Thesis (Ph.D.(Chemistry)) -- University of Limpopo, 2020 / The interest on the use of proton exchange membrane (PEM) fuel cells for vehicle application has increase due to its efficiency, high power density and rapid start up. The on-board reforming process is used to generate hydrogen; however, this process simultaneously produces 1% CO which poisons Pt-based anode catalyst. Previous studies have shown that supported Pd-based catalysts have very good stability on preferential oxidation (PROX) of CO, but these catalysts suffer from lower selectivity. Metal oxides such as Co3O4 and CeO2 are known to have high oxygen vacancy which promotes CO oxidation. Furthermore, the pre-treatment of the catalysts by hydrazine as well as the addition of MnOx species have been shown to improve the surface properties of metal/metal oxides catalysts. The study envisages that the modification of PROX catalysts will improve the CO conversion and its selectivity while maintaining higher stability. In this work, as-prepared (Co3O4) and hydrazine treated cobalt (Co3O4(H)) based catalysts were prepared by precipitation method and investigated at temperature range of 40-220 oC for preferential oxidation (PROX) of CO in excess hydrogen. The FTIR and XPS data of hydrazine treated Co3O4 does not show peak ratio differences, indicating that usual amounts of Co3+ and Co2+ were formed. An improved surface reducibility with smaller crystallite size was noted on Co3O4(H) catalyst, which indicate some surface transformation. Interestingly, the in-situ treatment of standalone Co3O4(H) decreased the maximum CO conversion temperature (T100%) from 160 oC (over Co3O4) to 100 oC. The Co3O4(H) catalyst showed good stability, with approximately 85% CO conversion at 100 oC for 21 h, as compared to fast deactivation of the Co3O4 catalyst. However, the Co3O4(H) catalyst was unstable in both CO2 and the moisture environment. Based on the spent hydrazine treated (CoO(H)) cobalt catalyst, the high PROX is associated with the formation of Co3+ species as confirmed by XRD, XPS, and TPR data. The Pd species was incorporated on different Co3O4 by improved wet impregnation method and this has improved the surface area of the overall catalysts. However, the presence of Pd species on Co3O4(H) catalyst decreased the CO conversion due to formation of moisture. Although, the Pd on Co3O4(H) had lower activity, the catalyst showed better stability under both moisture and CO2 conditions at 100 oC for 21 h. vi The 2wt.% metal oxides (MnO2, CeO2, Cr3O4, TiO2, MgO) on cobalt, and Pd on CeO2- Co3O4 and MnO2-Co3O4 were prepared by co-precipitation method and the structural composition was confirmed by XRD, FTIR, XPS and TPR data. Although, 2wt.%MnO2 on Co3O4(H) showed higher activity at 80 oC, both MnO2 and CeO2 improved the activity of Co3O4(H) at 100 oC. The higher activity of MnO2 is attributed to the higher surface area of the composite catalyst, in relation to ceria composite catalyst. Although the MnO2 species transformed the structure of Co3O4 by lowering the oxidation state to Co2+, the spent catalyst showed transformation from Co2+ to Co3+ during PROX, as confirmed by TPR data. Studies on the effects of CeO2 loading on Co3O4 catalysts, showed an optimum activity over 2wt.%CeO2-Co3O4 as compared to other ceria loadings (i.e., 3, 5, 8, 10, 15, 30wt.%CeO2). However, upon addition of 0.5wt.%Pd species on 2wt.%CeO2- Co3O4(H) composite, the activity of the catalyst decreased slightly at 100 oC, which could be due to a decreased surface area. Although its activity is lower, the catalyst has shown good stability in dry, moisture and CO2 conditions at 100 oC for 21 h. In addition, studies were also undertaken on the effect of MnO2 concentration on Co3O4 catalysts. The data shows that 7wt.%MnO2 species improved the activity of Co3O4 catalyst at 60 oC, however, the catalyst could not improve the activities at higher temperatures. This low activity is associated with a decrease in surface area as concentration increases. The presence of 0.5wt.%Pd species on 7wt.%MnO2-Co3O4 increased the activity at 60 and 80 oC, which could be due to reduction of Co3+ to Co2+ in the presence of Pd, as confirmed by XPS data. The catalyst has shown good stability in dry, moisture, and CO2 conditions at 100 oC for 21 h. The hydrazine treated cobalt-based catalysts in the presence of palladium and manganese oxide is the promising catalysts for proton exchange membrane fuel cells technology. / National Research Foundation (NRF) , Faculty of Science and Agriculture University of Limpopo and School of Physical and Mineral Sciences

In view of the unfavorable panorama of actual energy supply practices, alternative sustainable energy sources and conversion approaches have acquired noteworthy significance in recent years. Among these, proton exchange membrane fuel cells (PEMFCs) are being considered as a pivotal building block in the transition towards a sustainable energy economy. The proton exchange membrane (PEM) is a vital component, as well as a performance-limiting factor, of the PEMFC. Consequently, the development of high performance PEM materials is of upmost importance for the advance of the PEMFC field. In this work, alternative PEM materials based on semi-interpenetrated networks from blends of poly(vinyledene fluoride) (PVDF) and sulfonated crosslinked acrylic polyelectrolytes (PE), as well as tri-phase PVDF/PE/zirconium-based composites, are studied. To alleviate the burden resulting from the vast number of possible combinations of the different precursors utilized in the preparation of the membranes, custom high throughput screening systems have been developed for their characterization. By coupling the data spaces obtained via these systems with the appropriate statistical and data analysis tools it was found that, despite not being directly involved in the proton transport process, the inert PVDF phase plays a major role on proton conductivity. Particularly, a univocal inverse correlation between the PVDF crystalline characteristics (i.e., crystallinity and crystallite size) and melt viscosity, and membrane proton conductivity was discovered. Membranes based on highly crystalline and viscous PVDF homopolymers exhibited reduced proton conductivity due to precluded segmental motion of the PE chains during crosslinking. In addition, a maximum effective amount of PE (55-60wt%) beneficial for proton conductivity was revealed. In the case of composite membranes, despite the fact that nanoparticle dispersion was thermodynamically limited, a general improvement in proton conductivity was evidenced at low to medium nanoparticle loadings (0.5 to 1wt%) in comparison to non-hybrid PVDF/PE references. This beneficial effect was particularly noticeable in membranes based on PVDF homopolymers (7% to 14.3% increment), where the nanoparticles induced a "healing" effect by providing proton-conducting paths between non-crosslinked PE channels separated by dense PVDF areas resulting from large PVDF crystallites. In general, the results presented herein are promising for the development of new cost-effective alternative PEMs.

In this dissertation, the effect of temperature and humidity on the viscoelastic and fracture properties of proton exchange membranes (PEM) used in fuel cell applications was studied. Understanding and accurately modeling the linear and nonlinear viscoelastic constitutive properties of a PEM are important for making hygrothermal stress predictions in the cyclic temperature and humidity environment of operating fuel cells. In this study, Nafion® NRE 211, Gore-Select® 57, and Ion Power® N111-IP were characterized under various humidity and temperature conditions. These membranes were subjected to a nominal strain in a dynamic mechanical analyzer (DMA), and their stress relaxation behavior was characterized over a period of time. Hygral master curves were constructed noting hygral shift factors, followed by thermal shifts to construct a hygrothermal master curve. This process was reversed (thermal shifts followed by hygral shifts) and was seen to yield a similar hygrothermal master curve. Longer term stress relaxation tests were conducted to validate the hygrothermal master curve. The Prony series coefficients determined based on the hygrothermal stress relaxation master curves were utilized in a linear viscoelastic stress model. The nonlinear viscoelastic behavior of the membranes was characterized by conducting creep tests on uniaxial tensile specimens at various constant stress conditions and evaluating the resulting isochronal stress-strain plots. The nonlinearity was found to be induced at relatively moderate stress/strain levels under dry conditions. To capture the nonlinearity, the well known Schapery model was used. To calculate the nonlinear parameters defined in the Schapery model, creep/recovery tests at various stress levels and temperatures were performed. A one-dimensional Schapery model was developed and then validated using various experiments. The fracture properties were studied by cutting membranes using a sharp knife mounted on a specially designed fixture. Again, various temperature and humidity conditions were used, and the fracture energy of the membranes was recorded as a function of cutting rate. Fracture energy master curves with respect to reduced cutting rates were constructed to get some idea about the intrinsic fracture energy of the membrane. The shift factors obtained from the fracture tests were found to match with those obtained from the stress relaxation experiments, suggesting that the knife cutting process is viscoelastic in nature. The rate and temperature dependence for these fracture energies are consistent with the rate, temperature, and moisture dependence of the relaxation modulus, suggesting the usefulness of a viscoelastic framework for examining and modeling durability of fuel cell membranes. The intrinsic fracture energy was initially thought to be a differentiating factor, which would separate various membranes tested in this study from one another. However, it was later found that all the membranes tested showed similar values at lower cutting rates, but showed significant variation at higher reduced cutting rates, and thus was thought to be a more meaningful region to differentiate the membranes for durability understanding. While the preceding work was undertaken to characterize as-received commercial PEMs, it is possible to modify material properties through treatment processes including thermal annealing and water treatment. The transient and dynamic viscoelastic properties of water-treated Nafion membranes revealed unusual behavior. Such unusual properties might have originated from irreversible morphological changes in PEM. Besides the constitutive viscoelastic properties, another set of properties useful for the stress modeling is the hygral strain induced as a function of relative humidity (RH) The effect of pretreatment on hygral strains induced as a function of RH was also investigated. These studies suggest that pretreatment significantly changes the mechanical properties of proton exchange membranes. / Ph. D.

Over the past three decades, the steady decrease in fossil energy resources, combined with a sustained increase in the demand for clean energy, has led the scientific community to develop new ways to produce energy. As is well known, one of the main challenges to overcome with fossil fuel-based energy sources is the reduction or even elimination of pollutant gases in the atmosphere. Although some advances have helped to slow the emission of greenhouse gases into the atmosphere (e.g., electric cars and more fuel-efficient gas-burning automobiles), most experts agree that it is not enough. Proton Exchange Membrane (PEM) fuel cells have been widely recognized as a potentially viable alternative for portable and stationary power generation, as well as for transportation. However, the widespread commercialization Proton Exchange Membrane Fuel Cells (PEMFCs) involves a thorough understanding of complex scientific and technological issues. This study investigated the various structure-property relationships and materials durability parameters associated with PEMFC development. First, the correlation between perfluorinated ionomer membranes and processing/performance issues in fuel cell systems was investigated. As confirmed by small-angle X-ray scattering data, impedance analysis, and dynamic mechanical analysis, solution processing with mixed organic-inorganic counterions was found to be effective in producing highly arranged perfluorinated sulfonic acid ionomer (PFSI) membranes with more favorable organization of the ionic domain. Moreover, thermal annealing was shown to enhance the proton mobility, thereby facilitating reorganization of the polymer backbone and the hydrophilic region for improved crystallinity and proton transport properties. This research also confirmed an increase in water uptake in the solution-processed membranes under investigation, which correlated to an increase in proton conductivity. Thus, annealing and solution-processing techniques were shown to be viable ways for controlling morphology and modulating the properties/performance of PFSI membranes. Second, this study investigated the role of the morphology on water and proton transport in perfluorinated ionomers. When annealed at high temperatures, a significant decrease in water uptake and an increase in crystallinity were observed, both of which are detrimental to fuel cell performance. Additionally, controlling the drying process was found to be crucial for optimizing the properties and performance of these membranes, since drying at temperatures close or above the α-relaxation temperature causes a major reorganization within the ionic domains. Third, although many investigations have looked at key PEMFC components, (e.g., the membrane, the catalyst, and the bipolar plates), there have been few studies of more "minor" components—namely, the performance and durability of seals, sealants, and adhesives, which are also exposed to harsh environmental conditions. When seals degrade or fail, reactant gases leak or are mixed, it can degrade the membrane electrode assembly (MEA), leading to a performance decrease in fuel cell stack performance. This portion of the research used degradation studies of certain proprietary elastomeric materials used as seals to investigate their overall stability and performance in fuel cell environments with applied mechanical stresses. Additionally, characterization of the mechanical and viscoelastic properties of these materials was conducted in order to predict the durability based on accelerated aging simulations as well. Continuous stress relaxation (CSR) characterization was performed on molded seals over a wide range of aging conditions using a customized CSR fixture. The effects of temperature, stress, and environmental conditions are reported in terms of changes in momentary and stress relaxations, chain scission and secondary crosslink formation. Aging studies provided insights on how anti-degradants or additives affect the performance and properties of sealing materials, as well as how a variety of environmental considerations might be improved to extend the lifetime of these elastomers. / Ph. D.

In light of the world‟s growing demand for energy that is environmentally friendly and sustainable, energy sources such as hydrogen have been considered potential contenders. Hydrogen, which can be used for energy storage, can be produced efficiently by the membrane based Hybrid Sulfur (HyS) thermo-chemical process consisting of a decomposition and an electrolysis step. During the HyS electrolysis step, SO2 and H2O are converted to H2 and H2SO4, which implies that the proton exchange membranes (PEMs) to be used for this process should have a high proton conductivity, limited SO2 cross-over and good H2SO4 stability. In order to find alternatives to the costly and high-temperature unstable Nafion®, the aim of this study was to evaluate the H2SO4 stability of various novel membranes. To structure the study, the novel PEM materials were grouped according to the PBI-type base component within the blend membranes, resulting in three groups comprising non-PBI based membranes, PBIOO based membranes and F6-PBI based membranes. Nafion®212 was included as reference PEM. By repeating the H2SO4 treatment with three different Nafion®212 samples, the obtained Nafion® data was also used to determine the experimental and analytical error margins for the study. The stability of all membranes was determined by submerging the membrane samples in 80 wt% H2SO4 at 80 °C for 120 hours. To determine the influence of the acid on the membranes, all samples were characterised before and after the H2SO4 treatment and compared in terms of their acid stability. Physical characterisation of the PEMs included the evaluation of weight and thickness changes, while IEC, SEM-EDX, FTIR and TGA were used to elucidate possible chemical changes due to the H2SO4 treatment. According to the Nafion®212 data, which had been obtained in triplicate for each of the analytical techniques, the experimental error of both the analytical and H2SO4 treatment remained below 10 %, except for the SEM-EDX sulfur-content where significantly larger errors were observed. In spite of the high error margins of the SEM-EDX data (S-content), its results, combined with the results from the other analytical techniques, resulted in a better understanding (both physical and chemical) of the effect the H2SO4 had on the membrane. This further facilitated the evaluation and comparison of the various blended PEM materials in terms of their H2SO4 stability, and the subsequent relation obtained between the observed stability and the chemical constitution and cross-linking of the membranes. After the 80 wt% H2SO4 treatment, significant weight losses were reported for the non-PBI based and PBIOO based membrane groups in comparison with the minimal changes noted for the F6-PBI based group and Nafion®212. Furthermore, significant thickness changes were reported for most of the PBIOO based membranes. The small weight and thickness changes observed for the F6-PBI confirmed the improved stability of this group of membranes in an H2SO4 environment, most likely due to the protective role of the partially fluorinated basic polymer and the known strength of the C-F bonds present. The results showed a clear correlation between the H2SO4 stability and the specific polymers present in the PEM blends investigated. Specific effects found included sulfonation, salt formation, hydrolysis and the accompanied dissolution of membrane fragments. Significant physical changes, for example ascribed to sulfonation of the concerned polymers, were supported by increased IEC measurements and peak intensities of the FTIR spectra, corresponding to the additional –SO3H groups present, while a variation in TGA signals served to further support the altered membrane composition and structure due to the H2SO4 treatment. In the case of dissolution, the corresponding chemical changes (analytical techniques) were supported by the decreased peak intensities of FTIR spectra, IEC measurements and TGA signals associated with degradation of the polymer backbone. It was shown that the stability of the blended membranes depended on the composition (blend components) of the membrane and the effective cross-linking (interaction) between the blend components. For all three groups examined, it became apparent that blend components sFS and sPSU were, for example, more stable than sPEEK and that ionical cross-linking seemed more effective than covalent cross-linking of blend components. When considering all membranes tested, the non-PBI based blend membranes consisting of (s)PSU and PFS copolymers in the presence of fluorinated cross-linkers and the PBIOO-sPSU blended membranes including most of the F6-PBI based membranes showed sufficient stability to be recommended for SO2 electrolysis. / MSc (Chemistry), North-West University, Potchefstroom Campus, 2014

In recent years an emphasis has been placed on the development of alternative and clean energy sources to reduce the global use of fossil fuels. One of these alternatives entails the use of H2 as an energy carrier, which can be obtained amongst others using thermochemical processes, for example the hybrid sulphur process (HyS). The HyS process is based on the thermal decomposition of sulphuric acid into water, sulphur dioxide and oxygen. The subsequent chemical conversion of the sulphur dioxide saturated water back to sulphuric acid and hydrogen is achieved in an electrolyser using a platinum coated proton exchange membrane. This depolarised electrolysis requires a theoretical voltage of only 0.158 V compared to water electrolysis requiring approximately 1.23 V. One of the steps in the development of this technology at the North-West University, entailed the establishment of the platinum coating technology which entailed two steps; firstly using newly obtained equipment to manufacture the membrane electro catalyst assemblies (MEA’s) and gas diffusion electrodes (GDE’s) and secondly to test these MEA’s and GDE’s using sulphur dioxide depolarized electrolysis by comparing the manufactured MEA’s and GDE’s to commercially available MEA’s and GDE’s. Different MEA’s and GDE’s were manufactured using both a screen printing (for the microporous layer deposition) and a spraying technique. The catalyst loadings were varied as well as the type and thickness of the proton exchange membranes used. The proton exchange membranes that were included in this study were Nafion 117®, sPSU-PBIOO and SfS-PBIOO membranes whereas the gas diffusion layer consisted of carbon paper with varying thicknesses (EC-TP01-030 – 0.11 mm and EC-TP01-060 – 0.19mm). MEA and GDE were prepared by first preparing an ink that was used both for MEA and GDE spraying. The MEA’s were prepared by spraying various catalyst coatings onto the proton exchange membranes containing 0.3, 0.6 and 0.9 mg/cm2 platinum respectively. The GDE’s were first coated by a micro porous carbon layer using the screen printing technique in order to attain a suitable surface for catalyst deposition. Using the spraying technique GDE’s containing 0.3, 0.6, 0.9 mg/cm2 platinum were prepared. After SEM analysis, the MEA’s and GDE’s performance was measured using SO2 depolarized electrolysis. From the electrolysis experiments, the voltage vs. current density generated during operation, the hydrogen production, the sulphuric acid generation and the hydrogen production efficiency was obtained. From the results it became clear that while the catalyst loading had little effect on performance there were a number of factors that did have a significant influence. These included the type of proton exchange membrane, the membrane thickness and whether the catalyst coating was applied to the proton exchange membrane (MEA) or to the gas diffusion layer (GDE). During SO2 depolarized electrolysis VI curves were generated which gave an indication of the performance of the GDE’s and MEA’s. The best preforming GDE was GDE-3 (0.46V @ 320 mA/cm2), which included a GDE EC-TP01-060, while the best preforming MEA’s were NAF-4 (0.69V @ 320mA/cm2) consisting of a Nafion117 based MEA and PBI-1 (0.43V @ 320mA/cm2) made from a sPSU-PBIOO blended membrane. During hydrogen production it became clear that the GDE’s produced the most hydrogen (best was GDE-02 a in house manufactured GDE yielding 67.3 mL/min @ 0.8V), followed by the Nafion® MEA’s (best was NAF-4 a commercial MEA yielding 57.61 mL/min @ 0.74V) and the PBI based MEA’s. , (best was PBI-2 with 67.11 mL/min @ 0.88V). Due to the small amounts of acid produced and the SO2 crossover, a significant error margin was observed when measuring the amount of sulphuric acid produced. Nonetheless, a direct correlation could still be seen between the acid and the hydrogen production as had been expected from literature. The highest sulphuric acid concentrations produced using the tested GDE’s and MEA’s from this study were the in-house manufactured GDE-01 (3.572mol/L @ 0.8V), the commercial NAF-4 (4.456mol/L @ 0.64V) and the in-house manufactured PBI-2 (3.344mol/L @ 0.8V). The overall efficiency of the GDE’s were similar, ranging from less than 10% at low voltages (± 0.6V) increasing to approximately 60% at ± 0.8V. For the MEA’s larger variation was observed with NAF-4 reaching efficiencies of nearly 80% at 0.7V. In terms of consistency of performance it was shown that the Nafion MEA’s preformed most consistently followed by the GDE’s and lastly the PBI based MEA’s which for the PBI based membranes can probably be ascribed to the significant difference in thickness of the thin PBI vs. the Nafion based membranes. In summary the study has shown the results between the commercially obtained and the in-house manufactured GDE’s and MEA’s were comparable confirming the suitability of the coating techniques evaluated in this study. / MSc (Chemistry), North-West University, Potchefstroom Campus, 2014

In light of the world‟s growing demand for energy that is environmentally friendly and sustainable, energy sources such as hydrogen have been considered potential contenders. Hydrogen, which can be used for energy storage, can be produced efficiently by the membrane based Hybrid Sulfur (HyS) thermo-chemical process consisting of a decomposition and an electrolysis step. During the HyS electrolysis step, SO2 and H2O are converted to H2 and H2SO4, which implies that the proton exchange membranes (PEMs) to be used for this process should have a high proton conductivity, limited SO2 cross-over and good H2SO4 stability. In order to find alternatives to the costly and high-temperature unstable Nafion®, the aim of this study was to evaluate the H2SO4 stability of various novel membranes. To structure the study, the novel PEM materials were grouped according to the PBI-type base component within the blend membranes, resulting in three groups comprising non-PBI based membranes, PBIOO based membranes and F6-PBI based membranes. Nafion®212 was included as reference PEM. By repeating the H2SO4 treatment with three different Nafion®212 samples, the obtained Nafion® data was also used to determine the experimental and analytical error margins for the study. The stability of all membranes was determined by submerging the membrane samples in 80 wt% H2SO4 at 80 °C for 120 hours. To determine the influence of the acid on the membranes, all samples were characterised before and after the H2SO4 treatment and compared in terms of their acid stability. Physical characterisation of the PEMs included the evaluation of weight and thickness changes, while IEC, SEM-EDX, FTIR and TGA were used to elucidate possible chemical changes due to the H2SO4 treatment. According to the Nafion®212 data, which had been obtained in triplicate for each of the analytical techniques, the experimental error of both the analytical and H2SO4 treatment remained below 10 %, except for the SEM-EDX sulfur-content where significantly larger errors were observed. In spite of the high error margins of the SEM-EDX data (S-content), its results, combined with the results from the other analytical techniques, resulted in a better understanding (both physical and chemical) of the effect the H2SO4 had on the membrane. This further facilitated the evaluation and comparison of the various blended PEM materials in terms of their H2SO4 stability, and the subsequent relation obtained between the observed stability and the chemical constitution and cross-linking of the membranes. After the 80 wt% H2SO4 treatment, significant weight losses were reported for the non-PBI based and PBIOO based membrane groups in comparison with the minimal changes noted for the F6-PBI based group and Nafion®212. Furthermore, significant thickness changes were reported for most of the PBIOO based membranes. The small weight and thickness changes observed for the F6-PBI confirmed the improved stability of this group of membranes in an H2SO4 environment, most likely due to the protective role of the partially fluorinated basic polymer and the known strength of the C-F bonds present. The results showed a clear correlation between the H2SO4 stability and the specific polymers present in the PEM blends investigated. Specific effects found included sulfonation, salt formation, hydrolysis and the accompanied dissolution of membrane fragments. Significant physical changes, for example ascribed to sulfonation of the concerned polymers, were supported by increased IEC measurements and peak intensities of the FTIR spectra, corresponding to the additional –SO3H groups present, while a variation in TGA signals served to further support the altered membrane composition and structure due to the H2SO4 treatment. In the case of dissolution, the corresponding chemical changes (analytical techniques) were supported by the decreased peak intensities of FTIR spectra, IEC measurements and TGA signals associated with degradation of the polymer backbone. It was shown that the stability of the blended membranes depended on the composition (blend components) of the membrane and the effective cross-linking (interaction) between the blend components. For all three groups examined, it became apparent that blend components sFS and sPSU were, for example, more stable than sPEEK and that ionical cross-linking seemed more effective than covalent cross-linking of blend components. When considering all membranes tested, the non-PBI based blend membranes consisting of (s)PSU and PFS copolymers in the presence of fluorinated cross-linkers and the PBIOO-sPSU blended membranes including most of the F6-PBI based membranes showed sufficient stability to be recommended for SO2 electrolysis. / MSc (Chemistry), North-West University, Potchefstroom Campus, 2014

In recent years an emphasis has been placed on the development of alternative and clean energy sources to reduce the global use of fossil fuels. One of these alternatives entails the use of H2 as an energy carrier, which can be obtained amongst others using thermochemical processes, for example the hybrid sulphur process (HyS). The HyS process is based on the thermal decomposition of sulphuric acid into water, sulphur dioxide and oxygen. The subsequent chemical conversion of the sulphur dioxide saturated water back to sulphuric acid and hydrogen is achieved in an electrolyser using a platinum coated proton exchange membrane. This depolarised electrolysis requires a theoretical voltage of only 0.158 V compared to water electrolysis requiring approximately 1.23 V. One of the steps in the development of this technology at the North-West University, entailed the establishment of the platinum coating technology which entailed two steps; firstly using newly obtained equipment to manufacture the membrane electro catalyst assemblies (MEA’s) and gas diffusion electrodes (GDE’s) and secondly to test these MEA’s and GDE’s using sulphur dioxide depolarized electrolysis by comparing the manufactured MEA’s and GDE’s to commercially available MEA’s and GDE’s. Different MEA’s and GDE’s were manufactured using both a screen printing (for the microporous layer deposition) and a spraying technique. The catalyst loadings were varied as well as the type and thickness of the proton exchange membranes used. The proton exchange membranes that were included in this study were Nafion 117®, sPSU-PBIOO and SfS-PBIOO membranes whereas the gas diffusion layer consisted of carbon paper with varying thicknesses (EC-TP01-030 – 0.11 mm and EC-TP01-060 – 0.19mm). MEA and GDE were prepared by first preparing an ink that was used both for MEA and GDE spraying. The MEA’s were prepared by spraying various catalyst coatings onto the proton exchange membranes containing 0.3, 0.6 and 0.9 mg/cm2 platinum respectively. The GDE’s were first coated by a micro porous carbon layer using the screen printing technique in order to attain a suitable surface for catalyst deposition. Using the spraying technique GDE’s containing 0.3, 0.6, 0.9 mg/cm2 platinum were prepared. After SEM analysis, the MEA’s and GDE’s performance was measured using SO2 depolarized electrolysis. From the electrolysis experiments, the voltage vs. current density generated during operation, the hydrogen production, the sulphuric acid generation and the hydrogen production efficiency was obtained. From the results it became clear that while the catalyst loading had little effect on performance there were a number of factors that did have a significant influence. These included the type of proton exchange membrane, the membrane thickness and whether the catalyst coating was applied to the proton exchange membrane (MEA) or to the gas diffusion layer (GDE). During SO2 depolarized electrolysis VI curves were generated which gave an indication of the performance of the GDE’s and MEA’s. The best preforming GDE was GDE-3 (0.46V @ 320 mA/cm2), which included a GDE EC-TP01-060, while the best preforming MEA’s were NAF-4 (0.69V @ 320mA/cm2) consisting of a Nafion117 based MEA and PBI-1 (0.43V @ 320mA/cm2) made from a sPSU-PBIOO blended membrane. During hydrogen production it became clear that the GDE’s produced the most hydrogen (best was GDE-02 a in house manufactured GDE yielding 67.3 mL/min @ 0.8V), followed by the Nafion® MEA’s (best was NAF-4 a commercial MEA yielding 57.61 mL/min @ 0.74V) and the PBI based MEA’s. , (best was PBI-2 with 67.11 mL/min @ 0.88V). Due to the small amounts of acid produced and the SO2 crossover, a significant error margin was observed when measuring the amount of sulphuric acid produced. Nonetheless, a direct correlation could still be seen between the acid and the hydrogen production as had been expected from literature. The highest sulphuric acid concentrations produced using the tested GDE’s and MEA’s from this study were the in-house manufactured GDE-01 (3.572mol/L @ 0.8V), the commercial NAF-4 (4.456mol/L @ 0.64V) and the in-house manufactured PBI-2 (3.344mol/L @ 0.8V). The overall efficiency of the GDE’s were similar, ranging from less than 10% at low voltages (± 0.6V) increasing to approximately 60% at ± 0.8V. For the MEA’s larger variation was observed with NAF-4 reaching efficiencies of nearly 80% at 0.7V. In terms of consistency of performance it was shown that the Nafion MEA’s preformed most consistently followed by the GDE’s and lastly the PBI based MEA’s which for the PBI based membranes can probably be ascribed to the significant difference in thickness of the thin PBI vs. the Nafion based membranes. In summary the study has shown the results between the commercially obtained and the in-house manufactured GDE’s and MEA’s were comparable confirming the suitability of the coating techniques evaluated in this study. / MSc (Chemistry), North-West University, Potchefstroom Campus, 2014

Water management is a serious issue that affects the performance and durability of PEM fuel cells. It is known, from previous experimental investigations, that surface wettability has influence on water behaviour and fuel cell performance. This finding has lead researchers to develop numerical tools for further investigation of the liquid water behaviour in gas channels. The Volume-of-Fluid (VOF) method has been used in a wide range of studies for its advantage of showing the multi-phase interface in a Computational Fluid Dynamics (CFD) simulation to understand liquid water behaviour in gas channels. In this thesis, numerical study has been carried out to examine the behaviour of liquid water in gas channels. The dynamic movement of the liquid water in the channel and the associated pressure drop, water saturation and water coverage of the GDL have been investigated. Firstly, flow diffusion into the GDL was examined to determine its effect on liquid droplet behaviour in a small section of a gas channel. Furthermore, the effects of the percentage of flow diffusion, GDL wettability, pore size, and water inlet velocity were investigated. Fluid diffusion into GDL found to have insignificant impact on liquid water behaviour so further investigations has been carried with a solid GDL surface. Secondly, gas channel geometry effect on liquid water behaviour was studied. Square, semicircle, triangle, trapezoid with a long base and trapezoid with a short base were compared to find suitable cross section geometry to carry wall wettability investigations. Among the examined geometries, the square cross section showed reasonable results for both scenarios of geometry design, fixed Reynolds number and fixed GDL interface. The effect of wall wettability was assessed by comparing nine different wall/GDL wettability combinations for straight and bend channels. Wall wettability found to have an impact on liquid water behaviour but not as much as GDL wettability. It affects liquid water saturation in the channel by a great deal by accumulating water in the channel edges affecting water behaviour. This was also proven in the last test case of a long channel where water accumulation was investigated by running the calculation until the percentage of water saturation is stabilized. It is also concluded that changing wall wettability from hydrophobic to hydrophilic doubles the percentage of channel occupied by liquid water and increases the time to reach steady state.

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.