1kW Direct Methanol Fuel Cell

8/6/2019 1kW Direct Methanol Fuel Cell

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THE DEVELOPEN T OF A 1 KW DIRECTMETHANOL FUEL CELL SYSTEMANDREW KINDLER, THOM AS 1. VALDEZ,

S.R. NA W YA NA NJET PR OPULSION LABORATORY

CALIFORNIA INSTITUTE OF TECHNOLOGYCECILIA CROPE LY, SIMON STON E

GINER Inc.EUGENE VEKSLER

MER Corp.NOV.3-7, 003

ELECTROCHEMICAL TECHNOLOGIES GROUP


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I DESIGN OBJECTIVE IA DIRECT METHANOL FUEL CELL SYSTEM WITH THEFOLLOWING PRO PERTIES:

*AIR FED*CONVENTIONAL NAFION BASED MEAs*NET OUTPUT OF >= IK W

*OPERATING AMBIENT TEMPERATUR E RANG E 25OC - 4OoC*THERMAL BALANCE MAINTAINED WITHOUT EXTERNAL POWE R*LITTLE OR NO NET WATER CON SUMPTION



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SYSTEMCHARACTERISTICS

STACK OUTPUT I45 KILOWATTSNET SYSTEM OUTPUT 1.15 KILOWATTSSTACK OPERATING TEMPERATURE 6OoCSTACK PRESSURE I TM AIRFUEL CONCENTRATION .5M METHANO LSYSTEM EFFICIENCY 21 O%



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1.15 KW SYSTEM DESIGN ICO, METH ANO L, AND WATER VAPO R

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levelsensor

I sumpPump Fanmethanolsensor ai /wa erreturnn urefeed methanol

pump

Blower

EXHAUST AIRr

ELECTROCHEMICAL TECHN OLOGIES GROUP


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SYSTEM FEATURES

STACKLOW PRESSURE DROPINTERNALLY MANIFOLDED TO MINIMIZE VOLUME A ND SIMPLIFYPLUMBING- BLOWER AIR SUPPLY- GRAVITYIPRESSURE HYBRID WATER DRAINING SYSTEM

CONDENSERPOLYCAPILLARY MATRIX HEAT EXCHANGE ELEME NTSFIRST-OF-A-KINDLIGHT WEIGHTCOMPACT

ELECTROCHEMZCAL TECHNOLOGZES GROUP


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SYSTEM FEATURESDATA ACQUISITION AND CO NTROL



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SYSTEM DESIGN

THERMAL ANALYSIS- MAINTAIN STACK TEMPERATURE CONSTANT

WATER BALANCE- MINIMIZE OR ELIMINATE EVAPORATIVE WATER LOSS



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THERMAL ANA LYSIS

HEAT GENERATION*STACKHEAT DISSIPATIONMAJOR*RADIATOR*EVAPORATIVE COOLING AT EACH CATHODEMINOR*SURFACES OF STACK AND GAS LIQUID SEPARATOR*PLUMBING



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THERMAL ANALYSIS

CONDITION I 4OoC @ 100% RELATIVE HUMIDITYDETERMINES POTENTIAL FOR SYSTEM OVERHEAT*MAXIMUM HEAT LOAD ON RADIATOR - NO EVAPORATIVECOOLING*DETERMINES MINIMUM RADIATOR SIZECONDITION 2 25OC @ 0% RELA TIVE HUMIDITYDETERMINES POTENTIAL FOR SYSTEM UNDERHEAT*MAX EVAPORATIVE COOLING



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THERM AL ANALYSISSTACK HEAT GENERATION4126 WATTS HEAT FOR 1450 WATTS ELECTRICAL OUTPUT @ 26% STACKEFFICIENCY

CONDITION I OoC @ 100% RELA TIVE HUMIDITYRADIATOR HEAT D ISSIPATIONLIQUID FLOW RATE AND FAN SPEED CAN BE ADJUSTED TO INCREASECAPACITY MODE STLY4000 WATTS-NO MINAL

STACK, GAS lLlQU lD SEPAR ATOR, AND PLUMBING-NATUR AL CONVE CTION416 WATTS - 1664 WA TTS (NO INSULATION)TOTAL DISSIPATION 441 6 W AT TS 4664 WATTS @ NOMINAL

ELECTROCHEMICAL TECHNOLOGIES GROUPADIATOR CAPACITY


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THERMAL ANALYSISSTACK HEAT GENERATION4126 WATTS HEAT FOR 1450 WATTS ELECTRICAL OUTPUT @ 26%EFFICIENCY

CONDITION 2 25OC @ 0% R.H.EVAPORA TIVE WATER LOSS 56.7 gr/min AT 6OoCHEAT LOSS 2227 WATTSTACK, GAS/LIQU ID SEPARATO R, AN D PLUMB NG-NATU RALCONVECTION 728 WATTS - 2912 WATT (NO INSULATION)TOTAL HEAT LOSS 2743 WATT - 4927 WATT

ELECTROCHEMZCAL TECHNOLOGZES GROU P


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WATER BALANCE*WATER GENER ATION RATE FROM ELECTROCHEMICAL OXIDATIONOF METHANOL PLUS CHEM ICAL OXIDATION ARISING FRO M CROSSO VER18.16 GWM IN

.WATER LOSS BY EVAPORATION @ 40% AMBIENT 0% R.H. -WORST CASEASSUMING TEMPERATURE AT CO NDENSER EXIT = 45OC LOS S =23.1 gm /min

.WATER DEFICIT 4.9 gm/min @ 40% AMBIENT

.METHANOL FUEL MUST CONTA IN 25% WATER BY WEIGHTAT 4OoCAMBIENT.AT


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WATER BALANCEWATERGAINS AT DIFFERENT AMBIENT TEMPERATURESO%RELATlVE HUMIDITY 315 LITEWMIN AIR INPUT TO STACK (3.2 STOKE)

ASSUME CONDENS ER EXHAU ST IS 5OC ABO VE AMBIENTA

WATER BALANCE ACHIEVED AT 340C

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TEMP DEGC

ELECTROCHEMICAL TECHNOLOGZES GRO UP


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COM PONENT DEVELOPMENT-

STACKCONDENSERMETHANOL SENSOR



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STACKPRESSURE DROP


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STACK 1OPERATING TEMPERATUR E 6OoC68 CELLSI45 0 WATTSAIR FLOW RATE 315 Iiter/min (11.1 cfm)PRESSURE DROP < 10torrFUEL FLOW RATE 14-17.5 liter/min (3.7-4.6 gpm)ACTIVE CELL AREA 400 cm2 (62 in2STACK DIMENSIONS 9.7 X 10.2 X 13.75 (24.6 cm x 25.9 cm x 34.9 cm)INCLUDING ENDPLATEBIPLATE 22.86 cm x 24.1 (9 X 9.5)VOLUME 19.3 liter (.68 ft3 )WEIGHT 26 kg (57.3 Ib)CURRENT DENSITY 140 ma/cm2@ .4V (CROSSOVER - 32ma/cm2)56 watt/kg75 watt/liter

- AIR FLOW RATE ISAPPROX. 3.25 STOKE (CROSSOVER INCLUDED)



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I8 CELL STACK

GINER LLC1.45 kW DMFC STACKELECTROCHEMICAL TECHNO LOGIES GROUP


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CONDENSER

CONDENSER REQUIREMENTPROCESS STREAM 360 litlmin@ 6OoCAND 100% R.H.

1335 WATTS CO OLING CAPACITY4OoC AMBIENT AIR TEM P45OC CONDENSER EXIT TEM P4 0 orr PRESSURE DROP



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CONDENSER

CONVENTIONAL TUBE AND FIN HEAT EXCHANGERSTAINLESS STEEL TUBES ALUMINUM FIN AND CASE800 watt CAPACITY57.2 cm x 47.6 cm x 15.2 cm (41.4 LITER, 19.3 WATTWLITER)13.6 kg (30 LBS) 59 WATTS/KG-100 watt COOLING FAN

ADVANCED POLYCAPILLARY MATRIX (PCM) i iEAT EXCHANGERCHROME PLATED ALUMINUM HEAT EXCHANG E ELEMENTS2000 watt CAPACITY APPROX36.8 cm x 29.2 cm x 10.2cm (1 1 LITER, I 8 2 W ATTSLITER).7.5 kg (16.52 LBS) 266 WATTS/KG38 watt COOLING FAN

ELECTROCHEMICAL TECHNOLOGZES GROUP


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FUEL SYSTEMCONCENTRATION CONTROL

METHA OL SENSOR7

STACKMETHANOLINJECTIONPUMP DILUTE METHANOLC RCULATlONPUMP



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LMETHANOL CONCENTRATIONSENSOR

A CO NSTANT VOLTGE VS IS APPLIEDTHEN THE CURRENT IS PROPORTIONALTO THE METHANOL CONCENTRATIONSENSOR IS OPERATED IN A DIFFUSIONCONTROLLED MODE

METHANOL IS OXIDIZED AT THE A NODEHYDROGEN IS REDUC ED AT THE CATHODE

ELECTROCHEMICAL TECHN OLOGIES GROUP


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INCILLARY COM PONENT

POWER CO NSUMPTIONTOTAL - 295 WATTSSTACK AIR SUPPLY BLOWER 105WATTS.RADIATOR COOLING FAN 50 WATTSCO NDE NSE R COOLING FAN 38 WATTS.DILUTE METHANOL PUM P 66 WATTS.PURE METHA NOL METER ING PUMP 6 WATTS*RELAY BOX 5-10 WATTS



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COMPONENT W EIGHTSFUEL NOT INCLUDEDSTACK 26 KG (57.3 LB)RADIATOR 6.45 KG (14.2 LB)COND ENSER 7.5 KG (16.5 LB)STACK BLOWER AND DRIVE UNIT 2.27 KG (5 LB)RADIATOR FAN 1.54 KG (3.4 LB)COND ENSER FAN .82 KG (1.8 LB)COMPUTER 3.0 KG (6.6LB)DATA ACQUISITION AND CONTROL ELECTRONICS 2.18 KG (4.8 LB)DILUTE METHANO L PUMP 1.18 KG (2.6 LB)PURE METHANOL METERING PUMP AND DRIVE UNIT 5 6 KG (1.2 LB)STARTUP BATTERIES 1.27 KG (2.8 LB)LEVEL SENSORS .04 KG (.09 LB)PURE METHANOL TANK .43 KG (.95 KG)SUMP TANK 2 4 KG ( 5 3 LB)GAS LIQUID SEPARATOR (TANK) I K G (2.2 LB)PURE METHANOL 4 HOURS OPER ATION 5.2 KG (1 1.5 LB)DILUTE FU EL IN GAS LIQUID SEPARATOR 8 KG (17.5 LB)FITTINGS, TUBING AND ODDS AND ENDS 5 KG (1 1 LB)METHANOL SENSOR AND ELECTRONICS 500 GM (1.I B)

TOTAL 68KG ( I5 0 Ib)



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I KW DIRECT METHANOL FUEL CELL SYSTEM I

Front ViewJPL Fuel Cell SystemRear ViewJPL Fuel Cell System



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ACKNOWLEDGEMENTS

THIS PROJECT S JO NTLY SPONSORED BY THE:SOUTH COAST AIR QUALITY MANAG EMENT DISTRICT

AND THECALIFORNIA AIR RESOURCES BOAR DSTACK DESIGN AND DEVELOPMENT:

GINER ELECTROCHEM ICAL SYSTEMSCONDENSER DESIGN AND DEVELOPMENT:

n n r n p n n ni v i c n bunr.ELECTROCHEMICAL TECHNOLOGIES GROUP

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1kW Direct Methanol Fuel Cell