Development of Thermodynamic, Geometric, and Economic Models for Use in the Optimal Synthesis/Design of a PEM Fuel Cell Cogeneration System for Multi-Unit Residential Applications

Thermodynamic, geometric, and economic models are developed for a proton exchange membrane (PEM) fuel cell system for use in cogeneration applications in multi-unit residential buildings. The models describe the operation and cost of the fuel processing sub-system and the fuel cell stack sub-system. The thermodynamic model reflects the operation of the chemical reactors, heat exchangers, mixers, compressors, expanders, and stack that comprise the PEMFC system. Geometric models describe the performance of a system component based on its size (e.g., heat exchanger surface area), and, thus, relate the performance at off-design conditions to the component sizes chosen at the design condition. Economic models are based on data from the literature and address the cost of system components including the fuel processor, the fuel cell materials, the stack assembly cost, the fuel cost, etc. As demonstrated in a forthcoming paper, these models can be used in conjunction with optimization techniques based on decomposition to determine the optimal synthesis and design of a fuel cell system. Results obtained using the models show that a PEMFC cogeneration system is most economical for a relatively large cluster of residences (i.e. 50) and for manufacturing volumes in excess of 1500 units per year. The analysis also determines the various system performance parameters including an electrical efficiency of 39% and a cogeneration efficiency of 72% at the synthesis/design point.