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DOE OSTI2025

Bridging interfacial properties and cell performance: A multiscale model for proton-exchange-membrane fuel cells

Here, to elucidate the impact of local interfaces on mass-transport resistance and overall cell performance of low-loaded proton-exchange-membrane fuel cells (PEMFCs), we present a multiscale modeling framework incorporating a novel modified agglomerate model. The model considers three distinct Pt-electrolyte interfaces: Pt on the carbon surface covered by either ionomer or water film and Pt inside carbon nanopores. Detailed mass-transport voltage-loss breakdowns reveal that coupled agglomerate-interface-scale mass transport dominates the mass-transport loss. The ionomer poisons the exterior-Pt surface through suppressing O 2 adsorption and intrinsic ORR activity, leading to low current-density performance. Conversely, interior-Pt interface enhances the kinetic performance but limits high current-density performance due to its low interfacial permeability. The exterior-Pt/water interface demonstrates superior kinetic performance and mass transport, though its practical implementation requires ensuring proton transport. By coupling the multiscale CL properties with ink parameters, the model identifies an optimal I to C ratio of approximately 0.5, a moderate value where the ionomer content is sufficient to guarantee proton transport without fully covering the Pt surface and forming large agglomeration, thus allowing the utilization of the Pt-water interface and avoiding high mass-transport loss. Overall, the model helps unravel limiting phenomena across different operating regimes and provides routes for optimizing performance.

Cell diagnostic↗

DOE OSTI2020

Stable electrolyte matrix for molten carbonate fuel cells

An electrolyte matrix for use with molten carbonate fuel cells having an enhanced stability and lifetime is provided. The electrolyte matrix includes lithium aluminate as a support material and a coarsening inhibitor. The coarsening inhibitor may be in the form of discrete particles or a dopant present in the support material. The coarsening inhibitor may include MnO 2 , Mn 2 O 3 , TiO 2 , ZrO 2 , Fe 2 O 3 , LiFe 2 O 3 , or mixtures thereof. The coarsening inhibitor prevents the formation of large pores in the electrolyte matrix during operation of the fuel cell, increasing the performance and the service lifetime of the electrolyte matrix.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2020

Corrosion resistance of functionally graded TiN/Ti coatings for proton exchange membrane fuel cells

Bipolar Plates (BPP) are important components of proton exchange membrane fuel cell (PEMFC) stacks. In the development of innovative fuel cell designs, it is advantageous to use aluminum for these applications, however, this material lacks the necessary corrosion resistance. Since the performance of PEMFC stacks depends on BPP properties, in particular, corrosion resistance, depositing titanium nitride (TiN) thin films onto aluminum substrates may improve their efficiency and durability. Present work focuses on improving corrosion resistance and hydrophobicity of TiN/Ti by using N graded films deposited onto aluminum substrates (AA-1100) by grid-assisted magnetron sputtering (GAMS). Electrochemical impedance spectroscopy (EIS) with potentiodynamic and potentiostatic polarization are used to investigate the performance of the substrate/film system at room temperature and 70 oC, thus simulating a prototypic PEMFC electrolyte environment. Electrochemical test results showed that graded TiN films improved corrosion resistance when compared with both the homogeneous films and the AA1100 uncoated substrate. Furthermore, contact angle results reveal improved hydrophobicity for both homogeneous and graded TiN coatings when compared with the AA1100 substrate.

25 ENERGY STORAGE↗

DOE OSTI2024

Economic Case for Replacing High-Emitting Peaker Plants with Fuel Cells for Automotive Applications

The identification of clean and cost-effective solutions to replace high-emitting peaker plants and support a just transition is a challenge faced by utilities across the US today. However, falling costs of hydrogen production as well as the widespread availability of fuel cells for automotive applications have made them an attractive option for a zero-emission peak power supply. This study evaluates the techno-economics, operation, and environmental justice impacts of siting a peaker plant based on fuel cells for automotive applications through the lens of the existing Intermountain Power Plant, in order to supply peak power to the Los Angeles basin. Compared to the fossil fuel-fired peakers in operation today, the fuel cell peaker would be lower-cost up to a 17% capacity factor with Inflation Reduction Act incentives while also reducing air pollution in environmental justice communities. With corresponding transmission upgrades, the Intermountain site could host up to a 5 GW fuel cell peaker in the future.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

P-block single-metal-site tin/nitrogen-doped carbon fuel cell cathode catalyst for oxygen reduction reaction

This contribution reports the discovery and analysis of a p-block Sn-based catalyst for the electroreduction of molecular oxygen in acidic conditions at fuel cell cathodes; the catalyst is free of platinum-group metals and contains single-metal-atom actives sites coordinated by nitrogen. The prepared SnNC catalysts meet and exceed state-of-the-art FeNC catalysts in terms of intrinsic catalytic turn-over frequency and hydrogen–air fuel cell power density. The SnNC-NH 3 catalysts displayed a 40–50% higher current density than FeNC-NH 3 at cell voltages below 0.7 V. Additional benefits include a highly favourable selectivity for the four-electron reduction pathway and a Fenton-inactive character of Sn. Here, a range of analytical techniques combined with density functional theory calculations indicate that stannic Sn(iv)Nx single-metal sites with moderate oxygen chemisorption properties and low pyridinic N coordination numbers act as catalytically active moieties. The superior proton-exchange membrane fuel cell performance of SnNC cathode catalysts under realistic, hydrogen–air fuel cell conditions, particularly after NH 3 activation treatment, makes them a promising alternative to today’s state-of-the-art Fe-based catalysts.

25 ENERGY STORAGE↗

DOE OSTI2025

Fuel cells for single-aisle regional aircraft: System configuration, performance and cost

A hydrogen fuel cell propelled electric aircraft can compete with incumbent turbofan technologies for single-aisle regional aircraft by coupling design of stack, air handling, thermal management, propulsion, and airframe to optimize performance. The stack operates at 95°C to facilitate heat rejection during take-off and below 75°C during cruise to extend lifetime and is oversized to satisfy power requirements at end of life. A multi-stage turbocompressor with a compression ratio >10 is selected to reach high stack power density at 11,300-m cruise altitude. The propulsion system is configured to accommodate air handling within the core duct, an inclined heat exchanger in the outer duct to limit the nacelle size, and variable area nozzles to independently control mass flows through the core and bypass ducts. The airframe is modified for maximum lift coefficient and longer balanced field length for dramatically reduced thrust during take-off, and the fuselage is stretched by 20% to store liquid hydrogen (LH 2 ). Modularization of power systems promotes safety in one engine inoperative scenarios and allows reaching specific power metrics for stack, balance-of-plant and fuel cell system (FCS), necessary for acceptable take-off weight. In conclusion, cost parity requires increase in FCS lifetime, LH 2 cost reduction, and improved FCS specific power.

Catalyst durability↗

DOE OSTI2021

Advanced Nanocarbons for Enhanced Performance and Durability of Platinum Catalysts in Proton Exchange Membrane Fuel Cells

Insufficient stability of current carbon supported Pt and Pt alloy catalysts is a significant barrier for proton-exchange membrane fuel cells (PEMFCs). As a primary degradation cause to trigger Pt nanoparticle migration, dissolution, and aggregation, carbon corrosion remains a significant challenge. Compared with enhancing Pt and PtM alloy particle stability, improving support stability is rather challenging due to carbon's thermodynamic instability under fuel cell operation. In recent years, significant efforts have been made to develop highly durable carbon-based supports concerning innovative nanostructure design and synthesis along with mechanistic understanding. Here, this review critically discusses recent progress in developing carbon-based materials for Pt catalysts and provides synthesis–structure–performance correlations to elucidate underlying stability enhancement mechanisms. The mechanisms and impacts of carbon support degradation on Pt catalyst performance are first discussed. The general strategies are summarized to tailor the carbon structures and strengthen the metal–support interactions, followed by discussions on how these designs lead to enhanced support stability. Based on current experimental and theoretical studies, the critical features of carbon supports are analyzed concerning their impacts on the performance and durability of Pt catalysts in fuel cells. Finally, the perspectives are shared on future directions to develop advanced carbon materials with favorable morphologies and nanostructures to increase Pt utilization, strengthen metal-support interactions, facilitate mass/charge transfer, and enhance corrosion resistance.

25 ENERGY STORAGE↗

DOE OSTI2021

New roads and challenges for fuel cells in heavy-duty transportation

The recent release of hydrogen economy roadmaps for several major countries emphasizes the need for accelerated worldwide investment in research and development activities for hydrogen production, storage, infrastructure and utilization in transportation, industry and the electrical grid. Due to the high gravimetric energy density of hydrogen, the focus of technologies that utilize this fuel has recently shifted from light-duty automotive to heavy-duty vehicle applications. Decades of development of cost-effective and durable polymer electrolyte membrane fuel cells must now be leveraged to meet the increased efficiency and durability requirements of the heavy-duty vehicle market. This Review summarizes the latest market outlooks and targets for truck, bus, locomotive and marine applications. Required changes to the fuel-cell system and operating conditions for meeting Class 8 long-haul truck targets are presented. The necessary improvements in fuel-cell materials and integration are also discussed against the benchmark of current passenger fuel-cell electric vehicles.

08 HYDROGEN↗

DOE OSTI2024

X-ray-based technologies in emerging fuel cell research

The workshop titled `X-ray-based technologies in emerging fuel cell research', organized by Vivian Stojanoff from Brookhaven National Laboratory (BNL) and Narayanasami Sukumar from Cornell University/Advanced Photon Source-Northeastern Collaborative Access Team, was a notable segment of the National Synchrotron Light Source II and Center for Functional Nanomaterials Users' Meeting held 13–17 May 2024. This one-day event, on 13 May 2024, at BNL in New York, aimed to bring together researchers, beamline scientists, management and developers to propel fuel cell technology forward using model systems inspired by natural photosynthesis and redox enzymes. Furthermore, this summary encapsulates the key discussions, advancements and future implications of the workshop.

Xray↗

DOE OSTI2020

Multiobjective Optimal Controlled Variable Selection for a Gas Turbine–Solid Oxide Fuel Cell System Using a Multiagent Optimization Platform

Hybrid gas turbine–fuel cell systems have immense potential for high efficiency in electrical power generation with cleaner emissions compared with fossil-fueled power generation. We report a systematic controlled variable (CV) selection method is deployed for a hybrid gas turbine–fuel cell system in the HyPer (hybrid performance) facility at the U.S. Department of Energy’s National Energy Technology Laboratory (NETL) for maximizing its economic and control performance. A three-stage approach is used for the CV selection comprising a priori analysis, multiobjective optimization, and a posteriori analysis. The a priori analysis helps to screen off several candidate CVs, thus reducing the size of the combinatorial optimization problem for multiobjective CV selection. For optimal CV selection, a transfer function model of the HyPer facility is identified. By considering several candidate models, the final transfer function model is selected using Akaike’s Final Prediction Error criterion. Experimental data from the HyPer facility are used to estimate the noise in the measurement data. For solving the combinatorial multiobjective optimization problem for CV selection, a multiagent optimization platform comprising simulated annealing, genetic algorithm, and efficient ant colony optimization algorithms is used. Pareto-optimal CV sets exhibit a high trade-off between the economic and control objective. The a posteriori analysis is undertaken for several top Pareto-optimal CV sets. An optimal CV set is selected that shows the best compromise between process economics and controllability under both nominal and off-design conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Microscopy Studies of the Catalyst Inks for PEM Fuel Cells

The microstructure of the catalyst layer in proton exchange membrane fuel cells (PEMFC) is one of the key factors that determine fuel cell performance. The ink preparation, including dispersion solvent, mixing time, and mixing power, are among the less reported parameters that would influence the ionomer distribution on the catalyst surface and the continuity of the carbon network. In this work, novel characterization approaches have been used to investigate the effect of the Pt/C catalyst ink preparation conditions on the morphology and structures of the catalyst layer. Microscopy analysis revealed that longer mixing time led to better performing electrode structures than shorter mixing time. The longer mixing time enabled improved continuity of the ionomer network and high porosity in the cathode layer that contributes to improved proton conductivity and mass transport. This has been reflected in performance and durability tests, where the electrode made from a 5-day catalyst ink displayed improved performance compared to the one made from a 3-day ink. Durability studies showed 26% and 43% loss of the initial mass activity for 5 days and 3 days mixing, respectively. Finally, in addition, the catalyst layer prepared with ethylene glycol as the dispersion solvent showed better durability than water/1-propanol based solution.

25 ENERGY STORAGE↗

DOE OSTI2021

High-performance ammonia oxidation catalysts for anion-exchange membrane direct ammonia fuel cells

Low-temperature direct ammonia fuel cells (DAFCs) use carbon-neutral ammonia as a fuel, which has attracted increasing attention recently due to ammonia's low source-to-tank energy cost, easy transport and storage, and wide availability. However, current DAFC technologies are greatly limited by the kinetically sluggish ammonia oxidation reaction (AOR) at the anode. Herein, we report an AOR catalyst, in which ternary PtIrZn nanoparticles with an average size of 2.3 ± 0.2 nm were highly dispersed on a binary composite support comprising cerium oxide (CeO 2 ) and zeolitic imidazolate framework-8 (ZIF-8)-derived carbon (PtIrZn/CeO 2 -ZIF-8) through a sonochemical-assisted synthesis method. Additionally, the PtIrZn alloy, with the aid of abundant OH ad provided by CeO 2 and uniform particle dispersibility contributed by porous ZIF-8 carbon (surface area: ~600 m 2 g -1 ), has shown highly efficient catalytic activity for the AOR in alkaline media, superior to that of commercial PtIr/C. The rotating disk electrode (RDE) results indicate a lower onset potential (0.35 vs. 0.43 V), relative to the reversible hydrogen electrode at room temperature, and a decreased activation energy (~36.7 vs. 50.8 kJ mol -1 ) relative to the PtIr/C catalyst. Notably, the PtIrZn/CeO 2 -ZIF-8 catalyst was assembled with a high-performance hydroxide anion-exchange membrane to fabricate an alkaline DAFC, reaching a peak power density of 91 mW cm -2 . Unlike in aqueous electrolytes, supports play a critical role in improving uniform ionomer distribution and mass transport in the anode. PtIrZn nanoparticles on silicon dioxide (SiO 2 ) integrated with carboxyl-functionalized carbon nanotubes (CNT–COOH) were further studied as the anode in a DAFC. A significantly enhanced peak power density of 314 mW cm -2 was achieved. Density functional theory calculations elucidated that Zn atoms in the PtIr alloy can reduce the theoretical limiting potential of *NH 2 dehydrogenation to *NH by ~0.1 V, which can be attributed to a Zn-modulated upshift of the Pt–Ir d-band that facilitates the N–H bond breakage.

25 ENERGY STORAGE↗

DOE OSTI2021

Recent developments in Pt–Co catalysts for proton-exchange membrane fuel cells

Development of Pt-based oxygen reduction reaction catalysts with high efficiency and high durability is central to the application of proton-exchange membrane fuel cell systems. Pt–Co bimetallic catalysts have drawn extensive attention owing to their capability of delivering high performance and long lifetime for fuel cell applications including light-duty and heavy-duty vehicles. However, further improvements in durability and performance are needed to meet market requirements. To fully exploit the potential of Pt–Co catalysts, new insights into the relationship between catalyst properties and fuel cell performance and durability are needed, and more effective methods to tailor the features of Pt–Co catalysts need to be developed. This review provides a summary and perspective on recent efforts, including work on customizing the Pt shell and Pt:Co ratio, tailoring the crystal structure, and improving carbon support properties, with a particular emphasis on mechanisms leading to enhancement of mass activity, power density, and durability in membrane electrode assembly testing.

25 ENERGY STORAGE↗

DOE OSTI2023

Analysis of hydrogen infrastructure for the feasibility, economics, and sustainability of a fuel cell powered data center

Data centers used for internet data services, cloud computing, and/or data storage consume vast amounts of electricity and are increasing rapidly in capacity. Consequently, their power consumption has raised concerns about energy sustainability and environmental impacts. Large-scale, on-site renewable energy could help reduce data centers’ carbon footprint; however, wind and solar power alone cannot provide an uninterrupted power supply to computer servers due to their natural variability. Instead, reliable power integration can be achieved by using fuel cells powered by hydrogen from sustainable resources (e.g., wind and solar energy). Establishing a hydrogen infrastructure will be critical for realizing these benefits and establishing fuel cells as a viable power source for data centers. Here, to facilitate the development of novel carbon-free fuel cell data enters, this paper presents renewable power integrated with hydrogen infrastructures in four scenarios to provide reliable hydrogen supply from production to storage. Various paths were analyzed toward a hydrogen supply infrastructure by determining the proper component sizes and calculating the cost of meeting the server load. We used a microgrid modeling software, Hybrid Optimization of Multiple Energy Resources (HOMER), and studied the feasibility of fuel cell powered data centers employing renewable hydrogen. The modeling results show various renewable integration configurations to meet reliable and sustainable power requirement under four scenarios for a carbon-free data center.

08 HYDROGEN↗

DOE OSTI2024

In situ formed catalysts for active, durable, and thermally stable ammonia protonic ceramic fuel cells at 550 °C

Ammonia protonic ceramic fuel cells (NH 3 -PCFCs) are promising and attractive energy-conversion devices owing to their high energy density, zero-carbon emission, and safety. The development of NH 3 -PCFCs, however, depends largely on the insufficient activity and poor durability of typical Ni-based anodes for ammonia decomposition, especially at low temperatures such as 550 °C. Herein, we report a self-assembled heterostructured Ru 0.95 Cu 0.05 Ni x (RCN) catalyst obtained through an in situ reaction between the surface-decorated Ru 0.95 Cu 0.05 nanoparticles and the Ni grain in the anode under typical processing conditions. At 550 °C, Ni–BaZr 0.1 Ce 0.7 Y 0.1 Yb 0.1 O 3 anode-supported PCFCs with RCN catalysts exhibit a high peak power density of 0.732 W cm -2 and a significantly enhanced durability of 100 h in NH 3 . Moreover, the cells demonstrate improved thermal stability compared with the bare cell during a 31-cycle thermal cycling test in NH 3 between 550 and 700 °C. In conclusion, the enhanced performance is likely attributed to the synergistic effects of Ru and Cu in RCN for NH 3 decomposition, resulting in a more vital interaction of NH 3 than that of the bare anode surfaces, as confirmed by NH 3 thermal conversion, electrochemical performance, and theoretical simulations.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Advances and prospects to achieve high-performing and durable proton-exchange-membrane unitized regenerative fuel cells

Proton-exchange-membrane unitized regenerative fuel cell (PEM-URFC) is a promising energy storage and conversion device for large-scale and long-term applications. Previous research has primarily focused on materials development studies, with performance and durability not evaluated at relevant conditions. Such an approach becomes insufficient for making URFC technology commercially competitive. In this review, we highlight recent progress on high-performing PEM-URFCs, focusing on electrode engineering, key components, and operating approaches that take realistic operating conditions into consideration. Key components of a membrane electrode assembly (MEA), including catalyst layer, diffusion media, and membrane, which require different optimization strategies, are discussed in this review.

25 ENERGY STORAGE↗

DOE OSTI2024

A methodology to develop multi-physics dynamic fuel cell system models validated with vehicle realistic drive cycle data

Fuel cell (FC) technology has been identified as a technically attractive solution to decarbonize the transportation sector, especially for heavy-duty vehicles. In this context, the industry and the scientific community are in need of advanced fuel cell systems (FCS) models that are able to replicate real -world operating conditions. Due to the scarcity of said models in the open literature, this study aimed to develop a comprehensive methodology to calibrate and validate multi -physics dynamic FCS models. Therefore, the key contribution of this paper is the detailed description of the calibration process for each component and the calibration order. The specific focus here was to accurately describe the behavior of the FC stack as well as the cathode, anode, and cooling circuits of the balance of plant. The model was calibrated with the aid of experimental data from a Toyota Mirai FC electric vehicle, which was predominantly retrieved from the vehicle's Controller Area Network (CAN) bus system thereby negating the need for major intrusion into the powertrain system. The validation process was deemed successful with the model being able to truthfully replicate the characteristics of the FC vehicle operated on the World-wide harmonized Light duty Test Cycle (WLTC) 3b and US06 driving cycle. The time -resolved physical parameters such as the cathode pressure, mass flow, or the FC stack temperature were captured with high fidelity, while the overall performance parameters such as the H2 consumption in the stack and the system, and the compressor energy consumption were predicted accurately with a deviation lower than 0.47%, 1.75% and 1.89% with respect to the experimental data, respectively.

Lopez-Juarez, Marcos↗

DOE OSTI2024

Regulating catalyst and ionomer interactions to promote oxygen transport in fuel cells

The cost of proton exchange membrane fuel cells (PEMFCs) has been a major impediment to their widespread commercialization. Reducing platinum (Pt) usage in PEMFC represents an essential step in lowering the cost. However, decreasing Pt loading in the cathode catalyst layer (CCL) often leads to a significant increase in the local oxygen transport resistance (R Local ), which not only slows the oxygen reduction reaction but also causes a higher polarization overpotential. The poisoning of Pt by perfluorosulfonic acid ionomers also becomes more predominant at low Pt loadings. Therefore, regulating catalyst and ionomer interactions by optimizing their interface in the CCL is crucial to improving PEMFC performance. Here, in this review, the strategies of improving oxygen transport by controlling Pt-ionomer interactions and interfaces through catalyst design, ionomer structure, and incorporation of additives are summarized. Finally, perspectives on future optimization of catalyst and ionomer interactions are proposed.

25 ENERGY STORAGE↗