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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Migration and Precipitation of Platinum in Anion‐Exchange Membrane Fuel Cells

Abstract Despite the recent progress in increasing the power generation of Anion‐exchange membrane fuel cells (AEMFCs), their durability is still far lower than that of Proton exchange membrane fuel cells (PEMFCs). Using the complementary techniques of X‐ray micro‐computed tomography (CT), Scanning Electron Microscopy (SEM) and Energy Dispersive X‐ray (EDX) spectroscopy, we have identified Pt ion migration as an important factor to explain the decay in performance of AEMFCs. In alkaline media Pt +2 ions are easily formed which then either undergo dissolution into the carbon support or migrate to the membrane. In contrast to PEMFCs, where hydrogen cross over reduces the ions forming a vertical “Pt line” within the membrane, the ions in the AEM are trapped by charged groups within the membrane, leading to disintegration of the membrane and failure. Diffusion of the metal components is still observed when the Pt/C of the cathode is substituted with a FeCo−N−C catalyst, but in this case the Fe and Co ions are not trapped within the membrane, but rather migrate into the anode, thereby increasing the stability of the membrane.

Raut, Aniket↗
DOE OSTI2021

Understanding Carbon Dioxide Transfer in Direct Methanol Fuel Cells Using a Pore-Scale Model

Abstract The gas flow of carbon dioxide from the catalyst layer (CL) through the microporous layer (MPL) and gas diffusion layer (GDL) has great impacts on the water and fuel management in direct methanol fuel cells (DMFCs). This work has developed a liquid–vapor two-phase model considering the counter flow of carbon dioxide gas, methanol, and water liquid solution in porous electrodes of DMFC. The model simulation includes the capillary pressure as well as the pressure drop due to flow resistance through the fuel cell components. The pressure drop of carbon dioxide flow is found to be about two to three orders of magnitude higher than the pressure drop of the liquid flow. The big difference between liquid and gas pressure drops can be explained by two reasons: volume flowrate of gas is three orders of magnitude higher than that of liquid; only a small fraction of pores (<5%) in hydrophilic fuel cell components are available for gas flow. Model results indicate that the gas pressure and the mass transfer resistance of liquid and gas are more sensitive to the pore size distribution than the thickness of porous components. To buildup high gas pressure and high mass transfer resistance of liquid, the MPL and CL should avoid micro-cracks during manufacture. Distributions of pore size and wettability of the GDL and MPL have been designed to reduce the methanol crossover and improve fuel efficiency. The model results provide design guidance to obtain superior DMFC performance using highly concentrated methanol solutions or even pure methanol.

Electrochemistry↗
DOE OSTI2020

Predicting chemical reaction equilibria in molten carbonate fuel cells via molecular simulations

It has been recently suggested that hydroxide ions can be formed in the electrolyte of molten carbonate fuel cells when water vapor is present. The hydroxide can replace carbonate in transporting electrons across the electrolyte, thereby reducing the CO 2 separation efficiency of the fuel cell although still producing electricity. In this work, we obtain the equilibrium concentration of hydroxide in five molten alkali carbonate salts from molecular simulations. The results reveal that there can be a substantial amount of hydroxide in the electrolyte at low partial pressures of CO 2 . In addition, we find that the equilibrium concentration of molecular water dissolved in the electrolyte is over two orders of magnitude higher than that of CO 2 . Increasing the size and polarizability (or in other words reducing the “hardness”) of the cations present in the electrolyte can reduce the hydroxide fraction, but at the cost of lowering ionic conductivity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Fuel Cell Hybrid Electric Medium Duty Trucks, Rooftop Backup Power, and Advanced Hydrogen Refueling Components

The Fuel Cell Hybrid Electric Delivery Van final project report describes the vehicle development, build, and demonstration of 15 hydrogen fuel cell hybrid electric delivery vans (FCHEDVs) sponsored, in part, by the DOE. This report provides background for the project including goals and objectives, project implementation details, technical results and lessons learned, and recommendations for relevant technologies going forward.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

FCET Solid Oxide Fuel Cell Testing and Development (CRADA 526) (Final Report)

Pacific Northwest National Laboratory (PNNL) tested electrolyte coatings from Fuel Cell Enabling Technologies, Inc. (FCET) for use in solid oxide fuel cells (SOFCs). The key technology held by FCET is a process to deposit thin layers of oxide materials, less than 1 μm in thickness. The range of possible materials that can be deposited with their method is broad, but this project focused on the gadolinium-doped ceria (GDC) and yttria-stabilized zirconia (YSZ) electrolytes for SOFCs. Thin, gas tight electrolyte membranes have been a long-sought target in SOFC research. The thinner the electrolyte, the lower the cell resistance, and the higher performance of the cell (or the lower the operating temperature). A YSZ thickness of 1 μm would be a step change from the state-of-the-art, tape-cast electrolytes (~10 μm). An in-house prototype SOFC stack from FCET was first tested. The sealing geometry of the prototype stack was determined to be problematic, and testing shifted to button cells. Anode-supported solid oxide electrolysis cell (SOEC) button cells without an electrolyte layer were produced at PNNL and sent to FCET for coating with electrolyte. Three cells were tested with a gadolinium-doped ceria (GDC) electrolyte applied via spin coating. GDC was chosen for its conductivity at lower temperatures than YSZ. All three cells failed during initial reduction under hydrogen at 600°C. Testing then shifted to YSZ, which is the standard SOFC electrolyte. Several button cells were coated with YSZ and examined with scanning electron microscopy (SEM). A promising coating of ~1 mm thickness was observed under SEM. A similarly coated button cell was tested and failed similarly to previous tests during reduction at 600°C. The YSZ coating appeared dense and uniform in SEM analysis. The roughness of the underlying Ni/YSZ anode is on the order of 1 μm, and that may have compromised the gas-tightness of the coating. Further development is warranted to understand and refine the coating process. Thin YSZ applied via this spin-coating technique could be used as a low-cost, drop-in replacement in large-scale SOFC manufacturing processes, improving cell performance and lowering the cost per watt of SOFCs.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Nitrogen-Doped PtNi Catalysts on Polybenzimidazole-Functionalized Carbon Support for the Oxygen Reduction Reaction in Polymer Electrolyte Membrane Fuel Cells

PtM (M = 3d transition metals) alloys are known as the promising oxygen reduction reaction catalysts and have been considered as the replacement of pure Pt catalysts for the commercialization of proton exchange membrane fuel cells. Although great progress has been made in the past three decades, the performance and durability of PtM catalysts still face stringent challenges from practical applications. Functionalization of a catalyst carbon support with nitrogen-contained groups can add charges onto its surface, which can be utilized to build a more complete ionomer/catalyst interface, to reduce the catalyst particle size, and to improve particle size distribution. Nitriding of PtNi catalysts can effectively improve the catalyst activity and stability by the modification of lattice strain. Hereby, we propose a synergistic approach of combining polybenzimidazole-grafted Vulcan XC72 carbon as the catalyst carbon support and the nitriding of PtNi to develop PtNiN/XC72-polybenzimidazole catalysts. Such PtNiN/XC72-PBI catalysts exhibit the excellent performance of fuel cell membrane electrode assembly (i.e., mass activity, 440 mA mgPt –1 ; electrochemical surface area, 51 m 2 gPt –1 ; and rated power density, 836 mW cm –2 ) as well as promising catalyst stability. The developed PtNiN/XC72-PBI meets the US DOE 2020 targets of mass activity for the fuel cell catalysts. This work provides a novel approach and a promising pathway on the development of the catalyst using such a synergistic approach-modification of the catalyst structure by nitrogen doping and functionalization of carbon support by polybenzimidazole for both high performance and high durability.

25 ENERGY STORAGE↗
DOE OSTI2025

Studying the Durability of Molybdenum Carbide Aerogel as an Electrocatalyst Support for Proton Exchange Membrane Fuel Cells

Carbon-supported platinum nanoparticles (Pt/C) are currently the state-of-the-art catalyst in proton exchange membrane fuel cells (PEMFCs). Unfortunately, the carbon support lacks the ability to stabilize the metal catalyst, as platinum tends to dissolve and agglomerate, significantly compromising the durability. Herein, we synthesized a ceramic material, molybdenum carbide aerogel (MCAG), and utilized it as a Pt support for PEMFCs, as an alternative for conventional carbon supports. N 2 adsorption and XRD analysis showed that the MCAG possesses a combination of high porosity and a well-defined ceramic crystalline structure. The Pt/MCAG system was studied for its electrocatalytic activity toward ORR in a half-cell and demonstrated satisfactory reaction kinetics and electrochemical active surface area, comparable to the commercial Pt/C. For durability examination, an accelerated stress test (AST) in a single cell was conducted with the Pt/MCAG catalyst at the cathode, following the U.S. DOE electrocatalyst AST protocol. Intermediate polarization curves and cyclic voltammograms were recorded over the course of the AST to monitor the aging process. The results indicated that the MCAG support exhibited superior durability in long-term fuel cell operation compared to a carbon support. The Pt/MCAG system demonstrated stable behavior during the progressive stages of the AST, retaining more than 50% of its initial performance by the end of the test, whereas carbon-supported Pt preserved only 30%.

25 ENERGY STORAGE↗
DOE OSTI2023

Improved Fuel Cell Chemical Durability of an Heteropoly Acid Functionalized Perfluorinated Terpolymer-Perfluorosulfonic Acid Composite Membrane

Commercial proton exchange membrane heavy-duty fuel cell vehicles will require a five-fold increase in durability compared to current state-of-the art light-duty fuel cell vehicles. We describe a new composite membrane that incorporates silicotungstic heteroply acid (HPA), α -K 8 SiW 11 O 40 ▪13H 2 O, a radical decomposition catalyst and when acid-exchanged can potentially conduct protons. The HPA was covalently bound to a terpolymer of tetrafluoroethylene, vinylidene fluoride, and sulfonyl fluoride containing monomer (1,1,2,2,3,3,4,4-octafluoro-4-((1,2,2-trifluorovinyl)oxy)butane-1-sulfonyl fluoride) by dehydrofluorination followed by addition of diethyl (4-hydroxyphenyl) phosphonate, giving a perfluorosulfonic acid-vinylidene fluoride-heteropoly acid (PFSA-VDF-HPA). A composite membrane was fabricated using a blend of the PFSA-VDF-HPA and the 800EW 3M perfluoro sulfonic acid polymer. The bottom liner-side of the membrane tended to have a higher proportion of HPA moieties compared to the air-side as gravity caused the higher mass density PFSA-VDF-HPA to settle. The composite membrane was shown to have less swelling, more hydrophobic properties, and higher crystallinity than the pure PFSA membrane. The proton conductivity of the membrane was 0.130 ± 0.03 S cm −1 at 80 °C and 95% RH. Impressively, when the membrane with HPA-rich side was facing the anode, the membrane survived more than 800 h under accelerated stress test conditions of open-circuit voltage, 90 °C and 30% RH.

08 HYDROGEN↗
DOE OSTI2020

Electron and proton conductivity of Fe-N-C cathodes for PEM fuel cells: A model-based electrochemical impedance spectroscopy measurement

Impedance spectra of a PEM fuel cell with three Fe-N-C cathodes have been measured under the H 2 /N 2 testing regime. The spectra have been fitted using a recently developed physics-based impedance model, which takes into account finite proton ($σ_p$) and electron ($σ_e$) conductivity of the oxygen-free cathode catalyst layer. Fitting allowed to extract numerical data for $σ_p$, $σ_e$, the double layer capacitance, and the inductance of cables used for measuring impedance spectra. The values of σp and σe are close to what previously found for standard Pt/C electrodes, which is found for the first time using PGM-free catalysts. The method enables simultaneous measurement of reference proton and electron conductivity of PEMFC cathode.

25 ENERGY STORAGE↗
DOE OSTI2024

Fuel Cell Inverter Dataset

This data set contains the three phase AC voltage, three phase AC current, DC voltage and DC current. These data sets were captured during fuel cell inverter operation in grid-connected dispatch, islanded load changes, transition from grid-connected mode to islanded mode and vice-versa.

25 ENERGY STORAGE↗
DOE OSTI2020

Dual 3D Ceramic Textile Electrodes: Fast Kinetics for Carbon Oxidation Reaction and Oxygen Reduction Reaction in Direct Carbon Fuel Cells at Reduced Temperatures

Abstract Direct carbon fuel cells (DCFCs) are an efficient energy‐conversion technology capable of generating electricity with carbon‐dioxide‐capture chemistry with solid carbon as fuels. The efficiency and performance of DCFCs depend on the kinetics of the carbon oxidation reactions (COR) and the oxygen reduction reactions (ORR), each occurring at anode and cathode, respectively. The limited active sites paired with reduced temperatures greatly decrease the efficiency of the electrochemical reactions. Ultraporous dual‐3D ceramic textiles (dual‐3DCT) are integrated into electrolyte‐supported DCFCs to enhance charge and mass transfer at the electrodes. Improved COR at the anode is achieved by the synergy between the 3DCT NiO–Ce 0.8 Gd 0.2 O 1.95 (GDC) structure and optimal carbon fuel choice. In a comparative study, DCFCs using graphitic carbon (GC) as fuel show the best COR performance when compared to DCFCs utilizing alternative fuels such as carbon black (CB) and activated carbon (AC). The 3DCT Sm 0.5 Sr 0.5 CoO 3‐δ –GDC (SSC–GDC) composite cathode shows electrochemical performance superior to that of the conventional screen‐printed SSC–GDC. A peak power density of 392 mW cm −2 at 600 °C is obtained in a DCFC using the 3DCT‐anode/electrolyte/3DCT‐cathode configuration, an unprecedented value for any reported DCFC as of yet. This points toward promising applications of dual‐3DCT electrodes for reduced‐temperature DCFCs.

Bian, Wenjuan↗
DOE OSTI2024

Cooperative Atomically Dispersed Fe–N 4 and Sn–N x Moieties for Durable and More Active Oxygen Electroreduction in Fuel Cells

One grand challenge for deploying porous carbons with embedded metal–nitrogen–carbon (M–N–C) moieties as platinum group metal (PGM)-free electrocatalysts in proton-exchange membrane fuel cells is their fast degradation and inferior activity. Here, we report the modulation of the local environment at Fe–N 4 sites via the application of atomic Sn–N x sites for simultaneously improved durability and activity. We discovered that Sn–N x sites not only promote the formation of the more stable D2 FeN 4 C 10 sites but also invoke a unique D3 SnN x –Fe II N 4 site that is characterized by having atomically dispersed bridged Sn–N x and Fe–N 4 . This new D3 site exhibits significantly improved stability against demetalation and several times higher turnover frequency for the oxygen reduction reaction (ORR) due to the shift of the reaction pathway from a single-site associative mechanism to a dual-site dissociative mechanism with the adjacent Sn site facilitating a lower overpotential cleavage of the O–O bond. This mechanism bypasses the formation of the otherwise inevitable intermediate that is responsible for demetalation, where two hydroxyl intermediates bind to one Fe site. Lastly, a mesoporous Fe/Sn-PNC catalyst exhibits a positively shifted ORR half-wave potential and more than 50% lower peroxide formation. This, in combination with the stable D3 site and enriched D2 Fe sites, significantly enhanced the catalyst’s durability as demonstrated in membrane electrode assemblies using complementary accelerated durability testing protocols.

36 MATERIALS SCIENCE↗
DOE OSTI2021

SunLine Transit Agency Fuel Cell Electric Bus Progress Report (Data Period Focus Jan-Jun 2020) [Slides]

This report presents early results from a deployment of fuel cell electric buses (FCEBs) operated by SunLine Transit Agency in the Coachella Valley area of California. The five FCEBs, produced by New Flyer, feature an electric drive propulsion system powered by a Ballard fuel cell system. The project team is collaborating with the U.S. Department of Energy (DOE) and DOE's National Renewable Energy Laboratory (NREL) to evaluate the buses in revenue service. The goal of this evaluation is to compare the FCEB performance to that of conventional technology and to track progress over time toward meeting the technical targets set by DOE and the Department of Transportation (DOT). The FCEBs were delivered beginning in mid-2019. The data period covers January 2020 through July 2020. NREL collects data on five 2019 model year compressed natural gas (CNG) buses as a baseline comparison at SunLine. These new CNG buses were phased into service beginning in April 2020.

25 ENERGY STORAGE↗
DOE OSTI2021

Enhanced Performance of Pt Nanoparticles on Ni-N Co-Doped Graphitized Carbon for Oxygen Reduction Reaction in Polymer Electrolyte Membrane Fuel Cells

Since the reaction rate and cost for cathodic catalyst in polymer electrolyte membrane fuel cells are obstacles for commercialization, the high-performance catalyst for oxygen reduction reaction is necessary. The Ni encapsulated with N-doped graphitic carbon (Ni@NGC) prepared with ethylenediamine and carbon black is employed as an efficient support for the oxygen reduction reaction. Characterizations show that the Ni@NGC has a large surface area and mesoporous structure that is suitable to the support for the Pt catalyst. The catalyst structure is identified and the size of Pt nanoparticles distributed in the narrow range of 2–3 nm. Four different nitrogen species are doped properly into graphitic carbon structure. The Pt/Ni@NGC shows higher performance than the commercial Pt/C catalyst in an acidic electrolyte. The mass activity of the Pt/Ni@NGC in fuel cell tests exhibits over 1.5 times higher than that of commercial Pt/C catalyst. The Pt/Ni@NGC catalyst at low Pt loading exhibits 47% higher maximum power density than the Pt/C catalyst under H2-air atmosphere. These results indicate that the Ni@NGC as a support is significantly beneficial to improving activity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Flexible Grid-Based Electrolysis Hydrogen Production for Fuel Cell Vehicles Reduces Costs and Greenhouse Gas Emissions

Hydrogen fuel cell electric vehicles (FCEVs) have been proposed as an option for lowering carbon dioxide (CO 2 ) and pollutants emissions from the transportation sector, when implemented in combination with green hydrogen production methods such as water electrolysis powered by renewable electricity. FCEVs also have the added advantages of high specific energy density and rapid refueling, two important challenges that battery electric vehicles have not yet fully overcome. Moreover, flexible operation of electrolysis could support the grid and lower electricity costs. In this paper, we simulate time-varying FCEV hydrogen refueling demand for light, medium- and heavy-duty vehicles met using electrolysis systems distributed throughout the Western U.S. power system. We find that by oversizing electrolyzers the resulting load flexibility results in different hydrogen generation temporal profiles, average electricity costs, renewable curtailment levels, and CO2 emissions. Our results indicate that increasing hydrogen production flexibility lowers hydrogen and electricity generation cost and CO 2 emissions, but there is a tradeoff between lowering operational cost and increasing electrolyzer capital cost, yielding a minimum total system cost at a size corresponding to between 80% and 90% annual capacity factor assuming a future electrolyzer cost of $300/kW.

25 ENERGY STORAGE↗
DOE OSTI2021

Ammonia-fed reversible protonic ceramic fuel cells with Ru-based catalyst

Abstract The intermediate operating temperatures (~400–600 °C) of reversible protonic ceramic fuel cells (RePCFC) permit the potential use of ammonia as a carbon-neutral high energy density fuel and energy storage medium. Here we show fabrication of anode-supported RePCFC with an ultra-dense (~100%) and thin (4 μm) protonic ceramic electrolyte layer. When coupled to a novel Ru-(BaO) 2 (CaO)(Al 2 O 3 ) (Ru-B2CA) reversible ammonia catalyst, maximum fuel-cell power generation reaches 877 mW cm −2 at 650 °C under ammonia fuel. We report relatively stable operation at 600 °C for up to 1250 h under ammonia fuel. In fuel production mode, ammonia rates exceed 1.2 × 10 −8 NH 3 mol cm −2 s −1 at ambient pressure with H 2 from electrolysis only, and 2.1 × 10 −6 mol NH 3 cm −2 s −1 at 12.5 bar with H 2 from both electrolysis and simulated recycling gas.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Hydrocarbon Ionomeric Binders for Fuel Cells and Electrolyzers

Abstract Ionomeric binders in catalyst layers, abbreviated as ionomers, play an essential role in the performance of polymer–electrolyte membrane fuel cells and electrolyzers. Due to environmental issues associated with perfluoroalkyl substances, alternative hydrocarbon ionomers have drawn substantial attention over the past few years. This review surveys literature to discuss ionomer requirements for the electrodes of fuel cells and electrolyzers, highlighting design principles of hydrocarbon ionomers to guide the development of advanced hydrocarbon ionomers.

25 ENERGY STORAGE↗
DOE OSTI2023

Stationary Direct Methanol Fuel Cells Using Pure Methanol

This project developed stationary direct methanol fuel cells (DMFCs) using pure methanol as the fuel, integrating complementary institutional expertise on platinum group metals free (PGM-free) cathode catalyst (UB), supported anode catalysts (KSU), electrode fabrication, characterization, and optimization (CMU), and multi-phase mass transfer (KU). The proposed cost-effective prototype will deliver reliable and durable performance using a methanol-tolerant PGM-free cathode and a high-performance anode with low PtRu loading. At the end of the project, the research team is expected to deliver a single cell (50 cm 2 ) with ≤3 mg PGM /cm 2 that achieves 300 mW/cm 2 using pure methanol.

30 DIRECT ENERGY CONVERSION↗