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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

High-speed characterization of two-phase flow and bubble dynamics in titanium felt porous media for hydrogen production

Bubble dynamics and two-phase flow phenomena are closely related to the performance of proton exchange membrane electrolyzer cells (PEMECs). This paper reports an in-situ study of the oxygen bubble behavior and associated multiphase evolutions in the anode side of PEMECs with titanium (Ti) felt liquid gas diffusion layers (LGDLs) by a high-speed visualization system. The micro oxygen bubble dynamics was captured and analyzed at different locations and virous operating conditions. The results show that the bubble detachment frequency and detachment diameter greatly increase with the operating current density. Additionally, they are significantly impacted by the local pore structure and morphology of Ti felt LGDLs. In the flow channels, there exist only several discrete micro bubbles at a low current density (0.04 A/cm 2 ) and a large flow velocity (133 mm/s). At a current density (0.2 A/cm 2 ) and a flow velocity (67 mm/s), a number of gas slugs are formed in the follow channels, in addition to discrete micro bubbles. At a high current density (1 A/cm 2 ) and a flow velocity (67 mm/s), more bubbles appear in the channel, and the flow field is dominated by slug or annular flows. These investigations can help to better understand the two-phase flow and bubble detachment mechanism, and provide a foundation for electrochemical reaction, multiphase flow studies and optimize the design of gas diffusion layers and flow fields for PEMECs in the future.

08 HYDROGEN↗
DOE OSTI2015

Interactions between liquid-water and gas-diffusion layers in polymer-electrolyte fuel cells

Over the past few decades, a significant amount of research on polymer-electrolyte fuel cells (PEFCs) has been conducted to improve performance and durability while reducing the cost of fuel cell systems. However, the cost associated with the platinum (Pt) catalyst remains a barrier to their commercialization and PEFC durability standards have yet to be established. An effective path toward reducing PEFC cost is making the catalyst layers (CLs) thinner thus reducing expensive Pt content. The limit of thin CLs is high gas-transport resistance and the performance of these CLs is sensitive to the operating temperature due to their inherent low water uptake capacity, which results in higher sensitivity to liquid-water flooding and reduced durability. Therefore, reducing PEFC's cost by decreasing Pt content and improving PEFC's performance and durability by managing liquid-water are still challenging and open topics of research. An overlooked aspect nowadays of PEFC water management is the gas-diffusion layer (GDL). While it is known that GDL's properties can impact performance, typically it is not seen as a critical component. In this work, we present data showing the importance of GDLs in terms of water removal and management while also exploring the interactions between liquid-water and GDL surfaces. The critical interface of GDL and gas-flow-channel in the presence of liquid-water was examined through systematic studies of adhesion forces as a function of water-injection rate for various GDLs of varying thickness. GDL properties (breakthrough pressure and adhesion force) were measured experimentally under a host of test conditions. Specifically, the effects of GDL hydrophobic (PTFE) content, thickness, and water-injection rate were examined to identify trends that may be beneficial to the design of liquid-water management strategies and next-generation GDL materials for PEFCs.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Numerical investigation and experimental validation of water condensation in the gas diffusion layer with different properties

Liquid water in porous media hinders the transport of reactant to catalyst layer, where the electrochemical reactions occur, which in turn, reduces performance and lifetime of a proton exchange membrane fuel cell (PEMFC). In this study, two types of gas diffusion layer (GDL) materials are used to study the two-phase saturation distribution in a PEMFC. The correlations between the effective and anisotropic transport properties and porosity of the two GDLs are solved by the pore scale model. In addition, the anisotropic liquid water permeability and the relationship between saturation pressure and capillary pressure is determined by using the Lattice-Boltzmann method. Fuel cell performance as well as liquid water distribution in the GDL using neutron radiography are obtained for validation. Under wet conditions, the cell with Freudenberg GDL performs better than that using Toray GDL, especially at high current densities. The results of the two-phase model simulation show that the peak water saturation for Toray GDL occurs in the catalyst layer and can reach 40%, while the peak water saturation for Freudenberg GDL occurs inside the GDL directly under the ribs and only reaches 25% saturation. The combined results provide key insights to enable high power density operation of a PEMFC through GDL material optimization.

42 ENGINEERING↗
DOE OSTI2020

Investigating Liquid Water Transport in Different Pore Structure of Gas Diffusion Layers for PEMFC Using Lattice Boltzmann Method

Proton exchange membrane fuel cells (PEMFC) require a gas diffusion layer (GDL) to aid in the transport of liquid fuel to the catalyst layer. In this work, direct modeling using the Lattice Boltzmann Method (LBM) was applied to X-ray CT scans of four different carbon gas diffusion layers to understand the mass transport properties through the samples. Three injection orientations were used to study local saturation levels, water evolution through the sample, and mass transport behavior at breakthrough conditions. The LBM, combined with computational fluid dynamic modeling techniques, can accurately predict liquid saturation at the macro and micro scale, which provides more insight into the mass transport phenomena through the GDL. The change of pore structure and orientation in both the in-plane and through-plane determines the path that liquid water must take, which could aid or impact PEMFC performance. The outcomes from this work will also benefit any research that needs knowledge of internal mass transport qualities of gas diffusion media.

Sepe, M.↗
DOE OSTI2018

Developing Novel Multifunctional Materials for High-Efficiency Electrical Energy Storage

This is the final report for the program “Developing Novel Multifunctional Materials for High-efficiency Electrical Energy Storage”, funded by The U.S. Department of Energy’s (DOE) National Energy Technology Laboratory (NETL), and performed by University of Tennessee, from September 01, 2013 to August 31, 2018. Securing a sustainable energy economy by developing affordable and clean energy from renewable energy is a central element to the mission of DOE/NETL. To further this mission, NETL funds research and development of novel multifunctional materials that can be used for high-efficiency electrical energy storage. The main objective of this research program is to conduct fundamental and applied research that lead to successful development and demonstration of novel multifunctional materials, which can improve the efficiency and reduce the cost of hydrogen production with water electrolysis. The specific objectives of this research program include: 1) Design, fabrication and demonstration of thin/well-tunable liquid/gas diffusion layer (TT-LGDLs) with different pore morphologies, including pore sizes and pore porosities. 2) Development of comprehensive computational models of proton exchange membrane water electrolyzer cell (PEMECs) for the investigation of influence of different operating conditions and physical design parameters on its performance. 3) Surface modification of TT-LGDLs for better catalyst access and product/reactant removal, and smaller interfacial contact resistance (ICR). To achieve the above challenging goals, a multidisciplinary research team was formed to work on fundamental and applied research on the following three major technical areas: 1) Design, fabrication and demonstration of thin/well-tunable LGDLs (TT-LGDLs) by using photolithography and wet etching of thin titanium (Ti) foils. During the project period, the team has successfully fabricated TT-LGDLs with different pore morphologies, including pore sizes and pore porosities. The manufacturing steps mainly include cleaning thin Ti foil, supporting the foils, applying photoresist, patterning the photoresist with designed mask, exposing and developing, etching, removing photoresist, and lift-off and cleaning. The manufactured TT-LGDLs were characterized with optical microscopies and scanning electron microscopies. Their pore morphologies, including pore size and porosity, were derived based on advanced image process. The feasibility for scale-up manufacturing has been demonstrated. The TT-LGDLs have been successfully investigated for water splitting in PEMECs, which showing better performance than their counterparts fabricated with the traditional fiber-based materials. 2) Comprehensive computational modeling of a PEMEC. A comprehensive computational model has been successfully developed, and the influence of different operating conditions and physical design parameters on its performance has been investigated, including operating temperature, pressure, exchange current density, electrode thickness, membrane thickness, and interfacial resistance. Results obtained from the present model provide a comprehensive understanding of design parameter effects and consequently improve the design/performance in a PEMEC. 3) Surface modification of TT-LGDLs. The proposed surface modifications of TT-LGDLs by sputter coating and/ electroplating have been successfully demonstrated. It has been found that the performance of PEMECs can be improved by both methods, and the thickness of the electroplated gold thin layer has limited effects on the performance. With the help of the surface modifications, the PEMECs achieved the best ever performance compared with the public literatures. In addition to completion of the proposed method, microporous layers (MPLs) with both irregular micro and sphere nano titanium particles on novel TT-LGDLs was developed for the first time. The MPLs were fabricated by a low-temperature air spraying method, which provide a better catalyst access and product/reactant removal. In summary, under the close collaborations among the research team, all the tasks have been completed and the proposed research objectives have been fulfilled. All the technical milestones have been achieved and the project has been completed successfully. The technical breakthroughs obtained under this project provide novel LGDLs with well-tunable pore morphologies that can significantly improve the performance of water splitting and energy storage. This development can be directly used in existing and next generation energy storage and fuel systems.

08 HYDROGEN↗
DOE OSTI2022

Mass transport limitations in polymer electrolyte water electrolyzers using spatially-resolved current measurement

Here this work utilizes spatially-resolved current measurements to provide insight into mass transport limitations in electrolyzers that are not observable from traditional polarization measurement. In this study, two types of flow-fields (parallel and triple-serpentine) and two types of diffusion media (patterned porous thin titanium foil LGDLs and Ir-coated titanium felt PTLs) were examined. A non-uniform current distribution dominated by mass transport limitations was observed to be instigated by the restriction of liquid water transport to catalyst sites. Additionally, conditions are revealed which yield similar polarization performance but dissimilar current distributions. In such cases, the transport limitations for different architectures and porous media affect polarization in different regions of the active area. Furthermore, the triple-serpentine flow-field used in this study performs better than the parallel flow-field under mass transport limited operating conditions. This indicates that the parallel flow-field used in this study is more susceptible to starvation than the triple-serpentine flow-field for the electrolyzer studied.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Probing water distribution in compressed fuel-cell gas-diffusion layers using X-ray computed tomography

X-ray computed tomography was used to investigate geometrical land and channel effects on spatial liquid-water distribution in gas-diffusion layers (GDLs) of polymer-electrolyte fuel cells under different levels of compression. At low compression, a uniform liquid-water front was observed due to water redistribution and uniform porosity; however, at high compression, the water predominantly advanced at locations under the channel for higher liquid pressures. Lastly, at low compression, no apparent correlation between the spatial liquid water and porosity distributions was observed, whereas at high compression, a strong correlation was shown, indicating a potential for smart GDL architecture design with modulated porosity.

25 ENERGY STORAGE↗
DOE OSTI2018

Fundamental Understanding of Water Movement in Gas Diffusion Layer under Different Arrangements Using Combination of Direct Modeling and Experimental Visualization

In this paper, direct-modeling-based Lattice Boltzmann Method (LBM) combined with in-situ flow visualization, is used to explore fundamentally the transport of liquid-water inside the gas-diffusion layers (GDLs) used in polymer electrolyte fuel cells. Studies of the water evolution, water saturation, and breakthrough pressure inside a GDL with single and multiple injection points under land and channel geometries are explored. The model and experiment demonstrate good agreement between geometries of GDLs provided in this study which were obtained by a three-dimensional (3-D), reconstructed micro-structure from micro X-ray computed tomography (CT). The overall predictions of water evolution within the GDL agree well with the data visualized from the X-ray CT experiment for all cases studied. It also reveals that the liquid-water saturation profiles inside the GDL and breakthrough pressure are different when the location of the water injection point is altered, thereby providing analysis as to the impact of microporous layers or catalyst-layer functioning. Moreover, the uncompressed GDL undergoes a significantly different mechanism of water transport than that of the compressed GDL. Furthermore, the predictions show that the wettability variation is one of the key factors of the saturation characteristics.

42 ENGINEERING↗
DOE OSTI2017

Investigating Phase-Change-Induced Flow in Gas Diffusion Layers in Fuel Cells with X-ray Computed Tomography

The performance of polymer-electrolyte fuel cells is heavily dependent on proper management of liquid water. One particular reason is that liquid water can collect in the gas diffusion layers (GDLs) blocking the reactant flow to the catalyst layer. This results in increased mass-transport losses. At higher temperatures, evaporation of water becomes a dominant water-removal mechanism and specifically phase-change-induced (PCI) flow is present due to thermal gradients. This study used synchrotron based micro X-ray computed tomography (CT) to visualize and quantify the water distribution within gas diffusion layers subject to a thermal gradient. Plotting saturation as a function of through-plane distance quantitatively shows water redistribution, where water evaporates at hotter locations and condenses in colder locations. The morphology of the 2 GDLs on the micro-scale, as well as evaporating water clusters, are resolved, indicating that the GDL voids are slightly prolate, whereas water clusters are oblate. From the mean radii of water distributions and visual inspection, it is observed that larger water clusters evaporate faster than smaller ones.

25 ENERGY STORAGE↗
DOE OSTI2021

The Impact of Micro Porous Layer on Liquid Water Evolution inside PEMFC using Lattice Boltzmann Method

Proton exchange membrane fuel cells (PEMFCs) require a gas diffusion layer to aid in fuel transport to the catalyst sites. A microporous layer (MPL) is often added to the GDL to improve liquid saturation inside gas diffusion media. In this work, the lattice Boltzmann method was applied to four GDL samples with the addition of an MPL. Three injection orientations were used to study liquid evolution through the samples. Each orientation used four different injection pressures, ranging from 5,000 Pa to 8,000 Pa. Saturation data for GDL samples with and without an MPL were compared. Results showed that when adding an MPL, liquid tends to distribute laterally under the MPL until pressure is reached to allow liquid to travel through the cracks of the MPL surface and into the GDL geometry. A more uniform saturation distribution across the sample is seen when comparing both types of GDLs. The outcomes of this work will help research that requires knowledge of the internal liquid transport through gas diffusion media for PEMFC application.

Sepe, M.↗
DOE OSTI2022

3D Printed Carbon Aerogels for Polymer-Electrolyte Fuel Cells

Carbon aerogels (CA) are known for ultra-low density, very high surface area, fine porous structure, and excellent electrical conductivity. Recent advances in high resolution 3D printing at LLNL enable the manufacturing of complex structured CA electrodes which have been demonstrated in electrolysis, flow battery, and supercapacitor applications. Polymer-electrolyte fuel cells (PEFC) may be an excellent candidate for these materials/methods as designers seek to optimize membrane-electrode assemblies to achieve higher efficiencies. A major challenge to PEFC design is two-phase flow due to water production which causes pore flooding and leads to cell instability and degradation. To mitigate these effects, groups have investigated the creation of liquid specific pathways in the porous layers to alleviate liquid buildup and enhance gas diffusion. While some progress has been made, traditionally manufactured GDLs, which consist of randomly distributed carbon fibers, are limiting. 3D printed CAs are a promising solution as complex macroporous electrode structures can be manufactured out of micro and nano porous filaments with a high level of control. Additionally, the process may allow for the consolidation of multiple layers (MPL, GDL, & flow channels) into a single printed architecture. In this work various CA lattice structures were printed using a direct ink write (DIW) method and liquid breakthrough pressures were measured to demonstrate the ability to tune the water pathways to achieve specific pressure thresholds. Furthermore, a discussion of the prospects for printed CA electrodes in PEFC will focus on material properties, synthesis techniques, and current challenges.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Investigating fuel-cell transport limitations using hydrogen limiting current

Reducing mass-transport losses in polymer-electrolyte fuel cells (PEFCs) is essential to increase their power density and reduce overall stack cost. At the same time, cost also motivates the reduction in expensive precious-metal catalysts, which results in higher local transport losses in the catalyst layers. Here, we use a hydrogen-pump limiting-current setup to explore the gas-phase transport losses through PEFC catalyst layers and various gas-diffusion and microporous layers. It is shown that the effective diffusivity in the gas-diffusion layers is a strong function of liquid saturation. Additionally, it is shown how the catalyst layer unexpectedly contributes significantly to the overall measured transport resistance. This is especially true for low catalyst loadings. It is also shown how the various losses can be separated into different mechanisms including diffusional processes and mass-dependent and independent ones, where the data suggests that a large part of the transport resistance in catalyst layers cannot be attributed to a gas-phase diffusional process. The technique is promising for deconvoluting transport losses in PEFCs.

08 HYDROGEN↗
DOE OSTI2021

Experimental and computational study of the microporous layer and hydrophobic treatment in the gas diffusion layer of a proton exchange membrane fuel cell

Enabling fuel cell operation at high current density is critical for developing competitive alternative power system to replace internal combustion engine. However, liquid water management continues to be a challenge for high humidity or high current density operation. Water condensation in the porous media hinders efficient oxygen transport to the catalyst layer, which in turns, reduces fuel cell performance. To improve water management capability, the gas diffusion layer is often impregnated with Polytetrafluoroethylene (PTFE) and coated with a thin microporous layer, which have shown to improve fuel cell performance, especially under wet conditions. However, the fundamental mechanism that drives the performance enhancement is still not well understood. In this work, the effects of PTFE impregnation and MPL were studied using both experimental and computational techniques. Both limiting current and polarization tests under dry and wet operating condition are conducted to study the oxygen transport resistance and fuel cell performance. In addition, a 2-D, two-phase, multi-physics PEMFC model is developed to simulate performance and gain a fundamental understanding of local water saturation and oxygen concentration. The combined results show that 5 wt% PTFE impregnation with MPL significantly enhances liquid water management, which enables higher current density operation of a fuel cell.

25 ENERGY STORAGE↗
DOE OSTI2021

A Liquid–Vapor Two-Phase Model of Direct Methanol Fuel Cells With Platinum Group Metal-Free Cathode Catalyst

Abstract This study has developed a two-dimensional, two-phase transport model to investigate the transport characteristics in direct methanol fuel cells (DMFCs) using platinum group metal (PGM)-free cathode catalysts. The model considered anisotropic properties of the gas diffusion layer (GDL) caused by current collector’s mechanical compression, the interfacial mass transfer of water and methanol between liquid and vapor, and unique properties of the cathode PGM-free catalyst layer. Results showed that the liquid methanol solution from the anode could provide sufficient water to hydrate the proton exchange membrane (PEM), and the relative humidity of the cathode air did not impact the membrane hydration. Fully hydrating the cathode air may deteriorate the fuel cell performance, especially when the operating temperature is close to 100 °C because the exponential increase of the saturated water pressure with temperature decreased the partial pressure of oxygen. The optimized operating temperature increased with the increase of air pressure and was about 80 °C at 1.5 atm cathode pressure. To achieve the US Department of Energy’s performance target of 300 mW/cm2 peak power density, catalytic activities of both the anode and cathode catalysts need to be improved by one order of magnitude compared with the state-of-the-art commercial catalysts.

Electrochemistry↗
DOE OSTI2018

CFD Modeling of Boron Removal from Liquid Silicon with Cold Gases and Plasma

The present study focuses on a specific step of the metallurgical path of purification to provide solar-grade silicon: the removal of boron through the injection of H{sub 2}O(g)-H{sub 2}(g)-Ar(g) (cold gas process) or of Ar-H{sub 2}-O{sub 2} plasma (plasma process) on stirred liquid silicon. We propose a way to predict silicon and boron flows from the liquid silicon surface by using a CFD model (©Ansys Fluent) combined with some results on one-dimensional diffusive-reactive models to consider the formation of silica aerosols in a layer above the liquid silicon. The comparison of the model with experimental results on cold gas processes provided satisfying results for cases with low and high concentrations of oxidants. This confirms that the choices of thermodynamic data of HBO(g) and the activity coefficient of boron in liquid silicon are suitable and that the hypotheses regarding similar diffusion mechanisms at the surface for HBO(g) and SiO(g) are appropriate. The reasons for similar diffusion mechanisms need further enquiry. We also studied the effect of pressure and geometric variations in the cold gas process. For some cases with high injection flows, the model slightly overestimates the boron extraction rate, and the overestimation increases with increasing injection flow. A single plasma experiment from SIMaP (France) was modeled, and the model results fit the experimental data on purification if we suppose that aerosols form, but it is not enough to draw conclusions about the formation of aerosols for plasma experiments.

36 MATERIALS SCIENCE↗
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 OSTI2026

Spatially Mapping the CO 2 Alkaline Sorbent Diffuse Microenvironment Using Operando Raman Spectroscopy

When designing a chemical process, the local balance of transport and kinetics, collectively referred to as the diffuse microenvironment, plays a critical role in performance but is difficult to directly observe. This work demonstrates a method of two-dimensional spatial chemical mapping of the diffuse microenvironment in the context of alkali metal hydroxide direct air capture of carbon dioxide using a custom operando gas-absorption flow cell along with confocal Raman spectroscopy. Notably, we observe the concentration boundary layer near the gas–liquid interface and elucidate the interplay of carbonate and bicarbonate ions within it while inferring local hydroxide depletion through continuum modeling. These first of their kind observations provide a technique to compare the performance of direct air capture solvents based on diffuse microenvironment dynamics while also providing metrics important for air contactor design such as boundary layer thickness. Overall, this work showcases a new experimental platform to study interfacial diffuse microenvironments in and outside of the field of direct air capture of carbon dioxide.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

High Temperature Corrosion of a Pt-30 wt.% Rh Alloy in a Phosphorizing Gas

High temperature corrosion of a Pt-30 wt.% Rh alloy in a phosphorizing gas was isothermally investigated at 1285 K using a gas switching technique. Diffusion of P into the alloy created an outer layer of Pt-rich liquid and blocky (Pt, Rh) 2 P precipitates along with an inner layer of fcc and (Pt, Rh) 2 P plates in a cellular microstructure. Concentration profiles measured by SEM-WDS and EPMA across the layers at room temperature showed that there were three fcc phases: first was a 12 at.% Rh phase in the outer layer; second was a 37 at.% Rh phase in the cellular microstructure; and third was the initial 43 at.% Rh alloy. Also, the EPMA data registered approximately 0.1 at.% P in fcc of these layers. Based on the surrounding binary phase diagrams and the experimental data obtained in this study, a partial Pt-Rh-P phase diagram was constructed. A diffusion path for the corrosion microstructure was drawn on the partial phase diagram to help develop a step by step model for how the microstructure evolved. In conclusion, growth kinetics of the inner layer were used to calculate a P diffusivity of about 10 –12 m 2 /s in the Pt-Rh alloy at 1285 K, suggesting rapid diffusion by either an interstitial or interstitialcy mechanism.

36 MATERIALS SCIENCE↗