This research addresses the manufacturing problems of the fuel cell in an applied industrial approach with the aim of investigating the technology of manufacturing of Proton Exchange Membrane (PEM) fuel cells, and using this technology in reducing the cost of manufacturing through simplifying the design and using less exotic materials. The first chapter of this thesis briefly discusses possible energy alternatives to fossil fuels, arriving at the importance of hydrogen energy and fuel cells. The chapter is concluded with the main aims of this study. A review of the relevant literature is presented in chapter 2 aiming to learn from the experience of previous researchers, and to avoid the duplication in the current work. Understanding the proper working principles and the mechanisms causing performance losses in fuel cells is very important in order to devise techniques for reducing these losses and their cost. This is covered in the third chapter of this thesis which discusses the theoretical background of the fuel cell science. The design of the fuel cell module is detailed in chapter 4, supported with detailed engineering drawings and a full description of the design methodology. So as to operate the fuel cell; the reactant gases had to be prepared and the performance and operating conditions of the fuel cell tested, this required a test facility and gas conditioning unit which has been designed and built for this research. The details of this unit are presented in chapter 5. In addition to the experimental testing of the fuel cell under various geometric arrangements, a three dimensional 3D fully coupled numerical model was used to model the performances of the fuel cell. A full analysis of the experimental and computational results is presented in chapter 6. Finally, the conclusions of this work and recommendations for further investigations are presented in chapter 7 of this thesis. In this work, an understanding of voltage loss mechanism in the fuel cell based on thermodynamic irreversibility is introduced for the first time and a comprehensive formula for efficiency based on the actual operating temperature is presented. Furthermore, a novel design of a 100W (PEMFC) module which is apt to reduce the cost of manufacturing and improve water and thermal management of the fuel cell is presented. The work also included the design and manufacturing of a test facility and gas conditioning unit for PEM fuel cells which will be useful in performing further experiments on fuel cells in future research work. Taking into consideration that fuel cell technology is not properly revealed in the open literature, where most of the work on fuel cells does not offer sufficient information on the design details and calculations, this thesis is expected to be useful in the manifestation of fuel cell technology. It is also hoped that the work achieved in this study is useful for the advancement of fuel cell science and technology.

This thesis presents a compendium of work related to performance analyses of a proton electrolyte membrane (PEM) fuel cell with two novel design configurations. The finite element based numerical analysis has been carried out to solve the numerical transport models involved in a PEM fuel cell coupled with the flow in a porous medium, charge balance, electrochemical kinetics and membrane water content. The scope of this research work focuses on improving the performance of the PEM fuel cell by optimizing the thermo-fluid properties of the reactant species instead of analysing the complex electro-chemical interactions. Two new design configurations have been numerically analyzed; in the first design approach, a perforated-type gas flow distributor is used instead of a conventional gas flow distributor such as a serpentine, straight or spiral shape; the second design approach examines the effect of reactant flow pulsation on the PEM fuel cell performance. Results obtained from the numerical analyses were also compared with the experimental data and a good agreement was found. Performance of the PEM fuel cell with a perforated-type gas distributor was analyzed at different operating and geometric conditions to explore the merits of this new design configuration. Two-dimensional numerical analyses were carried out to analyze the effect of varying the different operating parameters; threedimensional numerical analyses were carried out to study the variation of different geometric parameters on overall performance of the new design configuration of the PEM fuel cell. The effects of the reactant flow pulsation on the performance of PEM fuel cell were analyzed using a two-dimensional numerical approach where both active and passive design configurations were numerically simulated to generate the pulsations in the reactant flow. The results showed a considerable increase in overall performance of the PEM fuel cell by introducing pulsations in the flow.

No / The need for greater energy efficiency has garnered increasing support for the use of fuel-cell technology, a prime example being the solid-oxide fuel cell1, 2. A crucial requirement for such devices is a good ionic (O2- or H+) conductor as the electrolyte3, 4. Traditionally, fluorite- and perovskite-type oxides have been targeted3, 4, 5, 6, although there is growing interest in alternative structure types for intermediate-temperature (400¿700 °C) solid-oxide fuel cells. In particular, structures containing tetrahedral moieties, such as La1-xCaxMO4-x/2(M=Ta,Nb,P) (refs 7,8), La1-xBa1+xGaO4-x/2 (refs 9,10) and La9.33+xSi6O26+3x/2 (ref. 11), have been attracting considerable attention recently. However, an atomic-scale understanding of the conduction mechanisms in these systems is still lacking; such mechanistic detail is important for developing strategies for optimizing the conductivity, as well as identifying next-generation materials. In this context, we report a combined experimental and computational modelling study of the La1-xBa1+xGaO4-x/2 system, which exhibits both proton and oxide-ion conduction9, 10. Here we show that oxide-ion conduction proceeds via a cooperative 'cog-wheel'-type process involving the breaking and re-forming of Ga2O7 units, whereas the rate-limiting step for proton conduction is intra-tetrahedron proton transfer. Both mechanisms are unusual for ceramic oxide materials, and similar cooperative processes may be important in related systems containing tetrahedral moieties.

M. Tech. (Department of Chemical Engineering, Faculty of Engineering and Technology), Vaal University of Technology. / Fuel cell technology is a promising clean energy source compared to internal combustion engines and electricity generating plants which are associated with high emissions of greenhouse gases. The aim of this study was to modify chitosan into polymer electrolyte membranes suitable for use in PEMFC and DMFC fuel cells. Chitosan modification was done with 2-aminoethanesulfonic acid (2-AESA), dimethylformamide (DMF) and silica nanoparticles. The effect of the modification on the properties of the developed chitosan membranes was studied using FTIR, XRD, SEM-EDS and TGA. The performance of the membrane electrode assemblies was investigated. The formation of electrostatic interactions in the developed sulfonated chitosan membranes was confirmed via the Fourier transform infrared (FTIR) analysis, indicating a shift in the wavenumber of the N-H bonds from 1581 cm-1 on the chitosan spectrum to a lower wavenumber of 1532 cm-1 in the FTIR spectra of the membranes and by the new peak at the wavenumber of ~1260 cm-1 attributed to the asymmetric O=S=O stretching vibrations of the sulphate groups and sulfonic acid groups from the cross-linking sulphuric acid solution and 2-aminoethanesulfonic acid incorporated on the chitosan polymer chain during the modification. Notably, the FTIR spectra of the developed sulfonated chitosan membranes lacked the peak at the wavenumber of ~1153 cm-1 attributed to the stretching of C-O-C bonds of the polysaccharide ring of chitosan. A reaction mechanism was proposed in this study illustrating the possible conversion of the polysaccharide rings of chitosan into a poly (cyclohexene-oxide) thermoplastic rings in the developed membranes. The TGA/DTGA results of the developed sulfonated chitosan membranes showed three degradation stages. The initial weight loss occurred at temperatures ˂100 °C due to the evaporation of volatile components and water molecules inside the membranes. The second degradation phase of the membranes occurred at 208 ℃ with a loss in weight of >30% resulting from the decomposition of cross-linking networks. The third degradation stage was associated with the decomposition of the main polymer backbone of the membranes and occurred at 263°C for the chitosan membranes modified with 2-aminoethanesulfonic acid and at 266 °C for the chitosan membrane modified with silica nanofiller. The TGA/DTGA curves of Nafion 117 showed a small loss in weight of ~ 5% before a sharp decomposition that occurred between 346–505 °C. The XRD diffractograms of the developed sulfonated chitosan membranes showed amorphous phases, the crystal peaks of chitosan at 2theta of 10° and 20° were flattened on the membranes. The SEM images showed a homogenous surface morphology for the sulfonated chitosan membrane with a higher weight percentage of 2-aminoethanesulfonic acid (13,6 wt.%). The SEM images performed on the surface of the sulfonated chitosan membrane modified silica nanoparticles showed a slight agglomeration associated with the migration of the unbonded silica to the surface. The methanol permeability coefficient of the developed sulfonated chitosan membrane modified with 2-aminoethanesulfonic acid was calculated to be 2.29x10-6 cm2/s. This value was close to the methanol permeability coefficient of 2.33x10-6 cm2/s associated with unfavourable depolarisation at the cathode in direct methanol fuel cells when using Nafion 117. The proton diffusion coefficient of Nafion 117 was calculated to be 1.64x10-5 cm2/s and that of the developed sulfonated chitosan membrane modified with 2-aminoethanesulfonic acid was found to be 6.56x10-6 cm2/s, respectively. The fuel cell performance of the developed sulfonated chitosan membrane modified with 2AESA was investigated in a hydrogen fuel cell (PEMFC) supplied with H2 and O2 directly from the electrolyser. The sulfonated chitosan membrane modified with 2-aminoethanesulfonic acid (13.6 wt.%) achieved an open-circuit voltage of ~0.9 V and a maximum power output of 64.7 mW/cm2 at a maximum current of 70 mA. The current produced by the developed chitosan membrane was applied into the load and was able to turn (power) the electric fan. The sulfonated chitosan membrane modified with silica nanoparticles (2 wt.%) yielded an open-circuit voltage of ~0.9 V and attained a maximum power output of 58 mW/cm2 at a maximum current output of 60 mA/cm2. The current generated by the membrane was also able to turn the electric fan. The Nafion 117 membrane was also investigated under similar conditions and obtained an open-circuit voltage of 0.6 V and a maximum power output of 130 mW/cm2 at the maximum current output of 308 mA. The current produced by Nafion 117 was supplied into the load and was able to turn the electric fan.