Development of a 1 kW polymer electrolyte fuel cell power source

This paper reports on the development of key components, specifications, configuration and operating characteristics of a hydrogen-fueled portable power source with polymer electrolyte fuel cell (PEFC). A 1 kW class fuel cell module operating on an exclusive method of internal humidification was developed for the power source. A dc–ac inverter, in which a general-purpose integrated power module (IPM) was used as a switching device for microprocessor-based power conversion control, was developed to save the cost of generating dc power output from the cell module. The power source supplies full power within 2 min from start-up, and is capable of generating rated 1 kW power for about 3 h and even longer if the cylinders are replaced. This power source has been confirmed to offer a high power generation efficiency of 30% or higher in overall output range, yielding good-quality power with little noise.     

Development of portable fuel cell arrays with printed-circuit technology

Portable hydrogen/oxygen fuel cell power sources were constructed using printed-circuit board (PCB) technology. Multiple iterations of miniature planar fuel cell devices were prototyped, demonstrating fast cycle innovation and dramatic power density improvements in <1 year of development. Several novel flow structure and gas routing designs were explored. Electrical interconnections for configurable voltage were wired on board by printed-circuit traces and vias. Fuel cell device voltages ranging from 1 V single cells to 16 V planar arrays were demonstrated, with power output ranging from <1 to >200 W. The lightweight laminate PCB technology allows the best prototypes to achieve >700 mW/cm² area power density and >400 mW/cm³ volumetric power density. PCB technology offers an intriguing platform for portable fuel cell development below 1 kW. Possibilities for on board diagnostics/control and further power density improvements are envisioned.     

燃料电池功率调节系统的研究

燃料电池电压输出范围比较宽，电压比较低。针对该特点本文设计了DC/DC和DC/AC两级变换的功率调节系统(PCS)。其中DC/DC将燃料电池输出的低压直流电高频变换成高压直流电，变换器为电压单环控制。DC／AC逆变器采用基于电压电流瞬时值反馈的双闭环控制，将高压直流电逆变为正弦交流电。分析了整个功率调节系统的工作原理及逆变器电路参数对稳定性的影响。0．5KVA佯饥实验结果表明整个系统具有电压输入范围宽、变换效率高、输出波形THD小等优点。为开发高效、高功率密度的燃料电池电源系统提供技术基础。     

Characterization of a high performing passive direct formic acid fuel cell

Small fuel cells are considered likely replacements for batteries in portable power applications. In this paper, the performance of a passive air breathing direct formic acid fuel cell (DFAFC) at room temperature is reported. The passive fuel cell, with a palladium anode catalyst, produces an excellent cell performance at 30 °C. It produced a high open cell potential of 0.9 V with ambient air. It produced current densities of 139 and 336 mA cm⁻² at 0.72 and 0.53 V, respectively. Its maximum power density was 177 mW cm⁻² at 0.53 V. Our passive air breathing fuel cell runs successfully with formic acid concentration up to 10 and 12 M with little degradation in performance. In this paper, its constant voltage test at 0.72 V is also demonstrated using 10 M formic acid. Additionally, a reference electrode was used to determine distinct anode and cathode electrode performances for our passive air breathing DFAFC.     

A new direct methanol fuel cell with a zigzag-folded membrane electrode assembly

We propose a new direct methanol fuel cell with a zigzag-folded membrane electrode assembly. This fuel cell is formed by a membrane, which is made up of anode and cathode electrodes on a zigzag-folded sheet, separated by insulation film and current collectors. Individual anodes, cathodes and membranes form a unit cell, which is connected to the adjacent unit cell. The fuel cell can achieve high output voltage through easy in-series connection. Since it is not necessary to connect electrodes, as in the manner of conventional bipolar plates, there is no increase in fabrication cost and no degradation in reliability. The fuel feeds for the anode and cathode are achieved through methanol and air feeds on each electrode, which do not require electricity to run a pump or blower. The experimental cells were formed with an active area of 16 cm × 2 cm on membrane-folded cells. Filter papers with slits were inserted between anodes to improve their methanol supply. A power density of 3 mW cm⁻² was obtained at a methanol concentration of 2 M at ambient temperature. The cell power was affected by the slit area on cathode.     

Testing of a small-scale stand-alone power system based on solar energy and hydrogen

An experimental small-scale stand-alone power system based on hydrogen and solar energy has been tested. The system performance and operational experience are reported. Future expansion of the test-facility is taken into consideration using solutions with wide working ranges. The test-facility is designed for testing of individual components, for subsystems, and for complete power system operation. The complete power system in this study consists of a 4.8 kW programmable power supply, 1.5 kW electrolyser, a hydrogen purification unit (99.999% H₂ quality), a 14 Nm³ H₂ metal hydride storage, a 0.5 kW fuel cell, a 300 Ah lead-acid battery, and a 0.6 kW programmable load. Possible applications for such small-scale power systems are mountain cabins, remote islands, and telecommunication stations, among others. The basic idea in this particular power system configuration was to make it as simple as possible; the fuel cell and the metal hydride unit were air-cooled, and the components were connected in parallel without DC/DC converters. The only control action possible in the power system (presented in this study) was to switch the components either ON or OFF. However, connecting the components electrically in parallel without DC/DC converters gives no degrees of freedom regarding the ability to regulate power and voltage levels of the different components. Air-cooled metal hydrides might fail to deliver hydrogen due to poor heat transfer.     

A 28-W portable direct borohydride–hydrogen peroxide fuel-cell stack

A 28-W direct borohydride–hydrogen peroxide fuel-cell stack operating at 25 °C is reported for contemporary portable applications. The fuel cell operates with the peak power-density of ca. 50 mW cm⁻² at 1 V. This performance is superior to the anticipated power-density of 9 mW cm⁻² for a methanol–hydrogen peroxide fuel cell. Taking the fuel efficiency of the sodium borohydride–hydrogen peroxide fuel cell as 24.5%, its specific energy is ca. 2 kWh kg⁻¹. High power-densities can be achieved in the sodium borohydride system because of its ability to provide a high concentration of reactants to the fuel cell.     

Performance characteristics of a vapor feed passive miniature direct methanol fuel cell

In this paper, a new vapor feed fuel delivery system for a passive direct methanol fuel cell (DMFC) is developed and tested. Anode hydrophilic layers, electrical heating power and carbon dioxide release are examined to find their effects on the power density, efficiency and average temperatures of the cell. The hydrophilic layers act as a buffer layer between the vapor chamber and the anode gas diffusion layer (GDL). This layer allows water and methanol to mix, as well as distribute uniformly across the anode surface. Measurement of several parameters such as current, voltage, power, internal resistance, vapor chamber pressure, relative humidity and carbon dioxide concentration are taken. A maximum power density of 33 mW cm^?2 is achieved as well as 120 h of continuous operation at a constant current of 50 mA cm^?2 using the vapor feed system. The fuel utilization efficiency during the 120 h test is 34.8% and the energy efficiency is 8.2%.     

Methanol decomposition fuel processor for portable power applications

A new fuel processor approach for portable fuel cell power sources significantly improves upon microreformers by overcoming the difficulties with heat deficiencies and contaminants in the product hydrogen. Instead of reforming, the processor uses methanol decomposition to enable the byproduct, carbon monoxide (CO), to be used as the heat source. A hydrogen permselective membrane segregates the CO for combustion in an integrated burner, maximizes the decomposition conversion, and provides pure hydrogen for a fuel cell. Discharging the CO-rich retentate through an ejector to draw combustion air into the burner greatly simplifies the system. High and stable hydrogen yields are attained with optimized catalysts and fuel compositions. The resultant simple, efficient, and self-heating processor produces 85% of the hydrogen content of the fuel. A 20 W autonomous power source based on this novel fuel processor demonstrates a fuel energy density >1.5 Wh g^?1_(electrical), nearly twice as high as microreformer power sources.     

Experimental study of a fuel cell power train for road transport application

The development of fuel cell electric vehicles requires the on-board integration of fuel cell systems and electric energy storage devices, with an appropriate energy management system. The optimization of performance and efficiency needs an experimental analysis of the power train, which has to be effected in both stationary and transient conditions (including standard driving cycles).In this paper experimental results concerning the performance of a fuel cell power train are reported and discussed. In particular characterization results for a small sized fuel cell system (FCS), based on a 2.5 kW PEM stack, alone and coupled to an electric propulsion chain of 3.7 kW are presented and discussed. The control unit of the FCS allowed the main stack operative parameters (stoichiometric ratio, hydrogen and air pressure, temperature) to be varied and regulated in order to obtain optimized polarization and efficiency curves. Experimental runs effected on the power train during standard driving cycles have allowed the performance and efficiency of the individual components (fuel cell stack and auxiliaries, dc–dc converter, traction batteries, electric engine) to be evaluated, evidencing the role of output current and voltage of the dc–dc converter in directing the energy flows within the propulsion system.     

Direct formic acid fuel cells

The performance of formic acid fuel oxidation on a solid PEM fuel cell at 60 °C is reported. We find that formic acid is an excellent fuel for a fuel cell. A model cell, using a proprietary anode catalyst produced currents up to 134 mA/cm² and power outputs up to 48.8 mW/cm². Open circuit potentials (OCPs) are about 0.72 V. The fuel cell runs successfully over formic acid concentrations between 5 and 20 M with little crossover or degradation in performance. The anodic polarization potential of formic acid is approximately 0.1 V lower than that for methanol on a standard Pt/Ru catalyst. These results show that formic acid fuel cells are attractive alternatives for small portable fuel cell applications.     

Dynamic behaviour of hydrogen fuel cells for automotive application

An experimental analysis was conducted on a 30 kW fuel cell power train with the aim to elucidate specific concerns of dynamic behaviour of hydrogen fuel cells in automotive applications. The study was conducted on a dynamic test bench able to simulate the behaviour of the reference vehicle, a minibus for historical centres collective service, on predefined driving cycle. The transient performance of the fuel cell system was firstly investigated without electric drive, using as load electric resistances electronically controlled. Experimental data were collected during warmup phases characterized by two acceleration slopes (150 W/s and 1500 W/s) and during a sequence of dynamic test cycles characterized by a very high acceleration slope of about 6 kW/s. The role of reactant feeding, humidification and cooling systems was investigated during all tests evaluating the performance during the transient steps in terms of cell voltage uniformity, expressed by the coefficient of variation C_v, used as statistical indicator. A driving cycle characterized by stop-and-go pattern and acceleration slopes compatible with a real utilization of the reference vehicle was finally adopted for tests on the overall power train. The results demonstrated a very good dynamic performance of the fuel cell stack as evidenced by the analysis of C_v, which resulted lower than 2.5% in all investigated working conditions, and by the overall power train efficiency which resulted about 30% with fuel cell system efficiency close to 50%.     

Control of miniature proton exchange membrane fuel cells based on fuzzy logic

A control strategy is presented in this paper which is suitable for miniature hydrogen/air proton-exchange membrane (PEM) fuel cells. The control approach is based on process modelling using fuzzy logic and tested using a PEM stack consisting of 15 cells with parallel channels on the cathode side and a meander-shaped flow-field on the anode side. The active area per cell is 8 cm². Commercially available materials are used for the bipolar plates, gas diffusion layers and the membrane-electrode assembly (MEA). It is concluded from a simple water balance model that water management at different temperatures can be achieved by controlling the air stoichiometry. This is achieved by varying the fan voltage for the air supply of the PEM stack. A control strategy of the Takagi Sugeno Kang (TSK) type, based on fuzzy logic, is presented. The TSK-type controller offers the advantage that the system output can be computed in an efficient way: the rule consequents of the controller combine the system variables in linear equations. It is shown experimentally that drying out of the membrane at high temperatures can be monitored by measuring the ac impedance of the fuel cell stack at a frequency of 1 kHz. Flooding of single cells leads to an abrupt drop of the corresponding single-cell voltage. Therefore, the fuzzy rule base consists of the ac impedance at 1 kHz and all single-cell voltages. The parameters of the fuzzy rule base are determined by plotting characteristic diagrams of the fuel cell stack at constant temperatures. The fuel cell stack can be controlled at T=60 °C up to a power level of 7.5 W. The fuel cell stack is controlled successfully even when the external electric load changes. At T=65 °C, a maximum power level of 8 W is found. A decrease of the maximum power level is observed for higher temperatures.     

Integrated modeling and control of a PEM fuel cell power system with a PWM DC/DC converter

A fuel cell powered system is regarded as a high current and low voltage source. To boost the output voltage of a fuel cell, a DC/DC converter is employed. Since these two systems show different dynamics, they need to be coordinated to meet the demand of a load. This paper proposes models for the two systems with associated controls, which take into account a PEM fuel cell stack with air supply and thermal systems, and a PWM DC/DC converter. The integrated simulation facilitates optimization of the power control strategy, and analyses of interrelated effects between the electric load and the temperature of cell components. In addition, the results show that the proposed power control can coordinate the two sources with improved dynamics and efficiency at a given dynamic load.     

Fuel-cell powered uninterruptible power supply systems: Design considerations

A 1-kVA fuel cell powered, line-interactive uninterruptible power supply (UPS) system that employs modular (fuel cell and power converter) blocks is introduced. Two commercially available proton-exchange membrane fuel cell (25–39 V, 500 W) modules together with suitable dc–dc and dc–ac power electronic converter modules are employed. A supercapacitor module is also used to compensate for the instantaneous power fluctuations and to overcome the slow dynamics of the fuel processor (reformers). Further energy stored in the supercapacitor is also utilized to handle a momentary overload such as 200% for a short duration. Due to the absence of batteries, the system satisfies the demand for an environmentally clean source of energy. A complete design that defines the amount of hydrogen storage required for a power outage of 1 h, and the sizing of the supercapacitors for transient load demand is presented for a 1-kVA UPS.     

Development of a small DMFC bipolar plate stack for portable applications

The direct methanol fuel cell (DMFC) is regarded as a promising candidate in portable electronic power applications. Bipolar plate stacks were systematically studied by controlling the operating conditions, and by adjusting the stack structure design parameters, to develop more commercial DMFCs. The findings indicate that the peak power of the stack is influenced more strongly by the flow rate of air than by that of the methanol solution. Notably, the stack performance remains constant even as the channel depth is decreased from 1.0 to 0.6 mm, without loss of the performance in each cell. Furthermore, the specific power density of the stack was increased greatly from ∼60 to ∼100 W l⁻¹ for stacks of 10 and 18 cells, respectively. The current status of the work indicates that the power output of an 18-cell short stack reaches 33 W in air at 70 °C. The outer dimensions of this 18-cell short stack are only 80 mm × 80 mm × 51 mm, which are suitable for practical applications in 10–20 W DMFC portable systems.     

A miniature air breathing direct formic acid fuel cell

Small fuel cells are considered likely replacements for batteries in portable power applications. In this paper, the performance of a $\text{2}\text{cm}\text{×2.4}\text{cm}\text{×1.4}$ cm passive miniature air breathing direct formic acid fuel cell (DFAFC) at room temperature is reported. The cell produced current density up to 250 mA/cm² and power density up to 33 mW/cm² at ambient conditions. The fuel cell runs successfully with formic acid concentration ranging from 1.8 and 10 M with little degradation in performance. These results show that passive fuel cells can compete with batteries in portable power applications.     

International Lead Award

The University of Duisburg-Essen and the Center for Fuel Cell Technology (ZBT Duisburg GmbH) have developed a compact multi-fuel steam reformer suitable for natural gas, propane and butane. Fuel processor prototypes based on this concept were built up in the power range from 2.5 to 12.5 kW thermal hydrogen power for different applications and different industrial partners. The fuel processor concept contains all the necessary elements, a prereformer step, a primary reformer, water gas shift reactors, a steam generator, internal heat exchangers, in order to achieve an optimised heat integration and an external burner for heat supply as well as a preferential oxidation step (PrOx) as CO purification. One of the built fuel processors is designed to deliver a thermal hydrogen power output of 2.5 kW according to a PEM fuel cell stack providing about 1 kW electrical power and achieves a thermal efficiency of about 75% (LHV basis after PrOx), while the CO content of the product gas is below 20 ppm. This steam reformer has been combined with a 1 kW PEM fuel cell. Recirculating the anodic offgas results in a significant efficiency increase for the fuel processor. The gross efficiency of the combined system was already clearly above 30% during the first tests. Further improvements are currently investigated and developed at the ZBT.     

Critical flow rate of anode fuel exhaust in a PEM fuel cell system

A manual purge line was added into the exterior fuel exhaust stream of a Ballard PEM stack in a Nexa™ power module. With the addition of manual exhaust purge, high levels of inert gases were intentionally added to the anode feed without changing normal operational procedures. A new method of determining the critical minimum flow rate in the anode exhaust stream was given by an anode mass balance. This type of operation makes dual use of membranes in the MEAs as both gas purifiers and as solid electrolytes. The PEM stack was successfully operated with up to ca. 7% nitrogen or carbon dioxide in the absence of a palladium-based hydrogen separator at ca. 200 W power level. Nitrogen in the anode stream was concentrated from 7.5% to 91.6%. The system maintained a fuel efficiency of 99% at a manual purge rate of 2.22 ml s⁻¹ and no auto purge. The fuel cell stack efficiency was 64% and the stack output efficiency was 75%. The overall system efficiency was 39%. After troublesome CO and H₂S poisons were removed, a hydrocarbon reformate containing high levels of CO₂ and H₂O was further used in the Nexa™ stack. The size and complexity of the fuel processing system may be reduced at a specified power level by using this operational method.     

Analysis of off-grid hybrid wind turbine/solar PV water pumping systems

While many remote water pumping systems exist (e.g. mechanical windmills, solar photovoltaic, wind-electric, diesel powered), few combine both the wind and solar energy resources to possibly improve the reliability and the performance of the system. In this paper, off-grid wind turbine (WT) and solar photovoltaic (PV) array water pumping systems were analyzed individually and combined as a hybrid system. The objectives were to determine: (1) advantages or disadvantages of using a hybrid system over using a WT or a solar PV array alone; (2) if the WT or solar PV array interfered with the output of the other; and (3) which hybrid system was the most efficient for the location. The WT used in the analysis was rated at 900 W alternating current (AC). There were three different solar PV arrays analyzed, and they were rated at 320, 480, and 640 W direct current (DC). A rectifier converted the 3-phase variable voltage AC output from the WT to DC before combining it with the solar PV array DC output. The combined renewable energies powered a single helical pump. The independent variable used in the hybrid WT/PV array analysis was in units of W/m². The peak pump efficiency of the hybrid systems at Bushland, TX occurred for the 900 W WT combined with the 640 W PV array. The peak pump efficiencies at a 75 m pumping depth of the hybrid systems were: 47% (WT/320 W PV array), 51% (WT/480 W PV array), and 55% (WT/640 W PV array). Interference occurred between the WT and the different PV arrays (likely due to voltage mismatch between WT and PV array), but the least interference occurred for the WT/320 W PV array. This hybrid system pumped 28% more water during the greatest water demand month than the WT and PV systems would have pumped individually. An additional controller with a buck/boost converter is discussed at end of paper for improvement of the hybrid WT/PV array water pumping system.