Modeling Methanol Crossover by Diffusion and Electro-Osmosis in a Flowing Electrolyte Direct Methanol Fuel Cell

A CFD model is created to analyze methanol transport in a flowing electrolyte direct methanol fuel cell (FE-DMFC) by solving the 3D advection-diffusion equation, with consideration of electro-osmosis. The average methanol flux at the anode and cathode surfaces is simulated and compared to equivalent direct methanol fuel cells. Methanol crossover is defined as methanol flux at the cathode surface, and the results reveal that methanol crossover can be drastically reduced by the flowing electrolyte. The performance of the FE-DMFC at peak power current density is evaluated, and diffusion is shown to be the dominant contribution, although electro-osmosis increases with current density. The power consumption of the electrolyte pump is shown to be negligible compared to the cell power output. This indicates that thin electrolyte channels with high flow rates could further improve the efficiency.     

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.     

Enhancement of the Passive Direct Methanol Fuel Cells Performance by Modification of the Cathode Microporous Layer Using Carbon Nanofibers

Mass transfer is a key parameter affecting the performance of the passive direct methanol fuel cells (DMFCs), which work under natural convection. In this study, effect of carbon nanofibers (CNFs) addition to the cathode microporous layer (MPL) on the performance of the passive DMFCs was investigated. The results indicated that CNFs content has a significant influence on both of the mass transport and the electrochemical surface area (ECSA). Interestingly, addition of the CNFs (20 wt.%) leads to increase the power density of the passive DMFC to 160% compared to pristine carbon black MPL. At low current density, the CNFs content has no influence on the performance, while at high current density the maximum performance can be obtained at 20 wt.% CNFs then the performance decreases with further increase in the CNFs content. Although the highest catalyst utilization is observed at 40 wt.% CNFs, a maximum power density of 36 mW cm^–2 can be obtained at 20 wt.% CNFs and this is related to the significant effect of the mass transfer resistance under the passive operation conditions. Overall, addition of CNFs to the MPL can be considered an effective strategy to modify the passive DMFCs performance.     

直接甲醇燃料电池技术及应用

本文回顾了直接甲醇燃料电池（ＤＭＦＣ）的研究开发历史,系统阐述了ＤＭＦＣ系统中电催化剂选择与设计基本原则、电解质膜材料与甲醇渗透的关系。分析了电池工作温度、工作压力和甲醇进料方式对ＤＭＦＣ电化学性能的影响。     

Empirical Model Equations for the Direct Methanol Fuel Cell DMFCs

Empirical model equations, proposed for polymer electrolyte fuel cells, are used to predict the cell voltage vs. current density response of a liquid feed direct methanol fuel cell. The model equations are validated against experimental data for a small-scale fuel cell over a wide range of methanol concentration and temperatures. A new empirical equation is presented which is able to predict the voltage response of liquid feed direct methanol fuel cells over a wide range of operating conditions and even in the case of very low current densities caused by, for example, the use of dilute methanol solutions or low cell temperatures.     

The Effect of Methanol Crossover on the Cathode Overpotential of DMFCs

The effects of methanol crossover on cathode overpotential of direct methanol fuel cells (DMFCs) were investigated by focusing on a mixed potential effect and surface poisoning of the catalyst. Experiments using different membranes and catalyst loadings were performed and compared with a semi‐quantitative model to discuss the main cause of the cathode overpotential. When the measured methanol crossover increased, cathode overpotential increased at particular threshold values, which were 150 mA cm^–2 at 0.3 mg cm^–2 of cathode platinum (Pt) loading and above 200 mA cm^–2 at 1.1 mg cm^–2. The modelling results also supported this tendency, and showed that Pt surface was poisoned to a great extent above the threshold methanol crossover where the cathode overpotential increased sharply, while the cathode overpotential remained low and was explained solely by the mixed potential below the threshold value. The threshold methanol crossover can be regarded as the acceptable value, below which the cathode overpotential from methanol crossover remains low, and was related with the Pt loading in the cathode. The reduction of methanol crossover through membranes below the acceptable values will contribute greatly to a decrease in the cathode overpotential and to the reduction of catalyst loadings.     

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.     

Effect of Porosity in Catalyst Layers on Direct Methanol Fuel Cell Performances

Effects of porosity of catalyst layers (CLs) on direct methanol fuel cell (DMFC) performances are investigated using silicon dioxide (SiO₂) particles as a pore former. The pore size and volume of CLs are controlled by changing the size and content of SiO₂. As the size of pore formed by removal of SiO₂ increases, DMFC performances are enhanced. The augmentation in performances can be explained by facilitation of fuel transport to catalyst particles, increase of utilization efficiency of catalysts, diminishment in methanol crossover, reduction in activation loss and facilitation of water discharging out of CLs of cathode due to the controlled porosity in CLs. The enhanced fuel transport, accessibility of fuels to Pt catalyst surface, is proved by the active areas of Pt catalyst. In addition to the active area of Pt catalyst, porous CLs exhibit a decline in methanol crossover, leading to increase of open circuit voltage (OCV). The porous CLs also show improvements in activation loss due to high porosity, causing enhancement in DMFC performances. In aspect of pore volume contribution to cathode performance, the SiO₂ content is optimized. Based on the DMFC performances, it can be suggested that the optimum conditions of SiO₂ are 500 nm in size and 20 wt.% in content. The porosity effect on both electrodes appears as follows: the pores in cathode are more effective on DMFC performances (55.5%) than those of anodes (44.5%) based on the maximum power of DMFC, indicating that the pores in CLs facilitate removal of water from electrodes.     

Experimental and Numerical Study of Serpentine Flow Fields for Improving Direct Methanol Fuel Cell Performance

Methanol crossover is an important issue as it affects direct methanol fuel cell (DMFC) performance. But it may be controlled by selecting a proper flow field design. Experiments were carried out to investigate the effect of single, double and triple serpentine flow field configurations on a DMFC with a 25 cm² membrane electrode assembly (MEA) with a constant open ratio. A three dimensional model was also developed for the anode of the DMFC to predict methanol concentration and cell current density distributions. Experimental and model results show that at lower methanol concentrations (0.25–0.5M), single serpentine flow field (SSFF) provides high peak power density, while a double serpentine flow field (DSFF) gives high peak power density at a high methanol concentration (1–2M). Single and double serpentine flow fields exhibit the same peak power density (33 mW cm⁻²) at 1M. But the cell efficiency of double serpentine flow field is 12.5% which is 3.5% point greater than single serpentine flow field. This is attributed to reduced mixed potential. triple serpentine flow field (TSFF) shows the lowest peak power density and cell efficiency, which is attributed to high mass transfer resistance.     

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.     

Development of a Direct Alcohol Alkaline Fuel Cell Stack

Direct alcohol alkaline fuel cells (DAAFC) are one of the potential fuel cell types in the category of low temperature fuel cells, which could become an energy source for portable electronic equipment in future. In the present study, a simple DAAFC stack has been developed and studied to evaluate the maximum performance for a given fuel (methanol or ethanol) and electrolyte (KOH) at various concentrations and temperatures. The open circuit voltage of the stack of four cells was nearly 4.0 V. A particular combination, 2 M fuel (methanol or ethanol) and 3 M KOH, results in maximum power density of the stack. The maximum power density obtained from the DAAFC stack (25 °C) was 50 mW cm^–2 at 20 mA cm^–2 for methanol and 17 mA cm^–2 for ethanol. The stack power density corroborated with that obtained from a single cell, indicating there was no further loss in the stack.     

Operating Temperature Dependency on Performance Degradation of Direct Methanol Fuel Cells

The effect of operating temperature on performance degradation of direct methanol fuel cell (DMFCs) is examined to disclose the main parameter of the degradation mechanism and the degradation pattern in the membrane electrode assemblies (MEAs). The DMFC MEA degradation phenomenon is explained through the use of various electrochemical/physicochemical tools, such as electrochemical impedance spectroscopy, electrode polarization, methanol stripping voltametry, field emission‐scanning electron microscopy, X‐ray diffraction, inductively coupled plasma‐atomic emission spectroscopy, and X‐ray photoelectron spectroscopy analysis. The operation of DMFC under high temperature accelerates the degradation process of the DMFC. The higher degradation rate under high temperature DMFC operation is mainly attributed to the formation of membrane pinhole with interfacial delamination and cathode degradation. A high operating temperature may result in more considerable thermal and mechanical stress of the polymeric membrane continuously due to frequent dry–wet cycling mode and substantial uneven distribution of water between the anode and the cathode during a long period of DMFC operation. On the other hand, the electrochemical surface area deterioration by Pt coarsening and ionomers loss is not directly related to the larger DMFC performance decay at high temperature.     

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.     

Alcohol Crossover Behavior in Direct Alcohol Fuel Cells (DAFCs) System

The alcohols (methanol, ethanol, and 1‐propanol) crossover behavior of through fuel cell membrane electrode assembly (MEA) in direct alcohol fuel cell (DAFC) system was studied. We divided five different factors which affect alcohol crossover behavior through MEA to analyze alcohol crossover behavior. Those are membrane effect, physical blocking effect of anode, alcohol oxidation effect of anode electrocatalysts, physical blocking effect of cathode, and alcohol oxidation effect of cathode. Among these five factors, the four factors caused by two different electrodes (anode and cathode) were evaluated by fabricating various types of MEA. In the case of alcohols through membrane without any electrode was increased when the cell temperature was raised from room temperature to 100 °C, but it was decreased above the cell temperature of 100 °C. Among the electrode effects on alcohol crossover rate, physical blocking effect of electrodes played dominant role below 100 °C. However alcohol oxidation effects of electrodes was predominant above the 100 °C.     

Catalysts for Direct Methanol Fuel Cells

The activity of in house prepared carbon-supported Pt-Ru catalysts for methanol oxidation and carbon-supported RuSe for the oxygen reduction reaction in direct methanol fuel cells (DMFCs) was investigated. The composition of Pt-Ru/C was varied both in terms of weight loading (ratio of total metal content to carbon) as well as the ratio of Pt to Ru. The measurements were carried out in a half cell arrangement in sulphuric acid at various temperatures. The weight loading and ratio of Pt to Ru were varied in order to find out the optimum weight loading of precious metal and the temperature dependence of Pt to Ru ratio on methanol oxidation reaction. It has been found that there exists an optimum in the weight loading at 60 wt.% for carbon-supported Pt-Ru catalyst towards its maximum mass activity. While 1:1 Pt to Ru ratio exhibits a higher activity than 3:2 Pt:Ru above 60 °C, 3:2 ratio exhibits a higher activity at lower temperature. It has been observed that RuSe is inactive towards methanol and it is realised that RuSe is a potential candidate as methanol tolerant oxygen reduction catalyst. The activity of carbon supported RuSe for oxygen reduction reaction (ORR) was tested in sulphuric acid in the presence of methanol. Even though the mass specific activity of the RuSe catalyst is somewhat lower than that of Pt/C, the surface activity of carbon-supported RuSe is superior than that of carbon supported Pt which indicate the unfavourable size distribution of RuSe/C catalyst.     

Sulphonated Tetramethyl Poly(ether ether ketone)/Epoxy/Sulphonated Phenol Novolac Semi‐IPN Membranes for Direct Methanol Fuel Cells

The sulphonated phenol novolac (PNBS) which was used as a curing agent of epoxy was synthesised from phenol novolac (PN) and 1, 4‐butane sultone and confirmed by FTIR and ¹H NMR. The degree of sulphonation (DS) in PNBS was calculated by ¹H NMR. The semi‐IPN membranes composed of sulphonated tetramethyl poly(ether ether ketone) (STMPEEK) (the value of ion exchange capacity is 2.01 meq g^–1), epoxy (TMBP) and PNBS were successfully prepared. The semi‐IPN membranes showed high thermal properties which were measured by differential scanning calorimeter (DSC) and thermogravimetric analyses (TGA). With the introduction of the cross‐linked TMBP/PNBS, the mechanical properties, dimensional stability, methanol resistance and oxidative stability of the membranes were improved in comparison to the pristine STMPEEK membrane. Although the proton conductivities of the semi‐IPN membranes were lower than those of the pristine STMPEEK membrane, the higher selectivity defined as the ratio of the proton conductivity to methanol permeability was obtained from the STMPEEK/TMBP/PNBS‐14 semi‐IPN membrane. The results indicated that the semi‐IPN membranes could be promising candidates for usage as proton exchange membranes in direct methanol fuel cells (DMFCs).     

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.     

Operation of the Alkaline Direct Formate Fuel Cell in the Absence of Added Hydroxide

The direct formate fuel cell (DFFC) has recently been demonstrated as a viable alkaline direct liquid fuel cell (DLFC) that does not require addition of hydroxide to the fuel stream for operation. In this work, we report that the DFFC can produce significant power at low temperatures without added hydroxide, especially when compared with other alkaline DLFCs powered by alcohols. Using oxygen at the cathode, the DFFC powered by 1 M HCOOK achieves a maximum power density of 106 mW cm^–2 at 50 °C and 64 mW cm^–2 at 23 °C. Using air at the cathode, the same DFFC achieves a maximum power density of 76 mW cm^–2 at 50 °C and 27 mW cm^–2 at 23 °C. These power densities were achieved without addition of hydroxide to the fuel stream. Constant current operation demonstrates that the maximum power density can be maintained at least for several hours of operation. Finally, we use electrochemical analysis to demonstrate that the formate oxidation reaction is not dependent on pH between 9 and 14, which permits the use of formate fuel without added hydroxide in the DFFC. An alkaline DLFC that does not require added hydroxide is promising for safe and practical operation.     

Chitosan/titanate Nanotube Hybrid Membrane with Low Methanol Crossover for Direct Methanol Fuel Cells

Titanate nanotubes (TNTs) about 10 nm in diameter and 200–600 nm in length were hydrothermally synthesized, and then incorporated into a chitosan (CS) matrix to fabricate chitosan/titanate nanotube (CS/TNT) hybrid membranes for a direct methanol fuel cell (DMFC). These hybrid membranes were characterized by scanning electron microscopy (SEM), transmission electron microscopy (TEM), X‐ray powder diffraction (XRD), thermogravimetry (TG), and positron annihilation lifetime spectroscopy (PALS). Moreover, their performances, including mechanical strength, water and methanol uptake, methanol permeability, and proton conductivity were determined. SEM results demonstrated that TNTs dispersed homogeneously in the hybrid membranes. Mechanical strength and TG measurements demonstrated that the mechanical and thermal stability of CS/TNT hybrid membranes were much higher than those of pure chitosan membranes. PALS analysis revealed that the fractional free volume (FFV) of CS/TNT hybrid membranes increased with the incorporation of TNTs and, thus, resulting in the reduction of methanol crossover. In all as‐prepared membranes, the hybrid membrane containing 15 wt % TNTs exhibited the highest mechanical strength of 85.0 MPa, low methanol permeability of 0.497 · 10^–6 cm²·s^–1, and proton conductivity of 0.0151 S·cm^–1, which had the potential for DMFC applications.     

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.