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1Energy Long Island 2007 Conference
Hydrogen, Methanol and Ethanol PEM Fuel Cell Development at IRTT
Hazem Tawfik, Ph.D., P.E., C.Mfg.E.SUNY Distinguished Service Professor
Director of the Institute for Research and Technology TransferFarmingdale State College – State University of New York
Guest Scientist Brookhaven National Laboratory (BNL)
Energy Long Island 2007 Conference 2
IRTT Mission Statements
• Support the regional economic growth through research & development and transfer of new technologies to industry
• Enrich the educational experience of students with real world applications and modern technologies
Energy Long Island 2007 Conference 3
IRTT’s VISION
To develop a National Center of Excellence For Fuel Cell
Applied Research and Education
Energy Long Island 2007 Conference 4
IRTT’s MOTIVATION
Renewable hydrogen generated from wind, solar, biomasses and nuclear energy holds an excellent potential to solve our national energy problem while maintaining our clean healthy environment free of pollution and eliminates greenhouse effect and global warming
Energy Long Island 2007 Conference 5
IRTT Organizational Chart
Energy Long Island 2007 Conference 6
IRTT Research Faculty & Staff
Dr. Hazem Tawfik, Director IRTTDr. Charles Rubenstein, Visiting Professor IRTTDr. Kamel El-Khatib, Visiting Professor IRTT Dr. Yeong Ryu, Assistant Professor MET Mr. Nick Yaron, Manager Industrial RelationsMr. Jeff Hung, Technical Specialist MET and IRTTMr. Joel Yeol, Visiting Research EngineerMr. Razwan Arif, Visiting Research TechnologistMr. Carl Vogel, Visiting Research Technologist
Areas of Research and Development at IRTT
More than 60 Senior Projects, Two Master Degrees Thesis Projects, and Thirty five Companies were benefited of IRTT’s R&D Technologies in the following areas:
• Polymer Electrolyte Membrane (PEM) Fuel Cells• Robotics and Automation• Computer Aided Engineering and Finite Element Analysis• Steriolithography and Rapid Prototyping• Metal Thermal Spray Technology
Energy Long Island 2007 Conference 7
Energy Long Island 2007 Conference 8
water
H2
primaryenergysources
energyconsuming
sectors
transportation
residential commercial industry
electricity generation
energycarrier
water
Hydrogen Economy orHydrogen Energy System
Energy Long Island 2007 Conference 9
Research is a Powerful Educational Tool
Fuel Cells: Metallic Bipolar Plate and Stacks1 kW Hydrogen Fuel Cell Power StackMethane and Ethane Fuel Cells
Renewable Energy Projects:Solar/Hydrogen Homes (Full size & Model)Bio-Diesel Vehicles
IRTT’s 2006-2007Areas of Research and Educational Programs
Energy Long Island 2007 Conference 10
Metallic Bipolar Plates
1. Development of durable, cost effective, lightweight, and highly conductive Metallic Bipolar Plates for Hydrogen Fuel Cells
Two Patents were issued for Dr. Tawfik and Mr. HungResearch Team:Kamel El-Khatib, Jeff Hung, Hazem Tawfik, and Devinder Mahajan
Energy Long Island 2007 Conference 11
Fuel Cells
2. Water Management and Humidity Control Systems inside the Fuel Cell
Research Team:Joe Yoel, Yeong Ryu, and Hazem Tawfik
Energy Long Island 2007 Conference 12
BNL FaST 2007 Projects Noel Blackburn, Manager
3. Fuel Cell Humidity Optimization and Water Management in Polymer Electrolyte Membranes (PEM)
Research Team:Andrew Fasano, Hazem Tawfik, and Devinder Mahajan
4. Thermal Management Inside the Fuel Cell, Measurement of Temperature Distribution, and Thermal Management Control System of PEM Power Stack
Research Team:Robert Schulz, Hazem Tawfik, and Devinder Mahajan
Energy Long Island 2007 Conference 13
1 kW Fuel Cell
5. Design and Development of One kW Fuel Cell Power Stack with Cooling System and Balance of Plant
Research team:Jeff Hung, Hazem Tawfik, Nick Yaron and Charles Rubenstein
Energy Long Island 2007 Conference 14
BNL SULI Program
6. Development of direct Methanol and Ethanol Fuel Cells
Research team:Raja Crowley, Glenn Musano, Hazem Tawfik, and Devinder Mahajan (Partial funding by BNL)
Energy Long Island 2007 Conference 15
Solar Power
7. Development of Solar Cells using thermally sprayed Silicon Carbide and Nickel Chrome
Research team:Ken Gilmore, John Turner (National Renewable Energy Laboratory),
Dr. Kamel El-Khatib and Hazem Tawfik
8. Energy and System Analysis on a Hybrid Hydrogen and Solar Powered Small House Model
Research team:Razwan Arif and Hazem Tawfik
Energy Long Island 2007 Conference 16
Hybrid Vehicles
9. Development of Bio-Diesel Vehicles
Research team:Carl Vogel and Hazem Tawfik
10. Further Development of aHybrid Hydrogen Fuel Cell small vehicle and Go Cart
Research team:Razwan Arif, Nick Yaron and Hazem Tawfik
17
• Fuel cell is an electrochemical devise that is fed by hydrogen and oxygen and produces electric power, heat, and clean drinkable water
• Fuel cells are two times more efficient than internal combustion engines
• Fuel cells have excellent potential for economic viability
Energy Long Island 2007 Conference
Energy Long Island 2007 Conference 18
Types of Fuel CellsFuel Cell
TypeElectrolyte Anode
GasCathode
GasTemp. Efficiency
Proton Exchange Membrane
(PEM)
Solid Polymer Membrane
Hydrogen Pure or Atmospheric
Oxygen
75 C180 F
35-60%
Alkaline(AFC)
PotassiumHydroxide
Hydrogen Pure Oxygen Below 80 C 50-70%
Direct Methanol (DMFC)
Solid polymer membrane
Methanol solution in
water
Atmospheric oxygen
75 C180 F
35-40%
Phosphoric Acid
(PAFC)
Phosphorous Hydrogen Atmosphericoxygen
210 C400 F
35-50%
Molten Carbonate
(MCFC)
Alkali-Carbonates
Hydrogen, methane
Atmospheric oxygen
650C1200 F
40-55%
Solid Oxide(SOFC)
Ceramic Oxide Hydrogen, methane
Atmospheric Oxygen
800-1000 C1500-1800 F
45-60%
19
PEM Fuel Cell Theory of Operation
• http://www.humboldt.edu/~serc/animation.htmlEnergy Long Island 2007 Conference
What is a bipolar Plate?
• It is the backbone of a fuel cell power stack
• Acts as the current collector in the fuel cell environment
• It provides conduits for the reactant gases
• Must be highly conductive and corrosion resistant
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21
Our IRTT technology“makes metallic bipolar plates endure and perform more
efficiently than graphite plates.”
Carbide based Corrosion Resistant Coating
Metallic bipolar plate
Energy Long Island 2007 Conference
22
Department of Energy (DOE) PEM Fuel Cell Targets
Energy Long Island 2007 Conference
Interfacial Contact ResistanceMeasurement Setup
Coupon Test Fixture
Powder Test FixtureDigital press, power supply & m ohm meter 23Energy Long Island 2007 Conference
Force N/cm2
Sample
X1 = contact Resistance Between copper and GDLX2 = Contact Resistance Between Bipolar plate and GDL
R1 = x1+x1 =2x1Rcell = x1+ x2 + x2+ x1=2x1+2x2 = R1 + 2x2ICR = (Rcell- R1)/2
Press
Copper Plate
Copper Plate
GDL
Force N/cm2
Press
V1
V2
R
VDC
I
V1 = I * R when R = 1 ohm then V1 = I
V2 = I * Rcell = V1* Rcell
Rcell = V2 / V124Energy Long Island 2007 Conference
22.58 24.81
131.80
63.60
168.60
58.53
13.551.35
14.27
0102030405060708090
100110120130140150160170180190200
PocoGraphite
CompositeGraphite
CarbideBase 20%
NiCr/SS
TitaniumCarbide
ZirconiumCarbide
SS310 SS316 Incoloy-800 Carbide base7% NiCr/SS
Material
Inte
rfaci
al C
onta
ct R
esis
tanc
e, (I
CR
) mO
hm c
m2
Interfacial Contact Resistance of different materials at 140 N cm2
DOE Target< 20 m ohm cm2 at 140 N cm2
Interface Contact Resistance (ICR) for Different Materials with Gas Diffusion Layer (GDL)
IRTT Coating
25Energy Long Island 2007 Conference
Corrosion Measurement Setup
Test Solution 0.5 M H2SO4 + 200 ppm HF @ room temperature
Counter Electrode
SCE reference Electrode
Working Electrode
Corrosion cell Kit
Corrosion AnalysisSoftware
26Energy Long Island 2007 Conference
3.86E-06
4.19E-07
1.07E-05
2.98E-06
5.47E-05
4.80E-06
2.12E-06
6.12E-07
2.78E-05
2.02E-06
1.33E-052.22E-05
1.00E-09
1.00E-08
1.00E-07
1.00E-06
1.00E-05
1.00E-04
1.00E-03
Corro
sion
Cur
rent
, (A
cm-2
)
Material
DOE Target< 1.0E-06 A cm-2
Corrosion Current of Different Bipolar Plate Materials For PEM Fuel Cell 27Energy Long Island 2007 Conference
Contact Resistance Measurments after Potentiostaic Test @ 0.6 Volt and different time of exposure
0
10
20
30
40
50
60
70
-1 0 1 2 3 4Time, hr
ICR,
( mO
hm c
m-2
)
Carbide base thermal spray coating
SS310
28Energy Long Island 2007 Conference
CNC Machining Center
29Energy Long Island 2007 Conference
Equipments for flatness measurements
30Energy Long Island 2007 Conference
55 Ton Press for MEA Fabrication
31Energy Long Island 2007 Conference
32
High Velocity Oxygen Fuel (HVOF) Thermal Spray Sys
MASK
AIR COOLING
Energy Long Island 2007 Conference
Tested materials
•Therma
• Blank Stainless Steel 310•Sprayed Carbide Base , 20%NiCr• Thermally Sprayed Pure Carbide Base
Thermal spray
Powder Flow Rate 5, 7.5 and 10 lb/hrStandoff Distance 8, 11 and 14 in.Nitrogen Shielding
Nitrogen Shielding
Powder Feeder
Thermal spray operating parameters
33Energy Long Island 2007 Conference
Single Cell Aluminum Bipolar Plates
34Energy Long Island 2007 Conference
Single Cell Graphite Bipolar Plates
35Energy Long Island 2007 Conference
Variable Loading Testing M/C
36Energy Long Island 2007 Conference
Typical Polarization Curve
37Energy Long Island 2007 Conference
Hydrogen Safety System For Fuel Cell Testing
38Energy Long Island 2007 Conference
39
Life time testing of graphite composite and carbide based coated aluminum plates under cyclic loading and 70oC
Energy Long Island 2007 Conference
Polarization and Power Curves for Carbide based coating at Various Operation Hours – Max
percentage difference -0.33
0
0.2
0.4
0.6
0.8
1
1.2
0 200 400 600 800 1000 1200 1400
Current density, ma/cm2
cell
Volta
ge, v
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
Pow
er d
ensi
ty/ m
W c
m-2
CrC2_120CrC2_500CrC2_700CrC2_300
H2/O2 =10/10 psiCell Tem. =70Air Temp.= 75RH= 77
40Energy Long Island 2007 Conference
Polarization and Power Curves for graphite Composite Bipolar Plates at Various Operation
Hours – Max percentage difference -0.49
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 100 200 300 400 500 600 700
Current density, mA/cm2
cell
Volta
ge, V
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
Pow
er d
ensi
ty/m
W c
m-2
G1_300G1_120G1_500G1_700
41Energy Long Island 2007 Conference
Power Density Curve For Comparison Between Aluminum Coated and Graphite
Bipolar Plates
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
0 100 200 300 400 500 600 700
Current density, mA/cm2
Pow
er d
ensi
ty, W
/cm
2
Surface treated metal
Graphite
Cell Temerature= 68 oFAir flow rate = 3 SCFHCell area 1 in2
H2/air pressure= 20/30 PSI
42Energy Long Island 2007 Conference
Power Density & Efficiency Curve For Comparison Between Aluminum Coated and Graphite Bipolar Plates
0
10
20
30
40
50
60
70
80
90
0 100 200 300 400 500
Current density, mA/cm2
% E
ffici
ency
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
Pow
er d
ensi
ty, W
/cm
2
surface TreatedMetal pow erEfficiencyGraphite pow er Eff iciency
Surface treatedmetal
Graphite
Cell Temerature= 68 oFAir flow rate = 3 SCFHCell area 1 in2
H2/air pressure= 20/30 PSI
43Energy Long Island 2007 Conference
Economics of Metal Vs. Graphite
• Relative savings in hydrogen Consumption and efficiencyimprovement by at least 12% due to higher electric and thermalconductivity of Aluminum vs. graphite bipolar plates at 20o C.
0
0.02
0.04
0.06
0.08
0.1
0.12
0 100 200 300 400 500 600 700
Current density, mA/cm2
Pow
er d
ensi
ty, W
/cm
2
0
5
10
15
20
25
30
35
40
45
50
Hydr
ogen
con
sum
ptio
n pe
r w
att,
SCCM
/W
Treated metal
Graphite
SCCM / W Treated metal
SCCM / W Graphite
Cell Temerature= 68 oFAir flow rate = 3 SCFHCell area 1 in2
H2/air pressure= 20/30 PSI
44Energy Long Island 2007 Conference
Polarization and Power Curves - After 30 hours of operation at 70o C For Comparison Between Aluminum Coated and Graphite
Bipolar Plates
45Energy Long Island 2007 Conference
Efficiency and Power Curves - After 30 hours of operation at 70o C
46Energy Long Island 2007 Conference
Hydrogen consumption and Power Curves - After 30 hours of operation at 70o C – Hydrogen
Consumption Savings of 24%
47Energy Long Island 2007 Conference
100cm2 Active Area at Room Temp 3 Cells Short Stack
0
0.5
1
1.5
2
2.5
3
0 10 20 30 40
A (Amps)
V (V
olts
)
-50510152025303540
Aluminum
Graphite
Power
48Energy Long Island 2007 Conference
$-
$2,000
$4,000
$6,000
$8,000
$10,000
$12,000
0 0.25 0.5 0.75 1 1.25 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4 4.25 4.5 4.75 5 5.25 5.5
Ye a r
Tota
l Cos
t, $
com p. Gra phiteAlum inum
Total C ost C om parison for P ow er Generated by Alum inum and Graphite B ipo lar P lates (F ixed + R unning ) C osts
49Energy Long Island 2007 Conference
50
Final Stack Design
Energy Long Island 2007 Conference
Metallic Vs Graphite bipolar plates
Energy Long Island 2007 Conference 51
IRTT Current Metallic Bipolar Plates Fuel Cell Power Stack Design using robust, highly conductive and efficient plates with 24% hydrogen consumption savings
Industry Standard Graphite Composites Fuel Cell Power Stack
Energy Long Island 2007 Conference 52
Humidity Conservation Flow Pattern Triple Serpentine (Standard)
Energy Long Island 2007 Conference 53
HE - Parallel Power
HE - Perpendicular Power
Triple Serpentine Power
0
1
2
3
4
5
6
0 5 10 15 20 25 30
Powe
r (W
)
Current (A)
Power Curve Comparison Base Run10psi Hydrogen 30C No Added Humidity
HE - Parallel Power HE - Perpendicular Power Triple Serpentine Power Poly. (HE - Parallel Power) Poly. (HE - Perpendicular Power) Poly. (Triple Serpentine Power)
Humidity Conservative Serpentine exhibited 20% power increase in comparison to the triple serpentine (Slandered)
Energy Long Island 2007 Conference 54
Power Curve Comparison Base Run1psi 5% Methanol 30C No Added Humidity
0
0.005
0.01
0.015
0.02
0.025
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14
Current Density (A/50cm^2))
Pow
er D
ensi
ty (W
/50c
m^2
)
HE-Parallel Methanol Triple Ser Methanol Poly. (HE-Parallel Methanol) Poly. (Triple Ser Methanol)
Humidity conservative serpentine exhibited 20% better performance than the standard triple serpentine
Energy Long Island 2007 Conference 55
Effect of inlet Air humidity on performance
Humidity at lower temperature could cause flooding and reduction in power
As the temperature continues to increase the humidity dissipates and the cell tends to recover as the Figures in the side exhibits.
Energy Long Island 2007 Conference 56
Effect of inlet Air humidity on performance
Humidity at lower temperature could cause flooding and reduction in power
As the temperature continues to increase the humidity dissipates and the cell tends to recover as the Figures in the side exhibits.
Energy Long Island 2007 Conference 57
Three instrumented plates with 5 thermocouples per plate as shown in the side figure. The plates are placed in the beginning, middle and end of the stack to measure the internal temperature of the fuel cell.
The objective is to design a cooling system Thermocouples instrumented plates
Energy Long Island 2007 Conference 58
Middle stack plates are subjected to higher temperature than the end plates as the figure above depicts.
Heat Transfer in Fuel Cell
59Energy Long Island 2007 Conference
Energy Long Island 2007 Conference 60
Direct Oxidation Methanol Fuel Cell Setup
Energy Long Island 2007 Conference 61
Effect of fuel type on cell performance
CH3OH Methanol
CH3CH2OH Ethanol
Energy Long Island 2007 Conference 62
Comparison between graphite and Metallic bipolar plate on the performance of fuel cell
20% Improvement in Performance
Energy Long Island 2007 Conference 63
Temperature enhances performance and reaction kinetics
Effect of cell temperature on the performance of fuel cell
Energy Long Island 2007 Conference 64
Effect of Dry and Humidified Air on the performance of fuel cell
Development of Fuel Cell Hybrid Vehicle (FCHV)
65Energy Long Island 2007 Conference
-Hybrid Fuel Cell Powered Vehicles
66Energy Long Island 2007 Conference
IRTT’s Fuel Cell Battery Hybrid Vehicle Layout
Battery Charger
67Energy Long Island 2007 Conference
Graphite PEM Fuel Cell (Ballard, Inc.)
68Energy Long Island 2007 Conference
Hybrid Fuel Cell Battery Pack - Powering a Go Cart
• 8 Volts Fuel Cell - 36 Volts Battery - Inverter 8/42 Volts - Battery Charger
69Energy Long Island 2007 Conference
70Energy Long Island 2007 Conference
Hydrogen and Alternative Energy Project• Integrated Solar Hydrogen with PEM Fuel Cell System for
Powering Residential Homes
71Energy Long Island 2007 Conference
72Energy Long Island 2007 Conference
Solving the Pollution, Noise and Cost at the truck stops
73Energy Long Island 2007 Conference
Bio Diesel Motorcycle
Energy Long Island 2007 Conference 74
Conclusions• IRTT is exited about its new metallic bipolar plates
technology and intends to continue this development in cooperation with industry and academia
• IRTT has completed the development of Fuel Cell Battery Hybrid Vehicle (FCBHV) with Battery as primary power and Fuel Cell as a secondary
• The fuel cell hybrid vehicle and the solar hydrogen powered house have excellent economic potential, environmental advantages and interdisciplinary educational merits for undergraduate and postgraduate students
• There is a number of research topics that lend itself for possible collaboration between IRTT and BNL and SBU/AERTC. 75Energy Long Island 2007 Conference
FUTURE PLAN
Designing, Manufacturing, and testing of a 5 kW Metallic Bipolar Plates Power Stack Prototype complete with combined air and fluid cooling systems and Balance of Plant.
Further Development of the Corrosion Resistant coating Quality to Meet the DOE 2010 Target
and apply this technology to small fue cells for cell phones and labtop computers
76Energy Long Island 2007 Conference