The aggregate size in fuel cell catalyst inks depends on the type of dispersion medium, particle concentration, and addition of stabilizing agents. In this work, ink stability and particle size of carbon black and carbon black/Nafion dispersions in four non-aqueous media, viz., methanol, ethanol, isopropanol and ethyl acetate are studied. Based on visual inspection, isopropanol is found to be the best medium for dispersion of carbon black inks. To rationalize this observation, a semi-empirical model based on diffusion-limited aggregation was developed to evaluate the rate of particle aggregation and predict the ink stability time for each dispersion medium. The proposed model supports the experimental observation by qualitatively predicting the same relationship between carbon stability and the dispersion media. The model also showed that the dielectric constant of the dispersion medium and the particle zeta potential are primarily responsible for the ink stability. Particle size for the different inks was determined by dynamic light scattering with and without dilution. Experimental results show that Nafion is a strong stabilizing agent, increasing the ink stability and decreasing the particle size of carbon aggregates. The beneficial effects of Nafion are independent of its concentration and are observed even at Nafion volume fractions of 10 wt%. The interaction energy is found to be a strong function of the surface potential for the dispersion medium with a higher dielectric constant.

Non-isothermal ice melting in the fibrous gas-diffusion layer (GDL) of a proton-exchange-membrane fuel cell (PEMFC) is investigated using differential scanning calorimetry (DSC). Non-isothermal ice-melting rates and ice-melting times are obtained from heat-flow measurements in water-saturated Toray GDLs at heating rates of 1, 2.5, 5, 10, and 25 K/min. In all cases, ice-melting times decrease nonlinearly with increasing heating rate. Nevertheless, melting temperatures remain at 272.9 ± 0.5 and 272.7 ± 0.4 K for bulk ice and ice within the GDL, respectively, reiterating that melting is thermodynamic-based at a rate limited by heat transfer. The slight GDL ice melting-point depression is consistent with the Gibbs-Thomson equation for equilibrium melting using an average pore diameter of 30 μm. Ice-melting endotherms are predicted from overall DSC energy balances coupled with a moving-boundary Stefan problem, where an ice-melting front within a GDL propagates with volume-averaged properties through an effective medium. Agreement between DSC experiment and theory is excellent. The proposed model accurately predicts ice-melting endotherms for Toray GDLs with two ice saturations and for bulk ice. Further, a pseudo-steady-state analysis obtains an analytical expression for ice-melting time, which is controlled by the time for heat addition to the propagating solid/liquid interface. Significantly, the new expression elucidates parameters controlling ice melting and allows for better design of both GDL materials and heating strategies to enhance the success of PEMFC cold-start.

The cost of a flow battery system can be reduced by increasing its power density and thereby reducing its stack area. If per-pass utilizations are held constant, higher battery power densities can only be achieved using higher flow rates. Here, a 3D computational fluid dynamics model of a flow battery flow field and electrode is used to analyze the implications of increasing flow rates to high power density operating conditions. Interdigitated and serpentine designs, and cell sizes ranging from 10 cm² to 400 cm², are simulated. The results quantify the dependence of pressure loss on cell size and design, demonstrating that the details of the passages that distribute flow between individual channels and the inlet and outlet have a major impact on pressure losses in larger cells. Additionally, in-cell flow behavior is analyzed as a function of cell size and design. Flow structures are interrogated to show how and where electrode parameters influence pressure drops, and how regions where transport is slow are correlated with the presence of experimentally observed cell degradation.

Water management remains a critical issue for polymer electrolyte fuel cell performance and durability, especially at lower temperatures and with ultrathin electrodes. To understand and explain experimental observations better, water transport in gas diffusion layers (GDLs) with macroscopically heterogeneous morphologies was simulated using a novel coupling of continuum and pore-network models. X-ray computed tomography was used to extract GDL material parameters for use in the pore-network model. The simulations were conducted to explain experimental observations associated with stacking of anode GDLs, where stacking of the anode GDLs increased the limiting current density. Through imaging, it is shown that the stacked anode GDL exhibited an interfacial region of high porosity. The coupled model shows that this morphology allowed more efficient water movement through the anode and higher temperatures at the cathode compared to the single GDL case. As a result, the cathode exhibited less flooding and hence better low temperature performance with the stacked anode GDL.

Nucleation and growth of ice in the catalyst layer of a proton-exchange-membrane fuel cell (PEMFC) are investigated using isothermal differential scanning calorimetry and isothermal galvanostatic cold-starts. Isothermal ice-crystallization rates and ice-nucleation rates are obtained from heat-flow and induction-time measurements at temperatures between 240 and 273 K for four commercial carbon-support materials with varying ionomer fraction and platinum loading. Measured induction times follow expected trends from classical nucleation theory and reveal that the carbon-support material and ionomer fraction strongly impact the onset of ice crystallization. Conversely, dispersed platinum particles play little role in ice crystallization. Following our previous approach, a nonlinear ice-crystallization rate expression is obtained from Johnson-Mehl-Avrami-Kolmogorov (JMAK) theory. A validated rate expression is now available for predicting ice crystallization within water-saturated catalyst layers. Using a simplified PEMFC isothermal cold-start continuum model, we compare cell-failure time predicted using the newly obtained rate expression to that predicted using a traditional thermodynamic-based approach. From this comparison, we identify conditions under which including ice-crystallization kinetics is critical and elucidate the impact of freezing kinetics on low-temperature PEMFC operation. The numerical model illustrates that cell-failure time increases with increasing temperature due to a longer required time for ice nucleation. Hence, ice-crystallization kinetics is critical when induction times are long (i.e., in the "nucleation-limited" regime for T > 263 K). Cell-failure times predicted using ice-freezing kinetics are in good agreement with the isothermal cold-starts, which also exhibit long and distributed cell-failure times for T > 263 K. These findings demonstrate a significant departure from cell-failure times predicted using the thermodynamic-based approach. © 2013 The Electrochemical Society. All rights reserved.

In this paper, direct-modeling-based Lattice Boltzmann Method (LBM) combined with in-situ flow visualization, is used to explore fundamentally the transport of liquid-water inside the gas-diffusion layers (GDLs) used in polymer electrolyte fuel cells. Studies of the water evolution, water saturation, and breakthrough pressure inside a GDL with single and multiple injection points under land and channel geometries are explored. The model and experiment demonstrate good agreement between geometries of GDLs provided in this study which were obtained by a three-dimensional (3-D), reconstructed micro-structure from micro X-ray computed tomography (CT). The overall predictions of water evolution within the GDL agree well with the data visualized from the X-ray CT experiment for all cases studied. It also reveals that the liquid-water saturation profiles inside the GDL and breakthrough pressure are different when the location of the water injection point is altered, thereby providing analysis as to the impact of microporous layers or catalyst-layer functioning. Moreover, the uncompressed GDL undergoes a significantly different mechanism of water transport than that of the compressed GDL. Furthermore, the predictions show that the wettability variation is one of the key factors of the saturation characteristics.

The hydrogen/bromine flow battery is a promising candidate for large-scale energy storage due to fast kinetics, highly reversible reactions and low chemical costs. However, today's conventional hydrogen/bromine flow batteries use membrane materials (such as Nafion), platinum catalysts, and carbon-paper electrode materials that are expensive. In addition, platinum catalysts can be poisoned and corroded when exposed to HBr and Br2, compromising system lifetime. To reduce the cost and increase the durability of H2/Br2 flow batteries, new materials are developed. The new Nafion/polyvinylidene fluoride electrospun composite membranes have high perm-selectivity at a fraction of the cost of Nafion membranes; the new nitrogen-functionalized platinum-iridium catalyst possesses excellent activity and durability in HBr/Br2 environment; and the new carbon-nanotube-based Br2 electrodes can achieve equal or better performance with less materials when compared to baseline electrode materials. Preliminary cost analysis shows that the new materials reduce H2/Br2 flow-battery energy-storage system stack and system costs significantly. The resulting advanced H2/Br2 flow batteries offer high power, high efficiency, substantially increased durability, and expected reduced cost.