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At least 307 records · Page 17

Modular, High-Volume Fuel Cell Leak-Test Suite and Process (Phase I)

Fuel cell stacks are typically hand-assembled and tested. As a result the manufacturing process is labor-intensive and time-consuming. The fluid leakage in fuel cell stacks may reduce fuel cell performance, damage fuel cell stack, or even cause fire and become a safety hazard. Leak check is a critical step in the fuel cell stack manufacturing. The fuel cell industry is in need of fuel cell leak-test processes and equipment that is automatic, robust, and high throughput. The equipment should reduce fuel cell manufacturing cost.

08 HYDROGEN↗

Generator module architecture for a large solid oxide fuel cell power plant

A solid oxide fuel cell module contains a plurality of integral bundle assemblies, the module containing a top portion with an inlet fuel plenum and a bottom portion receiving air inlet feed and containing a base support, the base supports dense, ceramic exhaust manifolds which are below and connect to air feed tubes located in a recuperator zone, the air feed tubes passing into the center of inverted, tubular, elongated, hollow electrically connected solid oxide fuel cells having an open end above a combustion zone into which the air feed tubes pass and a closed end near the inlet fuel plenum, where the fuel cells comprise a fuel cell stack bundle all surrounded within an outer module enclosure having top power leads to provide electrical output from the stack bundle, where the fuel cells operate in the fuel cell mode and where the base support and bottom ceramic air exhaust manifolds carry from 85% to all 100% of the weight of the stack, and each bundle assembly has its own control for vertical and horizontal thermal expansion control.

30 DIRECT ENERGY CONVERSION↗

Energy 101: Fuel Cell Technology

Learn how fuel cell technology generates clean electricity from hydrogen to power our buildings and transportation-while emitting nothing but water. This video illustrates the fundamentals of fuel cell technology and its potential to supply our homes, offices, industries, and vehicles with sustainable, reliable energy.

08 HYDROGEN↗

Maritime Fuel Cell Generator Project [FY2018]

Fuel costs and emissions in maritime ports are an opportunity for transportation energy efficiency improvement and emissions reduction efforts. Ocean-going vessels, harbor craft, and cargo handling equipment are still major contributors to air pollution in and around ports. Diesel engine costs continually increase as tighter criteria pollutant regulations come into effect and will continue to do so with expected introduction of carbon emission regulations. Diesel fuel costs will also continue to rise as requirements for cleaner fuels are imposed. Both aspects will increase the cost of diesel-based power generation on the vessel and on shore. Although fuel cells have been used in many successful applications, they have not been technically or commercially validated in the port environment. One opportunity to do so was identified in Honolulu Harbor at the Young Brothers Ltd. wharf. At this facility, barges sail regularly to and from neighboring islands and containerized diesel generators provide power for the reefers while on the dock and on the barge during transport, nearly always at part load. Due to inherent efficiency characteristics of fuel cells and diesel generators, switching to a hydrogen fuel cell power generator was found to have potential emissions and cost savings. Deployment in Hawaii showed the unit needed greater reliability in the start-up sequence, as well as an improved interface to the end-user, thereby presenting opportunities for repairing/upgrading the unit for deployment in another locale. In FY2018, the unit was repaired and upgraded based on the Hawaii experience, and another deployment site was identified for another 6-month deployment of the 100 kW MarFC.

08 HYDROGEN↗

Energy: Reimagine Fuel Cells

New types of fuel cell on the horizon could eliminate the need for such trade-offs and ease the integration of renewables into the grid. Currently, fuel cells are used to generate only electricity and heat. They can be modified to store energy and produce liquid fuels such as methanol, thanks to breakthroughs in materials and designs. Developing fuel cells with a battery mode is one focus of the programme I direct at the US Advanced Research Projects Agency–Energy (ARPA-E). I lead 13 projects across academia, industry and national laboratories.

36 MATERIALS SCIENCE↗

Space Shuttle Upgrades: Long Life Alkaline Fuel Cell

NASA has utilized the alkaline fuel cell technology to provide electrical power for manned launch vehicles such as Gemini, Apollo, and the Space Shuttle. The current Shuttle alkaline fuel cells are procured from UTC Fuel Cells, a United Technologies Company. The alkaline fuel cells are very reliable but the operating life is limited to 2600 hours due to voltage degradation of the individual cells. The main limiting factor in the life of the cells is corrosion of the cell's fiberglass/epoxy frame by the aqueous potassium hydroxide electrolyte. To reduce operating costs, the orbiter program office approved the Long Life Alkaline Fuel Cell (LLAFC) program as a shuttle upgrade in 1999 to increase the operating life of the fuel cell powerplant to 5000 hours. The LLAFC program incorporates improving the cell by extending the length of the corrosion path, which reduces the cell frame corrosion. UTCFC performed analysis to understand the fundamental mechanisms that drive the cell frame corrosion. The analysis indicated that the corrosion path started along the bond line between the cathode and the cell frame. Analysis also showed that the oxygen available at the cathode, the catalyst on the electrode, and the electrode substrate all supported or intensified the corrosion. The new cell design essentially doubled the corrosion path to mitigate the problem. A 10-cell stack was tested for 5000 hours during the development phase of this program to verify improved cell performance. A complete 96-cell stack was then tested for 5000 hours during the full manned-space qualification phase of this program. Additional upgrades to the powerplant under this program are: replacing the aluminum body in the pressure regulator with stainless steel to reduce corrosion, improving stack insulator plate with improved resistance to stress failure and improved temperature capability, and replacing separator plate elastomer seals with a more durable material and improved seal retention.

Kerri McCurdy↗

Efficient Oxygen Evolution Reaction Catalysts for Cell Reversal and Start/Stop Tolerance in Fuel Cells

Minute amounts of ruthenium and iridium on platinum nanostructured thin films have been evaluated in an effort to reduce carbon corrosion and Pt dissolution during transient conditions in proton exchange membrane fuel cells. Electrochemical tests showed the catalysts had a remarkable oxygen evolution reaction (OER) activity, even greater than that of bulk, metallic thin films. Stability tests within a fuel cell environment showed that rapid Ru dissolution could be managed with the addition of Ir. Membrane electrode assemblies containing a Ru to Ir atomic ratio of 1:9 were evaluated under startup/shutdown and cell reversal conditions for OER catalyst loadings ranging from 1 to 10 g/cm2. These tests affirmed that electrode potentials can be controlled through the addition of OER catalysts without impacting the oxygen reduction reaction on the cathode or the hydrogen oxidation reaction on the anode. The morphology and chemical structure of the thin OER layers were characterized by scanning transmission electron microscopy and X-ray photoelectron spectroscopy in an effort to establish a correlation between interfacial properties and electrochemical behavior.

Atanasoski, Radoslav↗

Development of a fuel cell for the EMU

The fuel cell technology for the advanced portable life support system is reviewed, using the breadboard test data, and the design concepts are presented for the development of the improved preprototype fuel cell. Subscale test results confirm the suitability of the solid polymer electrolyte fuel cell fueled by hydride stored hydrogen and oxygen for extravehicular mobility unit (EMU) power generation. Issues verified include passive, zero-G product water removal, nonventing operation in the EMU duty cycle, and complete recovery of product water in potable form. The long cycle life and quick rechargeability are confirmed in 600 h of testing including 150 deep discharge cycles.

Beckstrom, Paula↗