Periodic Reporting for period 1 - HIGHLANDER (HIGH performing uLtrA-durable membraNe electroDe assEmblies for tRucks)
Período documentado: 2023-01-01 hasta 2024-06-30
The objective of HIGHLANDER is to develop membrane electrode assemblies (MEAs) for Heavy-Duty Vehicles (HDV) with disruptive, novel components, targeting stack cost and size, durability, and fuel efficiency. The project will design, fabricate, and validate the HDV MEAs at cell and short stack level against heavy-duty relevant accelerated stress test and load profile test protocols. The unique approach of HIGHLANDER is to develop core fuel cell components in tandem, ensuring their greatest compatibility and lowest interface resistance: ionomer and reinforcement, catalyst and catalyst support, catalyst layer composition and property gradient in tune with the bipolar plate flow-field geometry. Materials screening efforts will be supported by the development and use of improved predictive degradation models bridging scales from reaction sites to cell level. Model parameterisation is implemented using experimental characterisation data at materials, component, and cell level. HIGHLANDER brings together a European supply chain of fuel cell materials and components producers and an OEM stack developer that makes this approach possible. HIGHLANDER aims to bring about a significant reduction in stack cost and fuel consumption through improvement of CCM performance and development of a new, lower cost single-layer gas diffusion layer. It will aim to achieve the 1.2 W/cm² at 0.65 V performance target at 0.3 g Pt/kW or below meeting a lifetime target of 20,000h. Sustainability considerations include benchmarking of fluorine-free membranes for HDV MEA application and re-use of platinum in the context of a circular economy.
A new analytical technique for the consortium was implemented comprising inductively coupled-mass spectroscopy (ICP-MS) analysis in-line with electrochemical cycling. By detecting metal ions released during potential cycling, this technique has already proven valuable for determining the relative stability of project catalysts (D3.1).
Novel intermetallic electrocatalysts for the oxygen reduction reaction at the fuel cell cathode were prepared, characterised ex situ (rotating disk electrode, RDE) for their activity and for their durability using internationally recognised accelerated stress test protocols. Selected catalysts display better retention of electrochemical surface area and equivalent or higher mass activity in RDE than the project reference catalyst (D3.2).
Novel modified carbon supports were prepared, which demonstrate greater resistance to electrochemical corrosion than the project reference carbon during cycling in situ to high voltage (D3.2).
A novel sulfonated hydrocarbon ionomer was developed and used to prepare membranes that were characterised for their protonic resistance, tensile properties and swelling characteristics in water. First samples were integrated into a membrane electrode assembly and the durability of this membrane during accelerated chemical degradation (open circuit voltage hold), along with the ex situ properties, provide a baseline for future developments (D4.1).
Short-side-chain perfluorosulfonic acid membranes with standard ePTFE reinforcements and comprising (or not) a supported radical scavenger, were comprehensively characterised ex situ (conductivity, tensile properties) and in situ (combined relative humidity cycling and open circuit voltage hold) with post mortem characterisation by scanning electron microscopy, to provide a set of reference data (D4.1).
A first version of a hierarchical degradation modelling framework was formulated and implemented as software code. The code was documented and is publicly available in an open access modelling platform (GitLab), accessible at D2.1(se abrirá en una nueva ventana)
A new low-cost approach for gas diffusion layers is under development. Materials have been screened and down-selected, and new characterisation methodologies developed. First anode gas diffusion layers are available and under test in situ.
Baseline catalyst coated membranes (CCM) were fabricated and used to establish the performance and voltage loss baseline when submitted to load profile testing over 500 hours.
Novel intermetallic electrocatalysts for the oxygen reduction reaction at the fuel cell cathode were prepared, characterised ex situ (rotating disk electrode, RDE) for their activity and for their durability using internationally recognised accelerated stress test protocols. Selected catalysts display better retention of electrochemical surface area and equivalent or higher mass activity in RDE than the project reference catalyst (D3.2).
Novel modified carbon supports were prepared, which demonstrate greater resistance to electrochemical corrosion than the project reference carbon during cycling in situ to high voltage (D3.2).
A novel sulfonated hydrocarbon ionomer was developed and used to prepare membranes that were characterised for their protonic resistance, tensile properties and swelling characteristics in water. First samples were integrated into a membrane electrode assembly and the durability of this membrane during accelerated chemical degradation (open circuit voltage hold), along with the ex situ properties, provide a baseline for future developments (D4.1).
Short-side-chain perfluorosulfonic acid membranes with standard ePTFE reinforcements and comprising (or not) a supported radical scavenger, were comprehensively characterised ex situ (conductivity, tensile properties) and in situ (combined relative humidity cycling and open circuit voltage hold) with post mortem characterisation by scanning electron microscopy, to provide a set of reference data (D4.1).
A first version of a hierarchical degradation modelling framework was formulated and implemented as software code. The code was documented and is publicly available in an open access modelling platform (GitLab), accessible at D2.1(se abrirá en una nueva ventana)
A new low-cost approach for gas diffusion layers is under development. Materials have been screened and down-selected, and new characterisation methodologies developed. First anode gas diffusion layers are available and under test in situ.
Baseline catalyst coated membranes (CCM) were fabricated and used to establish the performance and voltage loss baseline when submitted to load profile testing over 500 hours.
Validation of novel fuel cell electrocatalysts requires the use of operando or in-line diagnostics and characterisation tools. A new analytical technique for the consortium, comprising inductively coupled-mass spectrometry (ICP-MS) analysis in-line with electrochemical cycling,was implemented. By detecting metal ions released into the electrolyte during potential cycling, this technique has already proven valuable for determining the relative electrochemical stability of project intermetallic and alloy catalysts (D3.1).
A novel sulfur-doped carbon support has been prepared and used to support a high loading (50 wt%) of PtCo intermetallic catalyst particles. This novel supported electrocatalyst has greater retention of electrochemical surface area and higher mass activity, as determined using the rotating disk electrode, than the project reference catalyst. It also displays lower carbon corrosion in a membrane electrode assembly during cycling to high voltage than an equivalent MEA with the project reference catalyst (D3.2). Other ordered intermetallic catalysts associating platinum and non-CRM/non-PGM metals under development also display higher mass activity and electrochemical surface area than the reference catalyst, and they are being upscaled for fuel cell testing.
Current proton exchange membrane fuel cells use perfluorosulfonic acid membranes and ionomers. The use of such materials might be regulated in the short term or, if not, in the longer term, and HIGHLANDER has a pre-emptive approach by developing sulfonated hydrocarbon ionomers and membranes. A first novel sulfonated hydrocarbon ionomer was developed and used to prepare membranes that were characterised ex situ and in situ in a single fuel cell, providing a baseline for future developments (D4.1).
A new low-cost anode gas diffusion layer (GDL) has been developed. The task of reducing GDL cost requires measuring their important physical properties, so that they can be optimised both in terms of cost and function. Measurement methods for convective transport, electrical bulk conductivity and contact resistance of GDLs have been developed and applied to the new low-cost anode GDL (D5.1).
The above novel materials are amongst those being further upscaled, screened and tested in MEAs in work towards achieving the final performance, durability and PGM loading targets of HIGHLANDER.
A first version of a hierarchical degradation modelling framework was formulated and implemented as software code, which is documented and is publicly available in the open access modelling platform (GitLab) D2.1(se abrirá en una nueva ventana).
A novel sulfur-doped carbon support has been prepared and used to support a high loading (50 wt%) of PtCo intermetallic catalyst particles. This novel supported electrocatalyst has greater retention of electrochemical surface area and higher mass activity, as determined using the rotating disk electrode, than the project reference catalyst. It also displays lower carbon corrosion in a membrane electrode assembly during cycling to high voltage than an equivalent MEA with the project reference catalyst (D3.2). Other ordered intermetallic catalysts associating platinum and non-CRM/non-PGM metals under development also display higher mass activity and electrochemical surface area than the reference catalyst, and they are being upscaled for fuel cell testing.
Current proton exchange membrane fuel cells use perfluorosulfonic acid membranes and ionomers. The use of such materials might be regulated in the short term or, if not, in the longer term, and HIGHLANDER has a pre-emptive approach by developing sulfonated hydrocarbon ionomers and membranes. A first novel sulfonated hydrocarbon ionomer was developed and used to prepare membranes that were characterised ex situ and in situ in a single fuel cell, providing a baseline for future developments (D4.1).
A new low-cost anode gas diffusion layer (GDL) has been developed. The task of reducing GDL cost requires measuring their important physical properties, so that they can be optimised both in terms of cost and function. Measurement methods for convective transport, electrical bulk conductivity and contact resistance of GDLs have been developed and applied to the new low-cost anode GDL (D5.1).
The above novel materials are amongst those being further upscaled, screened and tested in MEAs in work towards achieving the final performance, durability and PGM loading targets of HIGHLANDER.
A first version of a hierarchical degradation modelling framework was formulated and implemented as software code, which is documented and is publicly available in the open access modelling platform (GitLab) D2.1(se abrirá en una nueva ventana).