Cost, fuel cells methods

Recently, rhodium and ruthenium-based carbon-supported sulfide electrocatalysts were synthesized by different established methods and evaluated as ODP cathodic catalysts in a chlorine-saturated hydrochloric acid environment with respect to both economic and industrial considerations [46]. In particular, patented E-TEK methods as well as a non-aqueous method were used to produce binary RhjcSy and Ru Sy in addition, some of the more popular Mo, Co, Rh, and Redoped RuxSy catalysts for acid electrolyte fuel cell ORR applications were also prepared. The roles of both crystallinity and morphology of the electrocatalysts were investigated. Their activity for ORR was compared to state-of-the-art Pt/C and Rh/C systems. The Rh Sy/C, CojcRuyS /C, and Ru Sy/C materials synthesized by the E-TEK methods exhibited appreciable stability and activity for ORR under these conditions. The Ru-based materials showed good depolarizing behavior. Considering that ruthenium is about seven times less expensive than rhodium, these Ru-based electrocatalysts may prove to be a viable low-cost alternative to Rh Sy systems for the ODC HCl electrolysis industry. 

In fuel cell development, the high cost of precious metals has led to ways to lower the platinum content. Methods include raising the activity of the catalyst, so less is needed and finding more stable catalyst structures that do not degrade over time while avoiding reactions that can... 

Figure 13.12. Shares of added value of the individual components of a fuel cell (by the target costing method) and a combustion engine drive system (Schirrmeister et al., 2002).

Despite the advantages offered by CNTs and CNFs, there are still many obstacles (cost, synthesis methods) to overcome to allow large-scale production. Another type of catalyst support material is mesoporous carbon that provides high surface area and conductivity [100, 141]. It can be classified into ordered (OMC) and disordered (DOMC) mesoporous carbon [100], OMCs have been extensively used as catalyst support materials for fuel cells [140,142-146], The large surface area and 3D connected monodis-persed mesospheres facilitate diffusion of the reactants, making them very attractive materials as catalyst supports [100]. 

Investigation of Design and Manufacturing Methods for Low-Cost Fabrication of High Efficiency, High Power Density PEM Fuel Cell Power Plant," prepared by International Fuel Cells, Final Report FCR-11320A, June 10, 1991. 

One method proposed for estimating the cost of fuel cell power plants is to calculate distributive (bulk) costs as a function of the equipment cost using established factors based on conventional generating technologies. When applied in such a way as to compensate for the differences associated with a fuel cell plant, this approach can yield reasonable results. NETL has elected, based on the international prominence of the Association for the Advancement of Cost Engineering (AACE), to utilize this approach in estimating the costs for fuel cell/turbine power plant systems currently under study. 

L.L. Pinkerton, "Express Method for Estimating the Cost of Fuel Cell Plants," 1998 Fuel Cell Seminar, November 16-19, 1998, Palm Springs Convention Center, Palm Springs, California. 

There have been few synthetic reports employing these monomers beyond the Ballard work, most likely as a result of presumed high cost and monomer availability. However, the performance and stability demonstrated by these materials in fuel cells may spur further developments in this area. The above-reported copolymers are believed to be random systems both in the chemical composition of the copolymer backbone and with regard to sulfonic acid attachment. Novel methods have been developed for the controlled polymerization of styrene-based monomers to form block copolymers. If one could create block systems with trifluorostyrene monomers, new morphologies and PEM properties with adequate stability in fuel cell systems might be possible, but the mechanical behavior would need to be demonstrated. 

Many potential applications are under study. Miniature chemical reactors could be used for portable applications in which they provide advantages of rapid startup and shutdown and of increased safety (intensification by requiring only small quantities of hazardous materials). The development of chip-scale chemical and biological analysis systems has the potential to reduce the time and cost associated with conventional laboratory methods. These devices could be used as portable analysis systems for detection of hazardous chemicals in air and water. There is considerable interest in using a microreactor to provide in situ production of hydrogen for small-scale fuel-cell power applications by conducting a reformation reaction from some liquid hydrocarbon raw material (e.g., methanol). 

In the future, if the cost of the fuel cell system approaches 50/kW, the cost of the electrolyzer is also expected to approach a low number (about 125/kW). Such low capital costs for electrolyzer units, together with levelized electricity costs in the neighborhood of 0.02 to 0.03/kWh, would result in a competitive hydrogen cost. It is also estimated that for a photoelectrochemical method to compete, its cost needs to approach 0.04 to 0.05/kWh. The order-of-magnitude reductions in cost for both hydrogen processes are similar. 

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