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.     

A feasibility study on direct methanol fuel cells for laptop computers based on a cost comparison with lithium-ion batteries

This paper compares the total cost of direct methanol fuel cell (DMFC) and lithium (Li)-ion battery systems when applied as the power supply for laptop computers in the Korean environment. The average power output and operational time of the laptop computers were assumed to be 20 W and 3000 h, respectively.     

Progress in poly(phenylene oxide) based cation exchange membranes for fuel cells and redox flow batteries applications

In fuel cell technologies, low-temperature proton exchange membrane fuel cells (LT-PEMFC), high-temperature proton exchange membrane fuel cells (HT- PEMFC), and direct methanol fuel cells (DMFC) are gained significant attention as a promising energy system for practical applications. The developments of cost-effective membrane materials with excellent physicochemical properties are indispensable for replacing the high cost of commercial membranes and achieving the higher performance of fuel cell systems. This review focuses on the developments and modifications of cost-effective poly(2,6-dimethyl-1,4-phenylene oxide) (PPO) as a cation exchange membrane for LT-PEMFC, HT- PEMFC and DMFC. Notably, this review bridges the understanding of PPO based membranes, current advancements, structure, physicochemical properties and fuel cell performances. Progressive developments and a systematic overview of PPO-based membrane developments are explained in detail in terms of functionalization, blend, composite, acid-base, cross-linking, copolymerization, coated and reinforcement. Moreover, the changes in physicochemical properties and fuel cell performances in the membrane are deeply reviewed. Additionally, the utilization of PPO based membranes in different kinds of redox flow battery systems are reviewed. Overall, this review provides an exclusive vision and perspectives to develop the PPO based advanced, cost-effective, and high-performance membranes for fuel cell technologies and redox flow battery systems.     

Performance improvement in direct methanol fuel cells using a highly porous corrosion-resisting stainless steel flow field

Power generation with direct methanol fuel cell (DMFC) systems requires only simple equipment, and has the important advantage of using a liquid fuel with higher energy density and easier handling characteristics than hydrogen. However, the power output of DMFC is lower than hydrogen fuel cells. To improve the power output of DMFC it is very important to reduce diffusion polarization at higher current density conditions. This research used a corrosion-resisting type porous stainless steel developed based on the technology for metal–hydride battery electrodes in the separator flow fields for reactants and products in a single cell DMFC and analyzed its influence on performance characteristics.     

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.     

Fast start-up of a diesel fuel processor for PEM fuel cells

Fuel cell systems based on liquid fuels are particularly suitable for auxiliary power generation due to the high energy density of the fuel and its easy storage. Together with industrial partners, Oel-Waerme-Institut is developing a 3 kW_el PEM fuel cell system based on diesel steam reforming to be applied as an APU for caravans and yachts. The start-up time of a fuel cell APU is of crucial importance since a buffer battery has to supply electric power until the system is ready to take over. Therefore, the start-up time directly affects the battery capacity and consequently the system size, weight, and cost.     

Development,analysis and assessment of fuel cell and photovoltaic powered vehicles

This paper deals with a new hybridly powered photovoltaic- PEM fuel cell – Li-ion battery and ammonia electrolyte cell integrated system (system 2) for vehicle application and is compared to another system (system 1) that is consisting of a PEM fuel cell, photovoltaic and Li-ion battery. The paper aims to investigate the effect of adding photovoltaic to both systems and the amount of hydrogen consumption/production that could be saved/generated if it is implemented in both systems. These two systems are analyzed and assessed both energetically and exergetically. Utilizing photovoltaic arrays in system 1 is able to recover 177.78 g of hydrogen through 1 h of continuous driving at vehicle output power of 98.32 kW, which is approximately 3.55% of the hydrogen storage tank used in the proposed systems. While, using the same photovoltaics arrays, system 2 succeeds to produce 313.86 g of hydrogen utilizing the ammonia electrolyzer system 2 appeared to be more promising as it works even if the car is not in operation mode. Moreover, the hydrogen produced from the ammonia electrolyzer can be stored onboard, and the liquefied ammonia can be used as a potential source for feeding PEM fuel cell with hydrogen. Furthermore, the effects of changing various system parameters on energy and exergy efficiencies of the overall system are investigated.     

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.     

Environmental and economic analyses of fuel cell and battery-based hybrid systems utilized as auxiliary power units on a chemical tanker vessel

This study aims to investigate the environmental and economic impacts of implementing fuel cell and battery-based hybrid configurations. Phosphoric acid and molten carbonate fuel cell systems in the place of diesel generators of a large tanker to supply the vessel's total electricity demand. Environmental and economic analyses of the utilization of the specified fuel cell systems with LiNiCoALO₂ and LiNiMnCoO₂ chemical types of battery cells on a large marine vessel are provided in this paper. In addition, the assessment of the most suitable battery cell and charge-discharge hours for fuel cell systems is carried out with a grid-search algorithm. Six different fuel cell and battery configurations are investigated to obtain the optimum system layout. The results show that the CO₂ emissions could be reduced by up to 49.75% and the lowest electricity production cost is found as 0.181 $/kWh for the current fuel prices with the utilization of molten carbonate fuel cells and LiNiMnCoO₂ battery cells.     

Directly connected series coupled HTPEM fuel cell stacks to a Li-ion battery DC bus for a fuel cell electrical vehicle

The work presented in this paper examines the use of pure hydrogen fuelled high temperature polymer electrolyte membrane (HTPEM) fuel cell stacks in an electrical car, charging a Li-ion battery pack. The car is equipped with two branches of two series coupled 1 kW fuel cell stacks which are connected directly parallel to the battery pack during operation. This enables efficient charging of the batteries for increased driving range. With no power electronics used, the fuel cell stacks follow the battery pack voltage, and charge the batteries passively. This saves the electrical and economical losses related to these components and their added system complexity. The new car battery pack consists of 23 Li-ion battery cells and the charging and discharging are monitored by a battery management system (BMS) which ensures safe operating conditions for the batteries. The direct connection of the fuel cell stacks to the batteries can only be made if the stacks are carefully dimensioned to the battery voltage. The experimental results of stationary fuel cell charging are presented, showing stable and efficient operation.     

Comparison of hydrogen storage with diesel-generator system in a PV–WEC hybrid system

Hydrogen as a storage medium in renewable energy systems has been the subject of various studies in recent years. Such a system consists of a long-term and a short-term storage system. In a battery, energy is stored for short term whereas the electrolyser, H₂-tank and fuel cell combination is used for long-term energy storage to increase the reliability of supply. The same purpose can be achieved by introducing a diesel generator instead of long-term storage. The advantage of such a system is that it needs low investment cost. However, the main disadvantage is that it needs to supply fuel for the operation of the generator. The advantage of hydrogen-based long-term storage over a diesel generator is that it does not need any supply of fuel. In photovoltaic–wind–diesel hybrid systems, the surplus energy during the good season is not stored.In the present study, the possible sites for renewable applications are specified depending on the seasonal renewable energy variation and fuel cost at the site of application. The critical fuel cost is calculated depending on the seasonal solar and wind energy difference. The actual fuel cost at the site of application is compared with critical fuel cost. To find out the actual fuel cost at the location of application, the transportation cost is also included. If the actual fuel cost is higher than the critical fuel cost, the location is cost-effective for hydrogen-based storage. Otherwise, the site is suitable for a diesel-generator backup system. It is found that at present hydrogen storage is not cost-effective compare to a diesel-generator-based system. In the near future when the target cost of the electrolyser and the fuel cell is achieved, the scope of the hydrogen-based storage system will also increase and it will also be cost competitive with diesel-generator system for remote applications.     

A Compact Electrical Model for Microscale Fuel Cells Capable of Predicting Runtime and $I$–$V$ Polarization Performance

The growing popularity and success of fuel cells (FCs) in aerospace, stationary power, and transportation applications is driving and challenging researchers to complement and in some cases altogether replace the batteries of portable systems in the hopes of increasing functional density, extending runtime, and decreasing size. Direct-methanol fuel cell (DMFC) batteries have now been built and conformed to low-cost technologies and chip-scale dimensions. Conventional FC models, however, fail to accurately capture the electrical nuances and runtime expectancies of these microscale devices, yet predicting that these electrical characteristics are even more critical when designing portable low-power electronics. A Cadence-compatible model of a DMFC battery is therefore developed to capture all pertinent dynamic and steady-state electrical performance parameters, including capacity and its dependence to current and temperature, open-circuit voltage, methanol-crossover current, polarization curve and its dependence to concentration, internal resistance, and time-dependent response under various loading conditions—the model can also be extended to other micro- and macroscale FC technologies. The simulation results of the proposed electrical model are validated and compared against the experimental performance of several DMFC prototypes, resulting in a runtime error of less than 10.8% and a voltage error under various current loads of less than 80 mV for up to 95% of its operational life. The root cause of the remaining errors and relevant temperature effects in the proposed model are also discussed.      

A direct methanol fuel cell system to power a humanoid robot

In this study, a direct methanol fuel cell (DMFC) system, which is the first of its kind, has been developed to power a humanoid robot. The DMFC system consists of a stack, a balance of plant (BOP), a power management unit (PMU), and a back-up battery. The stack has 42 unit cells and is able to produce about 400 W at 19.3 V. The robot is 125 cm tall, weighs 56 kg, and consumes 210 W during normal operation. The robot is integrated with the DMFC system that powers the robot in a stable manner for more than 2 h. The power consumption by the robot during various motions is studied, and load sharing between the fuel cell and the back-up battery is also observed. The loss of methanol feed due to crossover and evaporation amounts to 32.0% and the efficiency of the DMFC system in terms of net electric power is 22.0%.     

Performance and cost of fuel cells for urban air mobility

Several companies are developing enabling elements of urban air mobility (UAM) for air taxis, including prototypes of electric vertical take-off and landing (eVTOL) vehicles. These prototypes incorporate electric and hybrid powertrains for multi-rotor and tilt-rotor crafts. Many eVTOLS are using batteries for propulsion and charging them rapidly between the flights or swapping them for slow charging overnight. Rapid charging degrades the battery cycle life while swapping requires multiple batteries and charging stations. This study has conducted a technoeconomic evaluation of the eVTOL air taxis with alternate powertrains using hydrogen fuel cell systems being developed for light-duty and heavy-duty vehicles. We consider performance metrics such as fuel cell engine power, weight, and durability; hydrogen consumption and weight of storage system; and maximum take-off weight. The metrics for economic evaluation are capital cost, operating and maintenance cost, fuel cost, and the total cost of ownership (TCO). We compare the performance and TCO of battery, fuel cell and fuel cell – battery hybrid powertrains for multi-rotor and tilt-rotor crafts. We show that fuel cells are the only viable concept for powering multi-rotor eVTOLs on an urban scenario that requires 60-mile range, and hybrid fuel cells are superior to batteries as powertrains for tiltrotor eVTOLs.     

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.     

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.     

Mass and heat transport in direct methanol fuel cells

The direct methanol fuel cell (DMFC) is a better alternative to the conventional battery. The DMFC offers several advantages, namely, faster building of potential and longer-lasting fuel, however, there are still several issues that need to be addressed to design a better DMFC system. This article is a wide-ranging review of the most up-to-date studies on mass and heat transfer in the DMFC. The discussion will be focused on the critical problems limiting the performance of DMFCs. In addition, a technique for upgrading the DMFC with an integrated system will be presented, along with existing numerical models for modeling mass and heat transfer as well as cell performance.     

Reciprocating air flow for Li-ion battery thermal management to improve temperature uniformity

The thermal management of traction battery systems for electrical-drive vehicles directly affects vehicle dynamic performance, long-term durability and cost of the battery systems. In this paper, a new battery thermal management method using a reciprocating air flow for cylindrical Li-ion (LiMn₂O₄/C) cells was numerically analyzed using (i) a two-dimensional computational fluid dynamics (CFD) model and (ii) a lumped-capacitance thermal model for battery cells and a flow network model. The battery heat generation was approximated by uniform volumetric joule and reversible (entropic) losses. The results of the CFD model were validated with the experimental results of in-line tube-bank systems which approximates the battery cell arrangement considered for this study. The numerical results showed that the reciprocating flow can reduce the cell temperature difference of the battery system by about 4 °C (72% reduction) and the maximum cell temperature by 1.5 °C for a reciprocation period of τ = 120 s as compared with the uni-directional flow case (τ = ∞). Such temperature improvement attributes to the heat redistribution and disturbance of the boundary layers on the formed on the cells due to the periodic flow reversal.     

A hybrid power source for pulse power applications

Portable 12 V power supplies are used extensively for communications and power tool applications. These devices demand fast response times of the power supply. Fuel cells are generally best suited to continuous power applications and require an initial warm-up period, although they offer the prospect of increased operational duration over a battery for a given weight of portable system. This paper investigates the combination of specific energy performance from the fuel cell system with the specific power and response time of the battery. Two separate hybrid systems have been developed and tested; a planar, 20-cell, polymer electrolyte membrane fuel cell (PEMFC) stack together with either a lead–acid or nickel/cadmium battery; and a conventional 20-cell, bipolar, PEMFC stack. Both systems have been tested under pulse-load conditions at temperatures between −20°C and +40°C, and for comparison, the individual components have undergone similar tests. The hybrid systems have successfully operated continuously for several weeks under load profiles that the fuel cell alone could not sustain.     

A comparison of rule-based and model predictive controller-based power management strategies for fuel cell/battery hybrid vehicles considering degradation

Traditional power management systems for hybrid vehicles often focus on the optimization of one particular cost factor, such as fuel consumption, under specific driving scenarios. The cost factor is usually based on the beginning-of-life performance of system components. Typically, such strategies do not account for the degradation of the different components of the system over their lifetimes. This study incorporates the effect of fuel cell and battery degradation within their cost factors and investigates the impact of different power management strategies on fuel cell/battery loads and thus on the operating cost over the vehicle's lifetime. A simple rule-based power management system was compared with a model predictive controller (MPC) based system under a connected vehicle scenario (where the future vehicle speed is known a priori within a short time horizon). The combined cost factor consists of hydrogen consumption and the degradation of both the fuel cell stack and the battery. The results show that the rule-based power management system actually performs better and achieves lower lifetime cost compared to the MPC system even though the latter contains more information about the drive cycle. This result is explained by examining the changing dynamics of the three cost factors over the vehicle's lifetime. These findings reveal that a limited knowledge of traffic information might not be as useful for the power management of certain fuel cell/battery hybrid vehicles when degradation is taken into consideration, and a simple tuned rule-based controller is adequate to minimize the lifetime cost.