Proton Exchange Membrane Fuel Cell Research Articles

One-step electrodeposition of reduced graphene oxide-amorphous carbon composite coatings for proton exchange membrane fuel cell bipolar plates

In this paper, a convenient electrodeposition method is proposed to directly fabricate a reduced graphene oxide-amorphous carbon composite coating (rGO-ACC) on a 316L stainless steel substrate. The rGO-ACC coating is achieved through a one-step reduction by utilizing a choline chloride-ethylene glycol deep eutectic solvent (DES) with the dispersion of graphene oxide. The analysis results from SEM, Raman and XPS reveal that the obtained rGO-ACC coating, with layered wrinkle morphology, uniformly covers and covalently bonds to 316L stainless steel substrate. Potentiodynamic and potentiostatic polarization tests showed that the corrosion current densities of rGO-ACC coated 316L stainless steel were of the order of 10-7 A cm−2 in simulated proton exchange membrane fuel cells (PEMFC) working environment, indicating a significant improvement of corrosion resistance of 316L and an excellent electrochemical stability. Meanwhile, compared with the naked 316L steel, the interfacial contact resistance (ICR) of the coated stainless steel is significantly reduced due to the outstanding electrical conductivity of the coated rGO. The results manifested that deposited rGO-ACC on steel surface may be a highly promising modification method for PEMFC metal bipolar plates.

Parameter Estimation of Proton Exchange Membrane Fuel Cells Using Chaotic Newton-Raphson-Based Optimizer

This paper presents a novel improved metaheuristic algorithm, Chaotic Newton-Raphson-Based Optimizer (CNRBO), for the Proton Exchange Membrane Fuel Cells (PEMFCs) parameter extraction problem. In this study, ten distinct chaotic maps are integrated within the Newton-Raphson-based optimizer (NRBO) to improve its performance. The chaotic maps are employed to define the probability of the trap avoidance operator (TAO). The proposed CNRBO algorithm is validated using standard benchmark optimization problems. Results proved its advantages over the standard NRBO algorithm in terms of accuracy, robustness, and convergence speed. For PEMFC parameters extraction using the proposed CNRBO algorithm, the objective function to be minimized is the sum of squared errors (SSE) between estimated and measured stack voltages across various data points. To validate the effectiveness and reliability of the proposed CNRBO, its performance is compared with recent algorithms on eight different PEMFC stack models including NedStackPS6, BCS 500W, Horizon 500W, 250W stack, Avista SR-12 500W, Temasek 1KW, Ballard Mark V 5KW and Horizon H-1000XP stack. Statistical measures are employed to assess the superiority and robustness of the proposed CNRBO. Statistical analyses demonstrate that the proposed CNRBO algorithm outperforms existing algorithms in terms of accuracy, search capability, and convergence speed, solidifying its position as a powerful tool for PEMFC parameter estimation.

A novel PEMFC-GT-ST power generation system employing supercritical water gasification of coal for enhanced hydrogen production

This study presents an innovative coal-fired power generation system that integrates a Proton Exchange Membrane Fuel Cell (PEMFC), Gas Turbine (GT), and Steam Turbine (ST) with a supercritical water gasification (SCWG) process designed to efficiently convert coal into hydrogen. A pivotal feature of this system is the first-time integration of advanced two-step SCWG technology with PEMFC, which significantly boosts hydrogen yield, thereby elevating overall efficiency. By effectively addressing the thermodynamic limitations of the Carnot cycle, the proposed system achieves an impressive coal-to-electricity conversion efficiency of 51.61%. Economic viability is demonstrated through a competitive levelized cost of energy (LCOE) of $0.052 per kWh and a rapid payback period of approximately 2.87 years. Furthermore, the study analyzes the impact of various operational parameters—such as coal feed capacity, water-to-coal ratio, operating temperatures of the PEMFC, fuel utilization rates, airflow, and hydrogen bypass flow—on system performance. The findings not only advance the efficiency of coal-to-electricity conversion but also contribute valuable insights to the evolution of sustainable coal-fueled power generation technologies.

Numerical investigation of PEMFC performance enhancement through combined design of anodic fishbone ridge groove channel and optimal gas diffusion layer porosity gradient

The flow field plate is one of the core components of proton exchange membrane fuel cells (PEMFC), and its structure significantly influences the thermo-electrochemical coupling transport characteristics of PEMFCs. Optimizing the parameters of the flow channels of bipolar plates is crucial for enhancing the mass transfer of reacting gas and improving water removal capacity. In this study, an anodal fishbone ridge groove combined flow channel (F-SFC) is designed to enhance the diffusion uniformity of anode hydrogen gas, and a 3D multi-phase model of PEMFC is established using the multiphysics simulation software COMSOL Multiphysics. The F-SFC was compared with traditional bipolar plates featuring symmetric anode and cathode flow channels in terms of overall output performance, and the results are presented. The findings indicate that the F-SFC design achieves an average increase of 28.78% in current density and 21.07% in power density compared to conventional fishbone flow channels. When compared to traditional serpentine flow channels, the F-SFC design shows a 13.5% increase in current density and a 10.42% increase in power density. Furthermore, adding multilayer porosity gradients to gas diffusion layers (GDLs) greatly improves internal mass transfer. A gradient porosity of 0.7, 0.5, and 0.3 along the Z-axis produces a more equal distribution of current density and water concentration on the membrane. This work sheds fresh light on optimizing PEMFC design for increased power density, providing useful theoretical advice for future advances.

A Novel Development of Soft Computing based Hybrid Power Point Tracking Controllers for Hydrogen Vehicle Application with New Wide Source DC-DC Converter

From the present power generation scenario, most of the power production companies are focusing on renewable energy systems because their merits are easy to install, more reliable power sources, free from atmospheric pollution, and better adaptable to all weather conditions. In this article, a Polymer Electrolyte Membrane Fuel Cell (PEMFC) module is selected in the first objective to produce constant and continuous power to the hydrogen-based electrical vehicle systems. This fuel module provides fast power production and gives good energy density. However, the demerits of this module are more current production and low-level voltage generation. A new single-switch DC-DC circuit is introduced in the second objective of this work for optimizing the current levels of the fuel module thereby reducing the source power loss of the proposed system. Here, another problem of the fuel module is nonlinear power production which is linearized by proposing the Cuckoo Search Optimization (CSO)-based Adaptive Network-based Fuzzy Inference System (ANFIS) in the third objective to extract the maximum voltage from the fuel module. The merits of this introduced Maximum Power Point Tracking (MPPT) Controller are better tracking speed, low-level disturbances in the consumer load power, high robustness, more sustainability, and easy operation. The entire proposed system is investigated by selecting the MATLAB Simulink tool. The introduced converter circuit is analyzed by selecting the programmed DC supply.

Green hydrogen, power, and heat generation by polymer electrolyte membrane electrolyzer and fuel cell powered by a hydrokinetic turbine in low-velocity water canals, a 4E assessment

Thousands of kilometers of man-made low-velocity water transfer canals around the world can be used as a source of renewable energy for electricity and green hydrogen production. These canals have not been well investigated as an energy source, according to the literature. In the present paper, three technologies of Hydrokinetic Turbine (HKT), Polymer Electrolyte Membrane Fuel Cell, and Electrolyzer (PEM-FC/EL) are utilized to produce electricity, green hydrogen, and heat using these canals. Thermodynamic, economic, and environmental models of the cycle are presented, coded in the Engineering Equation Solver software, and finally validated with published research and manufacturers’ data. Two scenarios were examined, first HKT, PEMEL, and PEMFC were used for electricity generation (power-to-hydrogen-to-power, P2X2P) and second only HKT and PEMEL were used for green hydrogen production (power-to-hydrogen, P2X). While both scenarios are economical, the P2X scenario has a smaller payback period (less than 2 years) and a higher net present value. Practical correlations are derived to determine the rate of hydrogen production, power generation, and emission reduction as a function of water velocity. The round-trip energy and exergy efficiency of the system is 46.17% and 20.78% and it reduces carbon dioxide by 0.874 tons/year when water velocity is 1.5 m/s.

Evaluating membranes for hydrogen storage and utilization in next-generation aviation systems

This study aims to provide a comprehensive evaluation of membrane technologies for hydrogen-related processes in aviation, specifically focusing on hydrogen production, hydrogen separation, and fuel cells. As aviation seeks to transition to cleaner energy solutions, the selection of appropriate membranes is critical for ensuring efficiency and sustainability. The research utilizes the Analytic Hierarchy Process (AHP) to systematically assess membrane alternatives based on key criteria: economic factors, environmental impact, technical performance, and technological maturity. By conducting pairwise comparisons and detailed matrix calculations, this study establishes the relative importance of sub-criteria and ranks membrane types for each hydrogen-related application. The analysis identifies Nonporous Dense Films as the most effective membrane for hydrogen production, due to their balance of cost and technical performance. For hydrogen separation, Ceramic and Metal Membranes are determined to be the optimal choice, offering superior durability, hydrogen permeability, and thermal stability. In fuel cell applications, Electrically Charged Membranes are found to be the most suitable for Proton Exchange Membrane Fuel Cells (PEMFCs), while Ceramic and Metal Membranes excel in Solid Oxide Fuel Cells (SOFCs). The outcomes of this study not only highlight the most suitable membranes for different aviation hydrogen processes but also offer a strategic framework for decision-makers. By identifying the key factors driving membrane selection, this research contributes to advancing hydrogen adoption in aviation, facilitating the development of efficient, low-emission technologies for the future of sustainable air travel.

Low-Loaded Catalyst Layers For Proton Exchange Membrane Fuel Cell Dynamic Operation Part 1: Experimental Study

Low-Loaded Catalyst Layers For Proton Exchange Membrane Fuel Cell Dynamic Operation Part 1: Experimental Study

Liquid and gas permeabilities of nanostructured layers: Three-dimensional lattice Boltzmann simulation

Liquid water and gas permeabilities in nanostructured catalyst layers (CLs) (pore size ∼10–150 nm) and microporous layers (MPLs) (pore size ∼50 nm-5 μm) are crucial to reduce the mass transport loss in proton exchange membrane fuel cells (PEMFCs). Experimental measurement of their permeabilities poses great challenges due to their brittle and thin characteristics. Presently, considerable discrepancy exists in the reported permeability values for CLs and MPLs in the literature with variation spanning several orders of magnitude. This study digitally reconstructed various nanostructures of similar pore size as CLs and MPLs to calculate their permeabilities using the Lattice Boltzmann Method (LBM) based on no-slip (e.g. for liquid water flow in MPL and CL's secondary pores) or slip condition (e.g. for gas flow in MPL). Analysis was performed to evaluate the range of pore size in nanostructures for the two boundary conditions. A comprehensive investigation was conducted under various parameters such as the Reynolds number (Re), sphere diameter, porosity, and pore structure. The results revealed that permeability exhibits an increasing trend with the diameter and porosity. The predicted permeability of randomly arranged spheres agrees well with established correlations. The random sphere structure demonstrates higher permeability than their body-centered cubic (BCC) and face-centered cubic (FCC) counterparts. Under slip boundary condition, the permeability was enhanced, compared to the no-slip condition. This study's novelty lies in using distinct boundary conditions to assess the permeabilities of liquid and air, based on flow pattern analysis in the CL and MPL pore structures. A new empirical correlation describing the influence of the Knudsen number (Kn) on the slip permeability was developed, exhibiting consistency with simulation across the entire porosity spectrum.

Investigation of Ceria based Heterostructure Composite Mixed Matrix Membrane with Polybenzimidazole for Polymer Electrolyte Fuel Cell Application at High Temperature

In recent years Ceria based heterostructure composites are considered as one of the highest performing solid state ionic conductors, therefore we wanted to leverage the benefits of using these materials for high temperature Proton Exchange Membrane Fuel Cells (PEMFCs). In this study a Polybenzimidazole (PBI)/Ceria carbonate CHC (Ceria based heterostructure composite) membrane was prepared by drop casting method and tested as an electrolyte for a high temperature H2/Air PEMFC application in anhydrous condition. Inorganic composite of ceria and alkali metal carbonates (Li2CO3, Na2CO3) was prepared by solid state route to obtain Ceria carbonate CHC. X-Ray diffraction (XRD) study confirmed the formation of the heterostructure and their successful incorporation into the PBI membranes. Homogeneity of fillers inside the membrane was further verified by Energy Dispersive X-Ray Analysis (EDAX) and Scanning Electron Microscopy (SEM). 5wt% of inorganic powder induced inside the PBI fillers reduced the phosphoric acid uptake of composite membrane (∼17% less) compared to pristine PBI membrane, which ultimately resulted into a lower swelling and dimensional change of the composite membrane. Thermal robustness of the phosphoric acid doped composite and pristine PBI membranes was investigated by thermogravimetric analysis (TGA) which showed that the prepared membranes were gone under a less than 10% reduction in weight up till 200ºC, ensuring their validity of application in high temp PEM fuel cells. The added inorganic functionalities resulted in a slight increase in the proton conductivity of PA doped composite PBI membranes i.e., 42.3 mS cm-1 at 180 ºC while for pristine PBI membrane it is 36 mS cm-1 at same temperature. A single cell with composite PBI membranes outperformed a pristine PBI membrane resulted into a ∼120% higher peak power density i.e., 320.88 mW cm-2. The composite membrane also displayed the excellent durability and showed a less than 10-4 mV/h degradation in cell potential till 180 ºC.

Innovative fuzzy logic type 3 controller for transient and maximum power point tracking in hydrogen fuel cells

This study introduces an advanced Fuzzy Logic Type 3 (FLT3) controller for Proton Exchange Membrane Fuel Cells (PEMFCs), aiming to optimize Maximum Power Point Tracking (MPPT) under dynamically varying temperature conditions. The FLT3 controller advances fuzzy logic control by incorporating an additional layer of uncertainty modelling, which enhances its ability to manage the inherent nonlinearities in PEMFC systems, such as temperature fluctuations and gas pressure variations. The controller is developed and validated through MATLAB/Simulink simulations, using a refined rule based on mechanism with finely tuned membership functions for precise adaptation to changing conditions. When compared to traditional Perturb and Observe (P&O) and Fuzzy Logic Type 2 (FLT2) controllers, the FLT3 controller demonstrates superior performance by achieving faster sitting times, minimizing power fluctuations, and maintaining operation closer to the nominal power point, particularly under transient conditions for hydrogen-based fuel cell. This innovative approach significantly improves the efficiency and stability of PEMFC systems, marking a substantial advancement in their operational management.

Enhancing CO tolerance in hydrogen oxidation reaction through synergy of surface-modified MoOx with PtRu alloy

Even trace amounts of CO impurities present in low-cost crude hydrogen can severely poison Pt-based catalysts. For proton exchange membrane fuel cells (PEMFCs), the development of hydrogen oxidation reaction (HOR) catalysts capable of enduring CO contamination is of significant economic importance. In this study, we propose a new strategy to synergistically enhance the CO tolerance of PtRu alloys by incorporating MoOx. The MoOx modified on PtRu/C catalysts can initiate the oxidation of CO adsorbed on its surface at potentials as low as 0.125 V. The synergy effect of MoOx and bifunctional PtRu ensures sufficient HOR stability even under hydrogen containing high CO concentrations. The resulting PtRu-MoOx/C catalyst exhibits a 4.6-fold increase in remained HOR current compared to commercial PtRu/C, after two hours in a hydrogen environment containing 10,000 ppm CO. Under typical testing condition of H2/1,000 ppm CO, PtRu-MoOx/C maintains over 80 % of the initial current density even after ten hours, significantly outperforming PtRu/C (30 %) and most previously reported catalysts.

Tracking the Early-life of PtNi/C Shape-Controlled Catalysts upon their Integration in PEMFC

Abstract The integration of promising bimetallic electrocatalytic active materials for oxygen reduction reaction (ORR) into practical and functional proton-exchange membrane fuel cell (PEMFC) electrodes remains largely impeded by the poor performances that these exhibit at high current loads. The early life of PtNi/C catalysts presenting either structurally faceted/ordered or defective/disordered surface morphology is compared to that of both spherical PtNi/C and Pt/C catalysts. Different single-cell operating conditions were studied. At low current density, in the kinetically limited region, a good agreement between liquid electrolyte and single-cell configuration is reported and the kinetic benefit of PtNi/C catalysts compared to Pt/C is (at least partially) maintained. However, PtNi/C catalysts show severe limitations in the O2 mass transport limited region. Morphological and compositional changes were monitored at each stage showing that Ni atoms are leached at every step from ink formulation to the first PEMFC test. We show that Ni is already redistributed in the membrane in the fresh membrane electrode assembly (MEA) state. Ni2+ cationic contamination of the ionomer/membrane contributes to the disappointing results obtained in MEA configuration. In addition, for shaped-controlled PtNi/C, the surface faceting loss combined with restructuring via coalescence and crystallite growth further compromise their transfer in technological devices.

Deep learning based segmentation of binder and fibers in gas diffusion layers

Gas diffusion layers (GDLs) are vital parts for the performance of proton-exchange membrane fuel cells (PEMFCs). In many cases, they are made of Carbon-Carbon Composite Paper (CCCP), which consists of carbon fibers and a carbonized binder material. The distribution of the fibers and binder in the GDL strongly influences the performance of a PEMFC. Synchrotron scans are a great way to obtain information about the microstructural composition of carbon paper GDLs (Figure 2), but there is one major obstacle. Binder and fibers tend to have the same attenuation and, consequently, the same gray values in the scans. To overcome this, we introduce a machine learning-based method that segments fibers and binder from the local morphology of a CCCP. The training data is generated using FiberGeo, a module in the GeoDict software for fibrous microstructure generation. FiberGeo creates fibers based on stochastic geometry and adds binder using morphological opening and closing operations. We applied the machine learning-based method to four Scans of samples of Toray Carbon Paper with varying amounts of binder in them. The result is the quantification of individual voxels as fiber or binder material that can be used, for example, in performance simulations of property simulations in PEMFCs [1–4]. Here, we focus on the differences in the spatial distribution of the binder both in the through-plane and in-plane directions.

Continuous Graded Catalyst Layers for PEM Fuel Cells with Improved Humidity Range Tolerance

Abstract Grading electrodes is a promising approach to reduce ohmic and mass transport-related voltage losses in proton exchange membrane fuel cells. In graded electrodes, the ionomer and/or catalyst are spatially non-uniformly distributed to optimize performance over a wide operating range. In this study, through-plane ionomer gradients were fabricated with a simple wet-layer deposition technique that can readily be adapted in a roll-to-roll process. The presence of ionomer gradients was verified using scanning transmission electron microscopy and the profiles were found to be continuous despite using only two coating steps. Single cell tests revealed that the gradients outperform conventional electrodes and maintain the optimal performance for different relative humidities. These improvements were traced back to enhanced mass transport and protonic conduction properties identified by detailed electrochemical analysis. This manufacturing approach for electrodes offers an accessible toolbox to produce versatile and specialized multi-layered catalyst layers for different applications.

Discovery and Analysis of Key Core Technology Topics in Proton Exchange Membrane Fuel Cells Through the BERTopic Model

As a core component of clean energy technology, proton exchange membrane fuel cells (PEMFC) play a crucial role in promoting the evolution of energy structures and realizing sustainable development, representing an environmentally friendly energy conversion strategy. This paper identifies the key core technology themes in the field of the proton exchange membrane fuel cells by constructing patent and paper datasets in the field, applying the BERTopic model for theme identification, and calculating the key core technology scores of each theme using the importance, innovativeness, and high competitiveness barriers to identify the key core technology themes in the field, so as to provide guidance and references for the relevant research and practice. The results of the study show that patent documents and academic papers show obvious differentiation in technical themes: the key core technologies identified in patent texts include ‘battery separator materials’, ‘rubber sealing materials’, and ‘porous carbon fibre materials’. The key core technologies identified in the academic paper of the thesis include ‘palladium-based electrocatalys’, ‘graphene oxide composite film’, and ‘platinum-graphene oxide catalyst’.

Water Status Detection Method Based on Water Balance Model for High-Power Fuel Cell Systems

With the gradually accelerating pace of global decarbonization, highly efficient and clean proton exchange membrane fuel cells (PEMFCs) are considered to be an energy solution for the future. During the operation of a fuel cell, it is necessary to keep the internal proton exchange membrane in a good state of hydration, so an appropriate method of detecting the hydration state is essential. At present, fuel cell systems are rapidly developing towards high power, but methods for detecting the hydration state of high-power fuel cell systems are still relatively lacking. Therefore, this paper studies the hydration state of high-power fuel cell systems and builds a condensation tail-gas water collection device for calculating the water flow out of a fuel cell system, deriving the hydration status inside the high-power fuel cell system. To verify the proposed water balance model, a series of experiments were conducted based on controlled variables such as working temperature, air metering ratio, and load current. Experiments were conducted on a 100 KW fuel cell system to collect water flow from the fuel cell system. Finally, based on the experimental data, the change rate of the internal water content of the fuel cell system under different conditions was calculated. The results show that, under the same load current, as the working temperature and air metering ratio increase, the change rate of the internal water content of the fuel cell system gradually decreases. Therefore, at low power, it is necessary to maintain an appropriate working temperature, while at high power, maintaining an appropriate air metering ratio is more important.

Small-Signal Electrical Model of PEM Fuel Cell

Small-Signal Electrical Model of PEM Fuel Cell

Performance Investigation of a Novel Staggered Round Table Channel for Proton Exchange Membrane Fuel Cells

Based on the internal mass transfer of a proton exchange membrane fuel cell (PEMFC), a novel staggered round table channel is proposed, namely, round table stoppers are arranged on both sides of the channel and in the direction of gas flow. The study systematically investigates the effects of various structural parameters on the PEMFC performance, including the arrangement of round tables on both sides of the channel, radius, degree of sparseness, and number. It is found that the staggered arrangement can improve the cell performance more significantly, and the current density can be increased by 5.0% compared with the direct channel. With the proper increase of the radius and number of round tables, the round table stopper forces the reactant to diffuse downward and improves the uniformity of reactant distribution. Compared with other sparsity, the equidistant arrangement of stoppers in the channel is conductive to accelerating the convective mass transfer and drainage characteristics of the cell. As shown by numerical analysis results, the performance and dewatering efficiency of PEMFC are the best when the round tables on both sides are staggered, the radius is 0.65 mm, the number is 10, and the round table in the channel is arranged equidistantly.

Performance prediction and enhancement strategy of a new proton exchange membrane fuel cell-hydrophilic modified tubular still hybrid system

The abundant low-grade waste heat generation in proton exchange membrane fuel cell (PEMFC) not only leads to energy wasting but also degrades the cell durability. Herein, an innovative hybrid system model that integrates PEMFC with a hydrophilic modified tubular still (HMTS) is developed, aiming to remove and harness the waste heat for extra freshwater production. Based on thermodynamic and electrochemical theories and considering major irreversible losses within the system, the model is formulated to obtain the performance metrics. Computational results demonstrate that the hybrid system outperforms the independent PEMFC, exhibiting a 13.26 % increase in maximum output power density, as well as significant improvements in energy efficiency (6.49 %) and exergy efficiency (23.36 %). Exhaustive parametric studies show that raising the fuel cell's operation temperature and operation pressure and the wind velocity, or reducing the thermodynamic losses positively enhances the overall output performance. Nevertheless, enlarging the proton exchange membrane thickness, tube shell diameter, or length of the tube shell worsens the output performance. Local sensitivity analyses identify that the thickness of proton exchange membrane is the most sensitive factor affecting the output performance. These results are helpful for optimally designing and running a high-efficient system.