Fuel cells stack development included a new compression reducing costs, increases manufacturability, and minimizes leaks. Further, new gasket materials and designs were designed and tested. Other focus areas were the materials and design of bipolar plate and gasket, which were optimized for fuel cell pressurization, reduction of leakages and overall costs, and a new electrode formulas for reducing Pt consumption on the MEA.
Investigation of an innovative aqueous-phase reforming concept as a pre-reforming technology for methanol was as one of focus areas in reformer development. Promising Pt-based catalysts suitable for elevated process conditions were identified, but further research is needed for integration of this method as a pre-reforming unit. The complete gas-phase reformer system was designed, constructed, commissioned, and evaluated. Full functionality was demonstrated and complete methanol conversion could be achieved at 100% capacity.
The fuel cell system development successfully concluded with the completion of an HT-PEMFC system, which includes the fuel cell stack, reformer, and balance of plant components. A detailed P&I diagram was created, and major components were sized and specified. The developed system underwent a successful factory acceptance test, during which it demonstrated the proper functioning of control and safety systems while producing 5 kW of power. Additionally, manufacturing costs were analysed, suggesting that simplifying the reforming setup could reduce the manufacturing cost to 2,587 € per kilowatt for an annual production of 20,000 units.
The integration process commenced by identifying end users and customer segments. Based on gathered inputs, a mobile CHP container was designed and constructed. To enhance the system, a comprehensive safety analysis was conducted, and recommended improvements were incorporated. The fuel cell system was integrated into the finalized container workspace, and a short-term test of the CHP system was carried out. The final demonstration activities were focusing on a stand-alone performance demonstration of the fuel cell system in relevant conditions. The demonstration contained long-term operation period alongside 70 start-stop cycles. Throughout the demonstration period, it achieved a peak stack electrical efficiency of 53.7%, generated a maximum power output of 6.5 kW, and accumulated a total energy production of 1.8 MWh. Results were thoroughly analyzed, and development points were identified, with changes to components.
Communication activities focused on promoting the potential of fuel cell CHP systems and exploring the applications of renewable methanol in fuel cells. Four major dissemination events were organized, targeting the general public, academic audience, and industrial shareholders. The project yielded two peer-reviewed scientific articles, and the involvement of a PhD student and the completion of two MSc theses contributed to its academic dimension. Market potential and business analyses were conducted on methanol-fueled HT-PEMFC CHP units to identify potential market segments for the developed product. Comparative studies indicated a lower carbon footprint for the system when using any of the renewable methanol feedstocks compared to diesel generators.
The project has identified a range of exploitable results and partners are actively working on leveraging them. Below, a selection of these outcomes are listed.
• Integration of a 5-kW fuel cell system with a heat pump for 20-30 kW heat production
• Bipolar plate design for gasket stability
• Mechanical endplate design and compression system
• BoP component selection for the fuel cell system
• Integration of a thermoelectric generator in the fuel cell system
• GPR unit for methanol reforming
