FUEL CELL: INTRODUCTION

By R.C.Dohare B.E.(Mech),PGDCSc, M.E.(Env.Sc & Eng).

Fuel Cells are energy conversion devices set to replace combustion engines and
compliment batteries in a number of applications. They convert the chemical
energy contained in fuels, into electrical energy (electricity), with heat and water
generated as by-products. Fuel cells continue to generate electricity for as long
as a fuel is supplied, similar to traditional engines. However unlike engines,
where fuels are burnt to convert chemical energy into kinetic energy, fuel cells
convert fuels directly into electricity via an electrochemical process that does not
require combustion. This process enables fuel cells to be more efficient at
creating electricity than engines which have to go through an additional step to
convert the kinetic energy into electrical energy.

These technologies offer a combination of benefits that can:

• Lower your carbon footprint

• Reduce noise and air pollution
• Reduce fuel bills – through the use of more efficient technology
• Utlise renewable fuels produced onsite.
• Generate heat and power onsite
• Improve environmental credentials and corporate social responsibility
• Potential long-term money savings
• Earn ROQ’s

All fuel cells contain either solid or liquid Electrolytes sandwiched between two
electrodes. There are a number of different Types of Fuel Cells, and these are
characterized by their particular electrolyte. Different types of fuel cells operate at
different temperatures and on a variety of fuels, including both gaseous fuels
such as hydrogen, natural gas, propane and biogases, to liquid fuels such as
methanol and ethanol. Low temperature fuel cells require pure hydrogen,
whereas higher temperature fuel cells can operate directly on hydrocarbon fuels
such as natural gas. There are several main types of fuel cells, each more
suitable for particular applications.
Types of Fuel Cell

Polymer Electrolyte Membrane Fuel Cell (PEMFC)

Solid Oxide Fuel Cells (SOFC)

Phosphoric Acid Fuel Cells (PAFC)

Molten Carbonate Fuel Cells (MCFC)

Direct Methanol Fuel Cells (DMFC)

Alkaline Fuel Cells (AFC)

Applications

Proton exchange Membrane (PEM) fuel cells, also known as Polymer exchange
membrane fuel cells typically operate on pure (99.999%) hydrogen fuel. The PEM fuel
cell combines the hydrogen fuel with the oxygen from the atmosphere to produce Water,
heat (up to 90°C) and electricity.

How it Works

Fig-1

PEM Fuel cells typically utilize platinum based catalysts on the Anode to split the
Hydrogen into positive ions (protons) and negative electrons. The ions pass through the
membrane to the cathode to combine with oxygen to produce water. The electrons must
pass round an external circuit creating a current to rejoin the H2 ion on the cathode.
Chemical Equation:
Anode: 2H2 »» 4H+ + 4e-
Cathode: O2 + 4H+ + 4e- »» 2H2O

Each cell produces approximately 1.1 volts, so to reach the required voltage the cells are
combined to produce stacks. Each cell is divided with bipolar plates which while
separating them provide a hydrogen fuel distribution channel, as well as a method of
extracting the current.

PEM fuel cells are considered to have the highest energy density of all the fuel cells, and
due to the nature of the reaction have the quickest start up time (less than 1 sec) so they
have been favored for applications such as vehicles, portable power and backup power
applications.

The intolerance of the catalysts to impurities such as carbon monoxide has led to
developments of high temperature membranes which operate at 150°C +. This enables
the catalysts to tolerate greater impurities in the hydrogen supply.

Solid Oxide Fuel Cell (SOFC) A Solid Oxide Fuel Cell (SOFC) can operate
directly on Natural gas, bio gas, and propane, Hydrogen, coal bed methane or other
similar light hydrocarbons. The fuel streams and oxidant do not mix or burn, the SOFC
produces electricity electrochemically by converting the chemical energy of the fuel
directly into electrical energy thus increasing the efficiency of power production.
According to theory electrical efficiencies close to 70% are possible, however units being
sold on the market today (2009) are demonstrating 60% electrical efficiency or less. This
however has proven already to be competitive with incumbent technologies. Due to
SOFC systems operating at between 500 – 950 °C they also enable onsite production of
heat as well as power which is being effectively utilized for residential and industrial
combined heat and power applications.

SOFC Developers are starting to reach early commercial markets in the portable power
and micro CHP market due to the foresight of early adopters, however the larger mega
watt systems have yet to progress beyond global
demonstrations with strategic channel to market partners.
SOFC have also shown great promise in demonstrations as
auxiliary power units for vehicles.

Channel to market partners sought in the following markets:

• Portable
• Micro CHP
• Generators Fig-2
• Vehicle APU

How it Works
The Air is carried to the cathode, where oxygen is dissociated, yielding O2
anions. These migrate through the crystal structure of the electrolyte, going on to
oxidize the hydrogen atoms carried to the anode by the fuel. This reaction yields
electrons, heat and water.

Anode Reactions:
2H2 + 2O2- »» 2H2O + 4e-
2CO + 2O2- »» 2CO2 + 4e-

Cathode Reaction:
O2 + 4e- »» 2O2-

Phosphoric Acid Fuel Cells have a liquid phosphoric acid electrolyte, are suited for
medium to large-scale stationary combined heat & power, and require hydrogen as a fuel.
This hydrogen is usually generated by reforming light hydrocarbon fuels such as natural
gas.

How it Works

Phosphoric acid fuel cells are the most mature fuel cell technology, with over 200 units
installed and currently operating in banks, hotels, hospitals and police stations. Whilst
still requiring hydrogen, PAFC technology has the additional benefit in that is it more
tolerant to impurities, in particular reformed hydrocarbon fuels. PAFC technology
operates at between 150ºC and 220ºC with an electrical efficiency of between 37% &
42% - this rises to 85% with co-generation (CHP/CCP)

Fig-3

Chemical Equations:

Anode Reaction: 2 H2 »» 4 H+ + 4 e-
Cathode Reaction: O2(g) + 4 H+ + 4 e- »» 2 H2O

Overall Cell Reaction: 2 H2 + O2 »» 2 H2O

Molten carbonate fuel cells (MCFC’s) have a molten carbonate electrolyte
(usually sodium or lithium), are suited for large-scale stationary Combined Heat and
Power, and operate on hydrocarbon fuels including: natural gas, biogas, synthesis gas
(syngas), methane and propane.

How it Works

A major advantage of MCFC’s is that non-expensive catalysts can be used, in conjunction

with a variety of fuels. Due to high temperatures and long start-up times, MCFC’s are
unsuitable for domestic
applications. There is
considerable potential for multi- megawatt
applications

Fig-4

MCFC’s work very differently from most other types of fuel cells, and cannot operate on
pure Hydrogen alone. High temperatures prevent the need for an external reformer,
however high temperatures also enhance corrosion and catalyse the breakdown of
components. MCFC's operate around 650°C with an electrical efficiency of around 50% -
rising to 85% with cogeneration

Chemical Equations:

Anode Reaction: CO32- + H2 »» H2O + CO2 + 2e-

Cathode Reaction: CO2+ ½O2 + 2e- »» CO32-
Direct methanol fuel cells (DMFC’s) are the technology of choice for many
Portable Power Applications. DMFC is also very important for Micro Power Applications
which includes fuel cell systems for portable electronic equipment such as laptop
computers, 2-way radios, cell phones, PDA’s etc. The advantage of DMFC’s is that
Methanol is a liquid fuel and is therefore easier to store and transport than Hydrogen.
DMFCs use the same type of electrolyte as PEM Fuel Cells, but require thicker
membranes and greater loading (density) of catalysts.

How it Works

Using a liquid rather than gaseous fuel confers considerable advantages to DMFC
developers. As a liquid, Methanol can integrate effectively with transmission and
distribution systems that are already in existence. One drawback is that direct reforming
of the Methanol within the Fuel Cell Stack means that the electrodes presently require
large quantities of Platinum. DMFC technology is still in the early stages of development,
however DMFC technology has been demonstrated in automotive and portable
applications. DMFC's operate at between 50°C and 120°C with an efficiency of up to
40%

Chemical Equations:

Anode Reaction: CH3OH + H2O »» CO2 + 6H+ + 6e-

Cathode Reaction: 3/2O2 + 6H+ + 6e- »» 3H2O

Cell Reaction: CH3OH + 3/2O2 »» CO2 + 2H2O

AFCs were used on Apollo space missions to provide electricity for the on-board needs of
the shuttle. In addition to this, the major advantage of AFCs is that pure hot water is
produced as the ‘waste’ product. Therefore, on the shuttle in addition to providing
electricity the AFCs provided Heat, Cooling, Hot water, and ultimately – drinking water
for the astronauts!

How it Works

Although there are fewer companies developing AFC technology than PEM technology,
the possibility to use less expensive materials, such as non-platinum catalysts and other
plastic injected components makes them a commercially attractive technology option.
Alkaline fuel cells (AFC’s) have an alkaline electrolyte - commonly a liquid such as
Potassium Hydroxide (KOH). In an AFC, hydroxide ions (OH-) travel from cathode to
anode. This differentiates them from PEM Fuel Cells which have a solid polymer
electrolyte which conducts protons.
 Fig-5

Like PEM fuel cells, AFC's operate on pure hydrogen but have a lower power density.
Theoretical efficiency of Alkaline fuel cells is better than that of PEM. A typical Alkaline
fuel cell will have an electrical efficiency of ~50%, though 60% has been achieved by
UTC Power, who supply Alkaline fuel cells to NASA’s Space Shuttle Fleet.

There are both low temperature and high temperature AFC’s. Low temperature AFC’s
operate at temperatures as low as 25°C up to 75°C. High temperature AFC’s operate at
100°C up to 250°C.

Chemical Equations:

Anode Reaction: 2H2 + 4OH- »» 4H2O + 4e-

Cathode Reaction: O2 + 2H2O + 4e- »» 4OH-

Ref- http://www.eere.energy.gov/hydrogenandfuelcells/fuelcells/fc_types.html