Development of a Distributed Test Architecture for Reformed Methanol HT-PEM Fuel Cell Systems: with Real-Time Integration of Simulation and HiL Modules
Authors
Kristensen, Malte Krusborg ; Thorsteinsson, Johann
Term
4. term
Education
Publication year
2025
Submitted on
2025-05-28
Pages
100
Abstract
This thesis develops a distributed test platform for high‑temperature proton exchange membrane fuel cell (HT‑PEMFC) systems that use reformed methanol, intended for combined heat and power (CHP), producing electricity and useful heat, in microgrids. The platform blends real‑time computer simulation with hardware‑in‑the‑loop (HiL), where real equipment runs alongside simulated components, making tests modular, scalable, and close to real operating conditions. A key element is a physical methanol steam reformer test bench that feeds time‑varying gas composition data to a real‑time fuel‑cell model. The fuel‑cell model uses a gray‑box approach—combining basic physics with data‑driven fitting—to reproduce electrical and thermal behavior, and matched experiments with an average relative error of about 8.45%. A mid‑level control layer coordinates the reformer, fuel‑cell, and thermal modules and interfaces with a high‑level energy management system (EMS). A new gas‑composition control strategy limits carbon monoxide (CO) and unconverted methanol ("slip") by adjusting the reformer temperature; tests showed effective shaping of the gas across different flow rates. A full‑system test confirmed that the architecture can handle changing loads, coordinate module behavior, and maintain safety. These results point to potential for degradation studies, remote testing, and supporting wider adoption of HT‑PEMFCs in sustainable energy applications.
Dette speciale beskriver en distribueret testplatform for højtemperatur-protonbyttemembranbrændselsceller (HT‑PEMFC), der bruger reformeret methanol, målrettet kraft-varme (CHP), dvs. samtidig produktion af el og varme, i små, lokale elnet (mikrogrids). Platformen kombinerer realtidssimulering med hardware‑in‑the‑loop (HiL), hvor rigtigt udstyr kører sammen med simulerede komponenter. Det gør test modulære, skalerbare og tæt på virkelige driftsforhold. En central nyhed er et fysisk testbænk for methanoldampreformering, som leverer tidsvarierende gaskompositionsdata til en realtids brændselscellemodel. Modellen er en gray‑box model, der forener grundlæggende fysik med data‑tilpasning for at beskrive elektrisk og termisk adfærd, og den blev valideret mod forsøg med ca. 8,45 % gennemsnitlig relativ fejl. Et styrelag på mellemniveau koordinerer reformer, brændselscelle og termiske moduler og taler sammen med et overordnet energistyringssystem (EMS). En ny styrestrategi for gaskomposition begrænser kulilte (CO) og ikke‑omdannet methanol ("slip") ved at justere reformertemperaturen; test viste effektiv formning af gas ved forskellige gennemstrømninger. En samlet systemtest bekræftede, at arkitekturen kan håndtere skiftende belastninger, koordinere modulernes adfærd og opretholde sikkerhed. Resultaterne peger på et potentiale for degraderingsstudier, fjern‑test og at understøtte bredere brug af HT‑PEMFC i bæredygtige energiløsninger.
[This apstract has been rewritten with the help of AI based on the project's original abstract]
Keywords
HT-PEM ; Methanol Steam Reformation ; Hardware-in-the-Loop ; DTA ; Fuel Cells ; CHP ; Microgrid ; Experimental Framework ; Remote Communication ; Modular System Framework ; Methanol ; Chemcial Hydrides ; HiL ; Fuel Cell Modeling ; Heat Integration ; Optimization ; Real-Time Simulation ; Real-Time Communication ; EMS