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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]
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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.
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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.
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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
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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
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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.
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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/.
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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
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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
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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
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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
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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.
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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
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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
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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
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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.
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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.
Tasks and responsibilities:
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.
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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.
Tasks and responsibilities:
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.
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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.
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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]
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EERA
EUROPEAN ENERGY RESEARCH ALLIANCE
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>
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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.
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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.
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3. Description of foreseen activities (including time line)
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.
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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
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5. Participants and Human Resources
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
WP 2 W/S W/S W/S W/S W/S
WP 3 W/S W/S W/S W/S W/S
WP 4 W/S W/S W/S W/S W/S
WP 5 W/S W/S W/S W/S W/S
WP 6 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]
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EERA
EUROPEAN ENERGY RESEARCH ALLIANCE
SUB-PROGRAMME 2: Catalyst and Electrodes
A sub-programme within the
FCs & H2 Joint Programme
Description of Work
Version: <1.0>
Last modification date: <19/10/2011>
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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
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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.
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3. Description of foreseen activities (including time line)
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.
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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).
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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
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5. Participants and Human Resources
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
Activity S1 S2 S3 S4 S5 S6 S7 S8 S9 S10
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
Mx = milestone nr. X
S = annual status 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]
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EERA
EUROPEAN ENERGY RESEARCH ALLIANCE
SUB-PROGRAMME 3: Stack Materials and Design
A sub-programme within the
FCs&H2 Joint Programme
Description of Work
Version: <1.0>
Last modification date: <19.10.2011>
COMMERCIAL-IN-CONFIDENCE
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Summary Research Activity ‘Stack Materials and Design’
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.
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
‘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 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.
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Additionally, the programme aims at strengthening the cooperation between the groups
involved by promoting staff and student exchanges.
3. Description of foreseen activities
Justification of Programme
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
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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
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- 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
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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
Milestone Title Measurable
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
3.5 Annual meeting with decisions on further progress
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
3.7 Annual meeting with decisions on further progress
Continuation of programme
SP 3 meeting
held, contin.
decided
M36
3.7 Workshop on Proof-of-concept verification SP 3
Workshop held
M42
3.8 Annual meeting with decisions on further progress
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
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5. Participants and Human Resources
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
Activity S1 S2 S3 S4 S5 S6 S7 S8 S9 S10
Task 1.1 M3.1 W/S W/S W/S M3.7 W/S M3.9 W/S
Task 1.2 M3.1 W/S W/S W/S M3.7 W/S M3.9 W/S
Task 2.1 M3.1 W/S W/S W/S M3.7 W/S M3.9 W/S
Task 2.2 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
Task 4.2 M3.1 W/S W/S M3.6 W/S M3.7 W/S M3.9 W/S
Task 5.1 M3.1 W/S W/S M3.6 W/S M3.7 W/S M3.9 W/S
Task 5.2 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
Mx = milestone nr. X
S = annual status 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
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EERA
EUROPEAN ENERGY RESEARCH ALLIANCE
SUB-PROGRAMME 4: SYSTEMS
A sub-programme within the
FCs&H2 Joint Programme
Description of Work
Version: <1.0>
Last modification date: <19/10/2011>
COMMERCIAL-IN-CONFIDENCE
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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:
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• 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.
3. Description of foreseen activities
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).
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• 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.
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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
5. Participants and Human Resources
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
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EERA
EUROPEAN ENERGY RESEARCH ALLIANCE
SUB-PROGRAMME 5: MODELLING, VALIDATION AND
DIAGNOSTICS
A sub-programme within the
FCs&H2 Joint Programme
Description of Work
Version: <1.0>
Last modification date: <19/10/2011>
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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
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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
3. Description of foreseen activities (including time line)
Justification of Programme
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
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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
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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
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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.
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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
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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
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6. Participants and Human Resources
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],
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EERA
EUROPEAN ENERGY RESEARCH ALLIANCE
SUB-PROGRAMME 6: Hydrogen Production and Handling
A sub-programme within the
FCs&H2 Joint Programme
Description of Work
Version: <1.0>
Last modification date: <19/10/2011>
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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.
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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.
3. Description of foreseen activities
Justification of Programme
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.
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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
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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
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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,
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(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
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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
Milestone Title Measurable
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
5. Participants and Human Resources
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
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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
S = annual status report
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.)
www.polletresearch.com