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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

Iiimiimiiiniiumu 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: ýýl acýo 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: 2 "d A3pvi2 , 200

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.

1

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".

ii

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.

III

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

V

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

Vlll

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

ix

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

1

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.

2

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

3

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.

4

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).

5

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.

6

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.

7

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

8

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.

9

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.

10