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Multi-stack PEMFC cogeneration system with integrated multi-recovery: experimental characterization and optimization

Author

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  • Hua, Zhipeng
  • Wu, Jintao
  • Tang, Jiong
  • Cao, Xianguang
  • Cai, Shanshan
  • Tu, Zhengkai

Abstract

Multi-stack proton exchange membrane fuel cell (PEMFC) combined heat and power (CHP) systems represent a highly promising solution for high-power, high-efficiency distributed energy generation. This study experimentally investigates a novel six-stack PEMFC-CHP architecture featuring an integrated multi-energy recovery technique. The system comprehensively harvests sensible and latent heat from the cathode exhaust, kinetic energy from expanders, and waste heat from power conversion and auxiliary components. Steady-state and dynamic response characteristics were systematically evaluated under varying electrical loads and coolant pump speeds. The experimental results reveal that at an operating power of 180 kW, the proposed system achieves a remarkable heat recovery rate of 39.2% and an overall energy efficiency of 92.01%. Furthermore, comparative evaluations of operational strategies indicate that rationally selecting the number of active stacks boosts efficiency by 3.62%, while optimizing the spatial arrangement shortens the thermal response time by 11.65% and improves system efficiency by 1.31%. Regarding dynamic control, the step-variation pump control mode yields a 4.65% efficiency gain, whereas the gradual-variation mode effectively reduces parasitic energy inputs. By providing the first empirical validation of multi-recovery on a multi-stack pilot platform, this study establishes essential guidelines for the design of megawatt-scale modular cogeneration systems.

Suggested Citation

  • Hua, Zhipeng & Wu, Jintao & Tang, Jiong & Cao, Xianguang & Cai, Shanshan & Tu, Zhengkai, 2026. "Multi-stack PEMFC cogeneration system with integrated multi-recovery: experimental characterization and optimization," Applied Energy, Elsevier, vol. 420(C).
    • Handle: RePEc:eee:appene:v:420:y:2026:i:c:s0306261926008469
    DOI: 10.1016/j.apenergy.2026.128194
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