joint research programme on fuel cells and …€¦ · joint research programme on fuel cells and...

COMMERCIAL-IN-CONFIDENCE

DoW template version 2010/09

EERA

EUROPEAN ENERGY RESEARCH ALLIANCE

DESCRIPTION OF WORK (DOW)

Joint Research Programme on

Fuel Cells and Hydrogen technologies (FCs&H2)

Version: 1.1

Last modification date: 20/12/11

Contact person: Angelo Moreno [email protected]

mailto:[email protected]


2

Summary of the Joint Programme on Fuel Cells and Hydrogen technologies

The overall objective of this Joint Programme (JP) is to align medium to long term pre-

competitive research activities at EERA institutes and associated institutions to create a

technical-scientific basis for further improvement of Fuel Cells and Hydrogen technologies.

There are two main obstacles to commercialisation of FC and hydrogen technologies: life

time and costs. To find adequate and viable solutions long-term research is highly needed. In

this JP we aim to highlight the main areas where long-term research activities will help these

technologies to reach breakthroughs towards real market applications, to explore the

possibilities for joint European technology development, and identify and exploit the

potential synergies therein in order to enhance the solution of the problems that still prevent

commercialization of fuel cells and hydrogen technologies.

Initially, the joint program will focus on fuel cell and water electrolyser issues and related

electrochemical aspects, in addition to a sub programme on non-electrochemical hydrogen

production and handling . The intention is to add more topics on other technologies as soon

as this JP is established. The proposed sub programmes included at the initiation of the JP

are:

SP1 Electrolytes (Deborah Jones, CNRS)

The Sub-Programme Electrolytes will mainly deal with developing new generations of high

performance, low cost and durable electrolyte materials for low and high temperature fuel

cells and electrolysers. Activities will be harmonised with other SPs, and in particular with

SP2 on Catalysts and Electrodes, to develop an integrated mid and long term research

programme combining expertise from experimental approaches and computational modelling.

Synergies will be sought between research organisations for the rational use of facilities,

exchange of students and researchers, exchange of materials and information.

SP2 Catalysts & Electrodes (Luis Colmenares, SINTEF)

The sub programme will mainly target for developing a new generation highly active, low

cost and durable catalyst/electrode. This will be addressed by the identification of the

requirements of each electrochemical process which defines the type of electrode to be used.

By harmonizing activities with other SPs, a rational support and catalyst design will be

achieved combining expertises from computational models and experimental approaches.

Besides, synergy may be achieved by sharing facilities which are available in the EERA

laboratories to address specific problems and to investigate rate determining steps for the

processes involved in low, intermediate and high temperature fuel cells, electrolysers and

regenerative cells.

SP3 Stack Materials and Design (Robert Steinberger-Wilckens, FZJ)

The sub programme will concentrate on issues that allow the cost effective manufacturing of

‘robust’ stacks. The latter term denoting stacks that can be rapidly thermally and load cycled

and that can tolerate a defined degree of ‘mistreatment’ in the form of vibration, transient

operation, fuel and air impurities etc. The issues encountered are very much focussed on

materials and novel design development and, although related to a goal of successful product

engineering, specifically concern basic research in materials, materials processing, and

component design.

SP4 Systems (Jari Kiviaho, VTT)

This sub programme will deal with developments made on both a system level and a

component level. The system level approach includes development of innovative fuel cell

system concepts, while for the function/components level general targets will be decreased

costs of components, prolonged life-time and availability of components.


3

SP5 Modelling, Validation and Diagnosis (Valentina Vetere, CEA)

The sub programme aims at reaching better understanding of the degradation mechanisms

and the relationships with operating conditions. It also includes a more detailed development

of mathematical description of phenomena to be used in the prediction of whole

performances and lifetime. To improve data input to the modelling and verification of

models, specifications of experimental development of accelerated aging tests will be given.

SP6 Hydrogen Production and Handling (Bruno A. Pollet, UoB)

The sub programme will concentrate on researching and developing cost effective and

efficient non-electrochemical hydrogen production methods by improving materials and

identifying superior novel materials, optimising materials processing, and developing new,

break-through designs for hydrogen production systems. The SP will also be involved in the

development and implementation of new Codes and Standards related to the aforementioned

technologies, and strengthen the cooperation between the groups involved by promoting staff

and student exchanges.


4

Contents

Contents ......................................................................................................................... 4

1. Background ................................................................................................................ 5

2. Value added ............................................................................................................... 6

3. Objectives ................................................................................................................... 7

4. Description of foreseen activities (including time line) ............................................. 8

5. Milestones ................................................................................................................ 14

6. Participants and Human Resources ......................................................................... 15

7. Infrastructures and facilities .................................................................................... 15

8. Management of the Joint Programme on Fuel Cells and H2-technologies ............. 15

9. Interface with other JPs ........................................................................................... 19

10. Risks ....................................................................................................................... 19

11. Intellectual Property Rights of the JP on Fuel Cells and Hydrogen technologies 20

12. Contact Point for the Joint Programme on Fuel Cells and Hydrogen .................. 20

Attachments: SP DoWs ………………………………………………………..………………….21


5

1. Background

As an integral part of the effort to tackle climate change, the European Union (EU) has set

ambitious goals to drastically cut the green house gas (GHG) emissions towards 2050. New

energy technologies play a key role in this effort, and their further development is crucial for

meeting the targets of reducing GHG emissions by 20% by 2020 and 60-80% by 2050.

The Strategic Energy Technology (SET) Plan constitutes EU’s framework and agenda for

how to address these challenges including long-term energy research. Fuel Cells and

Hydrogen are explicitly mentioned in the SET-plan as key technologies to reach the goals.

Fuel Cells and Hydrogen technologies have been utilised for decades, initially for space

applications in the 1960s, but during the 1990s the passenger vehicle market became the main

driver for technology development. Stationary fuel cell applications, providing combined heat

and power (CHP) constitutes another main driver, due to high efficiency and modularity.

Around the turn of the millennium several car manufacturers announced mass production of

hydrogen powered Fuel Cell Electric Vehicles (FCEVs). Technological progress was slower

than foreseen, as both cost and durability of the fuel cells for vehicle propulsion were still

unsatisfactory. The year 2003, however, marked the start of defining the strategic research

agenda, as the High Level Group (HLG) launched their Vision Report1.

Early markets for hydrogen technologies are currently emerging, in areas such as remote

telecommunication towers, fuel cells for forklifts and critical load facilities. These markets

are expected to feed in to further technology development with time, and facilitate cost

reduction needed to enter other and larger market segments.

The New Energy World Industry Grouping represents the European Industry Initiative (EII)

in this field. In March 2008, the European research community joined forces and established

the New European Research Grouping for fuel cells and Hydrogen (N.ERGHY), currently

counting close to 70 member institutions with an overall number of researcher exceeding

2000. In October 2008, the European public-private partnership entitled Fuel Cells and

Hydrogen Joint Undertaking (FCH JU) was officially launched and FCH JU became

autonomous in 2010.

Over the last 5 years or so, we have witnessed significant technological progress. However,

there is a consensus in industry and academia that significant long term research is still

needed to realise the foreseen commercialisation of passenger vehicles from 2020 and to start

fuel cells commercialisation in the field of stationary application (both micro CHP and CHP

for residential/decentralised power plants).

1 Special Report: Hydrogen Energy and Fuel Cells - A Vision for Our Future (2003).

Available at: http://www.fch-ju.eu/page/documents

http://www.fch-ju.eu/sites/default/files/documents/hlg_vision_report_en.pdf


6

2. Value added

The Joint Programme on Fuel Cells and Hydrogen (JP FCs&H2) will provide the strategic

leadership in defining the research agenda for the next phase of fundamental and break-

through research in this field.

With the establishment of the Fuel Cells and Hydrogen platform and, subsequently, of the

Joint Undertaking (FCH JU) the prioritisation of activities related to fuel cells and hydrogen

technologies has been given to industrial stakeholders. The consequence is that most of the

research within FCH JU is mainly product/demonstration oriented, whereas basic or long

term research is not the focal point. The EERA partners strongly believe that long term

research is still needed, and thus we will first concentrate our effort on setting the Joint

Programme on Fuel Cells and Hydrogen (JP FCs&H2) with the idea of assembling critical

mass of research capability.

The JP FCs&H2 will gather the competence, knowledge and the research infrastructures of

main European research centres and Universities to substantially improve the cooperation on

common strategic topics between national research institutes and universities, by collectively

planning and implementing a joint research programme. The JP will be open to all European

academic institutions and research organisations. We especially encourage universities to

participate in the activities. At an early stage, we identified electrochemical energy

conversion in Fuel Cells and Water Electrolysers as a suitable area for starting the definition

of a joint research programme. This will be further developed as the initiative matures.

Acknowledging that more than 90 % of the European R&D budgets are provided at national

level, the JP on FCs&H2 will aim at aligning and harmonizing national activities, sharing

Research Infrastructures (RI) and establishing trans-European expert groups representing the

leading competence in each field of research. To speed up the realisation of the SET-plan

goals the JP will also look at other JPs, such as AMPEA, Energy Storage, and Smart Cities,

with the aim to share with them the definition of common topics where each JP will perform

part of the activities, and in such a way avoid overlapping and encourage synergies.


7

3. Objectives

The general objective of the JP FCs&H2 is to align medium to long term pre-competitive

research activities at EERA institutes and associated institutions to create a technical-

scientific basis for further improvement of Fuel Cells and Hydrogen technologies. The JP

will align and explore synergies with (i) the research grouping N.ERGHY2, (ii) the European

public-private partnership FCH JU, and (iii) other JPs. Most of the partners involved in the

present JP are also members of FCH –JU.

The initial focus of JP FCs&H2 is fuel cells and electrolysers. When the JP work has

commenced, complementary technologies/topics (i.e. new sub-programmes) will be added as

appropriate, taking into consideration other on-going and planned EERA joint programmes.

FCH JU has recently revised the Multi Annual Implementation plan (MAIP 2008-2013),

setting new very ambitious targets for 2015 and 2020. Our goal will be to contribute to 2020

targets and beyond accelerating the development and deployment of fuel cells and hydrogen

technologies by promoting the involvement and the cooperation of national research

institutions and universities. Moreover, JP FCs&H2 has the ambition to strengthen European

competitiveness enabling industry to bring fuel cell and hydrogen technologies to the market.

The JP FCs&H2 has been broken down into six sub programmes, with the following

objectives:

SP1 Electrolytes (Deborah Jones, CNRS)

Radically new fuel cell and electrolyser concepts, bridging the temperature gap (200-500 °C)

between polymer-based and oxide-based electrolytes providing required high stability of

performance and durability compatible with the target application.

SP2 Catalysts & Electrodes (Luis Colmenares, SINTEF)

Development a new generation highly active, low cost and durable catalyst/electrode based

on the reduction of loading and the replacement of Pt group metals. Definition of appropriate

routes for generating tailor-made catalysts.

SP3 Stack Materials and Design (Robert Steinberger-Wilckens, FZJ)

Cost effective manufacturing of ‘robust’ stacks, that means basic research in materials,

materials processing, and component design aiming at complete novel break-through design

for fuel cell stacks and modules.

SP4 Systems (Jari Kiviaho, VTT)

Optimization of balance of plant single components and sub system integration, required for

an operational system to overcome the main barriers preventing commercialization of fuel

cell systems. Creation of value change from research organization to BOP component

manufacturer and further to system integrator.

SP5 Modelling, Validation and Diagnosis (Valentina Vetere, CEA)

Better understanding of degradation mechanisms under different operating conditions,

development of kinetic models and of mathematical descriptions of chemical and physical

phenomena, prediction of whole performances and lifetime.

SP6 Hydrogen Production and Handling (Bruno A. Pollet, UoB)

Development of novel low cost and efficient non-electrochemical hydrogen production

systems by improving materials and identifying superior novel materials, optimising

2 New European Research Grouping on HYdrogen and fuel cells: http://www.nerghy.eu/.

http://www.nerghy.eu/


8

materials processing, and developing new, break-through designs for hydrogen production

systems. Development and implementation of new Codes and Standards.

4. Description of foreseen activities (including time line)

The foreseen activities in this JP relate to long-term research. The activities are based on the

idea of taking advantage of results that are publicly available and can be shared by the

partners. Contributions will stem from regional, national or European programmes. As

additional funding could considerably intensify research activities on the most critical topics,

some of the activities of the JP will also devoted to identifying such activities in order to

promote further collaboration in other funded frameworks.

The first 5 SPs are mainly FC oriented, ranging from cell components like electrolytes (even

for electrolysis), catalysts and electrodes to the stack, to the system and finally to modelling

and diagnostics. The way we addressed the above topics is "function oriented" and FC

technology neutral. All type of fuel cells can be investigated in relation with the established

topics.

The last SP is focused on non-electrochemical hydrogen production.

Internal synergies and harmonization among SPs will be constantly sought combining

expertise from experimental approaches and computational modelling

SP1: Electrolytes

Main goal: Radically new fuel cell and electrolyser concepts, bridging the temperature gap

(200-500 °C) between polymer-based and oxide-based electrolytes providing

required high stability of performance and durability compatible with the target

application.

Activities will be devoted to develop stable, high performance and low cost electrolytes for

polymer-based, solid oxide and proton conducting ceramic systems required for mid to long

term development of fuel cell and electrolyser technologies.

In details six research tasks have been defined: different membranes (task 1, 2 and 3), Anion

conducting electrolytes (Task 4) and solid state conductors (task 5 and 6).

Work Task 1. Perfluorosulfonic acid membranes

Development of ionomers membranes aiming at high temperature PEM, new membranes

(PFSA) will be investigated in order to understand their peculiar properties. New processing

methods will be set up to develop advanced PFSA with improved mechanical and chemical

stability.

Work Task 2. Hydrocarbon membranes

Develop cost effective hydrocarbon membranes for direct alcohol and PEM fuel cells starting

with the understanding of the relation between the structure and the property of the

membrane aiming at reduced cross-over, enhanced conductivity, increased durability.

Activities will include nanoscale control of structure and function, novel processing methods,

advanced membrane architectures, hydrocarbon polymer dispersions and their incorporation

into catalyst layers taking into account the need to increase thermal stability and chemical

and mechanical stability to guarantee adequate lifetime and propose strategies to combat

premature degradation.

Work Task 3. High temperature proton exchange membrane fuel cells

The activities will be divided into three parts: first parte devoted to the development of

advanced acid-polymer composites, solid acid conductors, inorganic proton conducting salts,

the second one dedicated to study compatibility between electrolyte and electrocatalyst . The


9

last one will concern the integration of electrolytes in membrane electrode assemblies and

cell testing.

Work Task 4. Anion conducting electrolytes

The activities will concern the study of new functionalised anion conducting polymers and

stabilised cross-linked co-polymer/block polymers investigating different electrolytes such as

immobilised/gel electrolytes, composite electrolytes, ionomer dispersions/solutions for

electrode layers, thin layer casting, high temperature/pressure electrolytes. Activities will also

be devoted to understand degradation mechanisms of electrocatalysts, and electrodes, and

membranes in cooperation with SP5.

Work Task 5. Solid oxide conductors

The aim is to lower the working temperature acting at different levels developing novel ionic

conductors, thin film deposition, multilayer structure with very thin electrolyte. Based on

these new component a new cell concept will be also investigated In connection with SP5,

accelerated testing methods for electrolyte degradation and improved understanding of

degradation mechanisms of electrolyte ceramics and interfaces with electrodes under

operating conditions will be studied.New concept of pressure-driven (non galvanic)

electrolysers will be investigated based on the development of mixed ionic-electronic ceramic

electrolytes.

Work Task 6. Proton conducting ceramics

This task will be dedicated to a new cell concept based on proton conducting ceramic

electrolytes. To this aim several aspects will be investigated : chemical and mechanical

stability, defect chemistry of electrolyte materials under operating conditions (temperature,

pressure, redox cycling, long term operation), development of electrode materials and mixed

electronic-ionic conductors having compatibility with proton conducting ceramic electrolytes

and of novel cells based, cell and electrolysers performance at intermediate temperatures.

SP2: Catalyst and Electrodes

Main Goal: Development a new generation highly active, low cost and durable

catalyst/electrode based on the reduction of loading and the replacement of Pt

group metals. Definition of appropriate routes for generating tailor-made

catalysts.

Work Task 1 – Catalyst Synthesis

Activities will concern the synthesis of alternative and improved materials in connection

with SP5 (Modelling, Validation and Diagnostics) in order to adapt both top-down and

bottom-up approaches for tailoring catalyst properties (physical and chemical) as function of

the required operating conditions. The nano scale chemistry will be investigated to produce a

portfolio of well controlled nanoparticles and nano-alloys (size, distribution size, shape)

together with DFT model for selecting the ‘best’ nano-electrocatalysts (mono-; bi-; multi-

metallic, alloy, core-shell) of high activity/stability.

Work Task 2 – Polymer Membrane Based Fuel Cells

The research aims at the development of optimal electrocatalysts for low temperature fuel

cells integrating the catalyst to the electrolyte and investigating the effectiveness of the three

phase boundary by optimizing the catalyst layer and the deposition techniques, besides the

assembling to the membrane. Combination of these issues will be addressed in cooperation

with SP1 and SP3. In addition, the knowledge from SP6 will be used as basis for characterize

the fuel electrode as function of the fuel quality which has a relevant impact on the fuel cell

performance and the required properties of the catalyst. Also for this task nano chemistry will


10

be the main tool develop new electrodes and supports. New catalysts based on non-noble

metal materials (non-PGM) including other than carbon support materials will be set up. Both

chemical-physical and electrochemical characterizations will be performed to study

activity/stability of electrodes under realistic operation conditions.

Work Task 3 – Polymer Membrane Based Electrolysers

This task is more oriented towards product realisaztion thus activities will be devoted to the

synthesis of supported OER electrocatalysts with low noble metal content and of nano-

structured catalyst for alkaline membrane electrolyser.

Work Task 4 – Ceramic cells (Fuel Cells and Electrolysis Cells – FC/EC)

The development of materials for ceramic cells (FC and EC) will be a task based on

combined effort from the sub-programs 1, 2 and 3, whit which electrolyte, catalyst and cell

design might be addressed as function of the needed operating conditions.

According to temperature ranges 200-600, 600-950, and to fuel/air impurity different issue

will be addressed concerning a) fuel electrodes such as : fuel electrodes for proton

conducting electrolytes, electro-catalysts for electrochemical synthesis via electrolysis,

development electrodes with high tolerance to impurities, direct hydrocarbon converting

electrodes (SOFC/MCFC), direct carbon fuel cells (MCFC/SOFC), Co-electrolysis; b)air

electrodes such as. development of oxygen electrodes, of air electrodes for proton conducting

electrolytes. Peculiar attention for HT-SOFC/SOEC (600-950 C) will be dedicated to

materials, reaction mechanisms, durability and tolerance to air impurities (H2O, Si, alkali

elements).

SP3: Catalyst and Electrodes

Main Goal: Cost effective manufacturing of ‘robust’ stacks, that means basic research in

materials, materials processing, and component design aiming at complete

novel break-through design for fuel cell stacks and modules.

Work Task 1: Interconnects and Bipolar Plates

The activities are devoted to the development of cost effective manufacturing of

interconnects with main emphasis to the development of thinner stainless steel plates with

new materials, new mass-manufacturing compatible, low cost corrosion resistant materials

and new coatings and coating application technologies.

Work Task 2: Contacting and Gas Distribution

In this task part of the activities will be devoted to PEM FC and electrolysers development

mainly focusing on gas diffusion layers targeting low resistance to gas flow whilst assuring

high mechanical stability and good electrical contacting, high electric conductivity, high gas

permeation and water rejection, stable hydrophobicity, mechanical integrity and mechanical

protection of MEA. For electrolysers completely new materials for contacting and gas

distribution will be investigated with main on stability and long –term conductivity. Another

part of the activities will concern the development of ceramic contact materials looking for

mechanically long-term stable contacting of the air electrode to interconnect to reduce the

area specific resistance (ASR) of the single repeating units (SRUs).

Work Task 3: Sealing

Sealing materials for low and high temperature fuel cells and electrolysers are a critical issue

since they have to remain chemically stable under oxidising and reducing conditions, in

atmospheres with high water content and under varying thermal stress. As a consequence

activities will be dedicated to develop novel sealing materials and seal design concepts both


11

for low temperature and high temperature FC. Multi-layer glass sealants, hybrid ceramic-

metallic seals, compressive and removable seals, reinforced glass ceramic materials

will be, among several options, the ones which will be investigated in this task.

Work Task 4: Novel Designs (Stacks)

The aim of the activities is to develop simplified stack designs with improved thermo-

mechanical properties that can sustain repeated thermal cycling (including load and redox

cycles taking into account they have to be cheap and simple to manufacture. Main addressed

issue will be the optimisation of flow-field designs to lower pressure drops and to ensure

homogenous distribution of fuel gases. Specific activities will concern the development of

CFD model and of a control system based on online diagnostics and early detection of

malfunctions (i.e. gas cross-over, ...)

Work Task 5: Novel Designs (Modules & Interface Stack – BoP)

The activities in this task will interact with the SP4 and complement the work done there

from the point of view of the fuel cell stack. the concept of integration of single unit in sub-

modules and of sub modules in bigger systems will be investigated resulting in activities

concerning the optimisation of the trade-off between single cell size, stack architecture and

number of stacks or modules in a system.

SP4: Systems

Main goal: Optimization of balance of plant single components and sub system

integration, required for an operational system to overcome the main barriers

preventing commercialization of fuel cell systems. Creation of value change

from research organization to BOP component manufacturer and further to

system integrator.

Work task 1 – Material development

As far as BoP materials are concerned the activities will face mainly the corrosion problems

aiming from one side at developing improved and cheaper corrosion resistant materials and

from the other side at developing new coating technologies

Another important issue is linked to the fuel processing and to the after burners: more

performing and more durable, robust and cheaper catalysts will be investigated.

Work task 2 – Component/function development

Several BoP functional units need improvement, thus research activities will concern clean

up, heat management, failure detection methods, air supply, humidification, water

management, power conditioning with the aim of having in general more robust more

reliable, more compact, more performing and cheaper new components and/or architecture.

Work task 3 – New system concepts

For new system development new process flow schemes and thermodynamic optimization,

identification and/or development of suitable system components and development and

testing of integrated systems will be the core of the activities of this task.

Work task 4 – Sensors and diagnostic tools

Diagnostic, will be the main issue of this task and, as consequence, sensors development (gas

quality monitoring, temperature and flow rate measurement) and set up of methods for

monitoring reliability of stacks and BOP components will be the subject of the research

activities of WT4


12

Work task 5 – System controls

The activities will be concentred on the development of the management strategies to control

fuel cell system in order to optimise the overall efficiency.

SP5 Modelling, Validation and Diagnostics

Main Goal: Better understanding of degradation mechanisms under different operating

conditions, development of kinetic models and of mathematical descriptions of

chemical and physical phenomena, prediction of whole performances and

lifetime.

Work Task 1: Cell Processes

The activities will concern the evaluation of physical phenomena and processes at cell level,

in particular concerning the flow channels, GDL, catalyst layer, membrane. Experimental

activities will be dedicated to ex-situ experiments and to the validation of the developed

models

Work Task 2: Stack level (flow distribution, heat transfer)

In this task the main investigated issues will be thermal and water management of stack

operation, in particular for accounting non-isothermal operations and the design of improved

channel geometry and bipolar plate design on the basis of pressure drop, flow distribution

and water management studies

Work Task 3: Systems System modelling and control:

Activities will concern both low and high temperature systems and will be devoted to the

development and test of systems under realistic operation conditions, the analysis of stack

performance and degradation in a complete system according to commonly agreed test

protocols.

Work Task 4: Development of new models

Taking into account the complexity od the entire systems and the different physical chemical

phenomena occurring into the system during its operation several model at different scale and

level will be development, just to mention some of them: kinetic models to better describe

oxygen reduction reaction (ORR), catalyst oxidation and carbon support corrosion, multiple

reaction mechanisms, CH4, internal reforming, etc..); model for mathematical description of

chemical and physical phenomena (chemical ionomer degradation, reactants crossover and

mixed-potential effects, metal catalyst re-crystallisation within the PEM, biphasic water

transfer phenomena in pore and ionomer phases, thermomechanical stresses etc); simulations

tools; model to reliably predict fuel cell performance and lifetime (durability); dynamic

models of complete systems; tools/models to implement a better control strategy; etc.

A big part of the activities, more experimental, will be the validation of the models.

Work Task 5: Development of characterization tools

As complement and in order to provide reliable data for model validation and for

performance prediction a big effort will be dedicated to the development of reliable

characterization tools. In particular the activities will concern: ex-situ and in situ cell tests for

the characterization of individual phenomena, accelerated aging experiments and post-

mortem analysis of the aged components and finally dedicated inelastic neutron scattering

experiments to analyse the relation between structure and dynamics of water and proton

As far as in situ characterization is concerned the possibility to couple synchrotron

techniques to operating EC cells will be further explored. Since these are pioneering

activities, much more R&D is needed to further develop the techniques. The complexity of

the topic and speciality of the equipment suggests that joint infrastructure development and

sharing as can be done in EERA is most effective.


13

SP6 Hydrogen Production and Handling

Main goal: Development of novel low cost and efficient non-electrochemical hydrogen

production systems by improving materials and identifying superior novel

materials, optimising materials processing, and developing new, break-through

designs for hydrogen production systems. Development and implementation of

new Codes and Standards.

Work Task 1: Hydrogen from Biomass/Biowaste

The two main routes for biomass-based hydrogen production, namely thermo-chemical and

bio-chemical will be investigated . For the thermo-chemical routes (pyrolysis, gasification,

and supercritical water gasification - SCWG) actvities will focus on the development of novel

catalysts aiming at more efficient tar removal, better methane reforming, more deactivation

resistant, easy to regenerate, cheaper and with significant

As far as bio-chemical processes the activities will concern the improvement of the processes

in order to improve the volumetric H2 productivity optimising culture conditions, biomass

retention, or selecting highly productive species

Work Task 2: Hydrogen from Algae

The effect of various algae materials on H2 production and its impurities under different

illumination conditions will be the main issue investigated in this WT

Work Task 3: Hydrogen from Thermolysis

In view of the prevailing material limitations, the possibility of lowering thermolysis

operating temperature (around 2.500°C) to some extent by catalysing the reaction appears as

an attractive option thus the activities will focus the development of a novel catalyst materials

for Hydrogen production at moderated temperatures and the development of new gas

separation membrane materials.

Work Task 4: Hydrogen from Photocatalyis

The activities will concern the development of nanostructured transition metal oxide

semiconductor to maximise the light harvesting efficiency and to overcome the electron-hole

recombination losses occurring are key challenges in a PEC water splitting cell. A range of

nanostructured transition metal oxide semiconductor electrodes with the emphasis of water

oxidation on photoanodic semiconductor/electrolyte interface will be investigated with the

aim of meeting those challenges. Effort will be dedicated to find a substitute for Pt

developing Transition Metal Carbides as possible co-catalyst in photocatalytic water splitting

Work Task 5: Hydrogen Handling (improved compression and liquefaction)

Activities will dedicated to improve the storage of compressed and liquid H2 investigating

various compressors using different gasket materials and physical processes with less energy

input; developing new magneto-caloric processes & insulating materials in order to

efficiently and rapidly transform ortho-hydrogen to para-hydrogen etc; improving tank

insulation materials to (i) minimise loss and (ii) improve liquefaction efficiencies in views of

reducing the energy required to cool and liquefy hydrogen gas

Work Task 6: Safety, Codes and Standards for Other Hydrogen Production Methods

A critical review of Safety, Codes and Standards requirements will be performed relevant to

Work Tasks 1-5 in collaboration with international partners, including US Department of

Energy. This Work Task will target a range of areas, including but not limited to general

issues of hydrogen safety, like formation and mitigation of flammable mixtures, and specific

issues such as toxicity of products and deterioration of materials for particular production


14

processes. Pre-normative research findings will be suggested for inclusion into existing and

development of new Codes and Standards to facilitate commercialisation of cost-efficient and

safe hydrogen production technologies.

The work will focus on: purity of hydrogen produced using various technologies; safety

strategies and engineering solutions for inherently safer hydrogen production (using methods

outlined in Work Tasks 1-5) and handling; codes and standards

5. Milestones

The table below gives the milestones for the general/management part of the JP. Each SP

presents its milestones in the SP DoWs following in this document.

Milestone Measurable Objective(s) Project

Month

General/management

M1 Management board meeting for kick-off

preparations

1

M2 First Steering Committee meeting and JP kick-off 3

M3 EERA JP FCs & H2 website 4

M4 Established cooperation with other JPs and

agreement on overlapping activities

4

M5 Identification of new SP/areas and potential

partners (from national mapping/overview of

FCs&H2 actors)

6

M6 Mapping of European research infrastructure,

complementing the CAPACITY project H2FC

12

M7 Annual progress report (Including an overall

internal review of the JP and SPs, restructuring and

planning of next period, updating the DoW, updated

priorities for further scientific work/project, annual

public report.)

will be adjusted

to the date of

EERA annual

congress


15

6. Participants and Human Resources

At the time of establishment of the EERA JP FCs&H2, there are 17 participants and

associates, see the table below:

Name Country Role Associated to

(if associate)

Human Resource

committed (Person

years per year)

ENEA Italy JP Coordinator 13

SINTEF Norway SP Coordinator 5

NBFCE United Kingdom SP Coordinator 17

Risø-DTU Denmark Participant 8

FZ-Jülich Germany SP Coordinator 5

DLR Germany Participant 6.5

CNRS France SP Coordinator 18

JRC EU/Netherlands Participant 5

CEA France SP Coordinator 6.1

VTT Finland SP Coordinator 5.5

CNR Italy Participant 12.6

UoB United Kingdom SP Coordinator 12

POLITO Italy Associate ENEA 2

TUD Netherlands Participant 8

UoU United Kingdom Associate UoB 2

CIEMAT Spain Participant 5

IMPPAN Spain Associate UoB 1

SUM 131.7

7. Infrastructures and facilities

Recently, the H2FC European Research Infrastructure-project was granted support from the

Capacity-programme. The initiative is lead by Karlsruhe Institute of Technology (KIT), and

incorporates 19 European research institutions, some of which are also partners in this JP

FCs&H2. The H2FC European Research Infrastructure will initially form the basis for

developing a joint European effort for enhanced utilisation of facilities. By mapping the

needs and identifying gaps, this framework will be supplemented by involving more

laboratories in agreement and close collaboration with KIT. Discussions have started on how

to organise such a harmonization of initiatives. The mapping is due to be completed by the

end of 2012.

8. Management of the Joint Programme on Fuel Cells and H2-technologies

There are a series of existing initiatives that the JP FCs & H2 needs to interact with. The

Research Association N.ERGHY is already in operation and collaborates closely with the

European Industry Initiative (EII) NEW Industrial Grouping and the European Commission

(EC) as partners in the FCH JU, as well as the States Representatives Group (SRG). This will

be extensively exploited to streamline the JP organization and effectively harmonize

activities and strategies.

JP membership

Publicly funded R&D organisations or private companies recognized as R&D organisations

by the European Commission, as well as universities can join the program as Participants if

they commit more than 5 person years/year (py/y) to the program. Other organisations or

those committing less than 5 py/y to the program can join as Associates. The contributions of

an Associate, both in terms of human resources and R&D work, are consolidated with those


16

of the Participant that the Associate has chosen. Several small members may associate and

name one of them as representative, becoming a Participant if the consolidated contribution

surpasses 5 py/y. The Participant will represent the interests of the Associates that are linked

to it. Any agreements governing the relationship between Participants and Associates are to

be set up by the respective Participants and Associates.

EERA membership is formalized by signing a Declaration of Support, JP membership (either

as participant or as associate) is formalized by signing program-specific Letter of Intent.

Institutes that do not (yet) participate in the EERA have the possibility to join working

meetings (e.g. workshops) as observers. An observer status can be awarded by the JP

Management Board (see below) on request. The observer status will end automatically after a

year or when the institute participates in the Joint Programme as Participant or Associate

Participant.

Any Participant or Associated Participant who fails to comply with terms or conditions set

out by the JP FCs & H2 or the EERA Executive Committee, and who does not cure such

noncompliance within a reasonable period of time after the provision of notice of such

noncompliance, can be dismissed as a member of the JP FCs&H2 by a decision of the JPSC.

The management structure of JP FCs&H2 is shown in the figure below.

Figure presenting the management structure and organization of SPs in the JP FCs&H2.

JP Steering Committee (JPSC)

The JP Steering Committee is composed of one representative of each JP participant and:

appoints the Joint Programme Coordinator

appoints the Sub-programme coordinators

reviews the progress and achievements of the JP

provides strategic guidance to the management board

approves new JP members (participants or associates)

approves updates of the Description of Work of the JP and SPs.


17

The JP Steering Committee is chaired by the JP Coordinator; the sub-programme

coordinators participate as observers in the Committee. It convenes twice a year. The JP

coordinator and the sub-programme coordinators may act as representatives of their

respective R&D organisation in the Steering Committee.

The following decisions from the JPSC require a 2/3 vote and the presence and voting of at

least 50% of the Participants in the JPSC:

Overall policies and strategic objectives

Strategic programme for the coming planning period

To arrange a JPSC meeting which has not been convened by the JPC

Acceptance of new members of the Joint Programme

Termination of Joint Programme membership of non-compliant Participants or

Associate Participants (in this case, the non-compliant Participants cannot participate

to the vote)

Amendment of the section ‘Management of the Joint Programme’ in the DoW

Any other decisions made by the JPSC are decided by simple majority when at least 50% of

the Participants in the JPSC are present and voting. In case of vote equality, the vote of the

JPC is decisive.

JP Management Board

The JP Management Board is the executive body of the JP and is composed of the JP

Coordinator (chair) and the sub-programme coordinators. A representative of an institute that

is responsible for internal and external communication may join JPMB meetings as an

observer.

Tasks and responsibilities:

Contractual oversight

IP (intellectual property) oversight

Scientific co-ordination, progress control, planning on programme and sub

programme level

JP internal communication

External communication with other organisations/actors/bodies (N.ERGHY, EC/FCH

JU, EII, SRG, SC.....)

Reporting to Steering Committee and EERA ExCo

The JP Management board meets four times a year.

Sub programme execution team

The sub programme execution team is the coordinating body on the sub programme level. It

is composed of the sub programme coordinator (chair) and the leaders of the projects within

the sub-programme. It meets on request.

JP Coordinator

The JP Coordinator (JPC) is selected by the JP steering committee for a mandate of two

years. The mandate can be renewed. The JPC chairs the Steering Committee and the

Management Board.


Coordination of the scientific activities in the joint programme and communication

with the EERA ExCo and the EERA secretariat.

Monitoring progress in achieving the sub-programmes deliverables and milestones.

Reporting scientific progress and unexpected developments to the EERA ExCo.


18

Propose and coordinate scientific sub-programmes for the joint programme.

Coordinate the overall planning process and progress reporting.

Sub programme coordinator

The sub programme coordinators (SPC) are selected by the JP steering committee for a

mandate of two years. The mandate can be renewed. The sub programme coordinator takes

part in Steering Committee meetings, is a member of the management board and chairs the

sub programme execution team.


Oversee the sub programme projects

Coordination of the scientific activities in the sub programme to be carried out by the

participants according to the agreed commitment. The SPC communicates with the

contact persons to be assigned by each participant.

Monitoring progress in achieving the sub programmes deliverables and milestones.

Reporting progress to joint programme coordinator

Propose and coordinate scientific actions for the sub programme

Monitor scientific progress and report unexpected developments

Project leaders

The joint activities will be performed in the form of projects that are expected to be set-up in

variable configurations (in terms of project members) and in the framework of project

specific contracts. The project leaders are responsible for the execution of their projects; they

are members of the sub-programme execution team.

To minimize costs and time spent on travelling, web- and phone meetings will be held as an

alternative to physical meeting where and when appropriate. In addition, physical meetings

will, if possible, be held in conjunction with other events, such as the EERA annual congress

and e.g. international workshops/conferences.


19

9. Interface with other JPs

Five other EERA JPs have been identified with potential overlaps with this FCs&H2 JP.

Clearly defined interfaces with these will be established, to avoid duplication of activities and

foster complementarities and synergies. The interfaces towards these 5 JPs and management

thereof are described in the Table below:

Interface with JP Interface description Interface Management

AMPEA Materials development and

characterization, relevant for all

but SP4 of JP FCs&H2

Interfaces have been discussed

in a face-to-face meeting with

the coordinators of the three

first JPs mentioned above.

The agreement is to exchange

DoW between JP and to have,

on regular basis (annual), either

teleconferences or physical

meetings to check the right

alignment of the JPs.

Smart Grid System aspects, BoP

component development,

mainly concerning power

conditioning, diagnostic and

control, interconnection

between FC system and the grid

primarily relevant in SP4 of JP

FCs&H2

Energy Storage Hydrogen storage, Solid state

storage, material development.

H2 Handling (improved

compression and liquefaction)

H2 Safety, Codes and

Standards

Bioenergy Hydrogen production from

Biomass/Biological waste and

Algae

A similar approach of interface

management as the one

described above will be taken

for the potential overlap with

these 2 JPs.

Concentrated Solar

Power

Hydrogen production from

solar energy, Thermolysis and

Photocatalysis

In the definition of objectives and activities of each SP of JP FCs&H2 we have taken into

account the above mentioned areas of possible overlap as far as this has been possible.

10. Risks

There are two different types of risks this JP is exposed to. One is scientifically related to

each sub programme, and the other is associated with the organisation and operation of the

joint programme in general. Firstly, there are scientific risks – these are pointed out for each

sub programme in the respective sections.

Secondly, the commitment of partners may diminish over time, especially limited benefits are

perceived to be associated with the efforts invested in this cooperation. This can lead to a loss

of synergies, competitiveness and reduced strength of the JP as an important actor in the field

of fuel cells and hydrogen. The general risk of decreasing partner commitment will be

addressed at the management meetings of the JP. Generally, this risk is perceived as fairly

low, as many partners have collaborated in various other settings European projects, and the

loss of one partner may be compensated by admitting new partner. The main way to deal with

this risk, however, is the communication culture established at the programme management

level, which involves frequent meetings and the potential to rotate or change responsibilities

within the JP.


20

11. Intellectual Property Rights of the JP on Fuel Cells and Hydrogen technologies

It is expected that the projects, i. e. the R&D work performed during the programme, will be

subject to individual project contracts (consortium agreements). This implies that the JP on

FCs and H2 members freely decide on the composition of any given project consortium. So,

while the JP on FCs and H2 is open to all R&D organisations provided they commit

themselves to a substantial contribution to the programme, any given project will be run as a

consortium with its agreed mechanisms for including new members. Within these consortia,

the members of the JP FC&H2 will follow the EERA IPR policy in projects to the maximum

extent possible.

12. Contact Point for the Joint Programme on Fuel Cells and Hydrogen

Angelo Moreno

ENEA, Italian National Agency for New Technologies, Energy and Sustainable Economic

Development

Via Anguillarese 301

00123 Rome – Italy

Phone: +39 0630484298 Mobile: +393209224140

Fax: +39 0630483795

e-mail: [email protected]



21

EERA


SUB-PROGRAMME 1: Electrolytes

A sub-programme within the

FCs&H2 Joint Programme

Description of Work

Version: <1.0>

Last modification date: <19/10/2011>


22

Summary Research Activity - Electrolytes

o Main objectives

Research efforts in electrolyte development must accompany the need to increase the

temperature of operation of proton exchange membrane fuel cells, and to lower that of solid

oxide fuel cells, while providing required high stability of performance and durability

compatible with the target application. Research will encompass development of stable, high

performance and low cost electrolytes for polymer-based , solid oxide and proton conducting

ceramic systems required for mid to long term development of fuel cell and electrolyser

technologies. Additionally, bridging the temperature gap (200-500 °C) between polymer-

based and oxide-based electrolytes could lead to radically new fuel cell and electrolyser

concepts.

For proton exchange membranes, the research includes development of ionomers, polymers

and membranes using novel polymer types with nanoscale control of structure and function,

novel processing methods, advanced membrane architectures. The critical need to increase

thermal stability of anion exchange membranes will be addressed. Research must specifically

target chemical and mechanical stability of polymer electrolyte membranes to guarantee

adequate lifetime and propose strategies to combat premature degradation.

In order to improve performance and durability of solid oxide fuel cells and electrolysers

(both galvanic and non galvanic) new electrolyte materials will be developed. Research will

be directed at elaboration of new materials and architectures, including multilayered

structures, with control at the nanoscale. Thin film electrolyte deposition methods will also

emerge. Improved proton ceramic electrolytes will result from increased understanding of

defect equilibria in solids/condensed media.

For all technologies, research should address scale-up and cost considerations, and enable

cost-effective manufacture of robust solid electrolytes for proton exchange, anion exchange

and oxide fuel cells.

o Expected results (milestones) and timeline

Electrolyte materials for higher temperature operation of PEMFC and lower temperature

operation of SOFC having high chemical and mechanical stability, and durability of

performance with time. Increased understanding of the fundamental processes governing

transfer, transport and diffusion of protonic species in low and high temperature fuel cells,

improved understanding of materials ageing phenomena specific to the fuel cell environment

and development of appropriate materials-based mitigation strategies building upon current

knowledge. Timeline: M1 – M36 (see Gannt chart and milestone list, sections 4 and 6).

o Use of resources (man years), equipment and infrastructure

26.3 man years will be dedicated to the Electrolytes sub-programme from 10 research

partners. Equipment and infrastructure will be mapped in year 1 and shared in years 2 and 3

to reach the common goals of the sub-programme.


23

1. Background

Electrolytes are at the core of fuel cells and electrolysers. General requirements of

electrolytes are: low area resistance, high ionic conductivity (proton, hydroxide ion, oxygen

ion) and mixed ionic-electronic conductivity for non-galvanic electrolysers, under target

operating conditions (temperature, pressure, relative humidity), chemical, mechanical and

thermal stability, processability, low cost. In addition the electrolyte must impede the direct

cross-over of fuel.

Advances in polymer based systems can be achieved by increasing the temperature range of

operation and accessing lower cost materials both for membranes and catalysts. Alternative

systems can also capitalise on the advantages of alkaline (anion i.e. OH- ion), conducting

material. Such membranes replace the liquid alkaline electrolyte and offer advantages of

reduced costs and high efficiency.

Advances in solid oxide systems will come about by the development of new materials with

increased ionic conductivity at lower temperatures, thanks to basic studies on structure-

related properties and on defect equilibria under strongly reducing or oxidising conditions in

fuel cell or electrolysis mode. Besides investigation of new materials, the thin film electrolyte

deposition is also an emerging and highly active field of research. If the electrolyte thickness

is reduced, new designs for the electrode/electrolyte structure are needed including, porous

electrolyte functional layers.

Furthermore bridging the temperature gap between polymer and solid electrolytes could lead

to radically new fuel cell and electrolyser concepts. For the use of synfuels such as

dimethylether, ethanol but also ammonia, a temperature region between 200-400 °C is highly

attractive, requiring specific electrolyte developments.

2. Objectives

The Sub-Programme Electrolytes will mainly deal with developing new generations of high

performance, low cost and durable electrolyte materials for low and high temperature fuel

cells and electrolysers. Activities will be harmonised with other SPs, and in particular with

WP2 on Catalysts and Electrodes, to develop an integrated mid and long term research

programme combining expertise from experimental approaches and computational modelling.

Synergies will be sought between research organisations for the rational use of facilities,

exchange of students and researchers, exchange of materials and information. The main

objectives of the sub-programme include:

To advance fundamental understanding of electrolyte materials for high and low

temperature fuel cells and electrolysers and to further the state of the art by

developing new generations of materials with target properties for these applications

To exchange information and materials with other SPs (in particular with SP2 –

Catalysts and Electrodes) so as to harmonise the findings with the achievements

these SPs to enable the optimum integration of novel electrolytes into membrane

electrode assemblies, and their testing and evaluation

To align activities, capabilities and expertise of the SP members in the field of

materials science, electrochemistry and processing of electrolyte membranes for

energy conversion.

The main risk associated with SP1 electrolytes is that partners will find no topic of common

interest, however the risk is considered low given the collective effort between partners in the

preparation of the work, and also the breadth of the topics included.


24


Plan according to start of activities in Mx, meaning month x after start of the EERA JP FCs

&H2.

Work Task 1. Perfluorosulfonic acid membranes

1.1 Fundamental understanding of short, medium and long side chain ionomer structure-

property relations

1.2 Novel processing methods for PFSA ionomers

1.3 Mechanical and chemical stabilisation of perfluorosulfonic acid membranes

1.4 PFSA membranes with improved properties and lifetime

Work Task 2. Hydrocarbon membranes

2.1 Fundamental understanding of structure-property relations

2.2 Cost-effective hydrocarbon membranes for direct alcohol and PEM fuel cells with

reduced cross-over, enhanced conductivity, increased durability

2.3 Polymers with nanoscale control of structure and function

2.4 Mechanical and chemical stabilisation of hydrocarbon membranes

2.5 Novel processing methods for non-fluorinated polymers

2.6 Advanced membrane architectures associating different polymers or functions

2.7 Hydrocarbon polymer dispersions and their incorporation into catalyst layers

Work Task 3. High temperature proton exchange membrane fuel cells

3.1 Advanced acid-polymer composites

3.2 Solid acid conductors, Inorganic proton conducting salts

3.3 Electrolyte/electrocatalyst compatibility

Integration of electrolytes from Work Tasks 1-3 in membrane electrode assemblies, and cell

testing.

Work Task 4. Anion conducting electrolytes

4.1 New functionalised anion conducting polymers and stabilised crosslinked co-

polymer/block polymers

4.2 Immobilised/gel electrolytes

4.3 Composite electrolytes. Increase operating temperatures of AEMs by incorporating

inorganic and organic building blocks into organic polymer membranes at the nano-scale to

stabilise cell performance

4.4 Ionomer dispersions/solutions for electrode layers

4.5 Thin layer casting

4.6 High temperature/pressure electrolytes

4.7 Understand degradation mechanisms of electrocatalysts, and electrodes, and membranes.

Work Task 5. Solid oxide conductors

5.1 Novel ionic conductors having high performance in the intermediate temperature range

5.2 Improvement and scale-up of the state-of-art and novel techniques including development

of thin film deposition methods and multilayer structures for the reduction of SOFC working

temperatures by reducing the electrolyte thickness

5.3 Development of novel SOFC cell design and concept with state-of-art or novel materials.

5.4 Accelerated testing methods for electrolyte degradation and improved understanding of

degradation mechanisms of electrolyte ceramics and interfaces with electrodes under

operating conditions.


25

5.5 Development of homogenous and composite ionic conducting ceramics for intermediate

temperature solid oxide fuel cells

5.6 Development of mixed ionic-electronic ceramic electrolytes for pressure-driven (non

galvanic) electrolysers.

Work Task 6. Proton conducting ceramics

6.1 Development of novel proton conducting ceramics for proton ceramic fuel cells

6.2 Investigation of the chemical and mechanical stability of proton ceramics and cells in

intermediate temperature solid oxide fuel cell operating conditions.

6.3 Study of defect chemistry of electrolyte materials under operating conditions

(temperature, pressure, redox cycling, long term operation).

6.4 Development of electrode materials and mixed electronic-ionic conductors having

compatibility with proton conducting ceramic electrolytes and of novel cells based on proton

conducting electrolytes.

6.5 Testing of proton conducting cells to measure the performances at intermediate

temperatures as fuel cells and electrolysers.

4. Milestones

Milestone Title Measurable

Objectives

Project

Month

M1 Kick-off workshop M3

M2 Scientific priorities agreed for each WP M6

M3 Identification of new funding sources and

opportunities for student/staff exchange

M12

M4 Synergies with WP2 established with communication

lines identified

M12

M5 Workshop - Synergies identified between high and

low temperature technologies

M18

M6 Workshop – low temperature fuel cells with joint

publication overview

M24

M7 Workshop – low temperature fuel cells with joint

publication overview

M24

M7 State of the art report on Electrolytes for high

temperature PEMFC

M30

M8 State of the art report on Electrolytes for high

temperature fuel cells

M30

M9 Workshop providing validation of research priorities

and of continuation of research programme

M36

M10 Identification of new electrolytes research topics M36

M11 Annual workshop and update of state of the art

reports on electrolytes for high and low temperature

fuel cells, update of research priorities

M48

M12 European-wide workshop on electrolytes for fuel cells

and electrolysers

M60


26


Name Country Human Resource committed PY/Y

NBFCE UK 8

CNRS France 4.5

CNR Italy 4

UoB UK 2

Risoe-DTU Denmark 2

TUD Netherlands 0.5

CEA France 0.3

ENEA Italy 3

JRC Netherlands 0.5

SINTEF Norway 1

Sum 25.8

6. GANNT Chart

S ... semester

Activity S1 S2 S3 S4 S5 S6 S7 S8 S9 S10

WP 1 W/S W/S W/S W/S W/S






W = workshop

D = draft report

R = report

Mx = milestone nr. X

S = annual status report

7. Contact Point for the sub-programme on Electrolytes

Deborah Jones

UMR 5253 CNRS - Universite Montpellier II

Place Eugene Bataillon, Building 15, CC 1502, 34095 Montpellier cedex 5, France

telephone : +33 467 14 3330, fax : +33 467 14 3304

mobile: +33 608 268598

email : [email protected]


27

EERA


SUB-PROGRAMME 2: Catalyst and Electrodes


FCs & H2 Joint Programme

Description of Work

Version: <1.0>



28

Summary Research Activity 'Catalyst and Electrodes'

Electrocatalysts vary widely depending upon the electrolyte used, the temperature of

operation and the fuel being used in the case of fuel cells. In fuel cells hydrogen is the most

favoured fuel, because of its high energy density per mass and easy oxidation kinetics. In

addition, significant efforts are currently being assigned to the direct electrochemical

oxidation of alcohols, because of their high energy densities as fuels. However, cost and

durability are still two major barriers for large-scale production and commercialization of

this technology, being the electrocatalysts the main contributors to both barriers.

Reduction in cost through reduced loading and replacement of Pt group metals (PGM) is a

major driver in fuel cells and hydrogen technologies and is set as one of the objectives to be

reached. Development of alternative active and robust catalyst for fuel cells and electrolyzers

is the main objective to be addressed in the SP2. Establishing as starting point a state-of-the-

art database on fundamental understanding of electrochemical processes and materials

properties required for those, the search for synthesis approaches will be the initial task to be

addressed in order to define appropriate routes for generating tailor-made catalysts which

are adapted to the specific electrochemical process and its operating conditions.

The catalyst and electrode sub-programme will actively contribute to the ongoing trends to

increase and lower polymer and ceramic cell operation temperatures, respectively, with a

potential for new materials combinations and thus applications areas. R&D on established

ceramic cells is still related to the durability of the solid oxide cells, in which the electrode

stability is an important factor related to both the fuel electrode and the air electrode. The

trend of lowering the operation temperature of ceramic cells for both fuel cell and electrolysis

application requires the development of more active electrode materials and structural

designs. One particular feature of the high temperature devices are their principle suitability

to address hydro carbon species, both a fuel in fuel cells, but also as a product in electrolysis

cells. The development and optimization of electrodes to better utilize will be addressed in

frame of the defined tasks. Thus, ways to contribute to solving persisting problems in state-

of-the-art cells but also searches for solutions and demonstration of alternative materials and

applications will be addressed through this SP in close collaboration with others SPs, such as

electrolytes (SP1), stack materials and design (SP3), and modelling, validation and

diagnostics (SP5) as an integrated effort within the framework of EERA JP for developing

new cost-effective fuel cell and electrolyser concepts.

In this sense, catalyst and electrode sub-programme expects to achieve a solid

interdisciplinary work, adapting catalyst synthesis for tailoring catalyst properties based on

theoretical models, as well as improving those by adapting ex-situ and in-situ physical and

electrochemical characterizations, which should provide a better fundamental understanding

of the relationship among catalyst structure, reactivity and stability. Development of

improved materials building upon current and gained knowledge through the sub-programme

will be supported by combining efforts with SP1 and SP3 for a better integration of the

catalyst into the whole system.

A total of eight research partners will participate within the framework of the Catalyst and

Electrode sub-programme with a total contribution of 24.2 man years. Equipment and

infrastructure will be mapped in year 1 and shared during the next years to reach the common

goals of the sub-programme.

1. Background

Fuel cell and electrolyser are electrochemical devices in which performance is much related

to the electrode materials, in particular the catalysts, and determines the efficiency for energy

and hydrogen production, respectively. The catalysts frequently used are very expensive,

especially if they are based on noble metals, as applied for low temperature fuel cell and

electrolyser. To reduce cost without sacrificing efficiency, much effort has been invested in


29

maximizing catalyst dispersion and electrochemical utilization of the electro-catalyst by e.g.

using different support materials and improving the coating procedure. In addition,

significant improvement in the catalyst activity (at the anode or cathode) has been achieved

when tuning electro-catalyst by using e.g. multi-component catalyst surface, where one of the

components (metal or non-metal) acts as co-catalyst. However, it is still required to improve

the long-term stability and efficiency of systems, where catalyst and electrode components

are main issues to be addressed. Significant efforts have also been addressed to Unitized

Regenerative Fuel Cells (URFCs), which alternatively generate, store and re-use energy,

being hydrogen as energy vector. However, the most critical point in the design of an URFC

is the oxygen electrode. Besides low temperature processes, the reduced temperature in

ceramic cells, namely intermediate temperature fuel cells (IT-FC) and electrolysis cells (IT-

EC), allows for the development of alternative supports compared to the state-of-the-art Ni-

YSZ cermet in e.g. IT-FC. Optimization of the fuel electrode to efficiently convert alcohols

or dimethyl ether is required here. Otherwise, focus on that direction is to develop fully

ceramic solid oxide fuel cell (SOFC) that can be fuelled by carbon-containing fuels.

Furthermore, the development of proper cathode materials having high electronic and ionic

conductivity (mixed conductivity) at intermediate temperatures is still an additional

challenge.

For all applications, the development of novel catalyst is a task which has to be addressed in

close cooperation with the development of specific electrolytes (SP1), as well as the design

of novel concepts for fuel cell and electrolyser systems (SP3).

2. Objectives

The Sub-Programme Catalyst and Electrode will mainly target for developing a new

generation highly active, low cost and durable catalysts and electrodes. This will be

addressed by the identification of the requirements of each electrochemical process which

defines the type of electrode to be used. By harmonizing activities with other SPs, a rational

support and catalyst design will be achieved combining expertises from computational

models and experimental approaches. Besides, synergy may be achieved by sharing facilities

which are available in the EERA laboratories to address specific problems and to investigate

rate determining steps for the processes involved in low, intermediate and high temperature

fuel cells, electrolysers and regenerative cells.

The main objectives of the sub-programme are:

To create a database of the state-of-the art on fundamental understanding of

electrochemical processes, materials properties and synthesis approaches in view of

the developing a new generation of materials.

Developing in combination with theoretical models (SP5) a new generation highly

active, low cost and durable electrodes for PEMFC, SOFC, and electrolysers.

To harmonize the findings with the achievements of others SPs (in particular with

SP1) that enables the integration of the modulate catalyst/electrode properties into

full cells and their impact on the system level (SP3 and SP4).

To align activities, capabilities and expertise of the SP members in the field of

material science, electrochemistry and electrocatalysis for energy conversion.


30


Justification of Programme

The developments of new techniques for ex-situ and in-situ characterization of materials, as

well as the advances made in theoretical and experimental models have motivated the

development and implementation of new materials for fuel cells and hydrogen generation

technologies. In addition to this, the progress made in the design of more efficient systems

have been an additional challenge to the development of catalyst and electrodes that reach the

demands of activity, durability and cost needed for the implementation of those technologies.

Thus, the development of highly active, but sufficiently robust and low cost materials are the

incentive for the implementation of this sub-program within the framework of the whole JP.

In order to achieve this challenge it is necessary to establish a concomitant work that links the

expertise of each SP participant for achieving improved electrode and (electro-)catalysts.

Risk and Mitigation strategy

1. Electrode/catalyst development is very sensitive area regarding IPR, and thus exchange

of information and personal can be problem that hinders progress in this sub-program.

IPR agreements should help to overcome this.

2. Integration of new materials (concepts) into cells may be challenging and require

unforeseen additional competences beyond the partner’s in that SP. In case of bottlenecks

active search for additional partners or associates is considered to mitigate this problem.

Work Task 1 – Catalyst Synthesis

Synthesis of alternative and improved materials is a task which will be coupled with the SP5

(Modelling, Validation and Diagnostics) in order to adapt both top-down and bottom-up

approaches for tailoring catalyst properties (physical and chemical) as function of the

required operating conditions.

1.1 To develop a DFT model for selecting the ‘best’ nano-electrocatalysts (mono-; bi-; multi-

metallic, alloy, core-shell) of high activity/stability.

1.2 Bifunctional electrodes for unitized regenerative fuel cells

1.3 To develop novel inorganic and organic electrocatalysts based on e.g.:

a. Wet Chemistry (WC)

b. Sono-electrochemistry (SE)

c. Flame Spray Pyrolysis (FSP)

d. Physical Vapour Deposition (PVD)

e. Magnetron Sputtering

1.4 To produce a portfolio of well controlled nanoparticles and nano-alloys (size, distribution

size, shape)

1.5 To fully characterise (physically and electrochemically) the produced nano-materials

under defined operating conditions.

Work Task 2 – Polymer Membrane Based Fuel Cells

The development of optimal electrocatalysts for low temperature fuel cells is also a matter of

integrating the catalyst to the electrolyte as well as the effectiveness of the three phase

boundary by optimizing the catalyst layer and the deposition techniques, besides the

assembling to the membrane. Combination of these issues will be addressed in cooperation

with SP1 and SP3. In addition, the knowledge from SP6 will be used as basis for characterize

the fuel electrode as function of the fuel quality which has a relevant impact on the fuel cell

performance and the required properties of the catalyst.


31

2.1 To identify nano-structured PEMFC supports based on carbides, nitrides and oxides.

2.2 To study catalysts bases on non-noble metal materials (non-PGM) including other than

carbon support materials.

2.3 To optimize the preparation methods for electrode inks and deposition technique.

2.4 To study catalyst layer optimisation for effective water and ionic transport.

2.5 To implement ex-situ and in-situ electrochemical catalyst and support characterization.

2.6 To study the catalytic activity and electrochemical characterization of the interface

anode/electrolyte.

2.7 To study activity/stability of electrodes in half cells and membrane electrode assemblies

(MEA) under realistic operation conditions.

Work Task 3 – Polymer Membrane Based Electrolysers

3.1 Synthesis of supported OER electrocatalysts with low noble metal content.

3.2 Nano-structured catalyst for alkaline membrane electrolyser.

Work Task 4 – Ceramic cells (Fuel Cells and Electrolysis Cells – FC/EC)

The development of materials for ceramic cells (FC and EC) will be a task based on

combined effort from the sub-programs 1, 2 and 3, with which electrolyte, catalyst and cell

design might be addressed as function of the needed operating conditions.

4.1 Fuel electrodes

4.1.1 IT-FC/EC (200-600 C).

a. Fuel electrodes for proton conducting electrolytes

b. Electro-catalysts (including supports) for electrochemical synthesis of e.g. methanol,

ammonia via electrolysis

4.1.2 HT-SOFC/SOEC (600-950C).

a. Addressing materials, processing, cell concepts reaction mechanisms.

b. Development of more robust electrodes (high tolerance to impurities).

c. Direct hydrocarbon, low molecular weight fuels converting electrodes

(SOFC/MCFC).

d. Direct carbon fuel cells (MCFC/SOFC).

e. Co-electrolysis (CO2& H2O) to syngas and integrated CH4/C production.

f. Pressurized operation.

4.2 Air electrodes

4.2.1 IT- FC/EC (200-600 C).

a. Development of oxygen electrodes for IT SOFC.

b. Development of air electrodes for proton conducting electrolytes.

c. Development of air electrodes (materials, microstructure design) for oxygen

reduction and evolution at 200-400 C on OH-, HCO3-H+ conducting electrolytes (Ag,

perovskites).

4.2.2 HT-SOFC/SOEC (600-950 C).

a. Addressing materials, processing, cell concepts reaction mechanisms.

b. R&D Durability and tolerance to air impurities (H2O, Si, alkali elements).

c. SOFC cathode activation (e.g. impregnation).


32

4. Milestones

SP2

MS Milestone Title Measurable Objectives

Project

Month

1 Annual SP2 meeting

Further progress in SP2

Joint publications, proposals, consortia

Report of activities to be addressed during the

following year

Planning annual work plan

Program of exchange of personal (researchers,

students) and share facilities

Identification of new funding sources

15

27

39

51

2

Workshop on

Electrochemical

processes in energy and

hydrogen production

A report of prioritized electrochemical processes to

reach the common goals within the SP 3

3 Develop a roadmap for

catalyst/electrodes

Creation of a network to share synthesis or

characterization facilities

State of the art definition of synthesis routes

Establishment common goals with others SPs

(particularly with SP1 and SP3) for elaborating a

rational catalyst design

Report with established synthesis routes, equipment

and infrastructure for catalyst development

A report of advances and results from participants

6

30

4

Workshop on Synergies

between SPs

technologies

Information of current activities of participants

Identification of contents for possible collaborations

Establishment of a common work plan

Joint publications, proposals, consortia

12

36

5 Workshop on Proof-of-

concept verification Intermediate status report 42

6 Annual JP / SP

coordination meeting

Continuation of the program

Annual/Intermediate/final report

Coordination with AMPEA program

12

24

36

48

7 First period closing

meeting Final report 60


33


Organization Country

Human

Resources

Committed

(py/y)

SINTEF Norway 3

CIEMAT Spain 4

NBFCE UK 7.5

Risø-DTU Denmark 4

CNRS France 4.5

CEA France 0.6

ENEA Italy 3

DLR Germany 1

TUD Netherlands 2

CNR Italy 5.2

UoB UK 6

FZJ Germany 1

JRC Belgium 1.5

Total 43.3

6. GANT Chart


Task 1 W

M3 W/S M1 W/S M1

M3 W/S W

M1 S M1 R

M6

Task 2 W

M3 W/S M1 W/S M1

M3 W/S W

M1 S M1 R

M6

Task 3 W

M3 W/S M1 W/S M1

M3 W/S W

M1 S M1 R

M6

Task 4 W

M3 W/S M1 W/S M1

M3 W/S W

M1 S M1 R

M6

W = workshop

D = draft report

R = report



7. Contact Point for the sub-programme on 'Catalyst and Electrodes'

Dr. Luis Colmenares

New Energy Solutions

SINTEF Materials and Chemistry

Sem Sælandsvei 12

NO-7465 Trondheim.

Norway

Tel: +47 932 07 505

Fax: +47 735 91 105

Email: [email protected]


34

EERA


SUB-PROGRAMME 3: Stack Materials and Design



Description of Work

Version: <1.0>

Last modification date: <19.10.2011>


35

Summary Research Activity ‘Stack Materials and Design’

The Sub Programme will concentrate on issues that allow the cost effective manufacturing of



operation, fuel and air impurities etc. The issues encountered are very much focussed on

materials and novel design development and, although related to a goal of successful product

engineering, specifically concern basic research in materials, materials processing, and

component design.

The topics addressed are

- interconnects and bipolar plates

- contacting and gas distribution

- sealing

- novel designs for stacks and stack modules, including the interfaces between stack

(modules) and system Balance of Plant

Over the initial five year period of the programme substantial improvements are expected in

the topics listed in order to enable industry to employ these results in pre-series

developments. Progress will be mapped during annual workshops and reviews in order to

fine-tune and readjust the programme, if necessary.

The activities are not only centred around research but also encompass student and staff

exchange in order to strengthen the networking between the groups involved.

The sub-programme encompasses around 14 person-years from 10 institutions across Europe.

1. Background

The performance of fuel cells and electrolysers mostly depends on the materials used for

MEA’s (low temperature fuel cells) and cells (SOFC and MCFC). The robustness and

lifetime, though, predominately depends on properties of the stack assembly, including

interconnects, sealants, gas manifolds, contacting and other elements. Therefore the choice of

materials for manufacturing stacks is not less vital than the careful design and fabrication of

cells / MEA’s.

On the other hand, many effects in stack assembly are not properly understood, especially all

issues related to thermal and humidity cycling. Corrosion protection – both with respect to

contacting, oxidation and cell contamination – will always remain an essential topic in the

presence of the highly oxidising and highly reducing atmospheres we encounter in a fuel cell,

paired with high water vapour content or even liquid water in the case of low-temperature

fuel cells. In Solid Oxide Fuel Cells and Solid Oxide Electrolysers (SOFC & SOE), the

question of stable sealants with high strength remains a problem to receive more (and

systematic) attention.

2. Objectives

This Sub Programme will concentrate on issues that allow the cost effective manufacturing of



operation, fuel and air impurities etc. The sub-programme uses resources from basic research

to improve materials and identify new materials, optimise materials processing, and develop

new, break-through designs for fuel cell stacks and modules.


36

Additionally, the programme aims at strengthening the cooperation between the groups

involved by promoting staff and student exchanges.

3. Description of foreseen activities


The programme described here concentrates on the more basic research topics attached to the

commercialisation of fuel cells and electrolysers. Insofar it is fully complementary to the

FCH JU programme and most national programmes, since these concentrate on technology

demonstration and market entry. As far as the field of stacks, stack materials and design go,

the topics presented address the main problems seen at the stack level today, both for low and

high temperature technologies.

The work tasks will be performed using existing funding and programmes whose results are

publicly available. Using additional funding, the scope and intensity of the task work could

be considerably intensified.

The main risk encountered in this sub-programme is the failure to find any materials and

materials combination that improve the current situation towards better performing, more

durable and robust stacks or to find materials and component combinations that result in

improvements not only in one field but combine into an overall improvement of properties.

This risk can be considered as rather low since a large number of options still exist to

improve fuel cell and electrolyser performance and robustness and that have already shown

reasonable first results. Nevertheless, the workshop series and annual meetings will offer a

platform via which the progress and deliverables of the various activities can be reviewed and

– if necessary – redirected.

Work Task 1: Interconnects and Bipolar Plates

Work Task 1.1: Cost effective manufacturing of interconnects

Interconnect and bipolar plate materials for fuel cells and electrolysers are subjected to

corrosive attack under rather severe conditions of, for instance, high water or oxygen content

etc. Therefore the materials applied today are expensive. Additionally, the forming of gas

channels (flow fields) is involved and costly under industrial manufacturing conditions. Work

will therefore concentrate on the issues of

- thinner stainless steel plates with new materials variants,

- new mass-manufacturing compatible procedures (stamping, cutting etc.) reducing

machining requirements

Work Task 1.2: Corrosion resistant materials

Due to the corrosive environment the interconnects and bipolar plates are operated in,

specific requirements apply to the materials that make them costly. The problem can also be

solved by coating the steel plates. The coating also may take on an additional function in the

case of SOFC/SOE where the coating also has to prevent chromium hydroxide evaporation

from the interconnect. For low-temperature fuel cells the development of coatings for

metallic bipolar plates, e.g. nitride coatings based on chromium, titanium, vanadium,

aluminium, zirconium and mixtures thereof is a high priority for technology improvement.

The tasks include

- low cost IC/BPP materials

- new coatings and coating application technologies (ALD, PVD/CVD, galvanic,

thermal spray, nano-coatings, reactive coatings, ceramic materials with high

electrical conductivity etc.)

- metal plate operation under H2/O2 operating conditions


37

Work Task 2: Contacting and Gas Distribution

The single cells in a fuel cell stack are connected to interconnect/bipolar plate by a gas

diffusion layer (GDL) (low temperature fuel cells) or ceramic contact materials (e.g. cathode

side of high temperature fuel cells or electrolysers). Contacting and gas distribution are vital

elements in reducing overall stack internal resistance and electrode overpotentials.

Work Task 2.1: Gas diffusion layers

In low temperature fuel cells, pressure drop across the flow fields and the electrodes can be

high depending on the specific stack design (e.g. interdigitated flow fields) and the

optimization of the interface flow field / GDL. GDL development must therefore target low

resistance to gas flow whilst assuring high mechanical stability and good electrical

contacting. These properties are mainly determined by the micro porous layer (MPL), a

component still lacking fundamental understanding. The development tasks concern

- high electric conductivity

- high gas permeation and water rejection

- stable hydrophobicity

- mechanical integrity and mechanical protection of MEA

For electrolysers completely new materials for contacting and gas distribution are needed.

Carbon materials are not stable and the state of the art titanium contacting elements suffer

from high contact resistances. The main focus of the work concerns the stability and long –

term conductivity.

Work Task 2.2: Ceramic contact materials

In high temperature fuel cells/SOE, the mechanically long-term stable contacting of the air

electrode to interconnect is of high importance to reduce the area specific resistance (ASR) of

the single repeating units (SRUs). Contact deterioration by sintering or mechanical fracture

can lead to progressive degradation since the current flow paths are continuously reduced and

local current density increases steadily to finally form ‘hot spots’. The research tasks include

- high electric conductivity

- high mechanical integrity

- low sintering properties

Work Task 3: Sealing

Sealing materials for low and high temperature fuel cells and electrolysers are a critical issue

since they have to remain chemically stable under oxidising and reducing conditions, in

atmospheres with high water content and under varying thermal stress.

Work Task 3.1: Novel sealing materials and concepts

It is desirable that single stack repeating units can be removed to repair or replace failing

units. This requires novel materials and seal design concepts, especially for high temperature

fuel cells and electrolysers. Seals that can be screen-printed and have a superior stability are

also necessary for low-temperature fuel cells. The often used silicone based materials are

known to be responsible for MEA contamination and are not adequate for HT polymer fuel

cells at 160-200 °C. Furthermore, due to mechanical stress on the membrane, sub-gaskets for

MEA protection are necessary that can be assembled rapidly and should be removable to

enable MEA exchange. Ideally, a seal suitable for use in a wide temperature range (-40°C up

to 180°C) is required. Tasks to cover include:

- multi-layer glass sealants,

- hybrid ceramic-metallic seals,

- compressive and removable seals,

- improved seals for operation between 80 and 120°C


38

- sealants for 400°C operating temperature (polymers).

Work Task 3.2: Reinforced glass ceramic materials

Glass ceramics are used for high temperature fuel cells and electrolysers. Though glass is not

the strongest material it delivers chemical stability and good bonding to steel interconnects.

Work is necessary in finding glass ceramics with higher strength or designing metal brazes

with electrically insulating layers. Possible solutions include:

- glass ceramic materials with higher strength,

- glass ceramic materials with self-healing properties,

- glass ceramic materials with reinforcing components,

- metallic sealants and brazes combined with electrically insulating layers

Work Task 4: Novel Designs (Stacks)

Fuel cell and electrolyser stacks today are still expensive to manufacture and require costly

materials and/or components. At the same time the requirement to thermally and electrically

cycle the stacks induces thermal and mechanical stress to the stacks which again makes

countermeasures necessary that increase the complexity of designs and manufacturing steps.

Simplified designs with improved thermo-mechanical properties are therefore necessary.

Work Task 4.1: New stack designs:

New designs are required that can sustain repeated thermal cycling (including load and redox

cycles, where applicable) and at the same time are cheap and simple to manufacture. This

task therefore interacts closely with Tasks 1.1 and 3.1 in looking at:

- flexible stacks with thermo-mechanical elasticity,

- stacks with defined contacting pressure,

- lightweight stacks,

- miniaturised stacks,

- removable SRU/repairable stacks

Work Task 4.2: New flow-field designs

As a sub-set of tasks 4.1, the fuel gas (or steam) distribution across the cells has to be

optimised to cause low pressure drops and at the same time ensuring homogenous

distribution of fuel gases, especially in the case of syn-gases. Goals of this task are:

- lower pressure losses

- better gas distribution (especially for syn-fuels)

- CFD modelling

-

Work Task 4.3 Novel Stack-Sensors

In-situ, locally resolved electrochemical impedance spectroscopy sensors with reduced

frequency range and low cost electronics are required for online diagnosis and early detection

of malfunctions. Integrated into the stack manufacturing process, such sensors can be cost-

effective. A control system based on online diagnostics has the potential for significant

durability improvement of the stack. For electrolysers and fuel cells the integration of

miniaturized gas sensors lead are used for an early detection of gas cross-over.

Segmented bipolar plates for investigation of temperature and current distribution in three

dimensions (2 D active area + cell location) during technical use in systems improve the

understanding of the relevant stack interactions and lead to design improvements.

Work Task 5: Novel Designs (Modules & Interface Stack – BoP)

In the same way stack manufacturing has to be simplified by more elaborate designs, the

interface between system (balance of plant components, BoP) and stack has to be


39

streamlined. The less components a fuel cell or electrolyser system has, the cheaper it

inherently becomes and the less options it has to fail. The work task closely interacts with the

SP Systems and complements the work done there from the point of view of the fuel cell

stack.

Work Task 5.1: Integrated designs

Stack and parts of the BoP can be integrated into ‘sub-modules’ in order to reduce thermal

losses and facilitate system integration.

Work Task 5.2: Module designs:

System ‘sub-modules’ can be combined into larger units (modules) to build up systems with

higher power (up to and beyond 1 MWel). This task is closely linked to Task 4.1 and will

result in optimisation of the trade-off between single cell size, stack architecture and number

of stacks or modules in a system. The task comprises activities towards:

- stack ‘towers’,

- multi-stack/element sub-modules for large systems (> 1 MW),

- removable sub-units/repairable modules.

4. Milestones

SP 3

MS


Objectives

Project

Month

3.1 Priorities of scientific work / projects

Programme of exchange of personnel (researchers,

students)

SP 3 Meeting M3

3.2 Workshop on Synergies between high and low

temperature technologies

SP 3

Workshop held

M6

3.3 Annual meeting with decisions on further progress

Joint publication overview

SP 3 meeting

held, report

completed

M12

3.4 Workshop on high temperature sealing systems SP 3

Workshop held

M18


Identification of new SP’s / areas to be added

SP 3 meeting

held, new SP’s

decided

M24

3.6 Workshop on new stack designs SP 3

Workshop held

M30


Continuation of programme

SP 3 meeting

held, contin.

decided

M36

3.7 Workshop on Proof-of-concept verification SP 3

Workshop held

M42


Identification of new SP’s / areas to be added

SP 3 meeting

held, new SP’s

decided

M48

3.9 Workshop on next period SP3 activities SP 3

Workshop held

M54

3.10 First period closing meeting SP 3 meeting

held

M60


40


Name Country Human Resources committed [py/y]

FZJ Germany 3

DLR Germany 2.5

VTT Finland 1

ENEA Italy 2

CIEMAT Spain 1

UoB UK 2

CNR Italy 0.2

TUD Netherlands 0.5

CEA France 0.5

CNRS France 2

NBFCE UK 1

SINTEF Norway 1

POLITO Italy 0.4

total 17.1 py/y

6. GANT Chart

S ... semester


Task 1.1 M3.1 W/S W/S W/S M3.7 W/S M3.9 W/S




Task 3.1 M3.1 W/S M3.4 W/S W/S M3.7 W/S M3.9 W/S

Task 3.2 M3.1 W/S M3.4 W/S W/S M3.7 W/S M3.9 W/S

Task 4.1 M3.1 W/S W/S M3.6 W/S M3.7 W/S M3.9 W/S




W = workshop

D = draft report

R = report



7. Contact Point for the sub-programme on ‘Stack Materials and Design’

Dr. Robert Steinberger-Wilckens

Forschungszentrum Jülich GmbH (JÜLICH)

Leo-Brandt-Str.

52425 Jülich

Germany

Tel. +49 2461 61 5124

Fax +49 2461 61 4155

[email protected]


41

EERA


SUB-PROGRAMME 4: SYSTEMS



Description of Work

Version: <1.0>



42

Summary Research Activity - Systems

1. Background

Fuel cells and hydrogen have a potential for reducing emissions of greenhouse

gases and air pollutants, facilitating the increased use of renewable energy

sources, raising overall efficiencies of conversion. Thus a sustainable energy

system becomes possible with zero or minimal contribution to global climate.

Long lifetime of fuel cell systems under permanent operation is a challenge for

the durability of all components, including both fuel cell stacks and system

components. At least 40,000 hours in case of small scale systems and even

more for large scale systems are required. Simultaneously the capital

investment cost has to be decreased for as low as possible for industrial use to

achieve a break through on the commercial markets

Whilst much effort and resources are devoted to cell and stack degradation

issues, less attention has been paid to the balance of plant, or components and

sub-systems required for an operational system. Cathode side subsystem

components such as heat exchangers, burners and blowers etc. can be

significant factors decreasing the electric efficiency of the whole system.

Relatively high mass flows and corresponding pressure drops together with

non-optimal components, sub-system solutions and the overall system layout

can decrease the total electrical efficiency many percent points, and may drop

the cost-effectiveness of the whole system below commercial profitability. The

fuel management, and especially recirculation, is a key question in achieving

high electric efficiency.

If the general criteria for the design of fuel cell systems are valid independently

by the specific application (optimal efficiency of all components, their

reliability and easy availability on market at reasonable costs, integration in an

overall energy management system), there are some key issues strictly

associated with the final application of the system. In particular, while size,

weight and noise concerns could not be essential for a stationary application,

they are to be taken into account when the system is designed for a vehicle,

together with satisfactory dynamic behaviour of the system and its correct

electric integration in the fuel cell power train.

These all can be one of the main barriers preventing commercialization of final

fuel cell systems.

2. Objectives

Improvements can be made on two levels one the system level into the

component level. On the system level several approaches could be following:


43

• Improved systems with higher efficiencies, lower number of

components by developing innovative fuel cell system concepts.

• Design of systems with new functionalities for example coproduction

of hydrogen and electricity or systems for combined cooling heating

and power. Also integration to the other plants should be taken under

consideration.

• Systems can be redesigned using totally new kind of components.

On the function/components level general targets could be decreased the price

of component, prolonged life-time and availability of component. Specific

work could be done with the following topics:

• Thermal management/heat exhangers

• Fuel processing and humidication

• Power conditioning and grid connection including batteries/super-

capacitors

• Fuel clening systems

• Sensors and diagnosis tools

• Thermomechanical integration of component

• Fluid supply and management: pumps, valves and flow meters

• Optimization of air supply system (pressure, power consumption and

dynamic requirements)

• Fuel supply with recirculation

This component improvement contains both low temperature and high

temperature fuel cell technologies.


Research activities in this sub-program should be basic research related instead

of having product oriented development. These research topics could be

divided into five different work tasks:

WT1 – Material development

• Corrosion resistant materials for BOP component

• New coating technologies

• Catalysts development for fuel processing and after burners

WT2 – Component/function development

• Innovative fuel cleaning technologies

• New concept for heat exchangers (materials and innovative lay-outs)

• Methods for early detection of component failure (preventive

maintenance)

• Evaluation of performance of different air supply devices integrated in

a fuel cell system (flow rate-pressure curves, power consumption and

dynamic response).


44

• Humidification methodologies and water recirculation

• Characterization of performance and efficiency of power electronic

converters in different operating conditions

WT3 – New system concepts

• Development and demonstration of new fuel cell system concepts shall

include development of process flow schemes and thermodynamic

optimization, identification and/or development of suitable system

components and development and testing of integrated systems.

• Development and deployment of Multi-fuel FC/Innovative Batteries

Hybrid Systems 100 W 100 kW for many applications

• Energy storage systems with fuel cell systems

WT4 – Sensors and diagnostic tools

• Sensor development for gas quality monitoring

• Sensor development for temperature and flow rate measurement

• Methods for monitoring reliability of stacks and BOP components

WT5 – System controls

• Development of the management strategies to control fuel cell system

in order to optimise the overall efficiency.

EERA could have active role in promoting these kinds of development topics

and the role could be for example:

o Pronounced collaboration between institutes active in this area

Input for the research needs could also come from

companies

o Creation of value change from research organization to BOP

component manufacturer and further to system integrator

All kind of research and development contains usually lot of risks and

uncertainties and this topic is not an exception. However, the main risks of this

topics is in finding active enough participants who are really willing to

participate and share the results with all EERA community. The second major

risk is to really find common topics between low temperature and high

temperature fuel cells. Third major risk is the nature of the work; in system

development the nature of work will easily be product oriented instead of

being basic and fundamental research.

How to avoid these risks? No ready answer for that but open dialogue between

possible partners when defining the content of the work tasks will probably

solve many problems and help avoiding risks.


45

4. Milestones

Milestone Milestone Title Measurable

Objectives

Project

Month

M1 Synergies between high and low

temperature technologies

All Tasks are

having nominated

leader and common

approach is defined

in each task

M6

M2 Kick of meeting of all Work tasks All WTs is having

specified and

written working

plan

M8

M3 Scientific workshops WS arranged M10, M20, M30

M4 Identification of new areas to be added Annual meeting

arranged

M12, M24

M5 Joint publication overview Annual overview –

presentation or

paper delivered

M8, M20

M6 Continuation/termination of program Annual meeting –

Decision has been

made about

continuation

M36


Organization Country Human Resources

Committed, PY/Y

ENEA I 3

VTT FI 2

CNR I 1.5

TU Delft ND 2

POLITO I 0.8

CNRS F 2

CEA F 0.5

FZJ Ge 1

Total 12.8

6. Contact Point for the sub-programme 3 on Systems

Jari Kiviaho

VTT

Biologinkuja 5

P.O.Box 1000

02044 VTT

FINLAND

Tel. +358 50 5116778

Fax. + 358 20 722 7048


46

EERA


SUB-PROGRAMME 5: MODELLING, VALIDATION AND

DIAGNOSTICS



Description of Work

Version: <1.0>



47

Summary Research Activity: MODELLING, VALIDATION AND

DIAGNOSTICS

Cost, durability and sometimes performances are ones of the mains shortcomings limiting

large-scale development and commercialization of proton exchange membrane fuel cell

(PEMFC), proton exchange membrane water electrolysers (PEMWE), solid oxide fuel cell

(SOFC) and solid oxide electrolysers (SOE). Due to strong coupling between different

physicochemical and thermo-mechanical phenomena, detailed interpretation of experimental

observations can be difficult, and analysis through modelling becomes crucial to elucidate

system degradation and failure mechanisms, and to help improving both electrochemical

performance and durability of these technologies. Within the framework of the Modelling,

Validation and Diagnostics SP project it is planned to develop the modelling activities

based on the following objectives:

better understanding of degradation mechanisms, water management, thermo-

mechanical stresses and their impact on system behaviour in real application

conditions

better understanding of the relationships between operating conditions, the structural

and chemical properties of components, and the long-term cell durability

further development of detailed kinetic models describing all single reactions

occurring in the systems (determination of the reaction mechanisms and evaluation

of the kinetic parameters to be used in the macroscopic models)

modelling at different scale levels of interconnected mechanisms

model validation on dedicated experiments

experimental development of accelerated aging tests

choice of the flow configuration in the BiPolar Plate (BPP)

prediction of overall performances and lifetime

The sub-programme encompasses around 21.4 person-years from 9institutions across Europe.

1. Background

Efficient utilization of sustainable energy sources requires an in depth knowledge of each

individual component of a given system and degradation mechanisms influencing the

lifetime. In this context, modelling becomes crucial to elucidate systems degradation and

failure mechanisms, and to help improving both electrochemical performance and durability.

In that respect, several initiatives, either national or European, are taking place, regarding the

development of efficient models and their coupling to dedicate experimental measurements

of individual processes, by using in situ and ex-situ experimental techniques. The first

important step consists to clearly define the area of interest of the model: at component level

(e.g. catalysts, membrane, gas diffusion layer GDL, electrodes), at single cell level (MEA,

including the channels) and/or higher level where individual fuel cells are forming a stack.

Mathematical models could provide a deeper understanding of individual parameters

impacting the FC and EC performance and durability: e.g. loss or decrease of porous layers

hydrophobicity; corrosion of the catalyst carbon-support; dissolution and redistribution of the

catalyst; Ni coarsening, ceramic destabilisation, interface delamination, and more generally

any thermal, mechanical and chemical degradation mechanisms. Validated, models can avoid

long experiments and supply useful trends. In this sense, suitable model should describe the

impact of the degradation mechanism on instantaneous performance (with the prediction of

the PEMFC MEA transient behaviour, such as cell potential degradation, or the specification

of SOFC inlet gas mixture to avoid carbon precipitation or Ni re-oxidation, or the


48

specification of thermal transient conditions to avoid cell failure). Numerical modelling must

be coupled to targeted experimental tests for providing inputs for model validation (e.g.

determination of physical properties of materials by tomography and 3D structure

reconstruction, catalyst size distribution, hydrophobicity of carbon support, electrokinetic

parameter determination) and validation (e.g. visualization of liquid water by tomography or

by optical methods, local impedance spectroscopy measurements, polarization curves, local

temperature measurements). Dedicated ex-situ andin-situ experiments have to be carried out

for supplying specific information (eg. physical properties) to support modeling.

In the current project it isplanned to establish the state of the art of all these initiatives, to

organise a round robin between these models, allowing harmonization of modelling and

diagnostics and identifying topics that still deserve more basic research activities.

This EERA project will benefit from strong interfaces with current FCH JU and national

programs.

2. Objectives

The main objectives will be the following:

better understanding of degradation mechanisms (catalyst dissolution, support

corrosion, ionomer degradation, Ni coarsening, ceramic destabilisation, interface

delamination),inlet fuel mixture composition, water management (biphasic water

transfer phenomena in pore and ionomer phases), thermo-mechanical stresses and

their impact on the FC& EC behaviour in real application conditions

better understanding of the relationships between operating conditions (e.g. type of

current cycle, relative humidity, temperature, pressure), structural and chemical

properties of components , and long-term cell durabilityfuther developpement of

existing kinetic models (e;g. better describing oxygen reduction reaction (ORR),

catalyst oxidation and carbon support corrosion, multiple reaction mechanisms, CH4,

internal reforming, etc..) based on parameters dependent on the catalyst chemical

and structural properties (determination of the reaction mechanisms and evaluation of

the kinetic parameters to be used macroscale models)

development of mathematical description of phenomena such as: chemical ionomer

degradation, reactants crossover and mixed-potential effects, Pt re-crystallisation

within the PEM, biphasic water transfer phenomena in pore and ionomer

phases,interface mechanical toughness,microstructure evolution thermomechanical

stresses, accumulated damages, etc

modeling at different scale levels of interconnected mechanisms

specification of experimental development of accelerated aging tests

recommendation forthe flow configuration in the BP

prediction of whole performances and lifetime



The programme described here concentrates on five basic research topics attached to our SP

program. The work tasks will take advantage of results that are publicly available and can be

shared by the partners. Contributions to this activity will stem from regional, national or

European programmes. Naturally, as additional funding will be necessary in the future in

order to intensify research activities on the most critical topics, the project will aim at

identifying them in order to promote further collaboration in other funded frameworks


49

The work program is organised in five work tasks covering respectively, Cell processes,

Stacks (flow distribution, heat transfer), Systems, Development of new models and

Development of characterization tools

Risks

Two risks could be associated with this activity. One is attributed to the financial risk and the

other ne to the Intellectual Property Rights. Since there is no financial support, the partners

could only share results which have been obtained from other national or regional

programmes and the results could be available in the public domain.

Mitigation strategy

A closer cooperation among the partners should be established by harmonizing national and

regional programmes, therefore providing a stimulus for a closer cooperation.

Work Task 1: Cell Processes

Task 1.1: Evaluation of physical phenomena and processes at cell level

Task 1.2: Identification of the individual processes that taking place in each

component within the cell to be included in the model:

1.2.1: Flow channels

study of liquid water behaviour inside the PEM channel including

geometry and surface properties

1.2.2: GDL

evaluation of effective physical properties of catalyst distribution to

include them in the macroscale model

indentify the operating conditions leading to GDL flooding

quantification of hydrofobicity loss in order to be included in the

macroscale model

1.2.3: Catalyst layer

evaluation of effective physical properties of anisotropic porous media

to include them in the macroscale model

study of the loss of catalytic activity to include them in the macroscale

model

1.2.4: Membrane

accounting of the mechanisms responsible for the transport of water,

other polar solvents and fuel through the membraneto include them in

the macroscale model.

Identify the operating conditions leading to membrane dry-outand

eventually degradation

Task1.3: Dedicated ex-situ experiments to be carried out in order to supply

specific data for feeding the various models. Such analyses should include

specific electrochemical experiments such as RRDE, half-cells

Task 1.4: Experimental validation of the developed model by e.g. visualization

of liquid water by tomography or by optical methods, locally resolved current

and impedance spectroscopy measurements, polarization curve, locally

resolved temperature and pressure measurements


50

Work Task 2: Stacks (flow distribution, heat transfer)

Task 2.1: Thermal and water management of stack operation, in particular

for accounting non-isothermal operations

Task 2.2: Determination of improved channel geometry and bipolar plate

design on the basis of pressure drop, flow distribution and water management

studies

Work Task 3: Systems System modelling and control:

Development and test of systems under realistic operation conditions. Analysis of

stack performance and degradation in a complete system according to commonly

agreed test protocols. ( low and high temperature systems).

Work Task 4: Development of new models

Task 4.1: Further developpement of existing kinetic models (e;g. better

describing oxygen reduction reaction (ORR), catalyst oxidation and carbon

support corrosion, multiple reaction mechanisms, CH4, internal reforming,

etc..) based on parameters dependent on the catalyst chemical and structural

properties (determination of the reaction mechanisms and evaluation of the

kinetic parameters to be used macroscale models)

Task 4.2: Development of mathematical description of phenomena such as:

chemical ionomer degradation, reactants crossover and mixed-potential effects,

metal catalyst re-crystallisation within the PEM, biphasic water transfer

phenomena in pore and ionomer phases, thermomechanical stresses etc

Task 4.3: Development of simulations tools able to simulate experimental

observables time-evolution under realistic operating conditions (e.g. time

evolution of polarisation curves, linear, current interrupt, cyclic voltammetry,

etc…) as a function of initial material compositions and structures (e.g. initial

Pt/C/ionomer loadings and volumetric distributions within the electrodes,

etc…)

Task 4.4 Investigation of the coupling between different mechanisms (e.g.

degradation, transport, electrochemistry) in order to reliably predict fuel cell

performance and lifetime (durability)

Task 4.5:

- Development of dynamic models of complete systems. Model validation

against experimental tests according to commonly agreed test protocols

(parts of the system and complete system).

- Prediction of the system behavior and enhancement of the control strategy

using the models.

Tasks 4.6 Development of model for high temperature technologies. This will

include coupled chemical, electrochemical thermal and mechanical cell

modeling for SOFC and SOEC


51

evaluation of effective physical and mechanical properties of cell ceramic

components to include them in the macroscale model

microstructure evolution and inclusion in a model

Task 4.7 Model validation against a numerical test case

Task 4.8: Model validation against experimental tests (i-V curves, liquid

water visualization techniques, local temperature measurements)

Work Task 5: Development of characterization tools

Task 5.1 Development of ex-situ cell tests for the characterization of

individual phenomena

Task 5.2 Development of accelerated aging experiments and post-mortem

analysis of the aged components

Task 5.3 Dedicated inelastic neutron scattering experiments to analyse the

relation between structure and dynamics of water and proton

Task 5.4 Development of microstructure 3D reconstruction tools

Recent progress in Focussed Ion Beam, large X-ray and neutron scattering

facilities and image processing software have trigged the 3 D reconstruction of

components , cells and stack from microscale structures to full stack size.

However, the computational methodology with respect to resolution and

distinction of individual phases still needs to be optimised.

Task 5.5. Develop new in-situ characterization techniques

While low T fuel cell R&D has been benefited a lot form coupling of spectroscopic,

and analytical techniques (GC/DEMS (differential EC MS)). At high temperatures

not many activities are related to this , mainly because of the additional complexity of

handling temperature and pressures. In situ IR spectroscopy to SOFCmaterials has

been developed since a couple of years, and recently coupling of scanning probe

microscopy with electrochemical testing under controlled atmosphere and pressure

has been developed at Risø DTU. The possibility to couple synchrotron techniques to

operating EC cells has been demonstrated but is not yet further explored. Since these

are pioneering activities, much more R&D is needed to further develop the

techniques. The complexity of the topic and speciality of the equipment suggests that

joint infrastructure development and sharing as can be done in EERA is most

effective.


52

4. Milestones

Gant Name Milestone Title Measurable

Objectives

Project

Month

M1 Exchange of personnel

(researchers, students)

programme for

following year

agreed

M12, M24, M36,

M48

W1 Workshop Results of

round robin on

CFD modelling

M12

W2 Workshop Results on

stack

modelling

M24

W3 Workshop Results on cell

processes

M36

W4 Workshop Results on

comparison of

modelling and

validation

experiments

M48

M2 Joint publication

overview

annual

overview

M12, M24, M36,

M48, M60

M3 Identification of new

funding sources

annual SP

coordination

meeting

M12, M24, M36,

M48

M4 Identification of new SP’s

/ areas to be added

annual SP

coordination

meeting

M12, M24, M36,

M48

M5 Priorities of scientific

work / projects

annual SP

coordination

meeting

M12, M24, M36,

M48

M6 Continuation of

programme

annual JP / SP

coordination

meeting

M36

M7 Advances in the

identification of cell

processes

Joints

publications

M25, M42, M30,

M54

M8 Advances in the stacks

design and thermal

management

Joints

publications

M24, M36, M58

M9 Advances in the

development of new

model

Joints

publications

M24, M36, M58

M10 Proof-of-concept

verification

overview of

activities at

annual SP

coordination

meeting

M12, M24, M36,

M48


53

5. GANT Chart

Activity 0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60

Task 1.1

Task 1.2

Task 1.2.1

Task 1.2.2

Task 1.2.3

Task 1.2.4

Task 1.3

Task 1.4

Task 2.1

Task 2.2

Task 3 M6

Task 4.1

Task 4.2

Task 4.3

Task 4.4

Task 4.5

Task 4.6

Task 4.7

Task 4.8

Task 5.1

Task 5.2

Task 5.3

Task 5.4

Task 5.5

W,

M,

S

W,

M,

S

W,

M,

S,R

W,

M,

S

M

W = workshop, , D = draft report, R = report, Mx = milestone nr. X, S = annual status report


54


Organization Country Human Resources

Committed PY/Y

CEA France 4.2

JRC Belgium 3

VTT Finland 2.5

DLR Germany 3

Risø-DTU Denmark 2

CNR Italy 0.7

NBFCE UK 0.5

TUD Netherlands 2

CNRS France 3

ENEA Italy 1

Total 22.7

7. Contact Point for the sub-programme on MODELLING, VALIDATION

AND DIAGNOSIS

Vetere Valentina

CEA>

17 av. Des Martyrs 38054 Grenoble

tel: +33(0) 4 38781101, fax: +33 (0)4 38 78 94 63, [email protected],



55

EERA


SUB-PROGRAMME 6: Hydrogen Production and Handling



Description of Work

Version: <1.0>



56

Summary Research Activity ‘Hydrogen Production and Handling’

The sub Programme will focus on development of novel low cost and efficient non-

electrochemical hydrogen production systems. Current production methods are inefficient

and further development of these technologies is required. The main issues are caused by

poor materials and designs. This SP will thus aim to address these important issues by

researching and developing new materials, materials processing methods, and component

design.

The topics addressed are:

Hydrogen production from Biomass/Biowaste

Hydrogen production from Algae

Hydrogen production from Thermolysis

Hydrogen production from Photocatalysis

Hydrogen Handling (improved compression and liquefaction)

Hydrogen Safety, Codes and Standards

Over the initial five year period of the programme substantial improvements are expected in

the topics listed in order to enable industry to employ these results in pre-series

developments. Progress will be mapped out during annual workshops and reviews in order to

fine-tune and readjust the programme, if required.

The activities are not only centred around research but also encompass student and staff

exchange in order to strengthen the networking between the groups involved.

The sub-programme encompasses around 6 person-years from 4 institutions across Europe.

Production of hydrogen by electrolysis is not covered by this Sub-Programme since it is

integral part of SP’s 1 to 5.

1. Background

Hydrogen is already widely manufactured, but it is now being considered for use as an energy

carrier for stationary and transportation applications. Around 20 million tonnes of hydrogen

are produced in the world each year, enough to power around 60 million vehicles or 16

million homes. Hydrogen is currently utilised in industry such as: (i) oil refining, (ii) food

production, (iii) metal treatment, and (iv) production of ammonia for fertilizer and other

industrial uses.

In addition to the conventional hydrogen production methods of steam methane reforming

(SMR) and grid-powered electrolysis, novel renewable production alternatives are emerging.

These include using renewable energy directly for water electrolysis (PEM), various biogas

production methods (using gasification), pyrolysis processes, biomass fermentation (using

microorganisms), and newly developed photocatalytic and thermo-chemical processes that

can facilitate water splitting into hydrogen and oxygen with lower energy requirements than

‘conventional’ electrolysis.

Codes and standards for hydrogen storage and transport have evolved dramatically over the

past 20 years and now cover most hydrogen applications. Hydrogen is now being transported

by trucks, pipelines etc, and is stored in vessels that are certified by ASME for stationary use

only.


57

Challenges to expand the utilisation of hydrogen for stationary and automotive applications

include better outreach, public engagement, education and training of local codes and

standards on the processes for hydrogen systems. This would allow continued efforts to

reduce the costs of electrolysers to enable renewable hydrogen production, improved

efficiencies and performances with low to zero emissions of greenhouse gases.

2. Objectives

The sub Programme will concentrate on researching and developing cost effective and

efficient non-electrochemical hydrogen production methods by improving materials and

identifying superior novel materials, optimising materials processing, and developing new,

break-through designs for hydrogen production systems. The SP will also be involved in the

development and implementation of new Codes and Standards related to the aforementioned

technologies, and strengthen the cooperation between the groups involved by promoting staff

and student exchanges.



The programme described here concentrates on the research and development of low cost and

efficient non-electrochemical hydrogen production methods. The proposed programme is

fully complementary to the FCH JU programme and most national programmes, since these

concentrate on technology demonstration and market entry.

The work tasks will be performed using existing funding and programmes whose results are

publicly available. Using additional funding, the scope and intensity of the task work could

be considerably intensified.

Work Task 1: Hydrogen from Biomass/Biowaste

There are two main routes for biomass-based hydrogen production, namely thermo-chemical

and bio-chemical. Thermo-chemical routes have three subheadings as pyrolysis, gasification,

and supercritical water gasification (SCWG). Pyrolysis means that biomass is heated absence

of air. It can be taken bio-oil, char and tar after pyrolysis processes. The conventional

gasification is used as an old technology, in which biomass is heated at high temperatures and

disengage to combustible gas. Air, steam or oxygen can be used as a gasification agent to

increase energy value. There are many studies using this kind of gasification method in the

literature. The third method of thermo-chemical routes is SCWG where water is miscible

with organic substance above the critical point. This method is preferred especially for high

moisture biomass.

Work Task 1.1: Development of Novel Catalysts for Thermochemical Methods

Generally, catalysts used in thermo-chemical methods of hydrogen production should

effectively remove tars, be capable of reforming methane, be resistant to deactivation, be easy

to regenerate, be inexpensive, and have significant strength (as fluidized beds are often used

for gasification). Dolomites, zeolites, olivines, alumina, alkali metals salts and supported

metal catalysts have all been used as catalysts for pyrolysis and gasification of biomass and

clean-up. However, all these catalysts suffer from deactivation either by sintering and/or coke

deposition. Thus, further work is needed to optimise the formulation of the catalysts: the

metal content, the average particle size of metal, the catalyst support and the concentrations

and type of doping additives.


58

Work Task 1.2: Novel Bioprocess Methods

For the designed 2-stage bioprocess, the volumetric H2 productivity in the thermophilic

fermentation step must be increased at least 10-fold in order to meet the production capacity

of 425 m3 H2/h. This can be done by conventional methods such as optimisation of culture

conditions, biomass retention, or selection of highly productive species or strains from the

broad range of available hydrogen producing micro-organisms. The productivity of the

photobiological fermentation step should be increased by at least a factor 15 through

optimization of sunlight conversion efficiency. In this case the main improvement has to

come from technological improvements of sunlight collection and light transfer systems, and

photobioreactor development. To support the profitable utilisation of the effluent of the

thermo-bioreactor, the conversion to methane should be considered as well. It is obvious that

during the night, sunlight is lacking. Instead of storing the effluent, methane production might

act as a substitute. When this option turns out favorable, the advantages of a partial

photofermentation supplemented with a methane fermentation have to be weighed against a

complete replacement of the photofermentation step. This issue needs to be evaluated

together with the progress in the field of the application of methane in fuel cells and the

utilisation of H2/CH4 mixtures as new energy carriers.

Work Task 1.3: Biowaste materials and compositions on Hydrogen production & purity

Range of biowaste of several compositions for Hydrogen production

Effect of biowaste materials on Hydrogen purity

Work Task 2: Hydrogen from Algae

Since the pioneering discovery by Gaffron et al. over 60 years ago, the ability of green algae

to produce Hydrogen upon illumination has been mostly a biological effect. Hydrogen

evolution from green algae is usually induced upon a prior anaerobic incubation of the cells

in the dark. A hydrogenase enzyme is expressed under such incubation and catalysed, with

high specific activity, a light-mediated Hydrogen evolution. The monomeric form of the

enzyme, a class of iron hydrogenases is encoded in the nucleus of the unicellular green algae.

Light absorption by photosynthesis is essential for the generation of hydrogen as light energy

facilitates the oxidation of water molecules, the release of electrons and protons, and the

endergonic transport of these electrons to ferredoxin.

Work Task 2.1: Algae materials and compositions on Hydrogen production

Range of various Algae materials on Hydrogen production under several illumination

conditions

Work Task 2.2: Algae materials and compositions on Hydrogen purity

Effect of Algae materials on Hydrogen purity

Work Task 3: Hydrogen from Thermolysis

Water thermolysis is a reversible process and involves one-step direct thermal

decomposition. Presently, the technically tolerable reaction temperature limit is around

2,500°C, which theoretically allows a dissociation level of slightly over 4% at atmospheric

pressure. A water thermolysis reactor involves components manufactured of very special

refractory materials able of enduring chemically active environment and very high


59

temperatures generally in the range of 1,500 K and higher is expected to withstand

temperature gradients of considerable magnitude and swift temperature swings without

degradation.

In view of the prevailing material limitations, the possibility of lowering the operating

temperature to some extent by catalysing the reaction appears as an attractive option.

Work Task 3.1: Development of new catalyst materials on Hydrogen production

Novel catalyst materials at moderated temperatures on Hydrogen production

Work Task 3.2: Novel gas separation membrane materials

Gas separation membrane materials and techniques on separation of gases

Work Task 4: Hydrogen from Photocatalyis

Semiconductor photoelectrolysis is currently being widely explored as a carbon-emission free

route to convert the solar energy to chemical energy and generate low-cost hydrogen. If

succeeded this technology has the potential to produce hydrogen to meet the fast growing

world energy demand while producing almost no pollution. One approach to water-splitting

uses light-absorption to excite an electron in a semiconductor from a filled valence band to a

vacant conduction band. In a typical water splitting photoelectrochemical (PEC) cell, once

the light is being absorbed by the semiconductor electrode and generated charges upon

excitation, the majority carriers (electrons in a n-type semiconductor) travel to the substrate.

The electrons collected at the substrate are transferred to the counter electrode where the H2

evolution takes place. The remaining holes need to travel to the semiconductor/electrolyte

interface to undergo water oxidation.

222 HeH

HOhOH 442 22

_________________________

222 22 OHOH hv

Work Task 4.1: Development of nanostructured transition metal oxide semiconductor

Maximising the light harvesting efficiency and overcoming the electron-hole

recombination losses occurring are key challenges in a PEC water splitting cell.

A range of nanostructured transition metal oxide semiconductor electrodes with the

emphasis of water oxidation on photoanodic semiconductor/electrolyte interface will

be investigated with the aim of meeting those challenges.

Work Task 4.2: Development and characterisation of Transition Metal Carbides

Transition metal carbides (e.g. WC, Fe3C) offer a potential substitute for Pt. Their

electronic structure is often called ‘noble metal-like’ but they also display distinct

activity in their own right. Preliminary investigations showed WC to be a promising

co-catalyst in photocatalytic water splitting


60

Work Task 4.3:Effect of alcohol nmaterials on photocatalysis

Nanostructured photocatalysts have to be investigated for the hydrogen production from

visible-light driven photocatalysis of various fluids (ethanol, glycerol, etc.) since recent works

showed promising results

Work Task 5: Hydrogen Handling (improved compression and liquification)

Pure hydrogen has the best energy-to-weight ratio of any fuel, but also has the lowest storage

density of all fuels at atmospheric pressure. There are a number of methods to store hydrogen

for fuel cell applications, such as gas, liquid, metal, and/or chemical form; depending upon

the application, hydrogen can be either compressed or liquefied.

(i) Compression of hydrogen is performed in the same way as for natural gas. It is often

even possible to use the same compressors, as long as the appropriate gaskets are used

and provided the compressed gas can be guaranteed to be oil free.

(ii) The energy density of hydrogen can be improved by storing hydrogen in a liquid form.

Liquefaction plants operate nowadays with liquid nitrogen pre-cooling of the feed

hydrogen with a pressure of at least 2 MPa. Before being liquefied, the hydrogen is

cleaned and then free of CO2, CO, CH4 and H2O. This is usually performed using a

pressure swing adsorption process. The energy required to liquefy hydrogen reduces

overall efficiency of the system; around 30% of the energy content of the gas. In all

cases the liquefaction is achieved by compression followed by some form of

expansion, either irreversible via use of a throttle valve or partly reversible via the use

of an expansion machine. However, hydrogen losses become a concern and improved

tank insulation is required to minimize losses from hydrogen boil-off.

Work Task 5.1: Development of novel compressors

Investigate various compressors using different gasket materials and physical

processes with less energy input

Work Task 5.2: Development of new magneto-caloric processes & insulating materials

Investigate and develop novel magneto-caloric processes and other processes in order

to efficiently and rapidly transform ortho-hydrogen to para-hydrogen etc

Improving tank insulation materials to (i) minimise loss and (ii) improve liquefaction

efficiencies in views of reducing the energy required to cool and liquefy hydrogen

gas

Work Task 6: Safety, Codes and Standards for Other Hydrogen Production Methods

A critical review of Safety, Codes and Standards requirements will be performed relevant to

Work Tasks 1-5 in collaboration with international partners, including US Department of

Energy. This Work Task will target a range of areas, including but not limited to general

issues of hydrogen safety, like formation and mitigation of flammable mixtures, and specific

issues such as toxicity of products and deterioration of materials for particular production

processes. Pre-normative research findings will be suggested for inclusion into existing and

development of new Codes and Standards to facilitate commercialisation of cost-efficient and

safe hydrogen production technologies.

Currently it is anticipated that the work will focus on:

(i) purity of hydrogen produced using various technologies,


61

(ii) safety strategies and engineering solutions for inherently safer hydrogen production

(using methods outlined in Work Tasks 1-5) and handling;

(iii) codes and standards

Work Task 6.1: Purity of Hydrogen produced using various Technologies

International Standards specify two grades of hydrogen fuel, namely: ‘Type I, Grade E’ and

‘Type II, Grade E’. Three categories are specified under Type I Grade E for both fuel cell

manufacturers and hydrogen suppliers.

The purpose of International Standards are to establish hydrogen quality supplied for

stationary and automotive applications as well as the infrastructure of hydrogen can be

implemented quickly and efficiently towards fuel cell commercialization. Quality verification

requirements should be determined at the inlet point of fuel cell systems between the supplier

and the user. Since fuel cell applications for stationary and automotive and related

technologies are developing rapidly, International Standards need to be revised according to

technological progress as required. Bearing in mind that the technical Committee ISO/TC

197, Hydrogen Technologies, will monitor this technology trend.

It is also important to emphasize that International Standards are currently being developed to

assist in the deployment of fuel cell applications for stationary and automotive and related

technologies.

Further research and development are required to generate specific information so that a final

consensus can be reached. These efforts should focus on, but not be limited to:

Impurity detection and measurement techniques and methods for laboratory,

manufacturing and in-field operations

Effects/mechanisms of impurities on fuel cell systems and related components

Work Task 6.2: Safety Strategies and Engineering Solutions

All aforementioned technologies (WT1-WT5) require safety studies starting from design

stage through pilot installation use to industrial scale exploitation and decommissioning.

Safety strategies relevant to hydrogen production (WT1-WT5) will be developed in WT6

based on the recent developments in the HySAFER centre at the University of Ulster and this

research project. This will be underpinned by access of partners to the best European

Infrastructure for Hydrogen and Fuel Cell Research (FP7 project H2FC European

Infrastructure, 2011-2015, €8M).

Safety of each of the methods outlined in Work Tasks 1-5 will be assessed from the

perspective of large-scale industrial production based on the analysis of published accident

case studies. For example, industrial experience shows that bio-generated hydrogen can cause

devastating accidents with life and property losses. Different routes of hydrogen production

will be assessed by their toxicity level, pyrophoric properties, effect of reacting components

on materials, propensity to self-heating and self-ignition when stored at large quantities,

potential to create flammable mixtures with hydrogen and combust them in deflagrative

and/or detonative regime, etc. Safety strategies will be developed following principles of

avoiding formation of flammable mixture at operation temperature, pressure and

composition, avoiding ignition sources or spontaneous ignition, and finally mitigation of

accidental combustion if previous is impossible by technological reasons. ”Standard” safety

issues like hydrogen leaks and dispersion in confined spaces, ignition and jet fires,

deflagrations and potential for detonations (minimisation of deflagration-to- detonation


62

transition potential in case of accidents) will be considered based on particularities of

hydrogen production and handling methods.

Work Task 6.3: Codes and Standards for Safe Production and Handling of Hydrogen

International Standards are intended to consolidate the hydrogen product specification needs

anticipated by fuel cell manufacturers and hydrogen suppliers as industry proceeds towards

achieving commercial opportunity and viability. Methods to monitor the hydrogen fuel

quality that is produced and delivered require to be addressed and are necessary due to

specific impurities which will adversely affect the fuel cell system. In addition, there may be

drastic performance loss implications in the fuel cell system if non-hydrogen constituent

levels are not properly controlled.

4. Milestones


Objectives

Project

Month

M1 Exchange of personnel (research staff,

students)

programme for

following year

agreed

M3, M12, M24,

M36, M48

M2 Synergies between PEM Electrolysers and

other Hydrogen Production technologies

Workshop M6

M3 Workshops annual SP meeting M12, M24, M36,

M48

M4 Joint publications overview annual overview M12, M24, M36,

M48, M60

M5 Identification of new funding sources annual SP

coordination

meeting

M12, M24, M36,

M48

M6 Identification of new SP’s / areas to be

added

annual SP

coordination

meeting

M12, M24, M36,

M48

M7 Priorities of scientific work / projects annual SP

coordination

meeting

M12, M24, M36,

M48

M8 Continuation of programme annual JP / SP

coordination

meeting

M36

M9 Proof-of-concept verification overview of

activities at annual

SP coordination

meeting

M12, M24, M36,

M48


Name Country Human Resource

committed PY/Y

UoB UK 2

UoU UK 2

TUD Netherlands 1

CNR Italy 1

ENEA Italy 1

IMPPAN Poland 1

CNRS France 2

Total 10


63

6. GANT Chart

Year 1 Year 2 Year 3 Year 4 Year 5

Task 1 R1 R2 R3 R5 R6

s1 s2 s3 s4 s5 s6 s7 s8 s9 s10

W1 W2 W3 W4 W5

S1 S2 S3 S4 S5

Hydrogen from Biomass/Biowaste

Task 1.1

Development of Novel Catalysts for Thermochemical Methods M1

Task 1.2

Novel Bioprocess Methods M2 R

Task 1.3 M3 R

Biowaste materials and compositions on Hydrogen production & purity

Task 2

Hydrogen from Algae M1 R

Task 2.1

Algae materials and compositions on Hydrogen production M2 R

Task 2.2

Algae materials and compositions on Hydrogen purity M3 R

Task 3

Hydrogen from Thermolysis

Task 3.1

Development of new catalyst materials on Hydrogen production M2 R

Task 3.2

Novel gas separation membrane materials M3 R

Task 4

Hydrogen from Photocatalyis

Task 4.1

Development of nanostructured transition metal oxide semiconductor M2 R

Task 4.2

Development and characterisation of Transition Metal Carbides M3

Task 4.3

Effect of alcohol materials on photocatalysis

Task 5

Hydrogen Handling (improved compression and liquification)

Task 5.1

Development of novel compressors M1 M2 R

Task 5.2

Development of new magneto-caloric processes & insulating materials M3 R

Task 6

Safety, Codes and Standards for Other Hydrogen Production Methods

Task 6.1

Purity of Hydrogen produced using various Technologies M1 M2 R

Task 6.2

Safety Strategies and Engineering Solutions M1 M2 M3 R

Task 6.3

Codes and Standards for Safe Production and Handling of Hydrogen M1 M2 M3 R

s: semester

W = Workshop

D = Draft report

R = Report

Mx = Milestone nr. X


7. Contact Point for the sub-programme on ‘Hydrogen Production and

Handling’

Dr. Bruno G. Pollet

School of Chemical Engineering

The University of Birmingham

Edgbaston, Birmingham B15 2TT (U.K.)

E: [email protected]

www.polletresearch.com

joint research programme on fuel cells and …€¦ · joint research programme on fuel cells and...

Documents