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The Solid Oxide Fuel Cell (SOFC) is a promising technology for electricity generation. It converts the chemical energy of the fuel gas directly to electricity energy and therefore, very high electrical efficiencies can be achieved. The high operating temperature of the SOFC also provides excellent possibilities for cogeneration applications. In addition to producing power very efficiently, the SOFC has the potential to concentrate CO₂ with a minimum of an overall efficiency loss. Concentration of CO₂ is a desirable feature of a power generation process so that the CO₂ may be subsequently sequestered thus preventing its contribution to global warming. The primary purpose of this research project was to investigate the role of the SOFC technology in power generation processes and explore its potential for CO₂ capture in power plants. <br /><br /> This thesis introduces an AspenPlus^TM SOFC stack model based on the natural gas feed tubular internal reforming SOFC technology. It was developed utilizing existing AspenPlus^TM functions and unit operation models. This SOFC model is able to provide detailed thermodynamic and parametric analysis of the SOFC operation and can easily be extended to study the entire process consisting of the SOFC stack and balance of plant. <br /><br /> Various SOFC-based power generation cycles were studied in this thesis. Various options for concentrating CO₂ in these power generation systems were also investigated and discussed in detail. All the processes simulations were implemented in AspenPlus^TM extending from the developed natural gas feed tubular SOFC stack model. The study shows that the SOFC technology has a promising future not only in generating electricity in high efficiency but also in facilitating CO₂ concentration, but the cost of the proposed processes still need be reduced so SOFCs can become a technical as well as economic feasible solution for power generation.

This project is aimed at developing and demonstrating highly conductive, lightweight, and low-cost thermoplastic blends to be used as flow field bipolar plates for polymer electrolyte membrane (PEM) fuel cells. <br><br> The research is focused on designing, prototyping, and testing carbon-filled thermoplastic composites with high electrical conductivity, as well as suitable mechanical and process properties. <br><br> The impact of different types of fillers on the composite blend properties was evaluated, as well as the synergetic effect of mixtures of fill types within a thermoplastic polymer matrix. A number of blends were produced by varying the filler percentages. Composites with loadings up to 65% by weight of graphite, conductive carbon black, and carbon fibers were investigated. Research results show that three-filler composites exhibit better performance than single or two-filler composites. <br><br> Injection and compression molding of the conductive carbon filled polypropylene blend was used to fabricate the bipolar plates. A Thermal Gravimetric Analysis (TGA) was used to determine the actual filler loading of composites. A Scanning Electron Microscope (SEM) technique was use as an effective way to view the microstructure of composite for properties such as edge effects, porosity, and fiber alignment. Density and mechanical properties of conductive thermoplastic composites were also investigated. During this study, it was found that 1:1:1 SG-4012/VCB/CF composites showed better performance than other blends. The highest conductivity, 1900 S/m in in-plane and 156 S/m in through plane conductivity, is obtained with the 65% composite. Mechanical properties such as tensile modulus, tensile strength, flexural modulus and flexural strength for 65% 1:1:1 SG-4012/VCB/CF composite were found to be 584. 3 MPa, 9. 50 MPa, 6. 82 GPa and 47. 7 MPa, respectively, and these mechanical properties were found to meet minimum mechanical property requirements for bipolar plates. The highest density for bipolar plate developed in this project is 1. 33 g/cm³ and is far less than that of graphite bipolar plate. <br><br> A novel technique for metal insert bipolar plate construction was also developed for this project. With a copper sheet insert, the in-plane conductivity of bipolar plate was found to be significantly improved. The performance of composite and copper sheet insert bipolar plates was investigated in a single cell fuel cell. All the composites bipolar plates showed lower performance than the graphite bipolar plate on current-voltage (I-V) polarization curve testing. Although the copper sheet insert bipolar plates were very conductive in in-plane conductivity, there was little improvement in single cell performance compared with the composite bipolar plates. <br><br> This work also investigated the factors affecting bipolar plate resistance measurement, which is important for fuel cell bipolar plate design and material selection. Bipolar plate surface area (S) and surface area over thickness (S/T) ratio was showed to have significant effects on the significance of interfacial contact resistances. At high S/T ratio, the contact resistance was found to be most significant for thermoplastic blends. Other factors such as thickness, material properties, surface geometry and clamping pressure were also found to affect the bipolar plate resistance measurements significantly.

Hydrogen fuel cell technology has emerged as an efficient and clean alternative to internal combustion engines for powering vehicles, and hydrogen powertrains will aid in addressing key environmental issues such as urban air quality and global warming. This work demonstrates the effectiveness of a „hardware-in-loop‟ (HIL) simulation system for validating the safety and effectiveness of control algorithms for a hydrogen fuel cell hybrid passenger vehicle. A significant amount of the work completed in conjunction with the thesis topic was the design and construction of the fuel cell vehicle for competition. Producing a „rolling test bench‟ that generates data to be used to create HIL simulation models required nearly two years of work before an acceptable level of reliability was reached to produce usable data. Some detail will be given in this thesis regarding the infrastructure modifications required to safely build a hydrogen fuel cell vehicle, as well as the design challenges faced in the integration of a fuel cell power module, two electric drive motors, a nickel metal hydride battery, and required power electronics into a small sport utility vehicle originally designed for an internal combustion powertrain. The virtual control validation performed involved designing dynamic models of the systems of interest and performing real-time simulation to ensure that the appropriate controller response is observed. For this thesis, emphasis was placed on several key vehicle control topics. Communication robustness was evaluated to ensure that the complicated vehicle communication network could effectively handle traffic from the six powertrain sub-controllers. Safety algorithms were tested for appropriate response to fault conditions. Control systems were developed and tuned offline reducing the amount of time required for in-vehicle development and testing. Software-in-the-loop simulation was used to check initial code integrity and to validate the hardware-in-the-loop vehicle models. The methodology presented in this work was found to be sufficient for a thorough safety and rationality evaluation of control strategies for hybrid fuel cell vehicles.

Microbial fuel cells were designed and operated using waste activated sludge as a substrate and as a source of microorganisms for the anodic chamber. Waste activated sludge provided a bacterial consortium predisposed to the solubilization of particulate matter and utilization of substrates commonly found in wastewater. Dissolved oxygen and ferricyanide were used as the electron acceptors in the catholytes. Microbial fuel cell comparisons were made while operating under identical conditions but using the two different electron acceptors. Comparisons were based on the electricity production observed during MFC operation, wastewater quality of the waste activated sludge anolytes and the community level physiological profiling of the microbial communities in the anolytes. Electrons liberated during substrate utilization in the anodic chamber traveled to the cathodic chamber where they reduced the electron acceptors. The anode and cathode chambers were connected by a Nafion ® proton exchange membrane to allow for cation migration. Various soluble carbon sources were dosed to the microbial fuel cells at measured intervals during operation via direct injection to the anolyte. During bovine serum albumin dosing, average power production levels reached 0.062 mW and 0.122 mW for the dissolved oxygen microbial fuel cell and the ferricyanide microbial fuel cell, respectively. These were 100% and 25% greater than the power production levels observed throughout the rest of the study. Increases in current production were observed following the dosing of sodium acetate, glucose and bovine serum albumin. No increase in current was observed following glycerol dosing. Sodium acetate dosing triggered an immediate response, while glucose and bovine serum albumin responded in approximately 2 minutes. A chemical oxygen demand mass balance was calculated for both microbial fuel cells. The lack of balance closure was attributed to unmeasured methane production. An accumulation of particulate waste activated sludge components was observed for both microbial fuel cells. The anolyte pH during operation was typically less than waste activated sludge pH, which was attributed to volatile fatty acid accumulation in the anolytes during fermentation processes. Community level physiological profiling was accomplished through the analysis of ecological data obtained with BIOLOG ® ECOplates. Samples were plated and analyzed under anaerobic conditions, mimicking the environment in the anode chamber of the MFCs. ECOplate data were transformed by a logarithmic function prior to principle component analysis. The community level physiological profiling indicated that shifts in the microbial community profile, as measured through the carbon source utilization patterns, occurred throughout acclimation and following the dosing of various carbon source substrates. Shifts due to glycerol dosing differed from shifts due to the dosing of sodium acetate, glucose and bovine serum albumin.

Distributed generation is expected to play a significant role in remedying the many shortcomings in today’s energy market. In particular, fuel cell power generation will play a big part due to several advantages. Still, it is faced with its own challenges to tap into its potential as a solution to the crisis. The responsibilities of the Power Conditioning Unit (PCU), and thus its design, are therefore complex, yet critical to the fuel cell system’s performance and ability to meet the requirements. To this end, the dc-dc converter, considered the most critical component of the PCU for optimum performance, is closely examined. The selected converter is first modeled to gain insight into its behavior for the purpose of designing suitable compensators. MATLAB is then used to study the results using the frequency domain, and it was observed that the converter offers its own unique challenges in terms of closed-loop performance and stability. These limitations must therefore be carefully accounted for and compensated against when designing the control loops to achieve the desired objectives. Negative feedback control to ensure robustness is then discussed. The insertion of a second inner loop in Current Mode Control (CMC) offers several key advantages over single-loop Voltage Mode Control (VMC). Furthermore, the insertion of a Current Error Amplifier (CEA) in Average Current Mode Control (ACMC) helps overcome many of the problems present in Peak Current Mode Control (PCMC) whilst allowing much needed design flexibility. It is therefore well suited for this application in an attempt to improve the dynamic behavior and overcoming the shortcomings inherent in the converter. The modulator and controller for ACMC are then modeled separately and combined with the converter’s model previously derived to form the complete small-signal model. A suitable compensation network is selected based on the models and corresponding Bode plots used to assess the system’s performance and stability. The resulting Bode plot for the complete system verifies that the design objectives are clearly met. The complete system was also built in MATLAB/Simulink, and subjected to external disturbances in the form of stepped load changes. The results confirm the system’s excellent behavior despite the disturbance, and the effectiveness of the control strategy in conjunction with the derived models. To meet the demand in many applications for power sources with high energy density and high power density, it is constructive to combine the fuel cell with an Energy Storage System (ESS). The hybrid system results in a synergistic system that brings about numerous potential advantages. Nevertheless, in order to reap these potential benefits and avoid detrimental effects to the components, a suitable configuration and control strategy to regulate the power flow amongst the various sources is of utmost importance. A robust and flexible control strategy that allows direct implementation of the ACMC scheme is devised. The excellent performance and versatility of the proposed system and control strategy are once again verified using simulations. Finally, experimental tests are also conducted to validate the results presented in the dissertation. A scalable and modular test station is built that allows an efficient and effective design and testing process of the research. The results show good correspondence and performance of the models and control design derived throughout the thesis.

Vehicle design and control is an attractive area of research in that it embodies a convergence of societal need, technical limitation, and emerging capability. Environmental, political, and monetary concerns are driving the automotive industry towards sustainable transportation, manifested as increasing powertrain electrification in a gradual transition to fossil-free energy vectors. From an electrochemical degradation and control systems perspective, this transition introduces significant technical uncertainty. Initial indications are that the initial battery designs will have twice the required capacity due to degradation concerns. As the battery is a major contributor to the cost of these vehicles the over-sizing represents a significant threat to the ability of OEMs to produce cost-competitive vehicles. This potential barrier is further amplified when the combustion engine is removed and battery-electric or fuel-cell hybrid vehicles are considered. This thesis researches the application of model-based design for optimal design of fuel cell hybrid powertrains considering power source degradation. The intent is to develop and evaluate tools that can determine the optimal sizing and control of the powertrain; reducing the amount of over-sizing by numerically optimization rather than a sub-optimal heuristic design. A baseline hybrid fuel cell vehicle model is developed and validated to a hybrid fuel cell SUV designed and built at the University of Waterloo. Lithium-ion battery degradation models are developed and validated to data captured off a hybrid powertrain test stand built as part of this research. A fuel cell degradation model is developed and integrated into the vehicle model. Lifetime performance is modeled for four hybrid control strategies, demonstrating a significant impact of the hybrid control strategy on powertrain degradation. A plug-in variation of the architecture is developed. The capacity degradation of the battery is found to be more significant than the power degradation. Blended and All-electric charge-depleting hybrid control strategies are integrated and lifetime performance is simulated. The blended charge-depleting control strategy demonstrated significantly less degradation than the all-electric strategy. An oversized battery is integrated into the vehicle model and the benefit of oversizing on reducing the battery degradation rate is demonstrated.

There has always been a desire to develop industrial processes that minimize the resources they use, and the wastes they generate. The problem is when new guidelines are forced upon long established processes, such as solvent based coating operations. This means instead of integrating an emission reduction technology into the original design of the process, it is added on after the fact. This significantly increases the costs associated with treating emissions. In this work the ultimate goal is the design of an “add-on” abatement system to treat emissions from solvent based coating processes with high destruction efficiency, and lower costs than systems in current use. Since emissions from processes that utilize solvent based coatings are primarily comprised of volatile organic compounds (VOCs), the treatment of these compounds will be the focus. VOCs themselves contain a significant amount of energy. If these compounds could be destroyed by simultaneously extracting the energy they release, operational costs could be substantially reduced. This thesis examines the use of model-based design to develop and optimize a VOC abatement technology that uses a Solid Oxide Fuel Cell (SOFC) for energy recovery. The model was built using existing HYSYS unit operation models, and was able to provide a detailed thermodynamic and parametric analysis of this technology. The model was validated by comparison to published literature results and through the use of several Design of Experiment factorial analyses. The model itself illustrated that this type of system could achieve 95% destruction efficiency with performance that was superior to that of Thermal Oxidation, Biological Oxidation, or Adsorption VOC abatement technologies. This was based upon design criteria that included ten year lifecycle costs and operational flexibility, as well as the constraint of meeting (or exceeding) current regulatory thresholds.

The Solid Oxide Fuel Cell (SOFC) is a promising technology for electricity generation. It converts the chemical energy of the fuel gas directly to electricity energy and therefore, very high electrical efficiencies can be achieved. The high operating temperature of the SOFC also provides excellent possibilities for cogeneration applications. In addition to producing power very efficiently, the SOFC has the potential to concentrate CO₂ with a minimum of an overall efficiency loss. Concentration of CO₂ is a desirable feature of a power generation process so that the CO₂ may be subsequently sequestered thus preventing its contribution to global warming. The primary purpose of this research project was to investigate the role of the SOFC technology in power generation processes and explore its potential for CO₂ capture in power plants. <br /><br /> This thesis introduces an AspenPlus^TM SOFC stack model based on the natural gas feed tubular internal reforming SOFC technology. It was developed utilizing existing AspenPlus^TM functions and unit operation models. This SOFC model is able to provide detailed thermodynamic and parametric analysis of the SOFC operation and can easily be extended to study the entire process consisting of the SOFC stack and balance of plant. <br /><br /> Various SOFC-based power generation cycles were studied in this thesis. Various options for concentrating CO₂ in these power generation systems were also investigated and discussed in detail. All the processes simulations were implemented in AspenPlus^TM extending from the developed natural gas feed tubular SOFC stack model. The study shows that the SOFC technology has a promising future not only in generating electricity in high efficiency but also in facilitating CO₂ concentration, but the cost of the proposed processes still need be reduced so SOFCs can become a technical as well as economic feasible solution for power generation.

This project is aimed at developing and demonstrating highly conductive, lightweight, and low-cost thermoplastic blends to be used as flow field bipolar plates for polymer electrolyte membrane (PEM) fuel cells. <br><br> The research is focused on designing, prototyping, and testing carbon-filled thermoplastic composites with high electrical conductivity, as well as suitable mechanical and process properties. <br><br> The impact of different types of fillers on the composite blend properties was evaluated, as well as the synergetic effect of mixtures of fill types within a thermoplastic polymer matrix. A number of blends were produced by varying the filler percentages. Composites with loadings up to 65% by weight of graphite, conductive carbon black, and carbon fibers were investigated. Research results show that three-filler composites exhibit better performance than single or two-filler composites. <br><br> Injection and compression molding of the conductive carbon filled polypropylene blend was used to fabricate the bipolar plates. A Thermal Gravimetric Analysis (TGA) was used to determine the actual filler loading of composites. A Scanning Electron Microscope (SEM) technique was use as an effective way to view the microstructure of composite for properties such as edge effects, porosity, and fiber alignment. Density and mechanical properties of conductive thermoplastic composites were also investigated. During this study, it was found that 1:1:1 SG-4012/VCB/CF composites showed better performance than other blends. The highest conductivity, 1900 S/m in in-plane and 156 S/m in through plane conductivity, is obtained with the 65% composite. Mechanical properties such as tensile modulus, tensile strength, flexural modulus and flexural strength for 65% 1:1:1 SG-4012/VCB/CF composite were found to be 584. 3 MPa, 9. 50 MPa, 6. 82 GPa and 47. 7 MPa, respectively, and these mechanical properties were found to meet minimum mechanical property requirements for bipolar plates. The highest density for bipolar plate developed in this project is 1. 33 g/cm³ and is far less than that of graphite bipolar plate. <br><br> A novel technique for metal insert bipolar plate construction was also developed for this project. With a copper sheet insert, the in-plane conductivity of bipolar plate was found to be significantly improved. The performance of composite and copper sheet insert bipolar plates was investigated in a single cell fuel cell. All the composites bipolar plates showed lower performance than the graphite bipolar plate on current-voltage (I-V) polarization curve testing. Although the copper sheet insert bipolar plates were very conductive in in-plane conductivity, there was little improvement in single cell performance compared with the composite bipolar plates. <br><br> This work also investigated the factors affecting bipolar plate resistance measurement, which is important for fuel cell bipolar plate design and material selection. Bipolar plate surface area (S) and surface area over thickness (S/T) ratio was showed to have significant effects on the significance of interfacial contact resistances. At high S/T ratio, the contact resistance was found to be most significant for thermoplastic blends. Other factors such as thickness, material properties, surface geometry and clamping pressure were also found to affect the bipolar plate resistance measurements significantly.