A new direct methanol fuel cell with a zigzag-folded membrane electrode assembly

We propose a new direct methanol fuel cell with a zigzag-folded membrane electrode assembly. This fuel cell is formed by a membrane, which is made up of anode and cathode electrodes on a zigzag-folded sheet, separated by insulation film and current collectors. Individual anodes, cathodes and membranes form a unit cell, which is connected to the adjacent unit cell. The fuel cell can achieve high output voltage through easy in-series connection. Since it is not necessary to connect electrodes, as in the manner of conventional bipolar plates, there is no increase in fabrication cost and no degradation in reliability. The fuel feeds for the anode and cathode are achieved through methanol and air feeds on each electrode, which do not require electricity to run a pump or blower. The experimental cells were formed with an active area of 16 cm × 2 cm on membrane-folded cells. Filter papers with slits were inserted between anodes to improve their methanol supply. A power density of 3 mW cm⁻² was obtained at a methanol concentration of 2 M at ambient temperature. The cell power was affected by the slit area on cathode.     

New borohydride fuel cell with multiwalled carbon nanotubes as anode: A step towards increasing the power output

A borohydride fuel cell has been constructed using a platinized multiwalled carbon nanotube (MWCNT) anode and an air cathode having an anionic exchange membrane separating the anode and cathode. The MWCNT was functionalized with carboxylic acid under nitric acid reflux. Platinum metal was subsequently incorporated into it by galvanostatic deposition. The platinized functionalized MWCNT was characterized by thermogravimetric analysis, Fourier transform infrared spectrum, scanning electron microscope and X-ray diffraction. The fuel cell produced a voltage of 0.95 V at low currents and a maximum power density of 44 mW cm⁻² at room temperature in 10% sodium borohydride in a 4 M sodium hydroxide medium. Another borohydride fuel cell under identical conditions using carbon as the anode produced a cell voltage of 0.90 V and power density of about 20 mW cm⁻². The improved performance of the MWCNT is attributed to the higher effective surface area and catalytic activity.     

Electrochemical oxidation of 1-methoxy-2-propanol in direct liquid fuel cells

Some interesting features have been observed when 1-methoxy-2-propanol was studied in direct liquid fuel cells. Air flow rate ranging from 180 to 920 ml/min had no effect on performance, but the performance increased largely when the cell temperature was increased from 40, to 60, and then to 80 °C. The open circuit voltage of the cell was around 0.70 V, which was 0.08–0.33 V higher than that when methanol was used. At low air flow rates, 1-methoxy-2-propanol performed much better than methanol in the entire current density region at 60 and 80 °C. At high air flow rates, methanol performed better than 1-methoxy-2-propanol at current densities higher than 100 mA/cm², but the latter performed better than the former at current densities less than ca. 50 mA/cm². The crossover current density of 1.0 M 1-methoxy-2-propanol through a Nafion^® 112 membrane was estimated electrochemically, and it was 25.6, 60.8 and 96.0 mA/cm² at cell temperatures of 40, 60, and 80 °C, respectively, measured at 0.90 V. These numbers were much smaller than those of methanol that, e.g. had a crossover current density of 232 mA/cm² at 0.9 V and 60 °C. One problem with using 1-methoxy-2-propanol as a fuel was that the cell anode seemed to be seriously poisoned by the oxidation intermediates at anode overpotentials lower than ca. 0.2 V.     

Methanol conditioning for improved performance of formic acid fuel cells

This paper considers the effect of methanol pretreatment on the performance of a direct formic acid fuel cell (DFAFC). We find that conditioning of the cell in methanol results in a substantial increase in current. The current at 60 °C increases from 95 to 320 mA/cm² at 0.3 V. The maximum power density increases from 33 to 119 mW/cm². The cell resistance decreases from 0.37 to 0.32 Ω cm². CO stripping experiments show that the catalyst is not being greatly affected by these changes. Our interpretation of the data is that the anode layer of membrane electrolyte assembly (MEA) undergoes some change during the methanol conditioning. The change improves the performance.     

Methoxy methane (dimethyl ether) as an alternative fuel for direct fuel cells

The electrooxidation of methoxy methane (dimethyl ether) was studied at different Pt-based electrocatalysts in a standard three-electrode electrochemical cell. It was shown that alloying platinum with ruthenium or tin leads to shift the onset of the oxidation wave towards lower potentials. On the other hand, the maximum current density achieved was lower with a bimetallic catalyst compared to that obtained with a Pt catalyst. The direct oxidation of dimethoxy methane in a fuel cell was carried out with Pt/C, PtRu/C and PtSn/C catalysts. When Pt/C catalyst is used in the anode, it was shown that the pressure of the fuel and the temperature of the cell played important roles to enhance the fuel cell electrical performance. An increase of the pressure from 1 to 3 bar leads to multiply by two times the maximum achieved power density. An increase of the temperature from 90 to 110 °C has the same effect. When PtRu/C catalyst is used in the anode, it was shown that the electrical performance of the cell was only a little bit enhanced. The maximum power density only increased from 50 to 60 mW cm⁻² at 110 °C using a Pt/C anode and a Pt_0.8Ru_0.2/C anode, respectively. But, the maximum power density is achieved at lower current densities, i.e. higher cell voltages. The addition of ruthenium to platinum has other effect: it introduces a large potential drop at relatively low current densities. With the Pt_0.5Ru_0.5/C anode, it has not been possible to applied current densities higher than 20 mA cm⁻² under fuel cell operating conditions, whereas 250 and almost 400 mA cm⁻² were achieved with Pt_0.8Ru_0.2/C and Pt/C anodes. The Pt_0.9Sn_0.1/C anode leads to higher power densities at low current densities and to the same maximum power density as the Pt/C anode.     

The effect of a ceria coating on the H2S tolerance of a molten carbonate fuel cell

To enhance the performance of anodes in molten carbonate fuel cells (MCFCs), in terms of their sulfur tolerance, we modified the surface characteristics of a conventional Ni–10 wt% Cr anode through dip coating using a ceria sol. The performance of the ceria-coated anode was 0.4 V higher than that of the uncoated anode when H₂S (80 ppm) was introduced under a current density of 150 mA cm⁻² for 180 h. H₂S acted as a poison of the non-modified Ni electrode, regardless of its operating conditions, to form Ni₃S₂, which caused the voltage drop. The ceria-coated anode had the ability to suppress such a voltage drop because ceria can react with H₂S to form Ce₂O₂S. Our results suggest that the presence of a CeO₂ coating layer can reduce the degree of sulfur poisoning of the anode under the operating conditions – e.g., a reducing atmosphere and a high temperature – experienced by MCFCs.     

Direct formic acid fuel cells

The performance of formic acid fuel oxidation on a solid PEM fuel cell at 60 °C is reported. We find that formic acid is an excellent fuel for a fuel cell. A model cell, using a proprietary anode catalyst produced currents up to 134 mA/cm² and power outputs up to 48.8 mW/cm². Open circuit potentials (OCPs) are about 0.72 V. The fuel cell runs successfully over formic acid concentrations between 5 and 20 M with little crossover or degradation in performance. The anodic polarization potential of formic acid is approximately 0.1 V lower than that for methanol on a standard Pt/Ru catalyst. These results show that formic acid fuel cells are attractive alternatives for small portable fuel cell applications.     

Optimization of water and air management systems for a passive direct methanol fuel cell

A multi-phase, multi-component, thermal and transient model is applied to simulate the operation of a passive direct methanol fuel cell and optimize the design. The model takes into consideration the thermal effects and the variation of methanol concentration at the feeding reservoir above the fuel cell. Polarization and constant current cases are numerically simulated and compared with experiments for liquid feed concentration, membrane thickness, water management and air management systems. Parameters considered when determining an optimal design include power density, fuel utilization and energy efficiencies and water balance coefficients. An optimal liquid feed concentration is determined to be 2.0 mol kg^?1, which achieved a maximum power density of 21 mW cm^?2 and a fuel utilization efficiency of 63.0%. An optimal design of a cell uses a thick membrane (Nafion 117) to reduce methanol crossover and two additional cathode GDLs to improve the water balance coefficient and efficiency of the cell. This combination results in a power density of 23.8 mW cm^?2 and a water balance coefficient of ?1.71. An air filter may also be added to improve the efficiency and water balance coefficient of the cell, however, a small loss in power density will also occur. Using an Oil Sorbents air filter the water balance coefficient is increased to ?0.85, the fuel utilization efficiency is improved by 27.35% and the maximum power density decreased to 21.6 mW cm^?2.     

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.     

Solid oxide fuel cells operated by internal partial oxidation reforming of iso-octane

Two types of solid oxide fuel cells (SOFCs), with thin Ce_0.85Sm_0.15O_1.925 (SDC) or 8 mol% Y₂O₃-stabilized ZrO₂ (YSZ) electrolytes, were fabricated and tested with iso-octane/air fuel mixtures. An additional Ru–CeO₂ catalyst layer, placed between the fuel stream and the anode, was needed to obtain a stable output power density without anode coking. Thermodynamic analysis and catalysis experiments showed that H₂ and CO were primary reaction products at ≈750 °C, but that these decreased and H₂O and CO₂ increased as the operating temperature dropped below ≈600 °C. Power densities for YSZ cells were 0.7 W cm⁻² at 0.7 V and 790 °C, and for SDC cells were 0.6 W cm⁻² at 0.6 V and 590 °C. Limiting current behavior was observed due to the relatively low (≈20%) H₂ content in the reformed fuel.     

Performance characteristics of a vapor feed passive miniature direct methanol fuel cell

In this paper, a new vapor feed fuel delivery system for a passive direct methanol fuel cell (DMFC) is developed and tested. Anode hydrophilic layers, electrical heating power and carbon dioxide release are examined to find their effects on the power density, efficiency and average temperatures of the cell. The hydrophilic layers act as a buffer layer between the vapor chamber and the anode gas diffusion layer (GDL). This layer allows water and methanol to mix, as well as distribute uniformly across the anode surface. Measurement of several parameters such as current, voltage, power, internal resistance, vapor chamber pressure, relative humidity and carbon dioxide concentration are taken. A maximum power density of 33 mW cm^?2 is achieved as well as 120 h of continuous operation at a constant current of 50 mA cm^?2 using the vapor feed system. The fuel utilization efficiency during the 120 h test is 34.8% and the energy efficiency is 8.2%.     

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.     

Transient phenomenon of step switching for current or voltage in PEMFC

The transient phenomenon of fuel cell with 5 cm² active area is investigated in this study by current density step increase and switching voltage under different conditions. It is found that there is an undershoot when the current density step increase is at the loading of 60% RH anode cathode, 3 stoic., 70 °C, 15 psi for automobile applications. The voltage is almost zero under 0.2 step increase to 1.0 A/cm² due to the H⁺ transport in membrane or H₂/O₂ in catalyst layer is almost used up. The undershoot phenomenon is more serious under gases stoichiometries of 3.0/3.0 when H₂ is fully humidified due to low gas concentration or flooding on the electrode. This phenomenon would induce the degradation of fuel cell components.     

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.     

Activation of raw pitch coke with alkali hydroxide to prepare high performance carbon for electric double layer capacitor

Powder of raw pitch coke was activated with alkali hydroxides at 500–900 °C to prepare carbon electrode of high capacitance for electric double layer capacitor (EDLC). KOH provided very high surface area of 2320 m²/g at 800 °C, while NaOH did moderate surface area of 1000 m²/g at 650–750 °C. High surface area provided by KOH led to a high capacitance per weight of 39 F/g. However, its capacitance per volume was as low as 16 F/ml. Although the coke of moderate surface area activated with NaOH showed a similar capacitance per weight, its capacity per volume was as high as 28 F/ml because of its high density. Adequate porosity must be selectively introduced by NaOH activation to the coke to obtain moderate surface area. Much smaller expansion of layers in the present needle type coke activated by NaOH than that by KOH is indicative for the higher density of the former activated coke.     

Development of micro direct methanol fuel cells for high power applications

A micro direct methanol fuel cell (μDMFC) with active area of 1.625 cm² has been developed for high power portable applications and its electrochemical characterization carried out in this study. The fragility of the silicon wafer makes it difficult to compress the cell for good sealing and hence to reduce contact resistance in the Si-based μDMFC. We have instead used very thin stainless steel plates as bipolar plates with the flow field machined by photochemical etching technology. For both anode and cathode flow fields, widths of both the channel and rib were 750 μm, with a channel depth of 500 μm. A gold layer was deposited on the stainless steel plate to prevent corrosion. This study used an advanced MEA developed in-house featuring a modified anode backing structure with a compact microporous layer. Maximum power density of the micro DMFC reached 62.5 mW cm⁻² at 40 °C, and 100 mW cm⁻² at 60 °C at atmospheric pressure, which almost doubled the performance of our previous Si-based μDMFC.     

Manganese dioxide as a cathode catalyst for a direct alcohol or sodium borohydride fuel cell with a flowing alkaline electrolyte

The oxygen reduction reaction at a manganese dioxide cathode in alkaline medium is studied using cyclic voltammetry and by measuring volume of oxygen consumed at the cathode. The performance of the manganese dioxide cathode is also determined in the presence of fuel and an alkali mixture with a standard Pt/Ni anode in a flowing alkaline-electrolyte fuel cell. The fuels tested are methanol, ethanol and sodium borohydride (1 M), while 3 M KOH is used as the electrolyte. The performance of the fuel cell is measured in terms of open-circuit voltage and current–potential characteristics. A single peak in the cyclic voltammogram suggests that a four-electron pathway mechanism prevails during oxygen reduction. This is substantiated by calculating the number of electrons involved per molecule of oxygen that are reacted at the MnO₂ cathode from the oxygen consumption data for different fuels. The results show that the power density of the fuel cell increases with increase in MnO₂ loading to a certain limit but then decreases with further loading. The maximum power density is obtained at 3 mg cm⁻² of MnO₂ for each of the three different fuels.     

Development of a miniaturized polymer electrolyte membrane fuel cell with silicon separators

The fabrication process and electrochemical characterization of a miniaturized PEM fuel cell with silicon separators were investigated. Silicon separators were fabricated with silicon fabrication technologies such as by photolithography, anisotropic wet etching, anodic bonding and physical vapor deposition (PVD). A 400 μm × 230 μm flow channel was made with KOH wet etching on the front side of a silicon separator, and then a 550 nm gold current collector and 350 nm TiN_x thin film heater were respectively formed on the front side and the opposite side by PVD. Two separators were assembled with the membrane electrode assembly (MEA) having a 4 cm² active area for the single cell. With pure hydrogen and oxygen under atmospheric pressure without humidification, the performance of the single fuel cell was measured. A single cell operation led to generation of 203 mW cm⁻² at 0.6 V at room temperature, which corresponded to 360 mW cm⁻³ in terms of volumetric fuel cell power density, with 20 ccm of gas flow rate of hydrogen and oxygen at the inlet.     

Direct use of alcohols and sodium borohydride as fuel in an alkaline fuel cell

The performance of an alkaline fuel cell (AFC) was studied at different electrolyte concentrations and temperatures for the direct feeding of methanol, ethanol and sodium borohydride as fuels. Potassium hydroxide is used as the electrolyte in the alkaline fuel cell. The anode was prepared by using Pt black, carbon paper and Nafion dispersion. Nickel mesh was used as the current collector. A standard cathode made of manganese dioxide/carbon paper/Ni-mesh/Teflon dispersion (Electro-Chem-Technic, UK) was used for testing the fuel cell performance. The experimental results showed that the current density increases with increase in KOH concentration. Maximum current densities of 300, 270 and 360 A m⁻² were obtained for methanol, ethanol and sodium borohydride as fuel respectively with 3 M KOH electrolyte at 25 °C. The cell performance decreases with further increase in the KOH concentration. The current density of the alkaline fuel cell increases with increase in temperature for all the three fuels. The increase in current density with temperature is not as high as expected for sodium borohydride. These results are explained based on an electrochemical phenomenon and different associated losses.     

Electrooxidation study of pure ethanol/methanol and their mixture for the application in direct alcohol alkaline fuel cells (DAAFCs)

Aliphatic alcohol mainly, ethanol, methanol and their mixture were subjected to electrooxidation study using cyclic voltammetry (CV) technique in a three electrodes half cell assembly (PGSTAT204, Autolab Netherlands). A single cell set up of direct alcohol alkaline fuel cell (DAAFC) was fabricated using laboratory synthesized alkaline membrane to validate the CV results. The DAAFC conditions were kept similar as that of CV experiments. The anode and cathode electrocatalysts were Pt-Ru (30%:15% by wt.)/Carbon black (C) (Alfa Aesar, USA) and Pt (40% by wt.)/High Surface Area Carbon (C_HSA) (Alfa Aesar, USA) respectively. The CV and single cell experiments were performed at a temperature of 30 °C. The anode electrocatalyst was in the range of 0.5 mg/cm² to 1.5 mg/cm² for half cell CV analysis. The cell voltage and current density data were recorded for different concentrations of fuel (ethanol or methanol) and their mixture mixed with different concentration of KOH as electrolyte. The optimum electrocatalyst loading in half cell study was found to be 1 mg/cm² of Pt-Ru/C irrespective of fuel used. The single cell was tested using optimum anode loading of 1 mg/cm² of Pt-Ru/C which was found in CV experiment. Cathode loading was kept similar, in the order of 1 mg/cm² Pt/C_HSA. In single cell experiment, the maximum open circuit voltage (OCV) of 0.75 V and power density of 3.57 mW/cm² at a current density of 17.76 mA/cm² were obtained for the fuel of 2 M ethanol mixed with 1 M KOH. Whereas, maximum OCV of 0.62 V and power density of 7.10 mW/cm² at a current density of 23.53 mA/cm² were obtained for the fuel of 3 M methanol mixed with 6 M KOH. The mixture of methanol and ethanol (1:3) mixed with 0.5 M KOH produced the maximum OCV of 0.66 V and power density of 1.98 mW/cm² at a current density of 11.54 mA/cm².