Intermediate temperature fuel cells based on doped ceria–LiCl–SrCl2 composite electrolyte

A new type of oxide-salt composite electrolyte, gadolinium-doped ceria (GDC)–LiCl–SrCl₂, was developed and demonstrated its promising use for intermediate temperature (400–700 °C) fuel cells (ITFCs). The dc electrical conductivity of this composite electrolyte (0.09–0.13 S cm⁻¹ at 500–650 °C) was 3–10 times higher than that of the pure GDC electrolyte, indicating remarkable proton or oxygen ion conduction existing in the LiCl–SrCl₂ chloride salts or at the interface between GDC and the chloride salts. Using this composite electrolyte, peak power densities of 260 and 510 mW cm⁻², with current densities of 650 and 1250 mA cm⁻² were achieved at 550 and 625 °C, respectively. This makes the new material a good candidate electrolyte for future low-cost ITFCs.     

Novel quasi-solid electrolyte for dye-sensitized solar cells

A novel alkyloxy-imidazole polymer was prepared by in situ co-polymerization of alkyloxy-imidazole and diiodide to develop an ionic polymer gel electrolyte for quasi-solid dye-sensitized solar cells (DSCs). The DSCs with the polymer gel electrolyte of 1-methyl-3-propylimidazolium iodide (MPII) showed good photovoltaic performance including the short-circuit photocurrent density (J_sc) of 3.6 mA cm⁻², the open-circuit voltage (V_oc) of 714.8 mV, the fill factor (FF) of 0.60 and the light-to-electricity conversion efficiency (η) of 1.56% under AM 1.5 (100 mW cm⁻²). As a comparison, the DSCs with the polymer gel electrolyte of 1,2-dimethyl-3-propylimidazolium iodide (DMPII) yielded a light-to-electricity conversion efficiency of 1.33%. The results indicated that the as-prepared polymers were suitable for the solidification of liquid electrolytes in DSCs.     

Thin yttria-stabilized zirconia electrolyte and transition layers fabricated by particle suspension spray

In order to develop high performance intermediate temperature (<800 °C) solid oxide fuel cells (SOFCs) with a lower fabrication cost, a pressurized spray process of ceramic suspensions has been established to prepare both dense yttria-stabilized zirconia (YSZ) electrolyte membranes and transition anode layers on NiO + YSZ anode supports. A single cell with 10 μm thick YSZ electrolyte on a porous anode support and ∼20 μm thick cathode layer showed peak power densities of only 212 mW cm⁻² at 700 °C and 407 mW cm⁻² for 800 °C. While a cell with 10 μm thick YSZ electrolyte and a transition layer on the porous anode support using a ultra-fine NiO + YSZ powder showed peak power densities of 346 and 837 mW cm⁻² at 700 and 800 °C, respectively. The dramatic improvement of cell performance was attributed to the much improved anode microstructure that was confirmed by both scanning electron microscopes (SEM) observation and impedance spectroscopy. The results have demonstrated that a pressurized spray coating is a suitable technique to fabricate high performance SOFCs and at lower cost.     

Sulfonated poly(ether sulfone) for universal polymer electrolyte fuel cell operations

The performances of the proton exchange membrane fuel cell (PEMFC), direct formic acid fuel cell (DFAFC) and direct methanol fuel cell (DMFC) with sulfonated poly(ether sulfone) membrane are reported. Pt/C was coated on the membrane directly to fabricate a MEA for PEMFC operation. A single cell test was carried out using H₂/air as the fuel and oxidant. A current density of 730 mA cm⁻² at 0.60 V was obtained at 70 °C. Pt–Ru (anode) and Pt (cathode) were coated on the membrane for DMFC operations. It produced 83 mW cm⁻² maximum power density. The sulfonated poly(ether sulfone) membrane was also used for DFAFC operation under several different conditions. It showed good cell performances for several different kinds of polymer electrolyte fuel cell applications.     

NiO–YSZ cermets supported low temperature solid oxide fuel cells

Solid oxide fuel cells with thin electrolyte of two types, Sm_0.2Ce_0.8O_1.9 (SDC) (15 μm) single-layer and 8 mol% Yttria stabilized zirconia (YSZ) (5 μm) + SDC (15 μm) bi-layer on NiO–YSZ cermet substrates were fabricated by screen printing and co-firing. A Sm_0.5Sr_0.5CoO₃ cathode was printed, and in situ sintered during a cell performance test. The SDC single-layer electrolyte cell showed high electrochemical performance at low temperature, with a 1180 mW cm⁻² peak power density at 650 °C. The YSZ + SDC bi-layer electrolyte cell generated 340 mW cm⁻² peak power density at 650 °C, and showed good performance at 700–800 °C, with an open circuit voltage close to theoretical value. Many high Zr-content micro-islands were found on the SDC electrolyte surface prior to the cathode preparation. The influence of co-firing temperature and thin film preparation methods on the Zr-islands’ appearance was investigated.     

Electrooxidation of ascorbic acid on polyaniline and its implications to fuel cells

l-Ascorbic acid (AA) has been shown to undergo oxidation on polyaniline (PANI) without a platinum-group catalyst. A direct ascorbic acid fuel cell (DAAFC) has been assembled by employing an anode coated with PANI catalyst. From the experimental studies using cyclic voltammetry, amperometry and IR spectroscopy, it has been concluded that PANI facilitates the oxidation of AA. It has been possible to achieve a maximum power density of 4.3 mW cm⁻² at a load current density of 15 mA cm⁻² at 70 °C. As both AA and PANI are inexpensive and environmental-friendly, the present findings are expected to be useful for the development of cost-effective DAAFCs for several low power applications.     

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.     

A study of Ni + 8YSZ/8YSZ/La0.6Sr0.4CoO3−δ ITSOFC fabricated by atmospheric plasma spraying

An intermediate temperature solid oxide fuel cell (ITSOFC) based on 8YSZ electrolyte, La_0.6Sr_0.4CoO_3−δ (LSCo) cathode, and Ni − 8YSZ anode coatings were consecutively deposited onto a porous Ni-plate substrate by atmospheric plasma spraying (APS). The spray parameters including current, argon and hydrogen flow rate, and powder feed rate were investigated by an orthogonal experiment to fabricate a thin gas-tight 8YSZ electrolyte coating (80 μm). By proper selection of the spray parameters to decrease the particles velocity and temperature, the sprayed NiO + 8YSZ coating after reducing with hydrogen shows a good electrocatalytic activity for H₂ oxidation. With the same treatment, 100–170 μm dimensions LSCo particle could keep phase structure after spraying. And the deposited LSCo cathode shows a good cathode performance and chemical compatibility with 8YSZ electrolyte after operating at 800 °C for 50 h. Output power density of the sprayed cell achieved 410 mW cm⁻² at 850 °C and 260 mW cm⁻² at 800 °C. Electrochemical characterization indicated that IR drop of 8YSZ electrolyte, cathodic polarization, and the contact resistance at LSCo/8YSZ interface were the main factors restricting the cell performance. The results suggested that the use of APS cell allowed the reduction of the operating temperature of the SOFC to below 850 °C with lower production costs.     

Anode-supported solid oxide fuel cell based on dense electrolyte membrane fabricated by filter-coating

A simple and cost-effective technique, filter-coating, has been developed to fabricate dense electrolyte membranes. Eight mole percent yttria-stabilized zirconia (YSZ) electrolyte membrane as thin as 7 μm was prepared by filter-coating on a porous substrate. The thickness of the YSZ film was uniform, and could be readily controlled by the concentration of the YSZ suspension and the rate of the suspension deposition. The YSZ electrolyte film was dense and was well bonded to the Ni-YSZ anode substrate. An anode-supported solid oxide fuel cell (SOFC) with a YSZ electrolyte film and a La_0.85Sr_0.15MnO₃ (LSM) + YSZ cathode was fabricated and its performance was evaluated between 700 and 850 °C with humidified hydrogen as the fuel and ambient air as the oxidant. An open circuit voltage (OCV) of 1.09 V was observed at 800 °C, which was close to the theoretical value, and the maximum power density measured was 1050 mW cm⁻². The results demonstrate that the dense YSZ film fabricated by filter-coating is suitable for application to SOFCs.     

Mono-ion transport electrolyte based on ionic liquid polymer for all-solid-state dye-sensitized solar cells

Ionic liquid polymers, poly(1-alkyl-3-(acryloyloxy)hexylimidazolium iodide), are synthesized and used as mono-ion transport electrolytes for all-solid-state dye-sensitized solar cells. For these ionic liquid polymers, imidazolium cations are tethered on polymer main chain and only iodide species is mobile. Such a mono-ion transport feature is favorable as solid-state electrolyte in dye-sensitized solar cells. High thermal stability up to 200 °C for these ionic liquid polymers is confirmed by thermogravimetric analysis. Among these ionic liquid polymers, poly(1-ethyl-3-(acryloyloxy)hexylimidazolium iodide) (PEI) exhibits the highest ionic conductivity (3.63 × 10^?4 S cm^?1) at room temperature. The dye-sensitized solar cell based on PEI electrolyte without the addition of iodine exhibits the open-circuit voltage of 838 mV, the short-circuit current density of 9.75 mA cm^?2 and the conversion efficiency of 5.29%, measured at AM 1.5 illumination (100 mW cm^?2). Incorporating iodine into PEI electrolyte results in the decrease of both the open-circuit voltage and the photocurrent density due to the visible light adsorption by iodine and the enhancement of the recombination between conduction band electrons and the triiodide.     

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.     

Sulfonic-functionalized heteropolyacid–silica nanoparticles for high temperature operation of a direct methanol fuel cell

Sulfonic-functionalized heteropolyacid–SiO₂ nanoparticles were synthesized by grafting and oxidizing of a thiol-silane compound onto the heteropolyacid–SiO₂ nanoparticle surface. The surface functionalization was confirmed by solid-state NMR spectroscopy. The composite membrane containing the sulfonic-functionalized heteropolyacid–SiO₂ nanoparticles was prepared by blending with Nafion^® ionomer. TG–DTA analysis showed that the composite membrane was thermally stable up to 290 °C. The DMFC performance of the composite membrane increased the operating temperature from 80 to 200 °C. The function of the sulfonic-functionalized heteropolyacid–SiO₂ nanoparticles was to provide a proton carrier and act as a water reservoir in the composite membrane at elevated temperature. The power density was 33 mW cm⁻² at 80 °C, 39 mW cm⁻² at 160 °C and 44 mW cm⁻² at 200 °C, respectively.     

Cresol–formaldehyde based carbon aerogel as electrode material for electrochemical capacitor

Carbon aerogels have been prepared through a polycondensation of cresol (Cm) with formaldehyde (F) and an ambient pressure drying followed by carbonization at 900 °C. Modification of the porous structures of the carbon aerogel can be achieved by CO₂ activation at various temperatures (800, 850, 900 °C) for 1–3 h. This process could be considered as an alternative economic route to the classic RF gels synthesis. The obtained carbon aerogels have been attempted as electrode materials in electric double-layer capacitors. The relevant electrochemical behaviors were characterized by constant current charge–discharge experiments, cyclic voltammetry and electrochemical impedance spectroscopy in an electrolyte of 30% KOH aqueous solution. The results indicate that a mass specific capacitance of up to 78 F g⁻¹ for the non-activated aerogel can be obtained at current density 1 mA cm⁻². CO₂ activation can effectively improve the specific capacitance of the carbon aerogel. After CO₂ activation performed at 900 °C for 2 h, the specific capacitance increases to 146 F g⁻¹ at the same current. Only a slight decrease in capacitance, from 146 to 131 F g⁻¹, was observed when the current density increases from 1 to 20 mA cm⁻², indicating a stable electrochemical property of carbon aerogel electrodes in 30% KOH aqueous electrolyte with various currents.     

Performance of a solid oxide fuel cell utilizing hydrogen sulfide as fuel

The electrochemical performance of a hydrogen sulfide solid oxide fuel cell having the configuration H₂S, Pt/(ZrO₂)_0.92(Y₂O₃)_0.08/Pt, air has been examined at atmospheric pressure and 750–800°C, using both pure and 5% H₂S anode feed streams. The performance of the cell is higher when using diluted H₂S feed compared with pure H₂S feed: current densities up to 100 mA cm⁻² and power densities up to 15.4 mW cm⁻² have been achieved using diluted H₂S gas (5%) at 800°C. However, the platinum anode degrades over time in H₂S stream due to the formation of PtS. Electrochemical oxidation of H₂S on the Pt anode significantly accelerated its degradation. Polarization and impedance spectroscopy measurements show that at low current density (i) electrochemical reaction is the major cause of polarization in the fuel cell. Ohmic loss due to the resistance of the electrolyte material and the electrical connecting wire is a major part of cell polarization at high i.     

Development and demonstration of a higher temperature PEM fuel cell stack

Research and development was conducted on a proton exchange membrane (PEM) fuel cell stack to demonstrate the capabilities of Ionomem Corporation's composite membrane to operate at 120 °C and ambient pressure for on-site electrical power generation with useful waste heat. The membrane was a composite of polytetrafluoroethylene (PTFE), Nafion^®, and phosphotungstic acid. Studies were first performed on the membrane, cathode catalyst layer, and gas diffusion layer to improve performance in 25 cm², subscale cells. This technology was then scaled-up to a commercial 300 cm² size and evaluated in multi-cell stacks. The resulting stack obtained a performance near that of the subscale cells, 0.60 V at 400 mA cm⁻² at near 120 °C and ambient pressure with hydrogen and air reactants containing water at 35% relative humidity. The water used for cooling the stack resulted in available waste heat at 116 °C. The performance of the stack was verified. This was the first successful test of a higher-temperature, PEM, fuel-cell stack that did not use phosphoric acid electrolyte.     

Using silica nanoparticles for modifying sulfonated poly(phthalazinone ether ketone) membrane for direct methanol fuel cell: A significant improvement on cell performance

Sulfonated poly(phthalazinone ether ketone) (sPPEK) with a degree of sulfonation of 1.23 was mixed with silica nanoparticles to form hybrid materials for using as proton exchange membranes. The nanoparticles were found homogeneously dispersed in the polymer matrix and a high 30 phr (parts per hundred resin) loading of silica nanoparticles can be achieved. The hybrid membranes exhibited improved swelling behavior, thermal stability, and mechanical properties. The methanol crossover behavior of the membrane was also depressed such that these membranes are suitable for a high methanol concentration in feed (3 M) in cell test. The membrane with 5 phr silica nanoparticles showed an open cell potential of 0.6 V and an optimum power density of 52.9 mW cm⁻² at a current density of 264.6 mA cm⁻², which is better than the performance of the pristine sPPEK membrane and Nafion^® 117.     

Advanced air-breathing direct methanol fuel cells for portable applications

A novel MEA is fabricated to improve the performance of air-breathing direct methanol fuel cells. A diffusion barrier on the anode side is designed to control methanol transport to the anode catalyst layer and thus suppressing the methanol crossover. A catalyst coated membrane with a hydrophobic gas diffusion layer on the cathode side is employed to improve the oxygen mass transport. It is observed that the maximum power density of the advanced DMFC with 2 M methanol solution achieves 65 mW cm⁻² at 60 °C. The value is nearly two times more than that of a commercial MEA. At 40 °C, the power densities operating with 1 and 2 M methanol solutions are over 20 mW cm⁻² with a cell potential at 0.3 V.     

Improvement in high temperature proton exchange membrane fuel cells cathode performance with ammonium carbonate

Proton exchange membrane (PEM) fuel cells with optimized cathode structures can provide high performance at higher temperature (120 °C). A “pore-forming” material, ammonium carbonate, applied in the unsupported Pt cathode catalyst layer of a high temperature membrane electrode assembly enhanced the catalyst activity and minimized the mass-transport limitations. The ammonium carbonate amount and Nafion^® loading in the cathode were optimized for performance at two conditions: 80 °C cell temperature with 100% anode/75% cathode R.H. and 120 °C cell temperature with 35% anode/35% cathode R.H., both under ambient pressure. A cell with 20 wt.% ammonium carbonate and 20 wt.% Nafion^® operating at 80 °C and 120 °C presented the maximum cell performance. Hydrogen/air cell voltages at a current density of 400 mA cm⁻² using the Ionomem/UConn membrane as the electrolyte with a cathode platinum loading of 0.5 mg cm⁻² were 0.70 V and 0.57 V at the two conditions, respectively. This was a 19% cell voltage increase over a cathode without the “pore-forming” ammonium carbonate at the 120 °C operating condition.     

Recycling of nickel from NiOOH/Ni(OH)2 electrodes of spent Ni–Cd batteries

In this work, nickel from the positive electrode of Ni–Cd batteries was recycled by chemical precipitation and electrodeposition. The structure of the material recovered by chemical precipitation is affected by temperature. Alfa nickel hydroxide is stable at low temperature but becomes beta nickel hydroxide with increasing of the synthesis temperature. Electrodeposition was accomplished by using the galvanostatic technique. The chronopotentiometric plots presented a plateau potential in the initial stage of the deposit growth due to the reduction of ionic nickel. Charge density of the plateau potential and charge efficiency decreased with increase in current density. Charge efficiency around 81.0% was the largest for current densities between 5.0 mA cm⁻² and 10.0 mA cm⁻² for q = 9.0 C cm⁻². As charge density increased to 90.0 C m⁻², the electrodeposition efficiency decreased. In this case, there is a second plateau potential at which the evolution of hydrogen on the nickel electrode, the principal reaction, is quickly reached. Charge density affects not only the reaction kinetics, but also the deposit morphology. A decrease in microporosity is observed with the increase in charge density. The microporosity increases as the current density increases for the same charge density.     

Solid-state Li/LiFePO4 polymer electrolyte batteries incorporating an ionic liquid cycled at 40 °C

The cycle behaviour and rate performance of solid-state Li/LiFePO₄ polymer electrolyte batteries incorporating the N-methyl-N-propylpyrrolidinium bis(trifluoromethanesulfonyl)imide (PYR₁₃TFSI) room temperature ionic liquid (IL) into the P(EO)₂₀LiTFSI electrolyte and the cathode have been investigated at 40 °C. The ionic conductivity of the P(EO)₂₀LiTFSI + PYR₁₃TFSI polymer electrolyte was about 6 × 10⁻⁴ S cm⁻¹ at 40 °C for a PYR₁₃⁺/Li⁺ mole ratio of 1.73. Li/LiFePO₄ batteries retained about 86% of their initial discharge capacity (127 mAh g⁻¹) after 240 continuous cycles and showed excellent reversible cyclability with a capacity fade lower than 0.06% per cycle over about 500 cycles at various current densities. In addition, the Li/LiFePO₄ batteries exhibited some discharge capability at high currents up to 1.52 mA cm⁻² (2 C) at 40 °C which is very significant for a lithium metal-polymer electrolyte (solvent-free) battery systems. The addition of the IL to lithium metal-polymer electrolyte batteries has resulted in a very promising improvement in performance at moderate temperatures.