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A solid oxide fuel cell (SOFC) is an energy conversion device that has the potential to efficiently generate electricity in an environmentally-friendly manner. In general, a SOFC operates between 750&deg;C and 1000&deg;C utilizing hydrogen or hydrocarbons as fuel and air as an oxidant. The three major components comprising a fuel cell are the electrolyte, the cathode, and the anode. At present, the state-of-the-art SOFC is made from a dense yttria-stabilized zirconia (YSZ) electrolyte, a porous lanthanum manganite cathode, and a porous nickel/YSZ composite anode. With the advent of the anode-supported SOFC and the increased interest in using a wider range of fuels, such as those containing sulphur, knowledge of the anode properties is becoming more important. <br /> The properties of the current anodes are limited due to the narrow range of nickel loadings imposed by the minimum nickel content for electrical conductivity and the maximum allowable nickel loading to avoid thermal mismatch with the YSZ electrolyte. In addition, there is little research presented in the literature regarding the use of nickel metal as a starting anode material, rather than the traditional nickel oxide powder, and how porosity may affect the anode properties. <br /> The purpose of this investigation is to determine the influence nickel morphology and porosity distribution have on the processing and properties of tape cast Ni/YSZ composites. Specifically, the sintering characteristics, electrical conductivity, and thermal expansion behaviour of tape cast composites created from YSZ, nickel, nickel oxide (NiO), nickel coated graphite (NiGr), and/or graphite (Gr) powders are investigated. In addition to samples made from 100% YSZ, 100% Ni, and 100% NiO powders, five composite types were created for this investigation: NiO/YSZ, NiO&Gr/YSZ, Ni/YSZ, NiGr/YSZ, and Ni&Gr/YSZ each with nickel loadings varying between 4 vol% Ni of total solids and 77 vol% Ni of total solids. Another set of composites with a fixed nickel loading of 27 vol% Ni and 47 vol% Ni of total solids and varying graphite loadings were also created. <br /> During the burnout stage, the composites made from nickel oxide powder shrink slightly while the composites made from nickel metal expand due to nickel oxidation. Graphite additions below 20 vol% of the green volume do not alter the dimensional changes of the composites during burnout, but graphite loadings greater than 25 vol% of the green volume cause significant expansion in the thickness of the composites. <br /> After sintering, the amount of volumetric sintering shrinkage decreases with higher nickel loadings and is greater for the composites made with nickel oxide compared to the composites made from nickel metal. The porosity generated in the composites containing graphite is slightly higher than the volume of graphite added to the composite and is much greater than the porosity contained in the graphite-free composites. <br /> Dimensional changes of the porous Ni/YSZ and NiO/YSZ composites during both burnout and sintering were analysed based on concepts of constrained sintering of composite powder mixtures. In some cases constrained sintering was evident, while in others, a more simple rule of mixtures behaviour for shrinkage as a function of YSZ content was observed. <br /> When nickel oxide is reduced to nickel metal during the reduction stage there is essentially no change in the composite volume for the composites containing YSZ because the YSZ prevents the composites from shrinking. After reduction the additional porosity generated in the composites is equivalent to the change in volume due to the reduction of nickel oxide to nickel metal. <br /> When measuring the electrical conductivity, each composite type demonstrated classic percolation behaviour. The NiGr/YSZ composites had the lowest percolation threshold, followed by the Ni/YSZ and NiO/YSZ composites. When graphite was added with a nickel coating, the added porosity did not disrupt the nickel percolation network and allowed the nickel to occupy a larger effective volume compared to a composite made with similar sized solid nickel particles. When graphite was added to the composites, the electrical conductivity was reduced and the percolation threshold increased. <br /> Generally, the coefficient of thermal expansion (CTE) for Ni/YSZ composites are expected to follow the rule of mixtures prediction since the elastic properties for nickel and YSZ are similar. However when porosity is distributed unevenly between the YSZ and nickel phases, the CTE prediction will deviate from the rule of mixtures. When cornstarch was added to the NiGr/YSZ composites, the CTE increased as the amount of porosity in the YSZ phase increased. The CTE of the NiGr/YSZ composites followed the rule of mixtures indicating that the porosity was evenly distributed between the nickel and YSZ phases. For the other composite types, the measured CTE was higher than the rule of mixtures prediction suggesting that more porosity was contained within the YSZ phase.

A solid oxide fuel cell (SOFC) is an energy conversion device that has the potential to efficiently generate electricity in an environmentally-friendly manner. In general, a SOFC operates between 750&deg;C and 1000&deg;C utilizing hydrogen or hydrocarbons as fuel and air as an oxidant. The three major components comprising a fuel cell are the electrolyte, the cathode, and the anode. At present, the state-of-the-art SOFC is made from a dense yttria-stabilized zirconia (YSZ) electrolyte, a porous lanthanum manganite cathode, and a porous nickel/YSZ composite anode. With the advent of the anode-supported SOFC and the increased interest in using a wider range of fuels, such as those containing sulphur, knowledge of the anode properties is becoming more important. <br /> The properties of the current anodes are limited due to the narrow range of nickel loadings imposed by the minimum nickel content for electrical conductivity and the maximum allowable nickel loading to avoid thermal mismatch with the YSZ electrolyte. In addition, there is little research presented in the literature regarding the use of nickel metal as a starting anode material, rather than the traditional nickel oxide powder, and how porosity may affect the anode properties. <br /> The purpose of this investigation is to determine the influence nickel morphology and porosity distribution have on the processing and properties of tape cast Ni/YSZ composites. Specifically, the sintering characteristics, electrical conductivity, and thermal expansion behaviour of tape cast composites created from YSZ, nickel, nickel oxide (NiO), nickel coated graphite (NiGr), and/or graphite (Gr) powders are investigated. In addition to samples made from 100% YSZ, 100% Ni, and 100% NiO powders, five composite types were created for this investigation: NiO/YSZ, NiO&Gr/YSZ, Ni/YSZ, NiGr/YSZ, and Ni&Gr/YSZ each with nickel loadings varying between 4 vol% Ni of total solids and 77 vol% Ni of total solids. Another set of composites with a fixed nickel loading of 27 vol% Ni and 47 vol% Ni of total solids and varying graphite loadings were also created. <br /> During the burnout stage, the composites made from nickel oxide powder shrink slightly while the composites made from nickel metal expand due to nickel oxidation. Graphite additions below 20 vol% of the green volume do not alter the dimensional changes of the composites during burnout, but graphite loadings greater than 25 vol% of the green volume cause significant expansion in the thickness of the composites. <br /> After sintering, the amount of volumetric sintering shrinkage decreases with higher nickel loadings and is greater for the composites made with nickel oxide compared to the composites made from nickel metal. The porosity generated in the composites containing graphite is slightly higher than the volume of graphite added to the composite and is much greater than the porosity contained in the graphite-free composites. <br /> Dimensional changes of the porous Ni/YSZ and NiO/YSZ composites during both burnout and sintering were analysed based on concepts of constrained sintering of composite powder mixtures. In some cases constrained sintering was evident, while in others, a more simple rule of mixtures behaviour for shrinkage as a function of YSZ content was observed. <br /> When nickel oxide is reduced to nickel metal during the reduction stage there is essentially no change in the composite volume for the composites containing YSZ because the YSZ prevents the composites from shrinking. After reduction the additional porosity generated in the composites is equivalent to the change in volume due to the reduction of nickel oxide to nickel metal. <br /> When measuring the electrical conductivity, each composite type demonstrated classic percolation behaviour. The NiGr/YSZ composites had the lowest percolation threshold, followed by the Ni/YSZ and NiO/YSZ composites. When graphite was added with a nickel coating, the added porosity did not disrupt the nickel percolation network and allowed the nickel to occupy a larger effective volume compared to a composite made with similar sized solid nickel particles. When graphite was added to the composites, the electrical conductivity was reduced and the percolation threshold increased. <br /> Generally, the coefficient of thermal expansion (CTE) for Ni/YSZ composites are expected to follow the rule of mixtures prediction since the elastic properties for nickel and YSZ are similar. However when porosity is distributed unevenly between the YSZ and nickel phases, the CTE prediction will deviate from the rule of mixtures. When cornstarch was added to the NiGr/YSZ composites, the CTE increased as the amount of porosity in the YSZ phase increased. The CTE of the NiGr/YSZ composites followed the rule of mixtures indicating that the porosity was evenly distributed between the nickel and YSZ phases. For the other composite types, the measured CTE was higher than the rule of mixtures prediction suggesting that more porosity was contained within the YSZ phase.

Polymer electrolyte membrane (PEM) fuel cells are promising alternative green power source for mobile, portable and stationary applications. However, their cost, durability, and performance are impacted by their sensitivity to impurities in fuel stream. Carbon monoxide (CO), an impurity commonly present in the hydrogen gas produced from hydrocarbon fuels, is known to have a significant degrading effect on PEM fuel cell performance because CO has a strong affinity to the platinum-based catalyst. At present, most studies in literature are limited to either experimental or simplified-dimensional analysis/modeling. In this thesis research, a three-dimensional (3D) multiphase PEM fuel cell model with the CO poisoning and O2 bleeding is developed based on the conservation laws for mass, momentum, energy, and species, and implemented in the commercial software Fluent (6.3.26) through the user-defined functions. Numerical simulations are conducted to simulate a single PEM fuel cell including flow channels, gas diffusion layers, catalyst layers, and PEM. The simulation results are compared with experimental data favorably. The result shows that the reaction rate of hydrogen in the anode catalyst layer is higher near the membrane layer, decreasing towards the gas diffusion layer (GDL) interface, and the reaction rate in general is higher in the inlet region and decreases towards the exit region of the flow channel. It means that the outlet of anode catalyst layer next to the flow channel and GDL has suffered the most significant poisoning effect. The result helps optimize the design of anode catalyst layer by embedding more platinum on the most poisoned area to increase available surface for hydrogen adsorption; similarly, reducing platinum loading on the less poisoned area. The fuel cell performance can be almost fully recovered when switching the anode fuel mixture to pure hydrogen, though it takes a long period of time. The reaction rate of hydrogen decreases significantly along the flow channel when impurity mixture is provided; while there is little change along the channel for pure hydrogen fuel. Adding oxygen into the anode fuel mixture can mitigate CO poisoning, but there is a time delay when the oxygen is introduced into the anode stream and when the performance starts to recover. It is observed that at the beginning of oxygen introduced in the anode stream the recovery rate in the region adjacent to the channel outlet is faster than the rate in the region close to the inlet. This difference in the recovery rate gradually becomes smaller over time. In addition, the influence of CO poisoning and oxygen bleeding on multi-phase water is investigated. The influence on dissolved water is only clearly seen in the anode catalyst layer next to the land area. Finally, response to sudden load changes is simulated by changing cell voltage. It is found that the overshoot and undershoot are more significant at high current densities.

Non-woven carbon paper is a porous material composed of carbon composite and is the preferred material for use as the gas diffusion layer (GDL) of polymer electrolyte membrane (PEM) fuel cells. This material is both chemically and mechanically stable and provides a free path for diffusion of reactants and removal of products and is electrically conductive for transport of electrons. The transport of species in the GDL has a direct effect on the overall reaction rate in the catalyst layer. Numerical simulation of these transport phenomena is dependent on the transport properties associated with each phenomenon. Most of the available correlations in literature for these properties have been formulated for spherical shell porous media, sand and rock, which are not representative of the structure of the GDL. Hence, the objective of this research work is to investigate the transport properties (diffusion coefficient, thermal conductivity, electrical conductivity, intrinsic and relative permeability and the capillary pressure) of the GDL using experimental and numerical techniques. In this thesis, a three-dimensional reconstruction of the complex, anisotropic structure of the GDL based on stochastic models is used to estimate its transport properties. To establish the validity of the numerical results, an extensive comparison is carried out against published and measured experimental data. It was found that the existing theoretical models result in inaccurate estimation of the transport properties, especially in neglecting the anisotropic nature of the layer. Due to the structure of the carbon paper GDL, it was found that the value of the transport properties in the in-plane direction are much higher than that in the through-plane direction. In the in-plane direction, the fibers are aligned in a more structured manner; hence, the resistance to mass transport is reduced. Based on the numerical results presented in this thesis, correlations of the transport properties are developed. Further, the structure of the carbon paper GDL is investigated using the method of standard porosimetry. The addition of Teflon was found have little effect on the overall pore volume at a pore radius of less than 3 micro meters. A transition region where the pore volume increased with the increase in pore radius was found to occur for a pore radius in the range 3<5.5 micro meters regardless of the PTFE content. Finally, the reduction of the overall pore volume was found to be proportional to the PTFE content. The diffusion coefficient is also measured in this thesis using a Loschmidt cell. The effect of temperature and PTFE loading on the overall diffusibility is examined. It was found that the temperature does not have an effect on the overall diffusibility of the GDL. This implies that the structure of the GDL is the main contributor to the resistance to gas diffusion in the GDL. A comparison between the measured diffusibility and that predicted by the existing available models in literature indicate that these models overpredict the diffusion coefficient of the GDL significantly. Finally, both the in-plane and through-plane thermal conductivity were measured using the method of monotonous heating. This method is a quasi-steady method; hence, it allows the measurement to be carried out for a wide range of temperatures. With this method, the phase transformation due to the presence of PTFE in the samples was investigated. Further, it was found that the through-plane thermal conductivity is much lower than its in-plane counterpart and has a different dependency on the temperature. Detailed investigation of the dependency of the thermal conductivity on the temperature suggests that the thermal expansion in the through-plane direction is positive while it is negative in the in-plane direction. This is an important finding in that it assists in further understanding of the structure of the carbon paper GDL. Finally, the thermal resistance in the through-plane direction due to fiber stacking was investigated and was shown to be dependent on both the temperature and compression pressure.