Cell Stacking

The actual flotation phenomenon occurs in flotation cells usually arranged in batteries (12) and in industrial plants and individual cells can be any size from a few to 30 m in volume. Column cells have become popular, particularly in the separation of very fine particles in the minerals industry and coUoidal precipitates in environmental appHcations. Such cells can vary from 3 to 9 m in height and have circular or rectangular cross sections of 0.3 to 1.5 m wide. They essentially simulate a number of conventional cells stacked up on top of one another (Fig. 3). Microbubble flotation is a variant of column flotation, where gas bubbles are consistently in the range of 10—50 p.m. 

Fig. 3. Schematics of gas manifolds for MCFC stacks (a) internally manifolded fuel cell stack (b) externally manifolded fuel cell stack.

A subsidiary of lEC and Toshiba Corp. called ONSI Corp. was formed for the commercial development, production, and marketing of packaged PAEC power plants of up to 1-MW capacities. ONSI is commercially manufacturing 200-kW PAEC systems for use in a PC25 power plant. The power plants are manufactured in a highly automated faciHty, using robotic techniques to assemble the repeating electrode, bipolar separator, etc, units into the fuel cell stack. 

A possible problem of sealing the electrolyte path is found in the Foreman and Veatch cell. This can be avoided by placing the cells in a vessel. The best known example of this is the Beck and Guthke cell shown in Figure 8 (74). The cell consists of a stack of circular bipolar electrodes in which the electrolyte is fed to the center and flows radially out. Synthesis experience using this cell at BASF has been described (76). This cell exhibits problems of current by-pass at the inner and outer edge of the disk cells. Where this has become a serious problem, insulator edges have been fitted. The cell stack has parallel electrolyte flow however, it is not readily adaptable to divided cell operation. 

Fig. 9. Monsanto stack cell, (a), Side view of cell stack (b), top view of flow paths across cells (78).

Like M( F(7s, S()F(7s can integrate fuel reforming within the fuel cell stack, A prereformer converts a substantial amount of the natural gas using waste heat from the fuel cell, (iornpoiinds containing sulfur (e,g, thiophene, which is cornrnonlv added to natural gas as an odorant) must be removed before the reformer. Typically, a hvdrodesiilfii-rizer combined with a zinc oxide absorber is used. 

As of 2000, it also looks as though more and more electric utilities are becoming interested in fuel cell stacks as local microgenerators to top up power from large power stations, without the need for long-distance transmission of electricity and its attendant expense and power losses. 

Fuel cell is an ambiguous term because, although the conversion occurs inside a fuel cell, these cells need to be stacked together, in a fuel cell stack, to produce useful output. In addition, various ancillai y devices are required to operate the stack properly, and these components make up the rest of the fuel cell system. In this article, fuel cell will be taken to mean fuel cell system (i.e., a complete standalone device that generates net power). 

Fuel cell stack voltage varies with external load. During low current operation, the cathode s activation overpotential slows the reaction, and this reduces the voltage. At high power, there is a limitation on how quickly the various fluids can enter and... 

Fuel Cell Stack with end-plates and connections... 

A complete fuel cell system, even when operating on pure hydrogen, is quite complex because, like most engines, a fuel cell stack cannot produce power without functioning air, fuel, thermal, and electrical systems. Figure 3 illustrates the major elements of a complete system. It is important to understand that the sub-systems are not only critical from an operational standpoint, but also have a major effect on system economics since they account for the majority of the fuel cell system cost. 

Alternatively, the fuel cell stack can he operated at ambient pressure. Although this simplifies the system considerably and raises overall efficiency, it docs reduce stack power and increase thermal management challenges. 

Heat rejection is only one aspect of thermal management. Thermal integration is vital for optimizing fuel cell system efficiency, cost, volume and weight. Other critical tasks, depending on the fuel cell, are water recovery (from fuel cell stack to fuel processor) and freeze-thaw management. 

Electrical management, or power conditioning, of fuel cell output is often essential because the fuel cell voltage is always dc and may not be at a suitable level. For stationai y applications, an inverter is needed for conversion to ac, while in cases where dc voltage is acceptable, a dc-dc converter maybe needed to adjust to the load voltage. In electric vehicles, for example, a combination of dc-dc conversion followed by inversion may be necessary to interface the fuel cell stack to a, 100 V ac motor. 

Fuel cells can run on fuels other than hydrogen. In the direct methanol fuel cell (DMFC), a dilute methanol solution ( 3%) is fed directly into the anode, and a multistep process causes the liberation of protons and electrons together with conversion to water and carbon dioxide. Because no fuel processor is required, the system is conceptually vei"y attractive. However, the multistep process is understandably less rapid than the simpler hydrogen reaction, and this causes the direct methanol fuel cell stack to produce less power and to need more catalyst. 

A variety of complexes exists in solid or liquid state at ambient temperature, in the range required for battery operation. Liquid polybromine phases are preferred since they enable storage of the active material externally to the electrochemical cell stack in a tank, hence enhancing the... 

Both share more or less the same merits but also the same disadvantages. The beneficial properties are high OCV (2.12 and 1.85 V respectively) flexibility in design (because the active chemicals are mainly stored in tanks outside the (usually bipolar) cell stack) no problems with zinc deposition in the charging cycle because it works under nearly ideal conditions (perfect mass transport by electrolyte convection, carbon substrates [52]) self-discharge by chemical attack of the acid on the deposited zinc may be ignored because the stack runs dry in the standby mode and use of relatively cheap construction materials (polymers) and reactants. 

Fuel cell technology probably offers a new emerging area for polyheterocyclic polymers as membranes. Fuel cells are interesting in transport applications and are now being evaluated in Chicago in transit buses with a 275-hp engine working with three 13 kW Ballard fuel cell stacks. 

FIGURE 5.40 Bill ions of unit cells stack together to recreate the smooth faces of the crystal of sodium chloride seen in this micrograph. The first inset shows some of... 

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