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FUEL CELL SYSTEMS S. Basu New Delhi Department of Chemical Engineering Indian Institute of Technology Delhi INDIA e- Load Water 1. Fuel chamber 2. Oxidant chamber 1 4 2 3. Anode (Pt) 4. Electrolyte Fuel 3 5 Oxidant 5. Cathode (Pt/C) (H ) 2 O2/Air + - H2 2 H +2e (Anode) + - 2 H +1/2 O2 +2e H2O (Cathode) H2 + 1/2 O2 H2O (Overall) 9 Automobile 9 Efficient Power Generation 9 Distributed Power Gen. 9 Environmental Friendly 9 Portable Electronics Eqpt. Fuel Cell Families Phosphoric Acid Cathode Anode o H+ 220 C Solid Polymer Cathode Anode o o H+ 30 C- 80 C Alkaline Air Cathode - Anode Fuel 50 oC- 200 oC OH Molten Carbonates o Cathode = Anode 650 C CO3 Solid Oxides Cathode Anode o o O= 700 C – 1000 C Alkaline Fuel Cell ALKALINE FUEL CELL Alkaline electrolyte - - Anode H2 + 2OH Æ 2H2O + 2e - - Cathode 1/2O2 + H2O + 2e Æ 2OH Overall H2 + 1/2O2 Æ H2O + electrical Energy +heat Poisoning: - 2- CO2 +2OH (CO3) + H2O ¾ Depletion of KOH ¾ Poisoning of cathode surface with carbonates Myth ! 9Kordesch, K. et al., (1999), Intermittent Use of a Low-Cost Alkaline Fuel Cell-hybrid System for Electric Vehicles, J. Power Sources, Vol. 80, pp. 9McLean, G. F. et al. (2002) An assessment of alkaline fuel cell technology, Int. J. Hydrogen Energy 27 507 9Gülzow, E., and Schulze, M. (2003), Long-Term Operation of AFC Electrodes With CO2- Containing Gases, J. Power Sources, Polymer Electrolyte Membrane Fuel Cell (PEMFC) Hydrogen Fuel Cell Direct Alcohol Fuel Cell (DAFC) Fuel Processor Fuel Cleaning System Fuel Pure H2 Electricity Fuel Cell Direct Methanol Fuel Cell Direct Ethanol Fuel Cell (DMFC) (DEFC) Reduce CO adsorption on Pt at High Temp Higher power density at high temperature Easy breakage C-C bond in DEFC at High Temp. Problems at high temperature operation- • Poor proton conduction at High temperature • Nafion membrane should remain hydrated for proton conduction e- Load Water 1. Fuel chamber 2. Oxidant chamber 1 2 3. Anode (Pt) 4 4. Polymer Electrolyte Membrane Fuel 3 5 Oxidant (PEM) (H ) 5. Cathode (Pt/C) 2 O2/Air + - H2 2 H +2e (Anode) + - 2 H +1/2 O2 +2e H2O (Cathode) H2 + 1/2 O2 H2O (Overall) DIRECT METHANOL FUEL CELL (DMFC) Load Air/H O CH3OH/H2O/CO2 Catalyst Layers 2 ANODE CATHODE PEM e- e- H+ H2O CH3OH Current collector + Reactant Distributor Current collector + Reactant Distributor Air CH3OH/H2O Diffusion Layers Reaction Mechanism Anode Reactions (Oxidation of Methanol) : + - CH3OH + Pt Pt - CH2OH + H + 1e (1) + - Pt-CH2OH + Pt Pt - CHOH + H + 1e (2) Pt-CHOH + Pt Pt-CHO + H+ + 1e- (3) Pt - CHO + Pt Pt - C≡O + H+ + 1e- (4a) or Pt Pt-CHO + Pt C=O + H+ + 1e- (4b) Pt Water dissociation + - Pt + H2O Pt-OH + H + 1e (5) + - Pt-OH + Pt-CO 2Pt + CO2 + H + 1e (6) Cathode Reactions (Reduction of Oxygen) : O2 + Pt Pt -O2 (7) + - Pt-O2 + H + 1e Pt -HO2 (8) Pt-HO2 + Pt Pt - OH + Pt -O (9) + - Pt -OH + Pt -O + 3H +3e 2 Pt + 2 H2O (10) Overall Reaction : CH3OH + 3/2 O2 CO2 +2H2O (11) Perfluro-sulphonic acid Membrane Hydrophilic part Hydrophobic part International Status • Published literatures are very few - 1. Doyle, M., Choi, S., Proulx, G., High-Temperature Proton Conducting Membranes Based on Perfluorinated Ionomer Membrane-Ionic Liquid Composites, J. Electrochem. Soc. 147 (2000), 34-37 2. Arico, A.S., Creti, P., Antonucci, P.L., Antonucci, V., (1998). Comparison of ethanol and methanol oxidation in a liquid-feed solid polymer electrolyte fuel cell at high temperature. Electrochemical and solid state letters, 1, 66-68. • Research work is going on – R & D Labs, Univ. (US, Canada, UK, Japan) National Status • Work on PEMFC/DMFC – IISc, SPIC, NCL, CECRI, IIT M • No work on membrane for high temperature operation • No work on DEFC - Some preliminary work by SPIC Science Foundation Electrode • Anode: Pt/Ru (40 % / 20%) /C Pt - 2 mg/cm2 0.4 mg/cm2 • Cathode: Pt/C (20%) Pt – 2mg/cm2 similar Polymer Electrolyte Membrane (PEM) • Perfluoro Sulphonic Membrane (Nafion DE 5112) PEM MEA 40 oC – 80 oC Anode PTFE Carbon cloth Cathode Bipolar plate Schematic of DEFC Load Air/H O C2H5OH/H2O/CO2 Catalyst Layers 2 ANODE CATHODE PEM e- e- + H H2O Current collect or + Reactant Distri butor Current collector + Reactant Distributor C2H5OH/H2O Diffusion Layers Air Anode: (catalyst : Pt / Ru / C ) - + C2H5OH + 3 H2O 12 e + 12 H + 2 CO2 Cathode: (catalyst : Pt / C ) - + 3 O2 + 12 e + 12 H 6 H2O Overall: C2H5OH + 3 O2 3 H2O + 2 CO2 Why Ethanol ? • Higher theoretical moles of H2 per moles (or litre) of fuel • Renewable resources • Lower toxicity, vapour pressure and flash point • Less corrosive Reaction Path Process Parameters Input 1. Temp : 145o – 150o C 2. Feed: anode - 1M EtOH Soln at 80 oC o cathode – O2 /Air humidified at 80 C 3. Catalyst loading : 2 mg/cm2 reduce loading 4. Anode / Cathode : 4 atm 5. Cross-sectional Area: 9 cm2 Output (single cell, expected) • Voltage (open circuit): 0.8 V • 0.5 V at 60-120 mA/cm2 • 30 – 60 mW/cm2 Solid Oxide Fuel Cell (SOFC) 2e- 2e- Porous Porous Cathode Anode Reaction Products + Heat O-2 ion (H2O, CO2, H2, CO etc.) O Air 2 H2 (and other fuels: CO, CH4 ...) Cathode Reaction: Anode Reactions: + - H 2H + 2e 1/2 O + 2e- O-2 Catalyst Thin Solid 2 2 ion Interfaces Electrolyte 2H + +O-2 H2O ion SOFC = High temperature (700 to 1000oC) solid state fuel cell with ceramic, oxygen ion conducting electrolyte Tubular SOFC Materials and Processing Component Material Fabrication Process Air Electrode Doped LaMnO3 Extrusion-Sintered Electrolyte ZrO2(Y2O3) Electrochemical Vapor Deposition Interconnection Doped LaCrO3 Plasma Spraying Fuel Electrode Ni-ZrO2 (Y2O3) Slurry Coat-Electrochemical Vapor Deposition Operating around 950-1000°C Courtesy of Siemens- Westinghouse, Pittsburgh, PA Tubular Geometry Solid Oxide Fuel Cell Interconnection Electrolyte Air Fuel Electrode Flow Air Flow Fuel Electrode Tubular SOFC Small Stack of Tubular SOFC 24 SOFCs, each tube with 2.2 cm diameter and 150 cm long. Planar Solid Oxide Fuel Cells Operating temperature ~ 700-750 ºC Use numerous fuels Efficiently produce power at varying loads The SOFC Stack Cells are sealed via a high temperature compressive gasket Delphi SOFC APU - Gen 1 to Gen 2 SOFC APU System Evolution Generation 1 Generation 2 SOFC APU SOFC APU Gen 1 Stacks Provided by Global Thermoelectric 155 Liters 60.5 Liters 12/2002 204 kg 12/2000 75 kg Delphi – Battelle Generation 2 Stack Cell and Stack Development Scale Up 106 cm2 Active Area 34 cm2 Active Area 34 cm2 3.5 cm2 Button-Cell Intermediate-Scale Full-Scale Small active area Full active area Primarily for repeating unit for repeating unit for cathode, stack –for design stack –for design electrolyte and performance and performance and anode optimization and optimization and materials development development development Delphi – Battelle Generation 2 Stack Development Summary Multiple sintered cells (12 cm x 12 cm) have been successfully fabricated. Research and development is being done in collaboration with Battelle. Process development being done internally at Delphi. Multiple stacks from 1-cell to 30-cell have been fabricated. Two 15- cell ISMs (Integrated stack module) have also been fabricated and have been tested in the APU systems. Integrated stack module-ISM Cassette with cell (repeating unit) 30-cell stack under test (Two 15-cell stacks+ current collector + load frame) FUTURE DIRECTION! SOFC Poisoning PEMFC Cost DAFC High Temperature MeOH cross over AFC Poisoning Karl Kordesch Zevco Company Zevco AFC Module (2000) 6000 hours 100 mA/cm2 Michael, P. D. ‘An Assessment of the prospect for fuel cell-powered cars ETSU, UK (2000) Most Advanced Fuel Cells Many fuels: Gaseous: H2, hydrocarbons, natural gas, biogas, coal gas Liquid: alcohol, gasoline, diesel Solid: gasified coal and biomass Many applications: Stationary and mobile Target: universal system? Comparisons ¾ Performance Current Den.(at 0.7V) Power at 0.7 V Pressure Temp mA/cm2 w/cm2 psig oC AFC 450 0.315 atm H2-air 75 115 0.081 same 40 PEMFC 250 0.175 same 60 125 0.088 same 70 ¾ Cost Astris (LC200-16) 240 W AFC 2400 USD H-Power (PowerPEM-PS250) 250 W PEMFC 5700 USD DAIS-Analytic (DAC-200) 200 W PEMFC 8500 USD Kordesch, K., et al.’Revival of AFC hybrid system for electric vehicles’ Proc. Fuel Cell Sem., Palm Springs 1998 Solid Oxide Fuel Cells - SOFCs Why: SOFCs Employ Solid State Electrolyte, hence: Corrosion Reduced; Water Management Eliminated; Very Thin Layers/Cell Components Possible; Fuel Flexibility High; Internal Reforming and Combined Heat/Power Cycles Possible, etc…. Problems: High Temperature (850-1000oC) Related, e.g., Longer Time Required for Start-up, Expensive Materials Involved, Durability/ Robustness/Cost Issues, etc… Reduced Temperature SOFCs: Dropping the Operating Temperature to Below 700oC ─ called Intermediate Temperature SOFCs. Eliminates high temperature problems Reformer Complexity - SOFC vs PEM Autothermal / Steam Reformer Solid Oxide Partial Oxidation Fuel Cell Reformer Stack > 900 °C 800 °C 700-1000 °C High Temperature SOFC Shift Reactor SOFC reformer and stack run at similar temperatures and can be closely coupled. Low Temperature Shift Reactor Preferential PEM Oxidation (CO clean-up) PEM reformer + stack run at very different temperatures. PEM A complex, multi-stage reformer system must be Fuel cell stack carefully thermally managed at each step. 80 °C Courtesy of Delphi Corp., Rochester, NY MULTI-FUEL ALKALINE FUEL CELL Fuels: MeOH, EtOH, NaBH4 Cathode: MnOx /Carbon paper Anode: Pt-black/Carbon paper/Ni 1 Fuel and electrolyte mixture 2 Exhausted fuel and electrolyte 3 Peristaltic pump for input 4 Peristaltic pump for output 5 Load 6 Anode terminal 7 Cathode terminal 8 Air 9 Anode electrode 10 Cathode electrode 11 Fuel and electrolyte mixture 12 Magnetic stirrer 13 Anode shield Comparative performance of alkaline fuel cell OCV: Open circuit voltage; SCCD: Short circuit current density Reference Fuel Anode Cathode Electrolyte Operating OCV SCCD Temp.
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