Lithium polymer batteries and proton exchange membrane fuel cells as energy sources in hydrogen electric vehicles

This paper deals with the application of lithium ion polymer batteries as electric energy storage systems for hydrogen fuel cell power trains. The experimental study was firstly effected in steady state conditions, to evidence the basic features of these systems in view of their application in the automotive field, in particular charge-discharge experiments were carried at different rates (varying the current between 8 and 100 A). A comparison with conventional lead acid batteries evidenced the superior features of lithium systems in terms of both higher discharge rate capability and minor resistance in charge mode. Dynamic experiments were carried out on the overall power train equipped with PEM fuel cell stack (2 kW) and lithium batteries (47.5 V, 40 Ah) on the European R47 driving cycle. The usage of lithium ion polymer batteries permitted to follow the high dynamic requirement of this cycle in hard hybrid configuration, with a hydrogen consumption reduction of about 6% with respect to the same power train equipped with lead acid batteries.     

A feasibility study on direct methanol fuel cells for laptop computers based on a cost comparison with lithium-ion batteries

This paper compares the total cost of direct methanol fuel cell (DMFC) and lithium (Li)-ion battery systems when applied as the power supply for laptop computers in the Korean environment. The average power output and operational time of the laptop computers were assumed to be 20 W and 3000 h, respectively.     

Estimating future prices for stationary fuel cells with empirically derived experience curves

Fuel cells presently require an order of magnitude cost reduction to become a commercial success in domestic energy markets. Previous analyses using learning curves have shown that competitive costs are feasible, but these have been unanimously based on theoretical estimates.     

A systematic approach for matching simulated and experimental polarization curves for a PEM fuel cell

Matching simulated and experimental polarization curves is an essential step in the modelling of polymer electrolyte membrane (PEM) fuel cells, but the numerical values of many input parameters like exchange current densities, charge transfer coefficients, protonic conduction coefficient and water removal coefficient are hard to be found experimentally. In this paper, the influence of these input parameters on the performance of PEM fuel cells has been investigated using the ANSYS PEM Fuel Cell Module. The simulation results show how the exchange current densities and charge transfer coefficients influence the activation losses; membrane resistance and contact resistance between the different components of a fuel cell contribute to the ohmic losses; and the coefficient of liquid water removal affects the concentration losses. A systematic procedure to match a simulated polarization curve with an experimental curve is presented and illustrated by application to an experimental PEM fuel cell with 5 cm² active area.     

Corrosion of metal bipolar plates for PEM fuel cells: A review

PEM fuel cells are of prime interest in transportation applications due to their relatively high efficiency and low pollutant emissions. Bipolar plates are the key components of these devices as they account for significant fractions of their weight and cost. Metallic materials have advantages over graphite-based ones because of their higher mechanical strength and better electrical conductivity. However, corrosion resistance is a major concern that remains to be solved as metals may develop oxide layers that increase electrical resistivity, thus lowering the fuel cell efficiency. This paper aims to present the main results found in recent literature about the corrosion performance of metallic bipolar plates.     

A nonlinear control strategy for fuel delivery in PEM fuel cells considering nitrogen permeation

Hydrogen energy shows its great potential to be one of the future sustainable energies with abundant storage and high energy content. Proton exchange membrane (PEM) fuel cells, as a hydrogen energy conversation plant with high efficiency, becomes a hot topic of many researches. This paper proposes a multi-input-multi-output (MIMO) nonlinear control strategy for fuel delivery in PEM fuel cell systems. Specifically, a control oriented dynamic model is developed for the fuel delivery system (FDS) with anode recirculation and anode bleeding. Based on the model, a MIMO nonlinear state feedback controller is proposed to maintain adequate hydrogen supply and suitable anode hydrogen concentration. Moreover, an optimized output feedback controller is proposed to improve the state feedback controller, where the unknown hydrogen partial pressures utilized are estimated by developed observers. Lyapunov based stability analysis is carried out to analyze the proposed output feedback controller and the observers. Simulation results show the effectiveness of the proposed controller under various current demands.     

A micro-scale model for predicting contact resistance between bipolar plate and gas diffusion layer in PEM fuel cells

Contact resistance between the bipolar plate (BPP) and the gas diffusion layer (GDL) in a proton exchange membrane (PEM) fuel cell constitutes a significant portion of the overall fuel cell electrical resistance under the normal operation conditions. Most current methods for contact resistance estimation are experimental and there is a lack of well developed theoretical methods. A micro-scale numerical model is developed to predict the electrical contact resistance between BPP and GDL by simulating the BPP surface topology and GDL structure and numerically determining the status for each contact spot. The total resistance and pressure are obtained by considering all contact spots as resistances in parallel and summing the results together. This model shows good agreements with experimental results. Influences of BPP surface roughness parameters on contact resistance are also studied. This model is beneficial in understanding the contact behavior between BPP and GDL and can be integrated with other fuel cell simulations to predict the overall performance of PEM fuel cells.     

A flow channel design procedure for PEM fuel cells with effective water removal

Proper water management in polymer electrolyte membrane (PEM) fuel cells is critical to achieve the potential of PEM fuel cells. Membrane electrolyte requires full hydration in order to function as proton conductor, often achieved by fully humidifying the anode and cathode reactant gas streams. On the other hand, water is also produced in the cell due to electrochemical reaction. The combined effect is that liquid water forms in the cell structure and water flooding deteriorates the cell performance significantly. In the present study, a design procedure has been developed for flow channels on bipolar plates that can effectively remove water from the PEM fuel cells. The main design philosophy is based on the determination of an appropriate pressure drop along the flow channel so that all the liquid water in the cell is evaporated and removed from, or carried out of, the cell by the gas stream in the flow channel. At the same time, the gas stream in the flow channel is maintained fully saturated in order to prevent membrane electrolyte dehydration. Sample flow channels have been designed, manufactured and tested for five different cell sizes of 50, 100, 200, 300 and 441 cm². Similar cell performance has been measured for these five significantly different cell sizes, indicating that scaling of the PEM fuel cells is possible if liquid water flooding or membrane dehydration can be avoided during the cell operation. It is observed that no liquid water flows out of the cell at the anode and cathode channel exits for the present designed cells during the performance tests, and virtually no liquid water content in the cell structure has been measured by the neutron imaging technique. These measurements indicate that the present design procedure can provide flow channels that can effectively remove water in the PEM fuel cell structure.     

A review of accelerated stress tests of MEA durability in PEM fuel cells

This paper is a review of recent work done on accelerated stress tests in the study of PEM fuel cell durability, with a primary focus on the main components of the membrane electrode assembly (MEA). The accelerated stressors for each component under different conditions are outlined, in an attempt to gain a detailed understanding of cell degradation with respect to microstructural change and performance attenuation in the perfluorosulfonic acid membrane, catalyst, and gas diffusion layers. Various techniques for evaluating the components' performance are presented, along with representative mitigation strategies. In addition, different degradation mechanisms proposed in recent publications are briefly reviewed.     

Dynamic performance assessment of the efficiency of fuel cell-powered bicycle: An experimental approach

Zero-emission fuel cell driven systems are regarded as promising technological advances in the future of the transportation industry that have the potential to replace internal combustion engines. The design, performance, and efficiency properties of a vehicle are often stated to be some of the key challenges in its commercialization. This paper highlights a polymer electrolyte membrane fuel cell (PEMFC)-powered system of an electric bicycle. The system consists of a 250-W fuel cell, ECU, battery pack, DC/DC converter, electric motor, and other supporting equipment. After introducing the different parts of the bicycle, its overall efficiency will be discussed in great detail. The efficiency of fuel cells is not specific; it is a subordinate to the power density where the system operates. Experimental work has been conducted to measure the values of the efficiency and energy flow. The results indicated a maximum fuel cell efficiency of 63% and an overall system efficiency of 35.4%. The latter value is expressed with regards to the Lower Heating Value (LHV) of hydrogen. All measurements were taken for the cruising conditions of the vehicle and its corresponding to power consumption. The results are superior to those of a standard internal ignition engine. The fuel cell performance is least efficient when functioning under maximum output power conditions.     

Dynamics of liquid water in the anode flow channels of PEM fuel cells: A numerical parametric study

A 3D volume of fluid (VOF) model for an anode channel in a PEM fuel cell has been built. The effects of the initial position of the water droplet, its size as well as the wettability of the gas diffusion layer (GDL) are investigated under different operating conditions. It is found that the initial position of the relatively small water droplet in the channel has almost no effect on the pressure drop and the time taken for the liquid water to move out from the channel; however, such effects become more profound as the size of the water droplet increases. Also, when the droplet is placed at the side wall of the channel, then it develops into pockets of water that are mainly located at the upper corners of the channel, thus causing a smaller pressure drop compared to the cases in which the water droplet is placed either on the surface of the GDL or on the top wall of the channel. Furthermore, the hydrogen velocity is found to have a negligible effect on the dynamics of liquid water; however, the pressure drop and removal time are significantly influenced by the hydrogen velocity. Moreover, as the size of the water droplet increases, the pressure drop increases and the time required for the liquid water to move out of the channel decreases. Finally, the pressure drop in the channel decreases and the removal time of the liquid water increases as the contact angle of the GDL decreases.     

An analysis of fluidic voltage statistical correlation for a diagnosis of PEM fuel cell flooding

The fault diagnosis is one of the most important topics on Proton Exchange Membrane Fuel Cell (PEMFC) stacks. Statistical methodologies for diagnosis are considered as one of the most relevant. This paper is dedicated to the diagnosis of flooding, using statistical methodology.     

An experimental study of a PEM fuel cell power train for urban bus application

An experimental study was carried out on a fuel cell propulsion system for minibus application with the aim to investigate the main issues of energy management within the system in dynamic conditions. The fuel cell system (FCS), based on a 20 kW PEM stack, was integrated into the power train comprising DC–DC converter, Pb batteries as energy storage systems and asynchronous electric drive of 30 kW. As reference vehicle a minibus for public transportation in historical centres was adopted. A preliminary experimental analysis was conducted on the FCS connected to a resistive load through a DC–DC converter, in order to verify the stack dynamic performance varying its power acceleration from 0.5 kW s⁻¹ to about 4 kW s⁻¹. The experiments on the power train were conducted on a test bench able to simulate the vehicle parameters and road characteristics on specific driving cycles, in particular the European R40 cycle was adopted as reference. The “soft hybrid” configuration, which permitted the utilization of a minimum size energy storage system and implied the use of FCS mainly in dynamic operation, was compared with the “hard hybrid” solution, characterized by FCS operation at limited power in stationary conditions. Different control strategies of power flows between fuel cells, electric energy storage system and electric drive were adopted in order to verify the two above hybrid approaches during the vehicle mission, in terms of efficiencies of individual components and of the overall power train.     

A review of processes and technologies for the recycling of lithium-ion secondary batteries

The purpose of this paper is to review the current status of the recycling technologies of spent lithium-ion secondary batteries. It introduced the structure and components of the lithium-ion secondary batteries, summarized all kinds of single recycling processes from spent lithium-ion secondary batteries and presented some examples of typical combined recycling processes. Also, the problems and prospect of the studies of their recycling technologies have been put forward.     

Investigation of tungsten carbide supported Pd or Pt as anode catalysts for PEM fuel cells

In this contribution, we present results of electrochemical characterization of prepared tungsten carbide supported palladium and platinum and Vulcan XC-72 supported palladium. These catalysts were employed as anode catalysts in PEMFC and results are compared to commercial platinum catalyst. Platinum seems to be irreplaceable as a proton exchange membrane fuel cell (PEMFC) catalyst for both the anode and the cathode, yet the high price and limited natural resources are holding back the commercialization of the PEMFCs. Tungsten carbide is recognized as promising catalyst support having the best conductivity among interstitial carbides. Higher natural resources and significantly lower price make palladium good candidate for replacement of the platinum catalyst. The presented results show that all prepared catalysts are very active for the hydrogen oxidation reaction. Linear sweep voltammetry curves of Pd/C and Pd/WC show existence of peaks at 0.07 V vs. RHE, which is assigned to absorbed hydrogen. H₂|Pd/WC|Nafion117|Pt/C|O₂ fuel cell has almost the same efficiency and similar power output as commercial platinum catalyst.     

Design and development of a multipurpose utility AWD electric vehicle with a hybrid powertrain based on PEM fuel cells and batteries

This paper presents the results obtained on the research project CIT-370000-2008-11, entitled “Multi-purpose remote-controlled all-wheel-drive tool-vehicle powered by fuel cells” funded by the Spanish Ministry of Science and Technology. A new concept multipurpose electric vehicle has been designed and manufactured, based on three basic features: a hybrid power system consisting in PEM fuel cells + batteries, an all-wheel-drive traction system, and the capability of being either on-site driven or remote-controlled. The vehicle is formed by two frames connected by a two-degree of freedom joint, and is powered by two 2.5 kW DC motors, one in each axle. All the electric circuits for the suitable control of the power hybrid system have been developed in our Laboratory, allowing a large flexibility. After the different tests performed, it has been verified that the vehicle presents good maneuverability, a good traction performance in off-road driving, as well as a good slope-climbing capability. Under the experimental conditions tested, the vehicle reached a maximum speed of 11 km/h on flat surface, keeping the maximum power consumption always around 3 kW.     

A review of PEM fuel cell durability: Degradation mechanisms and mitigation strategies

This paper reviews publications in the literature on performance degradation of and mitigation strategies for polymer electrolyte membrane (PEM) fuel cells. Durability is one of the characteristics most necessary for PEM fuel cells to be accepted as a viable product. In this paper, a literature-based analysis has been carried out in an attempt to achieve a unified definition of PEM fuel cell lifetime for cells operated either at a steady state or at various accelerated conditions. Additionally, the dependence of PEM fuel cell durability on different operating conditions is analyzed. Durability studies of the individual components of a PEM fuel cell are introduced, and various degradation mechanisms are examined. Following this analysis, the emphasis of this review shifts to applicable strategies for alleviating the degradation rate of each component. The lifetime of a PEM fuel cell as a function of operating conditions, component materials, and degradation mechanisms is then established. Lastly, this paper summarizes accelerated stress testing methods and protocols for various components, in an attempt to prevent the prolonged test periods and high costs associated with real lifetime tests.     

A study on polarization hysteresis in PEM fuel cells by galvanostatic step sweep

In this work, the galvanostatic step sweep was used to investigate the hysteresis phenomenon found in the polarization measurements in proton exchange membrane (PEM) fuel cells. Three different diffusion media including Toray, E-TEK and SGL as well as the PTFE content from 10% to 30% in the diffusion media were carefully examined. Based on these results along with the comparison between results using dry and fully humidified air, the reason for the formation of such hysteresis in polarization curves was clarified. The generation and storage of liquid water was correlated with the materials of diffusion layers as well as the cross point in polarization curves during the forward and backward sweeps. Experimental results on the effect of operation conditions, i.e. flow rates, cell temperature and the time at each current density were also explored to illuminate the transient behavior within fuel cells behind such hysteresis phenomenon.     

Dynamic analysis of PEM fuel cells and metal hydrides on a zero-emission ship: A model-based approach

As the interest in hydrogen and PEM fuel cells is growing, it is crucial to define the best technology for fuel storage, especially in the transportation field. Metal hydrides show different benefits, including the possibility of thermally coupling the hydrogen storage and utilization systems: fuel cells require heat subtraction for ensuring proper operation, while metal hydrides require heat to activate the hydrogen release reactions. This work describes the integration of PEMFCs and metal hydrides on board a zero-emissions ship, with a special focus on their thermal coupling; a model-based approach is developed to ensure the system's feasibility at different load demands for the vessel, including transient conditions. The study is based on the real application of an innovative zero-emissions ship (ZEUS) financed by Fincantieri-Isotta Fraschini S.p.A, where the total power installation is set at 144 kW by PEMFC and 50 kg of hydrogen are stored by metal hydrides.     

Surface treatments with perfluoropolyether derivatives for the hydrophobization of gas diffusion layers for PEM fuel cells

In the present work, preliminary results of different hydrophobic surface treatments for gas diffusion layer (GDL) for PEM fuel cells are presented. This hydrophobic coating consists of new perfluoropolyether (PFPE) derivatives, in comparison to standard polytetrafluoroethylene (PTFE) dispersions. Experimental conditions for an efficient coating of fluoropolymers onto carbon clothes were explored by wet chemical methods.The GDLs obtained were tested in a single fuel cell at the lab scale. The cell testing was run at two temperatures (60 °C and 80 °C) with a relative humidity (RH) of the feeding gases of 80/100%, hydrogen/air respectively.The new PFPE coatings measurably improve the cell performances, and this effect is more evident at 60 °C with respect to 80 °C.