Performance characteristics of a novel tubular-shaped passive direct methanol fuel cell

The present work consists of a tubular-shaped direct methanol fuel cell (DMFC) that is operated completely passively with methanol solution stored in a central fuel reservoir. The benefit of a tubular-shaped DMFC over a planar-shaped DMFC is the higher instantaneous volumetric power energy density (power/volume) associated with the larger active area provided by the tubular geometry. Membrane electrode assemblies (MEAs) with identical compositions were installed in both tubular and planar-shaped, passive DMFCs and tested with 1, 2, and 3 M methanol solutions at room temperature. The peak power density for the tubular DMFC was 19.0 mW cm⁻² and 24.5 mW cm⁻² while the peak power density for the planar DMFC was 20.0 mW cm⁻² and 23.0 mW cm⁻² with Nafion^® 212 and 115 MEAs, respectively. Even though the performance of the fuel cell improved with each increase in methanol concentration, the fuel and energy efficiencies decreased for both the tubular and planar geometries due to increased methanol crossover. The tubular DMFC experienced higher methanol crossover potentially due to a higher static fluid pressure in the anode fuel reservoir (AFR) caused by the vertical orientation of the tubular fuel reservoir. The performance of the tubular DMFC in this work represents an 870% improvement in power density from the previous best, passive, tubular DMFC found in the literature.     

Effect of the porous carbon layer in the cathode gas diffusion media on direct methanol fuel cell performances

The effect of cathode gas diffusion media with microporous layers (MPLs) on direct methanol fuel cell (DMFC) performances is studied by combining electrochemical analysis and physicochemical investigation. The membrane electrode assemblies (MEAs) using MPL-modified cathode gas diffusion layers (GDLs, GDL-1) showed slightly better performances (117 mW cm⁻²) at 0.4 V and 70 °C than commercial GDL (SIGRACET^® product version: GDL-35BC, SGL Co.) DMFC MEAs (110 mW cm⁻²). This might be due to high gas permeability, uniform pore distributions, and low water transport coefficient including methanol crossover. For GDL-1, the air permeability was 31.0 cm³ cm⁻² s⁻¹, while the one for SGL 35BC GDLs was 21.7 cm³ cm⁻² s⁻¹. Also, the GDL-1 in the pore-size distribution diagrams had distinct peaks due to more uniform distributions of macropores and micropores with smaller holes between aggregates of carbon particles compared to GDL-35 BC as confirmed by SEM images. Furthermore, the MEA using GDL-1 for the cathode had a lower water transfer coefficient compared to an MEA with a commercial 35 BC GDL.     

Performance of an integrated composite membrane electrode assembly in DMFC

We report here the performance of a metal-based integrated composite membrane electrode assembly (IC-MEA) in direct methanol fuel cell (DMFC). The IC-MEA integrates the multi-functions of a conventional MEA, gas diffusion layer (GDL) and current collector. It was fabricated by impregnating Nafion electrolyte into a sandwiched structure containing expanding-Polytetrafluoroethylene (e-PTFE) and porous titanium sheets and subsequently coating with catalyst layer and microporous layer (MPL). While operating with air and 2 M methanol under ambient pressure, the IC-MEA in DMFC can yield a maximum power density of 19 mW cm⁻² at 26 °C, higher than a in-house made Nafion 115 MEA under the same working conditions. The IC-MEAs has been successfully applied to planar multi-cell stacks.     

The influence of gas diffusion layer wettability on direct methanol fuel cell performance: A combined local current distribution and high resolution neutron radiography study

The influence of the anode and cathode GDL wettability on the current and media distribution was studied using combined in situ high resolution neutron radiography and locally resolved current distribution measurements. MEAs were prepared by vertically splitting either the anode or cathode carbon cloth into a less hydrophobic part (untreated carbon cloth ‘as received’) and a more hydrophobic part (carbon cloth impregnated by PTFE dispersion). Both parts were placed side by side to obtain a complete electrode and hot-pressed with a Nafion membrane. MEAs with partitioned anode carbon cloth revealed no difference between the untreated and the hydrophobised part of the cell concerning the fluid and current distribution. The power generation of both parts was almost equal and the cell performance was similar to that of an undivided MEA (110 mW cm⁻², 300 mA cm⁻², 70 °C). In contrast, MEAs with partitioned cathode carbon cloth showed a better performance for the hydrophobised part, which contributed to about 60% of the overall power generation. This is explained by facilitated oxygen transport especially in the hydrophobised part of the cathode gas diffusion layer. At an average current density of 300 mA cm⁻², a pronounced flooding of the cathode flow field channels adjacent to the untreated part of GDL led to a further loss of performance in this part of the cell. The low power density of the untreated part caused a significant loss of cell performance, which amounted to less than 40 mW cm⁻² (at 300 mA cm⁻²).     

Study on the membrane electrode assembly fabrication with carbon supported cobalt triethylenetetramine as cathode catalyst for proton exchange membrane fuel cell

An improved fabrication technique for conventional hot-pressed membrane electrode assemblies (MEAs) with carbon supported cobalt triethylenetetramine (CoTETA/C) as the cathode catalyst is investigated. The V-I results of PEM single cell tests show that addition of glycol to the cathode catalyst ink leads to significantly higher electrochemical performance and power density than the single cell prepared by the traditional method. SEM analysis shows that the MEAs prepared by the conventional hot-pressed method have cracks between the cathode catalyst layer and Nafion membrane, and the contact problem between cathode catalyst layer and Nafion membrane is greatly suppressed by addition of glycol to the cathode catalyst ink. Current density-voltage curve and impedance studies illuminate that the MEAs prepared by adding glycol to the cathode catalyst ink have a higher electrochemical surface area, lower cell ohmic resistance, and lower charge transfer resistance. The effects of CoTETA/C loading, Nafion content, and Pt loading are also studied. By optimizing the preparation parameters of the MEA, the as-fabricated cell with a Pt loading of 0.15 mg cm⁻² delivers a maximum power density of 181.1 mW cm⁻², and a power density of 126.2 mW cm⁻² at a voltage of 0.4 V.     

Alkyl chain modified sulfonated poly(ether sulfone) for fuel cell applications

A new alkyl chain modified sulfonated poly(ether sulfone) (mPES) was synthesized and formed into membranes. The MEAs were tested in the PEMFC and evaluated systematically in the DMFC by varying the methanol concentration from 0.5 to 5.0 M at 60 °C and 70 °C. The synthesized mPES copolymer has been characterized by nuclear magnetic resonance spectroscopy, fourier transform infrared spectroscopy, thermogravimetric analysis, and gel permeation chromatography. The proton conductivity of the resulting membrane is higher than the threshold value of 10⁻² S cm⁻¹ at room temperature for practical PEM fuel cells. The membrane is insoluble in boiling water, thermally stable until 250 °C and shows low methanol permeability. In the H₂/air PEMFC at 70 °C, a current density of 600 mA cm⁻² leads to a potential of 637 mV and 658 mV for 50 μm thick mPES 60 and Nafion NRE 212, respectively. In the DMFC, mPES 60's methanol crossover current density is 4 times lower than that for Nafion NRE 212, leading to higher OCV values and peak power densities. Among all investigated conditions and materials, the highest peak power density of 120 mW cm⁻² was obtained with an mPES 60 based MEA at 70 °C and a methanol feed of 2 M.     

Performance enhancement of membrane electrode assemblies with plasma etched polymer electrolyte membrane in PEM fuel cell

In this work, a surface modified Nafion 212 membrane was fabricated by plasma etching in order to enhance the performance of a membrane electrode assembly (MEA) in a polymer electrolyte membrane fuel cell. Single-cell performance of MEA at 0.7 V was increased by about 19% with membrane that was etched for 10 min compared to that with untreated Nafion 212 membrane. The MEA with membrane etched for 20 min exhibited a current density of 1700 mA cm⁻² at 0.35 V, which was 8% higher than that of MEA with untreated membrane (1580 mA cm⁻²). The performances of MEAs containing etched membranes were affected by complex factors such as the thickness and surface morphology of the membrane related to etching time. The structural changes and electrochemical properties of the MEAs with etched membranes were characterized by field emission scanning electron microscopy, Fourier transform-infrared spectrometry, electrochemical impedance spectroscopy, and cyclic voltammetry.     

The effect of Nafion content in a graphitized carbon nanofiber-based anode for the direct methanol fuel cell

The performance and stability of a direct methanol fuel cell (DMFC) with membrane electrode assemblies (MEA) using different Nafion^® contents (30, 50 and 70 wt% or MEA30, MEA50 and MEA70, respectively) and graphitized carbon nanofiber (GNF) supported PtRu catalyst at the anode was investigated by a constant current measurement of 9 days (230 h) in a DMFC and characterization with various techniques before and after this measurement. Of the pristine MEAs, MEA50 reached the highest power and current densities. During the 9-day measurement at a constant current, the performance of MEA30 decreased the most (−124 μV h⁻¹), while the MEA50 was almost stable (−11 μV h⁻¹) and performance of MEA70 improved (+115 μV h⁻¹). After the measurement, the MEA50 remained the best MEA in terms of performance. The optimum anode Nafion content for commercial Vulcan carbon black supported PtRu catalysts is between 20 and 40 wt%, so the GNF-supported catalyst requires more Nafion to reach its peak power. This difference is explained by the tubular geometry of the catalyst support, which requires more Nafion to form a penetrating proton conductive network than the spherical Vulcan. Mass transfer limitations are mitigated by the porous 3D structure of the GNF catalyst layer and possible changes in the compact Nafion filled catalyst layers during constant current production.     

Methanol permeability and performance of Nafion-zirconium phosphate composite membranes in active and passive direct methanol fuel cells

Methanol crossover through polymer electrolyte membranes represents one of the major problems to be solved in order to improve direct methanol fuel cell (DMFC) performance. With this aim, Nafion/zirconium phosphate (ZrP) composite membranes, with ZrP loading in the range 1-6 wt%, were prepared by casting from mixtures of gels of exfoliated ZrP and Nafion 1100 dispersions in dimethylformamide. These membranes were characterised by methanol permeability, swelling and proton conductivity measurements, as well as by tests in active and passive DMFCs in the temperature range 30-80 °C. Increase in filler loading results in a decrease in both methanol permeability and proton conductivity. As a consequence of the reduced conductivity the power density of active DMFCs decreases with increasing ZrP loading (from 46 to 32 mW cm⁻² at 80 °C). However, due to the lower methanol permeability, the room temperature Faraday efficiency of passive DMFCs, with 20 mA cm⁻² discharge current, nearly doubles when Nafion 1100 is replaced by the composite membrane containing 4 wt% ZrP.     

Chemical modification of Nafion membrane with 3,4-ethylenedioxythiophene for direct methanol fuel cell application

Nafion 117 membranes were modified by in situ chemical polymerization of 3,4-ethylenedioxythiophene using H₂O₂ as oxidant for direct methanol fuel cell application. Methanol permeability and proton conductivity of the poly(3,4-ethylenedioxythiophene)-modified Nafion membranes as a function of temperature were investigated. An Arrhenius-type dependency of methanol permeability and proton conductivity on temperature exists for all the modified membranes. Compared with Nafion 117 membrane at 60 °C, the methanol permeability of these modified membranes is reduced from 30% to 72%, while the proton conductivity is decreased from 4% to 58%, respectively. Because of low methanol permeability and adequate proton conductivity, the DMFC performances of these modified membranes were better than that of Nafion 117 membrane. A maximum power density of 48.4 mW cm⁻² was obtained for the modified membrane, while under same condition Nafion 117 membrane got 37 mW cm⁻².     

Design of a MEA with multi-layer electrodes for high concentration methanol DMFCs

According to the conventional MEA test, methanol and water crossover are the main factors to determine performance of a passive DMFC. Thus, to ensure the high cell performance of a passive DMFC using high concentration methanol of 50–95 vol%, the MEA in this study introduces the barrier layer to limit the crossover of high concentration methanol, a hydrophobic layer to reduce water crossover, and a hydrophilic layer to enhance the water recovery from the cathode to the anode. The functional layers of the MEA have the effect of improving the performance of the passive DMFC by decreasing the methanol and water crossover. In spite of the operation with 95 vol% methanol, the MEA with multi-layer electrodes for high concentration methanol DMFCs shows a maximum power density of 35.1 mW cm⁻² and maintains a high power density of 30 mW cm⁻² (0.405 V) under constant current operation.     

PBI-based composite membranes for polymer fuel cells

In the present study poly(2,2-(2,6-pyridin)-5,5-bibenzimidazole) was used for the preparation of novel MEAs for high-temperature polymer fuel cells (HT-PEMFCs). We prepared hybrid materials with two types of silica fillers in order to increase the MEA performances using this polymer. The membranes were characterized in terms of their microstructure and thermal stability. Cell operation tests and Electrochemical Impedance Spectroscopy were used for the characterization of the MEAs. A maximum power density of about 80 mW cm⁻² was obtained at 300 mA cm⁻² by using an imidazole-modified silica filler. The EIS technique showed that the fillers chiefly help to reduce the charge transfer resistance of the cathodic side. The gas transfer resistance may be neglected with respect to R_ct, at least at low current densities.     

Polyelectrolyte membranes based on hydrocarbon polymer containing fullerene

In the present study, composite polyelectrolyte membranes were prepared from sulfonated polystyrene and fullerene. The additive effect of the fullerene on the membrane properties – electric resistance, mechanical strength, oxidation resistance, and methanol permeability – were measured. The addition of fullerene improved the oxidation resistance, and reduced the methanol crossover. The mechanical strength of the fullerene-composite membrane, on the other hand, was not improved. The direct methanol fuel cell (DMFC) based on a 1.4 wt% fullerene-composite membrane showed the highest power density of 47 mW cm⁻² at the current density of 200 mA cm⁻² (this value is 60% of the Nafion-based DMFC). The transmission electron microscopy (TEM) observations suggest that the improved dispersity of the fullerene and the reduced number of micropores in the membranes would improve its performance in the fuel cell.     

A novel self-humidifying membrane electrode assembly with water transfer region for proton exchange membrane fuel cells

A novel self-humidifying membrane electrode assembly (MEA) with the active electrode region surrounded by a unactive “water transfer region (WTR)” was proposed to achieve effective water management and high performance for proton exchange membrane fuel cells (PEMFCs). By this configuration, excess water in the cathode was transferred to anode through Nafion membrane to humidify hydrogen. Polarization curves and power curves of conventional and the self-humidifying MEAs were compared. The self-humidifying MEA showed power density of 85 mW cm⁻² at 0.5 V, which is two times higher than that of a conventional MEA with cathode open. The effects of anode hydrogen flow rates on the performance of the self-humidifying MEA were investigated and its best performance was obtained at a flow rate of 40 ml min⁻¹. Its performance was the best when the environmental temperature was 40 °C. The performance of the self-humidifying MEA was slightly affected by environmental humidity. The area of WTR was optimized, and feasible area ratio of the self-humidifying MEA was 28%.     

Direct alkaline fuel cell for multiple liquid fuels: Anode electrode studies

A direct alkaline fuel cell with a liquid potassium hydroxide solution as an electrolyte is developed for the direct use of methanol, ethanol or sodium borohydride as fuel. Three different catalysts, e.g., Pt-black or Pt/Ru (40 wt.%:20 wt.%)/C or Pt/C (40 wt.%), with varying loads at the anode against a MnO₂ cathode are studied. The electrodes are prepared by spreading the catalyst slurry on a carbon paper substrate. Nickel mesh is used as a current-collector. The Pt–Ru/C produces the best cell performance for methanol, ethanol and sodium borohydride fuels. The performance improves with increase in anode catalyst loading, but beyond 1 mg cm⁻² does not change appreciably except in case of ethanol for which there is a slight improvement when using Pt–Ru/C at 1.5 mA cm⁻². The power density achieved with the Pt–Ru catalyst at 1 mg cm⁻² is 15.8 mW cm⁻² at 26.5 mA cm⁻² for methanol and 16 mW cm⁻² at 26 mA cm⁻² for ethanol. The power density achieved for NaBH₄ is 20 mW cm⁻² at 30 mA cm⁻² using Pt-black.     

The influence of anode gas diffusion layer on the performance of low-temperature DMFC

The influence of the anode gas diffusion layers (GDLs) on the performances of low-temperature DMFCs, and the properties of mass transport and CO₂ removal on these anode GDLs were investigated. The membrane electrode assembly (MEA) based on the hydrophilic anode GDL, which consisted of the untreated carbon paper and hydrophilic anode micro-porous layer (comprised carbon black and 10 wt.% Nafion), showed the highest power density of 13.4 mW cm⁻² at 30 °C and ambient pressure. The performances of the MEAs tended to decline with the increase of the PTFE content in the anode GDLs due to the difficulty of methanol transport. The contact angle measurements revealed that the wettabilities of the anode GDLs decreased as the increase of PTFE content. The wettabilities of the GDLs were improved by addition of hydrophilic Nafion ionomer to the GDLs. From the visualizations of CO₂ gas bubbles dynamics on the anodes using a transparent cell, it was observed that uniform CO₂ gas bubbles with smaller size formed on hydrophilic anode GDLs. And bubbles with larger size were not uniform over the hydrophobic anode GDLs. It was believed that adding PTFE to the anode GDL was not helpful for improving the CO₂ gas transport in the anode GDL of the low-temperature DMFC.     

Sulfonated poly(ether ether ketone) as an ionomer for direct methanol fuel cell electrodes

Sulfonated poly(ether ether ketone) has been investigated as an ionomer in the catalyst layer for direct methanol fuel cells (DMFC). The performance in DMFC, electrochemical active area (by cyclic voltammetry), and limiting capacitance (by impedance spectroscopy) have been evaluated as a function of the ion exchange capacity (IEC) and content (wt.%) of the SPEEK ionomer in the catalyst layer. The optimum IEC value and SPEEK ionomer content in the electrodes are found to be, respectively, 1.33 meq. g⁻¹ and 20 wt.%. The membrane-electrode assemblies (MEA) fabricated with SPEEK membrane and SPEEK ionomer in the electrodes are found to exhibit superior performance in DMFC compared to that fabricated with Nafion ionomer due to lower interfacial resistance in the MEA as well as larger electrochemical active area. The MEAs with SPEEK membrane and SPEEK ionomer also exhibit better performance than that with Nafion 115 membrane and Nafion ionomer due to lower methanol crossover and better electrode kinetics.     

Effects of hot pressing conditions on the performances of MEAs for direct methanol fuel cells

The effects of hot pressing conditions (hot pressing temperature, pressure and time) on the performances of membrane electrode assemblies for direct methanol fuel cells were investigated. The performances of membrane electrode assemblies (MEAs) were characterized by the polarization curves and electrochemical impedance spectra (EIS). The surface morphologies of the electrodes were observed by scanning electron microscopy (SEM). The compression ratios of electrodes were determined by testing the thicknesses of the anodes and the cathodes before and after the hot pressing process. The MEA which was hot pressed at 135 °C under 80 kg cm⁻² for 90 s, showed the highest power density of 46.0 mW cm⁻² at 80 °C and ambient pressure. As the hot pressing temperature, pressure and time increased, the compression ratios of the anodes and cathodes increased, and the activating time required for MEA to reach optimum performance increased, too. The cell resistances of the MEAs hot pressed at higher hot pressing temperature (135 °C) and pressure (120 kg cm⁻²), or for longer time (90 s), decreased because of the good contact between the membrane and electrodes. The MEAs that were hot pressed under higher temperature (135 °C) and higher pressure (120 kg cm⁻²) benefited for long-time cell operating.     

Nanoimprinted electrodes for micro-fuel cell applications

Nanoimprint lithography (NIL) was used to fabricate electrodes with high specific Pt surface areas for use in micro-fuel cell devices. The Pt catalyst structures were characterized electrochemically using cyclic voltammetry and were found to have electrochemical active surface areas (EAS) ranging from 0.8 to 1.5 m² g⁻¹ Pt. These NIL catalyst structures were tested in fuel cell membrane electrode assemblies (MEA) by directly embossing a Nafion 117 membrane. The features of the mold were successfully transferred to the Nafion and a 7.5 nm thin film of Pt was deposited at a wide angle to form the anode catalyst layer. The resulting MEA yielded a very high Pt utilization of 15,375 mW mg⁻¹ Pt compared to conventionally prepared MEAs (820 mW mg⁻¹ Pt). Embossing pattern transfer was also demonstrated for spin casted Nafion films which could be used for new applications.     

Factors affecting methanol transport in a passive DMFC employing a porous carbon plate

The effect of the pore structure and thickness of the porous carbon plate, PCP, as well as the gas barrier thickness on the methanol transport and the performance of a passive DMFC under the different cell voltages of 0.1, 0.2 and 0.3 V using different methanol concentrations was investigated. As a result of the mass transfer restrictions by employing the PCP, high methanol concentrations over 20 M could be efficiently used to produce the relatively high power density of 30 mW cm⁻² for more than 10 h. The DMFC was operated under limiting current conditions in all the PCPs at 0.1 and 0.2 V to more than 20 M. The main factors for controlling the methanol transport were the barrier of the gas layer with CO₂, which was formed between the anode surface and the PCP and the properties of the PCP. At the low current densities of less than 60 mA cm⁻², when no CO₂ bubbles are emitted, both the pore structure and thickness of the PCP did not affect the methanol transport and the current voltage relationship. At the higher current densities, CO₂ bubbles were evolved through the PCP and different resistances to the methanol transport were observed depending on the PCP pore structure and thickness. The CO₂ gas layer between the MEA and the PCP caused a major resistivity for the methanol transport, and its resistivity increased with its thickness increasing. By using the PCP at 0.1 V, the energy density of the passive DMFC was significantly increased, e.g., more than seven times.