PEM Fuel Cell Design,
Design Fabrication and Testing
in an Undergraduate Engineering Course
Denise McKayy
Assistant Professor, Smith College
Etta Grover
Grover-Silva
Silva ‘10
Smith College
Fuel Cell Seminar 2009
Slide 1 of 13
Engineering Science Curriculum
EGR 410D
Design Clinic
300 Level Electives
3 Technical Electives required
EGR 374
Fluids
EGR 375
Strength
of
Materials
EGR 220
Engineering
Ci it
Circuit
Theory
EGR 320
Signals
and
Systems
EGR 260
Energy and
M
Mass
Balances
EGR 363
Mass
and Heat
Transfer
EGR 270
Engineering
Mechanics
EGR 326
Dynamic
Systems
EGR 290
Engineering
Th
Thermo
-
EGR 100
Engineering
For
Everyone
Fuel Cell Seminar 2009
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Fuel Cell Course Overview
Initial Design Concepts
C
(in class, no constraints)
FC
C Fabrication
in machine shop
Physical Representation
(CAD or mock-up)
Finalize fabrication and
assembly
Peer Review
Design Charette
Add hardware constraints
Test Fuel Cells
in research lab
Lab report
FC polarization
Refine Design
CAD Drawings
Final Approval
Dimensioned CAD
Drawings
Legend
In class
FC System Design
Size a stack with
polarization data
Outside class
Fuel Cell Seminar 2009
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FC Design – Background Materials
Initial Design Objectives:
• Electrical conduction
• Reactant distribution from plumbing fitting to catalyst layer
• Gas sealing
Fuel Cell Seminar 2009
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FC Design – Design Ideation
Given materials and dimensions
• Gasketed MEA – 50cm2 active area
• GDL – cloth with integrated MPL
• Gaskets – Buna-N sheets
• Flow Field/Current collector – metal
screens or perforated metal
• Endplate – acrylic/Lexan
• Hardware – threaded rod, wing nuts,
bolts, hose/barb fittings
Fuel Cell Seminar 2009
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FC Design – Physical Representation
Fuel Cell Seminar 2009
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FC Design – Design Charette
Refine cell design directly with instructor prior to fabrication
Fuel Cell Seminar 2009
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Fabrication and Assembly
Laser cut endplates
Assembly
Fuel Cell Seminar 2009
Water Jet Cutter
Tapping endplates
Final Assembly
Machine Shop
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Performance Characterization – Test Cells
Fuel Cell Seminar 2009
Slide 9 of 13
Application of Test Data to FC System Design
Air Blowers
Supply Valve
Air Vent
Ai Plumbing
Air
Pl bi Diagram
Di
Pressure Isolation
Regulator Valve
Electrical Wiring Diagram
Fuel Cell Seminar 2009
Solenoid
Delivery
Valves
Purge Valve
FC Hydrogen Delivery Plumbing Diagram
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Life Cycle Cost Assessment
Item
Initial Costs
Single Present Uniform Present
Worth Year
Worth Year
PV Equipment
FC Equipment *
Installation Cost
0
0
0
Cost
Present
Present Worth
Worth Factor
Amount
$4,006,030
$1,621,110
$82,800
1.0
1.0
1.0
$4,006,030
$1,621,110
$82,800
$5,520
11.5
$63,314
0.94
0.89
0.84
0 79
0.79
0.75
0.70
0.67
0.63
0.59
0.56
0 53
0.53
0.50
0.47
0.44
0.42
0.39
0.37
0 35
0.35
0.33
0.75
0.56
0.42
0.89
0.79
0 70
0.70
0.63
$76,462
$72,134
$68,051
$64 199
$64,199
$60,565
$57,137
$53,903
$50,852
$47,973
$45,258
$42 696
$42,696
$40,279
$37,999
$35,848
$33,819
$31,905
$30,099
$28 395
$28,395
$26,788
$309,365
$231,175
$172,748
$3,480
$3,097
$2 756
$2,756
$2,453
A
Annual
lC
Costs
Annual Maintenance
0
20
Repair & Replacement
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
H2 Fuel †
Inverter Replacement
Inverter Replacement
Inverter Replacement
Water Pump Replacement
Water Pump Replacement
Water Pump Replacement
Water Pump Replacement
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
5
10
15
2
4
6
8
$81,050
$81,050
$81,050
$81 050
$81,050
$81,050
$81,050
$81,050
Air Blower Replacement
$81,050
Air Blower Replacement
$81,050
Air Blower Replacement
$81,050
Air Blower Replacement
p
$81 050
$81,050
Air Blower Replacement
$81,050
$81,050
Air Blower Replacement
$81,050
Air Blower Replacement
$81,050
Air Blower Replacement
$81,050
Air Blower Replacement
$81,050
$81 050
$81,050
23 FC Stacks Replacement
$81,050
23 FC Stacks Replacement
$414,000
23 FC Stacks Replacement
$414,000
$414,000
23 FC Stacks Replacement
$3,910
23 FC Stacks Replacement
$3,910
Salvage Value
$3 910
$3,910
$3,910
Salvage is 10% of Initial Equipment Cost
Water Pump Replacement
Water Pump Replacement
Water Pump Replacement
Water Pump Replacement
Water Pump Replacement
Total Life Cycle Cost
Fuel Cell Seminar 2009
10
12
14
16
18
2
4
6
8
10
12
14
16
18
3
6
9
12
18
20
$3,910
$3,910
$3 910
$3,910
$3,910
$3,910
0.56
0.50
0 44
0.44
0.39
0.35
$2,183
$1,943
$1 729
$1,729
$1,539
$1,370
$16,100
0.89
$14,329
$16,100
0.79
$12,753
$16,100
0.70
$11,350
$16,100
$
,
0.63
$10,101
$
,
$16,100
0.56
$8,990
$16,100
0.50
$8,001
$16,100
0.44
$7,121
$16,100
0.39
$6,338
$16,100
0.35
$5,641
$900 000
$900,000
0 84
0.84
$755 657
$755,657
$900,000
0.70
$634,464
$900,000
0.59
$532,709
$900,000
0.50
$447,272
$900,000
0.35
$315,309
-$400,603
0.31
-$124,910
$10,181,495
Slide 11 of 13
Summary
We have developed and implemented an upper division fuel cell
engineering course where students:
• apply fundamental science to fuel cell applications,
• design, develop and fabricate their own PEM fuel cell,
• test their design through polarization data,
• apply single cell data in the sizing of large fuel cell stacks, and
• demonstrate an integrated understanding of complex processes.
As engineers are increasingly challenged to apply theoretical
principles to complex and multidisciplinary problems, a curriculum
that teaches knowledge integration and system level design across
scales is critical to their future success.
Fuel Cell Seminar 2009
Slide 12 of 13
Acknowledgements
We quite graciously acknowledge:
• Smith College for considering this course as a permanent offering,
• Picker Engineering Program for providing tremendous financial and technical
support in developing this course in the Fall 2008,
• Center for Design and Rapid Prototyping for providing constant access to shop
equipment and support throughout the fabrication phase
Fuel Cell Seminar 2009
Slide 13 of 13
Performance Characterization – Test Systems
Fuel Cell Seminar 2009
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