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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Tailoring electrode microstructure via ink content to enable improved rated power performance for platinum cobalt/high surface area carbon based polymer electrolyte fuel cells

Improvements in polymer electrolyte fuel cell (PEFC) electrode performance have primarily focused on catalyst and ionomer developments, marginalizing the importance of catalyst ink formulation. In this study, the effect of ink formulation is examined across a series of cathodes comprised of PtCo supported on high surface area carbon (PtCo/ HSC ) and Nafion ionomer using an array of in situ electrochemical and ex situ characterization techniques. In contrast to prior work on Pt/Vu systems, ink water content had little effect on the electrochemically determined ionomer coverage for the PtCo/HSC electrocatalyst examined here. Characterization using nano-scale resolution X-ray computed tomography (nano-CT) demonstrated that water-rich ink formulations lead to a reduction in aggregate size (ionomer + PtCo/HSC), improving local O 2 transport. This understanding, combined with the use of a commercially-available electrocatalyst was used to produced state-of-the-art membrane electrode assemblies with Pt loadings of 0.03/0.08 mg Pt /cm 2 on the anode and cathode respectively, having; i) > 1 A/mg Pt (0.9 V iR-free , 150 kPa, 80 °C, 100% RH, H 2 /O 2 ), ii) 320 mA/cm 2 at 0.8 V, 150 kPa, 80 ° C, 100% RH, H 2 /Air), and iii) > 1 W/cm 2 elec at rated power (0.67 V, 250 kPa, 94 °C, 65% RH, H 2 /Air) or < 0.11 g Pt /kW rated .

25 ENERGY STORAGE↗
DOE OSTI2020

A Direct Ammonia Fuel Cell with a KOH-Free Anode Feed Generating 180 mW cm −2 at 120 °C

The motivations to operate the direct ammonia fuel cell (DAFC) with no addition of aqueous base, include facilitated fuel management and prevention of corrosion and shunt currents in the DAFC stack. We describe here a polymer electrolyte DAFC, operating at a cell temperature (T cell ) of 120 °C on ammonia and water alone as anode feed, that demonstrated peak power of 180 mW cm −2 —a record for this type of fuel cell. We offer a detailed analysis of polarization curves recorded for PE-DAFCs in the T cell range of 60 °C–120 °C, allowing to estimate the effects of KOH-free operation on the ionic and faradaic resistances, R i and R F , that determine together the value of R app , CL – an , the apparent resistance of the anode catalyst layer. The latter resistance drops ten times between 60 °C and 120 °C as result mainly of the drop in R F . Consequently, DAFC performance at T cell > 100 °C improves substantially, including the cell performance on a KOH-free anode feed. The demsontrated performance levels reported here for KOH-free DAFCs support further development of this type of ammonia/air fuel cells.

Achrai, Ben↗
DOE OSTI2021

An Analysis of the Impact of Particle Growth on Transport Losses in Polymer-Electrolyte Fuel Cells

Voltage cycling causes catalyst nanoparticles in polymer-electrolyte fuel cells to grow. The concomitant loss of interfacial area results in larger kinetic, transport, and possibly ohmic overpotentials. This paper uses recently published experimental data and mathematical models to investigate the evolutions of transport and ohmic resistances to platinum nanoparticles located on the surface and inside the micropores of carbon black supports. Resistance to oxygen transport rises as surface area declines primarily because the flux to each remaining larger platinum particle increases. The path lengths governing oxygen diffusion to surface and buried platinum sites also increase as nanoparticles grow. Platinum nanoparticles on the surface become relatively less favorable as voltage cycling proceeds because they grow faster than platinum in micropores. Because voltage cycling causes total interfacial area to decline, and the fraction located inside micropores to increase, nanoscale ohmic losses increase as a catalyst layer decays. The practical importance of this effect is difficult to discern because proton conductivity in carbon micropores is not well characterized.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2015

Pt Catalyst Degradation in Aqueous and Fuel Cell Environments studied via In-Operando Anomalous Small-Angle X-ray Scattering

The evolution of Pt nanoparticle cathode electrocatalyst size distribution in a polymer electrolyte membrane fuel cell (PEMFC) was followed during accelerated stress tests using in-operando anomalous small-angle X-ray scattering (ASAXS). This evolution was compared to that observed in an aqueous electrolyte environment using stagnant electrolyte, flowing electrolyte, and flowing electrolyte at elevated temperature to reveal the different degradation trends in the PEMFC and aqueous environments and to determine the relevance of aqueous measurements to the stability of Pt nanoparticle catalyst in the fuel cell environment. The observed changes in the particle size distributions (PSDs) were analyzed to elucidate the extent and mechanisms of particle growth and corresponding mass and active surface area losses in the different environments. These losses indicate a Pt nanoparticle surface area loss mechanism controlled by Pt dissolution, the particle size dependence of Pt dissolution, the loss of dissolved Pt into the membrane and electrolyte, and, to a lesser extent, the re-deposition of dissolved Pt onto larger particles. Based on the geometric surface area loss, mass loss, and mean particle size increase trends, the aqueous environment best reflecting the fuel cell environment was found to be one in which the electrolyte is flowing rather than stagnant. Pt nanoparticle surface area loss resulting from potential cycling can be inhibited by reducing the number of particles smaller than a critical particle diameter (CPD), which was found to be similar to 3.5 to similar to 4 nm, with the CPD dependent on both the cycling protocol (square wave vs triangle wave) and the catalyst environment (fuel cell, aqueous stagnant, aqueous flowing electrolyte, or elevated temperature flowing electrolyte)

Anomalous small-angle X-ray scattering↗
DOE OSTI2020

Examining Ohmic Losses in Fuel-Cell Catalyst Layers with Different Pt/C Ratios

A model of a fuel-cell cathode with distinct proton conductivities at the agglomerate and electrode scales was used to simulate polarization curves under conditions with facile oxygen transport. Here, the model was applied to electrodes containing agglomerates with different ratios of platinum to carbon in order to examine the hypothesis that intra-agglomerate proton conductivity is substantially lower than ionomer conductivity. The model predicts decreasing performance and increasing sensitivity to Pt/C ratio as intra-agglomerate conductivity declines relative to a constant through-electrode conductivity. Experiments on catalyst layers with Vulcan supports do not show the predicted trend indicating that mesoscale intra-agglomerate conductivity is not orders of magnitude lower than bulk ionomer conductivity.

08 HYDROGEN↗
DOE OSTI2019

Carbon-Based Metal-Free ORR Electrocatalysts for Fuel Cells: Past, Present, and Future

Replacing precious platinum with earth-abundant materials in fuel cells for oxygen reduction reaction (ORR) has been the objective worldwide for several decades. In last ten years, the carbon-based metal-free ORR electrocatalysts is the fastest-growing branch in this area. Great progresses have been made in promoting the performance and understanding the underlying ORR process. This article presents a comprehensive review of this filed by emphasizing on the emerging issues such as the design and controllable construction of porous structures and doping configurations, mechanistic understanding from the model catalysts and the combined experimental and theoretical studies, and more importantly, the performance evaluation in a full cell. Centering these topics, the most up-to-date results are presented, along with the remarks and perspectives for the future development of carbon-based metal-free ORR electrocatalysts.

Yang, Lijun↗
DOE OSTI2020

Thermal, mechanical, and electrical properties of LSCo/mullite composite contact materials for solid oxide fuel cells

Lanthanum strontium cobaltite (LSCo) is considered as a good candidate cathode contact material for solid oxide fuel cells, due to high electrical conductivity. However, LSCo has a very large coefficient of thermal expansion (CTE) than the cells and metallic interconnects. As a result, poor mechanical stability is expected during thermal cycling. To minimize the CTE mismatch, we investigate a composite approach involving mixing LSCo with an inert material of low CTE, such as mullite at volume fractions from 0.1 to 0.4. Composite’s CTE shows a decreasing trend with increasing mullite volume fractions, and is consistent with model predictions. X-ray powder diffraction analysis of sintered LSCo/mullite composites exhibits no presence of other phases for samples aged for 500h at 800oC, indicating chemical compatibility. Electrical conductivity by a 4-pt method shows a decreasing trend with increasing mullite content. Contact strength of as-sintered and thermally cycled samples show that only the composite with 0.4 volume fraction has a measurable strength; the other composites have no strength. Overall, the composite approach is demonstrated in the LSCo/mullite system to lower the CTE and hence achieve thermal cycle stability. The addition of the inert phase to the LSCo matrix; however, also reduces the electrical conductivity.

Contact materials, LSCo, mullite, CTE, electrical ↗
DOE OSTI2019

Fuel Cell Electric Vehicle Driving and Fueling Behavior

The objectives of this project are to validate hydrogen fuel cell electric vehicles in real-world settings and to identify the current status and evolution of the technology. The analysis objectively assesses progress toward targets and market needs defined by the U.S. Department of Energy and stakeholders, provides feedback to hydrogen research and development, and publishes results for key stakeholder use and investment decisions. Fiscal year 2018 objectives focused on analysis and reporting of fuel cell electric vehicle driving range, fuel economy, drive and fill behaviors, durability, fill performance, and fuel cell performance. This report specifically addresses the topics of driving range, fuel economy, drive and fill behaviors, and fill performance.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

Life-cycle implications of hydrogen fuel cell electric vehicle technology for medium- and heavy-duty trucks

This study provides a comprehensive and up-to-date life-cycle comparison of hydrogen fuel cell electric trucks (FCETs) and their conventional diesel counterparts in terms of energy use and air emissions, based on the ensemble of well-established methods, high-fidelity vehicle dynamic simulations, and real-world vehicle test data. For the centralized steam methane reforming (SMR) pathway, hydrogen FCETs reduce life-cycle or well-to-wheel (WTW) petroleum energy use by more than 98% compared to their diesel counterparts. The reduction in WTW air emissions for gaseous hydrogen (G.H2) FCETs ranges from 20-45% for greenhouse gases, 37-65% for VOC, 49-77% for CO, 62-83% for NOx, 19-43% for PM10, and 27-44% for PM2.5, depending on vehicle weight classes and truck types. With the current U.S. average electricity generation mix, FCETs tend to create more WTW SOx emissions than their diesel counterparts, mainly because of the upstream emissions related to electricity use for hydrogen compression/liquefaction. Compared to G.H2, liquid hydrogen (L.H2) FCETs generally provide smaller WTW emissions reductions. For both G.H2 and L.H2 pathways for FCETs, because of electricity consumption for compression and liquefaction, spatio-temporal variations of electricity generation can affect the WTW results. FCETs retain the WTW emission reduction benefits, even when considering aggressive diesel engine efficiency improvement.

air emissions↗
DOE OSTI2019

Computational design of CO-tolerant Pt 3 M anode electrocatalysts for proton-exchange membrane fuel cells

CO is a typical contaminant in hydrogen fuel produced via steam reforming. Development of a CO-tolerant Pt-based anode for the proton-exchange membrane fuel cells (PEMFC) is of great interest to avoid catalyst deactivation caused by strong CO adsorption on Pt. Pt–Ru, Pt–Mo, and Pt 3 Sn are three known Pt-based bimetallic CO-tolerant anode materials. The enhanced CO-tolerance of these alloys has been generally attributed to a bifunctional effect enabling oxidative CO removal at low applied potential and a ligand effect between the two metals which weakens CO bonding and reduces CO surface coverage. In this study, we use density functional theory to calculate surface adsorption states under reaction conditions for Pt-based alloys. Our calculations provide a molecular-level understanding of the enhanced CO-tolerance of Pt alloys induced by the second metal. We find that Mo and Sn dopants promote CO-tolerance by reducing CO surface coverage and enabling CO oxidative removal at low applied potential. In contrast, Ru is not able to promote CO electro-oxidation at the low applied potential of the operating conditions of a PEMFC anode. The CO-tolerance induced by Ru is attributed to the reduction of CO coverage on Pt sites. Based on these mechanisms, we carried out a computational screening of Pt 3 M electrocatalysts for CO-tolerant PEMFC anodes. A number of promising candidates have been identified for experimental examination.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

A Comparison of Models for Transport Resistance in Fuel-Cell Catalyst Layers

The vexing rise in resistance to oxygen transport that accompanies reductions in the amount of catalyst in polymer-electrolyte fuel cells is theoretically investigated. Expressions for transport resistance stemming from common models for oxygen transport in electrodes are developed and compared to published experiments. Particular emphasis is placed upon how predicted transport resistances vary with platinum loading, mass fraction of platinum in supported catalysts, ionomer to carbon ratio, and overpotential. Most frequently applied models do not match all empirically observed trends. Here, models that include nanoparticle diffusion or adsorption demonstrate qualitatively correct behavior and provide quantitatively reasonable predictions for transport resistance.

08 HYDROGEN↗
DOE OSTI2018

Control of Ionomer Distribution in Roll-to-Roll Coated Fuel Cell Catalyst Layers

Fuel cell catalyst layers are a complex mixture of catalyst particles and ion-conducting polymers. The performance of catalyst layers is highly dependent on microstructure, which must balance proton and electron conduction with gas transport. As fuel cells transition from the laboratory to industrial production for vehicles and other applications, there is a need to understand how manufacturing processes impact the microstructure and, ultimately, the performance of catalyst layers. In this work, we have focused on the roll-to-roll coating of catalyst layers for proton exchange membrane fuel cells. The catalyst layers are responsible for the electrochemical reactions that enable power production. In these devices the catalyst is commonly a Pt nanoparticle supported on porous carbon blacks. The ion conducting polymer, or ionomer, is typically a perfluorosulfonic acid. The most common being Nafion. To fabricate the catalyst layer, the catalyst particles are dispersed in an ink with the ionomer and cast to form the catalyst layer. Commonly, laboratory samples are prepared using spray coating or hand painting, which effectively coat many thin layers to achieve the desired catalyst layer thickness. This creates catalyst layers with uniform distributions of materials throughout the thickness of the full catalyst layer. In contrast, roll-to-roll methods, like slot die, gravure or screen printing, coat the catalyst layer as a single wet film. As the film dries, ink constituents are able to segregate, leading to a heterogeneous distribution of materials through the thickness of the layer. It is also known that the choice of solvent and drying rate can affect the morphology of the catalyst layer. Thus, there is a need to understand how ink formulation and the drying process influence the distribution of materials and catalyst layer morphology. Here, we have explored the influence of solvent and drying rate on morphology of roll-to-roll coated catalyst layers. We show the development of the Kelvin probe method as a rapid screening technique for qualitative analysis of ionomer distribution. We also utilize nano X-ray computed tomography to visualize electrode structure and to quantify particle-size and pore-size distributions, thickness-dependent ionomer distribution, tortuosity, and effective transport properties. We find that solvent has a strong influence on ionomer distribution, with less of an effect on porosity. Conversely, drying temperature has a strong influence on porosity, but less influence on ionomer distribution. Finally, we utilize in situ fuel cell performance testing and other advanced diagnostics to quantify the impact of catalyst layer properties on fuel cell performance and demonstrate that roll-to-roll coating is capable of coating high performance catalyst layers in multi-meter lengths.

14 SOLAR ENERGY↗
DOE OSTI2019

PGM-free Cathode Catalysts for PEM Fuel Cells: a Mini-Review on Stability Challenges

In recent years, significant progress has been achieved in the development of platinum group metal-free (PGM-free) oxygen reduction reaction (ORR) catalysts for proton exchange membrane (PEM) fuel cells. At the same time the limited durability of these catalysts remains a great challenge that needs to be addressed. In this mini-review, we summarize the recent progress in understanding the main causes of instability of PGM-free ORR catalysts in acidic environments, focusing on transition metal/nitrogen co-doped systems (M-N-C catalysts, M: Fe, Co, Mn). Of several possible degradation mechanisms, demetalation and carbon oxidation are found to be the most likely reasons for M-N-C catalysts/cathodes degradation.

Shao, Yuyan↗
DOE OSTI2020

Boosting solid oxide fuel cell performance via electrolyte thickness reduction and cathode infiltration

Increasing the power density and reducing the operating temperature of solid oxide fuel cells (SOFCs) is important for improving commercial viability. Here we discuss two strategies for achieving such improvements in Ni–YSZ supported SOFCs – electrolyte thickness reduction and cathode infiltration. Microstructural and electrochemical results are presented showing the effect of reducing YSZ/GDC electrolyte thickness from 8 to 2.5 μm, and the effect of PrO x infiltration into the LSCF–GDC cathode. Both of these measures are effective, particularly at lower temperatures, leading to an increase in the maximum power density at 650 °C from 0.4 to 0.95 W cm –2 , for example. Electrochemical impedance spectroscopy utilizing subtractive analysis shows that PrO x enhances the cathode charge transfer process. Reducing the electrolyte thickness reduces not only the cell ohmic resistance but also the electrode polarization resistance. Furthermore, the latter effect appears to be an artifact associated with a slight increase in the steam partial pressure at the anode due to minor gas leakage across the thinner electrolyte.

25 ENERGY STORAGE↗