The implementation of an energy recovery system for retreiving otherways wasted energy is an effective method for reducing the overall energy consumption of a mobile machine. In a fork lift, there are two subsystems that can be effectively modified for recovering energy. These are the driveline and the lift/lower function of the mast. This study focuses on the latter by studying a recovery system whose main component is a hydraulic transformer consisting of a hydraulic motor, a variable displacement pump and an induction motor. Since the flow rate/pressure - ratio can be modified, the utilization of the hydraulic transformer enables downsizing of the accumulator volume. However, the decrease of the gas volume leads to an increase in the compression ratio of the accumulator, which in terms leads to higher gas temperatures after charging and consequently to higher thermal losses during holding phase. In order to reduce these losses, a thermally regenerative unit was implemented to the gas volume of an accumulator to reduce the temperature build up during charging. In this study, the effect of improving the thermal characteristics of the accumulator to the efficiency of the whole energy recovery system is investigated by means of measurements.

A test system for the performance analysis of a novel thermally regenerative fuel cell (TRFC) using propiophenone and hydrogen as the oxidant and fuel respectively was designed and built. The test system is capable of either hydrogen-air or hydrogen-propiophenone operation. Membrane electrode assemblies (MEAs) were made using commercial phosphoric acid-doped polybenzimidazole (PBI) membranes and commercial electrodes. Using Pt/carbon paper electrodes with a catalyst loading of 1mg/cm2 and a membrane with an acid doping level of 10.2 mol acid/mol of polymer repeat unit, a maximum performance of 212 mW/cm2 at a current density of 575 mA/cm2 was achieved for baseline hydrogen-air testing at 110°C. Problems were encountered, however, in achieving consistent, reproducible performance for in-house fabricated MEAs. Furthermore, ex-situ electrochemical impedance spectrometry (EIS) showed that the phosphoric acid-doped PBI was unstable in the propiophenone and that acid-leaching was occurring. In order to have MEAs with consistent characteristics for verifying the test system performance, commercial phosphoric acid-doped PBI membrane electrode assemblies were used. At a temperature of 160°C and atmospheric pressure with hydrogen and air flowrates of 150 mL/min and 900 mL/min respectively a maximum power density of 387 mW/cm2 at a current density of 1.1 A/cm2 was achieved. This performance was consistent with the manufacturer’s specifications and these MEAs were subsequently used to verify the performance of TRFC test system despite the EIS results that indicated that acid-leaching would probably occur. The Pt catalyzed commercial MEAs achieved very limited performance for the hydrogenation of the ketone. However, the performance was less than but comparable to similar results previously reported in the literature by Chaurasia et al. [1]. For pure Pt catalyst loading of 1 mg/cm2, using a commercial PBI MEA operating at 160°C and atmospheric pressure, the maximum power density was 40 µW/cm2 at a current density of 1.3 mA/cm2. A 16 hour test was conducted for these conditions with a constant 1 ohm load, successfully demonstrating the operation of the test system. The test system will be used in the development of better catalysts for ketone hydrogenation. / Thesis (Master, Chemical Engineering) -- Queen's University, 2012-10-12 10:00:58.854

This thesis was concerned with the proof of concept for mid-grade, 250-500oC, industrial waste heat recovery using a thermally regenerative electrochemical system. Proposed thermally regenerative electrochemical systems are limited to high operating temperatures (> 900oC) and suffer from poor conversion efficiencies (< 20%). As such, a single chamber design that is free of moving parts was presented in this work. The concept for this novel regenerative system relies on gravity and a liquid medium to convey dissolved sodium hydride in a hydride-borohydride solution from cold to hot regions in a continuous circuit. Such a liquid transport medium could allow for operation below 500oC while stabilizing the hydride from thermal decomposition. Investigations on this system were carried out using a custom pressure differential thermal analyzer that was able to operate above temperatures of 700oC and pressures of 2.2MPa. The results of the experiments provided valuable information concerning the phase diagrams of various hydride-borohydride mixtures. The eutectic composition of the NaH-KBH4 system was found to be 43 mole% NaH. The corresponding eutectic temperature (503oC) was determined using the differential cooling curves. Appreciable NaH decomposition was noticed in mixtures above 59.0 mole% NaH. Mixtures up to 42.5 mole% KH in KBH4 were also investigated. The eutectic composition of the KH-KBH4 binary system was determined by extrapolating the liquidus curve to intersect the solidus curve. The KH-KBH4 eutectic temperature was found to be 390oC at 66 mole% KH. The experimental work successfully demonstrates that thermally unstable hydrides can be obtained in the liquid phase below their melting points, under moderate pressures, when mixed with alkali borohydrides. This significantly lowers the achievable operating temperature of the thermally regenerative electrochemical systems currently proposed. The use of the single chamber design with a hydride-borohydride liquid medium offers numerous advantages including: reduced maintenance, reduced operating temperature, reduced system weight, reduced parasitic losses, increased voltage, and increased reliability. The viability for mid-grade industrial waste heat recovery requires construction of a prototype which optimizes power outputs and explores the hydrodynamic transport of material. / Thesis (Master, Mining Engineering) -- Queen's University, 2009-09-24 14:33:22.627

The implementation of an energy recovery system for retreiving otherways wasted energy is an effective method for reducing the overall energy consumption of a mobile machine. In a fork lift, there are two subsystems that can be effectively modified for recovering energy. These are the driveline and the lift/lower function of the mast. This study focuses on the latter by studying a recovery system whose main component is a hydraulic transformer consisting of a hydraulic motor, a variable displacement pump and an induction motor. Since the flow rate/pressure - ratio can be modified, the utilization of the hydraulic transformer enables downsizing of the accumulator volume. However, the decrease of the gas volume leads to an increase in the compression ratio of the accumulator, which in terms leads to higher gas temperatures after charging and consequently to higher thermal losses during holding phase. In order to reduce these losses, a thermally regenerative unit was implemented to the gas volume of an accumulator to reduce the temperature build up during charging. In this study, the effect of improving the thermal characteristics of the accumulator to the efficiency of the whole energy recovery system is investigated by means of measurements.