An Integrated Heat Recovery System Design for a Fuel Cell Buggy With Hydrogen Preheating and Thermoelectric Generator

This study presents an integrated heat recovery-proton exchange membrane (IHR-PEM) fuel cell system designed for lightweight vehicles powered by a 2 kW PEM fuel cell. The IHR system captures waste heat through multiple heat exchangers and integrates thermoelectric generator (TEG) modules for electrical regeneration and hydrogen preheating, enhancing PEM fuel cell performance. Utilizing the temperature gradient between the fuel cell's exhaust and the ambient environment, the system effectively converts waste heat into electrical energy, improving energy efficiency. Experimental evaluation under various operating parameters, including cruising speeds, PEM fuel cell loads, rejuvenation conditions, and electrical regeneration strategies, demonstrated the system's effectiveness. Results revealed waste heat absorption of up to 8.5 W and hydrogen preheating by 19 degrees C, leading to an 11.5% increase in electrical power production and a maximum PEM fuel cell efficiency improvement of 11%. This study advances waste heat recovery (WHR) technologies in fuel cell-based transportation, significantly improving energy efficiency and reducing carbon emissions. The findings provide valuable insights into the integration of regenerative WHR systems for lightweight vehicles, fostering the development of sustainable and energy-efficient transportation solutions.