Design of a PEM fuel cell system for residential application

Muhsin Tunay Gencoglu*, Zehra Ural

Department of Electrical and Electronics Engineering, Faculty of Engineering, Firat University, 23119 Elazig, Turkey
a r t i c l e i n f o
Article history:
Received 2 September 2008
Accepted 19 September 2008
Available online 12 November 2008
Keywords:
PEM fuel cell
Hydrogen energy
Residential application
a b s t r a c t
Fuel cells are energy transformation technologies and they are clean, dont damage to
environment, have high efciency and provide uninterruptible energy generation.
Research and development studies about fuel cells have been done increasingly. In the
recent years, fuel cell technologies have performed in some sectors such as military,
industrial, space, portable, residential, transportation and trading.
Uninterruptible energy is becoming necessary because of high standard of living,
increasing of energy demand of residence. Therefore, there is a need for the systems
which will provide required energy if the fuel cell is unconnected to grid and the systems
will operate as reserve system when the fuel cell connect grid. A fuel cell system worked by
hydrogen can be used for the need. Otherwise, hydrogen energy utilization at residences is
an alternative method especially for supply power demand of stationary or portable
devices. In this paper, hydrogen energy and fuel cells were investigated and application
areas of fuel cell systems were researched. In addition, design of a fuel cell system was
achieved and the components of the system were dened for the residential application
which one of the application areas of fuel cell systems.
2008 International Association for Hydrogen Energy. Published by Elsevier Ltd. All rights
reserved.
1. Introduction
The Fuel Cell concept is more than 150 years old. William
Grove rstly exposing the fuel cell concept, have the idea to
study the opposite process of the electrolysis. Fuel cell
denomination arises in 1839, created by Ludwig Mond and
Charles Langer. The rst successful implementation was in
1932 by Francis Bacon. Since the ftys fuel cell developed by
NASA has been used as electric generators for the space
shuttles. Nowadays there are many big companies investing
a lot of money to the fuel cell technology success, especially
automobile industry [1,2].
Considerable attention has been devoted to distributed
sources of energy for meeting the power demand instead of
constructing new conventional power plants due to better
power quality, reliability, portability and ecological
constraints. Among the various types of distributed genera-
tion, fuel cells generated tremendous interest for electricity
and heat generation due to their low operating temperature,
fast start up characteristics, and ecological constraints [3].
Fuel cell power plants (FCPPs) are electrochemical devices
that convert the chemical energy of a reaction directly into the
electrical energy. Among the various next generation power
plants, the FCPPs has been found to be one of the most
promising energy sources due to high efciency and envi-
ronment-friendly operation [4]. Because fuel cells convert the
fuel to electricity through an electrochemical process rather
than a combustion process typical of most power plants, the
emissions are much cleaner. Compared to burning fossil fuels
like coal and oil, which produces emissions of sulfur dioxide,
nitrogen oxide, and carbon dioxide, the electrochemical
process used in fuel cells only has carbon dioxide and water as
* Corresponding author. Fax: 90 4242415526.
E-mail addresses: mtgencoglu@rat.edu.tr (M.T. Gencoglu), zural@rat.edu.tr (Z. Ural).
Avai l abl e at www. sci encedi r ect . com
j our nal homepage: www. el sevi er . com/ l ocat e/ he
0360-3199/$ see front matter 2008 International Association for Hydrogen Energy. Published by Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijhydene.2008.09.038
i nt e r na t i ona l j o ur na l o f hy d r o g e n e ne r g y 3 4 ( 2 0 0 9 ) 5 2 4 2 5 2 4 8
by products. The low emissions from fuel cells make them an
environmentally preferred form of power production. The use
of FCPPs is expected to become more widespread in the near
future, in spite of their high current capital cost [5]. However,
it should be emphasized that the rst generation of fuel cells
will likely operate on natural gas or propane, which are nite
fossil fuels whose extraction from the ground and delivery
produce negative environmental impacts. In the future, fuel
cells will run on gas derived from biomass or pure hydrogen
extracted from water using wind or solar energy, thus playing
a key role in ushering in a sustainable energy future.
In the recent years there was an increasing interest in fuel
cell technology and fuel cells have reached a high develop-
ment status. This development was mostly advanced by the
automotive industry, because fuel cells are suitable to
substitute the fossil fuels and also to provide an environment-
friendly propulsion. But there is also a growing market for
stationary fuel cell applications, e.g. for cogeneration of heat
and power, and as a substitute for batteries in portable
devices, e.g. for laptops.
Despite the progress made in rst realized fuel cell vehicle
eets and combined heat power units there is still lot of work to
be done to bring fuel cells to the market. The reduction of still
high costs has the biggest priority but the build up of hydrogen
infrastructure is not less important. Furthermore, the durability
and reliability of conventional systems has to be reached. By
means of mathematical modeling the development and design
of fuel cell systems can be highly accelerated [6].
2. Hydrogen energy and fuel cells
Hydrogen is the lightest, the simplest, and one of the most
abundant elements in nature. However, since it is not as a free
element, different production methods are required to extract
pure hydrogen from its natural form using advanced tech-
nologies that are still in research and development stages.
Fossil or renewable energy sources may be used for the
production process. Once generated, hydrogen may be used as
a fuel for transportation, a source for electricity and heating
[7]. The conversion of world energy system to hydrogen as
a fuel vector is logical when one looks at historical energy
production sequence from wood to coal, from coal to oil and
from oil to natural gas [8]. In this context, the optimal
endpoint is the replacement of hydrogen for the present fossil
fuels [9]. In addition, a worldwide transition from fossil fuels
to hydrogen would eliminate many problems such as climate
change, global warming, urban air pollution and their rami-
cations [710]. Using hydrogen as an alternative energy
resource is expected to be a method for remedying the energy
and environmental problems mentioned above. Hydrogen
energy system is a continuous, renewable, sustainable and
efcient system in harmony with the environment [11].
Fuel cell converts chemical energy of hydrogen into
electrical energy. As a result of this conversion just water and
heat are produced as waste. Fuel cells have advantages like
being environmentalist, having less moving parts and not
requiring maintenance continuously [12]. In a fuel cell,
hydrogen is fed at the anode, oxygen is fed at the cathode,
and an electrolyte is sandwiched between the two electrodes
for conveying ion e from the anode to the cathode. Elec-
trons are carried to the cathode through both anode and
a conducting wire, and a load is placed in between. There are
many auxiliary devices needed to operate the FCPPs, which
takes part in the gas and electricity management and are
used for regulating the parameters such as reactant owrate,
total pressure, reactant partial pressure, temperature and
membrane humidity at a desired value to ensure that FCPPs
can run smoothly without getting the stack either ooded or
drying out [13]. Accordingly, any malfunctioning, perfor-
mance loss, and/or failure in these auxiliaries can reduce the
overall performance of the FCPPs [5].
There are many types of fuel cell, classied according to
the electrolyte type (a liquid solution, a solid membrane or
even ceramic) [1,14,15]. The fuel cell electrolyte type has
a strong relation with fuel cell temperature operation. Liquid
electrolytes are more suitable for low temperatures operation,
instead of ceramic electrolytes used for high temperature fuel
cell [2]. Fuel cells are categorized based on the type of elec-
trolyte used. Generally, there are six basic types of fuel cells:
Alkaline fuel cell (AFC), proton exchange membrane or poly-
mer (electrolyte membrane) fuel cell (PEMFC), phosphoric acid
fuel cell (PAFC), molten carbonate fuel cell (MCFC), solid oxide
fuel cell (SOFC) and direct methanol fuel cell (DMFC). Although
different types of fuel cells have been developed, PEM fuel
cells are well suited for many applications including auto-
mobiles, buildings, and for smaller applications [1518].
Some of the popular type of fuel cells and their character-
istics are listed on Table 1.
2.1. PEM fuel cell
Fuel cells basically convert chemical energy of hydrocarbon
fuels directly into dc form of electrical energy. A FCPP mainly
consists of a fuel-processing unit (reformer), fuel cell stack
and power-conditioning unit. The fuel cell uses hydrogen as
input and produces dc power at the output of the stack. A
simple representation of a fuel cell system is shown in Fig. 1.
The performance of a fuel cell is generally characterized by
using the polarization curve, which is a plot of the fuel cell
output voltage as a function of load current. The polarization
curve is computed by using the Tafel equation [21], which
subtracts the various voltage losses from the open circuit dc
voltage, and is expressed as
V
stack
V
open
V
ohmic
V
activation
V
concentration
(1)
where,
V
open
N
0

E
0
E
1

N
0
"

Dg
0
f
2F

RT
2F
ln

pH
2

pO
2
p
pH
2
O
!#
(2)
V
ohmic
i i
n
R
FC
I
dc
R
FC
(3)
V
activation
N
0
RT
2aF
ln

I
dc
I
0

(4)
V
concentration
cln

1
I
dc
I
Lim

(5)
i nt e r na t i o na l j o ur na l o f hy d r og e n e ne r gy 3 4 ( 2 0 0 9 ) 5 2 4 2 5 2 4 8 5243
In the above equations, N
0
is the cell number, V
0
is the open
cell voltage, R is the universal gas constant, T is the temper-
ature of the fuel cell stack, F is the Faradays constant, pH
2
is
the hydrogen partial pressure, pH
2
O is the water partial
pressure, pO
2
is the oxygenpartial pressure, pOis the standard
pressure, a represents the charge transfer coefcient of the
electrodes, I
dc
is the current of the fuel cell stack, I
Lim
is the
limiting current of fuel cell stack, I
0
is the exchange current of
fuel cell stack and c is the empirical coefcient for concen-
tration voltage. The steady state voltage for one cell (N
0
1)
and power versus cell current density is obtained based on Eq.
(1) [5].
PEM fuel cells have gained international attention as
candidates for alternative automotive and stationary power
sources due to features such as their adaptable size and low
operating temperatures [2224]. The electrolyte of PEMFC, as
the name suggests, is a polymeric membrane/lm [22]. The
typical operation temperature of PEMFCs is in the range of 80
100

C [25].
3. The applications of fuel cells
Fuel cells are one of the most promising technologies for
delivering clean and efcient power for automotive and resi-
dential applications. With increased urgency in reducing
pollution and greenhouse gas emissions, a resurgence of
interest in fuel cells has occurred. Today, governments and
many corporations are making massive investments into the
development of these clean power sources. Although fuel cells
hold great promise for clean, inexpensive power, they are still
in their developmental infancy, and a great deal of research is
necessary before they are considered as viable power systems
[26]. Test capabilities that deliver reliable monitoring and
control, and offer the benet of a exible conguration, are
critical to these advances. The capabilities will permit scien-
tists to easily tailor their systems to keep in pace with the
evolving fuel cell technology [19].
Fuel cells are very useful as power sources in remote
locations, such as spacecrafts, remote weather stations,
parks, rural locations, and in certain military applications. A
fuel cell system running on hydrogen can be compact, light-
weight and has no major moving parts. Because fuel cells have
no moving parts, and do not involve combustion, in ideal
conditions they can achieve up to 99.99% reliability [27]. There
are a wide ranges of applications which are listed below [28].
1. Stationary power applications
Power generating stations
Auxiliary units
Distributed power generation
Residential use as combined heat and power generation
system
2. Transportation applications
Buses, track and cars
Airport intra-terminal vehicles
3. Portable applications
Laptops
Cellular phones
3.1. Stationary power systems
Stationary power products range from 1 kW to several mega-
watts. Applications include any place homes, businesses,
schools, hospitals, etc. These markets are typically served by
central generation. Another technique to serve the stationary
market is the employment of hydrogen turbines. The only
byproduct of burning hydrogen in oxygen is water that is free
from CO
2
, NO
x
, and SO
x
emissions [20].
Table 1 Comparison of different fuel cells and their operating characteristics [19,20].
Fuel cell type AFC PEMFC DMFC SOFC PAFC MCFC
Operating temperature (

C) 660250 80100 5090 7501000 160250 z650

Electrolyte Liquid Solid Solid Solid Liquid Liquid
Efciency (%) 5070 3560 3540 4560 3550 4055
Applications Transportation, space, military; Energy storage systems,
Portable power systems, Decentralized stationary systems
Combined heat and power for; Decentralized
stationary systems, Transportation
Fuel Cell
Power
Stack
DC/AC
Power
Inverter
Fuel
Processor
Natural
Gases
H
2
Steam
DC Power AC Power
Air
Heat and Water
Fig. 1 Basic fuel cell components.
i nt e r na t i ona l j o ur na l o f hy d r o g e n e ne r g y 3 4 ( 2 0 0 9 ) 5 2 4 2 5 2 4 8 5244
Residential fuel cell systems can be operated to provide
primary or backup power for the home. They can run inde-
pendently or in parallel to an existing power grid. A fuel cell
power systemfor a residence could be located inthe basement
or backyard, taking up about as much space as an ordinary
refrigerator, and providing clean, quiet, reliable power.
Residential fuel cell systems can produce about 5 kW of
power or 120 kWh of energy a day. A lack of performance data
on how well fuel cells work under different conditions is one
of the several factors slowing marketplace acceptance of the
new technology. There are several companies currently
working on residential fuel cells. Demonstration units are
being tested around the country by fuel cell manufacturers in
cooperation with local governments and/or utilities.
There are many problems which will be solved in resi-
dential fuel cell system. These problems are fuel reformer,
cost, heating time, method, storage and carrying of hydrogen,
economic hydrogen production, cogeneration system and
waste of CO
2
.
3.2. Transportation
One of the earliest applications of PEM fuel cells was the
General Electrical Corporation built 1 kW Gemini power plant
used on the Gemini spacecrafts built in the early 1960s. The
performance and life of the Gemini fuel cells were largely
limited by the membrane used at the time. Since then, cell
performance and power levels have increased signicantly.
For high power densities it is necessary to minimize weights
and volumes of fuel cell systems for marine, space, and
terrestrial applications. There are many companies working
to develop fuel cells for transportation applications: Ballard
Power Systems and Perry Energy have developed a Perry PC-14
unmanned underwater vehicle with a 3 kWPEMfuel cell stack
operating on hydrogen and oxygen cylinder gases. Treadwell
Corporation developed a 1 kW34 - cell PEMfuel cell stack with
an operating range of 1.32 h at top speed.
The development of fuel cell powered submarines has
been investigated for over a decade by German companies.
Some corporations are investigating the application of PEM
fuel cells for air independent propulsion in submarines. These
submarines will require 300400 kW for a PEM fuel cell battery
hybrid system to store an energy of 100200 MWh. Burlington
Northern Corporation and General Electric Transportation
Systems are investigating fuel cells as an alternative power
source for locomotives. A PEM fuel cell system developed by
Analytic Power Corp. System will operate on diesel fuel and
air. Analytic Power is currently developing a 10 kW DC power
plant consisting of 56 PEM fuel cells.
BallardPower Systems has developedthe rst zero-emission-
vehicle fuel cell bus. The 20-passenger bus requires a power of
100120 kWwith24 stacks of 35 cells eachcurrently operating on
hydrogen cylinder gas and an air compressor. The bus has
a range of 160 km with an acceleration of 050 km/h in 20 s and
a top speed of 70 km/h. The next stages in development will
increase the passengers capacity and travel range by improving
hydrogen storage and fuel cell performance.
Energy Partners are developing a zero-emission electric
vehicle EP Green Car using a PEM fuel cell battery hybrid
system. The 15 kW fuel cell system consists of 3 stacks with
a total of 180 cells which will operate on hydrogen and air at
2.4 atm producing a stack voltage of 125 V at 120 A. General
Motors Co. is developing an indirect methanolair PEM fuel
cell system with two 40 kW stacks. Ford Motor Co. is also to
develop a PEM fuel cell system for vehicles. In the rst stage of
development, the company is to develop a 1015 kW system
fuelled by hydrogen at 2.0 atm and weighing less than 4 kg/
kW. The ultimate goal is to produce a 50 kW system at less
than 3 kg/kW [29].
In automotive applications PEM fuel cells appear to be most
suitable, because their working conditions at low temperature
allow the system to start up faster than those Technologies
using high temperatures fuel cells; moreover the solid state of
their electrolyte (no leakages and low corrosion) and their high
power density make them t for transport applications [30].
3.3. Portable fuel cells
Applications include any system that requires power and is
not connected to an electrical outlet such as cameras, cell
phones, laptop computers, radios, electronic devices, power
tools, etc. The portable market has diverse requirements: long
run times, low weight, short response times, long life, low
cost, small physical size and safety and reliability.
Fuel cells have lacked commercialization due to high cost
and identication of a proper market application. The new
emerging handheld video communication and multimedia
devices that demand more power and energy will be a prime
market for fuel cell based portable power products as opposed
to batteries. There are, however, many current opportunities
for the application of fuel cells in small vehicles such as bikes
and motor scooters [20].
4. The residential application
Improving life quality and more dependency for electricity in
houses raises the demand for uninterrupted power systems.
For these reasons we need power systems which can work as
backup power while connected to the grid, or main power
system for places outside the grid. Fuel cell system powered
by hydrogen is a suitable candidate for this aim by its prop-
erties like high efciency, quite, low emission, low mainte-
nance need. Fuel cell system can be driven by direct hydrogen
or by fuels like natural gas and a reformer. Beside the main
electric output of the system, by using the waste heat the hot
water need for house can be obtained. So the total system
efciency will be increased.
In this section, a hybrid system consists of photovoltaic
panels and fuel cells were designed for a residence to supply
electrical demand. DC voltage obtained by photovoltaic panels
has been stored in batteries with charge regulators. The
voltage has been used in electrolysis unit which will generate
hydrogen used by fuel cell, as shown in Fig. 2. Hydrogen
obtained by electrolysis is stored in hydrogen tanks. DC
voltage obtained from fuel cell is converted to AC voltage and
electrical demand of the residence is supplied.
The photovoltaic system includes totally 20 PV modules
and the total installed power is 2.5 kW
p
in the standard
conditions (values correspond to 1000 W/m
2
, 25

C and the
i nt e r na t i o na l j o ur na l o f hy d r og e n e ne r gy 3 4 ( 2 0 0 9 ) 5 2 4 2 5 2 4 8 5245
total installed power 1.5 air mass). The specications of the
solar modules are determined as follows: maximum power is
125 W, maximum output voltage is 17.42 V, maximum output
current is 7.2 A, open circuit voltage is 22 V and short circuit
current is 7.62 A.
DC charge regulators of 30 A/12/24 V are used in this
system. DC energy obtained from photovoltaic panel groups
has been stored in 8 units of solar battery such that each unit
has 12 V to 350 Ah.
Electrolysis is a reaction, which produces hydrogen and
oxygen from water. The electricity required for this reaction
can be supplied from a renewable source. A PEM type elec-
trolyser is used to produce hydrogen by utilizing the electricity
generated by the PV panels. The net hydrogen production rate
of the electrolyser is 1.05 Nm
3
/h with a delivery pressure of
maximum of 13.8 bar. The purity of the product hydrogen is
99.9995% and the power consumed per volume of hydrogen
produced is 6.7 kWh/Nm
3
for optimal conditions. The elec-
trolyser is for indoor use for ambient temperatures ranging
from 5

C to 40

C, so the required ventilation and climatiza-
tion according to its requirements should be established
before the operation. The electrolyser is air-cooled and the
heat load from the system is maximum of 4.3 kW. The elec-
trolyser uses deionized water to produce hydrogen and to
actively cool the cell stack [31].
Hydrogen obtained from electrolysis is stored at metal
hydride tanks. Solid phase hydrogen storage is considered to
be the most futuristic storage techniques. This technique is
very advantageous because of providing the safe handling of
hydrogen and convenience with mobile applications.
Hydrogen storage as metal hydride is one of the solid phase
techniques [31].
Fuel cells are utilized to generate electrical energy from
hydrogenstored in hydrogentanks. The PEMfuel cells have an
compact structure, easiness and simple maintenance, for this
reason PEMfuel cell was chosen in this system. The used Nexa
fuel cell modules generate irregular DC power of maximum
1.2 kW. Nominal output voltage is 2250 V DC. These fuel cells
use the air as oxidant and output of the fuel cell is DC power,
water, heat and unused air. Each module of Nexa PEM fuel cell
has features such as, output power is 1.2 kW (total 46 A and
2250 V DC), hydrogen utilization purity of 99.99%, hydrogen
consumption is 18.5 l/min, maximum water emission is
870 ml/h, hydrogen input pressure is range of 0,717 bar [32].
Outputs of the fuel cells are parallel-connected and the
outputs are constituted input of an inverter.
Power demand of the residence is calculated as
The total installed power of the residence is 11.6 kW.
According to Guide of Electrical Internal Installations in
Turkey, while synchronous power of an apartment is dened,
synchronism coefcients must be considered in following:
60% for section of 8 kW of the set up power
40% for remainder section of the total power
If the synchronism coefcient is considered for this total
power as suitable Guide of Electrical Internal Installations,
using power at the same time is 8 0.6 3.6 0.4
4.8 1.4 6.24 kW. So a power of 6.24 kW is sufcient for this
residence. The total power of the hybrid system is 7.3 kW
p
consists of power of PV panels (2.5 kW
p
) and PEM fuel cells
(4.8 kW
p
).
Charge
regulator
Batteries
Elektrolyser
Hydrogen
tank
DC/AC
inverter
PEM
fuel cell
PV
panels
Demi
water
12 V DC/220V 50 Hz AC
30A /12/24V DC
12V 350 Ah
8 units
H
2
O
H
2
AC
H
2
DC
5-7 m
3
~(0.4-0.6 kg)
DC
1.05 Nm
3
H
2
/h
PEM type
O
2
1.2 kW x 4units
(4.8 kW)
125Wx20 modules
(2.5 kW)
Fig. 2 Block diagram of the hybrid system.
Washing machine 2.5 kW
Dishwasher 2.5 kW
Cooker 2 kW
Outlet line 1.8 kW
Outlet line 1.8 kW
Lightning line 0.5 kW
Lightning line 0.5 kW
i nt e r na t i ona l j o ur na l o f hy d r o g e n e ne r g y 3 4 ( 2 0 0 9 ) 5 2 4 2 5 2 4 8 5246
5. Conclusions
Another way of using hydrogen in our houses is gaining power
for stationary or portable devices in our houses. Especially
portable devices like vacuum cleaner can be attractive. It is
possible to provide longer working hours for electronic
devices like laptops, palms, and mobile phones. The customer
demand in this area, which is ready to pay more for energy,
makes the marketing more possible. Bicycles, scooters, wheel
chairs may be other marketing areas. The most important
problem for using hydrogen powered fuel cells that have lots
of technical advantages in our houses is their costs. This
problem can be solved by the improvements in technology,
increasing demand and starting of mass production. For
portable devices weight and dimensions must be comparable
with the existing designs. Building a reliable and global
infrastructure for hydrogen must be the main goal for reach-
ing the customer.
Electrical energy production fromrenewable energy sources
except hydroelectric energy is done mainly for local and small
applications in Turkey. It must be concentrated applications of
electrical energy production from hydrogen which is to be
accepted fuel of the future. The researches and projects related
to applications of residential fuel cells must be supported.
Before the institutions which will be energized with
renewable energy sources was not built, total energy
requirement of the institution and suitable energy sources
(photovoltaic panel, wind turbine or fuel cell) must be dened
and calculation of power is done.
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