• Polymer Electrolyte Membrane (PEM) 
• Phosphoric Acid 
• Direct Methanol 
• Alkaline 
• Molten Carbonate 
• Solid Oxide 
• Regenerative (Reversible) 
• Fuel Cell Comparisons 
• Electrochemical reactions of the Fuel Cell types

Polymer Electrolyte Membrane 

Polymer electrolyte membrane (PEM) fuel cells—also called proton exchange membrane fuel cells—deliver high power density and offer the advantages of low weight and volume, compared to other fuel cells. PEM fuel cells use a solid polymer as an electrolyte and porous carbon electrodes containing a platinum catalyst. They need only hydrogen, oxygen from the air, and water to operate and do not require corrosive fluids like some fuel cells. They are typically fueled with pure hydrogen supplied from storage tanks or onboard reformers.

PEM fuel cells are used primarily for transportation applications and some stationary applications. Due to their fast startup time, low sensitivity to orientation, and favorable power-to-weight ratio, PEM fuel cells are particularly suitable for use in passenger vehicles, such as cars and buses. 

A significant barrier to using these fuel cells in vehicles is hydrogen storage. Most fuel cell vehicles (FCVs) powered by pure hydrogen must store the hydrogen onboard as a compressed gas in pressurized tanks. Due to the low energy density of hydrogen, it is difficult to store enough hydrogen onboard to allow vehicles to travel the same distance as gasoline-powered vehicles before refueling, typically 300-400 miles. Higher-density liquid fuels such as methanol, ethanol, natural gas, liquefied petroleum gas, and gasoline can be used for fuel, but the vehicles must have an onboard fuel processor to reform the methanol to hydrogen. This increases costs and maintenance requirements. The reformer also releases carbon dioxide (a greenhouse gas), though less than that emitted from current gasoline-powered engines. 

Phosphoric Acid 

Phosphoric acid fuel cells use liquid phosphoric acid as an electrolyte—the acid is contained in a Teflon-bonded silicon carbide matrix—and porous carbon electrodes containing a platinum catalyst. The chemical reactions that take place in the cell are shown in the diagram to the right. 

PAFCs are more tolerant of impurities in the reformate than PEM cells, which are easily "poisoned" by carbon monoxide—carbon monoxide binds to the platinum catalyst at the anode, decreasing the fuel cell's efficiency. They are 85 percent efficient when used for the co-generation of electricity and heat, but less efficient at generating electricity alone (37 to 42 percent). This is only slightly more efficient than combustion-based power plants, which typically operate at 33 to 35 percent efficiency. PAFCs are also less powerful than other fuel cells, given the same weight and volume. As a result, these fuel cells are typically large and heavy. PAFCs are also expensive. Like PEM fuel cells, PAFCs require an expensive platinum catalyst, which raises the cost of the fuel cell. A typical phosphoric acid fuel cell costs between $4,000 and $4,500 per kilowatt to operate. 

Direct Methanol 

Direct methanol fuel cell technology is relatively new compared to that of fuel cells powered by pure hydrogen, and research and development are roughly 3-4 years behind that of other fuel cell types. 

Alkaline 

Alkaline fuel cells (AFCs) were one of the first fuel cell technologies developed, and they were the first type widely used in the U.S. space program to produce electrical energy and water onboard spacecraft. These fuel cells use a solution of potassium hydroxide in water as the electrolyte and can use a variety of non-precious metals as a catalyst at the anode and cathode. High-temperature AFCs operate at temperatures between 100ºC and 250ºC (212ºF and 482ºF). However, more-recent AFC designs operate at lower temperatures of roughly 23ºC to 70ºC (74ºF to 158ºF). 

The disadvantage of this fuel cell type is that it is easily poisoned by carbon dioxide (CO2). In fact, even the small amount of CO2 in the air can affect the cell's operation, making it necessary to purify both the hydrogen and oxygen used in the cell. This purification process is costly. Susceptibility to poisoning also affects the cell's lifetime (the amount of time before it must be replaced), further adding to cost. 

Cost is less of a factor for remote locations such as space or under the sea. However, to effectively compete in most mainstream commercial markets, these fuel cells will have to become more cost effective. AFC stacks have been shown to maintain sufficiently stable operation for more than 8,000 operating hours. To be economically viable in large-scale utility applications, these fuel cells need to reach operating times exceeding 40,000 hours. This is possibly the most significant obstacle in commercializing this fuel cell technology.

Molten Carbonate 

Molten carbonate fuel cells (MCFCs) are currently being developed for natural gas and coal-based power plants for electrical utility, industrial, and military applications. MCFCs are high-temperature fuel cells that use an electrolyte composed of a molten carbonate salt mixture suspended in a porous, chemically inert ceramic lithium aluminum oxide (LiAlO2) matrix. Since they operate at extremely high temperatures of 650ºC (roughly 1,200ºF) and above, non-precious metals can be used as catalysts at the anode and cathode, reducing costs.

Unlike alkaline, phosphoric acid, and polymer electrolyte membrane fuel cells, MCFCs don't require an external reformer to convert more energy-dense fuels to hydrogen. Due to the high temperatures at which they operate, these fuels are converted to hydrogen within the fuel cell itself by a process called internal reforming, which also reduces cost. 

Molten carbonate fuel cells are not prone to carbon monoxide or carbon dioxide "poisoning"—they can even use carbon oxides as fuel—making them more attractive for fueling with gases made from coal. Although they are more resistant to impurities than other fuel cell types, scientists are looking for ways to make MCFCs resistant enough to impurities from coal, such as sulfur and particulates. 

The primary disadvantage of current MCFC technology is durability. The high temperatures at which these cells operate and the corrosive electrolyte used accelerate component breakdown and corrosion, decreasing cell life. Scientists are currently exploring corrosion-resistant materials for components as well as fuel cell designs that increase cell life without decreasing performance. 

Solid Oxide 

Solid oxide fuel cells (SOFCs) use a hard, non-porous ceramic compound as the electrolyte. Since the electrolyte is a solid, the cells do not have to be constructed in the plate-like configuration typical of other fuel cell types. SOFCs are expected to be around 50-60 percent efficient at converting fuel to electricity. In applications designed to capture and utilize the system's waste heat (co-generation), overall fuel use efficiencies could top 80-85 percent.

SOFCs are also the most sulfur-resistant fuel cell type; they can tolerate several orders of magnitude more sulfur than other cell types. In addition, they are not poisoned by carbon monoxide (CO), which can even be used as fuel. This allows SOFCs to use gases made from coal. 

High-temperature operation has disadvantages. It results in a slow startup and requires significant thermal shielding to retain heat and protect personnel, which may be acceptable for utility applications but not for transportation and small portable applications. The high operating temperatures also place stringent durability requirements on materials. The development of low-cost materials with high durability at cell operating temperatures is the key technical challenge facing this technology. 

Scientists are currently exploring the potential for developing lower-temperature SOFCs operating at or below 800ºC that have fewer durability problems and cost less. Lower-temperature SOFCs produce less electrical power, however, and stack materials that will function in this lower temperature range have not been identified. 

Regenerative (Reversible) Fuel Cells