Technical cost analysis for PEM fuel cells

The present cost of fuel cells estimated at about $200 kW⁻¹ is a major barrier for commercialization and use in automotive applications. In the United States the target costs for fuel cell systems for the year 2004 as formulated by PNGV are $50 kW⁻¹. Lomax et al. have estimated the costs of polymer electrolyte membrane (PEM) fuel cells to be as low as $20 kW⁻¹. These estimates are based on careful consideration of high volume manufacturing processes. Recently, Arthur D. Little (ADL) has estimated the cost of a fuel cell system for transportation at $294 kW⁻¹. This estimate considers a fuel processor and directly related balance of plant components. The difference of the cost estimates results from the vastly different design assumptions. Both of these estimates are based on considering a single high volume of production, 500,000 fuel cells per year. This work builds on these earlier estimates by employing the methods of technical cost modeling and thereby including explicit consideration of design specifications, exogenous factor cost and processing and operational details. The bipolar plate is analyzed as a case study. The sensitivity of the costs to uncertainty in process conditions are explored following the ADL design. It is shown that the PNGV targets can only be achieved with design changes that reduce the quantity of material used. This might necessitate a reduction in efficiency from the assumed 80 mpg.     

Sonochemical synthesis of amorphous manganese oxide coated on carbon and application to high power battery

The nanocomposite material of amorphous manganese oxide and acetylene black (HSMO/AB), was synthesized by sonochemical method. The acetylene black particles were homogeneously coated with amorphous manganese oxide. In order to demonstrate that these characteristic structures were suitable for rapid discharge–charge, the composite material was tested under large current density. The result exhibited 185 mAh g⁻¹ in specific discharge capacity under 10 A g⁻¹ in current density. Assuming that an operating voltage of 2.5 V, this capacity corresponded 20 kW kg⁻¹ in power density and 90 Wh kg⁻¹ in energy density.     

Hybrid electrochemical capacitors based on polyaniline and activated carbon electrodes

The performance of a newly designed, polyaniline–activated carbon, hybrid electrochemical capacitor is evaluated. The capacitor is prepared by using polyaniline as a positive electrode and activated carbon as a negative electrode. From a constant charge–discharge test, a specific capacitance of 380 F g⁻¹ is obtained. The cycling behaviour of the hybrid electrochemical capacitor is examined in a two-electrode cell by means of cyclic voltammetry. The cycle-life is 4000 cycles. Values for the specific energy and specific power of 18 Wh kg⁻¹ and 1.25 kW kg⁻¹, respectively, are demonstrated for a cell voltage between 1 and 1.6 V.     

Techno-economic analysis of fuel cell auxiliary power units as alternative to idling

This paper presents a techno-economic analysis of fuel-cell-based auxiliary power units (APUs), with emphasis on applications in the trucking industry and the military. The APU system is intended to reduce the need for discretionary idling of diesel engines or gas turbines. The analysis considers the options for on-board fuel processing of diesel and compares the two leading fuel cell contenders for automotive APU applications: proton exchange membrane fuel cell and solid oxide fuel cell. As options for on-board diesel reforming, partial oxidation and auto-thermal reforming are considered. Finally, using estimated and projected efficiency data, fuel consumption patterns, capital investment, and operating costs of fuel-cell APUs, an economic evaluation of diesel-based APUs is presented, with emphasis on break-even periods as a function of fuel cost, investment cost, idling time, and idling efficiency. The analysis shows that within the range of parameters studied, there are many conditions where deployment of an SOFC-based APU is economically viable. Our analysis indicates that at an APU system cost of $ 100 kW⁻¹, the economic break-even period is within 1 year for almost the entire range of conditions. At $ 500 kW⁻¹ investment cost, a 2-year break-even period is possible except for the lowest end of the fuel consumption range considered. However, if the APU investment cost is $ 3000 kW⁻¹, break-even would only be possible at the highest fuel consumption scenarios. For Abram tanks, even at typical land delivered fuel costs, a 2-year break-even period is possible for APU investment costs as high as $ 1100 kW⁻¹.     

Synthesis and optimization of a PEM fuel cell system via reactor-separation network (RSN)

The main objective of this study is to develop the synthesis and optimization of reactor-separation network (RSN) models that can be simultaneously solved within Non-Linear Programming (NLP) for a PEM fuel cell system. The objective function for optimization was defined to minimize the overall cost and CO production. Five alternatives were synthesized to determine the best flow chart for the system based on cost and the output concentration of carbon monoxide. A Polymer Electrolyte Membrane Fuel Cell (PEMFC) system was taken as the case study. The results indicated that the optimum specific cost of a PEMFC stack was found to be in the region of US$ 500–700 kW⁻¹, while the specific manufacturing cost and the specific investment cost were calculated at the range of US$ 1000–1500 and 2500–3000 kW⁻¹, respectively. Furthermore, the infrastructure investment cost was determined to be in the range of US$ 10–30 billion with the specific cost for one unit in the range of US$ 2000–4000 kW⁻¹. The results obtained are comparable with other studies.     

Assessing the economic wind power potential in Austria

In the European Union, electricity production from wind energy is projected to increase by approximately 16% until 2020. The Austrian energy plan aims at increasing the currently installed wind power capacity from approximately 1 GW to 3 GW until 2020 including an additional capacity of 700 MW until 2015. The aim of this analysis is to assess economically viable wind turbine sites under current feed-in tariffs considering constraints imposed by infrastructure, the natural environment and ecological preservation zones in Austria. We analyze whether the policy target of installing an additional wind power capacity of 700 MW until 2015 is attainable under current legislation and developed a GIS based decision system for wind turbine site selection.Results show that the current feed-in tariff of 9.7 ct kW h⁻¹ may trigger an additional installation of 3544 MW. The current feed-in tariff can therefore be considered too high as wind power deployment would exceed the target by far. Our results indicate that the targets may be attained more cost-effectively by applying a lower feed-in tariff of 9.1 ct kW h⁻¹. Thus, windfall profits at favorable sites and deadweight losses of policy intervention can be minimized while still guaranteeing the deployment of additional wind power capacities.     

Nucleate pool boiling heat transfer coefficients of pure HFC134a,HC290, HC600a and their binary and ternary mixtures

An experimental test rig for study on the pooling-boiling heat transfer performance of pure and mixed refrigerants were designed and established. With this test system, the heat transfer coefficients (HTCs) of the nucleate boiling on a smooth flat surface were measured for pure fluids of HFC134a, HC290, HC600a and their binary and ternary mixtures. Extensive experimental measures were made for those pure and mixed refrigerants at different heat fluxes from 10 kW m⁻² to 300 kW m⁻² and different pressures from 0.2 to 0.6 MPa. Comprehensive measured data are presented in this paper. From experimental results, these binary mixtures and ternary mixtures show different heat transfer features according to their vapor–liquid phase equilibria behaviors. New heat transfer correlations were regressed from the measured data with average deviations within ±15% for pure refrigerants and within ±20% for mixtures.     

Experimental investigation of single-phase turbulent flow of R-134a in a multiport microchannel heat sink

This experimental study aims to investigate the heat transfer characteristics of single-phase turbulent flow of R-134a refrigerant in a rectangular multi-micro channel heat sink having 27 channels where each channel has a hydraulic diameter of 421 μm. Experimental results were obtained for inlet temperatures ranging from 24 to 33 °C, mass fluxes from 1485 to 2784 kg m^− 2 s^− 1 and wall heat fluxes from 3 to 24 kW m^− 2. The results indicate that the heat transfer coefficients are found to be higher at lower inlet temperatures than those at higher ones. In addition, when equal amount of heat supplied to the heat sink, the heat transfer coefficients increase with increasing the mass flux of refrigerant. They were also compared with 12 well-known correlations and it was seen that 4 of 12 were in good agreement with each other with the average deviation < 10%. The findings demonstrate that well-known correlations in fundamental sources can be used to predict the heat transfer coefficient of R-134a during its single phase flow in a multiport microchannel heat sink under turbulent regime.     

National-scale wave energy resource assessment for Australia

A nationally consistent wave resource assessment is presented for Australian shelf (<300 m) waters. Wave energy and power were derived from significant wave height and period, and wave direction hindcast using the AusWAM model for the period 1 March 1997 to 29 February 2008 inclusive. The spatial distribution of wave energy and power is available on a 0.1° grid covering 110–156° longitude and 7–46° latitude. Total instantaneous wave energy on the entire Australian shelf is on average 3.47 PJ. Wave power is greatest on the 3000 km-long southern Australian shelf (Tasmania/Victoria, southern Western Australia and South Australia), where it widely attains a time-average value of 25–35 kW m^?1 (90th percentile of 60–78 kW m^?1), delivering 800–1100 GJ m^?1 of energy in an average year. New South Wales and southern Queensland shelves, with moderate levels of wave power (time-average: 10–20 kW m^?1; 90th percentile: 20–30 kW m^?1), are also potential sites for electricity generation due to them having a similar reliability in resource delivery to the southern margin. Time-average wave power for most of the northern Australian shelf is <10 kW m^?1. Seasonal variations in wave power are consistent with regional weather patterns, which are characterised by winter SE trade winds/summer monsoon in the north and winter temperate storms/summer sea breezes in the south. The nationally consistent wave resource assessment for Australian shelf waters can be used to inform policy development and site-selection decisions by industry.     

Cultivation of Spirulina platensis by continuous process using ammonium chloride as nitrogen source

This work is focused on the influence of dilution rate (0.08⩽D⩽0.32 d⁻¹) on the kinetics of continuous cultivation of Spirulina platensis at two different concentrations of ammonium chloride (N₀=1.0 and 10 mM) as nitrogen source. Cell productivity increased in both series of runs up to D≅0.12–0.16 d⁻¹, and then decreased. While at N₀=1.0 mM biomass washing was certainly the cause of progressive cell concentration decrease, a combination of this phenomenon with the toxic effect of excess ammonia was responsible, at N₀=10 mM and D⩾0.20 d⁻¹, for quick stop of cell growth just beyond the achievement of maximum cell productivity (92.4 mg l⁻¹ d⁻¹). Similar profile was observed for protein productivity, that achieved a maximum value of 67.0 mg l⁻¹ d⁻¹, because of the very high protein content (72.5%) of biomass produced under these conditions. The yield of nitrogen-to-biomass was much higher at the lower N₀, because of the low protein content, and reached a maximum value of 9.7 g g⁻¹ at D=0.08–0.12 d⁻¹. The yield of nitrogen-to-protein showed less marked difference, being most of the nitrogen present in the cell as proteins or free amino-acids.     

Overall thermal energy and exergy analysis of hybrid photovoltaic thermal array

In this paper, overall thermal energy and exergy analysis has been carried out for different configurations of hybrid photovoltaic thermal (PVT) array. The hybrid PVT array (10.08 m × 2.16 m) is a series and parallel combinations of 36 numbers of PV modules. A one-dimensional transient model for hybrid PVT array has been developed using basic heat transfer equations. On the basis of this transient model, an attempt has been made to select an appropriate hybrid PVT array for different climatic conditions (Bangalore, Jodhpur, New Delhi, and Srinagar) of India. On the basis of high grade energy (i.e. overall exergy gain), case-III has been selected as the most appropriate configuration because overall exergy for case-III is 12.9% higher than case-II. The overall thermal energy and exergy gain for Bangalore is 4.54 × 10⁴ kW h and 2.07 × 10⁴ kW h respectively which is highest in comparison to the other cities.     

Technical and economic assessment of grid-independent hybrid photovoltaic–diesel–battery power systems for commercial loads in desert environments

Solar photovoltaic (PV) hybrid system technology is a hot topic for R&D since it promises lot of challenges and opportunities for developed and developing countries. The Kingdom of Saudi Arabia (KSA) being endowed with fairly high degree of solar radiation is a potential candidate for deployment of PV systems for power generation. Literature indicates that commercial/residential buildings in KSA consume an estimated 10–45% of the total electric energy generated. In the present study, solar radiation data of Dhahran (East-Coast, KSA) have been analyzed to assess the techno-economic viability of utilizing hybrid PV–diesel–battery power systems to meet the load requirements of a typical commercial building (with annual electrical energy demand of 620,000 kW h). The monthly average daily solar global radiation ranges from 3.61 to 7.96 kW h/m². NREL's HOMER software has been used to carry out the techno-economic viability. The simulation results indicate that for a hybrid system comprising of 80 kWp PV system together with 175 kW diesel system and a battery storage of 3 h of autonomy (equivalent to 3 h of average load), the PV penetration is 26%. The cost of generating energy (COE, US$/kW h) from the above hybrid system has been found to be 0.149 $/kW h (assuming diesel fuel price of 0.1 $/L). The study exhibits that for a given hybrid configuration, the operational hours of diesel generators decrease with increase in PV capacity. The investigation also examines the effect of PV/battery penetration on COE, operational hours of diesel gensets for a given hybrid system. Emphasis has also been placed on unmet load, excess electricity generation, percentage fuel savings and reduction in carbon emissions (for different scenarios such as PV–diesel without storage, PV–diesel with storage, as compared to diesel-only situation), cost of PV–diesel–battery systems, COE of different hybrid systems, etc.     

Tin and tin-based intermetallics as new anode materials for lithium-ion cells

The galvanostatic cycling behaviour of Sn/SnSb composite electrodes has been studied in 1 mol l⁻¹ LiClO₄/propylene carbonate (PC), 1 mol l⁻¹ LiPF₆/ethylene carbonate (EC)/diethyl carbonate (DEC) (1:1), and 1 mol l⁻¹ LiClO₄/PC saturated with trans-decalin (t-Dec). Capacities between 500 and 600 mA h g⁻¹ (with respect to the mass of active material) were obtained. Reasons for the irreversible capacities are given and film formation on lithium storage metals and alloys is discussed. The observed coulombic efficiencies were slightly higher for the EC-containing electrolyte than for the PC-based one. Alternatively, improved efficiencies and stand-time behaviour were obtained when the PC electrolyte was saturated with t-Dec, which acts as a surfactant.     

Influence of pore structure on electric double-layer capacitance of template mesoporous carbons

The behavior of two types of mesoporous carbons with different pore structures (i.e. unimodal and bimodal) as electrode material in an electrochemical double-layer capacitor has been analyzed. The carbon samples were prepared using mesostructured silica materials (MSM) as templating agents. The unimodal mesoporous carbon has a BET surface area of 1550 m² g⁻¹, and a pore volume of 1.03 cm³ g⁻¹; the porosity is mainly made up of structural mesopores of ca. 3 nm that exhibit a narrow pore size distribution (PSD). The bimodal carbon shows larger surface area (1730 m² g⁻¹) and larger pore volume (1.50 cm³ g⁻¹); the porosity is composed of two types of mesopores: structural (size around 3 nm) and complementary (size around 16 nm) mesopores. Both carbons show a disordered 3-D pore structure. Heat treatments at high temperatures (1000 °C) for long times (11 h) do not significantly change the pore structure with respect to the two synthesised carbons (800 °C). From the synthesized and heat-treated carbons, electrodes were processed as composites in which the carbons, polivinilidene fluoride (PVDF) and carbon black (CB) were the components. The effect of the heat treatment and relative CB content on specific capacitance, energy density and power density were studied. We found a specific capacitance of 200 F g⁻¹ for low current density (1 mA cm⁻²) and 110 F g⁻¹ for high current density (150 mA cm⁻²). Moreover, the curve of the specific capacitance versus current density shows three regimes, which are related to the three types of pore: micropores, structural mesopores and complementary mesopores. An energy density of 3 Wh kg⁻¹ at a power density of 300 W kg⁻¹ was obtained in some particular cases.     

Development of high energy density small flat spiral cells and battery pack based on lithium/carbon monofluoride (Li/CFx)

Small spiral-wound lithium–carbon monofluoride (Li/CF_x) cells, which were discharged at the C/40 rate, had a nominal capacity of 300 mAh and a gravimetric energy density of about 464 Wh kg⁻¹. These cells delivered pulse current loads (>22 mA) with good capacity (>200 mAh) if they were subjected to a pre-discharge step. A 17 V, 2.2 kW battery based on Li/CF_x flat cell technology has also been fabricated and tested. The battery had gravimetric and volumetric energy densities of 360 Wh kg⁻¹ and 700 Wh dm⁻³, respectively. This compares with a value of 330 Wh kg⁻¹ and 522 Wh dm⁻³ for an equivalent battery based on Li/SOCl₂.     

Dynamic behaviour of SOFC short stacks

Electrical output behaviour obtained on solid oxide fuel cell stacks, based on planar anode supported cells (50 or 100 cm² active area) and metallic interconnects, is reported. Stacks (1–12 cells) have been operated with cathode air and anode hydrogen flows between 750 and 800 °C operating temperature. At first polarisation, an activation phase (increase in power density) is typically observed, ascribed to the cathode but not clarified. Activation may extend over days or weeks. The materials are fairly resistant to thermal cycling. A 1-cell stack cycled five times in 4 days at heating/cooling rates of 100–300 K h⁻¹, showed no accelerated degradation. In a 5-cell stack, open circuit voltage (OCV) of all cells remained constant after three full cycles (800–25 °C). Power output is little affected by air flow but markedly influenced by small fuel flow variation. Fuel utilisation reached 88% in one 5-cell stack test. Performance homogeneity between cells lay at ±4–8% for three different 5- or 6-cell stacks, but was poor for a 12-cell stack with respect to the border cells. Degradation of a 1-cell stack operated for 5500 h showed clear dependence on operating conditions (cell voltage, fuel conversion), believed to be related to anode reoxidation (Ni). A 6-cell stack (50 cm² cells) delivering 100 W_el at 790 °C (1 kW_el L⁻¹ or 0.34 W cm⁻²) went through a fuel supply interruption and a thermal cycle, with one out of the six cells slightly underperforming after these events. This cell was eventually responsible (hot spot) for stack failure.     

Formulation of a low-cost medium for mass production of Spirulina

A new medium was formulated for mass production of Spirulina sp. by incorporating selected nutrients of the standard Zarrouk's medium (SM) and other cost-effective alternative chemicals. This newly formulated medium (RM₆) contains single super phosphate (1.25 g l⁻¹), sodium nitrate (2.50 g l⁻¹), muriate of potash (0.98 g l⁻¹), sodium chloride (0.5 g l⁻¹), magnesium sulphate (0.15 g l⁻¹), calcium chloride (0.04 g l⁻¹), and sodium bicarbonate (commercial grade) 8 g l⁻¹. The alga was grown in an illuminated (50 μmol photons m⁻² s⁻¹ white light) growth room at 30±1 °C. Maximum growth rate in terms of dry biomass, chlorophyll and proteins in SM was recorded between 6 and 9 days of growth and values were 0.114, 0.003 and 0.068 as compared to 0.112, 0.003 and 0.069 mg ml⁻¹ d⁻¹ in RM₆,. No significant differences were observed in the protein profiles of Spirulina sp. grown in both the media. From the scale up point of view, the revised medium was found to be highly economical, since it is five times cheaper than Zarrouk's medium.     

Evaporation heat transfer and pressure drop of HFC-134a in a helically coiled concentric tube-in-tube heat exchanger

The two-phase heat transfer coefficient and pressure drop of HFC-134a during evaporation inside a smooth helically coiled concentric tube-in-tube heat exchanger are experimentally investigated. The test section is a 5.786-m long helically coiled tube with refrigerant flowing in the inner tube and heating water flowing in the annulus. The inner tube is made from copper tubing of 9.52 mm outer diameter and 7.2 mm inner diameter. The heat exchanger is fabricated by bending a straight copper tube into a spiral coil. The diameter of coil is 305 mm. The test run are done at average saturated evaporating temperatures ranging between 10 and 20 °C. The mass fluxes are between 400 and 800 kg m⁻² s⁻¹ and the heat fluxes are between 5 and 10 kW m⁻². The inlet quality of the refrigerant in the test section is calculated using the temperature and pressure obtained from the experiment. The pressure drop across the test section is directly measured by a differential pressure transducer. The effects of heat flux, mass flux and, evaporation temperature on the heat transfer coefficients and pressure drop are also discussed. The results from the present experiment are compared with those obtained from the straight tube reported in the literature. New correlations for the convection heat transfer coefficient and pressure drop are proposed for practical applications.     

Polymeric composite bipolar plates for vehicle applications

At present membrane electrode assembly performance levels and stack operating conditions of PEM fuel cells, a plate area specific resistance of less than approximately 20 mΩ cm² and a plate thickness of less than 2 mm are required to meet the vehicular volumetric power density target (>2 kW l⁻¹). It is, however, difficult to meet these aggressive requirements, and simultaneously obtain good mechanical properties when using polymeric plate materials. Polymers become brittle and break frequently at the high conductive filler loadings (e.g., >50 v/o graphite) required for high conductivity. This study investigates a potential approach for obtaining high plate conductivity at low conductive filler loadings, thus enabling high volumes of thin and ductile plates to be manufactured at low scrap rates.     

Manganese oxide film electrodes prepared by electrostatic spray deposition for electrochemical capacitors from the KMnO4 solution

Manganese oxide film electrodes for electrochemical capacitors were deposited on the polished Pt foils by electrostatic spray deposition (ESD) from KMnO₄ precursor solution. The electrochemical properties of electrodes were systematically studied using cyclic voltammetry (CV), constant current charge–discharge tests, and electrochemical impedance spectroscopy (EIS). The specific capacitance (SC) of thick deposited film was 149 F g⁻¹ at the very high scan rate of 500 mV s⁻¹, in comparison with 209 F g⁻¹ at the low scan rate of 5 mV s⁻¹. The electrode shows good cyclic performance. The initial SC value was 163 F g⁻¹ and 103% of the initial SC can be retained after 10,000 cycles at the scan rate of 50 mV s⁻¹.