Kettering University Fuel Cell Project

Susanta K. Das and K. Joel Berry

Center for Fuel Cell Systems and Powertrain Integrations

Kettering UniversityMay 15, 2007

Project ID # FCP4

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2

Overview

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Overview

Timeline• Start – July 2006• Finish - June 2008• 40% Complete

Budget• Total project funding

- DOE - $600K• Funding received in FY06

- $150K• Funding for FY07

- $300K• Funding for FY08

- $150K

Barriers• Barriers

A. Materials and manufacturing costsB. Membrane performanceC. Water and thermal management

• Targets –Improved conductivity & membrane stability

Partners• Bei-Tech – Polymer Membranes• Umicore Fuel Cells

- MEA Development

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Objectives

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Overall • Development of Novel Proton Exchange Membranes (PEM) for Fuel Cells

• Development of CFD porous flow model for PEM fuel cells for improved water and thermal management

2006 • Low-cost, high-performance membrane- Design and Manufacturing Processes- Experimental Testing and Performance Validation

2007-2008 •Low-cost, high-performance membrane- Real-time membrane testing for single cell and stack- Real-time testing for stability and materials properties

• Integrated multiphase CFD model for PEM Fuel Cell- Complete unit fuel cell performance evaluation- Performance evaluation for fuel cell stack

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Approach

Plan & Approach

Task 1: New Fuel Cell Membrane- Literature survey- Theoretical analysis and model

development- Inexpensive materials search

Task 2: Chemical modification- Modification of polymer backbone- Increased proton conductivity- Reduced resistance than peer

Task 3: Thermal stability and Water management

- Test of water uptake and thermal stability

- Improved durability and efficiency- Test of stable proton conductivity

Task 4: CFD multiphase model for PEM fuel cell

- Literature survey- Developed CFD multiphase

mathematical model- Developing graphical user interface

90%C

ompleted

80%C

ompleted

70%C

ompleted

40%C

ompleted

This presentation does not contain any proprietary, confidential, or otherwise restricted information

5

ApproachApproach Overview

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• We used novel patented polymer Chain modification process through chemical treatment onto an inexpensive robust polymer backbone

• Patented Polymer backbone modification technology

• New SAS FC Membrane

• PerformanceValidation

H

At the Polymer Surface

HH

HH

H

HHHH

HHH

At the Polymer Surface At the Polymer Surface

At the Polymer Surface At the Polymer Surface

Paint or GlueBT Process- A

Attach Other SpeciesProcess- B

=Atoms= Functional Groups

DigitalPH Monitor

Test membraneholder

Acid CellWater Cell

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Accomplishments/Progress/Results

This presentation does not contain any proprietary, confidential, or otherwise restricted information

• Membrane’s proton exchange capacity

Schematic of proton exchange capacitytest method

PEM holder

Test Membrane

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3

4

5

6

7

0 50 100 150 200 250 300 350 400

Nafion 212SAS membrane type ISAS membrane type II

pH (w

ater

cel

l)

time, t (min.)

y=m1t+c

1

y=m2t+c

2

y=m3t+c

3

induction time limit

• Induction time (time required to start proton transfer) is 85% less than Nafion 212• Higher proton transfer rate than peer membrane (Nafion 212) materials • Steady proton transfer capacity at higher rate than Nafion 212 for extended period of time• Very inexpensive membrane materials and easy to manufacture than Nafion 212

AcidCell

WaterCell

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Accomplishments/Progress/Results

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• Membrane conductivity and resistance

0.8

1

1.2

1.4

1.6

1.8

2

0 50 100 150 200 250 300 350 400

Nafion 212SAS membrane type ISAS membrane type II

conc

entra

tion

of p

roto

ns fl

ow (H

+ ) thr

ough

mem

bran

es (m

ol.)

time, t (min.)

• 80% increased in proton conductivity than peer materials

• 85% increased in induction time

• Very low resistance in per unit area than peer (Nafion212) materials

• Ability to quickly reach equilibrium state

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Accomplishments/Progress/Results

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• Comparison of membrane quantities

Membrane Type

Maximum protons transfer

capacity (moles/min.)

Average protons transfer capacity

(moles/min.)

Induction time (min.)

(start of proton

transfer)

Resistance(ohm-cm-2)

Nafion 212 1.0515 1.03538 99.931 0.012707

SAS type I 1.8140 1.81175 15.534 0.007261

SAS type II 1.7174 1.71080 30.042 0.007690

• 80% higher proton transfer rate than Nafion 212• 50% less membrane resistance than Nafion 212• Less induction time than peer

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Accomplishments/Progress/Results

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• Membrane Water Uptake

• Experimental test is in progress. We will present this result during poster presentation

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Accomplishments/Progress/Results

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• Membrane Swelling Measurement

• Experimental test is in progress. We will present this result during poster presentation

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Accomplishments/Progress/Results

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• Membrane Thermal Stability

• Experimental test is in progress. We will present this result during poster presentation

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Future Work

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• Future Work (FY07-FY08)

• Performance improvement of SAS membrane

- Apply cross-linking agent to make membrane chemically inert towards reactant gases

- Test thermal effect and life-cycle sensitivity- Map membrane water history

• Development of integrated CFD porous media multiphase model

- FEA graphical user interface for unit PEM fuel cell and stack- Effect of flow, heat transfer and electrochemistry on fuel cell

performance- Improve design of single cell and stack- Develop 3D surface map for effective control of fuel cell systems

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Future Work

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• Future Work (FY07-FY08)

• Explore other avenues for membrane performance enhancement

- Replace sulfate group with phosphate group for better water management

- Real-time test of membrane performance with single cell and stack

- Membrane properties calculations and validation with peers

• Improve design of unit cell and stack based on CFD modeling results

- Perform parametric study for design sensitivity analysis

- Calculation of optimal combination of operating conditions basedon CFD surface map

- Identify water production and management precursors- Identify self-humidifying mechanism for effective fuel cells water

management

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Summary

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Project Summary

Relevance: Help to develop advanced membrane materials for fuel cell applications

Seek answers by identifying factors limiting PEM fuel cell performance

Proposed Future Research:

Approach: Using patented polymer structure modification technology, develop and experimentally characterize new membrane properties and validated with peers

Technical Accomplishments and Progress: Advanced fuel cell membrane manufacturing procedure has been developed. Mathematical formulation for CFD multiphase porous media flow model is completed

Technology Transfer/Collaborations: Active partnership with Bei-Tech, Unicore fuel cell, presentations, publication and patents

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Additional Slides 1

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-0.3

-0.25

-0.2

-0.15

-0.1

-0.05

0

0.05

0 20 40 60 80 100

SAS membrane type I

SAS membrane type II

rate

of c

hang

e (s

lope

) of p

H (i

n w

ater

cel

l)

time, t (min.)

• Rate of change of pH in water cell

• Concentration of protons (H+): 10-pH

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Additional Slides 2

This presentation does not contain any proprietary, confidential, or otherwise restricted information

-0.08

-0.06

-0.04

-0.02

0.0

0.02

0 50 100 150 200 250 300 350 400

Nafion 212

rate

of c

hang

e (s

lope

) of p

H (i

n w

ater

cel

l)

time, t (min.)

• Rate of change of pH in water cell

• Concentration of protons (H+): 10-pH