Rajan Wilcox
Hydrogen fuel cells are an alternative to traditional car fuel sources, with the potential to power cars, buses, and even spacecraft. Hydrogen fuel cells are created by splitting water into hydrogen and oxygen gases using electricity from a car battery. This process produces a fuel that is more powerful than gasoline and emits only water. While some people have tried to add hydrogen fuel cells to their cars, the process is complex and requires an understanding of the different parts of a fuel cell, such as proton exchange membranes (PEMs) and catalysts.
Characteristics and Values Table for Building a Hydrogen Fuel Cell for a Car
| Characteristics | Values |
|---|---|
| Parts of a Fuel Cell | PEMs or Proton Exchange Membranes, Catalyst, Catalyst Layers, Flowfield Plates, Gaskets |
| Function of PEMs | Allow the flow of hydrogen atoms through the membrane while filtering out the hydrogen electrons |
| Function of Catalyst | Breaks down the fuel (usually hydrogen) into protons and electrons |
| Function of Catalyst Layers | Include particles of platinum that help split hydrogen molecules into protons and electrons on the anode side; on the cathode side, the platinum catalyst supports oxygen reduction, reacting with protons to produce water |
| Function of Flowfield Plates | Regulate the flow of gasses and liquids (hydrogen, oxygen, and water) through the fuel cell to ensure a constant power output |
| Function of Gaskets | Prevent fuel leakage, ensuring pressure remains equal throughout the stack; made from rubber, silicon, or polytetrafluoroethylene (PTFE) |
| Power Requirements | Determined by the voltage required; fuel cell stacks can be used to power anything from phones to cars, depending on the size of the electrode area |
| Fuel Cell Output Voltage | Under normal conditions, the output voltage of a single cell is less than 1V (around 0.6 to 0.8 V); higher voltages can be achieved with optimal electronics, design, and materials |
| Fuel | Hydrogen, which is broken down into protons and electrons |
| Fuel Cell Kit | HydroCell Kit available on Amazon, which can be added to a gasoline-powered car |
| Alternative Method | Using an OxyHydrogen generator to convert water into hydrogen and oxygen gases, which can be used as fuel |
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What You'll Learn
Understanding the different parts of a fuel cell
The anode and cathode are the negative and positive electrodes, respectively. Hydrogen fuel is fed to the anode, and oxygen from the air is fed to the cathode. The catalyst, typically made of platinum, is located at the anode and facilitates the splitting of hydrogen molecules into protons and electrons. The protons pass through the porous electrolyte membrane, while the electrons are forced through a circuit, creating electricity. At the cathode, the protons, electrons, and oxygen combine to produce water.
The electrolyte membrane, or Proton Exchange Membrane (PEM), is a critical component in the fuel cell. PEMs are typically made of a polymer material and facilitate the passage of protons while blocking the flow of electrons, which are directed through the circuit. Gaskets are also essential in preventing fuel and air leakage, ensuring pressure remains equal throughout the cell. They are made of elastic materials like rubber, silicone, or PTFE to compensate for irregularities in the surface of the flow field plates.
The power requirements of the fuel cell stack determine the number of cells needed. Fuel cells produce low voltage individually, so multiple cells are often stacked together to increase the voltage for applications like powering a car. The flow field plates regulate the flow of gases and liquids (hydrogen, oxygen, and water) to ensure a constant power output.
Fuel cells are unique in their ability to cleanly and efficiently produce electricity from hydrogen, with the only byproducts being electricity, water, and heat. They are highly reliable due to their lack of moving parts, resulting in silent and efficient operation.
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Determining power requirements
When designing a hydrogen fuel cell for a car, there are many factors to consider, and the process can be complex. The first step is to determine the power requirements, which will then inform the design of the fuel cell stack.
The power requirements of the fuel cell will depend on the application and the type of vehicle. For example, a car will have different power requirements to an aircraft. The power output of a fuel cell stack is a product of stack voltage and current. The voltage of the fuel cell will vary according to the amount of power being drawn from it, so power conditioning is often required to regulate the power to work with the rest of the system. The power requirement will also determine the number of cells in the stack, which is often designed to meet a maximum voltage requirement and a desired operating voltage.
The size of the fuel cell is an important consideration, as a larger fuel cell stack will increase cost and weight. A smaller fuel cell may be sufficient if it is used in conjunction with a battery to help take peak loads. The efficiency of the fuel cell will also impact the power requirements, as a more efficient fuel cell will require less hydrogen fuel. The efficiency of a fuel cell is higher at the beginning of its life compared to the end of its life.
The power requirement will also inform the design of the fuel cell system, including the selection of materials and operating conditions. For example, a nominal voltage of 0.6 to 0.7 V at nominal power is commonly used, but higher voltages can be achieved with the correct design, materials, and operating conditions.
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Sourcing quality gaskets
When building a hydrogen fuel cell for a car, it is important to source quality gaskets to ensure gas tightness and prevent leakage. Gaskets are crucial components in fuel cells, and incorrect gaskets can lead to gas leaks and reduced fuel cell performance. Gaskets are positioned between the bipolar plate and the membrane unit in fuel cells. They play a vital role in maintaining system efficiency and safety by keeping materials inside the system and preventing them from escaping.
There are several factors to consider when choosing the right gasket material:
- Long-term chemical stability
- Preventing the mixing of fuel and oxidant
- Preventing the mixing of reactants with the environment
- Vibration and shock resistance
- Electrical insulation between components
- Minimal mechanical and thermal mismatch stresses
- Stability over the required temperature range
- Low cost
- Excellent sealing capability
- Ability to be produced using low-cost stack manufacturing methods
- Prevent mechanical bonding of components (for certain fuel cell types)
Commonly used gasket materials for low-temperature fuel cells include silicon, EPDM rubber, and PTFE. Silicon and EPDM gasket materials offer good compressibility and gas tightness. PTFE-based gaskets, on the other hand, often require greater compressibility and are more challenging to make gas-tight. For high-temperature fuel cells, gasket design becomes more challenging due to the difficulty of sealing ceramic components to prevent gas leakage.
When sourcing quality gaskets, it is essential to consider the specific requirements of your fuel cell application. Gaskets need to be elastic enough to compensate for any irregularities in the surface of the flow field plates and thick enough to endure compression. Reputable vendors, such as Eisenhuth GmbH & Co. KG, offer gasket materials tailored to the customer's specific needs. They have extensive experience in the industry and are ISO9001 and SpaEfV certified.
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Assembling the catalyst layers
When assembling the catalyst layers, it is important to remember that the catalyst breaks down the fuel (usually hydrogen) into protons and electrons. On the anode side, this includes particles of platinum that help split hydrogen molecules into protons and electrons. Meanwhile, on the cathode side, the platinum catalyst supports oxygen reduction, reacting with protons to produce water. A carbon fibre cloth (or other conductive paper) acts as a substrate, keeping the catalyst in place. It is often coated with Polytetrafluoroethylene (PTFE) on one side to aid water management in the fuel cell stack.
There are several ways to assemble the catalyst layers in your first fuel cell stack, including hand-painting, electroless deposition, and mechanical deposition. However, print screening is usually the most cost-effective method. This involves printing the catalyst layer onto the membrane and gas diffusion layer. The catalyst layer can also be deposited onto the membrane using a variety of techniques, such as spin coating, spray coating, or doctor blading.
It is important to ensure that the catalyst layer is uniform and of the correct thickness. This can be achieved through the appropriate selection of deposition techniques and process parameters. The catalyst layer must also be in good contact with the membrane and gas diffusion layer to ensure effective proton conduction and electron transport.
Additionally, the catalyst layer should be protected from corrosion and contamination. This can be achieved by incorporating corrosion-resistant materials or coatings into the catalyst layer or by using appropriate sealing and packaging techniques to prevent contamination from the external environment.
Overall, assembling the catalyst layers is a critical step in building a hydrogen fuel cell for a car, and it requires careful consideration of the materials, deposition techniques, and assembly processes to ensure optimal performance and durability.
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Sealing the fuel cell to prevent gas leakage and parasitic draw
Sealing the fuel cell is a critical step in preventing gas leakage and parasitic draw when building a hydrogen fuel cell for a car. Here are some detailed instructions and considerations for this process:
Gaskets and Seals:
Gaskets are essential components in preventing gas leakage. When selecting gasket materials, consider the operating temperature of the fuel cell. For low-temperature fuel cells, silicon, EPDM rubber, and PTFE are commonly used. EPDM rubber provides the best gas tightness, while silicon offers good compressibility. For higher temperature fuel cells, sealing ceramic components becomes more challenging. Glass and glass-ceramic seals can be used, but they have drawbacks, such as brittleness, and potential cell failure during cool down. Custom seal designs are often required for high-temperature fuel cells, with bonded and compressive seals being the two main types under development.
Compression Considerations:
Compression load is crucial in achieving adequate sealing pressure. Under-compression can lead to gas leakage, affecting efficiency and safety. On the other hand, over-compression should also be avoided. Gaskets should be thick enough to endure compression and elastic enough to compensate for irregularities in the surface of the flow field plates. In large or pressurised stacks, soft gasket materials may deform, and more rigid materials or alternative design approaches may be necessary to prevent gas blockage.
Assembly and Machining:
During assembly, ensure there are no cracks or gaps in the unit, as any fuel or air escape will cause problems with the flow of hydrogen or air. The machining precision of the seals is critical to minimising the risk of seal failure caused by misalignment. Ensure that the seals on both sides of the frame are symmetrical and evenly distributed.
Parasitic Draw:
Regarding parasitic draw, a comment on a Reddit thread discussing adding a hydrogen fuel cell to a car mentions the potential for improved performance and economy over time due to reduced parasitic draw. The user speculates that by generating electricity to charge the battery, the fuel cell may reduce the parasitic draw associated with the alternator.
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Frequently asked questions
A hydrogen fuel cell is a device that uses hydrogen to generate electricity. This electricity can then be used to power an electric motor in a car.
Building a hydrogen fuel cell typically involves the following steps:
- Determine the power requirements for the fuel cell.
- Understand the different parts of a fuel cell, such as the Proton Exchange Membranes (PEMs), catalyst, catalyst layers, flow field plates, and gaskets.
- Assemble the fuel cell stack, ensuring there are no cracks or gaps to prevent fuel or air leakage.
- Mount the electrode-PEM-electrode sandwich in the middle of a polyester film to keep gases and compounds separate.
Hydrogen fuel cells offer a cleaner and more sustainable alternative to traditional gasoline-powered engines. The only emission from using a hydrogen fuel cell is water, making it a more environmentally friendly option. Additionally, some users have reported improved gas mileage and better performance over time.
