A MINI DISSOLVED FUEL ALKALINE FUEL CELL

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DESIGN, CONSTRUCTION AND EXPERIMENTAL WORK OF A

MINI DISSOLVED FUEL AT.

T.

TNE FUEL CELL FOR NUCRO -

ELECTRONIC

& MECHANICAL

SIGNAL APPLICATION

Gan Yong Kiong

TP 318 Y55

2004

Bachelor of Engineering with Honours

(Mechanical Engineering and Manufacturing Systems) 2004

P. KHIDMAT MAKLUMATAKADEMIK UNIMAS

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1000125583 DESIGN, CONSTRUCTION AND EXPERIMENTAL WORK OF

A MINI DISSOLVED FUEL ALKALINE FUEL CELL

FOR MICRO-ELECTRONIC & MECHANICAL SIGNAL APPLICATION

Gan Yong Kiong

This project is submitted in partial fulfillment of

the requirements for the degree of Bachelor of Engineering with Honours (Mechanical Engineering and Manufacturing System)

Faculty of Engineering

UNIVERSITI MALAYSIA SARAWAK 2004

Borang Penyerahan Projek Tahun Akhir Universiti Malaysia Sarawak

R13a

BORANG PENGESAHAN STATUS PROJEK TAHUN AKHIR Judul: DESIGN, CONSTRUCTION AND EXPERIMENTAL WORK OF A

MINI-DISSOLVED FUEL ALKALINE FUEL CELL FOR

MICRO-ELECTRONIC AND MECHANICAL SIGNAL APPLICATION

SESI PENGAJIAN: 2003/2004

Saya GAN YONG KIONG

(HURUF BESAR)

mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:

1. _{Tesis adalah hakmilik Universiti Malaysia Sarawak.}

2. _{Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan untuk} tujuan pengajian sahaja.

3. _{Membuat pendigitan untuk membangunkan Pangkalan Data Kandungan Tempatan.}

4. _{Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan tesis ini} sebagai bahan pertukaran antara institusi pengajian tinggi.

5. _{"" Sila tandakan} () di kotak yang berkenaan

F",

SULIT

TERHAD

TAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan stau kepentingan

Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/

badan di mana penyelidikan dijalankan).

Disahkan _oleh

(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)

Alamat tetap: No. 315, Lot 2285, Jalan _{Semaba, Batu 5,}

93250 Kuching, Sarawak.

Dr. Mohammad Omar Bin Abdullah Nama Penyelia

Tarikh: -; ý /'' 1''ý L ? 'ý Tarikh:

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CATATAN * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda.

++ ]ika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis perlu dikelaskan sebagai SULIT dan TERHAD.

This Final Year Project report entitled "Design, Construction and Experimental Work of A Mini Dissolved Fuel Alkaline Fuel Cell For Micro-Electronic And Mechanical Signal Application" was prepared by GAN YONG KIONG as a partial fulfillment of the requirement for the Bachelor Degree of Engineering (Hons. ) Mechanical Engineering and Manufacturing System program is hereby read and approved by:

-ý... (ý

Dr. Mohd Omar bin Abdullah

(Final Year Project Supervisor)

Date:

Dedicated to my dearest parents and my lovely girlfriend

ACKNOWLEDGEMENT

First of all, I wish to express my grateful to my supervisor Dr. Mohammad Omar Bin Abdullah who had assisted me by giving many advisable instructions and supporting materials when I encountered any problem in this final year project. Furthermore, I would like to thank Mr. Masri Zaini, my Mechanical Laboratory Technician and all the staffs of Engineering Faculty in UNIMAS. The flexibility, good working environment and well attendance provided in UNIMAS had making me so unforgettable.

Secondly, I would like to express my appreciation to all my beloved mechanical and manufacturing lecturers in UNIMAS for teaching me many useful subjects which enable me to complete this project.

Last but not least, I would like to thank my course mates especially Hon Kah Jui, and friends who direct and indirectly helping me to complete my final year project in UNIMAS.

ABSTRAK

"Fuel Cell" dapat menjanakan kuasa elektrik tanpa sebarang proses pembakaran dalaman. Proses penjanaan "Fuel Cell" tidak mengeluarkan bunyi, getaran serta mencemarkan udara. Dalam projek tahun akhir ini, satu mini "Dissolved Fuel Alkaline Fuel Cell" telah direka bentuk, dibina dan ujian makmal dijalankan. Tujuan pelaksaaan ini ialah untuk mereka bentuk dan membina satu mini "Fuel Cell" yang boleh menghasilkan amaun elektrik yang sederhana kecil. Voltan yang dihasilkan telah terbukti untuk penggunaan bagi mikro-elektronik dan aplikasi isyarat mekanikal contohnya dalam kes ini ialah "Pico Oscilloscope". Oleh itu, is dapat digunakan sebagai penunjuk kepada isyarat yang tidak diingini seperti gangguan yang terjana semasa disambungkan dengan "Pico Oscilloscope".

ABSTRACT

Fuel cells produce electricity without involving combustion; they generate no noise, vibration nor air pollution. In the current project, a mini dissolved fuel alkaline fuel cell has been designed, constructed and laboratory tested. The purpose of the exercise is to design and construct a mini fuel cell for generating small amount of electricity. The voltage generated had been proven to be useful for micro-electronic and mechanical signal application i. e. the Pico Oscilloscope. As a result, it can be as an indicator of any unwanted signal or disturbance as well as interference when connected to a Pico Oscilloscope.

pusat KhidmaýYSiSAýp * UNIYERSI'Tlý ý. ý ýý LIST OF CONTENTS CONTENTS ACKNOWLEDGEMENT ABSTRAK ABSTRACT LIST OF CONTENTS LIST OF TABLES LIST OF FIGURES

CHAPTER 1- INTRODUCTION OF FUEL CELL 1.1 _{Introduction of Fuel Cell}

1.2 _{Principle of Fuel Cell} 1.3 _{Type of Fuel Cells}

1.4 Objectives

1.5 _{Methodology of Research} 1.6 Problems Statement

CHAPTER 2- LITERATURE REVIEWS 2.1 Introduction PAGE i ii iii iv vii Vlll 1 1

3

6 7

9

10 iv

CHAPTER 3- BACKGROUND STUDY 3.1 _{Introduction of Alkaline Fuel Cell}

3.2 _{Type of Alkaline Fuel Cells}

3.2.1 Alkaline Fuel Cell with Mobile Electrolyte 3.2.2 Alkaline Fuel Cell with Static Electrolyte 3.2.3 Dissolved Fuel Alkaline Fuel Cell

, 26

29 32 34

3.3 Operating Temperature And Pressure 37

CHAPTER 4- DESIGN, CONSTRUCTION AND EXPERIMENTAL WORK

4.1 Introduction 40

4.2 _{Design of Dissolved Fuel Alkaline Fuel Cell} 40

4.3 Construction Procedures 41

4.4 The Electrolyte Preparation Procedures

Procedures of preparing 1,2 and 4Mol of Potassium 42 4.4.1

Hydroxide aqueous

(KOH)

4.4.2 Experimental Procedures 43 The Application Procedures of Single Dissolved Fuel 44 4.4.3

Alkaline Fuel Cell

4.5 Precautions 46

4.6 Assumptions 48

CHAPTER 5- EXPERIMENTAL RESULTS, CALCULATION & DISCUSSION

5.1 Experimental Results 49

5.2 Calculation 59

5.3 Discussion 62

CHAPTER 6- CONCLUSIONS AND RECOMMEMDATIONS 6.1 Conclusion 6.2 Recommendations 67 69 REFERENCES 71 APPENDICES V1

LIST OF TABLES

TABLES

2.1 Proton Exchange Membrane Fuel Cells (PEMFC) 2.2 Direct Methanol Fuel Cells (DMFC)

2.3 Phosphoric Acid Fuel Cells (PAFC)

2.4

Molten Carbonate

Fuel Cell (MCFC)

2.5

Solid Oxide Fuel Cells (SOFC)

2.6 _{Alkaline Fuel Cell (AFC)}

PAGE 12 14 16

18

21 23 vii

LIST OF FIGURES

FIGURES _PAGE

1.1 Work Chart 8

3.1 _{Alkaline Fuel Cell that used in Apollo mission} 27 3.2 _{Electrode reactions and charge flow for an alkaline fuel cell. Electrons} 28

flow from anode to cathode, but conventional positive current flow from cathode and anode.

3.3 _{Diagram of an alkaline fuel cell with mobile electrolyte. 31} The electrolyte also serves as the fuel cell coolant.

3.4 _{Alkaline electrolyte fuel cell with static electrolyte held in matrix. 33} This system uses pure oxygen instead of air.

3.5

_{2D View of Dissolved fuel alkaline fuel cell}

₃₅

3.6 _{This simple, very low cost cell is of the "dissolved fuel" type. It is 36} designed for use in education and for demonstration, and works with

methanol, hydrazine and other liquid fuels.

3.7 _{Operating parameters for certain alkaline electrolyte fuel cells. [Data from 37} Warshay & Prokopius (1990) and Strasser (1990)] The pressure figure are

approximate, since there is usually small differences between each reactant gas

3.8 _{Graphs showing the change in vapour pressure with temperature for 39} different concentration of KOH solution. (Taken from Fuel Cell System

Explained, James Larminie, 2000)

4.1

_{3D View of Dissolved Fuel Alkaline Fuel Cell Design}

₄₀

5.1

_{Experiment I (KOH 1 M)- Voltage Versus Time For Single Cell}

₄₉

5.2

Experiment

2 (KOH 2M)- Voltage Versus Time For Single Cell

₅₀

5.3 Experiment 3 (KOH 4M)- Voltage Versus Time For Single Cell ₅₁ 5.4 _{Average Result of Experiment 1,2 &3- Voltage Versus Time 52} 5.5 Voltage Versus KOH Concentration ₅₃ 5.6 Experiment Result (KOH 4M)- Voltage Versus Time For 2 Single Cell 54

Connected in Series

5.7 Experiment Result (KOH 4M)- Voltage Versus Time For 6 Single Cell 55 Connected in Series

5.8 _{Voltage Versus Number of Dissolved Fuel Alkaline Fuel Cell} 56 5.9 _{Result of the Application Experiment before Disturbance Signal} 57 5.10 _{Result of the Application Experiment after Disturbance Signal} 58

CHAPTER 1

INTRODUCTION OF FUEL CELL

1.1 _{Introduction of Fuel Cell}

Fuel Cell is an electrochemical device that used to produce electricity without any internal combustion. As a result, it is considerably a device that generates no noise and vibration. In term of science-fiction fantasy, it is an efficient, nonpolluting power source or environmental friendly device.

1.2 _{Principle of Fuel Cell}

In general, fuel cell could generate electricity continuously by separating the fuel normally hydrogen gas via a catalyst'. Besides, it was considered as an energy conversion device which can transform the energy stored in the fuel into electricity and heat. And the fuel is oxidized electrochemically without burning in flame. The basic principle of any type of fuel cell is the protons from the hydrogen gas flow through a membrane and then combines with oxygen to form water by assistance of catalyst. The electrons are flowing from the anode (a negative electrode that repels electrons) to cathode (a positive electrode that attracts electrons) through the external circuit to create electricity. It is usually the pure hydrogen and oxygen as the reactants are supplied to the cell to produce electrical energy. Thus, a fuel cell can produce

electricity continuously as long as the oxygen and hydrogen are supplied to the cell.

In more particular form of explanation, a fuel cell is basically consisted of an anode, an electrolyte membrane in the middle, and a cathode. The fuel hydrogen will flow into the fuel cell anode, and is separated by a platinum coating on anode which then becomes protons, ion hydroxide and electrons. There is an electrolyte membrane in the middle which only allows the protons to pass through the membrane to the cathode of the cell. The electrons will flow through an external circuit in the form of electric current. Thus, the flowing electron will generate a DC (direct current) voltage. In the mean time, the gas oxygen in cathode will combine with protons and electrons to produce pure water and heat.

This individual fuel cell could be then combined into a fuel cell "stack". The number

of fuel cells in the stack determines

the overall voltage, and the surface area of each cell

determines

_{the overall current. Multiplying the voltage by the current yields the total electrical}

power generated.

1.3 _{Type of Fuel Cells}

Several types of fuel cells had been designed and used up all around the world. The following is the basic classification of a few types of fuel cell:

a) Alkaline Fuel Cells (AFC)

Alkaline Fuel Cells (AFC) was the first type of fuel cell that used for manned

space applications and it produces drinking water and electricity. Potassium hydroxide (KOH) solution is particular as the electrolyte in the cell. The operating temperature is within the range of 100°C -250°C. The Output of this type of cell is ranges from 300 watts (W) to 5 kilowatts (kW).

b)

Proton Exchange Membrane Fuel Cells (PEM)

This is the most common type of fuel cell that used in transportation field. Normally it will operate at the one kW per liter of volumetric powered level at a temperature under 100°C (212 °F). A PEM contains an electrolyte that is a layer of solid polymer (usually a sulfuric acid polymer) that allows protons to be transmitted from one face to the other (Gottesfeld and Zawadinski, 1998). PEM requires hydrogen and oxygen as its inputs. The cell outputs generally

range from 50 to 250 kW.

c) Solid Oxide Fuel Cell (SOFC)

This type of fuel cell can be used at high power consumption machines such as industrial and large scale central electricity generating stations. The output of this type fuel cell is up to 100KW. A hard ceramic compound of metal (such as calcium or zirconium) oxides (chemically, gas oxygen) as their electrolyte is basically used in this particular fuel cell. Reformer is not necessary used to extract hydrogen from fuel due to the high operating temperature that can be as high as 1000°C.

d)

Molten Carbonate Fuel Cell (MCFC)

A liquid solution of lithium, sodium and/or potassium carbonates, soaked in a matrix for an electrolyte is basically used in this kind of fuel cell. They promise high fuel-to-electricity efficiencies, about 60% normally or 85% with cogeneration, and operate at about 1,200 °F or 650° C. Units with output up to 2 megawatts (MW) have been constructed, and designs exist for units up to

100 MW. The nickel electrode-catalysts of molten carbonate fuel cells are inexpensive compared to those used in other cells.

e) Phosphoric Acid Fuel Cells (PAFC)

Phosphoric acid is used in this fuel cell as the electrolyte to produce electricity. Existing PAFC has outputs up to 200 kW, and 1 MW units have been tested. Its efficiency ranges from 40 to 80 % and operating temperature is around 150 to 200° C (about 300 to 400° F). Disadvantages of PAF include: it uses expensive platinum as a catalyst, it generates low current and power comparably to other types of fuel cells, and it generally has a large size and weight.

f) Direct Methanol Fuel Cells (DMFC)

This kind of cells is quiet similar to Proton Exchange Membrane Fuel Cells (PEM). Polymer membrane is basically as the electrolyte in both of the fuel cell. In DMFC, the anode catalyst itself draws the hydrogen from the liquid methanol, eliminating the need for a fuel reformer. Methanol is used as electrolyte instead of hydrogen. The Operating temperatures of direct methanol fuel cells are in the same range as PEM fuel cells - 50 to 100°C (122 to 212°F).

1.4 Objectives

The main objective for this final year project is the design, construction and experimental work on a mini alkaline fuel cell for micro-electronic and mechanical application. Besides, there are some others research objectives that need to achieve throughout this project as following:

a) Understanding the fundamental properties and the history of fuel cell. b) Literature review

c) Theoretical study/analytical method based on the reading

d) Design of a mini fuel cell (Dissolved Fuel Alkaline Fuel Cell).

e) Construction of a mini fuel cell prototype (Dissolved Fuel Alkaline Fuel Cell) f) Measurement of data, data collection and experimenting of the prototype built. g) Parametric study and optimization of the influence parameters.

1.5 _{Methodology of Research}

Below are some methods that have been carrying out in order to achieve this final year project:

a) Preliminary study and literature review.

- To understand the working principle of a fuel cell.

- To learn out various types of fuel cell and its elements.

- To understand the calculation of the efficiency and output voltage of a fuel cell.

b) Parametric Experiments

- To find some parameters that influences most of the efficiency in the fuel cell system.

c) Theoretical Calculations

-

To calculate the theoretical output voltage and efficiency of the fuel cell

d) Analytical method and theoretical study

- To analyze

the experimental

result based

on the theoretical study.

-

Find out the causes

and effects of these differences.

e) Work chart

- The work chart for this research is given in Figure 1.1 below.

Study & Research

Searching, analysis, and compiling the information about fuel cells.

i

System Concept

Types of electrodes, electrolyte, its fuels and operating temperature

ý

Design and Experiment

Construct and Experimental work on the method to minimize the failure of fuel cell.

No

Experiment & simulation

Operate the fuel cell in various types of

condition and the measurement data is collected

Yes

Analysis + Calculations

Analysis is done based on the results obtained from both experiments and theory (calculations)

A Prefect Fuel Cell (The final product)

Figure 1.1 Work Chart

1.6 Problems Statement

1) Cost - The high capital cost for fuel cells is a largest problem contributing to the development of fuel cell technology in Malaysia. In order for fuel cells to compete realistically with contemporary power generation technology, they must become more competitive from the standpoint of both capital and installed cost (the cost per kilowatt required to purchase and install a power system). For this project to design and construct as well as doing experimental work on a mini fuel cell in UNIMAS, the cost is a major problem in order to get high efficient electrode such as platinum.

2) Technology & Facilities - In Malaysia, this newer technology had came across a problem which there are no any suitable facilities such as a machine which can use to construct a bipolar plate for the best contact for producing high efficiency of fuel cell.

3) Lack Of Information - It is difficult to find any related information about Fuel Cell Technology in Malaysia. Furthermore, there are no any related consultancies that can assist me when doing this project. The information that had been taken from references such as Web site and reference books are all from oversea countries which are not in complete and still in fundamental research.

CHAPTER 2

LITERATURE REVIEWS

2.1 Introduction

This literature review is taken from several journals, books, articles as well as web site retrieved about fuel cells technology over the past few years. There are six different types of fuel cell technologies available -Alkaline Fuel Cells, Proton exchange Membrane Fuel cells, Solid Oxide Fuel Cells, Molten Carbonate Fuel Cells, Phosphoric Acid Fuel Cells and Direct Methanol Fuel Cells.

Some main points regarding to the physical and chemical properties of the various fuel cells, their advantages and disadvantages, applications are summarized in Table 2.1 to Table 2.6.

The literature had suggested that new potential technologies are now opening to offer alternative solution so as to meet the energy market needs. Perhaps, if the high cost of the materials used to construct fuel cell can be further reduced, fuel cells could become one of the main energy sources over the coming decades. Therefore, research and development should be carried out to find out the most efficiency technologies that can be use to construct a fuel cell.