Active layer of fuel cell electrode with polymer electrolyte: Nature of proton and oxygen supply channels

The nature of proton and oxygen supply channels in the active layer of a cathode of fuel cell with polymer electrolyte is discussed. There are three types of electron, proton, and oxygen carriers in the active layer: agglomerates of carbon particles with supported platinum (support grains), agglomerates of Nafion molecules (Nafion grains), and void grains. In computer simulation of the active layer structure, the three types of grains were assumed equal-sized, cube-shaped and arranged into a cubic node lattice (in the terms of the percolation theory). Impossibility of forming on the basis solely the above three grain types of three percolation clusters (??electron??, ??proton??, and ??gas??) that could supply all that is required for the electrochemical process is proved. But in this, the following question arises: how can satisfactory operation of the cathode with polymer electrolyte be provided? The required supply of protons and oxygen can be provided only if the support grains can feature not only electronic conductivity, but can also participate in transport of both protons and oxygen. As a result, the transport of protons and oxygen is carried out via special combined percolation clusters that must include apart from the support grains either Nafion grains (combined ??proton?? cluster) or void grains (combined ??gas?? cluster). The paper describes the technique of calculation of effective specific conductivity of a combined ??proton?? cluster. The effective specific diffusion coefficient of a combined ??gas?? cluster can also be calculated in a similar way.     

Computer simulation of active layer of fuel cell electrode with polymer electrolyte: Complete combined carbon support grains, calculation of overall characteristics

Full computer simulation of the active layer of a fuel cell cathode with polymer electrolyte and complete combined carbon support grains is carried out. The active layer structure included two types of equal-size cubic grains (combined support grains and voids) together forming a cubic lattice. Also, the structure of combined grains was modeled; a carbon cluster was formed in them, with the oxygen reduction process occurring on its surface; the rest of the grain volume was filled by polymer electrolyte. The completeness of the grains consisted in the fact that they were characterized by 3D electron conductivity, ability to take part in the transport of protons in the active layer and the carbon cluster in the grains had the maximum possible surface area. Calculation of overall currents of oxygen cathodes with full combined carbon support grains, Nafion, and platinum yielded the following result. At t = 80°C, pressure p* = 101 kPa, cathode potential E ₀ = 0.8 V, and optimum active layer thickness Δ* = 20 μm, maximum overall current I _max = 0.38 A/cm², maximum power density W _max = 0.31 W/cm². At potential E ₀ = 0.7 V, Δ* = 9.8 μm, I _max = 1.13 A/cm², W _max = 0.79 W/cm². At potential E ₀ = 0.6 V, Δ* = 3.8 μm, I _max = 2.95 A/cm², W _max = 1.76 W/cm². At potential E ₀ = 0.5 V, Δ* = 1.4 μm, I _max = 7.71 A/cm², W _max = 3.86 W/cm². The overall current values are higher than those observed experimentally at the given cathode potentials. The discrepancy is explained by the fact that calculations of active cathode layers with a practically regular structure were carried out. All combined support grains in them are full and identical, while in fact the active layer structure is not characterized by the properties of fullness and equivalence. The second circumstance is that experimental active layers rarely have a strictly optimum thickness. Meanwhile deviation from this optimum results in losses in current. Transition to cathodes with combined grains has additional advantages. (1) In such grains, all platinum participates in current generation, the catalyst utilization degree reaches 100%. (2) Oxygen can enter the active layer not through small Knudsen pores, but through large (with the diameter of hundreds and more nm) gas pores, in which usual molecular gas diffusion occurs, so that diffusion limitations in the active layer become less significant. 3. In the active layer, the danger of gas pore flooding by evolving water decreases. Now, water vapor is much more easily removed from large gas pores directing then into the gas-diffusion layer pores.     

Computer-aided simulation of the cathodic active layer in fuel cells with solid polymer electrolyte: the nature of overall current transient

Total computer-aided simulation of the structure and current-generation processes in the cathodic active layer of a fuel cell with solid polymer electrolyte is carried out. Not only the transport structure of the active layer but also the structure of support grains (agglomerates of carbon particles with platinum-covered surface) are modeled. The process of active layer functioning under potentiostatic conditions is studied. It is demonstrated for the first time how the moisture exchange in the pores of support grains affects the cathode overall characteristics. The time variations of the overall current, the average temperature of the active layer, and the total degree of water-flooding of support-grain pores within the active layer are calculated by numerical methods. It is shown that for the fuel cell voltage of 0.6 V and its working temperature of 80°C, the flooding process dominates over the process of drying of pores in support grains. In 10–15 s, all support-grain pores turn out to be entirely filled with water. Then they begin functioning not in the kinetic mode (in the moment of switching-on the current, the Knudsen diffusion of oxygen in the support grains is observed) but in the inner-diffusion mode. As a result, the overall cathodic current decreases from its initial value of 4.323 A/cm² to its final value of 0.526 A/cm² and the active layer temperature decreases from the initial value of 102°C to the final value of 82.5°C. The overall current transient is studied also experimentally, the qualitative coincidence of theoretical and experimental data is demonstrated.     

Active layer of the cathode of a fuel cell with a solid polymer electrolyte: The effect of the Nafion concentration on the overall characteristics

A computer-aided simulation of the structure of the active layer of the cathode of a fuel cell with a solid polymer electrolyte (Nafion) is performed under the assumption about equidimensionalness of dimensions of grains of the substrate (with platinum crystallites in them) and grains (agglomerates of molecules) of Nafion. It is analyzed how the Nafion concentration affects principal parameters, which include the specific surface area, in the vicinity of which electrochemical process goes on; the effective ionic electroconductivity, and the effective diffusion coefficient of a gas. It is demonstrated how one can determine the Nafion concentration at which the overall current takes on a maximum value. Dependences of the optimum value of the overall current and the thickness of the active layer and the weight of platinum, which correspond to it, on the Nafion concentration are calculated. It is demonstrated that there in principle cannot exist one individual optimum concentration of Nafion, which is suitable for all techniques used for the preparation of the active layer. The mutual relationship between values of the effective diffusion coefficient of a gas and the effective ionic electroconductivity of Nafion determines the value of the optimum of the Nafion concentration.     

A cathode for solid polymer electrolyte fuel cells: Designing the optimal structure of the active layer

The complete computer simulation of the cathodic active layer with solid polymer electrolyte (Nafion) is carried out. The active layer structure can be described by 8 parameters. In designing the optimal structure, it is shown that to provide the high overall characteristics of the cathode and save the catalyst, 0.5 of the active layer volume should be set aside for the support grains (agglomerates of carbon particles covered with platinum and containing Nafion incorporations and microvoids). Protons and oxygen molecules must be supplied to the active layer by means of peculiar combined percolation clusters. The latter consist of a combination of support grains with either Nafion grains (to produce “protonic” clusters) or grains-voids (to afford “gas” clusters). The volume fractions of Nafion grains and grain-voids are assumed to be 0.25 and 0.25. The computer simulation of the support grain structure is also carried out. Their composition, i.e., the volume fractions of the carbon component (g _e), Nafion (g _ii), and microvoids (g _gg), is varied. The support grains play the key role in the active layer functioning. It is impossible to organize three full-value percolation clusters (electronic, protonic, and gas); hence, one has to have one or two combined clusters in the active layer. Thus the double load fells on the support grains. Their optimal structure should not only sustain the transport of protons and electrons in the active layer but also create the best conditions for the electrochemical process in each grain. The maximum current I _max (realized upon reaching the optimal active layer thicknesses Δ*) is calculated. The dependences of I _max and Δ* on the main parameters characterizing the support grains (g _e and g _ii) are analyzed. Here, two goals are sought: (1) to obtain the high currents, (2) to provide the low consumption of platinum per power unit. To solve the first problem, one has to work with high values of g _e. The second problem requires the opposite: the values of g _e must be minimal possible.     

Numerical simulation of the ordered catalyst layer in cathode of proton exchange membrane fuel cells

A steady-state, one-dimensional numerical model based on cylindrical electrode structure is presented to analyze the performance of the ordered cathode catalyst layer in Proton Exchange Membrane Fuel Cells. The model equations account for the Tafel kinetics of oxygen reduction reaction, proton migration, oxygen diffusion in the cylindrical electrolyte and the gas pores, oxygen distribution at the gas/electrolyte interface. The simulation results reveal that ordered catalyst layers have better performance than conventional catalyst layers due to the improvements of mass transport and the uniformity of the electrochemical reaction rate across the whole width of the catalyst layer. The influences of oxygen diffusivity in gas phase and electrolyte, and the proton conductivity have been shown. The limitation by oxygen diffusion in gas phase drives the active region of the catalyst layer to the catalyst layer/gas diffuser interface. The limitation by proton migration confines the active region of the catalyst layer to the membrane/catalyst layer interface. The limitation due to oxygen diffusion in electrolyte film maintains the uniform distribution of the active region throughout the ordered catalyst layer.     

Optimizing Weights of Platinum in the Active Layer of the Cathode of a Hydrogen–Oxygen Fuel Cell with a Solid Polymer Electrolyte

The active layer of the cathode of a hydrogen–oxygen fuel cell with a solid polymer electrolyte is computer simulated. The active mass of the electrode consists of substrate grains (agglomerates of carbon particles with Pt particles embedded into them) and grains of a solid polymer electrolyte (Nafion). The substrate grains presumably contain hydrophobic pores, which facilitate the oxygen penetration into the active mass. A calculation of characteristics of such an electrode focuses on the optimization of platinum weights. The principal parameters of the system are concentration and size of grains of substrate and Nafion, Pt concentration in substrate grains, average diameter of hydrophobic pores in substrate grains, and the electrode polarization. The optimum, at a given electrode polarization, electrochemical activity of the active layer, its thickness, and the platinum weight are calculated. A link between these quantities and principal parameters of the active layer is revealed.     

Active layer of an electrode with polymer electrolyte: Estimation of platinum utilization degree

A specific feature of the electrode active layer with polymer electrolyte consists in the fact that the current generation process can occur only on the condition of the direct contact of the catalyst support (carbon black) particles with Nafion. However, in reality, the support particle agglomerates (grains) contact the Nafion particle agglomerates (grains). Therefore, one must expect a low catalyst (platinum) utilization degree. A hypothesis is offered that a fractal film of Nafion is formed on the surface of the support grain pores in the case of manufacturing the “catalytic ink” used to form the active layer. It can significantly increase the platinum utilization degree. A detailed computer simulation of the process of Nafion penetration into the support grain pores is performed. Factors are established allowing reaching a high platinum utilization degree. The data of computer simulation agree with the experimental estimates of platinum utilization degree.     

Cathode of a hydrogen-oxygen fuel cell with a solid polymer electrolyte: The effect of the flooding of pores by water on the characteristics of the active layer

A computer model of the active layer of the cathode of a hydrogen-oxygen fuel cell with a solid polymer electrolyte is studied. The active mass of the electrode consists of equidimensional grains of the substrate (agglomerates of carbon particles with platinum particles embedded in them) and a solid polymer electrolyte (Nafion). The flooding by water can be experienced by both the pores in the substrate grains, which facilitate the oxygen penetration into the active layer of the electrode, and the voids between the grains. All possible versions of the flooding of these pores by water are considered. A calculation of the optimum, at a given polarization of the electrode, value of electrochemical activity, the thickness of the active layer, and the weight of platinum is performed. The major parameters of the system are the concentrations of grains of the substrate and solid polymer electrolyte, the size of these grains, the platinum concentration in the substrate grains, the average diameter of pores in the substrate grains, and the polarization of electrodes. The ultimate aim of the work is to estimate how the flooding of pores of the active layer of the cathode by water affects the magnitude of the optimum current, the effective thickness of the active layer, and the weight of platinum.Translated from Elektrokhimiya, Vol. 41, No. 1, 2005, pp. 35–47.Original Russian Text Copyright © 2005 by Chirkov, Rostokin.     

Differences in water sorption and proton conductivity between Nafion and SPEEK

Water sorption, volumetric expansion, and proton conductivity of 1100 EW Nafion and 555 EW sulfonated polyetheretherketone (SPEEK) were compared as functions of water activity at 60 and 80 °C. Water sorption in Nafion occurs with a small positive volume of mixing, ～0.005 cm³/cm³. In contrast, water sorption in SPEEK has a large negative volume of mixing ～?0.05 cm³/cm³. The percolation thresholds for proton conduction occur at hydrophilic volume fractions of 0.10 in Nafion and 0.30 in SPEEK. Proton conductivity increases quadratically with hydrophilic volume fraction above the percolation threshold. The different percolation thresholds suggest the hydrophilic domains in Nafion grow from lamella, whereas the hydrophilic domains in SPEEK grow from spheres. © 2011 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 49: 1437–1445, 2011     

Calculating a Characteristic Bulk Current Density in the Cathode of a Hydrogen-Oxygen Fuel Cell with a Solid Polymer Electrolyte

The magnitude of currents of electrodes in hydrogen-oxygen fuel cells of all types is shown to be fully determined by values of the effective coefficient of gas diffusion, the effective coefficient of ionic conduction, and the characteristic bulk current density. The characteristic bulk current density is estimated in two versions for cathodes with Nafion: the catalyst is distributed in the bulk of substrate grains or at their external surface. The currents commensurate with those observed in experiments are given only by the second version. Means of computer-aided simulation are used to imitate the formation of fractal films composed of the catalyst particles on the surface substrate grains. The simulation means made it possible to link the magnitude of the specific surface area of platinum particles with its weight content in substrate grains. Electrochemical characteristics of the cathode with Nafion-the potential dependence of the optimum magnitude of the overall current and the thicknesses of the active layer and the weight of platinum in it, as well as the magnitudes of the optimum current generated by a unit weight of platinum—are calculated. A notion of “ norm” is introduced for the characteristic bulk current density of the cathode. 1 × 10^?3 A cm^?3 is the electrochemical-process intensity, which the technology of preparation of active layers of cathodes can provide at this stage in the development of fuel cells with a solid polymer electrolyte.     

Computer Simulation of the Cathode Active Layer in Hydrogen–Oxygen Fuel Cell with Polymer Electrolyte: The Nature of the Overall Current Variations

Full computer simulation of the cathode structure in hydrogen–oxygen fuel cell with polymer electrolyte is performed. Both transport, support grains (agglomerates of carbon particles onto whose surface Pt-catalyst is deposited), and the current generation in active layer are simulated. The active layer operation in potentiostatic mode is studied. The effect of variations of the active layer and the fuel cell temperature (T_s and Т, respectively) on the cathode overall current I and the support grain flooding with water is calculated. The changes in the temperature difference T_s–Т was shown for the first time, experimentally and by the simulation, to generate variations of I and the degree of the support grain flooding with water. In particular, with the increasing of T_s–Т the current I increased, whereas the support grain flooding with water decreased; and vice versa, with the decreasing of T_s–Т the current I drops down, while, the support grain flooding with water grows. An explanation of the phenomena is presented, which takes account of structure of the support grains in which О₂ reduction and Н₂О generation occur. There exist intrinsic channels for protons and О₂ molecules transportation to the catalyst. Water releasing in the support grains is able to fill partially or even entirely the gas pores through which oxygen is supplied to the platinum. As a result, the current generated in the support grains can drop down significantly; at the same time, the value of I also drops down. The degree of the support grainfilling with water is determined by two processes, namely, the flooding and draining. The source of flooding is the current generation; that of draining, the water saturated vapor diffusion and water filtration in nanopores. The lower cathode potential, the higher the flooding rate, whereas the water removal rate grows or drops down with the increasing of decreasing of the temperature difference Т_s–Т, respectively. Thus, the temperature difference variations naturally lead to those of the quantity I.     

Calculation of optimum thickness of active layer of oxygen and air cathodes of fuel cell with Nafion and platinum

It is shown that, for the electrodes of fuel cells with solid polymer electrolyte, the dependence of overall current on the active layer thickness contains an extremum. There is an optimum thickness of active layer, at which the overall current reaches its maximum possible value. The nature of this dependence is explained. The character of the distribution of electrochemical process intensity over the depth of active layer of cathode with solid polymer electrolyte is analyzed. The optimum thicknesses of active layers of oxygen and air cathodes of fuel cells with Nafion and platinum and the corresponding overall currents and contents of catalyst in the active layer are calculated. In the calculations, the temperature of fuel cell, the pressure in the cathode gas chamber, and the cathodic potential were varied. The optimization of active layer thickness of cathode with solid polymer electrolyte can reduce the platinum consumption, i.e. its amount per 1 kW of power produced in a membrane-electrode assembly.     

Computer simulation of positive electrode operation in lithium-ion battery: Optimization of active mass composition

The work of the positive electrode (cathode) of a lithium-ion battery is simulated. The model of equally sized grains of three types: the intercalating agent grains with a volume fraction g, the electrolyte grains with a volume fraction g _i, and the carbon black grains with a volume fraction g _e is studied. The optimal composition of cathode active mass providing maximum specific capacity of cathode is determined. It is shown that a fraction of carbon black grains should be as small as possible: g _e = 0.35. The variation in the fraction of intercalating agent grains within the allowable limits (0 ?? g ?? 0.3) changes the main parameters of cathode active mass: a fraction of electrochemically active intercalating agent grains g* (g* < g); a specific surface area S, on which the electrochemical process proceeds; and the conductivity k* by lithium ions in the ionic percolation cluster, which forms in the cathode active mass. The parameters g* and S decrease and parameter k* steeply increases with decreasing g. Therefore, in the range of possible values of g, specific capacity of cathode reaches the maximum value at g = g _opt. The value of g _opt is determined under the galvanostatic mode of cathode discharge. The cathode working parameters: the active layer thickness, discharge time, specific capacity, and potential at the cathode active layer/interelectrode space interface at the instant of discharge completion are calculated in relation to a fraction of intercalating agent grains g.     

Fuel cell with polymer electrolyte: calculation of overall characteristics of oxygen cathode with account for processes of gas,vapor, and heat exchange

Computer simulation was performed for the processes occurring in the basic elements of the cathode (active layer, gas-diffusion layer) and bipolar plate of a fuel cell with Nafion as electrolyte and a platinum catalyst. Current generation in the active layer was considered together with the heat exchange processes (release of the heat formed in the active layer through the gas-diffusion layer into the bipolar plate), gas and vapor exchange in the gas-diffusion layer and process of the gas reagent (oxygen) saturation by water vapor in the bipolar plate channels. Voltammetric curves and dependences on the cathode potential of the power density, vapor flow dissipated from the active layer to the bipolar plate, actual active layer temperature and reduced partial pressures of oxygen and water vapors near the interface between the active and gas-diffusion layers were calculated. Analysis is performed of the way the heating of the cathode active layer intensifies the process of current generation in it, significantly increasing the value of overall characteristics of the cathode (current and power density).     

A completely spray-coated membrane electrode assembly

We present a proton exchange membrane fuel cell (PEMFC) manufacturing route, in which a thin layer of polymer electrolyte solution is spray-coated on top of gas diffusion electrodes (GDEs) to work as a proton exchange membrane. Without the need for a pre-made membrane foil, this allows inexpensive, fast, large-scale fabrication of membrane-electrode assemblies (MEAs), with a spray-coater comprising the sole manufacturing device. In this work, a catalyst layer and a membrane layer are consecutively sprayed onto a fibrous gas diffusion layer with applied microporous layer as substrate. A fuel cell is then assembled by stacking anode and cathode half-cells with the membrane layers facing each other. The resultant fuel cell with a low catalyst loading of 0.1 mg Pt/cm² on each anode and cathode side is tested with pure H₂ and O₂ supply at 80 °C cell temperature and 92% relative humidity at atmospheric pressure. The obtained peak power density is 1.29 W/cm² at a current density of 3.25 A/cm². By comparison, a lower peak power density of 0.93 W/cm² at 2.2 A/cm² is found for a Nafion NR211 catalyst coated membrane (CCM) reference, although equally thick membrane layers (approx. 25 μm), and identical catalyst layers and gas diffusion media were used. The superior performance of the fuel cell with spray-coated membrane can be explained by a decreased low frequency (mass transport) resistance, especially at high current densities, as determined by electrochemical impedance spectroscopy.     

Fabrication of a micro-direct methanol fuel cell using microfluidics

A direct-methanol fuel cell containing three parts: microchannels, electrodes, and a proton exchange membrane (PEM), was investigated. Nafion resin (NR) and polystyrene-block-poly(ethylene-ran-butylene)-block-polystyrene (PS) were used as PEMs. Preparation of PEMs, including compositing with other polymers and their solubility, was performed and their proton conductivity was measured by a four point probe. The results showed that the 5 % Nafion resin has lower conductivity than the 5 % PS solution. The micro-fuel cell contained two acrylic channels, PEM, and two platinum catalyst electrodes on a silicon wafer. The assembled micro-fuel cells used 2 M methanol at the flow rate of 1.5 mL min^?1 in the anode channel and 5 × 10^?3 M KMnO₄ at the flow rate of 1.5 mL min^?1 in the cathode channel. The micro-fuel cell with the electrode distance of 300 ??m provided the power density of 59.16 ??W cm^?2 and the current density of 125.60 ??A cm^?2 at 0.47 V.     

Computer simulation of negative electrode operation in lithium—ion battery: Galvanostatic discharge,porous electrode model and film model

Computer simulation of the structure and methods of operation (galvanostatic discharge) of the negative electrode of a lithium-ion battery is performed. Two possible models of the active anode layer were compared. 1. The model of porous active layer (mixture of active substance grains with grains of electrolyte). Here, the electrochemical process occurs within a porous active layer. 2. The film model (constant-thickness layer) of pure active substance (intercalating agent) grains without admixture of grains of electrolyte. In this case, the electrochemical reaction occurs only on the planar active electrode layer/interelectrode space interface. In both cases, the optimum working parameters of anode active layers were calculated: porous active layer thickness (in the film model, this was the calculation parameter), duration of full anode discharge, specific electric capacitance and finite difference between the intercalating agent/electrolyte potentials at the active anode layer/interelectrode space interface. It is found that each of these two models has its advantages and faults. Specific electric capacitance C cannot exceed the values of the order of magnitude of 10 C/cm² when a porous active layer is used. Whereas in the film model, much higher values of C may be obtained: tens and even hundreds of C/cm². On the other hand, in the case of anode discharge, the reasonable discharge current density value, its maximum value, at which practically full recovery of lithium atoms from active intercalating agent grains is still possible, proves to be by orders of magnitude higher in the case of an anode with a porous active layer, as compared with a film-type anode. Thus, in the case of development of electrode active layers of lithium-ion batteries, there is a possibility of choosing from two variants. There is the variant of an active film-type layer providing high capacitance values, but low discharge current density. Or there is another variant: a porous active layer with limited capacitance but then much higher values of discharge current density.     

Active layer of the oxygen cathode in a fuel cell with Nafion and platinum: The role played by the diffusion and ohmic restrictions and the selection of the working thickness of the active layer

The basic parameters that characterize the operation of the active layer of a cathode with Nafion are the effective coefficient of the diffusion of oxygen, the effective ionic conductance, and the thickness of the active layer. One of the deficiencies intrinsic to the fuel cells containing Nafion is their extreme sensitivity to the heat and moisture exchange. Nafion demands an optimum degree of humidification. Upon thoroughly draining the active layer of a cathode with Nafion, its effective ionic conductance substantially lowers, and large diffusion restrictions arise following the flooding of pores in the active layer. The goal of this work is to perform a comparison of values of some dimensional characteristics pertaining to the flooded and thoroughly drained active layers of a cathode with similar indicators of an active layer in its optimum (normal) state. It is demonstrated how one should perform the selection of the working thickness of an active layer that would provide for the efficiency of its functioning.     

Fuel cell oxygen cathode with Nafion and platinum: the effect of active layer heating on overall cathode characteristics

A fuel cell with Nafion and platinum is considered. The effect of heating of the oxygen cathode active layer on the cathode overall characteristics (current and power density) is taken into account for the first time. Attention is focused on calculations of Tafel plots of oxygen cathodes and also on how the active layer temperature changes with the potential. Calculation parameters are as follows: fuel cell initial temperature, cathode active layer thickness, gas-diffusion layer effective heat conductivity and thickness. The following conditions of cathode operation are studied: (1) heat formed in the cathode active layer is almost completely removed, no active layer heating is observed, the active-layer temperature remains equal to that of fuel cell operation; (2) heat removal is impeded, the heat conductivity of the gas-diffusion layer is insufficiently high to remove heat. In the latter case, the active layer temperature may increase by several tens of degrees. A fundamental difference of Tafel plots for the catalytic layers studied in model experiments and the cathodic active layers is demonstrated. In the latter case, the first Tafel plot segment may extend further up to potentials of ∼0.6 V.