ADVANCED FUEL CELL PROGRAMME

TASK XVI
COLLABORATIVE RESEARCH ON
POLYMER ELECTROLYTE FUEL CELLS

TITLE: STATUS REPORT FOR PERIOD APRIL 1, 2004 TO OCTOBER 14, 2004

DATE: October 14, 2004

DISTRIBUTION
CLASSIFICATION: LEVEL 2

INTERNATIONAL
ENERGY AGENCY
 INSIDE FRONT COVER

Distribution List

Executive Committee
IEA Secretariat
All Operating Agents

Task Experts
Viktor Hacker Graz University of Technology Austria

Gilbert Van Bogaert Vito Belgium

Steven Holdcroft Simon Fraser University Canada

Brant Peppley Royal Military College "

Matti Valkiainen VTT Processes Finland

Hendrik Dohle FZ-Jülich Germany

Jürgen Mergel FZ-Jülich "

Marco Brocco ENEA Italy

Agostino Iacobazzi ENEA "

Chang-Soo Kim KIER Korea

In-Hwan Oh KIST "

Frank de Bruijn ECN Netherlands

Gaby Janssen ECN "

Børre Børresen NTNU Norway

Lars Pettersson KTH Sweden

Brian Hayden University of Southampton U. K.

Keith Scott University of Newcastle "
Clayton Barnes Loughborough University U.K.

Nancy Garland U. S. Department of Energy U. S. A.

Deborah Myers Argonne National Laboratory "
Piotr Zelenay Los Alamos National Laboratory "
 ADVANCED FUEL CELL PROGRAMME

TASK XVI

COLLABORATIVE RESEARCH ON
POLYMER ELECTROLYTE FUEL CELLS

STATUS REPORT FOR PERIOD APRIL 1, 2004 TO OCTOBER 10, 2004

CONTENTS

Page No

1. Duration .......................................................................................................................... 1

2. Operating Agent ............................................................................................................. 1

3. Participants ..................................................................................................................... 1

4. Objective ......................................................................................................................... 1

5. Task Description ............................................................................................................. 1

6. Summary ......................................................................................................................... 2

7. Progress In Period .......................................................................................................... 2

7.1 Overview ............................................................................................................ 2
7.2 Administration ................................................................................................... 2
7.3 Activities ............................................................................................................ 2
7.4 Technical Accomplishments .............................................................................. 2

8. Future Plans .................................................................................................................... 4

8.1 Summary ............................................................................................................ 4
8.2 Sub-Task Plans .................................................................................................. 4

9. Conclusion ....................................................................................................................... 4

Annexes
Annex A: Reports Published in Period ............................................................ 5
Annex B: Reports Planned in Next Period ...................................................... 5
Annex C: Meetings Held in Period .................................................................. 5
Annex D: Meetings Planned in Next Period ................................................... 5
 ADVANCED FUEL CELL PROGRAMME

TASK XVI

COLLABORATIVE RESEARCH ON
POLYMER ELECTROLYTE FUEL CELLS

STATUS REPORT FOR PERIOD APRIL 1, 2004 TO OCTOBER 14, 2004

1. Duration

This Task XVI entered into force on January 1, 2004, and is scheduled to remain in force for a
period of five years, i.e., until December 31, 2008.

2. Operating Agent

Argonne National Laboratory, Contractor, for the United States Department of Energy.

3. Participants

Agencies from thirteen countries are currently participating in this Annex:

Austria: Graz University of Technology

Belgium: Flemish Institute for Technological Research
Canada: The Government of Canada
Finland: VTT Processes
Germany: Forschungszentrum-Jülich GmbH
Italy: Ente per le Nuove Technologie, l'Energia e l'Ambient,
ENEA
Japan: New Energy and Industrial
Technology Development Organisation, NEDO
Korea: Korea Institute of Science and Technology, KIST
Korea Institute of Energy Research, KIER
The Netherlands: Netherlands Energy Research Foundation (ECN)
Norway: The Research Council of Norway
Sweden: Swedish National Energy Administration (STEM)
United Kingdom: Secretary of State for Industry
United States: The Department of Energy of the U. S. Government

4. Objective

The objective of this Task is to contribute to the identification and development of techniques to
reduce the cost and improve the performance of polymer electrolyte fuel cells (PEFCs), direct fuel
polymer electrolyte fuel cells (e.g., direct methanol or direct borohydride fuel cells), and
corresponding fuel cell systems.

5. Task Description

The work carried out by the Annex is divided into three subtasks:

Subtask 1. New Stack Materials

Research in this subtask aims to develop improved, lower-cost membranes, electrode
catalysts and structures, membrane-electrode assemblies (MEAs), bipolar plates and other stack
materials and designs. The effort includes:
- composite and high-temperature membranes
- membranes that conduct protons without external humidification
- reduced precious metal loadings in electrodes
- non-precious metal cathode and anode catalysts
- anode catalysts and electrode layer configurations with enhanced tolerance to
carbon monoxide
- higher-activity cathodes
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- lower-cost bipolar plates and other stack materials

- lower-cost, continuous fabrication techniques for MEAs
- stack materials for stacks operating at higher temperatures (>100°C)

Subtask 2. System and Balance-of-Plant Issues

This subtask addresses system-level and balance-of-plant issues in PEFC systems. This
subtask involves development, engineering, modelling, testing, and standardization of test
procedures involving:
- fuel processors, fuel processing catalysts, and supports
- gas purification membranes
- compact fuel reformers and micro-structured reactors
- the effect of contaminants, operating environments, duty cycles, and operating
temperatures including temperatures below 0°C
- system designs offering efficiency and dynamic response while maintaining
costs, weights, and volumes within target values.
- the reliability, durability, rapid-start, and dynamic behaviour of PEFC systems

Subtask 3. Direct Fuel Polymer Electrolyte Fuel Cells

The objective of this subtask is to improve the performance and lifetime of direct fuel
polymer electrolyte fuel cells, including direct methanol and direct sodium borohydride fuel cells.
This subtask involves identification and development of improved:
- anode and cathode catalysts
- electrode/electrolyte structures
- fuel impermeable membrane electrolytes
- anion-conducting membranes
- concepts in stack materials and designs

6. Summary

During this period, a meeting of the Annex XVI Working Group was held on May 6-7, 2004, in
Newcastle upon the Tyne, United Kingdom. All participants except Italy were represented at the
meeting. The meeting opened with welcoming remarks from the U.K. host, Professor
Keith Scott, and the Operating Agent, Deborah Myers. The new subtask structure for the
continuation of the annex under the 2004-2008 implementing agreement and the proposed
workshop on “Cost and Availability of Fuel Cell Materials” were presented by Deborah. The
participants then discussed their recent work in a series of summary presentations. These
discussions are summarized in section 7.4 of this report. The presentations were followed by a
tour of Professor Scott’s laboratories at the university

7. Progress In Period

7.1 Overview

Two new countries, Austria and Finland, participated in this first workshop of Annex XVI,
adding more depth to the new materials, modelling, and direct methanol fuel cell activities. Significant
progress was made in all three subtasks, as detailed below.

7.2 Administration

There have been no significant changes in the legal description or work plans for this Annex.

7.3 Activities

The Annex XVI Working Group met in Newcastle upon the Tyne, United Kingdom, May 6-7,
2004. The next meeting of this Working Group is scheduled for November 18-19, 2004 in Rome,
Italy.

7.4 Technical Accomplishments

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Some of the significant technical accomplishments during this reporting period are:

Subtask 1 – New Materials

 Modeling and electrochemical impedance spectroscopy were used to conclude that mass transport
in the cathode electrocatalyst layer is dominant near open circuit potential and under high
polarization. Under moderate polarization both charge transfer and mass transfer impedance are
significant. (Canada)

 Stacks were assembled under the POWERPEM project and the energetics of oxygen adsorption
on different platinum crystal faces were determined using molecular modeling. (Finland)

 Bilayer anodes of PtMo and PtRu were developed for reformate tolerance. The cathode catalyst
ink was improved by adding stabilizers to improve viscosity and sodium carbonate to form pores.
(The Netherlands)

 Achieved a maximum power density of 0.5 mW/cm² for a hydrogen/chlorine fuel cell with a
Nafion/HCl electrolyte. (Norway)

 Identified binary and ternary alloy compositions with oxygen reduction activity comparable to Pt
using rapid fabrication and screening methods. (United Kingdom)

Subtask 2 – System and Balance-of-Plant Issues

 Developed a fast fuel cell stack model and a power system simulation tool for the European
Space Agency (ESA). (Austria)

 Performed cell sensitivity analysis for ammonia and continued the development of an ammonia
reformer, an integrated system, and verification of the model for the European Ammonia
Cracking Clean Electric Power Team (ACCEPT) program. (Belgium)

 Developed control algorithms based on “fuzzy logic” for fuel cell/battery hybrid systems. A
proper load management strategy is important for improved system efficiency of the fuel cell
hybrid system. (Korea)

 Determined, via cell modeling, that membrane humidification and thickness affect not only the
membrane resistance, but also the cathode over-voltage via water content of this layer.
(United Kingdom)

 Modeled the effects of higher operating temperature (120°C) and low relative humidity on the
size of an automotive hydrogen-fueled polymer electrolyte fuel cell system. Determined that it is
desirable to operate under dry conditions or with <15% RH, depending on the humidification
scheme (i.e., condenser-humidifier or enthalpy wheel). (United States)

Subtask 3 – Direct Fuel Polymer Electrolyte Fuel Cells

 Achieved a maximum power density of ~200 mW/cm2 for a direct methanol fuel cells (DMFCs)
with liquid electrolyte. Developed an active methanol oxidation electrocatalyst of 10% tin and
90% platinum using combinatorial techniques. (Austria)

 Developed DMFCs with reduced methanol crossover for micro-power applications. (Finland)

 Improved the performance of the electrode layers by adding inert inorganic particles (silica,
graphite) to the catalyst inks which alters the electrode hydrophilicity. (Germany)

 Developed DMFCs for portable power applications. R&D in this area includes new polymer
electrolytes, membrane-electrode assemblies, and balance-of-plant issues. (Japan)
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 Enabled the release of CO2 from the DMFC anode using titanium mesh flow fields. The catalyst
is deposited on the titanium mesh and this mesh is imbibed with Nafion. (United Kingdom)

 Investigated electrode materials (e.g., gold, platinum, gold plated stainless steel, carbon and
titanium) suitable for borohydride oxidation for direct borohydride fuel cells and batteries.
(United Kingdom)

 Determined that ruthenium leaches out of the DMFC Pt-Ru anode and deposits on the cathode,
decreasing cell performance. (United States)

8. Future Plans

As indicated in previous reports of this series, each participating country is working from a broad
program plan rather than more specific task plans. The areas of active R&D for this Annex are
improved MEAs, reduced catalyst loadings, increased CO tolerance, compact fuel processors,
system design and analysis, and improved direct fuel (methanol, ethanol, and sodium
borohydride) fuel cells and stacks.

8.1 Summary

It is anticipated that research will be carried out in each of the subtasks of Annex XVI until the
end of the Task on December 31, 2008. These efforts, and the significant results from these
efforts, are discussed at the semi-annual workshops. The next workshop is scheduled for
November 18-19, 2004 at Rome, Italy.

8.2 Sub-Task Plans

As mentioned above, no detailed sub-task plans have been or will be developed.

9. Conclusion

The Executive Committee is invited to note/endorse the progress in the work of this Annex as
described above.
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ANNEXES

Annex A Reports Published in Period

Title Distribution Date

Level
Summary Report on Annex XVI Workshop, May 6-7, 2004, Newcastle upon the 2b Oct 2004
Tyne, United Kingdom
Status Report on Annex XVI: Collaborative Research on Polymer Electrolyte 2b Oct 2004
Fuel Cells

Annex B Reports Planned in Next Period

Title Distributio Date

n Level
Status Report on Annex XVI: Collaborative Research on Polymer Electrolyte 2b Apr 2005
Fuel Cells

Summary Report on the IEA Annex XVI, Nov. 18-19, 2004, Rome, Italy 2b Jan 2005

Annex C Meetings Held in Period

Annex XVI Working Group May 6-7, 2004 Newcastle upon the Tyne, U.K.

Annex D Meetings Planned in Next Period

Annex XVI Working Group Nov 18-19, 2004 Rome, Italy