Advances in Electrochemical Compression of Hydrogen

This paper evaluates the potential for electrochemical hydrogen compression systems (EHCs) regarding their engineering performance, manufacturability, and capital costs. EHCs could enhance or replace mechanical hydrogen compressors. The physical embodiment of EHCs is similar to that of low temperature (LT) proton exchange membrane (PEM) fuel cell systems (FCSs). They also share common operating principles with LT PEM FCS and with PEM electrolysis systems. Design for Manufacturing and Assembly (DFMA™) analysis is applied to EHCs to identify manufactured designs, manufacturing methods, projected capital costs under mass-production, and cost drivers for both the EHC stack and the balance of plant (BOP). DFMA™ analysis reveals that EHC stack costs are expected to be roughly equal to EHC BOP costs, under a variety of scenarios. (Total EHC system costs are the sum of stack and BOP costs.) Within the BOP, the primary cost driver is the electrical power supply. Within the stack, the primary cost drivers include the membrane electrode assembly (MEA), the stamped bipolar plates, and the expanded titanium (Ti) cell supports, particularly at lower hydrogen outlet pressures. As outlet pressure rises, capital costs escalate nonlinearly for several reasons. Higher pressure EHCs experience higher mechanical loads, which necessitate using a greater number of smaller diameter cells and a greater tie rod mass. Higher pressure EHCs also exhibit a higher degree of back-diffusion, which necessitates using more cells per system.

Lattice Boltzmann Modeling of Water Cumulation at the Gas Channel-Gas Diffusion Layer Interface in PEM Fuel Cells

Several experiments have proved that water in liquid phase can be present at the anode of a PEM fuel cell due to vapor condensation resulting in mass transport losses. Nevertheless, it is not yet well understood where exactly water tends to cumulate and how the design of the gas channel (GC) and gas diffusion layer (GDL) could be improved to limit water cumulation. In the present work a three-dimensional lattice Boltzmann based model is implemented in order to simulate the water cumulation at the GC-GDL interface at the anode of a PEM fuel cell. The numerical model incorporates the H2-H2O mixture equation of state and spontaneously simulates phase separation phenomena. Different simulations are carried out varying pressure gradient, pore size and relative height of the GDL. Results reveal that, once saturation conditions are reached, water tends to cumulate in two main regions: the upper and side walls of the GC and the GC-GDL interface, resulting in a limitation of the reactant diffusion from the GC to the GDL. Interestingly, the cumulation of liquid water at the interface is found to diminish as the relative height of the GDL increases.

Evaluation of Cathode Air Flow Transients in a SOFC/GT Hybrid System Using Hardware in the Loop Simulation

Thermal management in the fuel cell component of a direct fired solid oxide fuel cell gas turbine (SOFC/GT) hybrid power system, especially during an imposed load transient, can be improved by effective management and control of the cathode air mass flow. The response of gas turbine hardware system and the fuel cell stack to the cathode air mass flow transient was evaluated using a hardware-based simulation facility designed and built by the U.S. Department of Energy, National Energy Technology Laboratory (NETL). The disturbances of the cathode air mass flow were accomplished by diverting air around the fuel cell system through the manipulation of a hot-air bypass valve in open loop experiments. The dynamic responses of the SOFC/GT hybrid system were studied in this paper. The evaluation included distributed temperatures, current densities, heat generation and losses along the fuel cell over the course of the transient along with localized temperature gradients. The reduction of cathode air mass flow resulted in a sharp decrease and partial recovery of the thermal effluent from the fuel cell system in the first 10 seconds. In contrast, the turbine rotational speed did not exhibit a similar trend. The collection of distributed fuel cell and turbine trends obtained will be used in the development of controls to mitigate failure and extend life during operational transients.

Parametric Sensitivity Tests — European PEM Fuel Cell Stack Test Procedures

As fuel cells are increasingly commercialized for various applications, harmonized and industry-relevant test procedures are necessary to benchmark tests and to ensure comparability of stack performance results from different parties. This paper reports the results of parametric sensitivity tests performed based on test procedures proposed by a European project, Stack-Test. The sensitivity of a Nafion-based low temperature PEMFC stack’s performance to parametric changes was the main objective of the tests. Four crucial parameters for fuel cell operation were chosen; relative humidity, temperature, pressure, and stoichiometry at varying current density. Furthermore, procedures for polarization curve recording were also tested both in ascending and descending current directions.

Definition and Cost Evaluation of Fuel Cell Bus and Passenger Vehicle Power Plants

A design for manufacture and assembly (DFMA™) analysis is applied to future bus and automotive fuel cell vehicle (FCV) system designs. This DFMA™ analysis is used to identify (1) optimal fuel cell system (FCS) operating parameters for system cost minimization, (2) FCV designs appropriate for volume manufacture, (3) FCV manufacturing supply chain designs, (4) projected future capital costs of FCVs at varying manufacturing rates, and (5) primary cost drivers. This DFMA™ analysis focuses on the FCS drive train. It excludes fuel storage, the electric drive drain, and all other parts of the vehicle (chassis, exterior, etc.). These FCSs are envisioned to use low temperature proton exchange membrane (LT PEM) stacks to convert hydrogen fuel into electric power. Models are developed to minimize LT PEM fuel cell system costs by finding the cost optimal combination of (1) stack operating pressure, (2) cell voltage, (3) platinum (Pt) catalyst loading, (4) stoichiometric ratio of oxygen, and (5) coolant stack exit temperature. A multi-variable Monte Carlo sensitivity analysis indicates, with 90% confidence, that a FCS producing peak net 160 kilowatt-electric (kWe) for a bus application and produced at a rate of 1,000 FCS/year (yr) is expected to cost between $251/kWe and $334/kWe. Similarly, a peak net 80 kWe automotive FCS manufactured at a rate of 500,000 FCSs/year is estimated to cost between $51/kWe and $65/kWe, with 90% confidence. Total FCS costs are the sum of PEM stack and balance of plant (BOP) costs. The BOP components represent 32% of the bus FCS costs and 48% of the automotive system cost.

Operating Conditions and System Considerations for a Reversible Solid Oxide Cell System for Electrical Energy Storage

Electrical energy storage (EES) is an important component of the future electric grid. Given that no other widely available technology meets all the EES requirements, reversible (or regenerative) solid oxide cells (ReSOCs) working in both fuel cell (power producing) and electrolysis (fuel producing) modes are envisioned as a technology capable of providing highly efficient and cost-effective EES. However, there are still many challenges from cell materials development to system level operation of ReSOCs that should be addressed before widespread application. One particular challenge of this novel system is establishing effective thermal management strategies to maintain the high conversion efficiency of the ReSOC. The system presented in this paper employs a thermal management strategy of promoting exothermic methanation in the ReSOC stack to offset the endothermic electrolysis reactions during charging mode (fuel producing) while also enhancing the energy density of the stored gases. Modeling and parametric analysis of an energy storage concept is performed using a thermodynamic system model coupled with a physically based ReSOC stack model. Results indicate that roundtrip efficiencies greater than 70% can be achieved at intermediate stack temperature (∼680°C) and pressure (∼20 bar). The optimal operating conditions result from a tradeoff between high stack efficiency and high parasitic balance of plant power.

Advanced Integrated Flow Field (IFF) Design for High Performance Fuel Cell and Electrolyzer

Higher efficiency operation of PEM fuel cells needs an advanced passive way to remove product water. Water flooding in gas flow channels reduces efficiency and needs to be mitigated by a support of balance of plant design and components which results in parasitic power losses. ElectroChem’s Integrated Flow Field (IFF) design with the integration of hydrophobic and hydrophilic matrix has been proven to solve these challenges with no impact on the performance. The hydrophobic and hydrophilic matrix facilitates two phase (gas and liquid) flow to and away from the interface between the electrode membrane assembly and the flow field. A phase-separation feature of the IFF allowed the fuel cells to operate on a flow rate at its consumption rate. The IFF fuel cell has demonstrated operation at the ideal one stoichiometric ratio with 100% gas utilization and orientation independent. The IFF also served as gas humidifier through the creation of simultaneous distribution of gas and water within the cell. The self-humidification capability keeps the cell operating without the humidity of the input gas. The IFF design also enhanced the performance of water electrolysis which is a reverse process of fuel cell. The IFF supported the passive water feed to the cell and gas separation from the cell.

3-Dimensional Numerical Analysis of Solid Oxide Electrolysis Cells (SOEC) Steam Electrolysis Operation for Hydrogen Production

Hydrogen is a resource that provides energy and forms water only after reacting with oxygen. Because there are no emissions such as greenhouse gases when hydrogen is converted to produce energy, it is considered one of the most important energy resources for addressing the problems of global warming and air pollution. Additionally, hydrogen can be useful for constructing “smart grid” infrastructure because electrical energy from other renewable energy sources can be stored in the form of chemical energy by electrolyzing water, creating hydrogen. Among the many hydrogen generation systems, solid oxide electrolysis cells (SOECs) have attracted considerable attention as advanced water electrolysis systems because of their high energy conversion efficiency and low use of electrical energy. To find the relationship between operating conditions and the performance of SOECs, research has been conducted both experimentally, using actual SOEC cells, and numerically, using computational fluid dynamics (CFD). In this investigation, we developed a 3-D simulation model to analyze the relationship between the operating conditions and the overall behavior of SOECs due to different contributions to the over-potential. All SOECs involve the transfer of mass, momentum, species, and energy, and these properties are correlated. Furthermore, all of these properties have a direct influence on the concentration of the gases in the electrodes, the pressure, the temperature and the current density. Therefore, the conservation equations for mass, momentum, species, and energy should be included in the simulation model to calculate all terms in the transfer of mass, heat and fluid. In this simulation model, the transient term was neglected because the steady state was assumed. All governing equations were calculated using Star-CD (CD Adapco, U.S). The source terms in the governing equations were calculated with in-house code, i.e., user defined functions (UDF), written in FORTRAN 77, and these were linked to the Star-CD solver to calculate the transfer processes. Simulations were performed with various cathode inlet gas compositions, anode inlet gas compositions, cathode thickness, and electrode porosity to identify the main parameters related to performance.

Graphene as Cathode Material in Molten Carbon Fuel Cells

The molten carbonate fuel cell (MCFC) is considered one of the best technologies for stationary power. This is due to its high efficiency, medium–high operating temperature, and low emissions. The MCFC operates at a temperature range from 600oC to 700oC and normally is combined with the gas turbine (GT) as a topping cycle. This work investigates the impact of Platinum/Graphene (Pt/G) on a combined cycle of MCFC-GT by applying the first and second laws of thermodynamics. The maximum work output of the hybrid cycle is ultimately calculated to be 1350 kW. The overall exergy efficiency achieved is 59.82%. Our findings reveal that there is an average 23% gain in the maximum work output, energy and exergy efficiencies when Pt/G is used as the cathode material compared to other materials such as Platinum/Carbon (Pt/C) and Platinum/Carbon cloth (Pt/CC).

Towards the Development of a Fuel Cell System for Residential Applications: Propane Reforming via Catalytic Partial Oxidation

The Environmental Protection Agency (EPA) has estimated that 5% of air pollutants originate from small internal combustion engines (ICE) used in non-automotive applications. While there have been significant advances towards developing more sustainable systems to replace large ICEs, few designs have been implemented with the capability to replace small ICEs such as those used in the residential sector for lawn and garden equipment. Replacing these small residential internal combustion engines presents a unique opportunity for early market penetration of fuel cell technologies. This paper describes the initial efforts to build an innovative residential-scale fuel cell system using propane as its fuel source, and the deployment of this technology in a commonly used device found throughout the U.S. There are three main components to this program, including the development of the propane reforming system, fuel cell operation, and the overall system integration. This paper presents the reforming results of propane catalytic partial oxidation (cPOx). The primary parameters used to evaluate the reformer in this experiment were reformate composition, carbon concentration in the effluent, and reforming efficiency as a function of catalyst temperature and O2/C ratio. When including the lower heating value (LHV) for product hydrogen and carbon monoxide, maximum efficiencies of 84% were achieved at an O2/C ratio of 0.53 and a temperature of 940°C. Significant solid carbon formation was observed at catalyst temperatures below 750°C.