Development of a 1 W passive DMFC

In this paper, development techniques for a passive DMFC prototype in the 1 W range are described in detail. The prototype includes a fuel cell stack, a fuel tank and a passive ancillary system (termed “thermal-fluids management system” in this paper). The fuel cell stack in this study incorporates a window-frame structure that provides a large open area for more efficient mass transfer and is modular. Two stack units connected in series, with a total combined active area of 72.0 cm², are used in the prototype. The thermal-fluids management system utilizes passive approaches for fuel storage and delivery, air-breathing, water management, CO₂ release, and thermal management. The air filter also serves as a waterproof layer for the cathode in order to prevent water contamination. Water immersion tests are conducted to evaluate the air filter. The performance evaluation of the prototype is performed in two fuel feeding modes: dilute methanol solution and pure methanol. A peak power output of 1.5 W is achieved with the dilute methanol solution feed.     

Simulation of a hybrid vehicle powertrain having direct methanol fuel cell system through a semi-theoretical approach

Different operating scenarios can be used in a hybrid system based on a direct methanol fuel cell (DMFC) and a battery. In this paper, a DMFC system model is integrated into a model formed for a hybrid vehicular system that consists of a battery, a DMFC stack and its auxiliary equipments; and the model is simulated in Matlab/Simulink environment using a quasistatic approach. An algorithm for the energy management of the system is also developed considering the state of charge (SOC) of the battery. In the DMFC system model, the current and empirical data for the polarization curves as well as methanol crossover and water crossover rates are taken as the input parameters, whereas the stack voltage, the remaining methanol in the fuel tank, and the power demand of auxiliary equipments are taken as the output parameters. In this model, the methanol consumption, and the water and CO₂ production are found applying mass balances for each component of the system. The results of the simulations help to give more insights into the operation of a DMFC based hybrid system.     

Power management of a direct methanol fuel cell system

The effect of discharge rate of direct methanol fuel cell (DMFC) on fuel efficiency was comparatively investigated using a DMFC single cell and a DMFC system. The results obtained from the single cell were used to model the DMFC system. Several semi-empirical equations were derived that relate discharge current, voltage, power output, energy density and fuel consumption for a nominal 25 W DMFC system. The decrease in fuel efficiency with decreased power output that is observed for the DMFC system is attributable to the increase of methanol crossover that can be observed for an individual cell. A DMFC system can achieve maximum energy density and fuel efficiency at an appropriately high level of power output.     

Lightweight current collector based on printed-circuit-board technology and its structural effects on the passive air-breathing direct methanol fuel cell

To realize lightweight design of the fuel cell system is a critical issue before it is put into practical use. The printed-circuit-board (PCB) technology can be potentially used for production of current collectors or flow distributors. This study develops prototypes of a single passive air-breathing direct methanol fuel cell (DMFC) and also an 8-cell mono-polar DMFC stack based on PCB current collectors. The effects of diverse structural and operational factors on the cell performance are explored. Results show that the methanol concentration of 6 M promotes a higher cell performance with a peak power density of 18.3 mW cm⁻². The combination of current collectors using a relatively higher anode open ratio and inversely a lower cathode open ratio helps enhance the cell performance. Dynamic tests are also conducted to reveal transient behaviors and its dependence on the operating conditions. To validate the real working status of the DMFC stack, it is coupled with an LED lightening system. The performance of this hybrid system is also reported in this study.     

Performance tests of a double-passive μDMFC stack with parallel/dendrite flow field

We report an experimental study on the effect of different flow fields on the cell performance of a double-passive (both anode/cathode) μDMFC stack. Cell performance measurements were made and analyzed for seven different flow field combinations at the anode/cathode of a passive micro direct methanol fuel cell (μDMFC) stack. An optimum flow field combination, after taking a series of tests under different operating conditions, was obtained. The results show that the conventional parallel type flow field used at the anode with an innovative/new dendrite perforated type of 80° flow field can provide the best power density for both single cell and 8-cell stack which have a power density of 16.9 mA/cm² at 50 °C and 1 M methanol solution. Moreover, for an 8-cell stack, both the gravimetric and volumetric power densities can be up to 7.4 W/kg and 37.2 W/L, respectively.     

Operational characteristics of the direct methanol fuel cell stack on fuel and energy efficiency with performance and stability

This paper is presented to investigate operational characteristics of a direct methanol fuel cell (DMFC) stack with regard to fuel and energy efficiency, including its performance and stability under various operating conditions. Fuel efficiency of the DMFC stack is strongly dependent on fuel concentration, working temperature, current density, and anode channel configuration in the bipolar plates and noticeably increases due to the reduced methanol crossover through the membrane, as the current density increases and the methanol concentration, anode channel depth, and temperature decreases. It is, however, revealed that the energy efficiency of the DMFC stack is not always improved with increased fuel efficiency, since the reduced methanol crossover does not always indicate an increase in the power of the DMFC stack. Further, a lower methanol concentration and temperature sacrifice the power and operational stability of the stack with the large difference of cell voltages, even though the stack shows more than 90% of fuel efficiency in this operating condition. The energy efficiency is therefore a more important characteristic to find optimal operating conditions in the DMFC stack than fuel efficiency based on the methanol utilization and crossover, since it considers both fuel efficiency and cell electrical power. These efforts may contribute to commercialization of the highly efficient DMFC system, through reduction of the loss of energy and fuel.     

A DMFC stack operating with hydrocarbon blend membranes and Pt–Ru–Sn–Ce/C and Pd–Co/C electrocatalysts

Direct methanol fuel cell (DMFC) stacks consisting of 5 cells and 20 cells were assembled with low-cost hydrocarbon blend membranes and new electrocatalysts with better methanol tolerance and stability. The hydrocarbon blend membranes consisting of an acidic polymer (sulfonated poly (ether ether ketone), SPEEK) and a basic polymer (polysulfone-2-amide-benzimidazole, PSf-ABIm) exhibited low methanol crossover, high conductivity, and good mechanical stability. The Pt–Ru–Sn–Ce/C anode catalyst exhibited better stability than the commercial PtRu/C catalyst, while the cathode catalyst Pd–Co/C showed better methanol tolerance than the commercial Pt/C catalyst. A maximum power of around 20 W was achieved with a DMFC stack consisting of 20 membrane-electrode assemblies (MEAs) fabricated with the above membranes and electrocatalysts. The results demonstrate the feasibility of utilizing these acid-base blend membranes and novel catalysts for DMFC applications.     

Performance evaluation of direct methanol fuel cells for portable applications

This study examines the feasibility of powering a range of portable devices with a direct methanol fuel cell (DMFC). The analysis includes a comparison between a Li-ion battery and DMFC to supply the power for a laptop, camcorder and a cell phone. A parametric study of the systems for an operational period of 4 years is performed. Under the assumptions made for both the Li-ion battery and DMFC system, the battery cost is lower than the DMFC during the first year of operation. However, by the end of 4 years of operational time, the DMFC system would cost less. The weight and cost comparisons show that the fuel cell system occupies less space than the battery to store a higher amount of energy. The weight of both systems is almost identical. Finally, the CO₂ emissions can be decreased by a higher exergetic efficiency of the DMFC, which leads to improved sustainability.     

Li-ion batteries and portable power source prospects for the next 5–10 years

This paper describes the possible evolution of Li-ion technology, and evaluates the expected improvements, arising from new materials to cell technology. New active materials under investigation and electrode process improvements may allow an ultimate final energy density of more than 500 Wh/l and 200 Wh/kg, in the next 5–10 years, while maintaining sufficient power densities. A new rechargeable battery technology cannot be foreseen today that surpasses this. The possible use of small fuel cells is also discussed. The only solution would be direct methanol fuel cell (DMFC) technology, providing that the remaining important technological issues are solved. The association with a rechargeable battery could provide an optimised energy + power, hybrid power source. Several simulated comparisons for small- to medium-sized power sources are described, between fuel cells and batteries. Hybrid Li-ion/DMFC is a good option for systems larger than 1 kWh. The hybrid concept of high-energy–low-power primary lithium (as the fuel) with high-power Li-ion (as the cell stack) is an already available, cost effective solution where long run times are required.     

Development and characteristics of a 400 W-class direct methanol fuel cell stack

In this study, a 400 W-class direct methanol fuel cell (DMFC) stack is developed for large size portable applications and its operating behaviors under the various conditions are monitored. The DMFC stack comprising of 42-cells is assembled with graphite bipolar plates and membrane–electrode assemblies (MEAs) having an active area of 138 cm² per each. The stack is operated by varying the concentrations of methanol, stoichiometry (λ), and the electric load. In addition, other associated factors, such as voltage and temperature distributions along the individual unit cells, pressure drops inside the stack, voltage behaviors in response to the dynamic change of the electric load and the pHs of the effluent solutions from the outlets of both electrodes, are also studied in a detailed manner. The stack produces a power of 400 W under an operating condition of feeding 0.8 M methanol and 34 l/min air at 1 atm, and uniform distributions of temperature and voltage prevail in all the 42 unit cells. A long-term operation coupled with performance restoration processes shows that a typical single cell used in this stack is able to run with a good stability for more than 500 h without any substantial degradation in the performance.     

A small mono-polar direct methanol fuel cell stack with passive operation

A passive direct methanol fuel cell (DMFC) stack that consists of six unit cells was designed, fabricated, and tested. The stack was tested with different methanol concentrations under ambient conditions. It was found that the stack performance increased when the methanol concentration inside the fuel tank was increased from 2.0 to 6.0 M. The improved performance is primarily due to the increased cell temperature as a result of the exothermic reaction between the permeated methanol and oxygen on the cathode. Moreover, the increased cell temperature enhanced the water evaporation rate on the air-breathing cathode, which significantly reduced water flooding on the cathode and further improved the stack performance. This passive DMFC stack, providing 350 mW at 1.8 V, was successfully applied to power a seagull display kit. The seagull display kit can continuously run for about 4 h on a single charge of 25 cm³ 4.0-M methanol solution.     

Vapor feed direct methanol fuel cells with passive thermal-fluids management system

The present paper describes a novel technology that can be used to manage methanol and water in miniature direct methanol fuel cells (DMFCs) without the need for a complex micro-fluidics subsystem. At the core of this new technology is a unique passive fuel delivery system that allows for fuel delivery at an adjustable rate from a reservoir to the anode. Furthermore, the fuel cell is designed for both passive water management and effective carbon dioxide removal. The innovative thermal management mechanism is the key for effective operation of the fuel cell system. The vapor feed DMFC reached a power density of 16.5 mW cm⁻² at current density of 60 mA cm⁻². A series of fuel cell prototypes in the 0.5 W range have been successfully developed. The prototypes have demonstrated long-term stable operation, easy fuel delivery control and are scalable to larger power systems. A two-cell stack has successfully operated for 6 months with negligible degradation.     

Operation of a direct methanol fuel cell stack by self-heating at low temperatures

The operation characteristics of a direct methanol fuel cell (DMFC) are investigated at low temperatures of −5 °C and −10 °C by using a laboratory-made 10-cell stack. The stack is operated only by heat generation of internal exothermic reactions without any heating device and additional insulation means, to examine behaviors of the stack performance at low temperatures. The self-heating stack is successfully operated in a stable manner at −10 °C by control of the operation modes. An appropriate operation strategy using the fuel switching as well as selection of the operation modes is proposed, and possibility and limitation for operation of DMFC stacks by self-heating under cold conditions are discussed, based on the results.     

Heat and power management of a direct-methanol-fuel-cell (DMFC) system

In this paper, we describe the heat and the power management of a direct methanol fuel cell system. The system consists mainly of a direct methanol fuel cell stack, an anode feed loop with a heat exchanger and on the cathode side, a compressor/expander unit. The model calculations are carried out by analytical solutions for both mass and energy flows. The study is based on measurements on laboratory scale single cells to obtain data concerning mass and voltage efficiencies and temperature dependence of the cell power. In particular, we investigated the influence of water vaporization in the cathode on the heat management of a direct-methanol-fuel-cell (DMFC) system. Input parameters were the stack temperature, the cathode pressure and the air flow rate. It is shown that especially at operating temperatures above 90 °C, the combinations of pressure and air flow rate are limited because of heat losses due to vaporization of water in the cathode.     

Portable DMFC system with methanol sensor-less control

This work develops a prototype 20 W portable DMFC by system integration of stack, condenser, methanol sensor-less control and start-up characteristics. The effects of these key components and control schemes on the performance are also discussed. To expedite the use of portable DMFC in electronic applications, the system utilizes a novel methanol sensor-less control method, providing improved fuel efficiency, durability, miniaturization and cost reduction. The operating characteristics of the DMFC stack are applied to control the fuel ejection time and period, enabling the system to continue operating even when the MEAs of the stack are deteriorated. The portable system is also designed with several features including water balance and quick start-up (in 5 min). Notably, the proposed system using methanol sensor-less control with injection of pure methanol can power the DVD player and notebook PC. The system specific energy and energy density following three days of operation are 362 Wh kg⁻¹ and 335 Wh L⁻¹, respectively, which are better than those of lithium batteries (∼150 Wh kg⁻¹ and ∼250 Wh L⁻). This good energy storage feature demonstrates that the portable DMFC is likely to be valuable in computer, communication and consumer electronic (3C) markets.     

Operational characteristics of a 50 W DMFC stack

The characteristics of a 50 W direct methanol fuel cell (DMFC) stack were investigated under various operating conditions in order to understand the behavior of the stack. The operating variables included the methanol concentration, the flow rate and the flow direction of the reactants (methanol and air) in the stack. The temperature of the stack was autonomously increased in proportion to the magnitude of the electric load, but it decreased with an increase in the flow rates of the reactants. Although the operation of the stack was initiated at room temperature, under a certain condition the internal temperature of the stack was higher than 80 °C. A uniform distribution of the reactants to all the cells was a key factor in determining the performance of the stack. With the supply of 2 M methanol, a maximum power of the stack was found to be 54 W (85 mW cm⁻²) in air and 98 W (154 mW cm⁻²) in oxygen. Further, the system with counter-flow reactants produced a power output that was 20% higher than that of co-flow system. A post-load behavior of the stack was also studied by varying the electric load at various operating conditions.     

Development of an air-breathing direct methanol fuel cell with the cathode shutter current collectors

An air-breathing direct methanol fuel cell with a novel cathode shutter current collector is fabricated to develop the power sources for consumer electronic devices. Compared with the conventional circular cathode current collector, the shutter one improves the oxygen consumption and mass transport. The anode and cathode current collectors are made of stainless steel using thermal stamping die process. Moreover, an encapsulation method using the tailor-made clamps is designed to assemble the current collectors and MEA for distributing the stress of the edges and inside uniformly. It is observed that the maximum power density of the air-breathing DMFC operating with 1 M methanol solution achieves 19.7 mW/cm² at room temperature. Based on the individual DMFCs, the air-breathing stack consisting of 36 DMFC units is achieved and applied to power a notebook computer.     

空气抽吸式甲醇燃料电池传热与传质特性

空气抽吸式直接甲醇燃料电池不仅具有被动式燃料电池的优点,同时又便于将其串联成电堆提高输出电压。建立以阴极为管道抽吸式结构的直接甲醇燃料电池的三维、两相、非等温稳态数值模型,研究了质子交换膜性能、供给甲醇浓度以及电堆规模对电池性能及燃料利用率的影响。对于保温较好的大电堆,采用低甲醇穿透的改性质子交换膜能同时提升燃料利用率和比功率;此类电堆若采用穿透率低的改性膜,则2 mol/L的甲醇浓度就能保证电池在较大的电流密度区间内维持较高的功率与效率。作为影响电池运行温度的重要因素,电堆规模的大小将直接影响质子交换膜种类与甲醇浓度等关键参数的设计与选择。     

System integration of a portable direct methanol fuel cell and a battery hybrid

This paper introduces a complete system-level design and integration of a portable direct methanol fuel cell (DMFC) system. We describe hardware and software design for the balance of plant (BOP) control, including a 32-bit microprocessor and electronics for actuators and sensors, focusing on reliable operation and protection of the DMFC system. Various BOP components are characterized to find the optimal design for better portability, reliability, and energy efficiency, and we suggest effective and robust design of control loops for them. We demonstrate a hybrid operation of the DMFC stack and Li-ion battery to maintain a constant stack output current regardless of the load current to maximize the performance. We emphasize the design of subsystems for power supply, measurement, actuator drive, and protection in detail. We verify the robust operation of BOP control against environmental changes such as orientation and pressure variations with an implemented control board.