Carbon Nanotubes Based Nafion Composite Membranes for Fuel Cell Applications

Carbon nanotubes (CNTs) containing Nafion composite membranes were prepared via melt‐blending at 250 °C. Using three different types of CNTs such as pure CNTs (pCNTs), oxidised CNTs (oCNTs) and amine functionalised CNTs (fCNTs); the effect of CNTs surface oxidation as well as functionalisation in composite membranes was investigated by focussing on three aspects: thermo‐mechanical stability, thermal degradation and proton conductivity. The oCNTs‐containing Nafion composite membrane exhibited concurrent improvement in most of the properties as compared to that of pure Nafion or other CNTs‐containing Nafion composite membranes.     

Temperature and Humidity Control of a Micro PEM Fuel Cell Stack

This paper deals with the control of a miniaturised fuel cell system. A single air blower is used to control both heat and water management of the fuel cell. As the number of manipulated variables is smaller than the number of control variables, classical control algorithms are not applicable. To find a suitable controller, a system model is developed that shows the qualitatively same behaviour as the experimental setup. The dynamic behaviour of the model and the influence of the blower are studied by phase portraits. A control algorithm is then conceived by qualitative analysis of the phase portraits and tested in simulations.     

Analysis of Optimal Heat Transfer in a PEM Fuel Cell Cooling Plate

An analysis of three‐dimensional computational fluid dynamics (CFD) is conducted to investigate the coupled cooling process involved in fluid flow and heat transfer between the solid plate and the coolant flow for optimization of the cooling design of a fuel cell stack. A conception of IUT (Index of Uniform Temperature) across the entire area is presented to evaluate the degree of uniform temperature profile across the cooling plates. Six cooling modes, including three serpentine‐type modes and another three parallel‐type modes, are presented and analyzed for optimization of the cooling mode of fuel cells. The prediction finds that the cooling effect of serpentine‐type cooling modes could be better than that of parallel‐type cooling modes.     

Effects of Potential on Corrosion Behavior of Uncoated SS316L Bipolar Plate in Simulated PEM Fuel Cell Cathode Environment

The effect of potential on the corrosion behavior of uncoated stainless steel SS316L as bipolar plate material in proton exchange membrane (PEM) fuel cell cathode environment is studied. Electrochemical methods, X‐ray photoelectron spectroscopy, scanning electron microscope are employed to characterize the corrosion behavior of SS316L at different polarization potentials in PEM fuel cell cathode environment. The results show that the corrosion current density of SS316L increases with the increase of polarization potential significantly. When the potential is higher than 0.7 V versus SCE, severe corrosion occurs on SS316L. The work also shed light on the corrosion mechanisms of SS316L at different potential in the PEM fuel cell cathode environment.     

Carbon Nanotubes and Nanohorn Hybrid Composite Buckypaper as Microporous Layer for Proton Exchange Membrane Fuel Cell

In the present work, carbon nanotubes (CNT) and CNT‐carbon nanohorns (CNH) (0, 30, 50, 70 and 100 wt.% CNH) composite Buckypapers (BPs) were fabricated using vacuum filtration technique. Structure and property relation of composite BPs were studied using scanning electron microscope, four probe technique, BET surface area and contact angle measurements. Properties such as electrical conductivity, hydrophobic nature and microstructure of CNT‐30 wt.% CNH composite BP are superior to other composite BP. Hence, CNT‐30 wt.% CNH composite BP is chosen as a microporous layer (MPL) for PEMFCs and tested in fuel cell testing fixture. Polarization studies reveal that the cells performance with composite BPs is comparable with SGL‐MPL based cell. Hydrogen pumping and polarization studies of the cells confirms that composite BPs act as a good MPL at anode as well as cathode at 0.4 to 0.8 V. Hence, CNT‐CNH composite BPs are potential candidates for PEMFC applications.     

FLOX® Steam Reforming for PEM Fuel Cell Systems

Primary energy savings and CO₂ reduction is one of the key motivations for the use of fuel cell systems in the energy sector. A benchmark of domestic cogeneration by PEMFC with existing large scale power production systems such as combined steam‐gas turbine cycle, clearly reveals that only fuel cell systems optimising overall energy efficiency (> 85%) and electrical efficiencies (> 35%) show significant primary energy savings, about 10%, compared with the best competing technology. In this context, fuel processing technology plays a dominant role. A comparison of autothermal and steam reforming concepts in a PEMFC system shows inherent advantages in terms of efficiency at low complexity for the latter. The main reason for this is that steam reforming allows for the straightforward and effective use of the anode‐off gas energy in the reformer burner. Consequently, practical electrical system efficiencies over 40% seem to be achievable, most likely by steam reformers. FLOX®‐steam reforming technology has reached a high state of maturity, offering diverse advantages including: compact design, stable anode off‐gas usage, high efficiency, as well as simple control behaviour. Scaling of the concept is straightforward and offers an opportunity for efficient adaptation to smaller (1 kW) and larger (50 kW) units.     

Thermal Conductivity and Contact Resistance of Compressed Gas Diffusion Layer of PEM Fuel Cell

This paper discusses the effect of compression pressure on the mechanical and thermal properties of gas diffusion layers (GDL). The stress–strain curve of the GDL revealed one nonlinear and two piecewise linear regions within the compression pressure range of 0–5.5 MPa. The thermal conductivity of the compressed GDL seems to be independent of the compression pressure and was determined to be 1.18 ± 0.11 W m^–1 K^–1 at room temperature. The thermal contact resistance between the GDL and graphite was evaluated by augmenting experiments with computer modelling. The thermal contact resistance decreased nonlinearly with increasing compression pressure. According to the results here, the thermal bulk resistance of the GDL is comparable to the thermal contact resistance between the GDL and graphite. A simple one‐dimensional model predicted a temperature drop of 1.7–4.4 °C across the GDL and catalyst layer depending on compression pressures.     

Synergistic Effects of Carbon Fillers of Phenolic Resin Based Composite Bipolar Plates on the Performance of PEM Fuel Cell

The most essential and costly component of polymer electrolyte membrane fuel cells is the bipolar plate. The production of suitable composite bipolar plates for polymer electrolyte membrane fuel cell with good mechanical properties and high electrical conductivity is scientifically and technically very challenging. This paper reports the development of composite bipolar plates using exfoliated graphite, carbon black, and graphite powder in resole‐typed phenol formaldehyde. The exfoliated graphite with maximum exfoliated volume of 570 ± 10 mL g⁻¹ used in this study was prepared by microwave irradiation of chemically intercalated natural flake graphite in a few minutes. The composite plates were prepared by varying exfoliated graphite content from 10 to 35 wt.% in phenolic resin along with fixed weight percentage of carbon black (5 wt.%) and graphite powder (3 wt.%) by compression molding. The composite plates with filler weight percentage of 35/5/3/exfoliated graphite/carbon black/graphite powder offer in‐plane and trough‐plane electrical conductivities of 374.42 and 97.32 S cm⁻¹, bulk density 1.58 g cm⁻³, compressive strength 70.43 MPa, flexural strength 61.82 MPa, storage modulus 10.25 GPa, microhardness 73.23 HV and water absorption 0.22%. Further, I–V characteristics notify that exfoliated graphite/carbon black/graphite powder/resin composite bipolar plates in unit fuel cell shows better cell performance compared exfoliated graphite/resin composite bipolar plates. The composite plates own desired mechanical properties with low bulk density, high electrical conductivity, and good thermal stability as per the U.S. department of energy targets at low filler concentration and can be used as bipolar plates for proton exchange membrane fuel cells.     

The Use of Fluorocarbon Surfactants to Improve the Manufacture of PEM Fuel Cell Electrodes

Fluorocarbon surfactants are used to improve surface wetting during the screen printing of carbon black inks onto PEM fuel cell electrodes. The fluorosurfactants were tested in inks that comprised a Nafion® ionomer solution with platinum‐loaded carbon black. Four commercially available fluorosurfactants (Zonyl FSO, Zonyl 1033D, Forafac 1098 and Novec FC 4430) were screened and assessed for electrochemical activity (via cyclic voltammetry), leaching and the ability to form ink layers. Good wetting characteristics were observed and the inks showed a similar specific electrochemical active area (200–430 cm² mg^–1 Pt) to a standard reference ink (370 cm² mg^–1 Pt), indicating that the surfactants did not adversely adsorb on the platinum catalyst surface or block the adsorption/desorption of hydrogen. Additionally, the fluorosurfactants in the cured inks were shown to be electrochemically inactive in the potential region relevant to fuel cell operation.     

PS／炭黑复合材料导电性能的研究

本文通过炭黑（简称ＣＢ）用量、加工工艺、温度对ＰＳ／ＣＢ复合材料导电性能影响的探讨、复合导电材料亚微观结构的观察，研究了ＰＳ／ＣＢ复合材料的导电性能。结果表明，随着ＣＢ含量的增加，材料的电阻率呈非线性下降，当ＣＢ的质量分数在１０％～４０％的范围内时，电阻率下降明显，在此含量范围以后，体积电阻率变化不大；材料的导电性能与加工工艺有关，溶剂法的导电性能比混炼法好；电阻率随温度的升高均有上升的趋势。由复合材料的亚微观结构表明，随着ＣＢ含量的增加，ＣＢ由分散的单个颗粒逐渐连结在一起，最后与ＰＳ形成了一种相互交错式的结构     

Flow‐Field Designs of Bipolar Plates in PEM Fuel Cells: Theory and Applications

A generalized model developed by Wang was modified for flow field designs of the most common layout configurations with U‐type arrangement, including single serpentine, multiple serpentine, straight parallel, and interdigitated configurations. A direct and quantitative relationship was established among flow distribution, pressure drop, configurations, structures, and flow conditions. The model was used for a direct, systematic, and quantitative comparison of flow distributions and pressure drops among the most common layout configurations of interest. The straight parallel configuration had the lowest pressure drops but suffered the most possibility of the uneven flow distribution across the channels. The single serpentine had the best flow distribution but had the highest pressure drops. The flow distribution and the pressure drop in the multiple serpentine was between the straight parallel and the single serpentine. Finally, we suggested basic criteria of the flow field designs of bipolar plates for the industrial applications. This provides a practical guideline to evaluate how far a fuel cell is from design operating conditions, and measures how to improve flow distribution and pressure drop.     

Modelling and Analysis of Electro‐chemical,Thermal, and Reactant Flow Dynamics for a PEM Fuel Cell System

In this paper an approach for the dynamic modelling of polymer electrolyte membrane fuel cells is presented. A mathematical formulation based on empirical equations is discussed and several features, exhibiting dynamic phenomena, are investigated. A generalized steady state fuel cell model is extended for the development of a method for dynamic electrochemical analysis. Energy balance and reactant flow dynamics are also explained through physical and empirical relationships. A well‐researched system (Ballard MK5‐E stack based PGS‐105B system) is considered in order to understand the operation of a practical fuel cell unit. Matlab‐SIMULINK^TM has been used in simulating the models. The proposed method appears to be relatively simple and consequently requires less computation time. Simulation results are compared with available experimental findings and a good match has been observed.     

Preparation of a HDPE/Carbon Nanotube Composite

This experiment adopted mixed acid (H₂SO₄:HNO₃ = 3:1) to purify multi-walled carbon nanotubes, and used a silane coupling agent n-octyltriethoxysilane (OTES) to modify carbon nanotubes, respectively. Then we mixed OTES-modified carbon nanotubes (CNTs) with high-density polyethylene (HDPE) resin to make a composite. TGA analysis results revealed that as the CNTs'content increased, the Td₁₀ tended to rise. The amount of composite residual at 500°C also increased, as well as the composite electrical conductivity. When a concentration of 5% OTES was used to modify the CNT, the resultant composite exhibited better electrical conductivity.     

聚合物膜燃料电池NG/PP复合双极板研究

以热塑性聚丙烯树脂(PP),天然鳞片石墨(NG)为主要原料,采用模压工艺制备了NG/PP复合双极板,考察了不同模压压力、模压时间对双极板性能的影响。     

Carbon‐Polymer Composite Bipolar Plate for HT‐PEMFC

Graphene reinforced carbon‐polymer composite bipolar plate is developed using resole phenol formaldehyde resin, and conductive reinforcements (natural graphite, carbon black, and carbon fiber) using compression molding technique. Graphene is reinforced into the composite to alter various properties of the composite bipolar plate. The developed composite bipolar plate is characterized and the effect of temperature on mechanical and electrical properties is investigated with an overall aim to achieve benchmark given by US‐DOE and Plug Power Inc. The flexural strength and electrical conductivity of the composites was almost stable with the increase in temperature upto 175 °C. The composite bipolar plate maintained high in‐plane and through‐plane electrical conductivities, which is about 409.23 and 98 S cm^–1, respectively, at 175 °C. The flexural strength and shore hardness of the developed composite was around 56.42 MPa and 60, respectively, at 175 °C, and on further increase in the temperature the mechanical strengths deceases sharply. The electrical and mechanical properties of the composite bipolar plates are within the US‐DoE target. However, the various properties of the composite bipolar plate could not be sustained above 175 °C.     

Development of Low‐Cost Advanced Composite Bipolar Plate for Proton Exchange Membrane Fuel Cell�

The bipolar plate is one of the most imperative components of proton exchange membrane fuel cells (PEMFC) which consumes up to 80% of weight and near about 50% of the total cost of the cell. Development of cost‐effective composite bipolar plate with high electrical conductivity and high mechanical strength is both technically and economically demanding. In this paper, a low‐cost advanced composite bipolar plate is developed by bulk moulding compression (BMC) technique. It is clear from the experiments that by increasing the matrix volume fraction, bulk density and electrical conductivity of a composite bipolar plate decrease but shore hardness increases. Test results clearly show that best overall properties are achieved when a constant volume fraction of polymer matrix and natural graphite is reinforced with synthetic graphite, carbon black and carbon fibre. This bipolar plate was found to have high conductivity, less porosity and high mechanical strength. The I–V characteristics in single cell test exhibited more uniform power density at both higher and lower current densities     

Performance Assessment of a Combined PEM Fuel Cell and Triple‐Effect Absorption Cooling System for Cogeneration Applications

In this paper, a parametric study of a combined proton exchange membrane (PEM) fuel cell and triple‐effect absorption cooling system (TEACS) is undertaken to investigate the effect of different operating conditions and system parameters on the COPs, efficiency of the fuel cell and the integrated system's overall utilisation factor. It is found that the fuel cell efficiency increases from 40% to 44.5% as the operating temperature of the fuel cell increases. However, as the fuel cell's temperature and current density increase, the COPs decrease from 2.4 to 0.9 as a result of the increase in the energy output of the fuel cell ranging from 7.4 to 10.7 kW. The efficiency of the fuel cell decreases from 41% to 32% with an increase in both fuel cell's current density and membrane thickness. The overall utilisation factor of the integrated system decreases from 84% to 35% with an increase in the current density and molar flow rate. Finally, this study reveals that the present integrated PEM fuel cell unit with a TEACS can be considered as an attractive and environmentally benign option for cogeneration purposes in sustainable buildings.     

Development and Evaluation of Gas Diffusion Layer Using Paraffin Wax Carbon for Proton Exchange Membrane Fuel Cells

A gas diffusion layer (GDL) with carbon prepared from paraffin wax was developed for the first time to impart hydrophobicity and porosity for fuel cell application. It is also intended to reduce the non‐functional binder content in the microporous layer and to achieve optimum performance. The topography of the GDL was examined using 3D digital microscope. Membrane electrodes assemblies (MEAs) fabricated with GDLs of paraffin wax carbon (PWC) based microporous layer were evaluated in proton exchange membrane fuel cell between 50 and 100% RH conditions using H₂ and O₂ at ambient pressure. The fuel cell performance of the GDLs fabricated with Pureblack carbon was also evaluated under identical operating conditions for comparison. It was observed that the MEA with GDLs containing PWC showed excellent fuel cell performance at all RH conditions at 80 °C both with H₂/O₂.     

Evaluation of Ni‐Mo and Ni‐Mo‐P Electroplated Coatings on Stainless Steel for PEM Fuel Cells Bipolar Plates

Stainless steel bipolar plates (BPPs) are the preferred choice for proton exchange membrane fuel cells (PEMFCs); however, a surface coating is needed to minimize contact resistance and corrosion. In this paper, Ni–Mo and Ni–Mo–P coatings were electroplated on stainless steel BPPs and investigated by XRD, SEM/EDX, AFM and contact angle measurements. The performance of the BPPs was studied by corrosion and conduction tests and by measuring their interfacial contact resistances (ICRs) ex situ in a PEMFC set‐up at varying clamping pressure, applied current and temperature. The results revealed that the applied coatings significantly reduce the ICR and corrosion rate of stainless steel BPP. All the coatings presented stable performance and the coatings electroplated at 100 mA cm⁻² showed even lower ICR than graphite. The excellent properties of the coatings compared to native oxide film of the bare stainless steel are due to their higher contact angle, crystallinity and roughness, improving hydrophobicity and electrical conductivity. Hence, the electroplated coatings investigated in this study have promising properties for stainless steel BPPs and are potentially good alternatives for the graphite BPP in PEMFC.     

Fuel Pressure Distribution as a Criterion for the Bipolar Plate Geometry Optimization in PEM Fuel Cells,Modeling and Experiment

In this study the pressure distribution homogeneity on the catalytic surface is found to provide a simple and reliable fuel flow parameter that can be used to optimize the bipolar plate geometry and the PEM fuel cell performance. Finite element commercial ANSYS software was used to determine the fuel velocity, pressure and mass distribution on eight different bipolar plate geometries. These geometries were also fabricated and characterized experimentally in order to establish a correlation between the power densities with the fuel flow parameters obtained from the simulations. The results show that a highly uniform pressure distribution of the fuel in the bipolar plate is necessary to obtain higher power densities. Inversely, non‐homogeneous pressure distributions lead to lower power densities. Additionally, the measured power density increases when the geometry dependent effective catalytic surface area increases. These results are interesting since they provide an optimization methodology for PEM fuel cells that simplifies and reduces computing requirements, experimentation and manufacturing time.