The gas diffusion layer (GDL) is one of the key components in a polymer electrolyte membrane (PEM) fuel cell. It performs several functions including the transport of reactant gases and product water to and from the catalyst layer, conduction of both electrons and heat produced in the catalyst layer, as well as mechanical support for the membrane. The overarching goal of this work is to thoroughly examine the GDL structure and properties for use in PEM fuel cells, and more specifically, to determine how to characterize the GDL experimentally ex-situ, to understand its performance in-situ, and to relate theory to performance through controlled experimentation. Thus, the impact of readily measured effective water vapor diffusivity on the performance of the GDL is investigated and shown to correlate to the wet limiting current density, as a surrogate of the oxygen diffusivity to which it is more directly related. The influence of microporous layer (MPL) design and construction on the fuel cell performance is studied and recommendations are made for optimal MPL designs for different operating conditions. A method for modifying the PTFE (Teflon) distribution within the GDL is proposed and the impact of distribution of PTFE in the GDL on fuel cell performance is studied. A method for characterizing the surface roughness of the GDL is developed and the impact of surface roughness on various ex-situ GDL properties is investigated. Finally, a detailed analysis of the physical structure and permeability of the GDL is provided and a theoretical model is proposed to predict both dry and wet gas flow within a GDL based on mercury intrusion porosimetry and porometry data. It is hoped that this work will contribute to an improved understanding of the functioning and structure of the GDL and hence advance PEM fuel cell technology.

Os componentes do conjunto membrana/eletrodos (MEA) das células a combustível de membrana de eletrólito polimérico/Polymer Electrolyte Membrane Fuel Cells (PEMFC) são sensíveis a impurezas, as quais podem vir do ar, do gás combustível e/ou da degradação dos componentes do módulo. Amônia, sulfeto de hidrogênio e monóxido de carbono são juntos os três principais subprodutos cotaminadores nos processos de geração de hidrogênio por reforma de combustíveis. Estes contaminadores afetam negativamente o desempenho das PEMFCs, assim é importante o entendimento destes efeitos para mitigá-los e introduzir a tecnologia das PEMFCs no mercado consumidor. Desta forma experimentos foram realizados visando diagnosticar os efeitos da amônia e do sulfeto de hidrogênio sobre os componentes do MEA das PEMFCs. Para a contaminação por sulfeto de hidrogênio foi provado, utilizando-se da técnica de cromatografia gasosa e de stripping, que a contaminação ocorre através da interação química e eletroquímica do contaminador com a superfície do catalisador de platina, e que estas interações ocorrem via um processo dissociativo e um processo oxidativos respectivamente. Estes processos de interação geram enxofre adsorvido sobre a superfície da platina, a qual é bloqueada para posterior oxidação de hidrogênio, gerando sobrepotenciais que reduzem a diferença de potencial da célula. Utilizando-se da técnica de cromatografia gasosa e agora de voltametria cíclica foi mostrado na PEMFC, que durante o processo de remoção do enxofre adsorvido a platina dióxido de enxofre é gerado. Ainda na PEMFC, foi mostrado utilizando-se da técnica de \"air bleed\" que maiores tolerâncias ao sulfeto de hidrogênio podem ser alcançadas, apesar de ser insignificante. Para o caso da contaminação da PEMFC por amônia, indiretamente foi mostrado, utilizando-se técnicas eletroquímicas solução de ácido perclórico, que amônia pode afetar a reação de redução de oxigênio pela sua adsorção sobre a superfície do catalisador, ou pelo bloqueio da mesma para posterior adsorção/redução de oxigênio. Em estudos de absorção de água e condutividade de membranas de NafionTM, sob diferentes frações catiônicas (prótons/amônio), em contato com água na fase vapor sob diferentes atividades, foi mostrado que quanto maior a concentração de íons contaminadores no eletrólito menor a quantidade de água absorvida e menor a condutividade da membrana. Também foi mostrado que se tais membranas fossem usadas como eletrólito em PEMFCs, o desempenho da célula seria afetado drasticamente por perdas ôhmicas. Também foi mostrado que sob contaminação por amônia, PEMFCs sofrem aumentos em resistências ôhmicas devido a reduções na condutividade do eletrólito, contudo foi provado que esta representa menos de dez por cento do total de perdas observadas no desempenho da célula. Desde estudo foi concluído que amônia afeta o desempenho das PEMFCs principalmente pela redução na atividade dos prótons na camada catalítica catódica, que causa reduções no potencial misto de equilíbrio da reação de redução de oxigênio, e portanto na diferença de potencial da célula. Finalmente foi provado indiretamente que amônia deixa a célula através do equilíbrio de amônio com água, o qual deslocado gera amônia, a qual deixa a célula junto com o fluxo de gás cotódico. / The Membrane Electrode Assembly components of a PEMFC are sensitive to impurities, which can came with the air or hydrogen stream, or from the degradation of the stack components. Ammonia, hydrogen sulfide and carbon monoxide are together the main sub-products of fuel reforming processes for generating hydrogen. These contaminants negatively affect the PEMFC performance, so it is important to understand what those effects are in order to mitigate them and introduce PEMFC technology in the mass market. Therefore, experiments were carried out to diagnose the effects hydrogen sulfide and ammonia have on the MEA components of PEMFCs. For contamination by hydrogen sulfide it was proved utilizing EMS and stripping techniques that the poisoning process happens by chemical and electrochemical interactions of the contaminant with the Platinum catalyst surface, and that these interactions happen by a dissociative and oxidative process, respectively. Those processes generate sulfur adsorbed on the Platinum surface, which blocks it for further hydrogen oxidation, generating overpotentials, which reduce the cell potential. Utilizing the EMS and now the cyclic voltammetry technique it was shown that during the process of removing sulfur from the Platinum surface one generates sulfur dioxide. Using the Air Bleed technique it was shown that higher tolerances of the PEMFC against hydrogen sulfide can be reached, despite being insignificant. For contamination of the cell by ammonia it was indirectly proved utilizing electrochemical techniques in perchloric acid solutions that ammonia can affect the oxygen reduction reaction by adsorbing on the catalyst surface, or by blocking the surface for further oxygen adsorption/reduction. Studying water uptake and ionic conductivity of Nafion membranes under many different cation fractions (proton/ammonium) in contact with water vapor at different temperatures and water activities, it was proved that the more ammonium one has in the membrane the less will be the water uptake and ionic conductivity of it. It was also shown that if those membranes were used as electrolyte in PEMFC the cell performance would be severely affected by ohmic losses. It was also shown that under ammonia exposure PEMFCs suffer by ohmic resistance increases due to the lowering in the ionic conductivity of the electrolyte, however it was proved that it represent less than ten percent of the observed losses in the cell performance. From this study it was concluded that ammonia mainly affect the PEMFC performance by lowering the cathode catalyst layer proton activity, which lowers the oxygen reduction reaction equilibrium potential, and then the cell potential. Finally it was indirectly proved that ammonia leaves the cell by the equilibrium of ammonium and water, which dislocated generates ammonia that leaves the cell together with the cathode gas stream.

Hydrogen and oxygen or air polymer electrolyte membrane fuel cell is one of the most promising electrical energy conversion devices for a sustainable future due to its high efficiency and zero emission. Membrane electrode assembly (MEA), in which electrochemical reactions occur, is stated to be the heart of the fuel cell. The aim of this study was to develop methods for preparation of MEA with alternative polymer electrolyte membranes and compare their performances with the conventional Nafion&reg / membrane. The alternative membranes were sulphonated polyether-etherketone (SPEEK), composite, blend with sulphonated polyethersulphone (SPES), and polybenzimidazole (PBI). Several powder type MEA preparation techniques were employed by using Nafion&reg / membrane. These were GDL Spraying, Membrane Spraying, and Decal methods. GDL Spraying and Decal were determined as the most efficient and proper MEA preparation methods. These methods were tried to improve further by changing catalyst loading, introducing pore forming agents, and treating membrane and GDL. The highest performance, which was 0.53 W/cm2, for Nafion&reg / membrane was obtained at 70 0C cell temperature. In comparison, it was about 0.68 W/cm2 for a commercial MEA at the same temperature. MEA prepared with SPEEK membrane resulted in lower performance. Moreover, it was found that SPEEK membrane was not suitable for high temperature operation. It was stable up to 80 0C under the cell operating conditions. However, with the blend of 10 wt% SPES to SPEEK, the operating temperature was raised up to 90 0C without any membrane deformation. The highest power outputs were 0.29 W/cm2 (at 70 0C) and 0.27 W/cm2 (at 80 0C) for SPEEK and SPEEK-PES blend membrane based MEAs. The highest temperature, which was 150 0C, was attained with PBI based MEA during fuel cell tests.

Current environmental and energy sustainability trends have instigated considerable interest in alternative energy technologies that exhibit reduced dependence on fossil fuels. The advantages of such a direction are two-fold: reduced greenhouse gas emissions (notably CO2) and improved energy sustainability. Fuel cells are recognized as a potential technology that achieves both of these goals. However, improvements to fuel cell power density and stability must be realized to make them economically competitive with traditional, fossil-based technologies. The work in this dissertation is largely focused on the use of analytical tools for the study of transport processes in three fuel cell systems toward improvement of fuel cell performance. Polymer electrolyte membrane fuel cells (PEMFCs) are fueled by hydrogen and oxygen to generate electrical current. Microbial fuel cells (MFCs) use bacteria to degrade carbon compounds, such as those found in wastewaters, and simultaneously generate an electric current. Enzyme fuel cells (EFCs) operate similarly to PEMFCs but replace precious metal catalysts, such as platinum, with biologically-derived enzymes. The use of enzymes also allows EFCs to utilize simple carbon compounds as fuel. The operation of all three fuel cell systems involves different modes of ion and electron transport and can be affected negatively by transport limitations. Electrochemical impedance spectroscopy (EIS) was used in this work to study the distribution of transport resistances in all three fuel cell systems. The results of EIS were used to better understand the transport resistances that limited fuel cell power output. By using this technique, experimental conditions (including operating conditions, construction, and materials) were identified to develop fuel cells with greater power output and longevity. In addition to EIS, neutron imaging was employed to quantify the distribution of water in PEMFCs and EFCs. Water content is an integral aspect of providing optimal power output from both fuel cell systems. Neutron imaging contributed to developing an explanation for the loss of water observed in an operating EFC despite conditions designed to mitigate water loss. The findings of this dissertation contribute to the improvement of fuel cell technology in an effort to make these energy devices more economically viable.

The ionomer-membrane interface in a membrane electrode assembly connects the catalyst and membrane and allows hydrated protons to move between the catalyst and membrane. The continuous operation of the polymer membrane electrolyte fuel cell at high temperature and/or in frequent freeze/thaw cycles leads to membrane degradation and delamination of the interface, which lower the proton conductivity. In this dissertation, we modeled the chemical degradation and proton conductivity of perfluorosulfonic acid (PFSA) ionomers by ab initio calculations and macroscopic modeling. All ab initio calculations were performed using Gaussian 03 suites of program by employing B3LYP/6-311++G** method/basis set. The macroscopic modeling involves nonequilibrium thermodynamics. The results show that PFSA membranes can degrade both via side-chain and backbone in the presence of hydroxyl radical. The energetics of homolytic bond cleavage show that the C–S bond in the side-chain is the weakest link and breaks exothermally in the presence of hydroxyl radical. The C–S bond in the membrane fragment radical can break at low activation energy. The side-chain degradation also leads to the split of the backbone into two parts. The backbone degradation starts with the reaction of –COOH impurities in the backbone with the hydroxyl radical, which has the lowest activation energy, and follows an “unzipping mechanism”. The reactions in this mechanism are exothermic. The channels in the interface were modeled as cylindrical pores and the anionic charges were fixed on the pore wall. The analytical expression of proton conductivity was derived from the evolution equations for mass and momentum of hydronium ions by using an order of magnitude analysis. The results show that the conductivity increases with increasing water content and pore radius. The conductivity usually increases on decreasing the separation distance between sulfonates on the length and decreases with decreasing sulfonates separation distance on the circumference. The conductivity of the two pores, one of the interface and the other of the membrane, is closer to the conductivity of the pore with the lowest conductivity and its magnitude depends on the relative radius and length of the pores.

Os componentes do conjunto membrana/eletrodos (MEA) das células a combustível de membrana de eletrólito polimérico/Polymer Electrolyte Membrane Fuel Cells (PEMFC) são sensíveis a impurezas, as quais podem vir do ar, do gás combustível e/ou da degradação dos componentes do módulo. Amônia, sulfeto de hidrogênio e monóxido de carbono são juntos os três principais subprodutos cotaminadores nos processos de geração de hidrogênio por reforma de combustíveis. Estes contaminadores afetam negativamente o desempenho das PEMFCs, assim é importante o entendimento destes efeitos para mitigá-los e introduzir a tecnologia das PEMFCs no mercado consumidor. Desta forma experimentos foram realizados visando diagnosticar os efeitos da amônia e do sulfeto de hidrogênio sobre os componentes do MEA das PEMFCs. Para a contaminação por sulfeto de hidrogênio foi provado, utilizando-se da técnica de cromatografia gasosa e de stripping, que a contaminação ocorre através da interação química e eletroquímica do contaminador com a superfície do catalisador de platina, e que estas interações ocorrem via um processo dissociativo e um processo oxidativos respectivamente. Estes processos de interação geram enxofre adsorvido sobre a superfície da platina, a qual é bloqueada para posterior oxidação de hidrogênio, gerando sobrepotenciais que reduzem a diferença de potencial da célula. Utilizando-se da técnica de cromatografia gasosa e agora de voltametria cíclica foi mostrado na PEMFC, que durante o processo de remoção do enxofre adsorvido a platina dióxido de enxofre é gerado. Ainda na PEMFC, foi mostrado utilizando-se da técnica de \"air bleed\" que maiores tolerâncias ao sulfeto de hidrogênio podem ser alcançadas, apesar de ser insignificante. Para o caso da contaminação da PEMFC por amônia, indiretamente foi mostrado, utilizando-se técnicas eletroquímicas solução de ácido perclórico, que amônia pode afetar a reação de redução de oxigênio pela sua adsorção sobre a superfície do catalisador, ou pelo bloqueio da mesma para posterior adsorção/redução de oxigênio. Em estudos de absorção de água e condutividade de membranas de NafionTM, sob diferentes frações catiônicas (prótons/amônio), em contato com água na fase vapor sob diferentes atividades, foi mostrado que quanto maior a concentração de íons contaminadores no eletrólito menor a quantidade de água absorvida e menor a condutividade da membrana. Também foi mostrado que se tais membranas fossem usadas como eletrólito em PEMFCs, o desempenho da célula seria afetado drasticamente por perdas ôhmicas. Também foi mostrado que sob contaminação por amônia, PEMFCs sofrem aumentos em resistências ôhmicas devido a reduções na condutividade do eletrólito, contudo foi provado que esta representa menos de dez por cento do total de perdas observadas no desempenho da célula. Desde estudo foi concluído que amônia afeta o desempenho das PEMFCs principalmente pela redução na atividade dos prótons na camada catalítica catódica, que causa reduções no potencial misto de equilíbrio da reação de redução de oxigênio, e portanto na diferença de potencial da célula. Finalmente foi provado indiretamente que amônia deixa a célula através do equilíbrio de amônio com água, o qual deslocado gera amônia, a qual deixa a célula junto com o fluxo de gás cotódico. / The Membrane Electrode Assembly components of a PEMFC are sensitive to impurities, which can came with the air or hydrogen stream, or from the degradation of the stack components. Ammonia, hydrogen sulfide and carbon monoxide are together the main sub-products of fuel reforming processes for generating hydrogen. These contaminants negatively affect the PEMFC performance, so it is important to understand what those effects are in order to mitigate them and introduce PEMFC technology in the mass market. Therefore, experiments were carried out to diagnose the effects hydrogen sulfide and ammonia have on the MEA components of PEMFCs. For contamination by hydrogen sulfide it was proved utilizing EMS and stripping techniques that the poisoning process happens by chemical and electrochemical interactions of the contaminant with the Platinum catalyst surface, and that these interactions happen by a dissociative and oxidative process, respectively. Those processes generate sulfur adsorbed on the Platinum surface, which blocks it for further hydrogen oxidation, generating overpotentials, which reduce the cell potential. Utilizing the EMS and now the cyclic voltammetry technique it was shown that during the process of removing sulfur from the Platinum surface one generates sulfur dioxide. Using the Air Bleed technique it was shown that higher tolerances of the PEMFC against hydrogen sulfide can be reached, despite being insignificant. For contamination of the cell by ammonia it was indirectly proved utilizing electrochemical techniques in perchloric acid solutions that ammonia can affect the oxygen reduction reaction by adsorbing on the catalyst surface, or by blocking the surface for further oxygen adsorption/reduction. Studying water uptake and ionic conductivity of Nafion membranes under many different cation fractions (proton/ammonium) in contact with water vapor at different temperatures and water activities, it was proved that the more ammonium one has in the membrane the less will be the water uptake and ionic conductivity of it. It was also shown that if those membranes were used as electrolyte in PEMFC the cell performance would be severely affected by ohmic losses. It was also shown that under ammonia exposure PEMFCs suffer by ohmic resistance increases due to the lowering in the ionic conductivity of the electrolyte, however it was proved that it represent less than ten percent of the observed losses in the cell performance. From this study it was concluded that ammonia mainly affect the PEMFC performance by lowering the cathode catalyst layer proton activity, which lowers the oxygen reduction reaction equilibrium potential, and then the cell potential. Finally it was indirectly proved that ammonia leaves the cell by the equilibrium of ammonium and water, which dislocated generates ammonia that leaves the cell together with the cathode gas stream.

Polymer electrolyte membrane fuel cells (PEMFCs) are one of the most promising clean technologies under development. However, the main obstacles for commercialising PEMFCs are largely attributed to the technical limitations and cost of current PEM materials such as Nafion. Novel poly(2,5-benzimidazole) (ABPBI)/POSS based polymer composite electrolyte membranes with excellent mechanical and conductivity properties were developed in this project including (I) ABPBI, polybenzimidazole (PBI) and their copolymers were synthesised by solution polymerisation and their chemical structures were confirmed by FTIR and elemental analysis. ABPBI/ActaAmmonium POSS (ABPBI/AM) and ABPBI/TriSilanolPhenyl POSS (ABPBI/SO) composites were also synthesised in situ. High quality polymer and composite membranes were fabricated by a direct cast method; and (II) The mechanical and thermal properties, microstructure and morphology, water and H3PO4 absorbility and proton conductivity of phosphoric acid doped and undoped ABPBI and ABPBI/POSS composite membranes were investigated. SEM/TEM micrographs showed that a uniform dispersion of POSS nano particles in ABPBI polymer matrix was achieved. The best performances on both mechanical properties and proton conductivities were obtained from the ABPBI/AM composite membrane with 3 wt% of POSS (ABPBI/3AM). It was found that both the water and H3PO4 uptakes were increased significantly with the addition of POSS due to formation of hydrogen bonds between the POSS and H2O/H3PO4, which played a critical role in the improvement of the conductivity of the composite membranes at temperatures over 100oC. ABPBI/3AM membranes with H3PO4 uptake above 117% showed best proton conductivities at both hydrous and anhydrous conditions from room temperature to 160oC, which is comparable with the conductivity of commercial Nafion 117 at 20oC in water-saturated condition, indicating that these composite membranes could be excellent candidates as a polymer electrolyte membrane for high temperature applications. A new mechanism for illustrating the improved proton conductivity of composite membranes was also developed.

D. Tech. (Department of Mechanical Engineering, Faculty of Engineering and Technology), Vaal University of Technology. / On account of their lightweight, low-cost, corrosion resistance, and good formability, conductive polymer composites (CPCs) are promising for the production bipolar plate (BP) for polymer electrolyte membrane fuel cell (PEMFC). However, a high conductive filler loading is needed to impart the required level of electrical conductivity to the insulating polymer matrix and as a consequence, the toughness of the plate deteriorates considerably. By using immiscible blend of polymers that have complementary hardness and ductility as matrix, with conducting multi-fillers of different morphologies, it is possible to optimize the matrix strength characteristics and favour the formation of conducting network to produce CPC meeting BP performance standards. Of course, a lot will depend on the formulation of the most favourable composition and production variables. In this regard, polypropylene-epoxy and polyethylene-epoxy blends, filled with zero- and two-dimensional carbon forms – graphite, carbon black (CB), and graphene (Gr) – were investigated over an extensive range of compositions and compression moulding pressures, in this study. Several compounding runs (using melt mixing), at different stages, followed by compression molding, were done. The goal is to obtain combination of composite formulation and processing conditions that will produce the most promising combination of properties for BP application. In the first stage of the investigations, by using thermogravimetric analysis, two-stage decomposition behavior of PP-epoxy and PE-epoxy blends was revealed, which confirms the immiscibility of PP and PE with epoxy resin. Scanning electron microscope (SEM) micrographs of the PP-epoxy and PE-epoxy blends revealed a co-continuous structure, which can be attributed to the close-to-symmetric composition of the blend and compatibilizers added. Preferential localization of synthetic graphite (SG), CB, and Gr in the polymer blends was also revealed by the SEM micrographs. This confirms the fact that CPCs based on PP-epoxy and PE-epoxy blends can be explored further. PP-epoxy and PE-epoxy blends filled with only SG, 30 – 80 wt %, were produced and characterized for their electrical conductivity and flexural properties. In-plane electrical conductivity ranged from 12.09 to 68.03 Scm-1 for PP-epoxy/SG and 11.68 to 72.96 Scm-1 for PE-epoxy/SG composites produced. These are higher than values reported for several single matrix polymer composites at similar filler loadings. With reference to the United States Department of Energy performance targets for BPs, PE-epoxy/SG composites performed better in terms of electrical conductivity, while PP-epoxy/SG composites exhibited better flexural properties. Thereafter, using SG and CB double filler, PE-epoxy/SG/CB composites performed better than PP-epoxy/SG/CB composites in terms of electrical conductivity, while PP-epoxy/SG/CB composites exhibited superior flexural properties than the PE-epoxy/SG/CB composites at similar filler loadings. However, with respect to the DOE targets, composites based on PP-epoxy blend exhibited a more promising combination of electrical conductivity and flexural properties than PE-epoxy blend matrix. PP-epoxy filled with SG/CB was studied further, by using graphene (Gr) as second minor filler. In-plane and through plane electrical conductivities as well as thermal conductivity and thermal diffusivity of the PP-epoxy/SG/CB/Gr composites increased as total filler content was increased from 65 to 85 wt%. It implies that more conductive networks between filler particles were formed. Also, flexural strength, flexural modulus, and impact strength decreased as the total filler content increased from 65 to 85 wt%. The reduced flexural properties could be due to increased agglomeration of CB and Gr, and poor filler wetting at higher filler loadings and low matrix material, which leads to the formation of microvoids and a reduction of the load bearing capacity of composites. With respect to the DOE targets, PP-EP/SG/CB/Gr composite with 80 wt% (i.e., PP/EP/73G/6.2CB/0.8Gr) filler has the best combination of properties. Further improvement in properties of the PP-EP/SG/CB/Gr composite with 80 wt% filler was achieved by molding at higher pressures. As molding pressure was increased from 4.35 to 13.05 MPa, in-plane electrical conductivity increased from 116.31 to 144.99 Scm-1, while flexural strength increased from 29.62 to 42.57 MPa, satisfying the performance requirement targets for bipolar plates.

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