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The development of phosphoric acid fuel cell stack components, fuel selection and processing, integrated system design and development, and large stack design and development were examined.
The likely facets of a nationwide phosphoric acid fuel cell (PAFC) power plant commercial system are described. The beneficial and adverse environmental impacts produced by the system are assessed. Eleven specific system activities are characterized and evaluated. Also included is a review of fuel cell technology and a description of DOE's National Fuel Cell Program. Based on current and reasonably foreseeable PAFC characteristics, no environmental or energy impact factor was identified that would significantly inhibit the commercialization of PAFC power plant technology.
The technology development for phosphoric acid fuel cells is summarized. The preparation, heat treatment, and characterization of carbon composites used as bipolar separator plates are described. Characterization included resistivity, porosity, and electrochemical corrosion. High density glassy carbon/graphite composites performed well in long-term fuel cell endurance tests. Platinum alloy cathode catalysts and low-loaded platinum electrodes were evaluated in 25 sq cm cells. Although the alloys displayed an initial improvement, some of this improvement diminished after a few thousand hours of testing. Low platinum loading (0.12 mg/sq cm anodes and 0.3 mg/sq cm cathodes) performed nearly as well as twice this loading. A selectively wetproofed anode backing paper was tested in a 5 by 15 inch three-cell stack. This material may provide for acid volume expansion, acid storage, and acid lateral distribution.
A dry compliant overlapping seal for a phosphoric acid fuel cell preformed f non-compliant Teflon to make an anode seal frame that encircles an anode assembly, a cathode seal frame that encircles a cathode assembly and a compliant seal frame made of expanded Teflon, generally encircling a matrix assembly. Each frame has a thickness selected to accommodate various tolerances of the fuel cell elements and are either bonded to one of the other frames or to a bipolar or end plate. One of the non-compliant frames is wider than the other frames forming an overlap of the matrix over the wider seal frame, which cooperates with electrolyte permeating the matrix to form a wet seal within the fuel cell that prevents process gases from intermixing at the periphery of the fuel cell and a dry seal surrounding the cell to keep electrolyte from the periphery thereof. The frames may be made in one piece, in L-shaped portions or in strips and have an outer perimeter which registers with the outer perimeter of bipolar or end plates to form surfaces upon which flanges of pan shaped, gas manifolds can be sealed.
Aqueous processed cathodes for lithium-ion batteries are favorable for both cost and environmental reasons; however, these electrodes still face significant problems with increasing areal capacities (i.e. thickness). Highly basic slurry conditions (pH in excess of 12) corrode the current collector surface and evolve hydrogen gas. Consequently, bubbling at the electrode interface causes substantial damage to the dried electrode. As the loading of these electrodes is increased, damage becomes severe and results in lack of adhesion and cohesion. Here introduction of phosphoric acid to combat the rise in pH and suppress the corrosion at the current collector surface is investigated. Phosphoric acid was added in increments of 0.5, 1.0, and 1.5 wt% and the subsequent effects on slurry rheology, particle size, adhesion, and electrochemical cycling were investigated. A technique is reported for obtaining thick (6-8 mAh/cm2) cathodes that exhibit reduced surface cracking and improved rate performance as compared to control samples.
The automated process of coating catalyst layers on gas diffusion electrodes (GDEs) for high-temperature proton exchange membrane fuel cells results inherently into a number of defects. These defects consist of agglomerates in which the platinum sites cannot be accessed by phosphoric acid and which are the consequence of an inconsistent coating, uncoated regions, scratches, knots, blemishes, folds, or attached fine particles—all ranging from μm to mm size. These electrochemically inactive spots cause a reduction of the effective catalyst area per unit volume (cm2/cm3) and determine a drop in fuel cell performance. A computational fluid dynamics (CFD) model is presented that predicts performance variation caused by manufacturing tolerances and defects of the GDE and which enables the creation of a six-sigma product specification for Advent phosphoric acid (PA)-doped polybenzimidazole (PBI)-based membrane electrode assemblies (MEAs). The model was used to predict the total volume of defects that would cause a 10% drop in performance. It was found that a 10% performance drop at the nominal operating regime would be caused by uniformly distributed defects totaling 39% of the catalyst layer volume (~0.5 defects/μm2). The study provides an upper bound for the estimation of the impact of the defect location on performance drop. It was found that the impact on the local current density is higher when the defect is located closer to the interface with the membrane. The local current density decays less than 2% in the presence of an isolated defect, regardless of its location along the active area of the catalyst layer.
We have investigated phosphorus (P) doping into Ge(001) surfaces by using ultraviolet laser irradiation in phosphoric acid solution at room temperature. We demonstrated that the diffusion depth of P in Ge and the concentration of electrically activated P can be controlled by the number of laser shots. Indeed, a high concentration of electrically activated P of 2.4 × 10{sup 19} cm{sup −3} was realized by 1000-times laser shots at a laser energy of 1.0 J/cm{sup 2}, which is comparable or better than the counterparts of conventional n-type doping using a high thermal budget over 600 °C. The generation current is dominant in the reverse bias condition for the laser-doped pn-junction diodes independent on the number of laser shots, thus indicating low-damage during the pn-junction formation. These results open up the possibility for applicable low thermal budget doping process for Ge-based devices fabricated on flexible substrates as well as Si electronics.
Recent detailed articles by Twarowski indicate that small quantities of phosphorus oxides and acids in the fuel-rich combustion products of H2 + phosphine (PH3) + air should significantly catalyze H, OH and O recombination kinetics during high-speed nozzle expansions -- to reform H2O, release heat, and approach equilibrium more rapidly and closely than uncatalyzed kinetics. This paper is an initial feasibility study to determine (a) if addition of phosphoric acid vapor (H3PO4) to a H2 fuel jet -- which is much safer than using PH3 -- will allow combustion in a high-speed scramjet engine test without adverse effects on localized flameholding, and (b) if phosphorus-containing exhaust emissions are environmentally acceptable. A well-characterized axisymmetric straight-tube opposed jet burner (OJB) tool is used to evaluate H3PO4 addition effects on the air velocity extinction limit (flame strength) of a H2 versus air counterflow diffusion flame. Addition of nitric oxide (NO), also believed to promote catalytic H-atom recombination, was evaluated for comparison. Two to five mass percent H3PO4 in the H2 jet increased flame strength 4.2%, whereas airside addition decreased it 1%. Adding 5% NO to the H2 caused a 2% decrease. Products of H-atom attack on H3PO4 produced an intense green chemiluminescence near the stagnation point. The resultant exothermic production of phosphorus oxides and acids, with accelerated H-atom recombination, released sufficient heat near the stagnation point to increase flame strength. In conclusion, the addition of H3PO4 vapor (or more reactive P sources) to hydrogen in scramjet engine tests may positively affect flameholding stability in the combustor and thrust production during supersonic expansion -- a possible dual benefit with system design / performance implications. Finally, a preliminary assessment of possible environmental effects indicates that scramjet exhaust emissions should consist of phosphoric acid aerosol, with gradual conversion to phosphate aerosol. This is compared to various natural abundances and sources.
A review of the current commercial phosphoric acid fuel cell system development efforts is presented. In both the electric utility and on-site integrated energy system applications, reducing cost and increasing reliability are important. The barrier to the attainment of these goals has been materials. The differences in approach among the three major participants are their technological features, including electrodes, matrices, intercell cooling, bipolar/separator plates, electrolyte management, fuel selection and system design philosophy.
Measurement of pH is an integral component of chemical studies and process control; however traditional pH probes are difficult to utilize in harsh or complex chemical systems. Optical spectroscopy-based on-line monitoring offers a powerful and novel route for characterizing system parameters, such as pH, and is well adapted to deployment in harsh environments or chemically complex systems. Specifically, Raman spectroscopy combined with chemometric analysis can provide an improved method of on-line pH measurement. Therefore, multivariate curve resolution analysis of Raman spectra can be utilized to determine speciation as a function of pH and subsequent chemometric modeling can be used to correlate spectral response to pH. This was demonstrated with phosphoric acid, a chemical system known to challenge traditional pH probes. Raman spectra exhibit clear changes with pH due to changing speciation, and chemometric modeling can be successfully utilized to correlate those fingerprints to pH. Using this approach, true pH of the phosphoric acid system can be measured with greater accuracy than with traditional pH probes.
A review of the current commercial phosphoric acid fuel cell system technology development efforts is presented. In both the electric utility and on-site integrated energy system applications, reducing cost and increasing reliability are the technology drivers at this time. The longstanding barrier to the attainment of these goals, which manifests itself in a number of ways, has been materials. The differences in approach among the three major participants (United Technologies Corporation (UTC), Westinghouse Electric Corporation/Energy Research Corporation (ERC), and Engelhard Industries) and their unique technological features, including electrodes, matrices, intercell cooling, bipolar/separator plates, electrolyte management, fuel selection and system design philosophy are discussed.
An account is given of the development status of phosphoric acid fuel cells' high performance catalyst and electrode materials. Binary alloys have been identified which outperform the baseline platinum catalyst; it has also become apparent that pressurized operation is required to reach the desired efficiencies, calling in turn for the use of graphitized carbon blacks in the role of catalyst supports. Efforts to improve cell performance and reduce catalyst costs have led to the investigation of a class of organometallic cathode catalysts represented by the tetraazaannulenes, and a mixed catalyst which is a mixture of carbons catalyzed with an organometallic and a noble metal.
Cost analysis of phosphoric acid fuel cell power plant includes two parts: a method for estimation of system capital costs, and an economic analysis which determines the levelized annual cost of operating the system used in the capital cost estimation. A FORTRAN computer has been developed for this cost analysis.
Legal and institutional factors affecting the development and commercial diffusion of phosphoric acid fuel cells are assessed. Issues for future research and action are suggested. Perceived barriers and potential opportunities for fuel cells in central and dispersed utility operations and on-site applications are reviewed, as well as the general concept of commercialization as applied to emerging energy technologies.
A process of apatite decomposition with sulfuric acid was studied under the influence of ultrasound in the phosphoric acid production process. The studies were carried out with and without ultrasonic fields in the reaction mixture, which resembled the mixing ratio used in technical production processes. Ultrasound with a frequency of 20 kHz and an intensity of 1 W/sq cm was used in the studies. A very favorable ultrasonic effect upon the degree of apatite decomposition was observed. The ultrasonic field affects the shape of byproduct gypsum crystals. In the H3PO4 production process without ultrasound, the byproduct gypsum crystallizes as long, thin needles which cause problems in filtration. In the trials involving the application of wound, gypsum crystallized in the form of small platelets possessing a favorable ratio of length to width.
This work deals with the production of ethanol from phosphoric acid-impregnated, steam-exploded Eucalyptus benthamii. The whole conversion process, addressing pretreatment, enzymatic hydrolysis of the whole slurry, and fermentation of both C5 and C6-sugars including a presaccharification step, is covered in this study. This work deals with the production of ethanol from phosphoric acid-impregnated, steam-exploded Eucalyptus benthamii. The whole conversion process, addressing pretreatment, enzymatic hydrolysis of the whole slurry, and fermentation of both C5 and C6-sugars including a presaccharification step, is covered in this study. Two separate models were developed to maximize sugar content and minimize inhibitor concentrations, resulting in xylose yields of ~50% and ~60% after pretreatment. In addition, a Liquefaction plus Simultaneous Saccharification and co-Fermentation (L+SScF) was performed to compare the fermentability of the resulting pretreated biomass. After the 6-h liquefaction step using the Cellic CTec2 enzyme from Novozyme and 10% DW pretreated biomass, the total sugar concentration in the slurry was 47 g/L and 51 g/L for the two conditions respectively. Enzymatic hydrolysis continued during fermentation using an ethanologenic derivative of Escherichia coli KO11. Here, the sugars were completely consumed in 96 h with product yields of 0.217 and 0.243 g ethanol/g DW biomass for each condition, respectively. Furthermore, these yields are equivalent to 275 and 304 L/tonne DW, confirming the effectiveness of the L+SScF process using phosphoric-acid-pretreated Eucalyptus.
We present a detailed description of the construction and testing of an electrochemical cell setup allowing the investigation of a gas diffusion electrode containing carbon supported high surface area catalysts. The setup is designed for measurements in concentrated phosphoric acid at elevated temperature, i.e., very close to the actual conditions in high temperature proton exchange membrane fuel cells (HT-PEMFCs). The cell consists of a stainless steel flow field and a PEEK plastic cell body comprising the electrochemical cell, which exhibits a three electrode configuration. The cell body and flow field are braced using a KF-25 vacuum flange clamp, which allows an easy assembly of the setup. As demonstrated, the setup can be used to investigate temperature dependent electrochemical processes on high surface area type electrocatalysts, but it also enables quick screening tests of HT-PEMFC catalysts under realistic conditions.
The processes which contribute to the decay in performance of electrodes used in phosphoric acid fuel cell systems are discussed. Loss of catalytic surface area, corrosion of the carbon support, electrode structure degradation, electrolyte degradation, and impurities in the reactant streams are identified as the major areas for concern.