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Title: On-Board Vehicle, Cost Effective Hydrogen Enhancement Technology for Transportation PEM Fuel Cells

Abstract

Final Report of On-Board Vehicle, Cost Effective Hydrogen Enhancement Technology for Transportation PEM Fuel Cells. The objective of this effort was to technologically enable a compact, fast start-up integrated Water Gas Shift-Pd membrane reactor for integration into an On Board Fuel Processing System (FPS) for an automotive 50 kWe PEM Fuel Cell (PEM FC). Our approach was to: (1) use physics based reactor and system level models to optimize the design through trade studies of the various system design and operating parameters; and (2) synthesize, characterize and assess the performance of advanced high flux, high selectivity, Pd alloy membranes on porous stainless steel tubes for mechanical strength and robustness. In parallel and not part of this program we were simultaneously developing air tolerant, high volumetric activity, thermally stable Water Gas Shift catalysts for the WGS/membrane reactor. We identified through our models the optimum WGS/membrane reactor configuration, and best Pd membrane/FPS and PEM FC integration scheme. Such a PEM FC power plant was shown through the models to offer 6% higher efficiency than a system without the integrated membrane reactor. The estimated FPS response time was < 1 minute to 50% power on start-up, 5 sec transient response time, 1140 W/Lmore » power density and 1100 W/kg specific power with an estimated production cost of $35/kW. Such an FPS system would have a Catalytic Partial Oxidation System (CPO) rather than the slower starting Auto-Thermal Reformer (ATR). We found that at optimum WGS reactor configuration that H{sub 2} recovery efficiencies of 95% could be achieved at 6 atm WGS pressure. However optimum overall fuel to net electrical efficiency ({approx}31%) is highest at lower fuel processor efficiency (67%) with 85% H{sub 2} recovery because less parasitic power is needed. The H{sub 2} permeance of {approx}45 m{sup 3}/m{sup 2}-hr-atm{sup 0.5} at 350 C was assumed in these simulations. In the laboratory we achieved a H{sub 2} permeance of 50 m{sup 3}/(m{sup 2}-hr-atm{sup 0.5}) with a H{sub 2}/N{sub 2} selectivity of 110 at 350 C with pure Pd. We also demonstrated that we could produce Pd-Ag membranes. Such alloy membranes are necessary because they aren't prone to the Pd-hydride {alpha}-{beta} phase transition that is known to cause membrane failure in cyclic operation. When funding was terminated we were on track to demonstrated Pd-Ag alloy deposition on a nano-porous ({approx}80 nm) oxide layer supported on porous stainless steel tubing using a process designed for scale-up.« less

Authors:
; ; ; ;
Publication Date:
Research Org.:
United Technologies Research Center
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
861890
DOE Contract Number:
FC36-02AL67628
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
08 HYDROGEN; 30 DIRECT ENERGY CONVERSION; 36 MATERIALS SCIENCE; ALLOYS; CATALYSTS; CONFIGURATION; DEPOSITION; EFFICIENCY; FUEL CELLS; HYDROGEN; MEMBRANES; OXIDATION; OXIDES; PHYSICS; POWER DENSITY; POWER PLANTS; STAINLESS STEELS; START-UP; TRANSIENTS; WATER GAS; Hydrogen, On-Board Vehicle, Enhancement, PEM Fuel Cells

Citation Formats

Thomas H. Vanderspurt, Zissis Dardas, Ying She, Mallika Gummalla, and Benoit Olsommer. On-Board Vehicle, Cost Effective Hydrogen Enhancement Technology for Transportation PEM Fuel Cells. United States: N. p., 2005. Web. doi:10.2172/861890.
Thomas H. Vanderspurt, Zissis Dardas, Ying She, Mallika Gummalla, & Benoit Olsommer. On-Board Vehicle, Cost Effective Hydrogen Enhancement Technology for Transportation PEM Fuel Cells. United States. doi:10.2172/861890.
Thomas H. Vanderspurt, Zissis Dardas, Ying She, Mallika Gummalla, and Benoit Olsommer. Fri . "On-Board Vehicle, Cost Effective Hydrogen Enhancement Technology for Transportation PEM Fuel Cells". United States. doi:10.2172/861890. https://www.osti.gov/servlets/purl/861890.
@article{osti_861890,
title = {On-Board Vehicle, Cost Effective Hydrogen Enhancement Technology for Transportation PEM Fuel Cells},
author = {Thomas H. Vanderspurt and Zissis Dardas and Ying She and Mallika Gummalla and Benoit Olsommer},
abstractNote = {Final Report of On-Board Vehicle, Cost Effective Hydrogen Enhancement Technology for Transportation PEM Fuel Cells. The objective of this effort was to technologically enable a compact, fast start-up integrated Water Gas Shift-Pd membrane reactor for integration into an On Board Fuel Processing System (FPS) for an automotive 50 kWe PEM Fuel Cell (PEM FC). Our approach was to: (1) use physics based reactor and system level models to optimize the design through trade studies of the various system design and operating parameters; and (2) synthesize, characterize and assess the performance of advanced high flux, high selectivity, Pd alloy membranes on porous stainless steel tubes for mechanical strength and robustness. In parallel and not part of this program we were simultaneously developing air tolerant, high volumetric activity, thermally stable Water Gas Shift catalysts for the WGS/membrane reactor. We identified through our models the optimum WGS/membrane reactor configuration, and best Pd membrane/FPS and PEM FC integration scheme. Such a PEM FC power plant was shown through the models to offer 6% higher efficiency than a system without the integrated membrane reactor. The estimated FPS response time was < 1 minute to 50% power on start-up, 5 sec transient response time, 1140 W/L power density and 1100 W/kg specific power with an estimated production cost of $35/kW. Such an FPS system would have a Catalytic Partial Oxidation System (CPO) rather than the slower starting Auto-Thermal Reformer (ATR). We found that at optimum WGS reactor configuration that H{sub 2} recovery efficiencies of 95% could be achieved at 6 atm WGS pressure. However optimum overall fuel to net electrical efficiency ({approx}31%) is highest at lower fuel processor efficiency (67%) with 85% H{sub 2} recovery because less parasitic power is needed. The H{sub 2} permeance of {approx}45 m{sup 3}/m{sup 2}-hr-atm{sup 0.5} at 350 C was assumed in these simulations. In the laboratory we achieved a H{sub 2} permeance of 50 m{sup 3}/(m{sup 2}-hr-atm{sup 0.5}) with a H{sub 2}/N{sub 2} selectivity of 110 at 350 C with pure Pd. We also demonstrated that we could produce Pd-Ag membranes. Such alloy membranes are necessary because they aren't prone to the Pd-hydride {alpha}-{beta} phase transition that is known to cause membrane failure in cyclic operation. When funding was terminated we were on track to demonstrated Pd-Ag alloy deposition on a nano-porous ({approx}80 nm) oxide layer supported on porous stainless steel tubing using a process designed for scale-up.},
doi = {10.2172/861890},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Fri Dec 30 00:00:00 EST 2005},
month = {Fri Dec 30 00:00:00 EST 2005}
}

Technical Report:

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  • PEMFC technology for transportation must be competitive with internal combustion engine powertrains in a number of key metrics, including performance, life, reliability, and cost. Demonstration of PEMFC cost competitiveness has its own challenges because the technology has not been applied to high volume automotive markets. The key stack materials including membranes, electrodes, bipolar plates, and gas diffusion layers have not been produced in automotive volumes to the exacting quality requirements that will be needed for high stack yields and to the evolving property specifications of high performance automotive stacks. Additionally, balance-of-plant components for air, water, and thermal management are beingmore » developed to meet the unique requirements of fuel cell systems. To address the question of whether fuel cells will be cost competitive in automotive markets, the DOE has funded this project to assess the high volume production cost of PEM fuel cell systems. In this report a historical perspective of our efforts in assessment of PEMFC cost for DOE is provided along with a more in-depth assessment of the cost of compressed hydrogen storage is provided. Additionally, the hydrogen storage costs were incorporated into a system cost update for 2004. Assessment of cost involves understanding not only material and production costs, but also critical performance metrics, i.e., stack power density and associated catalyst loadings that scale the system components. We will discuss the factors influencing the selection of the system specification (i.e., efficiency, reformate versus direct hydrogen, and power output) and how these have evolved over time. The reported costs reflect internal estimates and feedback from component developers and the car companies. Uncertainty in the cost projection was addressed through sensitivity analyses.« less
  • The results of sensitivity and Monte Carlo analyses on PEM fuel cell components and the overall system are presented including the most important cost factors and the effects of selected scenarios.
  • This report summarizes project activities for Strategic Analysis, Inc. (SA) Contract Number DE-EE0005236 to the U.S. Department of Energy titled “Transportation Fuel Cell System Cost Assessment”. The project defined and projected the mass production costs of direct hydrogen Proton Exchange Membrane fuel cell power systems for light-duty vehicles (automobiles) and 40-foot transit buses. In each year of the five-year contract, the fuel cell power system designs and cost projections were updated to reflect technology advances. System schematics, design assumptions, manufacturing assumptions, and cost results are presented.
  • Air Products and Chemicals, Inc. has teamed with Plug Power, Inc. of Latham, NY, and the City of Las Vegas, NV, to develop, design, procure, install and operate an on-site hydrogen generation system, an alternative vehicle refueling system, and a stationary hydrogen fuel cell power plant, located in Las Vegas. The facility will become the benchmark for validating new natural gas-based hydrogen systems, PEM fuel cell power generation systems, and numerous new technologies for the safe and reliable delivery of hydrogen as a fuel to vehicles. Most important, this facility will serve as a demonstration of hydrogen as a safemore » and clean energy alternative. Las Vegas provides an excellent real-world performance and durability testing environment.« less
  • This is the first Technical Progress Report for DOE Contract No. DE-AC02-94CE50389 awarded to Ford Motor Company on July 1, 1994. The overall objective of this contract is to advance the Proton-Exchange-Membrane (PEM) fuel cell technology for automotive applications. Specifically, the objectives resulting from this contract are to: (1) develop and demonstrate on a laboratory propulsion system within 2-1/2 years a fully functional PEM Fuel Cell Power System (including fuel cell peripherals, peak power augmentation and controls), this propulsion system will achieve, or will be shown to have the growth potential to achieve, the weights, volumes, and production costs whichmore » are competitive with those same attributes of equivalently performing internal combustion engine propulsion systems; (2) select and demonstrate a baseline onboard hydrogen storage method with acceptable weight, volume, cost, and safety features and analyze future alternatives; (3) analyze the hydrogen infrastructure components to ensure that hydrogen can be safely supplied to vehicles at geographically widespread convenient sites and at prices which are less than current gasoline prices per vehicle-mile; (4) identify any future R and D needs for a fully integrated vehicle and for achieving the system cost and performance goals.« less