This thesis focuses on developing support materials for direct methanol fuel cell (DMFC) catalysts. The approach involves using graphene based materials including reduced graphene oxide (rGO), reduced graphene oxide-activated carbon (rGO-AC) hybrid and reduced graphene oxide-silicon carbide (rGO-SiC) hybrid as a support for Pt and Pt-Ru nanoparticles. Pt/rGO and Pt-Ru/rGO catalysts were synthesized by three chemical reduction methods: (1) modified polyol, (2) ethylene glycol (EG) reduction and (3) mixed reducing agents (EG + NaBH4) methods. The synthesized catalysts were characterized by physical and electrochemical techniques. The results demonstrated that Pt/rGO-3 and Pt-Ru/rGO-3 catalyst synthesized with Method-3 exhibit higher electrochemical active surface area (ECSA) than the other rGO supported and Vulcan supported commercial electrocatalysts. In addition, Pt/rGO-3 and Pt-Ru/rGO-3 catalysts showed better oxygen reduction reaction (ORR) and methanol oxidation reaction (MOR) activities, respectively. The DMFC tests under different cell temperature (30, 50 and 70°C) and methanol concentration (1, 2 and 4 M) conditions further demonstrated the higher catalytic activity of the catalysts. The peak power density obtained with Pt/rGO-3 cathode and Pt-Ru/rGO-3 anode catalysts at 70°C with 1 M methanol was 63.3 mW/cm2 which is about 59 % higher than that of commercial Pt/C and Pt-Ru/C catalysts. The enhanced performance was attributed to the highly accessible and uniformly dispersed nanoparticles on rGO support with large surface area and high conductivity. Pt/rGO-AC (reduced graphene oxide-activated carbon) and Pt-Ru/rGO-AC catalysts were synthesized with various rGO:AC support ratios by using biomass derived AC. The results showed that the catalysts with content of 20 wt. % AC support (Pt/rGO-AC20 and Pt-Ru/rGO-AC20) exhibited higher ECSA, better catalytic activity and stability among all the tested catalysts. With 1 M methanol and 70°C cell temperature, the MEA with Pt/rGO-AC20 cathode and Pt-Ru/rGO-AC anode catalysts gave 19.3 % higher peak power density (75.5 mW/cm2), than that of Pt/rGO-3 and Pt-Ru/rGO-3 catalysts. The better DMFC performance was due to the incorporation of AC particles into rGO structure which builds electron-conductive paths between rGO sheets, facilitates the transport of reactant and products and provides higher specific surface area for the uniform distribution of nanoparticles. Pt/rGO-SiC catalysts were synthesized with variable silicon carbide (SiC) content in the hybrid support. Pt/rGO-SiC10 (10 wt. % of SiC support) catalyst showed higher ECSA and better catalytic activity compared to the Pt/SiC, Pt/rGO-3 and Pt/rGO-SiC20 catalysts. In addition, the Pt/rGO-SiC10 gave 14.2 % higher DMFC performance than the Pt/rGO-3 catalyst in terms of power density. The high performance can be attributed to the insertion of the SiC nanoparticles into rGO structure that improves the conductivity and stability of the catalyst by playing a spacer role between rGO layers. In summary, the overall results showed that the catalytic performance of the catalysts followed the trend in terms of support material: rGO-AC20 > rGO-SiC10 > rGO > Vulcan. The study demonstrated that the novel rGO-AC and rGO-SiC hybrids are promising catalyst supports for direct methanol fuel cell applications.

Une pile à combustible microbiennes (PCM) est un dispositif capable de produire de l’énergie électrique à partir d’énergie chimique grâce à l’activité catalytique des bactéries en présence de combustibles organiques. Ces travaux de thèse ont eu pour objectif la synthèse des nouveaux matériaux d’anode et de cathode qui pourraient constituer des alternatives aux matériaux à base de platine. Coté anode, nous avons synthétisé des matériaux par précipitation chimique sur du graphite en poudre à partir de mélanges contenant des ions ferreux et sulfures. Les caractérisations physicochimiques ont montré la formation de composés soufrés (mackinawite, polysulfures et soufre élémentaire) qui se transforment en produits soufrés plus oxydés en présence d’air. La formation de vivianite a été confirmée dans le cas d’un excès d’ions ferreux par rapport aux ions sulfures. Les analyses électrochimiques montrent que ces matériaux ont un comportement réversible avec des densités de courant d’oxydation élevées à bas potentiel. Coté cathode, nous avons choisi la synthèse par voie électrochimique d’un film de MnOx sur substrat d’acier inoxydable. Les caractérisations physicochimiques ont démontré la formation de la birnessite. Les analyses électrochimiques montrent que la réduction de ce matériau conduit à des courants cathodiques significatifs mais avec une réversibilité limitée, même en présence d’air. La réalisation de prototypes de PCM dans lesquels l’anode à base de composés soufrés est immergée dans une solution de terreau et la cathode à base de MnOx est au contact de l’air, a permis d’obtenir des puissances instantanées maximales de l’ordre de 12 W.m-3 et 1,8 W.m-2, et des densités de courant de l’ordre de 25 A.m-3 et 3,8 A.m-2. Un travail d’optimisation du fonctionnement de PCM a été réalisé. Ainsi, l’augmentation de la conductivité de la solution anodique et la diminution de quantité de sédiment dans la solution de terreau a permis d’améliorer la réponse électrochimique du matériau anodique et d’obtenir des puissances instantanées maximales de l’ordre de 17,5 W.m-3 et 2,7 W.m-2, et des densités de courant de l’ordre de 60 A.m-3 et 9,2 A.m-2. Le facteur limitant reste toujours le comportement électrochimique du film de MnOx. / A microbial fuel cell (MFC) is a device allowing the production of electric power from chemical energy thanks to the catalytic activity of bacteria in presence of organic fuel. These works aimed the synthesis of new anode and cathode materials which could be an alternative to platinum materials. On the anode side, we synthesized the materials by chemical precipitation on powder graphite from mixtures containing ferrous and sulfide ions. Physicochemical characterizations showed the formation of sulfur compounds (mackinawite, polysulfide and elementary sulfur) which transform into sulfur products more oxidized in presence of air. Formation of vivianite was confirmed in the case of an excess of ferrous ions in relation to sulfide ions. Electrochemical analysis shows that these materials have a reversible behavior with high current densities at low voltage. On the cathode side, we chose electrochemical synthesis of an MnOx film on stainless steel substrate. Physicochemical characterizations showed birnessite formation. Electrochemical analysis show that the reduction of this material Leeds to significative cathodic currents but with a limited reversibility, even in presence of air. The realization of MFC prototypes in which the sulfur compounds-based anode is submerged in compost solution and the MnOx-based cathode is in contact with air, allowed the getting of maximum instantaneous powers on the order of 12 W.m-3 and 1,8 W.m-2, and current densities on the order of 25 A.m-3 et 3,8 A.m-2. An optimization work of the MFC functioning has been done. So, the conductivity increase of the anodic solution and the decrease of sediment quantity in the compost solution allowed the improvement of the electrochemical response of the anodic material and to obtain maximal instantaneous powers on the order of 17,5 W.m-3 and 2,7 W.m-2, and current densities on the order of 60 A.m-3 et 9,2 A.m-2. The limiting factor remains the electrochemical behavior of the MnOx film.

Tese de doutoramento. Engenharia Química e Biológica. Universidade do Porto. Faculdade de Engenharia. 2011

An investigation was conducted to determine the feasibility of using the technique of ultrasonic nebulization of water into the anode gas stream for evaporative cooling of a Proton Exchange Membrane (PEM) fuel cell. The basic concept of this form of internal evaporative cooling of the PEM fuel cell is to introduce finely atomized liquid water into the anode gas stream, so that the finely atomized liquid water adsorbs onto the anode and then moves to the cathode via electro-osmotic drag, where this water then evaporates into the relatively dry cathode gas stream, carrying with it the waste thermal energy generated within the fuel cell. The thermal and electrical performance of a 50 cm2 PEM fuel cell utilizing this technique was compared to the performance obtained with conventional water management. Both techniques were compared over a range of humidification chamber temperatures for both the anode and cathode gas streams so as to determine the robustness of the proposed method. The proposed method produced only meager levels of evaporative cooling (at best 2 watts, for which a minimum of 30 watts was required for adequate cooling), but the average cell voltage increased considerably (as much as a 10% gain), and the technique increased the fault tolerance of the fuel cell (the Nafion™ membrane did not dry out even if cell temperature went well in excess of 70° C despite both anode and cathode humidification temperatures of 55° C). An interesting phenomena was also observed wherein the fuel cell voltage oscillated regularly with a period of tens of seconds, and that the amplitude of this oscillation corresponded inversely with the level of humidification received by the fuel cell.

Using glycerol from biodiesel production as a fuel in a microbial fuel cell (MFC) will generate electricity and valuable by-products from what is currently considered waste. This research aims to screen E. coli (W3110, TG1, DH5, BL21), P. freudenreichii (subspecies freudenreichii and shermanii), and mixed cultures enriched from compost (AR1, AR2, AR3) as anodic biocatalysts in a glycerol-oxidizing MFC. Anaerobic fermentation experiments were performed to determine the oxidative capacity of each catalyst towards glycerol. Using an optimized medium for each strain, the highest anaerobic glycerol conversion from each group was achieved by E. coli W3110 (4.1 g/L), P. freudenreichii ssp. shermanii (10 g/L), and AR2 (20 g/L). These cultures were then tested in an MFC system. All three catalysts exhibited exoelectrogenicity. The highest power density was achieved using P. freudenreichii ssp. shermanii (14.9 mW m-2), followed by AR2 (11.7 mW m-2), and finally E. coli W3110 (9.8 mW m-2).

An air cathode, membrane-less microbial fuel cell (MFC) containing a co-culture of Geobacter sulfurreducens and Escherichia coli was constructed and compared to pure culture MFCs of both organisms. The E. coli containing MFCs were unsparged and relied on E. coli for oxygen removal. The pure G. sulfurreducens MFC had a power output of 128 mW/m2, compared to 63 mW/m2 for the co-culture at an early stage and 56 mW/m2 for the late stage co-culture. The limiting current density is 404 mA/m2 for the pure G. sulfurreducens culture, 184 mA/m2 for the early co-culture, and 282 mA/m2 for the late co-culture, despite an increase in internal resistance between the early and late co-culture cells. Analysis of metabolites has shown that succinate production is likely to have negatively affected current production by G. sulfurreducens, and the removal of succinate is responsible for the increased current density in the late co-culture cell.

An air cathode, membrane-less microbial fuel cell (MFC) containing a co-culture of Geobacter sulfurreducens and Escherichia coli was constructed and compared to pure culture MFCs of both organisms. The E. coli containing MFCs were unsparged and relied on E. coli for oxygen removal. The pure G. sulfurreducens MFC had a power output of 128 mW/m2, compared to 63 mW/m2 for the co-culture at an early stage and 56 mW/m2 for the late stage co-culture. The limiting current density is 404 mA/m2 for the pure G. sulfurreducens culture, 184 mA/m2 for the early co-culture, and 282 mA/m2 for the late co-culture, despite an increase in internal resistance between the early and late co-culture cells. Analysis of metabolites has shown that succinate production is likely to have negatively affected current production by G. sulfurreducens, and the removal of succinate is responsible for the increased current density in the late co-culture cell.

Polymer Electrolyte Membrane Fuel Cells (PEMFC) are promising power generating devices that use an electrochemical reaction to convert the energy from hydrogen fuel into usable electricity. One cell produces a small voltage so many cells are combined in series in order to produce a useful voltage, this configuration is referred to as a stack. Hydrogen is supplied to the anode of the stack in amounts greater than the electrochemical reaction requires to guarantee that enough hydrogen is available for every cell in the stack and to provide enough pressure throughout the cell flow channels for good mass transfer. For reasonable fuel efficiency, the anode outlet gas containing unconverted hydrogen is recycled (or recirculated) back to the anode inlet. PEMFC performance is highest when pure hydrogen fuel is supplied, however, nitrogen at the cathode will permeate through the membrane and accumulate in the anode gas with recirculation. Nitrogen buildup dilutes the hydrogen gas which adversely affects fuel cell performance at the anode. Also, in practical applications hydrogen-rich gas produced from reformed methane, called reformate, is used as the fuel. Reformate contains impurities such as, nitrogen, carbon dioxide, carbon monoxide, and sulfur compounds. This thesis will focus on trace levels of carbon monoxide entering in the hydrogen fuel stream, and the impact of contaminant build-up due to anode recirculation. Carbon monoxide adsorbs readily onto the platinum catalyst sites, called poisoning, thus decreasing PEMFC performance. In efforts to minimize the buildup of impurities and crossed over nitrogen, a portion of the anode outlet gas is periodically and continuously purged to the exhaust. How often the outlet gas is purged depends on a variable called the purge fraction. The purpose of this research is to study the effect of purge fraction on PEMFC performance, measured by the average cell voltage, for a Hydrogenics 10 cell stack. The operating parameters used for testing and the experimental apparatus were designed to mimic a Hydrogenics 8kW Hydrogen Fuel Cell Power Module. A pump connected between the anode outlet and anode inlet form the anode recirculation loop. In Phase 1 of the test program the effect of purge in the absence of carbon monoxide was studied to see if hydrogen dilution from nitrogen crossover and accumulation would cause significant cell voltage degradation. In Phase 2 the effect down to 0.2 ppm carbon monoxide was evaluated. The results showed that nitrogen buildup, in the absence of carbon monoxide, did not significantly penalize the cell performance in the range of purge fractions tested. However, for the same purge fraction but with as little as 0.2 ppm carbon monoxide present, the voltage loss was significant. A discussion of the effect of purge on the impurity concentration and the associated cell voltage degradation is detailed with particular emphasis on carbon monoxide poisoning.

Polymer electrolyte membrane (PEM) fuel cells are a promising zero-emission power source for transportation applications. An important tool for advancing PEM fuel cell technology is mathematical modeling. Mathematical models can be used to provide insight on the physical phenomena occurring within a fuel cell, as well as aid in the design of fuel cells by simulating the effect of changes in design or operating conditions on performance. A comprehensive, consistent and systematic general formulation for a mathematical PEM fuel cell model is presented in this thesis. The formulation is developed by considering the fuel cell to be composed of several, co-existing phases. The conservation of mass, momentum, species, and energy are applied to each phase in the fuel cell. The interactions between the phases are modeled by applying a volume-averaging procedure to the conservation equations in each phase. The solution of the governing equations for the general formulation are beyond the scope of this thesis research. Instead, simplifying assumptions are applied to the general formulation in order to reduce the number of governing equations. The cell is assumed to be two-dimensional, steady state and isothermal. As well, the polymer electrolyte is assumed to be impervious to the gas phase and liquid water is assumed to exist only in the gas phase or polymer electrolyte. The numerical solution of the simplified formulation is implemented using the computer language of C++ and the finite volume method. The numerical solution provides details of the transport phenomena within the anode and cathode gas flow channels, electrode backing layers, and catalyst layers, as well as the polymer electrolyte membrane layer. These details include the bulk velocity of the gas phase; the concentrations of the species within the gas phase; the potential and current density in the solid phase and polymer electrolyte; the water content in the polymer electrolyte; and the distribution of reaction rate within the catalyst layers.

The ‘Hydrogen Economy’ is a proposed system where hydrogen is produced from carbon dioxide free energy sources and is used as an alternative transportation fuel. The application of hydrogen on board fuel cell vehicles can significantly decrease air pollutants and greenhouse gases emission from the transportation sector. There must be significant transition of infrastructure in order to achieve the hydrogen economy with the investment required in both production and distribution infrastructure. This research focused on the projected demands for infrastructure transition of ‘Hydrogen Economy’ in Ontario, Canada. Three potential hydrogen demand and distribution system development scenarios were examined to estimate hydrogen fuel cell vehicle market penetration, as well as the associated hydrogen production and distribution. Demand of transportation hydrogen was estimated based on the type of hydrogen fuel cell vehicle. Upon the estimate of hydrogen demand from fuel cell vehicles in Ontario, the resulting costs of delivered hydrogen were investigated. In the longer term hydrogen is expected to be produced by utilizing nuclear heat and a thermochemical production cycle. A brief survey of thermochemical hydrogen production cycles was presented with a focus on S-I cycle. Sequential optimization models were developed to explore the minimum utility energy consumption and the minimum number of heat exchangers. Finally an optimal heat exchanger network for S-I thermochemical cycle was defined by a mixed integer optimization model using GAMS.