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At least 181 records · Page 10

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DOE OSTI2023

Direct Utilization of Pure and Denatured Ethanol in Metal Supported Solid Oxide Fuel Cells

Metal supported solid oxide fuel cells (MS-SOFC) are integrated with internal reforming catalyst for direct utilization of ethanol to generate electricity. MS-SOFCs are operated up to 500 h at 700°C, with water-ethanol blend fuel using high-purity ethanol and denatured ethanol. Performance and durability with denatured ethanol varies dramatically with the composition of the denaturant. Cells operated with three denatured ethanol fuels containing small amount of methanol, isopropanol, and denatonium benzoate demonstrate similar and relative stable performance after stabilization, suggesting that these fuels are fit for MS-SOFC operation. No or minimum carbon deposits are observed on the high entropy alloy-based reforming catalyst layer. Denatured ethanol containing gasoline and toluene leads to fast degradation. Here, MS-SOFCs are promising for direct utilization of denatured ethanol, offering a path to rapid-start, carbon-neutral operation with widely-available fuels.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2026

BIL High Speed Fuel Cell Stack Manufacturing

General Motors LLC (GM) was awarded a project to develop and implement technologies for manufacturing 20,000 units of Fuel Cell Stacks per year on two shifts per day basis. GM leveraged prior in-house expertise in designing the Fuel Cells, deploying the manufacturing process steps in the laboratory environment as well as the deployment in the industrial environment on a smaller scale. The project focus was to design, build, and deploy a manufacturing line consisting of an anode and cathode electrode processing, unitized electrode assembly, fuel cell stacking, compression, testing, and final assembly of the fuel cell stack. The project was terminated in the first budget period.

08 HYDROGEN↗

DOE OSTI2026

Cummins PEM Fuel Cell System for Heavy Duty Applications

The motivation for this project was to develop a high-pressure 100+ kW fuel cell stack that can be used in a modular fashion to power HD applications up to 1 MW. One of the issues that was identified during fuel cell system integration was the need for extra space for heat rejection systems(radiators) as well as additional fans and associated energy consumption to compensate for lower operating temperatures of fuel cells compared to internal combustion (IC) engines. To maximize the heat rejection capability of existing water-based coolant systems that are prevalent on IC engine-based systems, fuel cell stack design was developed to withstand and operate at IC engine coolant temperatures or higher, which in turn helps to reduce the radiator size requirement.

08 HYDROGEN↗

DOE OSTI2025

The search for high-entropy fuel-cell catalysts using disorder descriptors

The transition to a hydrogen economy depends on efficient, affordable catalysts for fuel cells. Platinum—the industry standard for fuel-cell electrodes—is costly and scarce, highlighting the need for practical alternatives. High-entropy alloys offer vast compositional diversity and tunable properties that can mitigate these issues, yet their chemical complexity and configurational disorder have hindered rational discovery. Here, we introduce a data-driven framework that couples machine learning with first-principles disorder descriptors—including the entropy forming ability, disordered enthalpy-entropy descriptor, and electronic-structure similarity metrics to platinum—to predict alloy synthesizability and catalytic performance. These descriptors are applied for the first time in the context of fuel-cell catalyst discovery. The workflow rapidly screens more than 20 000 compositions and identifies several platinum-free candidates that are economically viable, readily scalable, and exhibit promising predicted activity. These results demonstrate that disorder descriptors are reliably predicted by machine learning models and can be effectively integrated into materials-discovery pipelines, accelerating innovation across complex compositional spaces.

fuel-cell catalysts↗

DOE OSTI2022

Half-cell electrode assessments of a crossover-tolerant direct methanol fuel cell with a platinum group metal-free cathode

In this work, a platinum group metal- free (PGM-free) Fe-N-C oxygen reduction reaction (ORR) catalyst derived from metal organic framework precursors (Fe-MOF) is evaluated at the cathode side of a direct methanol fuel cell (DMFC). A wide range of methanol concentrations were used, and the performance of the DMFC using air was evaluated and compared to a commercial Pt/C cathode. We conducted our tests with a custom, integrated H 2 reference electrode that separately provided the anode and cathode overpotentials. This allowed us to perform a Tafel analysis on both electrodes and understand the dominant polarizations involved at the PGM-free cathode and the PtRu/C anode. Overall, we achieved a high cell performance using a Fe-N-C based catalyst under liquid methanol and air operation with a peak power density of 111 mW/cm 2 , where the cathode presented a markedly larger contribution to the voltage loss versus the anode. Additionally, we used nanoscale X-ray computed tomography (nano-CT) to image the Fe-N-C cathode and investigate the ionomer and pore size distributions allowing us to identify areas of improvement for catalyst layer fabrication.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Natural fiber-derived gas diffusion layers for high performance, lower cost PEM fuel cells

The gas diffusion layer (GDL) is a critical component of proton exchange membrane fuel cells. GDL manufacture is dominated by the use of polyacrylonitrile (PAN) fibers, resulting in high production costs. Those costs contribute to the high cost of fuel cell stacks. Thus, reducing GDL manufacturing costs without sacrificing performance, should help reduce the overall cost of the fuel cell stack. Using inexpensive, natural fiber-based papers and fabric as substrates, here we examine the inherent performance these materials as GDLs, and the improvements enabled by the addition of a microporous layer, gas-phase hydrophobic treatment, and densification. The resulting GDLs achieve equivalent performance the commercial baseline GDL and demonstrate the potential of lower cost GDLs.

25 ENERGY STORAGE↗

DOE OSTI2023

A Goldilocks Approach to Water Management: Hydrochannel Porous Transport Layers for Unitized Reversible Fuel Cells

Abstract This work presents a novel porous transport layer (PTL), the hydrochannel PTL, that enables improved water management and record high round trip efficiency in unitized reversible fuel cells (URFCs). URFCs require rapid transport of O 2 and H 2 O to provide high performance in both fuel cell and water electrolyzer operation, but cell design is complicated by conflicting water management requirements: electrolyzers perform best with high liquid water saturation, whereas fuel cells perform best when liquid water saturation is as low as possible while still maintaining effective ionomer hydration. The hydrochannel PTL circumvents this obstacle by providing hydrophilic channels for water transport through an otherwise hydrophobic PTL, enabling optimal performance in both fuel cell and water electrolyzer modes. Neutron radiography measurements of water content in both operating modes confirm that the hydrochannel PTL enables high performance due to its improved water management capabilities.

25 ENERGY STORAGE↗

DOE OSTI2026

Domestically Manufactured Fuel Cells for Heavy Duty Applications

This project, funded by the U.S. Department of Energy under Award DE-EE0009248, advances the domestic development of fuel-cell stack technologies for heavy-duty transportation applications. The work directly supports the Million-Mile Fuel Cell Truck (M2FCT) initiative by improving performance, durability, and manufacturability—key requirements for next-generation hydrogen fuel-cell systems.

08 HYDROGEN↗

DOE OSTI2022

Understanding the E balance for water management in hydroxide exchange membrane fuel cells

As a key challenge for hydroxide exchange membrane fuel cells (HEMFCs), understanding water management deeply is critical for performance and durability improvement. Here, in this work, we show that the balance between water generation and phase-change-induced (PCI) flow is the main factor controlling cell voltage over a wide range of conditions where the cells are vulnerable to severe flooding. The regulation of flooding by heat generation can be reflected by a stable voltage with increase of current density in the polarization curve. This PCI balance voltage (E balance ), which determines the shape of polarization curve, is modeled as a function of cell operating conditions and gas diffusion layer (GDL) properties. Temperature, pressure, and thermal conductivity of GDL were found important for tuning the level of E balance , both in HEMFCs and proton exchange membrane fuel cells. The understanding of E balance will help to generate strategies for resolving flooding in HEMFCs, and it offers a new perspective for polarization curve interpretation.

25 ENERGY STORAGE↗

DOE OSTI2023

Systems and methods for monitoring fuel cell membrane degradation

Systems and methods for real-time continuous monitoring of fuel cell membrane degradation are provided. At least one microsensor can be used as an inline sensor integrated at the cathode exhaust and/or the anode exhaust of a fuel cell, such as a proton exchange membrane fuel cell (PEMFC)). The microsensor can monitor the PEMFC degradation status by sensing the emission of fluoride.

Dong, Dongmei↗

DOE OSTI2024

Systems and methods for monitoring fuel cell membrane degradation

Dong, Dongmei↗

DOE OSTI2022

A completely precious metal–free alkaline fuel cell with enhanced performance using a carbon-coated nickel anode

Significance We present a groundbreaking advance in completely nonprecious hydrogen fuel cell technologies achieving a record power density of 200 mW/cm 2 with Ni@CN x anode and Co−Mn cathode. The 2-nm CN x coating weakens the O-binding energy, which effectively mitigates the undesirable surface oxidation during hydrogen oxidation reaction (HOR) polarization, leading to a stable fuel cell operation for Ni@CN x over 100 h at 200 mA/cm 2 , superior to a Ni nanoparticle counterpart. Ni@CNx exhibited a dramatically enhanced tolerance to CO relative to Pt/C, enabling the use of hydrogen gas with trace amounts of CO, critical for practical applications. The complete removal of precious metals in fuel cells lowers the catalyst cost to virtually negligible levels and marks a milestone for practical alkaline fuel cells.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Water Electrolyzers and Fuel Cells Supply Chain: Supply Chain Deep Dive Assessment

The report “America’s Strategy to Secure the Supply Chain for a Robust Clean Energy Transition” lays out the challenges and opportunities faced by the United States in the energy supply chain as well as the federal government plans to address these challenges and opportunities. It is accompanied by several issue-specific deep dive assessments, including this one, in response to Executive Order 14017 “America’s Supply Chains,” which directs the Secretary of Energy to submit a report on supply chains for the energy sector industrial base. The Executive Order is helping the federal government to build more secure and diverse U.S. supply chains, including energy supply chains. This report is one of a series that supports the analysis of the energy industrial base called for in Executive Order 14017 on America’s supply chains (Exec. Order No. 14017, 2021). Specifically, it provides a review of the supply chain for water electrolyzers and fuel cells with a focus on polymer electrolyte membrane electrolyzer cells (PEMEC), polymer electrolyte membrane fuel cells (PEMFC), solid oxide electrolyzer cells (SOEC), and solid oxide fuel cells (SOFC). Water electrolysis and fuel cells are a nascent industry with little prior information related to supply chain needs and constraints. This report provides a preliminary assessment; further industry peer review and revisions are expected.

08 HYDROGEN↗

DOE OSTI2022

Performance and cost of fuel cells for off-road heavy-duty vehicles

Hydrogen fuel cell-powered off-road vehicles can replace hydrocarbon-powered off-road vehicles to reduce carbon dioxide and criteria pollutant emissions in the agriculture, construction, and mining industries. Vehicle manufacturers and customers recognize health and environmental benefits of emissions reductions but are ultimately compelled by the total cost of ownership of their vehicles. In this study, we conduct a technoeconomic evaluation for three hallmark off-road vehicles, tractors, wheel loaders, and excavators, comparing vehicles with hydrogen fuel cell + battery hybrid powertrains to traditional diesel powertrains. Stakeholder-valued performance metrics include fuel cell engine power, engine durability, hydrogen consumption rate, hydrogen storage system volume, and energy-regenerative drivetrain efficiency. The total cost of ownership includes capital, operating and maintenance, fuel, and fuel storage costs. State-of-the-art fuel cell powered wheel loaders and excavators are currently cost competitive with diesel platforms. If targeted improvements to cost, performance, and durability improvements of fuel cell stacks and storage systems are achieved, fuel cell systems would be cost competitive for tractors and significantly lower total cost of ownership options for wheel loaders and excavators.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Locally developed electronic conduction in a yttria stabilized zirconia (YSZ) electrolyte for durable solid oxide fuel cells

In the present work, anode supported solid oxide fuel cells (SOFCs) based on a YSZ single layer electrolyte with locally developed electronic conduction near the anode side is fabricated to improve the cell durability under negative voltage conditions. A ceria added Ni/YSZ anode functional layer is utilized and co-sintered with the YSZ electrolyte at 1460 °C. Cerium ions are diffused into a limited region of the YSZ layer (~6 μm), establishing a ceria doped YSZ region. We successfully demonstrate that this YSZ single layer cell can operate stably for ~100 h without anode/electrolyte interface delamination, even under a negative voltage. The embedded probe technique and theoretical calculation reveal that the internal oxygen partial pressure (near the anode) is substantially reduced (stabilized) by means of local electronic conduction of ceria doped YSZ. Thus, we propose an SOFC electrolyte design comprising a YSZ single layer with a ceria added anode functional layer (locally formed ceria doped YSZ in the electrolyte) as a protection method against fuel cell stack degradation caused by negative voltage operation.

25 ENERGY STORAGE↗

DOE OSTI2022

DEVELOPMENT OF OIL FREE CENTRIFUGAL BLOWER AS ENABLING TECHNOLOGY FOR SOLID OXIDE FUEL CELL ANODE GAS RECYCLING

Broad commercialization of solid oxide fuel cells (SOFCs), requires anode offgas recycle blowers (AORB) that are specifically designed for handling the challenging operating conditions presented by the SOFC process gases. Otherwise, they can be susceptible to frequent maintenance, low reliability, and short life. This work presents details of the development and testing of an oil-free, low cost centrifugal AORB based on compliant foil bearing (CFB) technology for support of a 100 kW solid oxide fuel cell power plant. The advantages of this novel technology are discussed, particularly its long life and maintenance-free operation, which are derived from the use of CFBs. Also included are preliminary techno-economic analysis considerations for cost-effective deployment of the technology.

03 NATURAL GAS↗

DOE OSTI2021

Fuel Cell Buses in U.S. Transit Fleets: Current Status 2020

This report summarizes the progress of fuel cell electric bus (FCEB) development in the United States and discusses the achievements and challenges of introducing fuel cell propulsion in transit. The report provides a summary of results from evaluations performed by the U.S. Department of Energy's (DOE's) National Renewable Energy Laboratory (NREL). The 2020 summary results primarily focus on the most recent data on these FCEBs, from January 2020 through July 2020. The primary results presented in the report are from 25 FCEBs deployed at three agencies: Alameda-Contra Costa Transit District (AC Transit) in Oakland, California (10 FCEBs); Orange County Transportation Authority (OCTA) in Santa Ana, California (10 FCEBs); SunLine Transit Agency in Thousand Palms, California (5 FCEBs).

08 HYDROGEN↗

DOE OSTI2024

In-line, High-Throughput Quality Monitoring for Fuel Cell and Electrolyzer Components Based on Transmission and Reflection Imaging

During the manufacturing of fuel cell and electrolyzer membranes and membrane electrode assemblies (MEAs), real-time, in-line, high-throughput optical-based quality monitoring methods are essential for detecting defects and monitoring thickness variations, thus improving the performance and increasing the durability of fuel cell and electrolyzer in the hydrogen industry. For the MEAs with very opaque coatings, optical transmission-based imaging has been developed and applied in the Roll-to-Roll system using a flashlight and a high-sensitivity CCD camera. We observed high signal-to-noise ratio images while the Roll-to-Roll system ran at 5 ft/min. The entire sample image could quickly be recovered from the discrete frames using customized Python codes for automatic frame cropping and stitching. We detected significant non-uniformities in our experimental MEAs specimen. For fuel cell and low-temperature electrolysis (LTE) transparent membranes, we used optical reflectance hyperspectral imaging with interference fringe-based thickness mapping. We set up a hyperspectral camera to measure various rolls of commercial membranes. The measurement results are analyzed to find the thickness distribution of each roll and to check for defects. Transmission and reflection imaging-based quality monitoring techniques demonstrated in this project can be widely used in the mass production environment to improve the production yield and performance of hydrogen devices.

DIRECT ENERGY CONVERSION,ENGINEERING↗