High-temperature PEM Fuel Cells
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1 High-temperature PEM Fuel Cells Dr. Gerold Hübner
2 Volkswagen s Fuel- and Powertrain Strategy Renewable Electricity Hydrogen (regenerative) Electrotraction Fuel Cell From Natural Gas Cellulose-Ethanol SynFuel SunFuel Hybrid CCS From Oil Diesel Fuel Gasoline TDI/TSI Präsentation extern 2
3 4 /10 55 /9 5/ 11 4/ 2 8/ 1 Isenbüttel technology center (TZI) REGENR CKHALTEBECKEN Präsentation extern R = Feuerwehrumfahrt Erweiterung 55 / ERSCHLIESSUNGSSTRASSE 139 EP ERWEITERUNGSMÍGLICHKEIT HALLEN ANLI EFERUNG M LL TORANL AGE Feuerwehrumfahrt M LL hall Fahrrõder 20 EP hall 2 VORFAHRT TORANLAGE VEREINZELUNGSANLAGE = OK ATTIKA = (+7.44 = ³.NN ) II HALL EN IN PLANUNG hall 3 RANDSTR EIFEN KLETTERPF LANZEN, 50cm office ERWEITERUNGSMÍGLICHKEIT B ROGEB UDE BAUTEIL A - B ROGEB UDE BAUGRENZE Flaeche ca qm R = Site size Hall area Office area ca. ca. ca m² m² m²
4 H 2 -Infrastructure Demonstration Project - Solar Filling Station Isenbüttel 7 kw Photovoltaic Plant Solar- Power Electrolyser Pressure Vessel Präsentation extern 4
5 Fuel Cell Propulsion 1 st Generation Example: System Survey of VW Touran HyMotion NiMH- Battery Fuel Cell Hydrogen Tank Electric Engine Präsentation extern 5
6 Fuel Cell Vehicles 1 st Generation International Exhibition 85 kw Fuel Cell System High Power NiMH-Battery 80 kw Electric Engine 2.6 kg Hydrogen (350 bar) Inauguration Sacramento (2000) CaFCP Road Rallye 3 (2004) Challenge Bibendum (2004) CaFCP Road Rallye 4 (2005) Accession CEP (2006) Präsentation extern 6
7 Fuel Cell 1 st Generation vs. Combustion Engine Cooler Performance Highway (Simulation) Heat- Losses Exhaust 6 % 36 % Cooling 49 % Fuel FuelCell 20 % Combustion Engine Präsentation extern 7
8 Energy Balance for Fuel Cell Automobile 1 st Generation Example: VW Touran HyMotion (Simulation/Measurement) Tranferable Heat Flow [kw] Basis: Touran (Serial Car Body, 1700 kg, cw*a = 0.787) FC-Operation Temperature: 80 C (LT- Membrane) T env = 40 C Transferable Heat Flow Transferred Heat Flow Top Speed 49 km/h 6% Gradient No Gradient Top Speed 136 km/h PEM- BZ 80 C Speed [km/h] Präsentation extern 8
9 Characteristic of state of the art proton exchange membranes Humidification demand water demand [kg/h] water neutral water demand product water operation temperature [ C] Temperature dependent Humidification demand Impacts on fuel cell system: Additional control demand system complexity Lack of system reliability objective: Humidification free MEA Präsentation extern 9
10 Characteristic of state of the art proton exchange membranes Humidification demand performance drop at stop of humidification 1,4 100 Performance drop at stop of humidification p e r o r m a n c e d e n s it y [ W /c m ²] 1,2 1,0 0,8 0,6 0, h u m i d i fi c a ti o n in % complete break-in of performance irreversible damage of MEA mechanical shrinking of membrane: - Dissolution of electrode 0,2 - mechanical cracking at interface 0,0 0 24,7 25,2 25,7 26,2 26,7 operation time Präsentation extern10
11 Characteristic of state of the art proton exchange membranes Fuel Cells for Automobile Propulsion 180 C PAFC (Phosphoric Acid Fuel Cell) Application in Automobile C 60 C PEM-FC (Proton Exchange Membrane Fuel Cell) AFC (Alkaline Fuel Cell) Präsentation extern11
12 Innovative approaches for proton exchange membranes Fuel Cells for Automobile Propulsion 160 C PBI/H 3 PO 4 Dry gases membrane- / elektrode modification Innovative concepts Intrinsic proton conductivity Immobilised proton solvents, Immidazole Automotive MEA Dry operation Up to 130 C 80 C Modified spfsa Humidified Gases Increase of Tg, water reservoir, increase of IEC Production readiness Präsentation extern12
13 Innovative approaches for proton exchange membranes the Volkswagen High Temperature MEA State of the art: water based proton conductivity: water acting as electrolyte High Temperature Membrane: dry proton conductivity: High boiling electrolyte * F 2 C F 2 C x F 2 C C H F O C F 2 y H N H HO - O P O OH * F 2 C F 2 C x F 2 C C H F O C F 2 F C C F 3 O C F 2 C F 2 y S O 3 H H O H F C C F 3 H O H O C F 2 C F 2 S O 3 H O H H O H O H H PerFluoroSulfonate Ionomer Nafion (DuPont) PBI (Polybenzimidazol)/H 3 PO 4 HO O H + P O - H N OH O HO P OH H OH N O HO N P OH OH O HO P OH OH US DE US Präsentation extern13
14 Innovative approaches for proton exchange membranes the Volkswagen High Temperature MEA Application in Automobile C 160 C 80 C 60 C PAFC (Phosphoric Acid Fuel Cell) HT-PEM-FC (High Temperature Proton Exchange Membrane Fuel Cell) LT-PEM-FC (Low Temperature Proton Exchange Membrane Fuel Cell) AFC (Alkaline Fuel Cell) Präsentation extern14
15 Volkswagen fuel cell test and research Component validation Exclusive development project VW HT MEA Wordwide initiation and screening Funded projects on international level Component tests at automotive conditions VW HT electrode development Optimum adaption to: - membrane material - operation conditions - performance goals Siebdruckverfahren Präsentation extern15
16 Volkswagen fuel cell test and research Fuel cell test field Fullfilling power demands from 10 cm² single cell to 100 kw automotive stack tests + cold start tests Gen 1 Gen 2 Fuel cell stack development Identification of appropriate materials Simulation Gen 3 manufacturing Siebdruckverfahren Präsentation extern16
17 Breakthrough of the Volkswagen High Temperature MEA Temperature Cycleability 0,6 0,5 160 C performance [W/cm²] 0,4 0,3 0,2 0,1 40 C time [h] Weltneuheit aus Isenbüttel Präsentation extern17
18 Breakthrough of the Volkswagen High Temperature MEA Temperature Cycleability 0,8 performance density at 0,6 V [W/cm²] 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0,0 Standard HT-Membran (H 3 PO 4 -Membrane PBI MEA) tim e [h] Volkswagen HT-MEA Accelerated temperature cycle V: 160 C V: 40 C Degradation 6 % in 1000 h Präsentation extern18
19 Breakthrough of the Volkswagen High Temperature MEA Performance: 0,6 V; 3 bar Performance at 0,6 V [W/cm 2 ] 1,2 Commercial LT-Membrane 1,1 Single cell 10 cm² C 0,9 0,8 0,7 0,6 0,5 0,4 Commercial HT-Membrane Performance density [W/cm²] (0,6 V) 0,3 NT HT 0,2 Zelle Stack Zelle Stack 0,1 0 1,15 0,9 0,9 0, Präsentation extern19
20 Breakthrough of the Volkswagen High Temperature MEA Performance: 0,6 V; 3 bar; 40 C Leistungsdichte bei 0,6 V in W/cm 2 0,30 0,25 0,20 0,15 0,10 0,05 0 commercial LT-Membrane 40 C Single cell 10 cm² commercial HT-Membrane Präsentation extern20
21 HT Fuel Cell Stack Performance HT-stack 15 cell, 200 cm² 1,2 0,7 Voltage per cell [V] 1,0 0,8 0,6 0,4 0,2 Voltage/current Performance current 0,6 0,5 0,4 0,3 0,2 0,1 power density [W/cm²] 0,0 0,0 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 Current density [A/cm²] Präsentation extern21
22 Volkswagen High Temperature MEA cathode contamination, initial findings SO 2 CO ppm 1ppm 10ppm ppm 100 ppm 1000 ppm 30 current [A] ppm 1ppm current [A] ppm Strom NT (80 C) Strom HT (160 C) 10ppm 20 Strom HT (160 C) Strom NT (80 C) Zeit [min] Zeit [min] Präsentation extern22
23 Further optimization of VW High Temperature MEA electrode manufacturing process - Evaluation of different manufacturing processes - Up scaling to large cell areas - Paste composition - new catalyst compositions (e.g. alloys) - reduction of catalyst loading Präsentation extern23
24 Molecular Modeling of High Temperature MEA/membrane prediction of polymer and electrolyte properties - Glass transition temperature - mechanical properties - swelling behaviour - prediction of new polymer/electrolyte properties - prediction of polymer electrolyte interaction Präsentation extern24
25 Molecular Modeling of High Temperature MEA/membrane swelling behavior of membrane in acid Increasing acid content in membrane Präsentation extern25
26 Technology evaluation Target Area of Ability for Mass Market Performance Costs/Mass/Volume/Reliability LT-BZ HT-BZ (VW) LT = Low Temperature Fuel Cell (Based on Nafion) HT = High Temperature Fuel Cell (Technology of VW) Year Präsentation extern26
27 Next steps Still existing technological challenges of the existing high temperature MEA technology: Low temperature and cold start ability Scale Up (mechanical stability at high acid loading) Cathode losses Electrode/membrane contact Temperature stability of stack materials Präsentation extern27
28 Thank You! Präsentation extern28
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