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Study of Cathode Gas Diffusion Architecture for Improved Oxygen Transport in Hydroxide Exchange Membrane Fuel Cells
The high pH environment in hydroxide exchange membrane fuel cells (HEMFCs) has the potential to reach lower costs than the current proton exchange membrane fuel cells (PEMFCs), the incumbent technology. A significant difference between HEMFCs and PEMFCs is the location of water production within the cell. In PEMFCs, the water is produced on the cathode, limiting oxygen transport. In HEMFCs, the water is produced on the anode where the fuel is pure hydrogen. This allows the cathode to be optimized for oxygen transport without the presence of excess liquid water. Limiting current analysis, a technique previously used in PEMFCs, is adopted in HEMFCs to evaluate the oxygen mass transport resistances for different sections of the cathode. Through elimination of the microporous layer (MPL), gas diffusion layer (GDL), and traditional flow field and using porous nickel foam for gas distribution, the transport resistance at an operating condition of 150 kPa(g) and with the cell temperature at 80 °C was decreased from 112 s m −1 to 48 s m −1 , effectively halved. The optimal configuration for performance was found with Ni foam and a GDL, eliminating the MPL and traditional flow field, which vastly improved oxygen transport while maintaining adequate electrical contact with the cathode catalyst layer.
(La 0.8 Sr 0.2 ) 0.98 MnO 3-δ -Zr 0.92 Y 0.16 O 2-δ :PrOx for oxygen electrode supported solid oxide cells
(La 0.8 Sr 0.2 ) 0.98 MnO 3-δ (LSM)- Zr 0.92 Y 0.16 O 2-δ (YSZ) has been widely studied as the cathode for solid oxide fuel cells (SOFCs), but its low activity has been a cell performance limiting factor. Herein, LSM-YSZ:PrO x composite is developed as an active electrocatalyst for both oxygen reduction and evolution reactions. A single step PrO x infiltration into LSM-YSZ lowers the polarization resistance (Rp) 10–20 times depending on the test temperature. Distribution of relaxation times (DRT) calculation reveals that adding PrO x affects surface exchange between adsorbed/desorbed oxygen and lattice oxygen, and oxygen dissociative adsorption/desorption. A symmetrical cell with a thin YSZ electrolyte sandwiched between thick LSM-YSZ:PrO x electrode-supports is developed and its oxygen generation performance and stability are evaluated under various current densities and temperatures. Finally, reversible solid oxide cell (ReSOC) performance is also reported for LSM-YSZ:PrO x supported cells with the oxide fuel electrode Sr 0.95 (Ti 0.3 Fe 0.63 Ni 0.07 )O 3-δ (STFN).
Operating Stresses and Their Effects on Degradation of LSM-Based SOFC Cathodes
The performance of solid oxides fuel cells (SOFCs) with four different Mn excess of lanthanum strontium manganite (LSM) -based cathodes were examined under different temperatures (1,000 °C, 900 °C), current densities (0, 380, and 760 mA cm -2 ), and cathode atmospheres (p O 2 )=0.1,0.15,0.21) for durations ranging from 58 to 1,008 h. Each yttria-stabilized zirconia (YSZ) electrolyte-supported “button” cell had a porous Ni/YSZ composite anode and a porous LSM/YSZ composite cathode. The cells’ output voltage versus time were recorded and electrochemical impedance spectroscopy (EIS) and linear sweep voltammetry (LSV) measurements were performed every 24 hours. The total area specific resistance (ASR) was calculated from these measurements. The values of ASR from both EIS and LSV were comparable between each other but lower than that from durability test. Distribution of relaxation times (DRT) analysis was performed to investigate the electrochemical processes and their corresponding relaxation frequencies as well as their attributions to the total ASR. The series resistance and parallel resistance that obtained from the equivalent circuit fit of the Nyquist plot were higher at low temperature and low p O 2 regardless of LSM compositions. The area of the peaks derived from DRT analysis increased with time during individual tests. The microstructures of the tested cells were examined using scanning electron microscopy and energy-dispersive x-ray spectroscopy (SEM/EDS). Manganese oxide particles were observed near the cathode-electrolyte interface after prolonged (1,008 h) testing in air of a cell with LSM of 11% manganese excess, and after a short test (58 h) under low oxygen (p O 2 = 0.10) in a cell with LSM of 5% manganese excess. However, the role of MnOx in cell degradation is still unknown.
Mitigating Crack Formation When Using High Oxygen Permeability Ionomer in PEMFC Catalyst Layers
High oxygen permeability ionomers (HOPIs) are being developed as an alternative to conventional perfluorosulfonic (PFSA) ionomers for cathodes in proton exchange membrane fuel cells (PEMFCs). HOPIs aim to reduce local oxygen transport resistance, improving performance and reducing degradation as the catalyst loses surface area. However, HOPIs' more rigid, 3D backbone leads to increased crack density in the cathode, potentially causing accelerated degradation. This study investigates crack formation in HOPI-based and PFSA-bound catalyst layers (CLs). We conducted a comprehensive parametric study to identify conditions and catalyst slurry components that minimize cracking. CLs were fabricated with various ionomer and catalyst types, under different relative humidity (RH) levels, solids weight percentages, solvent ratios, and ionomer-to-carbon ratios (I/C). Results show that HOPI-based CLs exhibit less cracking when fabricated under low RH conditions, with lower solids weight percentage, higher alcohol content, and lower I/C. Additionally, catalysts with low/medium surface area carbon supports show less cracking than those with high surface area carbon supports.
Surface enhanced performance of La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3-δ cathodes by infiltration Pr-Ni-Mn-O progress
Herein the present study reports the enhancement of electrochemical oxygen reduction activity of porous La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3–δ (LSCF) cathodes by coating a thin film of Pr-Ni-Mn oxide (PNM5) using a multi-step infiltration process. XRD examination reveals that PNM5 mainly contains a multiphase mixture of Pr 6 O 11 , PrNiO 3 , MnO and NiO. SEM morphology shows a thin PNM5 film and small particles are formed on the surface of LSCF backbone particles. Impedance spectrum analysis indicates that PNM5 infiltrated LSCF exhibits dramatically reduced polarization resistance (R p ), reaching R p of 0.244 Ω cm 2 at 973 K, which is one-half of the baseline LSCF cathode. The activation energy of LSCF cathodes infiltrated with PNM5 is 1.45 eV, slightly lower than the baseline LSCF cathode (1.77 eV). Distribution of relaxation time (DRT) function analysis shows PNM5 infiltration layer significantly promotes the oxygen reduction reaction (ORR) of cathode surface. With the increase in firing temperature, the total resistance increases and R p changes from ion transport to oxygen reduction reaction. Degradation rate of the PNM5-infiltrated LSCF is also lower, 0.02168% vs 0.07093% for the baseline LSCF over a 200-h period. A single cell testing indicated that the peak power density of the PNM5-infiltrated cell was increased by 140.66%. Overall, PNM5 could be a potential catalyst for boosting the performance of a commercial LSCF cathode for solid oxide fuel cells (SOFC).
Enhancement of low-temperature solid oxide fuel cell performance and durability via surface chemistry modification
The development of active cathodes is one of the most critical challenges to lowering the operating temperature for solid oxide fuel cells (SOFCs). Here, in this work, we demonstrated that by modifying the cathode surface chemistry at a relatively low temperature, the cathode activity and durability can be simultaneously enhanced on high-performing, low-temperature cathodes such as (La 0.6 Sr 0.4 ) 0.95 Co 0.2 Fe 0.8 O 3-δ (LSCF) and Sr 0.5 Sm 0.5 CoO 3-δ (SSC). This low-temperature modification using multi-valent cations activates the highly defected surface and maintains the nanoscale electrocatalysts by bypassing the high-temperature sintering procedure for SOFC fabrication. The modified cathode at 600°C shows an order of magnitude reduction in impedance to only 0.05 Ωcm 2 with a peak power density of 1.1 W/cm 2 and increases stability over 2000 h. The combination of in situ characterization, distribution of relaxation time analysis on impedance spectroscopy, and surface chemistry analysis reveals the importance of surface chemistry control on the gas-solid reaction activity and durability and provides the design principle for numerous future solid oxide cells.
Spatially resolved performance and degradation in a perfluorinated anion exchange membrane fuel cell
Anion exchange membrane fuel cells may enable future operation with non-precious metal-based catalysts. These systems have a delicate sensitivity to operating conditions such as humidification levels and the presence of CO2 in the air oxidant stream. We present spatially resolved in-situ performance results that shed light on phenomena that are unique to anion exchange membrane fuel cells. For cell construction, a highly conductive perfluorinated anion exchange polymer was used as the membrane and the material in powder form as the ionomer. Experiments were conducted to investigate the effects of humidification, fuel/oxidant concentration, and carbonation effects on the performance and its distribution in the cell. The results indicated that (i) dry conditions at the cathode have a stronger effect than at the anode on overall cell performance, (ii) performance significantly suffered when humidification was below 90%, (iii) fuel and oxidant dilution effects lead mass-transport losses and were stronger than flow rate effects, (iv) CO2 in the cathode feed stream creates an equilibration disparity between the inlet and outlet sections and CO2 purging is affected by flooding conditions, and (v) after >500 h of operation, performance deteriorates predominantly at the inlet.
Development & Validation of Low-Cost, Highly-Durable, Spinel-Based Materials for SOFC Cathode-Side Contact (Final Report)
A cathode-side contact layer is required to provide and maintain stable electrical conduction paths between the interconnect and cathode in a solid oxide fuel cell (SOFC) stack assembly and thus minimize the ohmic resistance and stack power loss. Current cathode-interconnect contact materials are based on noble metals, electrically-conductive perovskites, their composite materials, etc. These materials are either too expensive or do not possess the overall balanced performance required for the cathode-side contact application. To achieve the DOE SOFC system cost and performance stability goals, a new generation of low-cost, high-performance contact materials needs to be developed. In this project, spinel-based materials thermally converted from the Fe-Ni and Co-Mn based alloy precursors were developed and validated for the cathode-side contact application. The precursor alloy compositions were optimized via a combination of composition screening in the (Ni,Fe) 3 O 4 and (Mn,Co) 3 O 4 spinel system, alloy design using physical metallurgy principles, and cost considerations. The alloy powders with the desired composition and particle size were manufactured via gas atomization. The optimal process parameters for thermal conversion of these alloy precursor layers to a spinel-based layer were identified, i.e., 900°C x 2h in air, which is close to the initial stack firing condition. The area-specific resistances (ASRs) of the interconnect/contact/cathode test assemblies with the developed contact layer were determined for various durations (up to 5000 h) under simulated cathodic operation conditions. Some of the alloy-derived spinel contacts exhibited the lowest ASR and ASR degradation rate. The in-stack performance of the most promising alloy-derived contact layer is currently being evaluated via stack testing. To reduce the stack cost, the Co-Mn based alloy powders were utilized as the precursor for synthesis of dense spinel-based interconnect coating. By optimizing both the initial powder size/distribution and the alloy powder composition, a dense (Mn,Co) 3 O 4 -based spinel coating was achieved. Furthermore, co-sintering of the coating/contact dual-layer structure under the initial stack firing condition was realized by utilizing the tailored Co-Mn alloy precursors. Cost analysis of the developed technology indicated a total stack cost reduction of around 10.6% with the implementation of co-sintering of the interconnect coating and the contact layer during initial stack firing. Since low-cost processes such as screen printing is utilized in the precursor application and no reduction heat treatment is needed for the coating formation, the developed technology can be readily implemented at the industrial partner’s manufacturing facilities with no additional capital investment needed.
Influence of Proton Activity Gaps between Electrodes on Open-Circuit Potential of H 2 /H 2 and H 2 /Air Cells
Polymer -electrolyte-fuel-cell open-circuit voltages (OCVs) are exactly defined by equation (1), where cathode and anode proton activities [(aH+)cathode and (aH+)anode, respectively] usually are identical, so the third term in the right-hand side of equation (2) is ignored. OCV=E0+RT/2F*ln(a1/2 O2*(a2 H+)cathode/aH2O)-RT/2F*ln((a2 H+)anode/aH2) (1) =E0+RT/2F*ln(a1/2 O2*aH2/aH2O)+RT/2F*ln((a2 H+)cathode/(a2 H+)anode) (2) Water vapor pressure is a colligative property that fundamentally correlates to electrolyte concentrations in aqueous solutions. Proton activity is a function of acid concentration, such as pH, when electrolytes are acids. In polymer-electrolyte membranes, water vapor pressure and acid concentration are understood as relative humidity (RH) and water uptake (λ), respectively, where λ represents number of water molecules per sulfonic acid molecule. Several investigations have reported the relationship between RH and λ, meaning that proton activities and associated water uptakes are intimately related to RH. In actual fuel cell operation, cathode RH is determined by ambient-atmosphere and/or humidifier RH(s), and anode RH depends on hydrogen-circulator RH. Therefore, RH is not always identical at both electrodes, and the difference between electrode RHs is considerable during dry operation of polymer electrolyte fuel cells. Therefore, the third term in the right-hand side of equation (2) may be significant for dry operation. We measured OCVs when hydrogen was supplied to both electrodes at 80°C. One electrode (A) was fixed at 30% RH, while RH at the other electrode (B) was varied (0, 5, 10, 20, and 30%). Measured OCVs varied from 0 to 75 mV. For fuel cell tests, electrode A was supplied with hydrogen at 30% RH; electrode B, oxygen at 0, 5, 10, 20, and 30% RH. OCVs deviated from that measured when RH at electrode B was 30%, increasing from 0 to 60 mV with decreasing RH at electrode B. Results are also shown in Figure 1. Proton activities of both electrodes were thermodynamically calculated. The Gibbs–Duhem relation was applied to obtain molar Gibbs free energies of water and sulfonic acid, and proton activity coefficient was calculated using the Gibbs free energy of sulfonic acid and the relationship between RH and λ1–4, assuming that protons and sulfonic anions show identical ionic-activity coefficients. OCVs were estimated using the third term in the right-hand side of equation (2). Results are shown in Figure 1. Fuel-cell current–voltage performance was poor when RHs at the anode and cathode were 30 and 20%, respectively. To determine kinetic current, we measured the oxygen-reduction reaction (ORR) using a rotating-disk electrode (RDE) in concentrated-acid aqueous solutions, which modeled catalyst-layer ionomers. Kinetic currents decreased with acid concentrations. References T. A. Zawodzinski, Jr., C. Derouin, S. Radzinski, R. J. Sherman, V. T. Smith, T. E. Springer and S. Gottesfeld , J. Electrochem. Soc., 140,1041 (1993) P. K. Das and A. Z. Weber, Proceedings of the ASME 2013 11th Fuel Cell Science, Engineering and Technology Conference, Fuel Cell 18010 (2013) V. A. Sethuraman, J. W. Weidner, A. T. Haug, S. Motupally,b and L. V. Protsailo, J. Electrochem. Soc., 155, B50 (2008) A. Kusoglu and A. Z. Weber, Chem. Rev., 117, 987 (2017) Figure 1
Durable Mn-Based PGM-Free Catalysts for Polymer Electrolyte Membrane Fuel Cells
This proposed project aims to develop and evaluate novel manganese based, nitrogen-derived, PGM-free electrocatalysts (denoted as Mn-N-C) to fully address the membrane electrolyte assemblies (MEA)’s ionomer degradation issue resulting from iron. Four thrusts will be pursed in this proposed project. First, advanced first-principles computation methods will be employed to accelerate the rational catalyst design and synthesis. Second, an effective hydro-gel method will be used to maximize atomic Mn active sites embedded in carbon matrix. Next, state-of-the art methods in fuel cell companies will be used to fabricate MEAs containing the Mn-N-C catalysts. Finally, industry standards will be rigorously followed to evaluate fuel cell performance and durability of the Mn-N-C catalysts. With successful completion of the project, it is expected that the following outcomes will be achieved. (1) A set of MEAs containing the Mn-N-C catalysts and with active area large than 50 cm 2 for independent testing, (2) testing results demonstrating that the MEAs of Mn-N-C catalysts have mass activity of 0.044 A/cm 2 at 0.9 VIR-free and H 2 /air performance of 0.50 V at 1.0 A/cm 2 ; (3) fundamental understanding of the composition-structure-property relation of the PGM-free Mn- N-C catalysts, and (4) computational data, measurement data, and publications deposited into the database of ElectroCat Consortium.
Coupled continuum and network model framework to study catalyst layers of polymer electrolyte fuel cells
The nanostructured thin film (NSTF) catalyst layers which have demonstrated high power densities, mass activities, and exceptional metal and support stability can have limited operational robustness due to their thin thickness and the hydrophilicity of the metal-coated nano whiskers. The dispersed nanostructured thin film (dNSTF) catalyst layers have been developed by dispersing the NSTF Pt whiskers with ionomer and carbon support to increase the thickness and hydrophobicity. Continuum and network models (NM) are coupled through boundary conditions to study the polymer electrolyte fuel cell with a dNSTF cathode catalyst layer. The coupled model combines the computational efficiency of the continuum model with the pore-scale information in the dNSTF cathode catalyst layer of the NM. It captures the special morphology of the partially ionomer/water covered cylindrical whiskers, as well as water percolation through the pore structures and their impact on the cell performance. Here we observe optimal ionomer coverage on whiskers to be 0.5, ionomer to carbon ratio to be 0.9 and higher whisker to carbon ratios to be desired.
High-Performance Pt–Co Nanoframes for Fuel-Cell Electrocatalysis
Pt-based alloy catalysts are promising candidates for fuel-cell applications, especially for cathodic oxygen reduction reaction (ORR) and anodic methanol oxidation reaction (MOR). The rational design of composition and morphology is crucial to promoting catalytic performances. Here, we report the synthesis of Pt–Co nanoframes via chemical etching of Co from solid rhombic dodecahedra. The obtained Pt–Co nanoframes exhibit excellent ORR mass activity in acidic electrolyte, which is as high as 0.40 A mg Pt –1 initially and 0.34 A mg Pt –1 after 10 000 potential cycles at 0.95 V RHE . Furthermore, their MOR mass activity in alkaline media is up to 4.28 A mg Pt –1 and is 4-fold higher than that of commercial Pt/C catalyst. Furthermore, experimental studies indicate that the weakened binding of intermediate carbonaceous poison contributes to the enhanced MOR behavior. More impressively, the Pt–Co nanoframes also demonstrate remarkable stability under long-term testing, which could be attributed to the negligible electrochemical Co dissolution.
Tailoring a Three-Phase Microenvironment for High-Performance Oxygen Reduction Reaction in Proton Exchange Membrane Fuel Cells
Despite tremendous progress in catalyst development for rate-limiting cathodic oxygen reduction reaction (ORR), reducing Pt usage while meeting performance requirements in practical proton exchange membrane fuel cells (PEMFCs) remains a challenge. The ORR in PEMFCs occurs at a catalyst–electrolyte–gas three-phase interface. A desirable interface should exhibit highly active and available catalytic sites, as well as allow efficient oxygen and proton feeding to the catalytic sites and timely removal of water to avoid interface flooding. In this work, we report the design of a three-phase microenvironment in PEFMCs, showing that carbon surface chemistry can be tuned to modulate its interaction with the ionomers and create favorable transport paths for rapid delivery of both reactants and products. With such an elaborate interfacial design, for the first time we have demonstrated PEMFCs with all key ORR catalyst performance metrics, including mass activity, rated power, and durability, surpassing the US Department of Energy targets.
Methods of forming bilayer cathodes for electrochemical cells
Materials for electrochemical cells are provided. BaZr 0.4 Ce 0.4 M 0.2 O 3 compounds, where M represents one or more rare earth elements, are provided for use as electrolytes. PrBa 0.5 Sr 0.5 Co 2−x Fe x O 5+δ is provided for use as a cathode. Also provided are electrochemical cells, such as protonic ceramic fuel cells, incorporating the compounds as electrolytes and cathodes.
Reformer-electrolyzer-purifier (REP) assembly for hydrogen production, systems incorporating same and method of producing hydrogen
A high temperature electrolyzer assembly comprising at least one electrolyzer fuel cell including an anode and a cathode separated by an electrolyte matrix, and a power supply for applying a reverse voltage to the at least one electrolyzer fuel cell, wherein a gas feed comprising steam and one or more of CO2 and hydrocarbon fuel is fed to the anode of the at least one electrolyzer fuel cell, and wherein, when the power supply applies the reverse voltage to the at least one electrolyzer fuel cell, hydrogen-containing gas is generated by an electrolysis reaction in the anode of the at least one electrolyzer fuel cell and carbon dioxide is separated from the hydrogen-containing gas so that the at least one electrolyzer fuel cell outputs the hydrogen-containing gas and separately outputs an oxidant gas comprising carbon dioxide and oxygen.
Deep removal of SO2 from cathode air over polyethylenimine-modified SBA-15 sorbents for fuel cells
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