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Hybrid PV/fuel cell system design and simulation

Article in Renewable Energy · November 2002

DOI: 10.1016/S0960-1481(01)00062-3

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 Renewable Energy 27 (2002) 479–485
www.elsevier.nl/locate/renene

Technical note
Hybrid PV/fuel cell system design and
simulation
Th.F. El-Shatter *, M.N. Eskandar, M.T. El-Hagry
Electronics Research Institute, Dokki, Giza, Egypt

Received 21 November 2000; accepted 24 January 2001

Abstract

In this paper, a hybrid Photovoltaic (PV)-fuel cell generation system employing an electro-
lyzer for hydrogen generation is designed and simulated. The system is applicable for remote
areas or isolated loads. Fuzzy regression model (FRM) is applied for maximum power point
tracking to extract maximum available solar power from PV arrays under variable insolation
conditions. The system incorporates a controller designed to achieve permanent power supply
to the load via the PV array or the fuel cell, or both according to the power available from
the sun. Also, to prevent corrosion of the electrolyzer electrodes after sunset, i.e. when its
current drops to zero, the electric storage device is designed so as to isolate the electrolyte
from the electrolysis cell.  2002 Elsevier Science Ltd. All rights reserved.

1. Introduction

Renewable energy sources (solar, wind, etc) are attracting more attention as alter-
native energy sources to conventional fossil fuel energy sources. This is not only
due to the diminishing fuel sources, but also due to environmental pollution and
global warming problems. Among these sources is the solar energy, which is the
most promising, as the fabrication of less costly PV devices becomes a reality. With
increased penetration of solar PV devices, various antipollution apparatus can be
operated such as water purification through electrochemical processing and stopping
desert expansion by PV water pumping with tree plantation.
However, control problems arise due to large variances of PV output power under
different insolation levels. To overcome this problem, PV power plants are integrated

* Corresponding author.

0960-1481/02/$ - see front matter  2002 Elsevier Science Ltd. All rights reserved.
PII: S 0 9 6 0 - 1 4 8 1 ( 0 1 ) 0 0 0 6 2 - 3
480 T.F. El-Shatter et al. / Renewable Energy 27 (2002) 479–485

with other power sources or storage system such as hydrogen generator, storage and
fuel cells.
The fuel cell (FC) is an electrochemical device that produces direct current elec-
tricity through the reaction of hydrogen and oxygen in the presence of an electrolyte.
They are an attractive option for use with intermittent sources of generation, like
the PV, because of high efficiency, fast load response, modularity, and fuel flexibility.
Unlike a battery, a FC does not require recharging. Their feasibility in coordination
with PV systems has been successfully demonstrated for both grid-connected and
stand alone applications [1]. Other advantages of FC are the reusability of exhaust
heat, on-site installation, and diversity of fuels. The fuel for the FC can be hydrogen
or any other hydrogen-containing compound, which on reprocessing can produce
hydrogen. The use of electrolysis to produce hydrogen from water is an efficient
method from very small to very large scales. Additionally, when PV is used with
the electrolyzer, it is the cleanest source of hydrogen with no pollutants produced. On
the small scale, a PV array coupled to an electrolyzer and H2 storage tank provides a
flexible system, which could be installed in any location with little maintenance.
In this paper a 2.24 kW PV-fuel cell hybrid generation system is designed. An
electrolyzer coupled to the PV array is employed for hydrogen production. Maximum
power tracking for PV array is achieved using fuzzy regression. A controller is
designed to ensure continuous constant power generation through the day and after
sunset via the PV and fuel cell stack. Protection of the electrolyzer electrodes, a
novel H2 storage device is used to isolate the electrolyte from the electrolysis cell
and inject N2 to protect electrodes from corrosion. Electrical models for each of the
system components are introduced. The system is simulated using Matlab software.
The system characteristics obtained from simulation are analyzed.

1.1. System description

The proposed PV–electrolyzer–FC system is shown in Fig. 1. The major compo-

nents of the system are: a polycrystalline PV array Solarex module type MSX-56,
a Unipolar Stuart cell electrolyzer, a hydrogen storage tank, proton exchange mem-

Fig. 1. Isolated hybrid PV–FC generation system.

 T.F. El-Shatter et al. / Renewable Energy 27 (2002) 479–485 481

brane (PEM) fuel cell stack, and the 72 dc V, 31 A load. A control system is
employed to monitor the state of the system, and control power and hydrogen flows.

1.2. PV subsystem

The power generation system with a PV system has two application types: a local
(isolated) type and an interconnected (grid connected) type. The isolated type system
works independent of other power systems, where the load locally consumes the
electric power from the PV system. The output power of the PV system, however,
fluctuates depending on solar insolation and surface temperature. Then a storage
system must be used to deliver the required power at lower insolation levels and
during the night. Fig. 2 shows the measured insolation levels during one year (1996).
The panel surface temperature varies between 14 and 60°C during the year. The
MPP voltage and current Vm, Im respectively are determined on-line using FRM [2].
The fuzzy model input parameters are:

1. The solar insolation incident on the panel surface (W).

2. The panel surface temperature (T).

Fig. 2. Solar insolation against time.

482 T.F. El-Shatter et al. / Renewable Energy 27 (2002) 479–485

The determined MPP current is fed to the electrolyzer model to calculate the amount
of H2 generated. The H2 is fed with the amount of air required for FC operation.

2. Electrolyzer subsystem

The Unipolar Stuart cell is a high efficiency low maintenance, rugged and reliable
cell. Each electrode has a single polarity producing either H2 (cathode) or O2 (anode).
The electrolyzer consists of a number of cells isolated from one another in separate
cell compartments. Cell voltage under normal operating conditions are in the range
of 1.7–1.9 V. Circulation of the electrolyte is facilitated by the H2 and O2 gases
rising in the channels formed between the respective electrodes and cell separator.
The operating temperature of the electrolyzer does not exceed 70°C, thus reducing
the material constraints. H2 is directly produced at 99.9% purity. Also the current
efficiency is 100%, and hence the hydrogen production rate [3] is:
XHZ⫽5.18e−6 Ie mole/s.
Where Ie is the current between electrodes. H2 is stored at 3 bar in a tank to feed
the FC at low insolation levels and hence supply the required load power.

3. Fuel cell subsystem

However, an important factor affects the electrolysis process, which should be

considered in the system design. This factor takes place after sunset when the electro-
lyzer current drops to zero, which means that the electrolyzer must be kept under
protective voltage in order to prevent the cathodic potentials from being excessively
attacked by active corrosion. To overcome this defect, the proposed electric storage
device is designed to isolate the electrolyte from the electrolysis cell and inject N2
to the electrolyzer to protect electrodes from corrosion as shown in Fig. 1.
Proton Exchange Membrane (PEM) fuel cells stack is used. The PEM uses a
polymer membrane as its electrolyte. With such solid polymer electrolyte, electrolyte
loss is not an issue with regard to stack life. H2 produced by the electrolyzer is
consumed at the anode, yielding electrons at the anode and producing H2 ions, which
enter the electrolyte. At the cathode, H2 combines with H2 ions to produce water,
which is rejected from the back of the cathode into the oxidant gas stream as the
PEM operates at 75°C, water produced is carried out of the FC by excess oxidant
flow [4].
In the proposed system air is used as the oxidant, cell pressure is atmospheric and
cell temperature 70°C. Current density is designed as 400 mA/cm2. This leads to
the use of 90 fuel cells in a stack. At atmospheric pressure, Nernest equation relates
the electrical performance of the FC to the state variables [5]:
0.5
R.T xH2xO2
Vo⫽Eo⫹ ln
2F xH2O
 T.F. El-Shatter et al. / Renewable Energy 27 (2002) 479–485 483

where

Vo Open circuit reversible cell potential (V)

Eo Standard reversible cell potential (V)
Xi Mole fractions of species (g mole)

Under load cell voltages are affected by ohmic losses, anode and cathode polariz-
ation, and temperature. Neglecting polarization losses, the cell voltage under load is:
V⫽Vo⫺iAR⫺b log(iA)
where

i current density
A cell area
R ohmic resistance
b Tafel slope

Fig. 3. Photovoltaic output power against time.

484 T.F. El-Shatter et al. / Renewable Energy 27 (2002) 479–485

Fig. 4. Output voltage against current density for PEMFC.

4. Results

The proposed system is represented in the simulink form under the Matlab. The
output simulation results are shown in Figs. 3 and 4. Fig. 3 shows the PV output
power during the year. The output from the PV array is varies from season to another
as shown. Fig. 4 shows the voltage against the current density for the Fuel cell. The
output power from the FC is independent on the fluctuations in the solar insolation.
Table 1 shows the amount of Im, sun hours/day, H2 and Pfc output.

5. Conclusion

1. The electrolyzer can be used to generate H2 during excess of power from PV.

Table 1
The amount of Im, sun hours/day, H2 and Pfc output

Im (A) Sun hours/day H2 (g mole) Pfc (kW/day)

Summer 22.786 10 4.249 11.299

Autumn 19.77 8 2.949 7.842
Winter 16.997 6 1.902 5.058
Spring 20.705 10 3.865 10.278
 T.F. El-Shatter et al. / Renewable Energy 27 (2002) 479–485 485

2. The generated H2 can be stored in a tank for lower insolation levels or at night
FC operation.
3. The pumping for irrigation can be operated at night for minimizing the losses
of water.

References

[1] Ro K, Rahman S. Two-loop controller for maximizing performance of a grid-connected photovoltaic-

fuel cell hybrid power plant. IEEE Trans Energy Conver 1998;13(3):276–81.
[2] Elshatter TF, Elhagree MT, Aboueldahab ME, Elkousy AA. Fuzzy modelling and simulation of photo-
voltaic system. In: Proceedings of the 14th European Photovoltaic Solar Energy Conference, Barce-
lona, Spain, 30 June–4 July 1997.
[3] Sapru K, Stetson NT, Ovshinsky SR, Yang J, Fritz G, Fairlie M, Stuart ATB. Development of a
small scale hydrogen production–storage system for hydrogen applications. IECEC’s 97:1947–52.
[4] Hirschenhofer JH. Fuel cell status. IECEC’s 1995:165–170.
[5] Lukas MD, Lee KY, Ghezel-Ayagh H. Development of a stack simulation model for control study
on direct reforming molten carbonate fuel cell power plant. IEEE Trans Energy Conver
1999;14(4):1651–7.

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