a membrane with an anode side and a cathode side opposite the anode side.
Embodiment 7. The energy control system of embodiment 6, wherein the electrolyzer/fuel cell includes a direct electrical contact on both the anode side and the cathode side.
Embodiment 8. The energy control system of embodiment 7, wherein the electrolyzer/fuel cell comprises a plurality of cell portions each with flow field tubing with non-conductive flow fields, such that current from the direct electrical contact is evenly distributed across each of the plurality of cell portions.
Embodiment 9. The energy control system of embodiment 1, wherein the first energy tier is a residential or industrial electricity consumer and the second energy tier is a storage system.
Embodiment 10. The energy control system of embodiment 1, wherein the consumption system comprises a third energy tier such that power consumption for the first and second energy tiers is prioritized over the third energy tier.
Embodiment 11. An energy production system, comprising: an electrolyzer/fuel cell configured to produce hydrogen gas and/or electricity; and a hydride storage tank connected to the fuel cell and configured to receive and store the produced hydrogen gas, wherein the hydride storage tank comprises a heat exchanger disposed in association with the electrolyzer/fuel cell, wherein waste heat emitted from the electrolyzer/fuel cell is received by the heat exchanger and used to facilitate release of the produced hydrogen gas from the hydride storage tank.
Embodiment 12. The energy production system of embodiment 11, wherein the hydride storage tank comprises a doped graphene hydride material.
Embodiment 13. The energy production system of embodiment 11, wherein the hydride storage tank comprises one or more alanate (IH4) materials.
Embodiment 14. The energy production system of embodiment 11, wherein the electrolyzer/fuel cell comprises a conductive graphene membrane.
Embodiment 15. The energy production system of embodiment 11, wherein the electrolyzer/fuel cell includes a membrane with an anode side and a cathode side opposite the anode side.
Embodiment 16. The energy production system of embodiment 15, wherein the electrolyzer/fuel cell includes a direct electrical contact on both the anode side and the cathode side.
Embodiment 17. The energy production system of embodiment 16, wherein the electrolyzer/fuel cell comprises a plurality of cell portions each with flow field tubing with non-conductive flow fields, such that current from the direct electrical contact is evenly distributed across each of the plurality of cell portions.
Embodiment 18. A method of producing and storing energy, comprising: producing electricity and hydrogen with an electrolyzer/fuel cell; storing the produced hydrogen in a hydride storage tank fluidically connected to the electrolyzer/fuel cell; controlling the production of hydrogen gas with a power control module; and implementing a consumption system with the power control module, the consumption system comprising a first energy tier and a second energy tier, wherein power consumption by the first energy tier using energy produced by the fuel cell is prioritized over power consumption by the second energy tier such that energy produced in excess of the power consumption by the first energy tier is stored in the hydride storage tank for the second energy tier.
Embodiment 19. The method of embodiment 18, wherein the first energy tier is a residential or industrial consumer, wherein the second energy tier is a storage system.
Embodiment 20. The method of embodiment 19, wherein the consumption system comprises a third energy tier such that power consumption for the first and second energy tiers is prioritized over the third energy tier.
Although several example embodiments have been described in detail above, the embodiments described are example only and are not limiting, and those of ordinary skill in the art will readily appreciate that many other modifications, changes and/or substitutions are possible in the example embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.

Claims

What is claimed is:

1. An energy control system, comprising:

an energy production system comprising an electrolyzer/fuel cell configured to produce hydrogen gas and/or electricity;

a hydride storage tank fluidically connected to the energy production system and configured to receive and store the produced hydrogen gas; and

a power control module configured to control the production of hydrogen gas by the energy production system and the storage of produced hydrogen gas in the hydride storage tank, the power control module further configured to implement a consumption system comprising a first energy tier and a second energy tier, wherein power consumption by the first energy tier using energy produced by the electrolyzer/fuel cell is prioritized over power consumption by the second energy tier such that energy produced in excess of the power consumption by the first energy tier is stored by the hydride storage tank for the second energy tier.

2. The energy control system of claim 1, wherein the hydride storage tank comprises a heat exchanger, wherein waste heat from the fuel cell is used by the heat exchanger.

3. The energy control system of claim 2, wherein the hydride storage tank comprises a doped graphene hydride material.

4. The energy control system of claim 2, wherein the hydride storage tank comprises one or more alanate (IH4) materials configured to releasably store gas containing hydrogen.

5. The energy control system of claim 1, wherein the electrolyzer/fuel cell comprises a conductive graphene membrane.

6. The energy control system of claim 1, wherein the electrolyzer/fuel cell includes a membrane with an anode side and a cathode side opposite the anode side.

7. The energy control system of claim 6, wherein the electrolyzer/fuel cell includes a direct electrical contact on both the anode side and the cathode side.

8. The energy control system of claim 7, wherein the electrolyzer/fuel cell comprises a plurality of cell portions each with flow field tubing with non-conductive flow fields, such that current from the direct electrical contact is evenly distributed across each of the plurality of cell portions.

9. The energy control system of claim 1, wherein the first energy tier is a residential or industrial electricity consumer and the second energy tier is a storage system.

10. The energy control system of claim 1, wherein the consumption system comprises a third energy tier such that power consumption for the first and second energy tiers is prioritized over the third energy tier.

11. An energy production system, comprising:

an electrolyzer/fuel cell configured to produce hydrogen gas and/or electricity; and

a hydride storage tank connected to the fuel cell and configured to receive and store the produced hydrogen gas, wherein the hydride storage tank comprises a heat exchanger disposed in association with the electrolyzer/fuel cell, wherein waste heat emitted from the electrolyzer/fuel cell is received by the heat exchanger and used to facilitate release of the produced hydrogen gas from the hydride storage tank.

12. The energy production system of claim 11, wherein the hydride storage tank comprises a doped graphene hydride material.

13. The energy production system of claim 11, wherein the hydride storage tank comprises one or more alanate (IH4) materials.

14. The energy production system of claim 11, wherein the electrolyzer/fuel cell comprises a conductive graphene membrane.

15. The energy production system of claim 11, wherein the electrolyzer/fuel cell includes a membrane with an anode side and a cathode side opposite the anode side.

16. The energy production system of claim 15, wherein the electrolyzer/fuel cell includes a direct electrical contact on both the anode side and the cathode side.

17. The energy production system of claim 16, wherein the electrolyzer/fuel cell comprises a plurality of cell portions each with flow field tubing with non-conductive flow fields, such that current from the direct electrical contact is evenly distributed across each of the plurality of cell portions.

18. A method of producing and storing energy, comprising:

producing electricity and hydrogen with an electrolyzer/fuel cell;

storing the produced hydrogen in a hydride storage tank fluidically connected to the electrolyzer/fuel cell;

controlling the production of hydrogen gas with a power control module; and

implementing a consumption system with the power control module, the consumption system comprising a first energy tier and a second energy tier, wherein power consumption by the first energy tier using energy produced by the fuel cell is prioritized over power consumption by the second energy tier such that energy produced in excess of the power consumption by the first energy tier is stored in the hydride storage tank for the second energy tier.

19. The method of claim 18, wherein the first energy tier is a residential or industrial consumer, wherein the second energy tier is a storage system.

20. The method of claim 19, wherein the consumption system comprises a third energy tier such that power consumption for the first and second energy tiers is prioritized over the third energy tier.