06213 – Hydrogen Fuel Cell Test Station Preliminary Design Review February 24 th, 2006

Group Members Team Leader: Chad Byler (ME) Mechanical Press & Fuel Flow: Dan Upton (ME), Brian Holzberger (ME), & Sean Ashman (ME) Electrical Sensors & Power Supply: Dennis Farley (EE) & Steve Yang (EE) Data Acquisition & Software: Shan Hu (CE) Process and Safety: Corey Reynolds (ISE) Project Mentor: Dr. Bailey(ME)

Project Sponsor Nanopower Research Laboratory –Funding Dr. Rafaelle – Department of Physics at RIT –Customer Contact Cory Cress – PhD student in Microsystems

Subsystem Topics Layering of Fuel Cell Mechanical Assembly Process Heating of the Fuel Cell Humidification of gas Exhaust/Back Pressure Control Electrical Sensors and Power Supply Heating elements Layout of program logic Data Acquisition Budget But First…

Cathode Reactions: 1/2 O 2 + 2e-O -2 ion Porous gas diffusion layer 2e- - Reaction Products (H 2 O only) Air/O 2 H2H2 O 2 Catalyst Layers Active Material: Platinum or Platinum/Ruthenium Thin solid hydrated Membrane as an Electrolyte Anode Reactions: H2H2 2H + + 2e - H + ion proton 2H + + O -2 ion H2OH2O PEM = Low temperature (80 o C) hydrogen fuel cell with polymer electrolyte and precious metal electrodes Fuel Cell Operation Cathode = gas diffusion layer + catalyst layer Anode = gas diffusion layer + catalyst layer

Location - Fuel Cell Assembly

Electrode Plate –Raised center portion to ensure maximum pressure of electrode with nano- tube catalyst. –Three different sizes for reaction area.

Fuel Cell Assembly Nano-tube catalyst PEM

Fuel Cell Stack

Location - Fuel Cell Assembly

Mechanical Assembly Ease of Operation Backing Plate rotates to allow assembly on horizontal surface. Pegs hold fuel cell assembly in place until it can be compressed. Repeatability Use of power screw in combination with a pressure sensor or a torque wrench will allow for a repeatable mechanical pressure applied to the fuel cell. The use of the mechanical assembly gives the ability to encapsulate the fuel cell and regulate the temperature.

Mechanical Assembly Animation

Power Screw Calculations Internal Pressure120psi Surface Area2.64in^2 Max Force316.8lb tan( ) must be less than the coefficient of friction in order to be postitive locking Screw Type: 1/2" - 10 LeadL=0.1in Root Dia.Dr=Dr=0.45in tan( )=L/(  *D r ) tan( )=  = 0.3 Coefficient of friction steel to steel tan( ) < , therefore the screw is self locking T=F*D r /2*((L+  *  *D r )/(  *D r -  *L) T =26.999Lb/in T =2.25Lb/ft

Location - Fuel Cell Heating

Fuel Cell Heating

Steady-State Temperature Distribution without Insulation (O 2 side) -Shows need for cell Insulation -With insulation all cell components reach 80°C at S.S.

Location - Humidification

Gas Humidification Method H 2 or O 2 inlet in base Bubble up through water Temperature of water controls the humidity of exit gas Resistive heater used to heat water Water temperature monitored to ensure safe heating

Expansion Valve Contains: Pressure Sensor Humidity Sensor Temperature Sensor Pros: Interchangeable Non-Intrusive to flow

Location – Back Pressure

Exhaust/Pressure Regulation Constant Upstream Pressure Bleeds overpressure Ability to dry PEM Bubbles prove flow Water seal provides no upstream airflow

Overview Schematic

Important Sensor Parameters National Semiconductor LM34 Temperature Sensor: –Maximum Current Draw: 90μA –Maximum Output Current: 160μA –Maximum Output Voltage: 6V –Accuracy: 0.555°C –Operating range: -45°C to 150°C Honeywell HIH-3610 Humidity Sensor: –Maximum Current Draw: 200μA –Maximum Output Current: 100μA –Maximum Output Voltage: 3.9V –Accuracy: 2% Relative Humidity –Operating Range: 0 to 100% Relative Humidity in -40°C to 85°C

Important Sensor Parameters Cont. Honeywell ASDX100G24R Gas Pressure Sensor : –Maximum Current Draw: 10mA –Maximum Output Current: 2mA –Maximum Output Voltage: 5V –Accuracy: 2% of Operating range –Operating range: 0 to 100 PSI in 0°C to 85°C Honeywell TD4A Liquid Temperature Sensor: –Maximum Current Draw: 26.3mA –Maximum Output Current: 1mA –Maximum Output Voltage: 2.5V –Accuracy: 1°C –Operating Range: -40°C to 150°C

Worst Case Analysis Maximum Current Draw: For Heaters: 0.83A maximum per heater * 3 = 2.5A maximum For LM34 Temperature Sensors: 90μA * 3 = 270μA For HIH-3610 Humidity Sensors: 200μA * 2 = 400μA For ASDX100G24R Gas Pressure Sensor: 10mA * 2 = 20mA For Underwater Temp Sensor: 26.3mA * 3 = 78.9mA Total Current Draw = A

Heater Analysis Joules are needed to heat the water in our largest tank, L, from 20°C to 80°C –Using an Omega CIR-3016 (100 Watt) –Therefore, the longest time needed to heat the water is 9.7 minutes

Omega Immersion Cartridge Heater 150 Watt Heater Incoloy ® Sheath - Efficient heat transfer - Sealed tip - Corrosion resistant. Special Insulation - High dielectric strength - Faster heat-up time Small size - 1/2 inch diameter Water Heating Source

Water Temperature Sensor TD4A - Liquid Temperature Sensor RTD (resistance temperature detector) sensors Respond rapidly to temperature changes Accurate to ± 0.7 °C at 20 °C Temp. range: -40 °C to 150 °C (-40 °F to 302 °F) Supply Voltage/Current: 10Vdc, 1mA typ. Linear outputs.

Power Controllers Power-IO Solid State Relays Surge protection DC control input: 4-32VDC Operating Voltage: V Max Load Current: 25A Affordable price (under $40)

Software Design Flowchart I Start User input desired testing parameters (Temp/Humidity/Pressure/Duration) and the max pressure, max temperature should be allowed Test Temperature sensor Is temp sensor ok? Show error message! Terminate the program! End Set up testing environments Start testing? All desired testing parameters are satisfied? Show violation message! Timer counts End test? Record testing results Continue without adjustment? N Y Y Y Y Y N N N N

Software Design Flowchart II Set up testing environments Heat H 2 and O 2 water tank Exceed max water temp? Show warning! Desired gas humidity? Y N End set up testing environments Display Gas Temp (H 2 and O 2 ) Display water temperature Display gas humidity (H 2 and O 2 ) Desired temp? Display PEM temperature N Y Y N Y Desired gas pressure? Adjust pressure of H 2 and O 2 gas Display pressure of H 2 and O 2 gas line Heat PEM water tank Exceed max water temp? N Y N Dangerous level? Shut Off! Y N Show warning! Dangerous level? Shut Off! Y N Exceed max gas pressure? Y N Show warning! Dangerous level? Shut Off! Y N

USB-1208LS + LabVIEW™ drivers USB-based DAQ module ( $ x 2 + $ 49.00) 8 Single-Ended or 4 Differential Analog Inputs 12-bit (Diff.)/11-bit (SE) Resolution Two 10-bit Analog Outputs One 32-bit External Event Counter 16 Digital I/O Lines External Trigger Input Sample Rate 1.2KS/s

Design Process Original Project Objectives 1.Flow Systems 2.H2 & O2 Electrolysis and Delivery 3.Temperature Systems 4.Pressure Systems 5.Humidity Systems 6.Mechanical Assembly (Optional) Current Project Objectives 1.Mechanical Assembly 2.H2 & O2 Creation and Delivery 3.Temperature Systems 4.Pressure Systems 5.Humidity Systems Flow System Electrolysis System H2 & O2 Tanks Flow System Major Project Scope Changes Scope Change Impact Research Concept Generation Concept Selection Feasibility Analysis Time

Project Schedule

Budget

Questions