Regan Brown
Building a fuel cell gas tank requires careful planning and consideration of various factors, including materials, size, and power requirements. The first step is to determine the power requirements needed to power the specific device or application, such as a phone, laptop, car, or bus. The output voltage of a single cell is typically less than 1 V, but fuel cell developers aim for a higher voltage through optimal design and material selection. The choice of materials is crucial, with options including stainless steel, aluminium, and mild steel, each offering advantages and disadvantages in terms of corrosion resistance, weight, and weldability. To prevent tank slosh, which can lead to fuel pump issues, fuel cell foam or baffles can be used to stabilise the fuel. Gaskets are essential to prevent fuel leakage and maintain equal pressure, while current collectors gather electrons from the flow field plates. End plates provide support and help components stay in place, and claps, screws, nuts, and bolts hold everything together.
| Characteristics | Values |
|---|---|
| Materials | Platinum or platinum-coated wire, popsicle stick, 9-volt battery and battery clip, clear tape, glass of water, table salt, thin metal rod, volt meter, aluminium, stainless steel, carbon fabric or paper, graphite, gasket material, metal, end plates, clamping mechanism, hydrogen source, testing instruments, carbon powder, carbon fiber cloth, polytetrafluoroethylene (PTFE), fuel cell foam |
| Power Requirements | Determined by the device or application to be powered. |
| Size | Dependent on power requirements. |
| Operating Conditions | Must maintain a consistent temperature and prevent the polymer electrolyte from drying out or becoming oversaturated with water. |
| Design | Must be sturdy, tightly sealed to minimise gas leakage, and able to withstand necessary environmental conditions. |
| Assembly | Wind wire strips around a thin metal rod to shape them into springs for electrodes. Cut and strip wires from a 9-volt battery clip and attach to electrode coils. Tape electrodes to a popsicle stick. Prepare the polymer electrolyte membrane. |
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What You'll Learn
Choosing the right material
Aluminum is another popular choice for fuel cell gas tanks due to its excellent corrosion resistance and lightweight properties. Aluminum is about 33% lighter than steel of equal strength, making it a favourable option for gas tank construction. However, one of the main drawbacks of aluminum is the difficulty in welding it. Many fabricators have given up on using aluminum due to this challenge. If you decide to use aluminum, you may need to enlist the help of a local welder.
Another consideration when choosing a material for your fuel cell gas tank is the issue of "tank slosh". This occurs when the fuel moves around in the tank during acceleration or turning, potentially starving the fuel pump of fuel and causing serious issues. One way to mitigate this problem is to use fuel cell foam, which slows down the sloshing motion of the fuel. However, some people report that foam does not always solve the problem.
Before committing to a particular material, it is advisable to create a cardboard model of your fuel tank to ensure it fits your desired specifications. This step can save you time and resources by allowing you to identify any design adjustments before finalising the tank construction.
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Dealing with tank slosh
Tank slosh occurs when the vehicle is undergoing cornering or hard acceleration and braking, causing the fuel to slosh around in the tank. This movement can produce unpredictable weight transfer and adversely affect the handling of the vehicle. In the worst-case scenario, the fuel pump could burn out, or a lean air-fuel condition could cause a motor to grenade.
One way to deal with tank slosh is to use fuel cell foam. This is a fuel-resistant foam that is stuffed into the fuel tank to slow the sloshing motion of the fuel. While foam has been proven to help, some have reported that it did not solve the problem. Additionally, manipulating the foam to fit more fuel into the tank creates a significant safety hazard, as it makes the fuel cell more likely to explode in an accident.
Another option is to use a fuel cell, a metal can fitted with a flexible bladder that contains the fuel. The most important part of the fuel cell is the safety foam baffling, which helps to prevent the fuel from sloshing around. This option provides additional levels of safety and became standard for auto racing after a fatal accident in 1964.
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Power requirements
One of the most important considerations when building a fuel cell gas tank is determining the power requirements. Fuel cell stacks can be used to power anything from phones to laptops, automobiles, buses, and even spacecraft. The power requirements will dictate the size, materials, components, and operating conditions of the fuel cell.
The output voltage of a single cell is typically less than 1V (around 0.6 to 0.7 V) under normal conditions. However, it is possible to achieve higher voltages by increasing the size of the active electrode area or the number of cells. For example, an e-bike with a 250W motor would require a minimum of 4 to 10 cells, depending on the cell size and power density.
The materials used in the construction of the fuel cell will also impact its power capabilities. For instance, the catalyst layer, typically made of platinum, is responsible for breaking down the fuel into protons and electrons, and the efficiency of this process will affect the overall power output. Other materials to consider include the proton exchange membrane, carbon fabric or paper, flow field plates, gasket material, and metal for current collectors.
Additionally, it is important to address the issue of "tank slosh," which occurs when the fuel moves around during acceleration or turning, potentially starving the fuel pump of fuel. This can be mitigated by using fuel cell foam or baffles to slow down the sloshing motion, ensuring a consistent fuel supply to the pump.
Overall, building a fuel cell gas tank with specific power requirements involves careful consideration of the cell size, number of cells, choice of materials, and measures to prevent fuel slosh, all of which contribute to the overall power output and performance of the fuel cell.
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Sealing the stack
When selecting a gasket, it is important to consider the type of fuel cell being constructed. For low-temperature proton exchange membrane fuel cells (PEMFC), a commonly used gasket material is Nafion®, a thin, clear polymer electrolyte membrane that can be cut to fit your unique fuel cell design. The gasket material should be chosen to be compatible with the specific fuels and operating temperatures of your fuel cell.
In addition to gaskets, another important consideration for sealing the stack is the use of a catalyst layer, such as platinum or a combination of platinum and carbon powder. This layer helps to manage water within the fuel cell stack, ensuring that the polymer electrolyte does not dry out or become oversaturated. Proper water management is crucial to maintaining the performance and integrity of the fuel cell.
Furthermore, the fuel cell stack should be designed to minimise restrictive losses and ensure good contact between conductive components. This allows electrons to flow freely with minimum resistance, improving the overall efficiency of the fuel cell.
Finally, it is worth noting that the choice of materials for the fuel cell stack can impact the sealing process. For example, aluminium is a popular choice for fuel tanks due to its corrosion resistance and lightweight properties. However, it is challenging to weld, and fuel cell builders may need to consult a specialist welder or consider using stainless steel, which is also corrosion-resistant and easier to weld.
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Building a prototype
Design and Planning:
Start by determining the power requirements of the device or application you want to power with your fuel cell. This could be anything from a phone to a car or even a spacecraft. The power requirements will dictate the size and number of cells needed. You can increase or decrease the size of the electrode area to meet the power requirements. Consider the size, materials, components, and operating conditions for your prototype.
Materials and Components:
For a low-temperature proton exchange membrane fuel cell (PEMFC), you will need the following basic materials:
- A proton exchange membrane, such as Nafion® 117, and a Nafion® solution.
- Carbon fabric or paper for the electrode layer.
- A catalyst, typically platinum, which breaks down the fuel into protons and electrons.
- Flow field plates made of graphite or another conductive material.
- Gasket material to seal the gases and prevent leakage.
- Metal to create current collectors, which collect the electrons.
- End plates for support and component stability.
- Clamping mechanisms like nuts and bolts.
- A hydrogen source.
- Testing instruments such as a multimeter and oscilloscope.
Assembly:
- Prepare the polymer electrolyte membrane.
- Create the electrode layer by combining platinum and carbon powder with a gas diffusion layer (GDL), which can be a conductive carbon fiber cloth or paper.
- Assemble the catalyst layers using methods like hand-painting, electroless deposition, mechanical deposition, or print screening for cost-effectiveness.
- Ensure good contact between conductive components to allow free electron flow with minimum resistance.
- Seal the fuel cell stack tightly to minimise gas leakage using appropriately sized gaskets.
- Test and optimise your prototype by varying design requirements, such as material and component selections, flow field, gas diffusion, gasket design, and current collector design.
Additional Considerations:
- Tank slosh, which occurs when fuel moves around during acceleration or turning, can be minimised by using fuel cell foam or baffles.
- Consider the weight and weldability of the materials you choose. For example, aluminium is lightweight but challenging to weld, while stainless steel is easier to weld and highly resistant to corrosion.
- Cardboard prototyping can help ensure your design fits before final fabrication.
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Frequently asked questions
Some materials that can be used to build a fuel cell gas tank include aluminium, stainless steel, and mild steel.
Aluminium is about 33% lighter than steel of equal strength, highly resistant to corrosion, and can be made into any size and shape.
Aluminium is incredibly difficult to weld.
Mild steel is fine to use, but it is corrosive. To prevent corrosion, you will need to coat the inside and outside of the tank, which can be tedious and may not hold up well over time.
Some important design considerations include power requirements, size, materials, components, and operating conditions. It is also important to consider "tank slosh", which is when fuel moves around in the gas tank and can cause the fuel pump to run dry. This can be mitigated by using fuel cell foam to slow the sloshing motion.
