Model for the Degradation Performance of a Single‐Cell Direct Methanol Fuel Cell under Varying Operational Conditions

The effect of varying operating parameters on the degradation of a single‐cell direct methanol fuel cell (DMFC) with serpentine flow channels was investigated. Fuel cell internal temperature, methanol concentration, and air and methanol flow rates were varied in experimental tests and fuel cell performance was chronologically recorded. A DMFC semi‐empirical performance model was developed to predict the polarization curves of the DMFC and validated at different operating conditions. Performance degradation was observed and modeled over time by a linear regression model. Unlike previous studies, the cumulative exposure of the operating factors to the fuel cell was considered in the degradation analysis. The degradation model shows the cell voltage generation capacity does not significantly degrade. However, the Tafel slope of the cell changes with cumulative exposure to methanol concentration and air flow, and the ohmic resistance changes with cumulative exposure to temperature, methanol and air flow.     

Electrochemical Evaluation of Porous Non‐Platinum Oxygen Reduction Catalysts for Polymer Electrolyte Fuel Cells

A porous non‐platinum electrocatalyst for the oxygen reduction reaction (ORR), obtained by pyrolysing a cobalt porphyrin precursor, was evaluated by electrochemical means. The reactivity of the non‐platinum ORR catalyst was investigated with a rotating disc electrode (RDE) experimental set up. RDE data were collected in an acidic electrolyte containing N₂, O₂, CO and under mixed reactant O₂/methanol conditions. The electrochemical performance of such‐obtained non‐platinum catalyst is discussed and compared to platinum‐based ORR catalysts. Based on the results collected here, we are able to propose and test possible proton exchange fuel cell (PEFC) operating conditions where non‐platinum ORR catalysts can be utilised. Direct methanol fuel cell (DMFC) data demonstrating a superior performance of the non‐platinum catalyst relative to platinum black, often perceived as the state‐of‐the‐art oxygen–reduction catalyst for the DMFC cathode is presented.     

Toward Fully‐ and Semi‐passive Operation of a Liquid‐Fed Direct Methanol Fuel Cell

This work reports the performance characteristics of a liquid‐fed direct methanol fuel cell (DMFC) operated in both fully‐ and semi‐passive conditions. For the latter case, a blower is used to provide forced air convection at the cathode so as to reveal how and how much a passive DMFC suffers from its structural constraint and also the mass and heat transfer limitations. The results based on the fully passive operation suggest that the cell performance is greatly affected by the level of methanol concentration. In this study, 2 M performs the best when the cell uses different structural setups. Besides, the effects of ambient temperature and the cathode self‐heating mechanisms are also explored under a fully passive condition. For the semi‐passive operation, forced air convection is proved to be helpful in enhancing oxygen delivery but may lead to faster heat and water dissipation and thus significantly reduces the cell performance. An optimal blowing intensity is obtained when the blower operates at a half speed. When the cathode diffusion layer is removed, the effects of active air supply become weakened. Considering the limited performance improvement and parasitic losses caused by a blower, we believe the self‐breathing mode is still an attractive choice.     

Operation Characteristic Analysis of a Direct Methanol Fuel Cell System Using the Methanol Sensor‐less Control Method

The application of methanol sensor‐less control in a direct methanol fuel cell (DMFC) system eliminates most of the problems encountered when using a methanol sensor and is one of the major solutions currently used in commercial DMFCs. This study focuses on analyzing the effect of the operating characteristics of a DMFC system on its performance under the methanol sensor‐less control as developed by Institute of Nuclear Energy Research (INER). Notably, the influence of the dispersion of the methanol injected on the behavior of the system is investigated systematically. In addition, the mechanism of the methanol sensor‐less control is investigated by varying factors such as the timing of the injection of methanol, the cathode flow rate, and the anode inlet temperature. These results not only provide insight into the mechanism of methanol sensor‐less control but can also aid in the improvement and application of DMFC systems in portable and low‐power transportation.     

Development of a Self‐Adaptive Direct Methanol Fuel Cell Fed with 20 M Methanol

A passive and self‐adaptive direct methanol fuel cell (DMFC) directly fed with 20 M of methanol is developed for a high energy density of the cell. By using a polypropylene based pervaporation film, methanol is supplied into the DMFC's anode in vapor form. The mass transport of methanol from the cartridge to the anodic catalyst layer can be controlled by varying the open ratio of the anodic bipolar plate and by tuning the hydrophobicity of anodic diffusion layer. An effective back diffusion of water from the cathode to the anode through Nafion film is carried out by using an additive microporous layer in the cathode that consists of 50 wt.% Teflon and KB‐600 carbon. Accordingly, the water back diffusion not only ensures the water requirement for the methanol oxidation reaction but also reduces water accumulation in the cathode and then avoids serious water flooding, thus improving the adaptability of the passive DMFC. Based on the optimized DMFC structure, a passive DMFC fed with 20 M methanol exhibits a peak power density of 42 mW cm^–2 at 25 °C, and no obvious performance degradation after over 90 h continuous operation at a constant current density of 40 mA cm^–2.     

Durable Transition‐Metal‐Carbide‐Supported Pt–Ru Anodes for Direct Methanol Fuel Cells

Molybdenum carbide (MoC) and tungsten carbide (WC) are synthesized by direct carbonization method. Pt–Ru catalysts supported on MoC, WC, and Vulcan XC‐72R are prepared, and characterized by X‐ray diffraction, X‐ray photoelectron spectroscopy, and transmission electron microscopy in conjunction with electrochemistry. Electrochemical activities for the catalysts towards methanol electro‐oxidation are studied by cyclic voltammetry. All the electro‐catalysts are subjected to accelerated durability test (ADT). The electrochemical activity of carbide‐supported electro‐catalysts towards methanol electro‐oxidation is found to be higher than carbon‐supported catalysts before and after ADT. The study suggests that Pt–Ru/MoC and Pt–Ru/WC catalysts are more durable than Pt–Ru/C. Direct methanol fuel cells (DMFCs) with Pt–Ru/MoC and Pt–Ru/WC anodes also exhibit higher performance than the DMFC with Pt–Ru/C anode.     

Two‐Phase 1D+1D Model of a DMFC: Development and Validation on Extensive Operating Conditions Range

A two‐phase 1D+1D model of a direct methanol fuel cell (DMFC) is developed, considering overall mass balance, methanol transport in gas phase through anode diffusion layer, methanol and water crossover. The model is quantitatively validated on an extensive range of operating conditions, 24 polarisation curves. The model accurately reproduces DMFC performance in the validation range and, outside this, it is able to predict values under feasible operating conditions. Finally, the estimations of methanol crossover flux are qualitatively and quantitatively similar to experimental measures and the main local quantities' trends are coherent with results obtained with more complex models.     

Fabrication of Function‐Graded Proton Exchange Membranes for Direct Methanol Fuel Cells Using Electron Beam‐Grafting

Function‐graded proton exchange membranes (G‐PEMs) based on poly(tetrafluoroethylene‐co‐hexafluoropropylene) were fabricated for direct methanol fuel cells (DMFCs) via electron beam‐grafting using the heterogeneous energy deposition technique. The G‐PEMs had a water uptake gradient in the proton transfer direction, originating from the sulfonic acid group gradient. The distribution of sulfonic acid groups in the various G‐PEMs was evaluated using X‐ray photoelectron spectroscopy. Four types of PEMs (flat‐type, strong‐gradient, meso‐gradient, and weak‐gradient types) were fabricated. By varying the direction of the G‐PEMs, the methanol permeation test and DMFC operation were performed with two orientations of the sulfonic acid group gradient, decreasing from the methanol injection (anode) side (decrease‐type) or the other (cathode) side (increase‐type). The methanol permeability of the strong‐gradient, meso‐gradient, and weak‐gradient G‐PEMs was lower than that of Nafion®117 and the flat‐type PEM. The “increase‐type” orientation of the strong‐gradient G‐PEM resulted in the lowest methanol permeability. The DMFC performance of the G‐PEMs was influenced by the thickness direction, such as “decrease‐type” and “increase‐type.” The performance of the “decrease‐type” assembly was higher than that of the “increase‐type.” The “decrease‐type” assembly with P‐200 k (weak‐gradient G‐PEM) exhibited the highest performance of the fabricated PEMs, comparable to that of Nafion®117.     

Portable Size DMFC‐Stack

A small, low temperature, direct methanol fuel cell stack for portable applications has been developed. Several flow field designs were investigated with respect to stable operation and high performance. Due to carbon dioxide and water production on the anode and cathode, respectively, methanol and oxygen access to the electrodes is hindered. During single cell operation the effect of both carbon dioxide evolution and water production on the current output was observed. The difference between parallel and serial feeding of both fuel and oxidant to the DMFC stack was also investigated. It was found that it is very important to remove reaction products from the active cell surface in order to ensure stable stack operation at low temperatures. The maximal power realised with the 12‐cell direct methanol fuel cell stack was 30 W.     

Effect of block composition on the morphology,hydration, and transport properties of sulfonated PS‐b‐PEGPEM‐b‐PS

This work discusses the effect of block composition on the properties of proton conducting polymer membranes. A homopolymer and two block copolymers were synthesized using atom transfer radical polymerization. The homopolymer poly(ethylene glycol phenyl ether methacrylate) (PEGPEM) was used as a bifunctional macroinitiator. Polystyrene (PS), was added to both sides of PEGPEM (A) with two different percentages of PS (B) (i.e., 18 and 31%). These copolymers, BAB 18, BAB 31 and the homopolymer A, were completely sulfonated (SA, SBAB 18 and SBAB 31). The resulting polymers produced different water absorption values and transport properties for direct methanol fuel cell (DMFC) applications. The nanostructure and morphology of the casted membranes were studied using small‐angle X‐ray scattering and atomic force microscopy. The results revealed that all six membranes exhibited a disordered phase‐segregated morphology, which changed on sulfonation into small‐interconnected ionic domains. Normalized DMFC selectivities (proton conductivity over methanol permeability divided by the respective values for Nafion^®) were calculated and ranged from 1.16 (SBAB 31) to 15.30 (BAB 18), indicating that the performance of these materials can be comparable or better than Nafion^®. Transport property results also suggest that chemistry (block nature and composition), morphology and water content play a critical role in the transport mechanism of protons and methanol. For example, the percentage of B in BAB 18 provides shorter interstitial ionic distances and sufficient water content to produce high proton conductivity, while maintaining low methanol permeability in a multi‐ionic proton exchange membrane. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 44343.     

A Sulfophenylated Polysulfone as the DMFC Electrolyte Membrane – an Evaluation of Methanol Permeability and Cell Performance

A sulfophenylated polysulfone (PSU‐sph), carrying 0.8 sulfonic acid units per repeating unit of the polymer, is evaluated as a membrane electrolyte for DMFC applications. The liquid uptake, methanol transport characteristics, electrolyte conductivity, and fuel cell performance are investigated. The methanol transport and DMFC performance results are compared to those of Nafion® 117. The PSU‐sph membrane investigated shows superior qualities with regard to methanol crossover, with a methanol permeability of approximately 25% compared to that of Nafion®. The conductivity was measured to be 15% compared to that of Nafion®. However, this could not fully account for the internal resistance of the cell, implying that the contact resistance between the electrodes and electrolyte is higher when PSU‐sph is used, probably because the electrodes are developed for use with Nafion® membranes. The stability of the PSU‐sph membrane seems promising, with very low degradation observed over a period of 72 hours. It was concluded that although the mass transport properties of the PSU‐sph membrane sample investigated were superior, it could not match the performance of Nafion® 117 in a DMFC application. However, a higher degree of sulfonation may have a significant positive effect on cell performance. The results also showed that a fully intergrated MEA is needed to fully assess new menbrane materials.     

Current Status of and Recent Developments in the Direct Methanol Fuel Cell

The direct methanol fuel cell (DMFC) has been discussed recently as an interesting option for a fuel‐cell‐based mobile power supply system in the power range from a few watts to several hundred kilowatts. In contrast to the favoured hydrogen‐fed fuel cell systems (e.g. the polymer electrolyte membrane fuel cell, PEMFC), the DMFC has some significant advantages. It uses a fuel which is, compared to hydrogen, easy to handle and to distribute. It also comprises a fairly simple system design compared to systems utilising liquid fuels (like methanol) to produce hydrogen from them by steam reforming or partial oxidation to finally feed a standard PEMFC. Nevertheless, many severe problems still exist for the DMFC, hindering its competitiveness as an option to hydrogen‐fed fuel cells. This work reviews the major research activities concerned with the DMFC by highlighting the problems (slow kinetics of the anodic methanol oxidation, methanol permeation through the membrane, carbon dioxide evolution at the anode) and their possible solutions. Special attention is devoted to the steady state and dynamic simulation of these fuel cell systems.     

Tubular Cathode Prepared by a Dip‐Coating Method for Low Temperature DMFC

A novel tubular cathode for the direct methanol fuel cell (DMFC) is proposed, based on a tubular titanium mesh. A dip‐coating method has been developed for its fabrication. The tubular cathode is composed of titanium mesh, a cathode diffusion layer, a catalyst layer, and a recast Nafion® film. The titanium mesh is present at the inner circumference of the diffusion layer, while the recast Nafion® film is at the outer circumference of the catalyst layer. A DMFC single cell with a 3.5 mgPt cm^–2 tubular cathode was able to perform as well, in terms of power density, as a conventional planar DMFC. A peak power density of 9 mW cm^–2 was reached under atmospheric air at 25 °C.     

Enhanced transport properties in polymer electrolyte composite membranes with graphene oxide sheets

Polymer electrolyte membranes have been widely investigated for high performance fuel cells. Here, we report the synthesis of ionic conductive Nafion/graphene oxide (GO) composite membranes for application in direct methanol fuel cells. GOs interact with both the non-polar backbone and the polar ionic clusters of Nafion because of their amphiphilic characteristics attributable to hydrophobic conjugation and hydrophilic functional groups. Accordingly, GO sheets serve to modify the microstructures of two domains of Nafion. In particular, the transport properties of Nafion are favorably manipulated by the incorporation of GO. This modulated the ionic channels of Nafion and decrease methanol crossover while preserving ionic conductivity. Furthermore, strong interfacial interactions due to the insertion of GO nanofillers into the Nafion matrix improve the thermal and mechanical properties of the material. In particular, we exploit Nafion/GO composite membrane as electrolyte material for direct methanol fuel cell (DMFC) in order to resolve current issue of methanol crossover. This composite membrane-based DMFC compared to the Nafion 112-based DMFC remarkably enhanced cell performance, especially in severe operating conditions.     

Characterization and fuel cell performance analysis of polyvinylalcohol–mordenite mixed-matrix membranes for direct methanol fuel cell use

Polyvinylalcohol–mordenite (PVA–MOR) mixed matrix membranes were synthesized for direct methanol fuel cell (DMFC) use. For the structural and the morphological characterization, Scanning Electron Microscopy and Thermal Gravimetric Analysis methods were used. Zeolite distribution within the polymer matrix was found to be homogeneous. An impedance spectroscope was used to measure the proton conductivity. In order to obtain information about methanol permeation characteristics, swelling tests and a series of pervaporation experiments were carried out. 60–40 wt% PVA–MOR membranes were found to give the optimum transport properties. Proton conductivity of these membranes was found to be slightly lower than that of Nafion117™ whereas their methanol permeability was at least two orders of magnitude lower than Nafion117™. DMFC performance of the PVA–MOR membranes was also measured. The inferior DMFC performance of PVA–MOR membranes was linked to drying in the fuel cell medium and the consequent proton conductivity loss. Their performance was improved by adding a dilute solution of sulfuric acid into the feed methanol solution. Future studies on the improvement of the proton conductivity of PVA–MOR membranes, especially via sulfonation of the polymer matrix, can overcome the low-performance problem associated with insufficient proton conductivity.     

Chloride free Pt‐ and PtRu‐ Nanoparticles Stabilised by “Armand's Ligand” as Precursors for Fuel Cell Catalysts

Chloride residues on the surface of fuel cell catalysts are known to decrease the catalytic activity, especially for O₂ reduction. Using Armand's ligand, which contains the chloride free DCTA anion, for the colloidal stabilisation of nanoscopic Pt and PtRu catalysts precursors (< 2 nm size) leads to PEMFC and DMFC catalysts with improved activity compared to commercial E‐TEK catalysts as evidenced by both methanol oxidation and CO‐stripping voltametric studies.     

Partially Sulfonated Poly(1,4‐phenylene ether‐ether‐sulfone) and Poly(vinylidene fluoride) Blend Membranes for Fuel Cells

Blend membranes based on high conductive sulfonated poly(1,4‐phenylene ether‐ether‐sulfone) (SPEES) and poly(vinylidene fluoride) (PVDF) having excellent chemical stability were prepared and characterized for direct methanol fuel cells. The effects of PVDF content on the proton conductivity, water uptake, and chemical stability of SPEES/PVDF blend membranes were investigated. The morphology, miscibility, thermal, and mechanical properties of blend membranes were also studied by means of scanning electron microscopy (SEM), thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and dynamic mechanical analysis (DMA) measurements. The blend membrane containing 90 wt.% SPEES (degree of sulfonation – DS = 72%) and 10 wt.% PVDF (M_w = 180,000) exhibits optimum properties among various SPEES72/PVDF membranes. Addition of PVDF enhanced resistance of the SPEES membrane against peroxide radicals and methanol significantly without deterioration of its proton conductivity. It's proton conductivity at 80 °C and 100% relative humidity is higher than Nafion 115 while it's methanol permeability is only half of that of Nafion 115 at 80 °C. The direct methanol fuel cell performance of the SPEES membranes was better than that of Nafion 115 membrane at 80 °C.     

Combinatorial investigation of Pt–Ru–M as anode electrocatalyst for direct methanol fuel cell

The addition of Au/TiO₂ and zeolites as active components to PtRu/C electrode in DMFC was investigated by using combinatorial high-throughput-screening test. Addition of Au/TiO₂ to PtRu/C electrode, especially in the ratio of PtRu/C: Au/TiO₂ 9:1, 8:2, 7:3, were effective to improve the performance of direct methanol fuel cell. The electrochemical properties of the prepared electrodes were compared using cyclic voltammetry, impedance spectroscopy and a single cell performance test of a direct methanol fuel cell (DMFC). The adsorbed CO on Pt might be easily oxidized on the surface of Au/TiO₂ by interaction between PtRu/C and Au/TiO₂. The addition of the solid acid proton conducting materials (ZSM-5) on PtRu/C anode leads to the high temperature operation. The cell performance was maintained over the cell temperature 120 °C (maximum current density was 200 mA/cm² at 160 °C) by the addition of ZSM-5 as proton conducting materials.     

A Pumpless Methanol Feeding Method for Application in Direct Methanol Fuel Cell Systems

This paper presents a simple and reliable pumpless methanol feeding (PLMF) method for application in direct methanol fuel cell (DMFC) systems. The primary feature and advantage of the PLMF is as follows: it employs an approach that allows the cathode gas pressure to be connected with a fuel container for supplying the methanol fuel into the anode fuel loop, instead of using any feeding pump or other specially designed apparatuses. The PLMF has been used in a portable 25 W DMFC system and realised feeding methanol in real time for meeting the requirements of the system. The PLMF method not only is suitable for the DMFC system, but also can be used in other liquid‐feeding fuel cell systems.     

Influence of Contamination with Inorganic Impurities on the Durability of a 1 kW DMFC System

IEK‐3 at Forschungszentrum Jülich successfully replaced the battery tray of a horizontal order picker (ECE 220, Jungheinrich) with a direct methanol fuel cell (DMFC) hybrid system in the kilowatt class. The DMFC combined with a lithium‐ion battery forms the hybrid drive for electrically driven horizontal order pickers. Such vehicles are used to transport and collect goods for orders in warehouses. The order picker is fueled by pure methanol to achieve a maximum range with the smallest possible space for the battery tray. An advantage of such energy systems is that there is no need for the relatively complicated and time‐consuming recharging of the conventional lead‐acid batteries, nor are spare batteries required for multishift operation. This study focuses on the influence of contamination with inorganic impurities on the durability of the 1 kW DMFC system V3.3‐1. The data from a long‐term test will be presented, in which the DMFC system was subjected to a realistic dynamic load profile for 3,000 h. The impurities identified in the post‐mortem analysis of the membrane electrode assembly will be outlined as well the influence of selected impurities, the sources of these impurities and how the DMFC V3.3‐2 system was modified on the basis of these findings.