HYDROGEN ECONOMY & $PEM$ FUEL CELLS Dr. Hazem Tawfik

$Page 1: HYDROGEN ECONOMY & $PEM$ FUEL CELLS Dr. Hazem Tawfik$
HYDROGEN ECONOMY HYDROGEN ECONOMY & (PEM) FUEL CELLS& (PEM) FUEL CELLS

bybyDr. Hazem TawfikDr. Hazem Tawfik

Director of the Institute for Manufacturing ResearchDirector of the Institute for Manufacturing ResearchDistinguished Professor Mechanical Engineering Distinguished Professor Mechanical Engineering

TechnologyTechnology

September 2003September 2003

Agenda Agenda

•• Why Hydrogen ?Why Hydrogen ?•• Hydrogen EconomyHydrogen Economy•• Hydrogen Infrastructure Hydrogen Infrastructure •• Types of Fuel CellsTypes of Fuel Cells•• Polymer Electrolyte Membrane (PEM)Polymer Electrolyte Membrane (PEM)•• IRTT Fuel CellsIRTT Fuel Cells•• DemonstrationDemonstration

Fuel Energy DensityFuel Energy Density

1 1 79.11 79.11 0.206 0.206 29.3 29.3 AluminumAluminum

0.8 0.8 63.76 63.76 0.12 0.12 31.88 31.88 CoalCoal

0.22 0.22 17.12 17.12 WoodWood

0.48 0.48 38.7175 38.7175 0.32 0.32 45.55 45.55 Crude OilCrude Oil

0.46 0.46 36.8 36.8 0.21 0.21 46 46 KeroseneKerosene

0.23 0.23 18.16 18.16 0.16 0.16 22.722.7EthanolEthanol

0.0005031 0.0005031 0.039810.039810.39 0.39 55.5555.55MethaneMethane

0.0005032 0.0005032 0.03981 0.03981 0.33 0.33 47.21 47.21 Natural Natural

GasGas

0.45 0.45 35.775 35.775 0.330.3347.27 47.27 GasolineGasoline

0.0001610.0001610.012740.0127411141.9 141.9 HydrogenHydrogen

Relative Factor Relative Factor (volume basis)(volume basis)

Energy Density Energy Density (MJ/L.0(MJ/L.0°°C, 1 C, 1

AtmAtm))Relative Factor Relative Factor

Mass Basis Mass Basis Energy DensityEnergy Density

(MJ/KG.25(MJ/KG.25°°C)C)

Why HWhy H22? Why Fuel Cells?? Why Fuel Cells?

Why Hydrogen?Why Hydrogen? It’s It’s abundantabundant, , cleanclean, , efficient,efficient, and can be derived from diverse and can be derived from diverse

domesticdomestic resourcesresources..

.

Distributed Generation

TransportationBiomass

HydroWindSolar

Coal

Nuclear

Natural Gas

Oil

With

Car

bon

Sequ

estr

atio

n

HIGH EFFICIENCY& RELIABILITY

ZERO/NEAR ZEROEMISSIONS

President Bush Launches the President Bush Launches the Hydrogen Fuel InitiativeHydrogen Fuel Initiative

"Tonight I am proposing $1.2 billion in research funding so that America can lead the world in developing clean, hydrogen-powered automobiles.

"A simple chemical reaction between hydrogen and oxygen generates energy, which can be used to power a car producing only water, not exhaust fumes.

"With a new national commitment, our scientists and engineers will overcome obstacles to taking these cars from laboratory to showroom so that the first car driven by a child born today could be powered by hydrogen, and pollution-free.

"Join me in this important innovation to make our air significantly cleaner, and our country much less dependent on foreign sources of energy."

2003 State of the Union AddressJanuary 28, 2003

2004 Hydrogen and Fuel Cell Budget Request (Key 2004 Hydrogen and Fuel Cell Budget Request (Key Activities)Activities)

`

Production/Delivery ($23.0M)

Storage ($30.0M)

Infrastructure Validation ($13.2M)

Safety, Codes & Standards and Utilization ($16.0M)

Education and Cross-Cutting ($5.8M)Transportation Systems ($7.6M)

Distributed Energy Systems ($7.5M)

Stack Component R&D($28.0M)

Fuel Processor R&D($19.0M)

Technology Validation ($15.0M)

Total FY 04 Request $165.5M

Technical Support ($0.4M)

Hydrogen Infrastructure and Fuel Cell Technologies put on an Accelerated Schedule

• President Bush commits $1.7 billion over first 5 years:

$1.2 billion for hydrogen and fuel cells RD&D ($720 million in new money)$0.5 billion for hybrid and vehicle technologies RD&D

• Accelerated, parallel track enables industry commercialization decision by 2015.

Fuel Cell Vehicles in the Showroom and Hydrogen at Fueling Stations

by 2020

President’s Hydrogen Fuel Initiative Complements FreedomCAR

•• Freedom from foreign Freedom from foreign petroleum dependencepetroleum dependence

•• Freedom from pollutant Freedom from pollutant and carbon dioxide and carbon dioxide emissionsemissions

•• Freedom for Americans to Freedom for Americans to drive where they want, drive where they want, when they want, in the when they want, in the vehicle of their choicevehicle of their choice

•• Freedom to obtain fuel Freedom to obtain fuel affordably and affordably and conveniently

On January 9, 2002, Energy Secretary Abraham announced the FreedomCAR Partnership

conveniently

Advantages of Fuel cellsAdvantages of Fuel cells

•• Clean Reliable Source of EnergyClean Reliable Source of Energy•• High EfficiencyHigh Efficiency•• Hydrogen is available in abundanceHydrogen is available in abundance•• Combined Heat and PowerCombined Heat and Power•• Distributed GenerationDistributed Generation•• Peak Load ShavingPeak Load Shaving•• Low Operating TemperatureLow Operating Temperature

Further Advantages of PEM fuel cell Quiet - no operational noise

Low or No EmissionsLow or No EmissionsComparison of EmissionsComparison of Emissions

High EfficiencyHigh EfficiencyComparison of Fuel Cell EfficiencyComparison of Fuel Cell Efficiency

Fuel Cells Fuel Cells vsvs ICEICE

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PEM PAFC ICE/GAS Diesel

EfficSP/10Cost

“The next great economic era will be powered by “The next great economic era will be powered by hydrogen” said Rifkin, president of the Foundation on hydrogen” said Rifkin, president of the Foundation on Economic TrendsEconomic Trends

Drawing on a variety of wellDrawing on a variety of well--balanced research studies, his balanced research studies, his basic premise is that the world must switch soon from a fossilbasic premise is that the world must switch soon from a fossil--fuel economy to a hydrogen economy for three reasons:fuel economy to a hydrogen economy for three reasons:

1.1.The imminent peak of global oil production, The imminent peak of global oil production, 2.2.The increased concentration of remaining oil reserves in The increased concentration of remaining oil reserves in the Middle East one of the most politically and socially the Middle East one of the most politically and socially unstable regions of the world unstable regions of the world 3.3.The steady pollution and heating up of the world's The steady pollution and heating up of the world's atmosphere from fossilatmosphere from fossil--fuel dependency. fuel dependency.

Detailing the shortcomings of traditional energy sources in Detailing the shortcomings of traditional energy sources in light of possible terrorist attacks, Rifkin then covers the light of possible terrorist attacks, Rifkin then covers the merits of hydrogen as a "forever fuel"merits of hydrogen as a "forever fuel"

Hydrogen Economy & Infrastructure Hydrogen Economy & Infrastructure

“Positive efforts made by government, “Positive efforts made by government, corporations, environmentalists, and corporations, environmentalists, and scientists to promote hydrogen as a clean, scientists to promote hydrogen as a clean, relatively safe, and potentially cheap relatively safe, and potentially cheap alternative to carbonalternative to carbon--heavy fuels”heavy fuels”

Peter Hoffman, Author Peter Hoffman, Author

Hydrogen Infrastructure is currently in the Hydrogen Infrastructure is currently in the research and development stageresearch and development stage

Institute for Research & Institute for Research & Technology Transfer (IRTT)Technology Transfer (IRTT)

Mission StatementMission Statement

Supports the Regional Economic Supports the Regional Economic Growth and Enriches the Education Growth and Enriches the Education Experience of the Students with Experience of the Students with Modern TechnologiesModern Technologies

Research And Development of Research And Development of New Technologies that Can Lead New Technologies that Can Lead

to Commercial Productsto Commercial Products

•• Bridge the Gap between New Bridge the Gap between New Technologies Developed in the Technologies Developed in the Laboratories and Industrial Laboratories and Industrial CommercializationCommercialization

•• Technology Transfer to Industry for Technology Transfer to Industry for Mass Production and opening New Mass Production and opening New Job OpportunitiesJob Opportunities

Current R&D ProjectsCurrent R&D Projects

•• PEM Fuel Cells (Residential & Mobile PEM Fuel Cells (Residential & Mobile Applications)Applications)

•• Customized Bone and Dental ImplantsCustomized Bone and Dental Implants•• Automated Robotics and Manufacturing Automated Robotics and Manufacturing

Islands Islands –– Pharmaceutical CompaniesPharmaceutical Companies•• Wind TurbinesWind Turbines

IRTT Provides Outsourcing IRTT Provides Outsourcing Opportunities for Small and Medium Opportunities for Small and Medium Size Companies to use IRTT’s State Size Companies to use IRTT’s State

of the Art Technologies and of the Art Technologies and Advanced Systems to Enhance their Advanced Systems to Enhance their

Industrial CompetitivenessIndustrial Competitiveness

•• Reduce Production Cycle Time and Bring Products Reduce Production Cycle Time and Bring Products to the Market Faster than the Competitionto the Market Faster than the Competition

Offers Specialized WorkshopsOffers Specialized Workshops

•• To Sharpen the Students Skills with the To Sharpen the Students Skills with the State of the art Technology and Enrich their State of the art Technology and Enrich their Education Experience with Practical Education Experience with Practical Knowledge and Faculty at the Cutting Edge Knowledge and Faculty at the Cutting Edge of Technology.of Technology.

HYDROGEN INSTITUTEHYDROGEN INSTITUTE

R&DR&D ofof Alternative/Renewable Sources Alternative/Renewable Sources of Energyof Energy

•• PEM Fuel CellsPEM Fuel Cells

•• Membraneless Fuel CellsMembraneless Fuel Cells

•• Wind TurbinesWind Turbines

Technical & Economical Technical & Economical Challenges of Fuel Cells:Challenges of Fuel Cells:

FCFC AdvantagesAdvantages ChallengeChallengePEMPEM Quick Start/upQuick Start/up Thermal & Thermal &

water water ManagManag..MEA DurabilityMEA Durability

SOFCSOFC 12 hrs Start up12 hrs Start up Thermal CyclingThermal Cycling

MCFCMCFC 12 hrs start up12 hrs start up Thermal CyclingThermal CyclingCost must be reduced at least five foldCost must be reduced at least five fold

PEM Fuel CellsPEM Fuel Cells

•• According to the U.S. Department of Energy, " According to the U.S. Department of Energy, " Proton Exchange Membrane (PEM) fuel cells are Proton Exchange Membrane (PEM) fuel cells are the primary candidates for lightthe primary candidates for light--duty vehicles, for duty vehicles, for buildings, and potentially for much smaller buildings, and potentially for much smaller applications. applications.

•• They provide clean energy and operate at relatively They provide clean energy and operate at relatively low temperatures (about 200 degrees F), produce low temperatures (about 200 degrees F), produce high power density and can vary their output high power density and can vary their output quickly to meet shifts in power demand and are quickly to meet shifts in power demand and are suited for applications such as in automobiles, suited for applications such as in automobiles, where quick startup is required.where quick startup is required.

Fuel cell OperationFuel cell Operation

DOE Targets/Challenges for PEMDOE Targets/Challenges for PEM

•• MEA Tolerance for CO in Reformed HMEA Tolerance for CO in Reformed H22With dry composition of 40% HWith dry composition of 40% H22, 21% CO, 21% CO22, 39% N, 39% N2 2 , and 10, and 10--15 15

ppmppm COCO–– High Temperature MEA > 120 CHigh Temperature MEA > 120 C–– MembranelessMembraneless

•• MEA DurabilityMEA Durability–– 40,000 hrs with < 10% Degradation, <1% Cross 40,000 hrs with < 10% Degradation, <1% Cross

Over, Area Resistance < 0.1 ohm.cmOver, Area Resistance < 0.1 ohm.cm22

•• CostCost–– $1,500 / kW for PEM Power System $1,500 / kW for PEM Power System –– $10/kW for MEA$10/kW for MEA

•• EfficiencyEfficiency–– 35% to 50%35% to 50%

Economic Evaluation of Bipolar Plates Heat Economic Evaluation of Bipolar Plates Heat loss/year due to Electric Resistanceloss/year due to Electric Resistance

FC Unit SizeFC Unit Size Aluminum Aluminum GraphiteGraphite

1 1 kwkw $0.01$0.01 $2.13$2.135 5 kwkw $0.063$0.063 $10.67$10.6710 10 kwkw $0.12$0.12 $21.35$21.3520 20 kwkw $0.25$0.25 $43.0$43.050 50 kwkw $0.63$0.63 $107.0$107.0100 100 kwkw $1.26$1.26 $213.53$213.53500 500 kwkw $6.296$6.296 $1068.0$1068.0

Second Year Stack Designs and TestingSecond Year Stack Designs and Testing

External Manifold DesignExternal Manifold Design

External Manifold DesignExternal Manifold Design

•• Manifolds are Labor IntensiveManifolds are Labor Intensive

•• MEA(s) are Too Large to MEA(s) are Too Large to FabricateFabricate

•• Manifolds are Prone to LeaksManifolds are Prone to Leaks

•• No Possibility of Leaks from the No Possibility of Leaks from the Bipolar Stack PlatsBipolar Stack Plats

Stack design (Internal Manifold)Stack design (Internal Manifold)

An internal manifold fuel cell stack was fabricated using our recent research findings, such as plates and gaskets thickness as well as coating and gaskets materials. (Note: This design is prone to reactant gas leak from the end plates.

Final Stack DesignFinal Stack Design

Final Stack DesignFinal Stack Design

•• No external gas leaks from:No external gas leaks from:–– between front and bipolar plates between front and bipolar plates

–– between bipolar platesbetween bipolar plates

•• Medium size MEA, easy to fabricateMedium size MEA, easy to fabricate

•• Bipolar plates are thinBipolar plates are thin

•• Gasket is 0.020 inch thicknessGasket is 0.020 inch thickness


Equipments for flatnessEquipments for flatness measurementsmeasurements

Research procedure to reduce deformationResearch procedure to reduce deformation

MASK

AIR COOLING TUBE

55 Ton Press for MEA Fabrication55 Ton Press for MEA Fabrication

55 Ton Press for MEA Fabrication55 Ton Press for MEA Fabrication

Composition of Membrane Electrode Composition of Membrane Electrode Assembly (MEA) : (Carbon diffusion Assembly (MEA) : (Carbon diffusion layer+ Mix of carbon, Pt(Catalyst) layer+ Mix of carbon, Pt(Catalyst) and liquid and liquid Nafion Nafion

Adhesion requirement for MEA (high Adhesion requirement for MEA (high temp & pressure)temp & pressure)

•• Two heating plates with temp Two heating plates with temp controller and 4 releasing springscontroller and 4 releasing springs

•• 55 ton hydraulic pressure55 ton hydraulic pressure


Graphite Bipolar PlatesGraphite Bipolar Plates

Five Single CellsFive Single Cells –– 1 Gold Plated, 2 1 Gold Plated, 2 Graphite Composite, and 2 coated ALGraphite Composite, and 2 coated AL

Hydrogen Safety System For Fuel Hydrogen Safety System For Fuel Cell TestingCell Testing

Variable Loading Testing M/CVariable Loading Testing M/C

Life Time Test of Life Time Test of Metallic vs. Graphite BipolarMetallic vs. Graphite Bipolar PlatesPlates

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Time, hr

Pow

er, W

att

Treated MetalGraphite

Cell Temerature= 68 oFAir flow rate = 3 SCFHCell area 1 in2

H2/air pressure= 20/30 PSI

Polarization Curve For Comparison Between Surface Treated Metal and Graphite

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Current density, mA/cm2

Cell

volta

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Surface treated metal

Graphite



Power Density Curve For Comparison Between Surface Treated Metal and Graphite

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Graphite



Power Density & Efficiency Curve For Comparison Between Surface Treated Metal and Graphite

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% E

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surface TreatedMetal powerEfficiencyGraphite power Efficiency

Surface treatedmetal

Graphite



Economics of Metal Vs. GraphiteEconomics of Metal Vs. Graphite•• Relative savings in hydrogen Consumption and efficiency improvemRelative savings in hydrogen Consumption and efficiency improvement by at ent by at

least 12% due to higher electric and thermal conductivity of metleast 12% due to higher electric and thermal conductivity of metal vs. graphite al vs. graphite bipolar plates.bipolar plates.

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Graphite

SCCM / W Treated metal

SCCM / W Graphite



Economic Viability of Metallic PlatesEconomic Viability of Metallic Plates

Fixed Costs (Materials and Manufacturing Costs) Base on Fixed Costs (Materials and Manufacturing Costs) Base on 14.6 x 14.6 cm active area fuel cell14.6 x 14.6 cm active area fuel cell

GraphiteGraphite AluminumAluminumMaterial cost (per lb)Material cost (per lb) $10.00 $10.00 $ 2.80 $ 2.80 Material weight per plate (lb)Material weight per plate (lb) 0.8590.859 1.121.12Material cost (per plate)Material cost (per plate) $ 8.59$ 8.59 $ 3.14$ 3.14

Mass production costMass production costTooling cost (Injection molding / Die casting) Tooling cost (Injection molding / Die casting) minimum 250,000 platesminimum 250,000 plates $35,000.00 $35,000.00 $32,000.00 $32,000.00 Cost of Secondary Operation Cost of Secondary Operation $10.00$10.00 $ 20.08$ 20.08(per plate)(per plate)

Total cost per each plateTotal cost per each plate $ 13.88$ 13.88 $ 23.22$ 23.22Bipolar plate cost per (cm^2)Bipolar plate cost per (cm^2) $ 0.065 $ 0.065 $ 0.109$ 0.109

Running Costs Running Costs -- Hydrogen ConsumptionHydrogen ConsumptionGraphite AluminumGraphite Aluminum

687.75687.75750750Hydrogen consumption (Liter Hydrogen consumption (Liter

per 1 kW hr)per 1 kW hr)

8.30%8.30%EfficiencyEfficiency

11.462511.462512.512.5Hydrogen consumption Hydrogen consumption

(SCCM/watt)(SCCM/watt)

Summary of Fixed and Running CostsSummary of Fixed and Running Costs

GraphiteGraphite AluminumAluminum

0.372 0.372 0.405 0.405 Running Cost of Hydrogen Running Cost of Hydrogen

per kilowatt hourper kilowatt hour

$ 266 $ 266 $ 130 $ 130 Fixed Cost of bipolar plates Fixed Cost of bipolar plates

per kilowattper kilowatt

Comparison of energy cost generated by Comparison of energy cost generated by aluminum and graphite bipolar platesaluminum and graphite bipolar plates

$-$2,000.00$4,000.00$6,000.00$8,000.00

$10,000.00$12,000.00$14,000.00$16,000.00$18,000.00$20,000.00

0.25

0.75

1.25

1.75

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2.75

3.25

3.75

4.25

4.75

Years

GraphiteAluminum

c

IRTT Fuel Cell DevelopmentIRTT Fuel Cell Development

•• Metallic bipolar platesMetallic bipolar plates•• Design and development of new serpentine Design and development of new serpentine

configurationsconfigurations –– Patent Pending#1Patent Pending#1•• New power stack designNew power stack design –– Patent Pending#1Patent Pending#1•• New manufacturing technique and high New manufacturing technique and high

corrosion resistance metal treated bipolar platescorrosion resistance metal treated bipolar plates–– Patent Pending#2Patent Pending#2

IRTT PEM Stack Design AdvantagesIRTT PEM Stack Design Advantages

Rigid and durableRigid and durableInternal manifoldInternal manifoldLeak freeLeak freecompactcompactSuitable for all applicationsSuitable for all applicationsMore suitable than graphite for transportation More suitable than graphite for transportation applicationsapplicationsDoes not require elaborate cooling system like Does not require elaborate cooling system like graphite graphite –– Aluminum is much more conductive Aluminum is much more conductive than graphitethan graphite

IRTT’sIRTT’s New Technology in a NutshellNew Technology in a Nutshell

•• High corrosion Resistance with high electrical and High corrosion Resistance with high electrical and thermal conductivity Metallic Bipolar Plates thermal conductivity Metallic Bipolar Plates –– (Low (Low Hydrogen Consumption 12% less than Graphite and Hydrogen Consumption 12% less than Graphite and Simple Cooling System)Simple Cooling System)

•• Compact, rigid and leak free stack design with Compact, rigid and leak free stack design with internal manifoldinternal manifold

Note: IRTT PEM Technologies cover all fuel cell’s mobile Note: IRTT PEM Technologies cover all fuel cell’s mobile and stationary applicationsand stationary applications

Potential Markets for PEM TechnologyPotential Markets for PEM Technology

The main market for PEM is the BACK UP POWERThe main market for PEM is the BACK UP POWER

•• Telecommunication TowersTelecommunication Towers

•• HospitalsHospitals

•• BanksBanks

•• Police PrecinctPolice Precinct

•• Peak load ShavingPeak load Shaving

These markets require max lifetime of 4000 hrsThese markets require max lifetime of 4000 hrs

Projected PEM Fuel Cell MarketProjected PEM Fuel Cell Market

Cost to Operate 1kw PEM Fuel Cell for a Year

$1,500.00

$1,625.00

$1,350.00$1,400.00$1,450.00$1,500.00$1,550.00$1,600.00$1,650.00$1,700.00$1,750.00

Die-cast Aluminum Moldable Graphite

•• Local back up Power SystemsLocal back up Power Systems•• Estimated at one MW for the first Estimated at one MW for the first

yearyear•• $5000/kW $5000/kW –– Market size for first Market size for first

year is $ 5 millionyear is $ 5 million•• Hydrogen Savings per kW/year Hydrogen Savings per kW/year

$125 $125 –– For backup power about For backup power about 800 hrs a year 800 hrs a year –– Hydrogen Savings Hydrogen Savings $12.5/kW of back up power over $12.5/kW of back up power over one yearone year

•• Total Savings for one MW in the Total Savings for one MW in the first year = $12,500 first year = $12,500

To Put the New Technology under To Put the New Technology under one Umbrella we are Developing The one Umbrella we are Developing The

HYDROGEN INSTITUTEHYDROGEN INSTITUTE•• Provide Awareness of Alternative Sources of Provide Awareness of Alternative Sources of

Energy to the Public.Energy to the Public.

•• National Research and Education Institute for National Research and Education Institute for undergraduate, postgraduate, and continuing undergraduate, postgraduate, and continuing education studies in alternative sources of energy:education studies in alternative sources of energy:–– Fuel CellsFuel Cells

–– WindWind

–– SolarSolar

–– GeothermalGeothermal

Effect of Hydrogen Pressure on PowerEffect of Hydrogen Pressure on Power

Pressure H2/O2

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Effect of Oxygen Pressure on PowerEffect of Oxygen Pressure on Power

Pressure H2/O2

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m2

20/20 psi20/30 psi20/40 psi20/50 psi

Effect of cell temperature on the polarization Effect of cell temperature on the polarization curvecurve

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Effect of Cell Temperature on PowerEffect of Cell Temperature on Power

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m2 20 oC

40 oC60 oC

Humidity Effect at Room TempHumidity Effect at Room Temp

00.20.40.60.8

11.21.41.61.8

2

0 1 2 3Current (Amps)

Wat

ts NoHumidificationWith Bubbler

Cell temperature has the most significant effect Cell temperature has the most significant effect on fuel cell performance on fuel cell performance

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S (Temp)=0.85

S(H2)=0.35

S(O2)=0.14

S(Hum)=0.42

Air & O2 Effect on Power at Room TempAir & O2 Effect on Power at Room Temp

0123456789

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Pow

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O2Air

O2 produced 30% more power than Air

Single cell w ith large heat sink - temp effect is negligible

Effect of Air & O2 on PowerEffect of Air & O2 on Power

02468

10121416

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Volts Air

O2

40% increase in power

Stack temp effect may existed

Effect of Air vs. O2 on FC OutputEffect of Air vs. O2 on FC Output

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Pow er w ith H2, O2

52.9 % increase in power by using O2

34.6% decrease in power by using Air

Performance Testing of the Final Stack PrototypePerformance Testing of the Final Stack Prototype

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StackTemp

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32 Minutes test time

Interdigitated Flow Field Design Interdigitated Flow Field Design •• Plate Design and optimization of Plate Design and optimization of InterdigitatedInterdigitated flow flow

fields fields –– To enhance and change the interaction To enhance and change the interaction mechanism between reactant gases, electrolyte, and mechanism between reactant gases, electrolyte, and catalyst from diffusion to convective.catalyst from diffusion to convective.

Fully Interdigitated 1/3 Interdigitated

2/3 Interdigitated Regular Serpentine

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1/3 blockedSerpentine

Effect of Flow Field Interdigitated design on the

Performance of PEMFC

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Net power, wattpower GeneratedAir Pumping power

Effect of Flow Field Interdigitated design on

Net Power OF PEMFC

Design of Interdigitated Flow FieldDesign of Interdigitated Flow Field

•• Changes the diffusion mechanism to a more effective Changes the diffusion mechanism to a more effective connective flow fieldconnective flow field

•• Uniform pressure distribution is necessary to produce Uniform pressure distribution is necessary to produce

uniform power density across the plateuniform power density across the plate

•• Uniform pressure distribution is necessary to avoid Uniform pressure distribution is necessary to avoid hot spots and crossover of reactantshot spots and crossover of reactants

•• Crossover causes sever damage to MEACrossover causes sever damage to MEA

•• Computer simulationComputer simulation using STAR CD to generate using STAR CD to generate uniform flow fieldsuniform flow fields

•• InterdigitationInterdigitation does improve power densitydoes improve power density

Water ManagementWater Management

•• Is very crucial to the PEM Fuel Cell performanceIs very crucial to the PEM Fuel Cell performance•• Dry out and flooding are very detrimental to the Dry out and flooding are very detrimental to the

PEM performancePEM performance•• Humidity must be kept around 90% R.H. inside Humidity must be kept around 90% R.H. inside

the PEM fuel cellthe PEM fuel cell•• Efficient serpentine design was developed at Efficient serpentine design was developed at

IRTT/Farmingdale to minimize or eliminate the IRTT/Farmingdale to minimize or eliminate the need for external humidification and allows the use need for external humidification and allows the use of dry gases (Air & Hydrogen)of dry gases (Air & Hydrogen)

Water Transfer Mechanisms Across the MEAWater Transfer Mechanisms Across the MEA

Flow Field Design RequirementsFlow Field Design Requirements

•• Plate design must allow for Plate design must allow for water/humidity conservation inside the water/humidity conservation inside the power stack power stack

•• Common straight serpentine plate Common straight serpentine plate design does not allow for humidity design does not allow for humidity conservationconservation

•• IRTT/Farmingdale developed two IRTT/Farmingdale developed two Flow Fields that allow for dry gases Flow Fields that allow for dry gases operating at 70 Degree C without any operating at 70 Degree C without any Dry out Dry out

Common Serpentine DesignCommon Serpentine Design

•• Straight Serpentine Straight Serpentine –– requires external humidificationrequires external humidification

•• Straight Serpentine Straight Serpentine –– requires external humidificationrequires external humidification

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20 oC serpentine flow channel,H2/air = 20/18 Psi , R/H= 77.130 oC serpentine flow channel,H2/air = 20/18 Psi , R/H= 77.140 oC serpentine flow channel,H2/air = 20/18 Psi , R/H= 77.1

IRTT New Serpentine DesignIRTT New Serpentine Design

Flow Field 1Flow Field 1

Flow Field 2Flow Field 2

Flow Field 1Flow Field 1–– No External humidification is requiredNo External humidification is required

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25 oC Flow Field 1, H2/air 10/8 Psi







5.55 cm2 active area0.3 mg/cm2 Pt loadingFeed and Exit from the Top

Flow Field 2 Flow Field 2 –– No External humidification is requiredNo External humidification is required

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20 oC Flow field 2, H2/air 20/18.5 Psi, R.H. = 86.430 oC Flow field 2, H2/air 20/18.5 Psi, R.H. = 86.440 oC Flow field 2, H2/air 20/18.5 Psi, R.H. = 86.440 oC Flow field 2, H2/air 20/18.5 Psi, R.H. = 86.460 oC Flow field 2, H2/air 20/18.5 Psi, R.H. = 86.470 oC Flow field 2, H2/air 20/18.5 Psi, R.H. = 86.480 oC Flow field 2, H2/air 20/18.5 Psi, R.H. = 86.4


New flow field 2 design showed the best New flow field 2 design showed the best performance at 40 degree Cperformance at 40 degree C

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40 oC Flow field 2, H2/air20/18.5 Psi

40 oC Flow field 1, H2/air20/18.5 Psi

40 oC serpentine flowchannel, H2/air = 20/18 Psi,R/H= 77.1

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40 oC Flow Field 2, H2/air20/18.5 Psi

40 oC Flow Field 1, H2/air20/18.5 Psi

40 oC serpentine flowchannel, H2/air = 20/18 Psi,R/H= 77.1

Effect of Hydrogen Pressure and Air Back Pressureon PEM Fuel Cell Performance

00.010.020.030.040.050.060.070.080.09

0.10.110.120.130.140.150.16

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40 oC Flow field 1, H2/air10/8 Psi, R.H. = 81.6

40 oC Flow field 1, H2/air20/18.5 Psi, R.H. = 92.0

40 oC Flow field 1, H2/air40/35 Psi, R.H. = 87.1


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40 oC Flow field 1, H2/air 10/8 Psi, R.H. = 81.6

40 oC Flow field 1, H2/air 20/18.5 Psi, R.H. = 92.0

40 oC Flow field 1, H2/air 40/35 Psi, R.H. = 87.1

Poly. (40 oC Flow field 1, H2/air 40/35 Psi, R.H. =


IRTT/ New MEA TechnologyIRTT/ New MEA Technology

•• Front Loading of High Concentration Supported Front Loading of High Concentration Supported Catalyst at the Nafion interfaceCatalyst at the Nafion interface

•• Increase the triIncrease the tri--interface between Catalyst, Electrolyte, interface between Catalyst, Electrolyte, and Reactant Gasesand Reactant Gases

This results in the following:This results in the following:•• Low cost MEALow cost MEA•• High efficiencyHigh efficiency•• Cost effective MEA design with front catalyst loadingCost effective MEA design with front catalyst loading•• Unsupported catalyst optimizationUnsupported catalyst optimization

Cost Effective Technique of Front Catalyst LoadingCost Effective Technique of Front Catalyst Loading

•• Pronounced effect of high catalyst concentration in the micro laPronounced effect of high catalyst concentration in the micro layer adjacent to the yer adjacent to the thin film Nafion interfacethin film Nafion interface

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olt20% Pt/C

40% Pt/C

80% Pt/C

(80%+20%)Pt/C

Fuel Cell ApplicationsFuel Cell Applications::

•• Small hybrid fuel cell/ battery pack powered Small hybrid fuel cell/ battery pack powered vehiclesvehicles

•• Provide green power to residential homes Provide green power to residential homes using “net metering” using “net metering”

Hybrid Fuel Cell Battery Pack Hybrid Fuel Cell Battery Pack -- Powering a Go CartPowering a Go Cart

•• 8 Volts Fuel Cell 8 Volts Fuel Cell -- 36 Volts Battery 36 Volts Battery -- Inverter 8/42 Volts Inverter 8/42 Volts -- Battery ChargerBattery Charger


ConclusionsConclusions

•• The world has moved from the steam economy The world has moved from the steam economy to the ICE economy and is starting the new era to the ICE economy and is starting the new era of the hydrogen economyof the hydrogen economy

•• Fuel Cells powered by hydrogen produce clean Fuel Cells powered by hydrogen produce clean & environmentally friendly energy and are & environmentally friendly energy and are receiving considerable attention from the U.S. receiving considerable attention from the U.S. government. government.

•• Aluminum bipolar plates are proven to have Aluminum bipolar plates are proven to have very good performance and longevity.very good performance and longevity.

Conclusions (Continue)Conclusions (Continue)

•• Robust, efficient, and safe aluminum stack Robust, efficient, and safe aluminum stack design has been achieved by IRTT with no design has been achieved by IRTT with no crossover or outside leak of reactant gases crossover or outside leak of reactant gases

•• Aluminum bipolar plates have excellent Aluminum bipolar plates have excellent economic potential with 12% better economic potential with 12% better hydrogen consumption than graphitehydrogen consumption than graphite

•• IRTT has the experience, equipment, and IRTT has the experience, equipment, and instrumentation to fabricate, assemble, and instrumentation to fabricate, assemble, and test metal and/or graphite FC stacks.test metal and/or graphite FC stacks.


•• Three patent bending were filed by IRTT Three patent bending were filed by IRTT on the design and manufacturing of light on the design and manufacturing of light weigh, corrosion resistance PEM metal weigh, corrosion resistance PEM metal power stackspower stacks

•• IRTT’sIRTT’s PEM Technologies are Ready to PEM Technologies are Ready to be Transferred and licensed to industry be Transferred and licensed to industry and Benefit the Local and National Market and Benefit the Local and National Market EconomiesEconomies


•• Temperature and Humidity has the most Temperature and Humidity has the most significant influence on the FC power output significant influence on the FC power output and must be optimizedand must be optimized

•• We are very excited about our newly We are very excited about our newly developed technologies and intend to developed technologies and intend to continue moving forwardcontinue moving forward

Proposals for Future PEM Development under the Proposals for Future PEM Development under the

Hydrogen InstituteHydrogen Institute in cooperation with Industryin cooperation with Industry

Important Areas for PEM Development :Important Areas for PEM Development :•• MembranelessMembraneless Fuel Cells Fuel Cells -- $ 285,000$ 285,000•• Test Metal Bipolar Plates at Higher Temp. 70Test Metal Bipolar Plates at Higher Temp. 70ooC C --

$65,000$65,000•• Interdigitated Flow Field Interdigitated Flow Field -- $145,000$145,000•• Water Management using new Serpentine Design for Water Management using new Serpentine Design for

Dry Reactant Gases $ 175,000Dry Reactant Gases $ 175,000•• MEA Cost Effective Studies for Supported and MEA Cost Effective Studies for Supported and

Unsupported Catalyst Loading Unsupported Catalyst Loading -- $150,000 $150,000 •• Hydrogen and Air Pressure and Temperature Hydrogen and Air Pressure and Temperature

optimization optimization -- $145,000$145,000•• PEM Cost Reduction Studies PEM Cost Reduction Studies –– $125,000$125,000•• Fuel Cell Powered Vehicle Fuel Cell Powered Vehicle -- $ 150,000$ 150,000

Documents

HYDROGEN ECONOMY & \(PEM\) FUEL CELLS Dr. Hazem Tawfik