Thermal management of a proton exchange membrane fuel cell stack with pyrolytic graphite sheets and fans combined

This work characterizes the thermal management of a proton exchange membrane fuel cell (PEMFC) stack with combined passive and active cooling. A 10-cell PEMFC stack with an active area of 100 cm² for each cell is constructed. Six thermally conductive 0.1-mm-thick Pyrolytic Graphite Sheets (PGSs) are cut into the shape of flow channels and bound to the six central cathode gas channel plates. These PGSs, which are lightweight and have high thermal conductivity, function as heat spreaders and fins and provide passive cooling in the fuel cell stack, along with two small fans for forced convection. Three other cooling configurations with differently sized fans are also tested for comparisons (without PGSs). Although the maximum power generated by the stack with the configuration combining PGSs and fans was 183 W, not the highest among all configurations, it significantly reduced the volume, weight, and cooling power of the thermal management system. Net power, specific power, volumetric power density, and back work ratio of this novel thermal management method are 179 W, 18.54 W kg⁻¹, 38.9 kW m⁻³, and 2.1%, respectively, which are superior to those of the other three cooling configurations with fans.     

Connected evaluation of polymer electrolyte membrane fuel cell with dehydrogenation reactor of liquid organic hydrogen carrier

Recently, hydrogen energy technologies attract attention as power systems. To develop hydrogen energy systems, hydrogen storage methods with high storage density and good safety are required. Liquid organic hydrogen carrier (LOHC) is one of the novel hydrogen storage technologies. LOHC has advantages of high storage density, good safety, and easy handling. In this study, a polymer electrolyte membrane fuel cell (PEMFC) stack is operated with hydrogen released from LOHC to evaluate the feasibility of the connected operation of the PEMFC stack and LOHC dehydrogenation reactor. Dibenzyltoluene (H0-DBT) is used as a LOHC material, and the dehydrogenation of perhydro dibenzyltoluene (H18-DBT) is conducted at 240–300 °C. Released hydrogen is purified by adsorbent of activated carbon to remove impurities. However, 100–1400 ppm of methane is observed after the purification, and the PEMFC stack power is reduced from 39.4 W to 39.0 W during the operation by hydrogen dilution and physical adsorption of methane. Then, to evaluate the irreversible damage, pure hydrogen was supplied to the PEMFC stack. The stack power is recovered to 39.4 W. It is concluded that the connected operation of the LOHC dehydrogenation reactor and PEMFC stack is feasible, and the activated carbon adsorbent can be a cost-effective purification method for LOHC.     

Portable PEMFC stack using sulfonated poly (fluorenyl ether ketone) ionomer as membrane

Portable polymer electrolyte membrane fuel cells (PEMFCs) stack was assembled with sulfonated poly(fluorenyl ether ketone) (SPFEK) ionomer membranes. The portable PEMFC stack was studied by means of cell performance tests at high temperatures under low relatively humidity (RH). The experimental results showed that the output power of the stack increased from 28.74 W to 37.11 W with increasing operating temperature from 30 to 90 °C under 100% RH. When the operating temperature was over 100 °C, the output power decreased with further increasing temperature from 27.68 W (100 °C, 85% RH) to 19.87 W (120 °C, 50% RH). The output at 120 °C and under 50% RH was 69% output power of the stack at 30 °C and under 100% RH. These results demonstrated that the self-prepared SPFEK ionomer membrane was a promising PEM for the application in high-temperature PEMFC.     

Improvement of thermal management of proton exchange membrane fuel cell stack used for portable devices by integrating the ultrathin vapor chamber

UVC (ultrathin vapor chamber) simultaneously has a high heat-conducting property, excellent temperature uniformity and simple structure. These advantages are very suitable for thermal management of the open-cathode PEMFC (proton exchange membrane fuel cell) stack. In this work, two-type UVCs with different appearances are integrated into a conventional PEMFC stack respectively. The effect of UVC on the output performance, thermal management and operating stability is investigated by the experiment combined with simulation. The results show that UVC can significantly increase the output voltage under high current density. In 35 A, the output voltage of the stack integrated the vertical UVC increases by 20.25% relative to the conventional stack. Thermal management is also improved by UVC. The highest temperature inside the stack decrease by 9 °C in 35 A, and the membrane temperature is decreased obviously. But it still exceeds the optimal operating temperature of open-cathode PEMFC stack due to the poor cooling type in the condensation side of UVC. UVC improves the operation stability of the stack and slows the deteriorative speed of output performance. This work hopes to attract more attention to the application of UVC on the thermal management of portable power sources used open-cathode PEMFC stack.     

Development of a 30 W class direct formic acid fuel cell stack with high stability and durability

A medium-scale DFAFC stack was designed and fabricated in this work. The power output of this stack was high to 32 W, which can satisfy the power requirement of most portable electrical devices. The ultrasonically mixed Pt/C + Pd/C catalyst was optimized as the anode catalyst for the stack fabrication by using a single cell. The feeding formic acid concentration and oxygen flow rate respectively in anode and cathode side were also experimentally optimized before the stack fabrication. Under the optimal operation conditions, the life time test was carried out for the DFAFC stack using the optimal anode catalyst. The stack can stably operate for about 50 h with 1.5 L fuel supplied, and its high durability was confirmed by the 240 h continuous life time test.     

Quantitative analysis on cold start process of a PEMFC stack with intake manifold

To systematically explore the low-temperature operating characteristics of polymer electrolyte membrane fuel cell (PEMFC) stack, a three-dimensional PEMFC stack model with intake manifold is developed in this study. The characteristics of different cold start modes in the stack are compared and analyzed. The distribution and transmission characteristics of water, ice, and heat in each cell of the stack are analyzed in detail. The location of water accumulation in each cell of the stack is also explored. Finally, finite difference sensitivity is calculated for the cumulated charge transfer density to quantify the effects of operating parameters on the cold start process at low temperature. And how these parameters affect the operation of the PEMFC stack at low temperature is investigated. The results show that inconsistency exists in stack operation due to the position particularity of the intermediate cell. Irreversible heat is the main heat source for the cold start of the stack, and the cathode catalyst layer is the main heat-generating component. The heat production proportion of cathode catalyst layer can reach 90%, which decreases with the increment of current density and the running time, especially for the edge cell. The initial ionomer water content is most sensitive to the cold start process of the stack, followed by the porosity of cathode catalyst layer. These parameters are sensitive to the cold start process mainly because of the change in volumetric exchange current density and oxygen concentration.     

Experimental analysis of dynamic characteristics on the PEM fuel cell stack by using Taguchi approach with neural networks

This study determines the optimum operating parameters for a proton exchange membrane fuel cell (PEMFC) stack to obtain small variation and maximum electric power output using a robust parameter design (RPD). The operating parameters examined experimentally are operating temperatures, operating pressures, anode/cathode humidification temperatures, and reactant flow rates. First, the dynamic Taguchi method is used to obtain the maximum and stable power density against the different current densities, which are regarded as the systemic inputs considered a signal factor. The relationship between control factors and responses in the PEMFC stack is determined using a neural network. The discrete parameter levels in the dynamic Taguchi method can be divided into desired levels to acquire real optimum operating parameters. Based on these investigations, the PEMFC stack is operated at the current densities of 0.4–0.8 A/cm². Since the voltage shift is quite small (roughly 0.73–0.83 V for each single cell), the efficiency would be higher. In the range of operation, the operating pressure, the cathode humidification temperature and the interactions between operating temperature and operating pressure significantly impact PEMFC stack performance. As the operating pressure increasing, the increments of the electric power decrease, and power stability is enhanced because the variation in responses is reduced.     

Operating characteristics of an air-cooling PEMFC for portable applications

Optimal design and proper operation is important to get designed output power of a polymer electrolyte membrane fuel cell (PEMFC) stack. The air-cooling fuel cell stack is widely used in sub kW PEMFC systems. The purpose of this study is to analyze the operating conditions affecting the performance of an air-cooling PEMFC which is designed for portable applications. It is difficult to maintain well balanced operating conditions. These parameters are the relative humidity, the temperature of the stack, the utility ratio of the reactant gas and so on. In this study a 500 W rate air-cooling PEMFC was fabricated and tested to evaluate the design performance and to determine optimal operating conditions. Moreover, basic modeling also is carried out. These results can be used as design criteria and optimal operating conditions for portable PEMFCs.     

Fuel cell/electrochemical capacitor hybrid for intermittent high power applications

A hybrid power source was demonstrated to successfully power a simulated power load encountered in portable military electronics and communications equipment. The hybrid system consisted of a 25 W proton exchange membrane fuel cell (PEMFC) stack connected in parallel with a 70 F capacitor bank. The cyclic regime of 18.0 W for 2 min followed by 2.5 W for 18 min was chosen as the baseline for the simulation of power load. The operating potential cut-off voltage for pass/failure was set to 3.0 V. At room temperature (23–25°C), the PEMFC alone could not handle the described baseline regime with the PEMFC operating potential dropping below the cut-off voltage within 10 s. The hybrid, however, continuously powered the same regime for 25 h. Its operating potential never reached the voltage cut-off point, not even during the high load of 18.0 W. The tests with hybrid configuration were aborted after 25 h of operation with no signs of output degradation, suggesting that further extended operation was possible.     

Preliminary experimental study of the performances for a print circuit board based planar PEMFC stack

This paper presents a novel planar proton exchange membrane fuel cell (PEMFC) stack designed for portable electronic devices, consisting of twenty homemade membrane electrode assemblies (MEAs) arranged on a planar surface and three printed circuit boards (PCBs, including anode, interlayer and cathode PCBs) used to load these MEAs. The current collectors and electrical connectors are manufactured using printed circuit technology. The inlet holes of reaction gases are also machined on PCB substrates. The output performance tests are performed on the MEAs and the assembled planar PEMFC stack. The results show that the power densities of the MEAs and the planar PEMFC stack are 0.6 W/cm² and 0.361 W/cm² at rated voltage under ambient temperature and forced convection air conditions, respectively. The stability tests are also conducted on the planar PEMFC stack, and the results show no significant fluctuations in output current. The feasibility of the application of planar PEMFC stacks in portable electronic devices is preliminarily demonstrated, and the improvement directions for further improving the output performance are proposed accordingly.     

High performance PEMFC stack with open-cathode at ambient pressure and temperature conditions

An open-air cathode proton exchange membrane fuel cell (PEMFC) was developed. This paper presents a study of the effect of several critical operating conditions on the performance of an 8-cell stack. The studied operating conditions such as cell temperature, air flow rate and hydrogen pressure and flow rate were varied in order to identify situations that could arise when the PEMFC stack is used in low-power portable PEMFC applications. The stack uses an air fan in the edge of the cathode manifolds, combining high stoichiometric oxidant supply and stack cooling purposes. In comparison with natural convection air-breathing stacks, the air dual-function approach brings higher stack performances, at the expense of having a lower use of the total stack power output. Although improving the electrochemical reactions kinetics and decreasing the polarization effects, the increase of the stack temperature lead to membrane excessive dehydration (loss of sorbed water), increasing the ohmic resistance of the stack (lower performance).     

Comparison of the performance and degradation mechanism of PEMFC with Pt/C and Pt black catalyst

Proton exchange membrane fuel cell (PEMFC) has been used in supplying power for Unmanned Underwater Vehicle which operate in a closed environment and dead-ended anode and cathode (DEAC) mode is deemed as an effective way to enhance the fuel utilization rate. Catalyst is an important factor that influences the performance and durability of PEMFC, especially in DEAC mode. In this paper, the degradation characteristics of PEMFCs with Pt black and Pt/C catalyst after 100 h operation have been investigated by electrochemical techniques and morphological characterization methods. It's shown that the degradation of Pt black catalyst layer (CL) was more severe than that of Pt/C CL. The difference of performance degradation is due to the dominant decay mechanism of these two catalysts is different. According to SEM, TEM and XPS results, the decay of Pt black catalyst is mainly caused by Pt agglomeration and oxidation, causing a higher ohmic resistance, higher mass transfer resistance and severer degradation of performance. The degradation of Pt/C catalyst is mainly due to the reduction of electrochemical surface area and carbon corrosion because the larger carbon corrosion makes micropores and the thicker supporting structure, resulting in the performance degradation.     

XPS investigations of the proton exchange membrane fuel cell active layers aging: Characterization of the mitigating role of an anodic CO contamination on cathode degradation

This paper presents new results from XPS quantitative characterizations of cathode catalyst layers aged in a PEMFC with an anode operated under pure hydrogen and air and with 5 ppm CO contaminated hydrogen. Both oxygen rich and oxygen poor zones of the cathode catalyst layer were analyzed in order to show up heterogeneous degradation linked with gas distribution. The detailed chemical XPS analysis of the aged samples demonstrates in particular that in our operating conditions, the catalyst layer aging is mainly attributed to the oxidation of the carbon catalyst-support. A loss of the Nafion^® ionomer in the cathode is also highlighted by XPS. Furthermore, the characterization of the cathodic catalyst layer chemical composition when CO is introduced in the anode side shows that the catalyst layer degradation is lower. These results are in agreement with the experimental-modeling work by Franco et al. [1] demonstrating that anodic CO contamination decreases the reverse proton pumping effect between the cathode and the anode and enhances the PEMFC durability.     

Rapid self-start of polymer electrolyte fuel cell stacks from subfreezing temperatures

Polymer electrolyte fuel cell (PEFC) systems for light-duty vehicles must be able to start unassisted and rapidly from temperatures below −20 °C. Managing buildup of ice within the porous cathode catalyst and electrode structure is the key to self-starting a PEFC stack from subfreezing temperatures. The stack temperature must be raised above the melting point of ice before the ice completely covers the cathode catalyst and shuts down the electrochemical reaction. For rapid and robust self-start it is desirable to operate the stack near the short-circuit conditions. This mode of operation maximizes hydrogen utilization, favors production of waste heat that is absorbed by the stack, and delays complete loss of effective electrochemical surface area by causing a large fraction of the ice to form in the gas diffusion layer rather than in the cathode catalyst layer. Preheating the feed gases, using the power generated to electrically heat the stack, and operating pressures have only small effect on the ability to self-start or the startup time. In subfreezing weather, the stack shut-down protocol should include flowing ambient air through the hot cathode passages to vaporize liquid water remaining in the cathode catalyst. Self-start is faster and more robust if the bipolar plates are made from metal rather than graphite.     

Degradation analysis of the core components of metal plate proton exchange membrane fuel cell stack under dynamic load cycles

The durability of metal plate proton exchange membrane fuel cell (PEMFC) stack is still an important factor that hinders its large-scale commercial application. In this paper, we have conducted a 1000 h durability test on a 1 kW metal plate PEMFC stack, and explored the degradation of the core components. After 1000 h of dynamic load cycles, the voltage decay percentage of the stack under the current densities of 1000 mA cm^?2 is 5.67%. By analyzing the scanning electron microscopy (SEM) images, the surfaces of the metal plates are contaminated locally by organic matter precipitated from the membrane electrode assembly (MEA). The SEM images of the catalyst coated membrane (CCM) cross section indicate that the MEA has undergone severe degradation, including the agglomeration of the catalyst layer, and the thinning and perforation of the PEM. These are the main factors that cause the rapid increase in hydrogen crossover flow rate and performance decay of the PEMFC stack.     

Experimental analysis of cathode flow stoichiometry on the electrical performance of a PEMFC stack

The paper describes an experimental analysis on the effect of cathode flow stoichiometry on the electrical performance of a PEMFC stack. The electrical power output of a PEMFC stack is influenced by several independent variables (factors). In order to analyse their reciprocal influence, an experimental design methodology was adopted in a previous experimental session, to determine which factors deserve particular attention. In this work, a further experimental analysis has been carried out on a very significant factor: cathode stoichiometry. Its effects on the electrical power of the PEMFC stack have been investigated. The tests were performed on a 3.5 kW_el ZSW stack using the GreenLight GEN VI FC Test Station. The stack characteristics have been obtained running a predefined loading pattern. Some parameters were kept constant during the tests: anode and cathode inlet temperature, anode and cathode inlet relative humidity, anode stoichiometry and inlet temperature of the cooling water. The experimental analysis has shown that an increase in air stoichiometry causes a significant positive effect (increment) on electric power, especially at high-current density, and up to the value of 2 stoichs. These results have been connected to the cathode water flooding, and a discussion was performed concerning the influence of air stoichiometry on electrode flooding at different levels of current density operation.     

Mechanisms of performance degradation induced by thermal cycling in solid oxide fuel cell stacks with flat-tube anode-supported cells based on double-sided cathodes

In this work, the degradation in output power of a stack with flat-tube anode-supported cells based on double-sided cathodes and its mechanism are studied. After 102 thermal cycles, the OCV keeps about 1.1 V and remains stable, showing that the one-cell stack exhibits a good sealing performance. During the first 100 thermal cycles, when the temperature ranges from 750 to 200 °C with a heating/cooling rate of 3 °Cmin⁻¹, the stack degradation mainly occurs during the first 34 thermal cycles, and the degradation rate is ~0.89%/cycle. During the 101th and 102nd thermal cycles, an additional loading force is applied on the cathode side of the stack at room temperature, and the results shows that the output power at 750 °C increases and finally exceeds the initial output. As a result, the primary cause for degradation induced by thermal cycling is believed to originate from the weak interface between the cathode and the interconnect, resulting in an increase in ohmic resistance. The stack degradation can therefore be recovered by a secondary loading force on the cathode side.     

Dynamic performance for a kW-grade air-cooled proton exchange membrane fuel cell stack

In this study, a kW-grade air-cooled proton exchange membrane fuel cell (PEMFC) stack with a dead-end anode (DEA) operation is designed and manufactured. The gravity-assisted drainage principle is applied for the stack to design the wettability of gas diffusion layers (GDLs) and the anode channel geometry, which can help the liquid water that diffuses to the anode to drain out of the anode porous electrode and move down the anode channel outlets. As a result, the stack can stably operate in a long purge interval of 268 s and in a short purge time of 2 s. In addition, using this design, only four small-power fans are employed to pump air to the cathode to provide oxygen for the electrochemical reaction and cool the stack. With a constant load current of 30, 45, or 60 A, the stack output voltage is experimentally tested at various cathode air flow rates (CAFRs). The local temperatures (60 measurement points) inside the stack and the pressure differences across anode channels are also monitored to understand heat dissipation and the back diffusion of liquid water. In a wide range of operating conditions, the designed stack possesses superior and stable voltage output characteristics with relatively uniform temperature distributions. The measured maximum output power is 3.83 kW, and the parasitic powers of fans are only 80～112 W.     

Effect of air purging and dry operation on durability of PEMFC under freeze/thaw cycles

The effect of air purging and dry operation on durability of polymer electrolyte membrane fuel cell (PEMFC) under repeated freeze/thaw cycles between −20 °C and 60 °C was investigated. The cathode air purging and the operation with dry air feed were highly effective to mitigate freeze damage. The removal of the air purging of the anode compartment did not lead to the degradation of the anode catalyst layer. It is of practical importance, because the air purging of the anode could cause carbon corrosion of the cathode. The performance degradation by the freeze/thaw cycles was associated with the increased charge transfer and mass transfer resistances. After the freeze/thaw cycles, any discernable morphological changes were not observed in the scanning electron microscopic images of the anode, the membrane and the membrane/electrode interface, however, mechanical damage of the poly(tetrafluoroethylene) phases in the cathode diffusion layer was detected.