Real-time monitoring of proton exchange membrane fuel cell stack failure

Uneven pressure drops in a 75-cell 9.5-kWe proton exchange membrane fuel cell stack with a U-shaped flow configuration have been shown to cause localised flooding. Condensed water then leads to localised cell heating, resulting in reduced membrane durability. Upon purging of the anode manifold, the resulting mechanical strain on the membrane can lead to the formation of a pin-hole/membrane crack and a rapid decrease in open circuit voltage due to gas crossover. This failure has the potential to cascade to neighbouring cells due to the bipolar plate coupling and the current density heterogeneities arising from the pin-hole/membrane crack. Reintroduction of hydrogen after failure results in cell voltage loss propagating from the pin-hole/membrane crack location due to reactant crossover from the anode to the cathode, given that the anode pressure is higher than the cathode pressure. Through these observations, it is recommended that purging is avoided when the onset of flooding is observed to prevent irreparable damage to the stack

Additive manufacturing for solid oxide cell electrode fabrication

© The Electrochemical Society.Additive manufacturing can potentially offer a highly-defined electrode microstructure, as well as fast and reproducible electrode fabrication. Selective laser sintering is an additive manufacturing technique in which three-dimensional structures are created by bonding subsequent layers of powder using a laser. Although selective laser sintering can be applied to a wide range of materials, including metals and ceramics, the scientific and technical aspects of the manufacturing parameters and their impact on microstructural evolution during the process are not well understood. In the present study, a novel approach for electrode fabrication using selective laser sintering was evaluated by conducting a proof of concept study. A Ni-patterned fuel electrode was laser sintered on an yttria-stabilized zirconia substrate. The optimization process of laser parameters (laser sintering rate and laser power) and the electrochemical results of a full cell with a laser sintered electrode are presented. The challenges and prospects of using selective laser sintering for solid oxide cell fabrication are discussed

New method for the deposition of nickel oxide in porous scaffolds for electrodes in solid oxide fuel cells and electrolyzers

A simple chemical bath deposition is used to coat a complex porous ceramic scaffold with a conformal nickel layer. The resulting composite is used as a Solid Oxide Fuel Cell electrode and its electrochemical response is measured in humidified hydrogen. X-Ray tomography is used to determine microstructural parameters of the uncoated and Ni-coated porous structure, among other, the surface area to total volume, the radial pore size and size of the necks between pores

Characterising the distribution of methane and carbon dioxide emissions from the natural gas supply chain

Methane and CO2 emissions from the natural gas supply chain have been shown to vary widely but there is little understanding about the distribution of emissions across supply chain routes, processes, regions and operational practises. This study defines the distribution of total methane and CO2 emissions from the natural gas supply chain, identifying the contribution from each stage and quantifying the effect of key parameters on emissions. The study uses recent high-resolution emissions measurements with estimates of parameter distributions to build a probabilistic emissions model for a variety of technological supply chain scenarios. The distribution of emissions resembles a log-log-logistic distribution for most supply chain scenarios, indicating an extremely heavy tailed skew: median estimates which represent typical facilities are modest at 18 – 24 g CO2 eq./ MJ HHV, but mean estimates which account for the heavy tail are 22 – 107 g CO2 eq./ MJ HHV. To place these values into context, emissions associated with natural gas combustion (e.g. for heat) are approximately 55 g CO2/ MJ HHV. Thus, some supply chain scenarios are major contributors to total greenhouse gas emissions from natural gas. For methane-only emissions, median estimates are 0.8 – 2.2% of total methane production, with mean emissions of 1.6 - 5.5%. The heavy tail distribution is the signature of the disproportionately large emitting equipment known as super-emitters, which appear at all stages of the supply chain. The study analyses the impact of different technological options and identifies a set of best technological option (BTO) scenarios. This suggests that emissions-minimising technology can reduce supply chain emissions significantly, with this study estimating median emissions of 0.9% of production. However, even with the emissions-minimising technologies, evidence suggests that the influence of the super-emitters remains. Therefore, emissions-minimising technology is only part of the solution: reducing the impact of super emitters requires more effective detection and rectification, as well as pre-emptive maintenance processes

Comparative analysis of battery electric, hydrogen fuel cell and hybrid vehicles in a future sustainable road transport system

This paper compares battery electric vehicles (BEV) to hydrogen fuel cell electric vehicles (FCEV) and hydrogen fuel cell plug-in hybrid vehicles (FCHEV). Qualitative comparisons of technologies and infrastructural requirements, and quantitative comparisons of the lifecycle cost of the powertrain over 100,000 mile are undertaken, accounting for capital and fuel costs. A common vehicle platform is assumed. The 2030 scenario is discussed and compared to a conventional gasoline-fuelled internal combustion engine (ICE) powertrain. A comprehensive sensitivity analysis shows that in 2030 FCEVs could achieve lifecycle cost parity with conventional gasoline vehicles. However, both the BEV and FCHEV have significantly lower lifecycle costs. In the 2030 scenario, powertrain lifecycle costs of FCEVs range from 7360 dollars to 22,580 dollars, whereas those for BEVs range from 6460 dollars to 11,420 dollars and FCHEVs, from 4310 dollars to 12,540 dollars. All vehicle platforms exhibit significant cost sensitivity to powertrain capital cost. The BEV and FCHEV are relatively insensitive to electricity costs but the FCHEV and FCV are sensitive to hydrogen cost. The BEV and FCHEV are reasonably similar in lifecycle cost and one may offer an advantage over the other depending on driving patterns. A key conclusion is that the best path for future development of FCEVs is the FCHEV

A fast two-phase non-isothermal reduced-order model for accelerating PEM fuel cell design development

A reduced-order model (ROM) is developed for proton exchange membrane fuel cells (PEMFCs) considering the non-isothermal two-phase effects, with the goal of enhancing computational efficiency and thus accelerating fuel cell design development. Using analytical order reduction and approximation methods, the fluxes and source terms in conventional 1D conservation equations are reduced to six computing nodes at the interfaces between each cell component. The errors associated with order reduction are minimized by introducing new approximation methods for the potential distribution, the transport properties, and the membrane hydration status. The trade-off between model accuracy and computational efficiency is studied by comparing the simulation results and computational times of the new model with a full 1D model. The new model is nearly two orders of magnitude faster without sacrificing too much accuracy (<4% difference) compared to the 1D model. The new model is then used to analyze the influence of the membrane electrode assembly (MEA) design on cell performance and internal state distributions, offering insights into MEA structural optimization. The model can be readily extended to account for more detailed physico-chemical processes, such as Knudsen diffusion or the influence of micro-porous layers, and it can be an effective tool for understanding and designing PEMFCs