Development and operation of a 150 W air-feed direct methanol fuel cell stack

A five-cell 150 W air-feed direct methanol fuel cell (DMFC) stack was demonstrated. The DMFC cells employed Nafion 117^® as a solid polymer electrolyte membrane and high surface area carbon supported Pt-Ru and Pt catalysts for methanol electrooxidation and oxygen reduction, respectively. Stainless steel-based stack housing and bipolar plates were utilized. Electrodes with a 225 cm² geometrical area were manufactured by a doctor-blade technique. An average power density of about 140 mW cm^–2 was obtained at 110 °C in the presence of 1 M methanol and 3 atm air feed. A small area graphite single cell (5 cm²) based on the same membrane electrode assembly (MEA) gave a power density of 180 mW cm^–2 under similar operating conditions. This difference is ascribed to the larger internal resistance of the stack and to non-homogeneous reactant distribution. A small loss of performance was observed at high current densities after one month of discontinuous stack operation.     

Direct methanol alkaline fuel cells with catalysed anion exchange membrane electrodes

Membrane electrodes prepared by chemical deposition of platinum directly onto the anion exchange membrane electrolyte were tested in direct methanol alkaline fuel cells. Data on the cell voltage against current density performance and anode potentials are reported. The relatively low fuel cell performance was probably due to the low active surface area of Pt deposits on the membrane comparing to other membrane electrode assembly (MEA) fabrication methods. However, the catalysed membrane electrode showed good performance for oxygen reduction. A reduction in cell internal resistance was also obtained for the catalysed membrane electrode. By combining the catalysed membrane electrodes with a catalysed mesh, maximum current density of 98 mA cm^–2 and peak power density of 18 mW cm^–2 were achieved.     

Bifunctional electrodes for an integrated water-electrolysis and hydrogen-oxygen fuel cell with a solid polymer electrolyte

An alternative concept of an integrated water electrolysis/hydrogen-hydrogen fuel cell using metal electrocatalysts and a solid polymer electrolyte is described. Instead of operating both electrodes as hydrogen and oxygen electrodes respectively the electrodes are used as oxidation and reduction electrodes in both modes of operation. A more suitable selection of electrocatalysts and an improved cell design are possible; both can increase the efficiency of the cell considerably. New results on the electrocatalytic activity of various noble-metal containing catalysts with respect to both oxygen evolution and hydrogen oxidation in a proton exchange membrane-cell at 80°C are reported. Kinetic data derived from Tafel plots of the oxygen evolution polarization curves agree closely with those of experiments with aqueous sulphuric acid electrodes. This agreement allows the determination of kinetic parameters for electrocatalysts difficult to prepare in solid smooth electrodes but easy to be made into porous deposits. Polarization curves of the hydrogen oxidation reaction clearly indicate a relative activity rating of the studied catalysts. In cycling tests the lifetime stability of the new bifunctional oxidation electrode was determined. Polarization data obtained under these conditions agree with those obtained in earlier experiments where electrodes were exposed to only one type of oxidation reaction. During a test of 10 cycles (30 min of electrolyser and 30 min of fuel cell mode each) no changes in the electrode potential were observed. With the conventional cell design employing a hydrogen and an oxygen electrode both catalyzed with platinum and a current density of 100 mA cm^–2 a storage efficiency of 50% was calculated; with the alternative concept of oxidation and reduction electrodes and selected oxidation catalysts this was improved to 57%. With further improvements these efficiencies seem possible even at current densities of 500 mA cm^–2.     

An improved-performance liquid-feed solid-polymer-electrolyte direct methanol fuel cell operating at near-ambient conditions

Results on the performance of a 25 cm² liquid-feed solid-polymer-electrolyte direct methanol fuel cell (SPE-DMFC), operating under near-ambient conditions, are reported. The SPE-DMFC can yield a maximum power density of c. 200 mW cm⁻² at 90 °C while operating with 1 M aqueous methanol and oxygen under ambient pressure. While operating the SPE-DMFC under similar conditions with air, a maximum power density of ca. 100 mW cm⁻² is achieved. Analysis of the electrode reaction kinetics parameters on the methanol electrode suggests that the reaction mechanism for methanol oxidation remains invariant with temperature. Durability data on the SPE-DMFC at an operational current density of 100 mA cm⁻² have also been obtained.     

Development and electrochemical studies of gas diffusion electrodes for polymer electrolyte fuel cells

Electrochemical studies on low catalyst loading gas diffusion electrodes for polymer electrolyte fuel cells are reported. The best performance is obtained with an electrode formed from 20 wt% Pt/C, 0.4 mg Pt cm^–2 and 1.1 mg Nafion^® cm^–2 in the catalyst layer and 15% PTFE in a diffusion layer of 50 µm thickness, for both the cathode and the anode. However, it is also observed that the platinum requirement can be diminished to values close to 0.2 mg Pt cm^–2 in the cathode and 0.1 mg pt cm^–2 in the anode, without appreciably affecting the good characteristics of the fuel cell response. The experimental fuel cell data were analysed using theoretical models of the electrode structure and of the fuel cell system. It is seen that most of the electrode systems present limiting currents and some also show linear diffusion components arising from diffusion limitations in the gas channels and/or in the thin film of electrolyte covering the catalyst particles.     

Durability test of SOFC cathodes

The durability of solid oxide fuel cell (SOFC) composite cathodes of lanthanum strontium manganite and yttria stabilised zirconia was investigated. The cathodes were kept at constant, realistic operating conditions (–300 mA cm^–2 at 1000 °C in air) for up to 2000 h. After the 2000 h test the increase in electrode overvoltage exceeded 100% of the initial value. Nominally identical cathodes kept for 2000 h at 1000 °C in air without current load for comparison showed little or no degradation. Thus, the current load of –300 mA cm^–2, rather than the operation temperature of 1000 °C, was responsible for the degradation. Structural analysis showed an increase in the porosity at the electrode interfaces, when the electrode had been polarised. No such structural changes were found for electrodes tested without current load. The degradation is primarily ascribed to pore formation in the electrode material induced by an electric field.     

Experimental results on the direct electrochemical oxidation of methanol in PEM fuel cells

The cell performance of direct methanol fuel cells (DMFC) is 0.5 V at 0.5 A cm^–2 under high pressure oxygen operation (3 bar abs.) at 110 °C. However, high oxygen pressure operation at high temperatures is only useful in special market niches. Therefore, our work has now focused on air operation of a DMFC under low pressure (up to 1.5 bar abs.). At present, a power density of more than 100 mW cm^–2 can be achieved at 0.5 V on air operation at 110 °C. These measurements were carried out in single cells with an electrode area of 3 cm² and the air stoichiometry only amounted to 10. The effects of methanol concentration and temperature on the anode performance were studied by pseudo half cell measurements and the results are presented together with their impact on the cell voltage. A cell design with an electrode area of 550 cm², which is appropriate for assembling a DMFC stack, was tested. A three-celled stack based on this design revealed nearly the same power densities as in the small experimental cells at low air excess pressure and the voltage–current curves for the three cells were almost identical. At 110 °C a power output of 165 W at a stack voltage of 1.5 V can be obtained in the air mode.     

Iron(III) tetramethoxyphenylporphyrin(FeTMPP) as methanol tolerant electrocatalyst for oxygen reduction in direct methanol fuel cells

Carbon supported iron (III) tetramethoxyphenylporphyrin (FeTMPP) heat treated at 800°C under argon atmosphere was used as catalysts for the electroreduction of oxygen in direct methanol polybenzimidazole (PBI) polymer electrolyte fuel cells that were operated at 150°C. The electrode structure was optimized in terms of the composition of PTFE, polymer electrolyte and carbon-supported FeTMPP catalyst loading. The effect of methanol permeation from anode to cathode on performance of the FeTMPP electrodes was examined using spectroscopic techniques, such as on line mass spectroscopy (MS), on line Fourier transform infrared (FTIR) spectroscopy and conventional polarization curve measurements under fuel cell operating condition. The results show that carbon supported FeTMPP heat treated at 800°C is methanol tolerant and active catalyst for the oxygen reduction in a direct methanol PBI fuel cell. The best cathode performance under optimal condition corresponded to a potent ial reached of 0.6V vs RHE at a current density of 900 mAcm–2.     

Aluminium alloys in sulfuric acid Part II: Aluminium-oxygen cells

Aluminium alloys were tested in Al/O₂ cells with strongly acidic electrolytes containing minor amounts of chloride ions. The faradaic efficiency, the maximum discharge capacity and the peak power of various Al/O₂ cells were evaluated. The temperature dependence of the faradaic efficiency was measured for an Al/O₂ cell over the temperature range from 15 to 50°C. With a zinc-containing aluminium alloy, a faradaic efficiency of 84% and a cell voltage of 1.6 V at open circuit and 0.7 V at 100 mA cm^–2 could be reached. The highest peak power 120 mW cm^–2, was obtained with an Al-Zn/Sn alloy. On the basis of the solubility of the anode products in the electrolyte, a limiting specific energy of 70 Wh kg^–1 was estimated. The cell voltage depends on the Al-alloys and on the catalyst used in the oxygen electrode. The cell voltage could be increased by about 200 mV when replacing the Pt-catalysed oxygen electrode with a noble-metal-free (CoCAA/DCD) electrode.     

Inhibition of sintering in molten carbonate fuel cell anodes

Molten carbonate fuel cells operate at 600–700°C. At these high temperatures, high surface area nickel anodes lose their activity rapidly due to sintering. A study of the sintering kinetics of Ni, Ni-Ag and Ag powder revealed that when Ni and Ag particles are present in similar numbers, sintering is significantly inhibited. This is achieved by minimizing volume diffusion between adjacent particles — Ni and Ag have virtually no solid solubility at any temperature. Paste electrolyte cells using such electrodes gave 114 mA/cm² at 0.65 V on 80% H₂/20% CO₂ fuel, compared to 80 mA/cm² at 0.65 V for a cell using sintered nickel anodes.     

Phosphoric acid doped polybenzimidazole membranes: Physiochemical characterization and fuel cell applications

A polymer electrolyte membrane fuel cell operational at temperatures around 150–200 °C is desirable for fast electrode kinetics and high tolerance to fuel impurities. For this purpose polybenzimidazole (PBI) membranes have been prepared and H₃PO₄-doped in a doping range from 300 to 1600 mol %. Physiochemical properties of the membrane electrolyte have been investigated by measurements of water uptake, acid doping level, electric conductivity, mechanical strength and water drag coefficient. Electrical conductivity is found to be insensitive to humidity but dependent on the acid doping level. At 160 °C a conductivity as high as 0.13 S cm^–1 is obtained for membranes of high doping levels. Mechanical strength measurements show, however, that a high acid doping level results in poor mechanical properties. At operational temperatures up to 190 °C, fuel cells based on this polymer membrane have been tested with both hydrogen and hydrogen containing carbon monoxide.     

Optimization of operating parameters of a direct methanol fuel cell and physico-chemical investigation of catalyst–electrolyte interface

A physico-chemical investigation of catalyst–Nafion® electrolyte interface of a direct methanol fuel cell (DMFC), based on a Pt–Ru/C anode catalyst, was carried out by XRD, SEM-EDAX and TEM. No interaction between catalyst and electrolyte was detected and no significant interconnected network of Nafion micelles inside the composite catalyst layer was observed. The influence of some operating parameters on the performance of the DMFC was investigated. Optimal conditions were 2 M methanol, 5 atm cathode pressure and 2–3 atm anode pressure. Power densities of 110 and 160 mW cm⁻² were obtained for operation with air and oxygen, respectively, at temperatures of 95–100°C and with 1 mg cm⁻² Pt loading.     

Performance of a direct methanol fuel cell

The performance of a direct methanol fuel cell based on a Nafion® solid polymer electrolyte membrane (SPE) is reported. The fuel cell utilizes a vaporized aqueous methanol fuel at a porous Pt–Ru–carbon catalyst anode. The effect of oxygen pressure, methanol/water vapour temperature and methanol concentration on the cell voltage and power output is described. A problem with the operation of the fuel cell with Nafion® proton conducting membranes is that of methanol crossover from the anode to the cathode through the polymer membrane. This causes a mixed potential at the cathode, can result in cathode flooding and represents a loss in fuel efficiency. To evaluate cell performance mathematical models are developed to predict the cell voltage, current density response of the fuel cell.     

The physical–chemical properties and electrocatalytic performance of iridium oxide in oxygen evolution

An IrO₂ anode catalyst was prepared by using the Adams method for the application of a solid polymer electrolyte (SPE) water electrolyzer. The effect of calcination temperature on the physical–chemical properties and the electrochemical performance of IrO₂ were examined to obtain a low loading and a high catalytic activity of oxygen evolution at the electrode. The physical–chemical properties were studied via thermogravimetry–differential scanning calorimetry (TG–DSC), X-ray diffraction (XRD) and X-ray photoelectron spectroscopy (XPS). The electrochemical activity was investigated by using cyclic voltammetry (CV), electrochemical impedance spectroscopy (EIS), and chronopotentiometry in 0.1 mol L⁻¹ H₂SO₄ at room temperature. The optimum condition was found to be at the calcination temperature of 500 °C, where the total polarization reached a minimum at high current densities (>200 mA cm⁻²). The optimized catalyst was also applied to a membrane electrode assembly (MEA) and stationary current–potential relationships were investigated. With an optimized catalytic IrO₂ loading of 1.5 mg cm⁻² and a 40% Pt/C loading of 0.5 mg cm⁻², the terminal applied potential difference was 1.72 V at 2 A cm⁻² and 80 °C in a SPE water electrolysis cell.     

Material properties and processing in the production of fuel cell components: I. Hydrogen anodes from Raney nickel for lightweight alkaline fuel cells

The production steps of Raney nickel based, PTFE bonded hydrogen anodes for alkaline fuel cells are examined. The Raney nickel catalyst has been made by leaching the nickel aluminium alloy and additional stabilization. The electrode is fabricated by mixing the catalyst with copper oxide for enhancing electronic conductivity and aqueous PTFE emulsion as a hydrophobic binder. Each process step, starting from the nickel aluminium alloy is described and the physical properties of catalyst and electrode are evaluated. At an overpotential of 100 mV the optimized hydrogen anode exhibits at negligable excess hydrogen pressure (1·02bars) a current density of nearly 400 mA cm^–2 at 80°C in 30 wt% KOH. Long term performance test shows that electrode overpotential of more than 60 mV should be avoided. A life time of 5000 hrs at 50°C and a current density of 100 mA cm^–2 has been proven.     

A Solid-polymer Electrolyte Direct Methanol Fuel Cell with a Methanol-tolerant Cathode and its Mathematical Modelling

Solid-polymer electrolyte direct methanol fuel cells (SPE-DMFCs) employing carbon-supported Pt–Fe as oxygen-reduction catalyst to mitigate the effect of methanol on cathode performance while operating with oxygen or air have been assembled. These SPE-DMFCs provided maximum power densities of 250 and 120 mW cm^–2 at 85 °C on operating with oxygen and air, respectively. The polarization data for the SPE-DMFCs and their constituent electrodes have also been derived numerically employing a model based on phenomenological transport equations for the catalyst layer, diffusion layer and the membrane electrolyte.     

Ambient temperature gas phase electrochemical nitrogen reduction to ammonia at ruthenium/solid polymer electrolyte interface

The direct gas phase electrochemical reduction of nitrogen to ammonia is reported at ruthenium/solid polymer electrolyte interface using cells of the general configuration N₂, Ru/Nafion417/Pt, Ar(90%), H₂(10%).The Faradaic efficiency for reducing nitrogen to ammonia was found to be 0.0015% at a current density of 3.12 mA/cm² corresponding to 1.75 × 10^–9 moles cm^–2h^–1 on a 9.65 cm² electrode. Substitution of N₂ by Ar in the cathode chamber of these cells gave no detectable ammonia, suggesting introduced N₂ as the source used during NH₃ synthesis.     

Electrochemical impedance spectra of solid-oxide fuel cells and polymer membrane fuel cells

Electrochemical impedance spectroscopy (EIS) is a very useful method for the characterization of fuel cells. The anode and cathode transfer functions have been determined independently without a reference electrode using symmetric gas supply of hydrogen or oxygen on both electrodes of the fuel cell at open circuit potential (OCP). EIS are given for both polymer electrolyte fuel cells (PEFC) and solid oxide fuel cells (SOFC) at current densities up to 0.76 A cm⁻² (PEFC) and 0.22 A cm⁻² (SOFC). With increasing current density the PEFC-impedance decreases significantly in the low frequency range reaching a minimum at 0.4 A cm⁻². At even higher current densities an increasing contribution of water diffusion is observed: the cell impedance increases again. From EIS of SOFC a finite diffusion behavior is observed even at OCP, depending on water partial pressure of the anodic gas supply. This additional element reflects the influence of water partial pressure on the cell potential. The simulation of the measured EIS with an equivalent circuit enables the calculation of the individual voltage losses in the fuel cell.     

Influence of Methanol Crossover on the Fuel Utilization of Passive Direct Methanol Fuel Cell

The effect of methanol crossover on the fuel utilization of a passive direct methanol fuel cell (DMFC) was reported. The results revealed that the Faradaic efficiency decreased from 46.9 to 17.4% when methanol concentration increased from 1.0 to 8.0 mol L^–1 at the lower current density 11.1 mA cm^–2. However, the Faradaic efficiency increased from 14.7 to 31.3% when methanol concentration increased from 1.0 to 8.0 mol L^–1 at a higher current density of 44.4 mA cm^–2. On the other hand, although the amount of methanol was increased, the Faradaic efficiency did not change, obviously due to the uniform methanol crossover and methanol diffusion at the same methanol concentration and constant current.     

Radiation-grafted membrane/electrode assemblies with improved interface

Recent progress is reported in preparing membrane/electrode assemblies for polymer electrolyte fuel cells based on radiation-grafted FEP-g-poly(styrenesulfonic acid) membranes. MEAs with an improved interface between the membrane and commercially available gas diffusion electrodes were obtained by Nafion®-coating of the membrane and hot-pressing. These improved MEAs showed both, performance data comparable to those of MEAs based on Nafion® 112 and an operation lifetime in H₂/O₂ fuel cells of more than 2000 h at 60 °C and 500 mA cm⁻² current density.