ROFCC

Financing contract no.: PD146 / 2018

Project No.: PN III/PN-III-P1-1.2-PCCDI-2017-0194

Project implementation period: 12.03.2018-12.11.2020


Hydrogen energy revolution driver – fuel cells, on the way from research towards production by mitigation of main technological barriers – ROFCC


Abstract

Fuel cell is unanimously considered the core of the hydrogen –based energy revolution. It promises to impact environmental and economic issues facing the world every day. Modern lifestyles, high prices for diminishing supplies of fossil fuels, and the environmental impact of energy production have all made alternative power generation technology like fuel cells a necessity. The proposed project is looking to find bridges between several scientific disciplines in order to reduce the main technological barriers which hinder the commercialization of PEM fuel cell at large scale.
Electrochemical energy conversion involves complex developments of materials: due to the close link between electricity flow and corrosion processes, morphological changes, building of resistive layers and exhaustion of catalytically active components, material development for enhanced lifetimes becomes the major challenge in fuel cell basic research and development. At the same time, the topics of low-cost materials and processing have to be additionally tackled in order to achieve acceptable market costs. Advances in the development of new catalysts, new bipolar plates, enhanced solid electrolyte are only few of the foreseen development within the project, based on joining the existing capabilities proved in other topics by the partners. The proposal covers entire range of research from applicative industrial research focused onto optimization materials/processes until experimental development for testing and validation of the production technology including a comprehensive cost analysis on life time.
By connecting the capabilities of several research partners in complementary topics, from physics, chemistry (especially electrochemistry but not only), mechanics, processes automation, etc. the project will bring the fuel cell development technology close to the market and ready to fulfill the requirements of the new hydrogen based chain energy system.

Objectives

The ROFFC project aims to bring fuel cell technology closer to commercialization and ready to meet the new requirements of the hydrogen-based energy chain. The production of fuel cells for power generating units and the reduction of major technological barriers by improving performance, sustainability, and reducing cost is a complex process requiring the interaction of several activities and expertise. Thus, a number of specific objectives were established, namely:
– optimized components regarding the fluid dynamics
– two experimental models for bipolar plates
– one experimental model for a gas diffusion layer.
– the development of catalytic materials with high electrochemical performance for fuel cell electrodes
– new electrolyte polymers
– PEM manufacturing technology laboratory demonstration.
– The development of a semi-automatic assembly system for the fabrication of the power generator (<5kW) using the developed components, followed by testing and validation.
– Developing and implementing an auxiliary supply system for the power generator – „BOP – balance-of-plant”.
– building the first fuel cell power generator, in a commercially available version (TLR5)
– testing protocols for both in-situ characterization of single cells and for the evaluation of fuel cell stacks and systems.
– Validation of fuel cell power generator on a real-life case – testing in the „Passive House” Infrastructure.
– Life cycle cost analysis for fuel cell technology: environmental impact; costs and aspects regarding the technological penetration in the economy.
– Technical penetration analysis in the context of EU energy and climate change strategies.

Results

– Numerical model for two-phase flow in bipolar plates and gas diffusion layers. Report on optimized configurations and properties
– Technical project for bipolar plates.
– Anticorrosive deposition technology for metallic bipolar plates. Report on investigating the various materials deposition for corrosion protection
– Technology for obtaining gas diffusion layers (GDL) by electrospinning with control of density and volume parameters; Experimental model of gas diffusion layer.
– Experimental model for bipolar metal plate with cooling system included
– Experimental model for hybrid bipolar plate with cooling system included
– Report on long-term corrosion resistance of bipolar plates in PEMFC-specific environments. Assessment regarding the electrical contact resistance
– Ex-situ accelerated test protocols
– Report on testing the developed components (BP, GDL) in a reference fuel cell
– Report on the investigation of catalytic materials for hydrogen oxidation
– Report on catalytic materials for the oxidation reduction reaction. Reaction kinetics, stability
– Report on the development of catalytic nanostructures based on graphene functionalized with halogens
– Report on electrochemical characterization of catalysts with low Pt content
– Report and Technology for obtaining mesoporous for electrochemical applications
– Report regarding the catalyst testing. Intercomparison between theoretical and experimental result with validation of the numeric model
– Protocol for testing and electrochemical characterization of the catalysts with low Pt content
– Technology for electrochemical catalysts production
– Experimental model of catalytic nano-structure based on graphene functionalized with halogens
– Experimental model of mesoporous carbon for electrochemical applications
– Experimental model of anode-cathode electrodes on grafenic support
– Report on the identification of new solid polyelectrolytes with applications in electrochemistry
– Technical specification for obtaining polymeric membranes
– Development of a methodology for the production of conductive proton polymer membranes
– Report on analysing the structure-composition-mechanical /thermal properties corellation
– Technology for producing polymeric membranes
– Report on the MEA implementation methodology
– Experimental model of MEA assemblies
– Report on chemical and mechanical degradation testing of polymer membranes
– Protocol for testing the membrane degradation
– Report on the MEA assemblies development and technology validation
– Assembly technology and project for „PEM fuel cell stack”
– Report regarding the influence of the assembly process parameters on the fuel cell operation
– Experimental model of automatic system for assemblying fuel cell stacks <5kW
– Report on testing the automatic system for assemblying fuel cell stacks
– Report on reproducibility and accuracy in fuel cell assemblying proccess
– Model for medium power generator using fuel cell stacks(<5kW)
– BoP project for fuel cell power generators
– Experimental model for auxiliary system for the ROFCC power generator
– BoP test report under various operating conditions
– Technology cost analysis study regarding the hydrogen-based energy generation system.
– Report on testing the power generator of a 5 kW fuel cell for various operating conditions
– Test report of the power generator in a real case –the research Infrastructure – „Passive house”
– Market research study for small and medium power systems based on hydrogen.
– Software-Hardware Demonstrator for fuel cells management – FCM
– Study on life cycle cost and environmental impact analysis.
– Protocol for testing the fuel cell power generator
– Test programs for automotive, stationary and portable applications
– Fuel cell assemblies, small and medium power
– Articles (12)
– Patent applications (7)
– An updated service offer on erris (12)

Elena Carcadea

PhD, Scientific Researcher

National R&D Institute for Cryogenics and Isotopic Technologies – ICSI Rm. Valcea

National Centre for Hydrogen & Fuel Cells

Phone +40.250.732.744/ext 200

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