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Direct methanol fuel cells – ready to go commercial?

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FEATURE<br />

<strong>Direct</strong> <strong>methanol</strong><br />

<strong>fuel</strong> <strong>cells</strong> – <strong>ready</strong><br />

<strong>to</strong> <strong>go</strong> <strong>commercial</strong><br />

By George Apanel (SRI Consulting, Hous<strong>to</strong>n, Texas, USA) and Eric Johnson<br />

(Atlantic Consulting, Zürich, Switzerland)<br />

DMFCs are about <strong>to</strong> come of age as transportable power supplies. A mo<strong>to</strong>r<br />

scooter is al<strong>ready</strong> headed <strong>to</strong>wards serial production; next in line will be cell<br />

phone power packs, portable genera<strong>to</strong>rs and perhaps even au<strong>to</strong>mobiles. This<br />

article reviews the development of direct <strong>methanol</strong> <strong>fuel</strong> <strong>cells</strong>, current players in<br />

the market, key technical challenges and the current cost picture.<br />

and the presumption is that it will stay that<br />

way or even increase.<br />

• For stationary applications, hydrogen or natural<br />

gas appear <strong>to</strong> be the best <strong>fuel</strong>s (if a lowcost<br />

distribution infrastructure is in place),<br />

but liquids are more desirable for mobile<br />

applications. Methanol is attractive: first,<br />

because it is cheap, and secondly, because it<br />

converts directly <strong>to</strong> electricity without the<br />

need for a bulky reformer in the middle.<br />

Reflect for a moment, if you will, on the title of<br />

this article. To some it will seem completely<br />

mundane: ‘Of course DMFCs are <strong>ready</strong> <strong>to</strong> <strong>go</strong><br />

<strong>commercial</strong>!’ To others, especially those who<br />

have seen energy crises and fads come and <strong>go</strong>,<br />

the title might seem more provocative.<br />

Remember, only a few decades a<strong>go</strong> it was<br />

thought that by now we would eat pills for<br />

meals and drive flying cars.<br />

Besides, <strong>fuel</strong> <strong>cells</strong> have been waiting in the<br />

wings for a long time. It was back in 1839<br />

when William Grove, a Welsh judge, constructed<br />

the first known <strong>fuel</strong> cell. His device<br />

electrochemically reacted hydrogen with oxygen.<br />

But it <strong>to</strong>ok more than another century<br />

for the first practical application of <strong>fuel</strong> <strong>cells</strong><br />

<strong>to</strong> occur. This was for US outer-space exploration<br />

in the early 1960s. The need for an<br />

efficient, long-lasting, non-polluting, compact<br />

power source within the cramped confines<br />

of a space vehicle made <strong>fuel</strong> <strong>cells</strong> the<br />

right choice, despite their high initial cost of<br />

materials and development.<br />

All well and <strong>go</strong>od for technological progress,<br />

but this was still a long ways off from <strong>commercial</strong><br />

viability. The US space program, with its<br />

famed $640 <strong>to</strong>ilet seats, is hardly a conventional,<br />

for-profit market.<br />

Nonetheless, our research suggests that<br />

DMFCs’ time is nearly come. They could soon<br />

be used on a competitive, <strong>commercial</strong> basis <strong>to</strong><br />

power cell phones, portable electric genera<strong>to</strong>rs<br />

and vehicles. Indeed, a DMFC-driven mo<strong>to</strong>r<br />

scooter is about <strong>to</strong> see its market debut.<br />

Why should we be any more optimistic than<br />

the Welsh judge There are two main reasons:<br />

• As readers of the Fuel Cells Bulletin know,<br />

the beauty of <strong>fuel</strong> <strong>cells</strong> is their energy efficiency,<br />

as shown in Figure 1. (The other<br />

attraction is their relatively mild operating<br />

conditions.) For economic, social and environmental<br />

reasons, efficiency has become<br />

much more important in the past few years,<br />

Stranded gas – the reason<br />

behind cheap <strong>methanol</strong><br />

The earth’s proven reserves of natural gas are –<br />

in terms of energy value – about 80% of the<br />

size of its proven oil reserves. Unfortunately,<br />

60% of this gas (an estimated 3000 trillion<br />

cubic feet) is so impolite as <strong>to</strong> locate itself in<br />

inconvenient places such as Tierra del Fue<strong>go</strong> or<br />

Figure 1. High efficiency – the promise of <strong>fuel</strong> <strong>cells</strong>. [Source: A.J. Appleby et al.: Fuel cell handbook<br />

(Van Nostrand Reinhold, NY, USA, 1989).]<br />

12<br />

Fuel Cells Bulletin November 2004


FEATURE<br />

on the North Slope of Alaska. This so-called<br />

‘stranded’ gas can be drilled and brought <strong>to</strong> the<br />

surface, but it is still <strong>to</strong>o remote <strong>to</strong> be transported<br />

economically <strong>to</strong> its potential markets.<br />

Sometimes stranded gas is brought <strong>to</strong> the<br />

surface anyway, because it is locked in underground<br />

formations <strong>to</strong>gether with oil that can be<br />

(and is) extracted economically. This stranded,<br />

‘associated’ gas is either re-injected in<strong>to</strong> the<br />

earth (11 trillion cubic feet in 1998), burnt<br />

near the wellhead (known as ‘flaring’) or even<br />

just vented <strong>to</strong> the atmosphere. If the 3.8 trillion<br />

cubic feet that were flared and vented in 1998<br />

were instead reacted with water at the right<br />

temperature and pressure, the result would be<br />

approximately 74 million <strong>to</strong>nnes of <strong>methanol</strong>.<br />

This is about three times the 25.7 million<br />

<strong>to</strong>nnes actually produced that year, so the<br />

potential here is huge. Moreover, burning or<br />

venting <strong>fuel</strong> is terribly ‘politically incorrect’<br />

these days, not least thanks <strong>to</strong> concerns about<br />

global warming and sustainability. Finally, the<br />

spike in oil prices of the past few years has<br />

shifted the economics of stranded gas – some of<br />

those far-off places are looking closer than they<br />

used <strong>to</strong>.<br />

One option, of course, is <strong>to</strong> compress the gas<br />

in<strong>to</strong> liquefied natural gas (LNG), and then ship<br />

it <strong>to</strong> market. This involves construction of a<br />

costly liquefaction plant, as well as specialized<br />

shipping and terminal facilities, and in some<br />

cases captive power plants bound by long-term<br />

supply contracts. A typical grassroots LNG project<br />

liquefying approximately 980 million standard<br />

cubic feet (SCF) per day of natural gas for<br />

producing about 6 million <strong>to</strong>nnes per year of<br />

LNG could cost US$5–10 billion if the cost of<br />

the power plant is included with the production<br />

facilities.<br />

Another option is a gas-<strong>to</strong>-liquids (GTL)<br />

plant, where the natural gas is converted by a<br />

series of reactions in<strong>to</strong> a <strong>fuel</strong> similar <strong>to</strong> diesel.<br />

Shell is building a major gas-<strong>to</strong>-liquids unit <strong>to</strong><br />

liberate stranded gas in Qatar, and other such<br />

projects are on the drawing board.<br />

Yet another option is <strong>to</strong> use stranded gas <strong>to</strong><br />

make either of two petrochemicals: ammonia or<br />

<strong>methanol</strong>. (Indeed, most recent additions <strong>to</strong><br />

capacity of these products are in remote locations.)<br />

A major attraction of these is that the<br />

capital investment required for such projects is<br />

an order of magnitude lower than for LNG or<br />

gas-<strong>to</strong>-liquids. Furthermore, a world-scale<br />

<strong>methanol</strong> plant can operate on a gas field that is<br />

<strong>to</strong>o small <strong>to</strong> justify an LNG or gas-<strong>to</strong>-liquids<br />

operation. Indeed, such <strong>methanol</strong> plants can<br />

even be mounted on barges, and then moved<br />

from field <strong>to</strong> field. On the other hand, pricing<br />

in chemical markets is no<strong>to</strong>riously volatile.<br />

Great ideas can be – and often are – washed<br />

away in a flood of overcapacity or a shift in<br />

demand.<br />

If there were a stable <strong>fuel</strong> market for<br />

<strong>methanol</strong>, so much the better. (Currently there<br />

are <strong>fuel</strong> markets for it, but they are anything<br />

but stable.) Rest assured, <strong>methanol</strong> producers<br />

are watching <strong>fuel</strong> cell markets anxiously.<br />

Indeed, one of the major producers, Methanex,<br />

is co-sponsoring the development of a DMFCpowered<br />

mo<strong>to</strong>r scooter.<br />

Choose me, choose me –<br />

<strong>methanol</strong>’s mobility<br />

advantage<br />

In mobile applications, liquid <strong>fuel</strong>s are usually<br />

preferable <strong>to</strong> gaseous ones, and often <strong>to</strong> solid<br />

ones as well. So, not surprisingly, researchers<br />

have long been on the lookout for a fluid that<br />

would also be a suitable <strong>fuel</strong>.<br />

Methanol was an obvious candidate early on,<br />

because it:<br />

• can be readily made via a well known manufacturing<br />

process from plentiful raw materials;<br />

• remains liquid under normal s<strong>to</strong>rage conditions<br />

(unlike, say, butane, which tends <strong>to</strong><br />

evaporate much more easily);<br />

• is compatible with the existing <strong>fuel</strong> distribution<br />

infrastructure;<br />

• is relatively hydrogen-dense, i.e. four of the<br />

six a<strong>to</strong>ms in <strong>methanol</strong> (CH 3 OH) are hydrogen;<br />

and<br />

• is environmentally acceptable.<br />

Figure 2. First through a reformer – an indirect <strong>methanol</strong> <strong>fuel</strong> cell.<br />

In the 1990s, development began of an indirect<br />

<strong>methanol</strong> <strong>fuel</strong> cell (Figure 2). A <strong>fuel</strong> processor<br />

(also known as a reformer) was used <strong>to</strong> convert<br />

<strong>methanol</strong> in<strong>to</strong> hydrogen-rich gas for pro<strong>to</strong>nexchange<br />

membrane (PEM) <strong>fuel</strong> <strong>cells</strong>.<br />

Reforming <strong>to</strong> produce hydrogen from<br />

<strong>methanol</strong> is well known on an industrial scale.<br />

At temperatures of 250–300°C, <strong>methanol</strong> is<br />

reacted with steam over a copper-zinc or copper-chromium<br />

catalyst in<strong>to</strong> hydrogen and CO 2<br />

via the following reaction:<br />

CH 3 OH + H 2 O → CO 2 + 3H 2<br />

Methanol enters the <strong>fuel</strong> processor where it is<br />

vaporized, combined with water and converted<br />

in<strong>to</strong> moist, hydrogen-rich reformate. The carbon<br />

monoxide byproduct is removed from the<br />

reformate via a gas purification system.<br />

The purified, hydrogen-rich reformate is fed<br />

<strong>to</strong> the <strong>fuel</strong> cell’s anode chamber, where the<br />

hydrogen is oxidized while oxygen (in the<br />

form of air) is reduced at the cathode. Air is<br />

supplied <strong>to</strong> the cell via a compressor. The<br />

compressed cathode effluent gas passes<br />

through an expander <strong>to</strong> recover some of the<br />

energy from the compression step. The spent<br />

<strong>fuel</strong> from the anode chamber contains some<br />

residual hydrogen, and is fed <strong>to</strong> a catalytic<br />

burner <strong>to</strong> provide heat for <strong>methanol</strong> vaporization<br />

and the endothermic steam <strong>methanol</strong><br />

reformer.<br />

The downsides here are:<br />

• because this reaction consumes energy, the<br />

reformer needs supplemental heat; and<br />

• the reformer adds sizable capital costs, and it<br />

can be bulky.<br />

Nevertheless, DaimlerChrysler has shown that<br />

it can work. In 2001 its Necar 5 pro<strong>to</strong>type –<br />

which used a <strong>methanol</strong> reformer based system<br />

– was driven in a pilot test right across the<br />

United States.<br />

November 2004<br />

Fuel Cells Bulletin<br />

13


FEATURE<br />

Of course, other liquid hydrocarbons can<br />

also be reformed <strong>to</strong> hydrogen. In fact, the same<br />

features that make <strong>methanol</strong> a <strong>go</strong>od <strong>fuel</strong> candidate<br />

also apply generally <strong>to</strong> gasoline, although<br />

the gasoline reformer would be even more complicated<br />

and less efficient. What sets <strong>methanol</strong><br />

apart from those hydrocarbon <strong>fuel</strong>s is its ability<br />

<strong>to</strong> be fed directly in<strong>to</strong> a <strong>fuel</strong> cell, which cuts out<br />

the reformer with its associated costs and<br />

headaches. This is possible because, like all alcohols,<br />

<strong>methanol</strong> contains oxygen: this makes it<br />

more reactive than plain hydrocarbons.<br />

This was first recognized in 1922 by the<br />

German researcher E. Müller, who studied<br />

electro-oxidation of <strong>methanol</strong>. By 1951, Karl<br />

Kordesch and Adolf Marko had begun construction<br />

of a direct <strong>methanol</strong> <strong>fuel</strong> cell based on<br />

Müller’s early concept.<br />

DMFC interest fired up again about a decade<br />

later, this time focused on military applications.<br />

Alkaline electrolytes were tested by researchers at<br />

Allis-Chalmers in 1963. DMFCs based on aqueous<br />

acid electrolytes, which do not react with<br />

CO 2 produced at the anode, were developed by<br />

researchers at Esso and Shell in 1965. Esso<br />

developed a 100 We DMFC for powering communication<br />

equipment. Shell found Pt-Ru <strong>to</strong> be<br />

most effective as an anode electrocatalyst, and<br />

developed a 300 We system pro<strong>to</strong>type in 1968.<br />

Progress then mostly hibernated until 1992,<br />

when DuPont’s Nafion solid polymer electrolyte<br />

membrane was found <strong>to</strong> be far superior<br />

<strong>to</strong> the old medium of sulfuric acid (Figure 3).<br />

In 1994, the Jet Propulsion Labora<strong>to</strong>ry in<br />

California demonstrated a Nafion-based<br />

DMFC, and since then, a new wave of development<br />

has been rolling.<br />

Key players in DMFCs<br />

In our research, we have identified 15 companies<br />

that are leading the development of<br />

DMFCs. They are listed here in alphabetical<br />

order, with a brief discussion of each.<br />

Ball Aerospace & Technologies<br />

20 W electrical output for medical devices, cell<br />

www.ball.com/aerospace<br />

phones, PDAs, lap<strong>to</strong>ps and other wireless<br />

The Colorado-based company is developing a devices. Giner Electrochemical Systems, which<br />

handheld 20 We DMFC power system for the is a joint venture between Giner Inc and<br />

US Defense Advanced Research Projects General Mo<strong>to</strong>rs, has also delivered a complete<br />

Agency (DARPA) Palm Power Program. This liquid-feed direct <strong>methanol</strong> <strong>fuel</strong> cell system providing<br />

a 50 We/12 V output <strong>to</strong> the US Army<br />

compact electrical power source is primarily<br />

intended for foot soldiers and robotics under Research Labora<strong>to</strong>ry.<br />

battlefield conditions, but may find other<br />

emerging, non-military applications. If this<br />

1.5 lb (700 g) device were used <strong>to</strong> power a lap<strong>to</strong>p<br />

computer, it could run continuously for<br />

three days between <strong>methanol</strong> refills. While the<br />

DMFC device is similar in size <strong>to</strong> three videocassette<br />

tapes, 22 lbs (10 kg) of conventional<br />

batteries would otherwise be required for such a<br />

continuous service interval.<br />

<strong>Direct</strong> Methanol Fuel Cell<br />

Lynntech Industries (nowFideris)<br />

Corporation<br />

www.dmfcc.com<br />

This company, founded in California in 2002,<br />

aims <strong>to</strong> <strong>commercial</strong>ize DMFC knowhow developed<br />

at the California Institute of Technology/<br />

NASA Jet Propulsion Labora<strong>to</strong>ry (JPL) and the<br />

University of Southern California. The company<br />

has acquired the rights <strong>to</strong> 26 issued and<br />

more than 40 pending US and foreign patents<br />

on JPL’s DMFC technology.<br />

Figure 3. The power (and voltage) of Nafion. [Source: S. Srinivasan et al.: Techno-economic challenges<br />

for PEMFCs and DMFCs entering energy sec<strong>to</strong>r. First International Conference on Fuel Cell<br />

Science, Engineering & Technology, Rochester, NY, USA, April 2003.]<br />

Giner Electrochemical Systems<br />

www.ginerinc.com<br />

Massachusetts-based GES has announced its<br />

demonstration of a simplified DMFC, based on<br />

a novel method of supplying <strong>methanol</strong> <strong>to</strong> the<br />

<strong>fuel</strong> cell. This is particularly attractive <strong>to</strong> micro<br />

and low-power <strong>fuel</strong> <strong>cells</strong> of up <strong>to</strong> approximately<br />

H Power/Plug Power<br />

www.plugpower.com<br />

US-based H Power (subsequently acquired by<br />

Plug Power) was in a joint development agreement<br />

with DuPont Fluoroproducts <strong>to</strong> develop<br />

DMFCs in the range from 100 <strong>to</strong> 1000 We for<br />

portable and mobile applications.<br />

www.fideris.com<br />

A new generation of test systems for DMFCs<br />

has been launched by this company, which<br />

recently changed its name and relocated <strong>to</strong><br />

Massachusetts. The company has also delivered<br />

four pro<strong>to</strong>type, self-contained DMFC 15 W/<br />

12 V power supplies <strong>to</strong> the US Army Research<br />

Labora<strong>to</strong>ry.<br />

Manhattan Scientifics<br />

www.mhtx.com<br />

NY-based Manhattan Scientifics is <strong>commercial</strong>izing<br />

DMFC technology developed by former<br />

Los Alamos National Labora<strong>to</strong>ry researcher<br />

Bob Hockaday at Energy Related Devices in<br />

Arizona. The company has a proprietary<br />

method for the use and manufacture of<br />

MicroFuel Cell power devices, which are<br />

aimed at portable electronics such as cell<br />

phones, lap<strong>to</strong>p computers, camcorders and<br />

power <strong>to</strong>ols. Manhattan Scientifics has used<br />

MicroFuel Cell technology <strong>to</strong> create its Power<br />

Holster, a portable charger/cell phone carrier.<br />

Fueled by disposable ampoules containing<br />

<strong>methanol</strong>, the <strong>fuel</strong> <strong>cells</strong> can also use cartridges<br />

that provide hydrogen gas generated by a sodium<br />

borohydride/water reaction. Generating<br />

approximately 1 W of electric power, the<br />

MicroFuel Cell array in the unit consists of 10<br />

<strong>cells</strong> in a 4.7 inch long × 1.8 inch wide × 0.02<br />

inch thick (120 × 46 × 0.5 mm) package. The<br />

<strong>cells</strong> are formed on paper-thin plastic sheets<br />

intended for roll-fed mass production. The<br />

14<br />

Fuel Cells Bulletin November 2004


FEATURE<br />

specific energy density of its MicroFuel Cell is<br />

940 Wh/kg, which is between six and nine<br />

times that of <strong>commercial</strong> Li-ion batteries.<br />

Mechanical Technology Inc/<br />

MTI Micro Fuel Cells<br />

Medis Technologies<br />

www.medistechnologies.com<br />

US/Israeli-based Medis has completed the first<br />

phase in the development of its direct liquid Technology<br />

<strong>methanol</strong> (DLM) <strong>fuel</strong> cell for portable electronic<br />

devices. The 1 × 1 × 3/8 inch (25 × 25 × 10 In Korea, Samsung has demonstrated a 40 We<br />

www.sait.samsung.co.kr<br />

mm) DLM <strong>fuel</strong> cell module delivers 0.24 We at DMFC (12 V/3.4 A) that operates a notebook<br />

0.9 V. The company plans <strong>to</strong> package its <strong>fuel</strong> PC for more than 6 h without charging. Core<br />

<strong>cells</strong> as individual modules (‘chips’) for manufacturers<br />

of portable electronic<br />

technologies for miniature DMFC cell packs<br />

devices.<br />

Mo<strong>to</strong>rola Labs<br />

NEC<br />

up the PDA. Thus, it is anticipated that the<br />

www.labs.nec.co.jp/Eng/innovative/E1/<strong>to</strong>p.html<br />

battery will be replaced by an ultracapaci<strong>to</strong>rtype<br />

device before the DMFC is <strong>commercial</strong>-<br />

Japanese electronics giant NEC has announced<br />

a miniature DMFC based on applied nanotechnology.<br />

The power output is claimed <strong>to</strong> be market a DMFC for notebook PCs.<br />

ized. Toshiba has also announced plans <strong>to</strong><br />

about 10 times that of a Li-ion battery with the<br />

Samsung Advanced Institute of<br />

are under development that will power cell<br />

phones and PDAs. The company has also<br />

developed a credit-card-sized DMFC which<br />

www.mo<strong>to</strong>rola-labs.com<br />

would fit in<strong>to</strong> a cell phone, which it hopes <strong>to</strong><br />

US giant Mo<strong>to</strong>rola has demonstrated a pro<strong>to</strong>type<br />

of a miniature integrated, ceramic-based, power density of 50 mW/cm 2 , and a <strong>to</strong>tal<br />

<strong>commercial</strong>ize by 2005. It has a maximum<br />

reformed <strong>methanol</strong>-<strong>to</strong>-hydrogen <strong>fuel</strong> cell electric power output of 2000 mW.<br />

(RHFC). The device incorporates an integrated<br />

<strong>methanol</strong> vaporizer and steam reformer.<br />

The company has also demonstrated a pro<strong>to</strong>type<br />

ceramic-based DMFC which could power<br />

www.smart<strong>fuel</strong>cell.com<br />

German-based Smart Fuel Cell is developing<br />

a cell phone for a month between <strong>methanol</strong><br />

compact DMFC systems for the portable electronics<br />

and small portable genera<strong>to</strong>r markets. A<br />

refills. The <strong>fuel</strong> cell assembly fits in<strong>to</strong> a belt<br />

holster, with <strong>methanol</strong> s<strong>to</strong>red in a small cartridge.<br />

The device is designed <strong>to</strong> either power<br />

portable DMFC power supply unit, <strong>fuel</strong>ed by a<br />

replaceable <strong>methanol</strong> cartridge, will soon be<br />

a cell phone directly, or <strong>to</strong> recharge a conventional<br />

battery pack for powering the phone.<br />

<strong>commercial</strong>ly available on a limited basis <strong>to</strong><br />

industrial cus<strong>to</strong>mers. SFC has demonstrated a<br />

The assembly measures about 2 × 4 × 0.5<br />

inches (50 × 100 × 12 mm). The device integrates<br />

miniature <strong>methanol</strong> concentration sensors,<br />

liquid-gas separation for CO 2 release,<br />

pumps and control electronics. A highly simplified<br />

and miniaturized passive air design www.<strong>to</strong>shiba.co.jp/rdc<br />

Toshiba<br />

eliminates the need for condensers, heatexchangers<br />

and other complex devices. The <strong>to</strong>type DMFC for powering a PDA. It has a<br />

The Japanese company has demonstrated a pro-<br />

company appears <strong>to</strong> be planning <strong>commercial</strong> power density of 30 mW/cm 2 at a constant<br />

<strong>fuel</strong> cell product introductions for cell phones average power output of 5 We. However, an<br />

by 2005–2006.<br />

auxiliary rechargeable battery is required <strong>to</strong> start<br />

Yuasa Corporation<br />

same volume. The company says it plans <strong>commercial</strong><br />

product introductions by 2005 for<br />

www.mtimicro<strong>fuel</strong><strong>cells</strong>.com<br />

MTI Micro in Latham, NY is using technology<br />

www.yuasa.co.jp<br />

notebook computers and cell phones.<br />

licensed from Los Alamos National Labora<strong>to</strong>ry,<br />

This Japanese battery manufacturer has demonstrated<br />

DMFC pro<strong>to</strong>types with electric power<br />

from where some of its key staff (including its<br />

chief technology officer, Dr Shimshon PolyFuel<br />

levels of 100 and 300 W, and says it intends<br />

Gottesfeld) have moved. The company has www.poly<strong>fuel</strong>.com <strong>to</strong> introduce <strong>commercial</strong> products in the near<br />

partnered with DuPont <strong>to</strong> develop Nafionbased<br />

DMFCs, and plans <strong>to</strong> <strong>commercial</strong>ize a from independent research consultancy SRI<br />

The California-based company – a spinoff future.<br />

DMFC for cell phone applications in 2005. International – appears <strong>to</strong> be targeting <strong>commercial</strong><br />

product introductions by 2005. In late<br />

Run DMFC – the key<br />

The planned DMFC product would be about<br />

the same size as a conventional cell phone battery,<br />

but have a considerably longer operational reportedly ruled that a PolyFuel DMFC The two main barriers <strong>to</strong> economic DMFCs<br />

2002 the US Department of Transportation technical challenges<br />

time span between <strong>methanol</strong> cartridge replacements<br />

as well as being more environmentally allowed on board <strong>commercial</strong> aircraft. This ini-<br />

designed <strong>to</strong> power lap<strong>to</strong>p computers could be are <strong>methanol</strong> crossover and slow anode kinetics.<br />

• Methanol crossover is the diffusion of<br />

acceptable.<br />

tiated the process of regula<strong>to</strong>ry acceptance for<br />

<strong>methanol</strong> through the membrane from<br />

DMFCs as an alternative <strong>to</strong> conventional bat-<br />

the anode side <strong>to</strong> the cathode. This<br />

teries in such applications.<br />

reduces DMFC efficiency, primarily<br />

because (1) the crossed-over <strong>methanol</strong> is<br />

essentially wasted, and (2) the cathode’s<br />

catalyst can be poisoned by the carbon<br />

a<strong>to</strong>ms in the <strong>methanol</strong>. This generally<br />

limits <strong>methanol</strong> concentrations at the<br />

anode compartment <strong>to</strong> around 2–5 wt%,<br />

and may require recirculation of water<br />

produced in the cathode compartment<br />

back <strong>to</strong> the anode compartment in order<br />

<strong>to</strong> keep the <strong>methanol</strong> dilute. Such constraints<br />

generally limit the overall DMFC<br />

efficiency <strong>to</strong> around 15–20% and the<br />

power density <strong>to</strong> around 30 mW/cm 2 .<br />

Methanol crossover losses can be 30%<br />

or higher of the <strong>methanol</strong> <strong>fuel</strong> for some<br />

DMFC membranes and design configurations.<br />

• DMFC anode kinetics are slower than<br />

those of PEM <strong>fuel</strong> <strong>cells</strong> running on<br />

hydrogen. This means in turn that either<br />

power densities are lower, or more expensive<br />

platinum catalysts are needed. On<br />

the other hand, DMFCs do not require<br />

cooling plates or supplemental membrane<br />

hydration systems, which could ultimately<br />

make them more compact than hydrogen<br />

PEM <strong>fuel</strong> <strong>cells</strong>.<br />

SFC Smart Fuel Cell GmbH<br />

DMFC that can power a lap<strong>to</strong>p for an entire<br />

The key <strong>to</strong> resolving <strong>methanol</strong> crossover lies<br />

day on a single <strong>methanol</strong> cartridge.<br />

in the membrane, whereas the key <strong>to</strong> faster<br />

kinetics lies in the catalyst and the membrane-electrode<br />

assembly (MEA). The development<br />

of a DMFC membrane that is also<br />

capable of operation at elevated temperatures<br />

would have particularly profound significance,<br />

by also enhancing kinetics while<br />

reducing catalyst requirements. All are the<br />

subjects of intense research.<br />

November 2004<br />

Fuel Cells Bulletin<br />

15


FEATURE<br />

Membranes<br />

Nafion was a great advance in its day, but for<br />

DMFCs there are better materials. Research<br />

has focused on three types: perfluorinated<br />

(which includes Nafion), partially fluorinated<br />

and non-fluorinated.<br />

Perfluorinated membranes currently cost<br />

well upwards of US$800 per m 2 for DMFC<br />

applications, which could be as much as $300<br />

per kW of electric power output. The major<br />

offerings are:<br />

• Micro-reinforced perfluorinated ionomer<br />

composite membranes – such as those<br />

marketed by W.L. Gore under the trade<br />

name Gore-Select. They are microporous<br />

stretched PTFE filled with perfluorinated<br />

ionomer. The thickness of the membrane<br />

can be reduced <strong>to</strong> 20–35 µm. Another<br />

membrane of this type is the Aciplex<br />

range from Asahi Glass in Japan.<br />

• Perfluorinated membranes/inorganic<br />

particle composites – these are produced<br />

by recasting Nafion solution and introducing<br />

inorganic additives (such as<br />

nanoporous, highly hydrophilic silica<br />

particles) or heteropolyacids, such as<br />

phosphotungstic acid or phosphomolybdenic<br />

acid. The principal problem with<br />

such membranes is the hydrosolubility<br />

of the heteropolyacids. Improved performances<br />

have been reported for DMFCs<br />

in some cases because of reduced<br />

<strong>methanol</strong> crossover, with a maximum<br />

power density of 240 mW/cm 2 at 0.4 V.<br />

However, the claims of reduced <strong>methanol</strong><br />

crossover for such membranes appear <strong>to</strong><br />

be controversial.<br />

• Other Nafion-based composites – impregnating<br />

a Nafion membrane with poly-(1-<br />

methyl pyrrole) via in situ polymerization<br />

using UV radiation or H 2 O 2 results in<br />

reduced <strong>methanol</strong> permeation. Unfortunately,<br />

the ionic conductivity was also<br />

reduced. A plasma processing technique<br />

has been devised <strong>to</strong> deposit a thin plasma<br />

polymerized film on Nafion membranes,<br />

<strong>to</strong> improve their barrier properties. The<br />

use of layered membrane structures has<br />

been investigated. Another approach<br />

involves a three-layered laminar electrolyte<br />

system, consisting of a dense, <strong>methanol</strong>impermeable<br />

pro<strong>to</strong>nic conduc<strong>to</strong>r sandwiched<br />

between electronically insulating<br />

layers.<br />

Partially fluorinated membranes under<br />

active investigation include the grafting of fluorinated<br />

base polymer films by various techniques<br />

with select materials. Other partially<br />

fluorinated membranes under investigation<br />

Figure 4. Cell phone with DMFC – external view (left) and exploded internal view (right).<br />

include poly(α, β, β-trifluorostyrene) and<br />

copolymers:<br />

• Grafted ionomer membranes – this involves<br />

bathing base polymer films in gamma radiation<br />

<strong>to</strong> generate free radicals for subsequent<br />

grafting. One developer claims <strong>to</strong><br />

have reduced <strong>methanol</strong> crossover relative <strong>to</strong><br />

Nafion 117 by up <strong>to</strong> 66%, adding that the<br />

membrane can be manufactured at a small<br />

fraction of the cost of Nafion.<br />

• Ionomer membranes based on poly(α, β,<br />

β-trifluorostyrene) and copolymers – these<br />

have been pioneered by Ballard Power<br />

Systems, which has developed several partially<br />

fluorinated pro<strong>to</strong>n-conducting membranes<br />

of sulfonated or phosphonated polymers<br />

plus either poly(phenyl quinoxaline):<br />

BAM 1G (2, 6-diphenyl 1,4-phenylene<br />

oxide), BAM 2G, or a trifluoro styrene<br />

based membrane, BAM 3G.<br />

A variety of novel non-fluorinated ionomer<br />

membranes have been reported in the general<br />

literature. These include ionomers based on<br />

phosphazene, arylene main chains, and<br />

poly(benzimidazole) or PBI. One developer is<br />

making impressive claims not only about reducing<br />

<strong>methanol</strong> crossover, but also operating at<br />

higher temperatures and <strong>methanol</strong> concentrations<br />

– these are critical hurdles for DMFCs, if<br />

they are <strong>to</strong> be economic in au<strong>to</strong>mobiles.<br />

Catalysts and MEAs<br />

Catalyst preparation and MEA manufacturing<br />

techniques are major areas of research.<br />

There are two general catalyst preparation<br />

approaches:<br />

• Impregnation – this is typically a deposition<br />

step of the Pt and Ru precursors (for<br />

example H 2 PtCl 6 , RhCl 3 , Pt(NH 3 ) 2 (OH) 2 ,<br />

Ru 3 CO 2 , Pt(NH 3 ) 2 (NO) 2 etc.) followed<br />

by a reduction step. Reduction can be via<br />

the chemical reduction of the electrocatalyst<br />

slurry in aqueous solution using N 2 H 4 ,<br />

NaS 2 O 5 , NaS 2 O 3 or NaBH 4 , or via the gas<br />

phase reduction of the impregnated carbon<br />

black using a hydrogen gas stream. A drawback<br />

of this procedure is that high dispersions<br />

may not be achievable in the presence<br />

of high metal loadings.<br />

• Colloidal – the advantage here is higher<br />

surface areas with high metal loading. The<br />

main disadvantages are the complexity of<br />

the preparation, the need for organic compounds/solvents,<br />

and generally higher production<br />

costs.<br />

MEA manufacturing research includes experimentation<br />

in:<br />

• Incorporation of PTFE/carbon composite<br />

ducts.<br />

• Modification of the hydrophobichydrophilic<br />

properties of the ionomer in<br />

the electrocatalyst layer.<br />

• Use of pore formers <strong>to</strong> increase the porosity<br />

of the cathode active layer.<br />

• Sputter deposition fabrication.<br />

• Bipolar flow-field plates.<br />

DMFC costs –<br />

competitive in small<br />

mobile applications<br />

Based on a detailed review of patents and<br />

technical papers, we have designed a DMFC<br />

16<br />

Fuel Cells Bulletin November 2004


RESEARCH TRENDS<br />

Conventional Power Cost of DMFC power<br />

Device power source output Base case Optimistic case<br />

Cell phone Rechargeable 2 We 43% lower 82% lower<br />

batteries<br />

Small portable Internal combustion Under 22% lower 67% lower<br />

genera<strong>to</strong>r engine 500 We<br />

Au<strong>to</strong>mobile Internal combustion 75 kWe 188% higher 17% higher<br />

engine<br />

Source: Process Economics Program Report 243A, <strong>Direct</strong> Methanol Fuel Cells, <strong>to</strong> be published in Oc<strong>to</strong>ber 2004<br />

by SRI Consulting.<br />

Table 1. Cost of DMFC power output compared <strong>to</strong> conventional power sources (on a $/kWe basis).<br />

engineering concept for three mobile applications:<br />

cell phones (Figure 4), small portable<br />

genera<strong>to</strong>rs, and au<strong>to</strong>mobiles. Some of these<br />

applications may well be competitive with<br />

conventional power systems (Table 1).<br />

DMFCs for cell phones and small portable<br />

genera<strong>to</strong>rs are now below the cost of conventional<br />

power technologies. For au<strong>to</strong>mobiles,<br />

DMFCs are not yet cost-competitive, but<br />

on<strong>go</strong>ing progress is dramatic, and the technology<br />

is readily scalable. If environmental concerns<br />

keep increasing the costs of conventional<br />

engines and <strong>fuel</strong>s, then it is only a matter of<br />

time until DMFC au<strong>to</strong>mobiles become <strong>commercial</strong>ly<br />

viable.<br />

Convinced At least one company is. Parker-<br />

Hannifin has begun selling its Vectrix DMFC<br />

mo<strong>to</strong>r scooter on a pilot basis. The aim is <strong>to</strong> <strong>go</strong><br />

fully <strong>commercial</strong> in 2006.<br />

For more information, contact: George Apanel,<br />

SRI Consulting, 16945 Northchase Drive, Suite 1910,<br />

Hous<strong>to</strong>n, TX 77060, USA. Tel: +1 281 876 6929,<br />

Email:gapanel@sriconsulting.com,<br />

Web:www.sriconsulting.com<br />

Or contact: Eric Johnson, Atlantic Consulting,<br />

Obstgartenstrasse 14, CH-8136 Gattikon, Switzerland.<br />

Tel:+41 1 772 1079,Email:ejohnson@ecosite.co.uk<br />

Research Trends<br />

Performance of highly dispersed<br />

Pt/C catalysts for PEM and DMFCs<br />

P.K. Shen and Z. Tian: Electrochimica Acta<br />

49(19) 3107–3111 (15 August 2004).<br />

Zirconia-bridged hydrocarbon/<br />

phosphotungstic acid hybrid materials<br />

for high-temperature PEMFCs<br />

J.-D. Kim and I. Honma: Electrochimica Acta<br />

49(19) 3179–3183 (15 August 2004).<br />

Preparation and characterization<br />

of solution-cast Nafion ionomer<br />

membranes<br />

R.F. Silva, M. De Francesco and A. Pozio: Electrochimica<br />

Acta 49(19) 3211–3219 (15 Aug. 2004).<br />

Palladinized Nafion for DMFCs<br />

Y.J. Kim et al.: Electrochimica Acta 49(19) 3227–<br />

3234 (15 August 2004).<br />

3D carbon nanotube network based<br />

on hierarchical structure grown on<br />

carbon paper, for PEMFC electrodes<br />

X. Sun et al.: Chemical Physics Letters 394(4–6)<br />

266–270 (21 August 2004).<br />

Pro<strong>to</strong>n-conducting PDMS/metal<br />

oxide hybrid membranes with<br />

phosphotungstic acid, for hightemperature<br />

PEMFCs<br />

J.-D. Kim and I. Honma: Electrochimica Acta<br />

49(20) 3429–3433 (30 August 2004).<br />

XRD/XPS analysis of as-prepared<br />

and conditioned DMFC array MEAs<br />

R.R. Díaz-Morales et al.: J. Electrochem. Soc.<br />

151(9) A1314–1318 (September 2004).<br />

SOFC anodes based on Cu-Ni and<br />

Cu-Co bimetallics in CeO 2<br />

-YSZ<br />

S.-I. Lee, J.M. Vohs and R.J. Gorte: J. Electrochem.<br />

Soc. 151(9) A1319–1323 (Sep. 2004).<br />

Temperature-dependent kinetics of<br />

DMFC anode<br />

J. Nordlund and G. Lindbergh: J. Electrochem.<br />

Soc. 151(9) A1357–1362 (September 2004).<br />

High-temperature, pro<strong>to</strong>n-conducting<br />

polytetramethylene oxide/zirconia<br />

hybrid membranes<br />

J.-D. Kim and I. Honma: J. Electrochem. Soc.<br />

151(9) A1396–1401 (September 2004).<br />

LaNi(Fe)O 3<br />

as SOFC cathode<br />

H. Orui et al.: J. Electrochem. Soc. 151(9)<br />

A1412–1417 (September 2004).<br />

Effect of segregation <strong>to</strong> interface<br />

on H 2<br />

–H 2<br />

O–Ni–YSZ electrode<br />

performance<br />

K. Vels Hansen, K. Norrman and M. Mogensen:<br />

J. Electrochem. Soc. 151(9) A1436–1444 (September<br />

2004).<br />

Model and procedure <strong>to</strong> optimize<br />

PEMFC internal structure and external<br />

shape, for maximum net power<br />

J.V.C. Vargas, J.C. Ordonez and A. Bejan: Int. J.<br />

Heat & Mass Transfer 47(19/20) 4177–4193<br />

(September 2004).<br />

Preparation of Ni/YSZ anode for IT-<br />

SOFCs by coating precipitation<br />

F.H. Wang et al.: Materials Letters 58(24)<br />

3079–3083 (September 2004).<br />

Ionic, electronic transport in stabilized<br />

β-La 2<br />

Mo 2<br />

O 9<br />

SOFC electrolytes<br />

I.P. Marozau et al.: Electrochimica Acta 49(21)<br />

3517–3524 (1 September 2004).<br />

Subsolidus phase equilibria in Al 2<br />

O 3<br />

–<br />

CeO 2<br />

–PbO and Al 2<br />

O 3<br />

–CeO 2<br />

–RuO 2<br />

systems<br />

M. Hrovat et al.: Materials Research Bulletin<br />

39(11) 1723–1728 (1 September 2004).<br />

Hydrogen generation by hydrolysis<br />

reaction of lithium borohydride<br />

Y. Kojima et al.: Int. J. Hydrogen Energy 29(12)<br />

1213–1217 (September 2004).<br />

H 2<br />

s<strong>to</strong>rage in wind turbine <strong>to</strong>wers<br />

R. Kottenstette and J. Cotrell: Int. J. Hydrogen<br />

Energy 29(12) 1277–1288 (September 2004).<br />

High-temperature membranes in<br />

power generation with CO 2<br />

capture<br />

R. Bredesen, K. Jordal and O. Bolland: Chem.<br />

Eng. & Processing 43(9) 1129–1158 (Sep. 2004).<br />

November 2004<br />

Fuel Cells Bulletin<br />

17

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