Man-Portable Power Generation Devices: Product Design and Supporting Algorithms

A methodology for the optimal design and operation of microfabricated fuel cell systems is proposed and algorithms for relevant optimization problems are developed. The methodology relies on modeling, simulation and optimization at three levels of modeling detail. The first class of optimization problems considered are parametric mixed-integer linear programs and the second class are bilevel programs with nonconvex inner and outer programs; no algorithms exist currently in the open literature for the global solution of either problem in the form considered here. Microfabricated fuel cell systems are a promising alternative to batteries for manportable power generation. These devices are potential consumer products that comprise a more or less complex chemical process, and can therefore be considered chemical products. With current computational possibilities and available algorithms it is impossible to solve for the optimal design and operation in one step since the devices considered involve complex geometries, multiple scales, time-dependence and parametric uncertainty. Therefore, a methodology is presented based on decomposition into three levels of modeling detail, namely system-level models for process synthesis, intermediate fidelity models for optimization of sizes and operation, and detailed, computational fluid dynamics models for geometry improvement. Process synthesis, heat integration and layout considerations are addressed through the use of lumped algebraic models, general enough to be independent of detailed design choices, such