Two-stage model predictive stack control for PEM fuel cell systems

Computers & Chemical Engineering, vol. 214, pp. 109791

Abstract

Proton-exchange membrane fuel cells (PEMFCs) play a pivotal role in decarbonizing the transport sector due to their high efficiency and zero local emissions. This work proposes an embedded, nonlinear, two-stage model predictive control (MPC) that optimally allocates the stack supply from the air, hydrogen, and coolant subsystems. A physics-based process model of the stack captures the dominant dynamics of membrane hydration, temperature, and reactant pressures, representing key internal states that influence performance and durability. The two-stage structure separates the optimal economic planning from the real-time tracking MPC, (1) ensuring constraint-compliant regulation of the considered states under highly dynamic operation, (2) maintaining efficient stack operation, and (3) resolving the over-actuated nature of the multi-input system. Experimental validation on a full-scale PEMFC test bench demonstrates a reduction in hydrogen consumption by an average of 5.24 % per kilowatt of electric power compared to a nominal stack control. At the same time, membrane temperature and water content remain within prescribed limits.

Authors 6

1. Nikolai Weber corresponding Aachen Institute of Automatic Control (IRT)

   RWTH Aachen University

   Affiliation as printed

   Institute of Automatic Control, RWTH Aachen University, Campus-Boulevard 30, Aachen, 52074, Germany

2. Daniel Sallach Aachen Chair of Thermodynamics of Mobile Energy Conversion Systems (TME)

   RWTH Aachen University

   Affiliation as printed

   Chair of Thermodynamics of Mobile Energy Conversion Systems, RWTH Aachen University, Forckenbeckstraße 4, Aachen, 52074, Germany

3. Alexandre Ennen Aachen Chair of Thermodynamics of Mobile Energy Conversion Systems (TME)

   RWTH Aachen University

   Affiliation as printed

   Chair of Thermodynamics of Mobile Energy Conversion Systems, RWTH Aachen University, Forckenbeckstraße 4, Aachen, 52074, Germany

4. Maximilian Basler Aachen Institute of Automatic Control (IRT)

   RWTH Aachen University

   Affiliation as printed

   Institute of Automatic Control, RWTH Aachen University, Campus-Boulevard 30, Aachen, 52074, Germany

5. Stefan Pischinger Aachen Chair of Thermodynamics of Mobile Energy Conversion Systems (TME)

   RWTH Aachen University

   Affiliation as printed

   Chair of Thermodynamics of Mobile Energy Conversion Systems, RWTH Aachen University, Forckenbeckstraße 4, Aachen, 52074, Germany

6. Heike Vallery Aachen Institute of Automatic Control (IRT)

   RWTH Aachen University

   Affiliation as printed

   Institute of Automatic Control, RWTH Aachen University, Campus-Boulevard 30, Aachen, 52074, Germany