A fuel cell is an electrochemical power source with advantages of both the combustion engine and the battery. Like a combustion engine, a fuel cell will run as long as it is provided fuel; and like a battery, fuel cells convert chemical energy directly to electrical energy. As an electrochemical power source, fuel cells are not subjected to the Carnot limitations of combustion (heat) engines. Fuel cells bear similarity to batteries, with which they share the electrochemical nature of the power generation process and to the engines that, unlike batteries, will work continuously consuming a fuel of some sort. A fuel cell operates quietly and efficiently and, when hydrogen is used as a fuel, it generates only power and water. Thus, a fuel cell is a so called ‘zero-emission engine’. In the past, several fuel cell concepts have been tested in the laboratory but the systems that are being potentially considered for commercial developments are: (i) Alkaline Fuel Cells (AFCs), (ii) Phosphoric Acid Fuel Cells (PAFCs), (iii) Polymer Electrolyte Fuel Cells (PEFCs), (iv) Solid Polymer Electrolyte Direct Methanol Fuel Cells (SPE-DMFCs), (v) Molten Carbonate Fuel Cells (MCFCs) and (vi) Solid Oxide Fuel Cells (SOFCs). Among the aforesaid systems, PEFCs that employ hydrogen as fuel are considered attractive power systems for quick start-up and ambient temperature operations. Ironically, however, hydrogen as fuel is not available freely in the nature. Accordingly, it has to be generated from a readily available hydrogen carrying fuel such as natural gas, which needs to be reformed. But, such a process leads to generation of hydrogen contaminated with carbon monoxide, which even at minuscule level is detrimental to the fuel cell performance. Pure hydrogen can be generated through water electrolysis but hydrogen thus generated needs to be stored as compressed/liquefied gas, which is cost-intensive. Therefore, certain hydrogen carrying organic fuels such as methanol, ethanol, propanol, ethylene glycol and diethyl ether have been considered for fueling PEFCs directly. Among these, methanol with hydrogen content of about 12.8 wt.% (specific energy = 6.1kWh kg-1) is the most attractive organic liquid. PEFCs using methanol directly as fuel are referred to as SPE-DMFCs. But SPE-DMFCs suffer from methanol crossover across the polymer electrolyte membrane, which affects the cathode performance and hence the fuel cell during its operation. SPE-DMFCs also have inherent limitations of low open-circuit-potential and low electrochemical-activity. An obvious solution to the aforesaid problems is to explore other promising hydrogen carrying fuels such as sodium borohydride (specific energy = 12kWh kg-1), which has a capacity value of 5.67Ah g-1 and a hydrogen content of about 11wt.%. Such fuel cells are called direct borohydride fuel cells (DBFCs). This thesis is directed to studies on SPE-DMFCs and DBFCs

Direct methanol fuel cells (DMFC) are appealing as a power source for portable devices as they do not require recharging with an electrical outlet. However, the DMFC technology is confronted with the high crossover of methanol fuel from the anode to the cathode through the currently used Nafion membrane, which not only wastes the fuel but also poisons the cathode platinum catalyst. With an aim to overcome the problems encountered with the Nafion membrane, this dissertation focuses on the design and development of new polymeric membrane materials for DMFC and a fundamental understanding of their structure-property-performance relationships. Several polymeric blend membranes based on acid-base interactions between an aromatic acidic polymer such as sulfonated ploy(ether ether ketone) (SPEEK) and an aromatic basic polymer such as heterocycle tethered poly(sulfone) (PSf) have been explored. Various heterochylces like nitro-benzimidazole (NBIm), 1H-Perimidine (PImd), and 5-amino-benzotriazole (BTraz) have been tethered to PSf to understand the influence of pKa values and the size of the hetrocycles. The blend membranes show lower methanol crossover and better performance in DMFC than plain SPEEK due to an enhancement in proton conductivity through acid-base interactions and an insertion of the heterocycle side groups into the ionic clusters of SPEEK as indicated by small angle Xray scattering and TEM data. The SPEEK/PSf-PImd blend membrane shows the lowest methanol crossover due to the larger size of the side groups, while the SPEEK/PSf-BTraz blend membrane shows the highest proton conductivity and maximum power density. To further investigate the methanol-blocking effect of the heterocycles, N,N’-Bis- (1H-benzimidazol-2-yl)-isophthalamide (BBImIP) having two amino-benzimidazole groups bonded to a phenyl ring has been incorporated into sulfonated polysulfone (SPSf) and SPEEK membranes. With two 2-amino-benzimidazole groups, which could greatly increase the proton transfer sites, and three phenyl rings, which are compatible with the aromatic polymers, the BBImIP/SPSf and BBImIP/SPEEK blend membranes show suppressed methanol crossover and increased fuel cell performance in DMFC. Novel sulfonated copolymers based on poly(aryl ether sulfone) (SPS-DP) that exhibit low methanol crossover have been synthesized and explored as a methanol-barrier center layer in a multilayer membrane configuration having SPEEK as the outer layers. These multilayer membranes exhibit better performance in DMFC than plain SPEEK and Nafion 115 membranes due to suppressed methanol crossover. To address the issue of incompatibility between the new hydrocarbon-based membranes synthesized and the Nafion ionomer used in the catalyst layer in fabricating membrane-electrode assemblies (MEAs), the MEAs have been fabricated with the SPEEK membranes and 10 to 30 % SPEEK ionomer in the catalyst layer. These MEAs exhibit better performance in DMFC compared to the MEAs fabricated with the SPEEK membranes and Nafion ionomer in the catalyst layer due to lower interfacial resistance. / text

Proton exchange membrane fuel cells (PEMFC) and direct methanol fuel cells (DMFC) are attractive power sources as they offer high conversion efficiencies with low or no pollution. However, the most commonly used platinum electrocatalyst is expensive and the world supply of Pt is limited. In addition, the slow oxygen reduction and methanol oxidation kinetics as well as the poisoning of the Pt catalyst at the cathode resulting from methanol permeation from the anode through the Nafion membrane to the cathode lead to significant performance loss. Also, the electrocatalyst utilization in the electrodes also needs to be improved to reduce the overall cost of the electrocatalysts and improve the fuel cell performance. This dissertation explores nanostructured Pt alloys with lower cost and higher catalytic activity than Pt for oxygen reduction in PEMFC to understand the effect of synthesis and structure on the catalytic activity, methanol tolerant Pt/TiOx nanocomposites for oxygen reduction in DMFC, nanostructured Pt-Ru alloys for methanol oxidation in DMFC, and improvement in the utilization of Pt by optimizing the membrane-electrode assembly (MEA) fabrication. From a systematic investigation of a series of Pt-M alloys (M = Fe, Co, Ni, and Cu), the catalytic activity of Pt-M alloys is correlated with the extent of atomic ordering. More ordered Pt alloys exhibit higher catalytic activity than disordered Pt alloys. The higher activity of the ordered Pt alloys is found to relate to various factors including the Pt-Pt distance, Pt: 5d orbital vacancy, {100} planar density and surface atomic configuration. The catalytic activity of the Pt alloys is also influenced by the synthesis method. Low temperature solution methods usually result in smaller particle size and higher surface area, while high temperature routes result in larger particle size and lower surface area but with a greater extent of alloying. Pt/TiOx/C nanocomposites exhibit higher performance than Pt for oxygen reduction in DMFC. The nanocomposites show higher electrchochemical surface area, lower charge transfer resistance, and higher methanol tolerance than Pt. Pt-Ru alloy synthesized by a reverse microemulsion method exhibits higher catalytic surface area than the commercial Pt-Ru. The higher catalytic activity is attributed to a better control of the particle size, crystallinity, and microstructure. Membrane-electrode assemblies (MEAs) fabricated by a modified thin film method exhibit much higher electrocatalyst utilization efficiency and performance than the conventional MEAs in PEMFC. Power densities of 715 and 610 mW/cm2 are obtained at a Pt loading of, respectively, 0.1 and 0.05 mg/cm2 and 90 oC. The higher electrocatalyst utilization is attributed to the thin catalyst layer and a better continuity of the membrane/catalysts layer interface compared to that in the conventional MEAs. / text

Thesis (M. Tech. Engineering: Electrical--Vaal University of Technology) / The air-breathing Direct Methanol Fuel Cell (DMFC) and Zinc Air Fuel Cell (ZAFC)were experimentally studied in a climate chamber in order to investigate the impact of climatic environmental parameters such as varying temperature and relative humidity conditions on their performance. The experimental results presented in the form of polarization curves and discharge characteristic curves indicated that these parameters have a significant effect on the performance of these fuel cells. The results showed that temperature levels below 0ºc are not suitable for the operation of these fuel cells. Instead, it was found that air-breathing DMFC is favored by high temperature conditions while both positive and negative effects were noticed for the air-breathing ZAFC. The results of the varying humidity conditions showed a negative impact on the air-breathing DMFC at a lower temperature level but a performance increase was noticed at a higher temperature level. For air-breathing ZAFC, the effect of humidity on the performance was also found to be influence by the operating temperature. Furthermore, common atmospheric air pollutants such as N20, S02, CO and N02 were experimentally investigated on the air-breathing DMFC and ZAFC. At the concentration of 20 ppm, these air contaminants showed to have a negative effect on the performance of both air-breathing DMFC and ZAFC. For both air-breathing DMFC and ZAFC, performance degradations were found to be irreversible. It is therefore evident from this research that the performance of the air-breathing fuel cell will be affected in an application situated in a highly air-polluted area such as Vaal Triangle or Southern Durban. It is recommended the air-breathing fuel cell design include air filters to counter the day-to-day variations in concentration of air pollutants.

Magister Scientiae - MSc / Fuel cells convert chemical energy from a fuel into electricity through chemical reaction with oxygen. This possesses some challenges like slow oxygen reduction reaction (ORR), overpotential, and methanol fuel cross over in a direct methanol fuel cell (DMFC). These challenges cause inefficiency and use of higher amounts of the expensive platinum catalyst.Several binary catalysts with better ORR activity have been reported. In this study we investigate the best catalyst with better ORR and MOR performances and lower over-potentials for PEMFC and DMFC applications by comparing the in-house catalysts (10%Pt/C, 20%Pt/C,30%Pt15%Ru/C, 40%Pt20%Ru/C, 30%PtCo/C, 20%Pt20%Cu/C and 20%PtSn/C) with the commercial platinum based catalysts (10%Pt/C, 20%Pt/C, 20%Pt10%Ru/C, 20%PtCo/C,20%PtCu/C and 20%PtSn/C) using the cyclic voltammetry and the rotating disk electrode to determine their oxygen reduction reaction and methanol tolerance. HRTEM and XRD techniques were used to determine their particle size, arrangement and the atomic composition. It was observed that the 20%Pt/C in-house catalyst gave the best ORR activity and higher methanol oxidation current peaks compared to others catalysts followed by 20%Pt10%Ru/C commercial catalyst. The 20%PtCo/C commercial, 30%PtCo/C in-house and 20%PtSn/C in-house catalysts were found to be the most methanol tolerant catalysts making them the best catalysts for ORR in DMFC. It was observed that the ORR activity of 20%PtCo/C commercial and 30%PtCo/C inhouse catalysts were enhanced when heat treated at 350 0C. From XRD and HRTEM studies, the particle sizes were between 2.72nm to 5.02nm with little agglomeration but after the heat treatment, the particles were nicely dispersed on the carbon support.

>Magister Scientiae - MSc / The purpose of this study was to develop a high performance-lower cost catalyst to be applied in Direct Methanol Fuel Cells (DMFC). The study also aimed to prepare plurimetallic supported platinum (Pt), platinum-ruthenium (PtRu), platinum-ruthenium-vanadium (PtRuV) and platinum ruthenium-vanadium-iron (PtRuVFe) upon multi-walled carbon nanotube (MWCNT) as well as upon multiwalled carbon nanotube-titanium oxide (MWCNT/TiO2) supports. Platinum is very active but prone to poisoning by carbon monoxide (CO), which may be present in the fuel used in fuel cells. The focus on the use of methanol was because of its better reaction kinetics, and better performance in direct methanol fuel cells (DMFC) better than proton exchange membrane fuel cell (PEMFC). When Pt is alloyed with another platinum group metals (PGM) the alloying decreases the over-potential for reactions critical in the fuel cells. Proton exchange membrane fuel cell (PEMFC) performance may be improved at low metal loading, when supported pluri-metallic catalysts are applied since the trimetallic catalysts may promote high catalyst utilisation. In practice, DMFC require electrodes with a Pt loading to achieve acceptance fuel cell (FC) power performance. The aim of this study was therefore the reduction of the catalyst loading through further improvement of mass activity of Pt based catalysts by partial substitution of the noble metal/metals, and the use of a carbon support that will provide high surface area, good electrical conductivity and high stability. MWCNT supported pluri-metallic (PtRuVFe,) and bimetallic (PtRu) nanoparticles possessed characteristic of increased surface area, improved electron transfer rate, enhance electro-catalytic activity and promoted stability.

Carbon supported PtNi nanoparticles were prepared by hydrazine reduction of Pt and Ni precursor salts under different conditions, namely by conventional heating (PtNi-1), by prolonged reaction at room temperature (PtNi-2) and by microwave assisted reduction (PtNi-3). The nanocomposites were characterized by XRD, EDX, XPS and TEM and used as electrocatalysts in direct methanol fuel cell (DMFC) reactions. Investigations into the mechanism of PtNi nanoparticle formation revealed that platinum nanoparticle seeding was essential for the formation of the bimetallic nanoparticles. The average particle size of PtNi prepared by microwave irradiation was the lowest, in the range of 2.9 – 5.8 nm. The relative rates of electrooxidation of methanol at room temperature as measured by cyclic voltammetry showed an inverse relationship between catalytic activity and particle size in the following order PtNi-1 < PtNi-2 < PtNi-3. / Singapore-MIT Alliance (SMA)

In this research the effects of the fabrication processes of MEA on the output power of a DMFC stack are studied by changing hot-pressing conditions including pressure, temperature and time. Additionally, the effects of the various treatments of the MEAs on the output voltage and power are also studied after the hot-pressing process of MEA is finished. In the first experimental study the catalyst of cathode is 4.0mg/cm unsupported HP Pt black, Anode is 4.0mg/cm 80% HP Pt-Ru Alloy (1: 1), membrane is Nafion 117, and bipolar plates is heterogeneous carbon fiber bipolar plate developed by our fuel cell laboratory. The MEA for single cell includes the area of membrane 3*3 cm2 the active area of electrode 1.5*1.5 cm2. Under the hot-pressing conditions 120 oC, 100 bar and 90s, the maximum power density can reach a value of 18 mW/cm2 at the conditions of methanol concentration 3 M, air-breathing, and room temperature After several experiments, we observed that performances of MEAs decayed with time. So we designed a series of experiments to inspect the various possible reasons and try to solve this problem. The cylindrical DMFC is one of the most important developments in our lab. However, the MEAs made for plate-type DMFC do not fit the cylindrical DMFC stack properly. The electrodes easily pealed off from the membrane and the contact resistance increases after certain periods. So the hot-pressing device had been redesigned to fit the cylindrical DMFC stack. After that the total power of the 6-cell stack with total active area 15 cm2 can reach a value 135 mW. If the performance of each cell of the 6-cell stack is uniform, we expect that the total power of this stack can reach a higher value 195 mW, which can be applied to some portable electronic products.

Membrane electrode assembly (MEA) is the foundation of the single cell as well as the core of the fuel cell when generating electricity. Its work efficiency is the key factor for single cell performance. This study aims to understand the variation between the conventional method and the decal method during the MEA process. By observing the microstructure morphology of electrode and the performance of single cell, as well as analyzing internal resistance and its stabilization, the advantages and disadvantages of MEA in the two methods is analyzed. The decal condition is 135¢XC, 15 kg/cm , 2.5 min at a high temperature (50¢XC 3M methanol), in air-breathing under atmosphere system. The maximum power density is approximately 22.5 mW/cm which is very close to the result of conventional method. The decal method is better than the conventional method particularly in regards to the high current density performance. It shows that there is an efficient influence of the decal method on the methanol mass transfer and it also improves its polarization and enlarges the current. If the single cell is operated in the high temperature, the fuel mass transfer can be advanced in the decal method and its performance can be raised. However, in the manufacturing process, more time has to be spent when producing the MEA. This experiment can be used as a reference on the single cell operation environment and manufacturing time for future studies.

Proton exchange membrane fuel cells (PEMFCs) and direct methanol fuel cells (DMFCs) are two types of low-temperature fuel cells (LTFCs) that operate at temperatures less than 100 °C and are appealing for portable, transportation, and stationary applications. However, commercialization has been hampered by several problems such as cost, efficiency, and durability. New electrocatalysts must be developed that have higher oxygen reduction reaction (ORR) activity, lower precious metal loadings, and improved durability to become commercially viable. This dissertation investigates the development and use of new electrocatalysts for the ORR. Core-shell (shell@core) Pt@Pd[subscript x]Cu[subscript y]/C electrocatalysts, with a range of initial compositions, were synthesized to result in a Pt-rich shell atop a Pd[subscript x]C[subscript y]-rich core. The interaction between core and shell resulted in a delay in the onset of Pt-OH formation, accounting in a 3.5-fold increase in Pt-mass activity compared to Pt/C. The methanol tolerance of the core-shell Pt@PdCu₅/C was found to decrease with increasing Pt-shell coverage due to the negative potential shift in the CO oxidation peak. It was discovered that Cu leached out from the cathode has a detrimental effect on membrane-electrode assembly performance. A spray-assisted impregnation method was developed to reduce particle size and increase dispersion on the support in a consistent manner for a Pd₈₈W₁₂/C electrocatalyst. The spray-assisted method resulted in decreased particle size, improved dispersion and more uniform drying compared to a conventional method. These differences resulted in greater performance during operation of a single DMFC and PEMFC. Additionally, Pd₈₈W₁₂/C prepared by spray-assisted impregnation showed DMFC performance similar to Pt/C with similar particle size in the kinetic region while offering improved methanol tolerance. Pd₈₈W₁₂/C also showed comparable maximum power densities and activities normalized by cost in a PEMFC. Lastly, the activation of aluminum as an effective reducing agent for the wet- chemical synthesis of metallic particles by pitting corrosion was explored along with the control of particle morphology. It was found that atomic hydrogen, an intermediate, was the actual reducing agent, and a wide array of metals could be produced. The particle size and dispersion of Pd/C produced using Al was controlled using PVP and FeCl₂ as stabilizers. The intermetallic Cu₂Sb was similarly prepared with a 20 nm crystallite size for potential use in lithium-ion battery anodes. Lastly, it was found that the shape of Pd produced with Al as a reducing agent could be controlled to prepare 10 nm cubes enclosed by (100) facets with potentially high activity for the ORR. / text