Mercedes Mullins
Fuel cells can be used to power anything from phones to laptops, cars, and even spacecraft. Building your own fuel cell gas tank can be a complex process, but it is possible to do it yourself. The first step is to determine the power requirements needed to power the particular device or application. The next step is to understand the different parts of a fuel cell and gather the necessary materials. A simple electrolytic cell can be made with common household materials, while more complex fuel cells require specific components like platinum wire, a polymer electrolyte membrane, a catalyst, and a hydrogen source. Once you have your materials, you can start constructing your fuel cell by preparing the polymer electrolyte membrane and assembling the components. For a fuel cell gas tank, you will also need to consider factors such as tank slosh and ensure that your tank is properly sealed to prevent gas leakage.
Characteristics and Values of a Fuel Cell Gas Tank
| Characteristics | Values |
|---|---|
| Materials | Aluminium, platinum wire, platinum-coated wire, popsicle stick, 9-volt battery, battery clip, clear tape, glass of water, table salt, thin metal rod, voltmeter, carbon fabric, paper, catalyst, graphite, flow field plates, gasket material, metal, end plates, clamping mechanism, hydrogen source, testing instruments, carbon powder, gas diffusion layer, etc. |
| Construction | Cut platinum wire into strips, wind them around a thin metal rod, cut battery leads, strip insulation, attach exposed ends to the wire coils, tape the coils to a popsicle stick, dip in water, connect wires to voltmeter/bulb, etc. |
| Power Requirements | Fuel cells can be used to power phones, laptops, cars, buses, houses, businesses, spacecraft, etc. The power requirements can be adjusted by increasing or decreasing the size of the electrode area. |
| Performance | Uniform temperature is important for optimal performance. Resistive losses should be minimised by ensuring good contact between conductive components. Proper sealing is necessary to prevent gas leakage. |
| Tank Slosh | Fuel cell foam or baffles can be used to control the movement of fuel during acceleration or turning, preventing fuel pump issues and engine damage. |
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What You'll Learn
Power requirements
One of the most important steps in building a fuel cell is determining the power requirements. Fuel cells can be used to power anything from phones to laptops, cars, buses, and even spacecraft. The power requirements will depend on the specific device or application that the fuel cell is intended to power.
The output voltage of a single fuel cell is typically less than 1 volt under realistic operating conditions. However, most fuel cell developers aim for a voltage of around 0.6 to 0.7 volts at nominal power. Expert fuel cell engineers can achieve higher voltages of over 0.8 volts per cell by optimising the electronics, design, materials, and operating conditions.
The power generated by the fuel cell depends on several factors. Firstly, the size of the active electrode area plays a crucial role in determining the current produced by the fuel cell. Increasing or decreasing the size of the electrode area can be used to achieve any desired current. Additionally, the rate of power distribution is influenced by temperature; a uniform temperature ensures a consistent rate of power distribution, while water management becomes more challenging as temperatures increase.
Another factor to consider is the contact between conductive components. Minimising resistive losses is essential, and this can be achieved by ensuring good contact between these components, allowing electrons to flow with minimal resistance. Proper sealing of the fuel cell stack is also critical to prevent gas leakage, and the gaskets used must be appropriately sized and made from materials such as rubber, silicone, or polytetrafluoroethylene (PTFE).
Furthermore, the stack must be designed to withstand the necessary environmental conditions, and the proton exchange membrane (PEM) plays a vital role in allowing the flow of hydrogen atoms while filtering out hydrogen electrons. The PEM requires careful preparation, including dipping it into heated solutions of DI water, hydrogen peroxide, and dilute sulfuric acid to activate essential gas groups.
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Materials
Metals:
Aluminum is a popular choice for fuel cell construction due to its lightweight nature and excellent corrosion resistance. It is about 33% lighter than steel, making it a preferred option. However, aluminum's major downside is the difficulty in welding, which may require specialized skills or outsourcing to a professional welder. Alternatively, steel can be used, but it is heavier and more prone to corrosion if not properly treated.
Platinum is another critical metal in fuel cell construction. It serves as a catalyst, facilitating the breakdown of fuel (usually hydrogen) into protons and electrons. Platinum wires or platinum-coated wires are recommended to prevent unwanted reactions with oxygen or salt, which could pollute the solution.
Other noble metals like gold or silver can be used in place of platinum if needed.
Gaskets:
Gaskets play a vital role in preventing fuel leakage and maintaining equal pressure throughout the stack. They should be made of elastic and durable materials like rubber, silicone, or polytetrafluoroethylene (PTFE). The gaskets must be appropriately sized and placed around the flow field plates to create a tight seal, ensuring no gas leakage.
Polymer Electrolyte Membrane (PEM):
The PEM allows the flow of hydrogen atoms while filtering out electrons. It is typically made from a polymer electrolyte, such as Nafion®, in the form of a thin, clear film. The PEM requires careful preparation by dipping it into heated solutions of distilled water (DI water), hydrogen peroxide, and dilute sulfuric acid to activate essential gas groups and remove impurities.
Flow Field Plates:
These components regulate the flow of gases and liquids (hydrogen, oxygen, and water) through the fuel cell, ensuring a constant power output. They can be made of graphite or other suitable materials.
Electrode:
The electrode layer is a combination of platinum and carbon powder bonded to a gas diffusion layer (GDL). The GDL is typically made of conductive carbon fiber cloth or paper. The electrode area can be increased or decreased to meet specific power requirements.
End Plates and Clamping Mechanism:
End plates provide structural support and should have appropriate holes for clamping to the outer case of the stack. They can be made of metal or polymers. A clamping mechanism, such as nuts and bolts, is necessary to secure the assembly.
Hydrogen Source and Testing Instruments:
A hydrogen source is required for the fuel cell to function. Additionally, testing instruments such as a multimeter, oscilloscope, or voltmeter are essential for measuring and monitoring the fuel cell's performance.
Fuel Cell Foam:
To address the issue of "tank slosh," where fuel moves around during acceleration or cornering, fuel cell foam can be used. This foam is fuel-resistant and helps slow down the sloshing motion, preventing fuel pump issues and lean air-fuel conditions.
Cardboard (for Prototyping):
Before constructing the fuel cell with metal, it is advisable to create a prototype using cardboard. Cardboard allows for testing the design's fit and making any necessary modifications without wasting expensive materials.
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Assembly
To assemble a fuel cell gas tank, you must first determine the power requirements needed to power the particular device or application. This is because fuel cell stacks can be used to power anything from phones to laptops, cars, buses, and even spacecraft. The output voltage of a single cell is typically less than 1V, but most fuel cell developers use a voltage of 0.6 to 0.7 V.
The next step is to gather the necessary materials. For a simple household fuel cell, you will need 12 inches (30 cm) of platinum or platinum-coated wire, a popsicle stick, a 9-volt battery and battery clip, clear tape, a glass of water, table salt (optional), a thin metal rod, and a voltmeter.
Once you have your materials, you can start constructing the fuel cell. Cut two 6-inch strips of platinum wire and wind them around a thin metal rod, shaping them into springs. These will serve as the fuel cell's electrodes. Cut the leads from the 9-volt battery clip in half, strip the insulation off, and attach the exposed wire ends to the electrode coils. Tape the springs to the popsicle stick and lay it over the glass of water, ensuring the springs are submerged. Finally, connect the wires to a voltmeter or LED bulb to see the fuel cell's current.
If you are constructing a fuel cell gas tank for a vehicle, there are additional considerations. One important factor is "tank slosh," which occurs when fuel moves around during acceleration or turning, potentially starving the fuel pump of fuel. To mitigate this, you can use fuel cell foam to slow the sloshing motion. Another option is to add baffles or use aluminium to construct the tank, as it is extremely resistant to corrosion and about 33% lighter than steel. However, aluminium is challenging to weld, so you may need to seek assistance from a professional welder.
Overall, assembling a fuel cell gas tank requires careful planning, the right materials, and an understanding of the basic construction process.
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Tank slosh
Firstly, fuel cell foam can be used to slow the sloshing motion of the fuel. This method has been proven to be successful by many, but some also report that it did not solve the problem. The foam also serves another important function: it prevents a concentration of the fuel vapour and air mixture, which significantly reduces the probability that the fuel cell will explode in case of a fire. However, it is important to note that the foam should not be manipulated to increase fuel capacity as this creates a major safety hazard.
Another way to address tank slosh is to switch from a float-arm design to a tube-style sender design. The tube-style sender design acts as a damper, providing consistent readings despite fuel slosh.
Additionally, a fuel-gauge sending unit can be installed in a fuel cell that has foam inside, and a ground strap should be added to the fuel cell to prevent static electricity build-up, which could lead to an explosion.
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Welding
Choosing the Right Material for Welding:
Aluminum is a popular choice for fuel cell gas tanks due to its lightweight and corrosion-resistant properties. However, aluminum can be challenging to weld, and many fabricators opt for other materials or enlist the help of experienced welders. If you decide to use aluminum, ensure you have the necessary skills and equipment to weld it effectively.
TIG welding is a common technique used for aluminum fuel cell construction. This method allows for precise control over the welding process, enabling you to create custom shapes and sizes. Ensure you are familiar with the TIG welding process and have the appropriate equipment and safety measures in place before beginning.
Addressing "Tank Slosh":
"Tank slosh" refers to the movement of fuel within the gas tank during acceleration, deceleration, or cornering. This can lead to fuel pump issues and unsafe conditions. To mitigate tank slosh, consider installing baffles or using fuel cell foam to slow down the movement of fuel. Baffles are structures welded inside the tank to control the fuel's movement, while fuel cell foam fills the tank and restricts fuel movement.
Sealing and Treating the Welded Tank:
Once your fuel cell is welded together, it's crucial to seal and treat the tank to prevent rust and leaks. Apply a fuel tank sealer, such as US Std. Fuel Tank Sealer, to the interior of the tank. This will help prevent rust and seal any pinholes created during welding. Follow the manufacturer's instructions for proper application and curing times.
Safety Considerations:
Always prioritize safety when welding and working with fuel cell gas tanks. Ensure proper ventilation, wear appropriate protective gear, and follow local safety guidelines. Stay informed about any racing or regulatory safety standards, especially if your fuel cell is intended for a vehicle.
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Frequently asked questions
You will need 12 inches (30 cm) of platinum or platinum-coated wire, a popsicle stick, a 9-volt battery and battery clip, clear tape, a glass of water, table salt (optional), a thin metal rod, and a voltmeter.
Tank slosh is when the fuel moves around in the gas tank, starving the fuel pump of fuel. This can be prevented by stuffing the fuel tank with fuel cell foam or by putting baffles in the tank.
PEMFC stands for proton exchange membrane fuel cell. It is a type of fuel cell commonly used in vehicles.
The first step in building a fuel cell is to determine the power requirements needed to power the device or application.
The next step is to understand the different parts of a fuel cell and how they work.
