FuelCellsWorks

VANCOUVER and TORONTO– Ballard Power Systems (TSX: BLD; NASDAQ: BLDP) and K2 Pure Solutions (K2) today announced that they have finalized a sales agreement for deployment of a clean energy fuel cell power generator to be sited at a K2 Pure Solutions bleach plant in Pittsburg, California. Ballard’s CLEARgen(TM) fuel cell system will convert by-product hydrogen into clean load-following electricity that will partially offset power demand at the state-of-the-art bleach plant.

K2’s vertically integrated plant will generate the highest quality safer produced bleach. For water utilities and other industries, K2’s safer produced bleach provides an alternative to conventionally made bleach, typically manufactured from chlorine transported by railcar.

The CLEARgen(TM) system will utilize by-product hydrogen that would otherwise be burned to generate heat. In supplementing its power requirements with the 163 kilowatt fuel cell generator, K2 Pure Solutions will displace approximately 220 tons of CO2 emissions annually, equivalent to removing almost 40 passenger cars from the road. This initial small-scale installation will be supported by California’s Self Generation Incentive Program (SGIP), which has to date created over 337 megawatts of clean, rebated energy capacity for the state.

David Cynamon, Executive Chairman of K2 Pure Solutions said, “The Ballard fuel cell solution is a great fit with our sustainable energy strategy. By combining our Inherently Safe Technology with Ballard’s CLEARgen(TM) fuel cell solution, we will be able to produce high-quality bleach with nothing more than water, inert salt and affordable, environmentally clean electricity.”

“The CLEARgen(TM) fuel cell system is designed to be scalable to customers’ requirements, from 163 kilowatts to over 10 megawatts. It can offset power demand at industrial process plants, and can also be used in a clean energy storage solution for grid-scale renewable energy projects,” added Michael Goldstein, Ballard’s Chief Commercial Officer. “The Ballard system provides dependable clean power at a lower cost and higher efficiency than any other zero-emission product.”

Ballard’s CLEARgen(TM) fuel cell system converts hydrogen into cost-effective electricity that may be used onsite by the customer or sold back to the grid for use in the community. The agreement between Ballard and K2 Pure Solutions anticipates receipt of a routine air permit exemption for the fuel cell system from the Bay Area Air Quality Management District and a grant from the SGIP, with installation and commissioning planned for completion in early- to mid-2012.

About Ballard Power Systems

Ballard Power Systems (TSX: BLD; NASDAQ: BLDP) provides clean energy fuel cell products enabling optimized power systems for a range of applications. To learn more about Ballard, please visit www.ballard.com.

About K2 Pure Solutions

K2 Pure Solutions manufactures products essential to modern life through environmentally sustainable and Inherently Safe Technology. K2 Pure Solutions was founded by David Cynamon and Howard Brodie, the founders of KIK Custom Products, North America’s largest contract manufacturer of private label household bleach, personal care and household cleaning products. K2 also includes Centre Partners (www.centrepartners.com) among its partners; a leading middle market private equity firm with offices in New York and Los Angeles. David Cynamon and Howard Brodie have partnered with Centre Partners since 1997. For more information visit: www.k2pure.com.

Ceramic Fuel Cells Limited (AIM/ASX: CFU) – a leading developer of high efficiency and low emission electricity generation units for homes and other buildings – today announced its first BlueGen product sale in the United States to one of the United States’ largest energy companies.

Ceramic Fuel Cells will install a BlueGen gas-to-electricity generator at the energy utility’s engineering center in California. The BlueGen unit is scheduled to be installed in September 2010.

Ceramic Fuel Cells’ local partner, California-based Smart Hybrid Systems, Inc., will provide local installation and support services, including integrating the BlueGen unit with thermal and electrical management systems as well as metering equipment. Smart Hybrid Systems, a US energy appliance manufacturer, also plans to develop innovative hybrid fuel cell and energy storage products utilizing the Ceramic Fuel Cells solid oxide fuel cell as the core generator of electricity and heat.

About the size of a dishwasher, BlueGen is the latest breakthrough in small scale electricity generation. BlueGen uses patented fuel cell technology to convert natural gas into electricity and heat with very high efficiency. BlueGen units can generate electricity at a peak electrical efficiency of 60 percent, far higher than any other technology in the large global market for small scale electricity generation. When heat is recovered for hot water, total efficiency is up to 85 percent – twice as efficient as the current power grid.

By generating power close to where it is used, Ceramic Fuel Cells’ products can meet the future demand for low emission electricity without the need for huge investments in electricity transmission and distribution infrastructure.

Brendan Dow, Ceramic Fuel Cells’ Managing Director said: “It is a great achievement for us to have made our first BlueGen sale in the United States, to one of the largest utilities in the country. Together with our existing sales in Europe, Japan and Australia, this sends a strong message about the size of the global markets that Ceramic Fuel Cells is targeting. It is exciting for us that large utilities not only in the USA but throughout the western world are investing seriously in low-emission power generation.”

Since late 2009 Ceramic Fuel Cells has secured orders for 50 BlueGen units from other major utilities and foundation customers in Germany, Switzerland, The Netherlands, the United Kingdom, Japan and Australia, including E.ON Ruhrgas (the largest gas utility in Germany), the German Gas Association, and Osaka Gas (the second largest gas utility in Japan).

Ceramic Fuel Cells is also operating fully integrated power and heating products with leading energy companies E.ON UK (the second largest electricity retailer in the United Kingdom), GdF Suez (the largest gas utility in France) and EWE in Germany.

WALLINGFORD — Proton Energy Systems of Technology Drive is one of two state companies to receive grants to study how the nation uses energy, according a press release announcing the grants.

Proton will work with reserachers at Penn State University to develop an advanced energy storage device inocrporating a fuel cell, that unlike most fuel cells, does not require the use of expensive precious metals such as platinum.

United Technologies Corp. will receive $9 million to develop an air-conditioning system using alternative resources and on other projects.

PROVIDENCE, R.I. — United Natural Foods, Inc. (Nasdaq: UNFI) today announced that the hydrogen fuel cell technology project at its Sarasota, FL distribution center has been successfully completed and is fully operational.  Designed to improve efficiency, productivity and reliability, 65 GenDrive™ fuel cell powered lift trucks have been mobilized at the Sarasota distribution facility.  The conversion of UNFI’s Sarasota lift truck fleet to hydrogen fuel cells is expected to reduce carbon emissions by approximately 132 metric tons annually, an amount equivalent to the annual emissions of 35 automobiles, and is expected to create annual energy savings of approximately 640,000 kilowatt hours.  The project was previously announced on March 12, 2010.

Tom Dziki, Senior Vice President of Sustainable Development, commented, “We’re pleased to successfully complete this project, which retrofitted 36 existing lift trucks to hydrogen fuel cell technology and added 29 new hydrogen fuel cell-powered lift trucks to our fleet.  We are happy to be pioneering the use of this technology in Florida as hydrogen fuel cells not only provide greater productivity and lower operating costs but will be an important component of a clean energy future.”  

As background, a hydrogen fuel cell produces energy by combining hydrogen and oxygen in an electrochemical reaction that yields electricity, heat and water.  Hydrogen is non-toxic, non-poisonous, the lightest of all gases and the most abundant element in the universe.  

UNFI partnered with a number of companies to successfully implement the roll-out, including Plug Power Inc., (Nasdaq: PLUG), Air Products and Chemicals, Inc. (NYSE: APD) and Abel Womack, Inc.

About United Natural Foods

United Natural Foods, Inc. (http://www.unfi.com) carries and distributes more than 60,000 products to more than 17,000 customer locations nationwide. The Company serves a wide variety of retail formats including conventional supermarket chains, natural product superstores, independent retail operators and the food service channel. United Natural Foods, Inc. was ranked by Forbes in 2005 as one of the “Best Managed Companies in America,” ranked by Fortune in 2006 – 2010 as one of its “Most Admired Companies,” winner of the Supermarket News 2008 Sustainability Excellence Award, and recognized by the Nutrition Business Journal for its 2009 Environment and Sustainability Award.

For more information on United Natural Foods, Inc., visit the Company’s website at www.unfi.com.

LATHAM, N.Y. and GREENE, N.Y. — Plug Power Inc. (Nasdaq:PLUG), a leader in providing clean, reliable energy solutions, and The Raymond Corporation, a global provider of material handling solutions, participated in a ribbon cutting event at United Natural Foods, Inc.’s 352,000 square-foot distribution center today. During the tour portion of the event, Plug Power and Raymond demonstrated the seamless integration of Plug Power’s GenDrive™ fuel cell unit into UNFI’s full fleet of Raymond® electric lift trucks.

The ribbon cutting event celebrated UNFI’s commitment to adopt a hydrogen economy at its Sarasota, FL facility. In addition to eliminating time for battery charging, changing and maintenance, UNFI anticipates the use of fuel cells will be a key component in enhancing sustainability goals.

“As North America’s largest organic and natural food distributor, UNFI prides itself in its positive attitude toward building a sustainable future at the local and national levels,” said Andy Marsh, CEO at Plug Power. “It’s quite rewarding for Plug Power, knowing that our GenDrive fuel cell units help UNFI as it continues to achieve operational excellence. UNFI understands the efficiencies that are gained by using alternative energy power solutions, such as Plug Power’s fuel cell technology.”

“UNFI is the first organization to install Raymond’s new fuel cell-compatible orderpicker, which features a 21-inch battery box to easily accommodate the fuel cell,” said Frank Devlin, segment manager for Raymond. “UNFI is able to maximize the uptime of its fleet as the Raymond truck and GenDrive fuel cell maintains constant power in all working environments, specifically cold storage areas.”

The event attracted several VIP guests championing the fuel cell-powered fork lift discussion. Speakers included Thomas Dziki, Senior Vice President of Sustainable Development for UNFI; David Matthews, President, Eastern Region for UNFI; and Shannon Staub, Sarasota County Commissioner, District 3.

The architects of modern fuel cell technology, Plug Power revolutionized the industry with cost-effective power solutions that increase productivity, lower operating costs and reduce carbon footprints. Long-standing relationships with industry leaders forged the path for our key accounts, including Wegmans, Whole Foods, and FedEx Freight.  With more than 1,000 units in the field and over 1.5 million hours of runtime, Plug Power manufactures tomorrow’s incumbent power solutions today. Visit us at www.plugpower.com.

A recently completed preliminary study demonstrated the first hardware simulation of a fuel cell/turbine hybrid with a distributed fuel cell model capable of operating in real-time.  The study described the system level impact of fuel cell load changes and described fuel cell temperature profiles, species concentration gradients, and current density variations over the fuel cell length. 

Significant current density variations were observed at the fuel cell inlet, while sequential temperature variations were greatest at the fuel cell outlet.  The peak temperature gradient increased by 40%.  Fuel cell diffusion losses were greatly impacted during a load transition, changing by as much as 20% over a 3-second period.  Quantifying these expected gradients is essential to specifying stack geometry design and cathode flow control actuator requirements for the fuel cell system in a hybrid.

This study provided the international hybrids research community with a glimpse of distributed fuel cell performance during coupled transient operation and employed the unique capability of the NETL Hyper (hybrid performance) facility. The Hyper facility provides a unique opportunity for researchers to explore issues related to the coupling of fuel cell and gas turbine technologies.

This research was recently presented at the 2010 International Colloquium on Environmentally Preferred Advanced Power Generation.

By Jorn Madslien Business reporter, BBC News, Hethel, Norfolk

The Lotus-built cab is much quicker than diesel-powered versions

The sound of squeaking plastic parts is a minor irritant as the black cab surges into a sharp corner, its body leaning heavily.

Normally, at high speed, the rattling would have been drowned out by a rumbling, whining diesel engine.

But this taxi is different.

This is the first hydrogen-powered London cab, developed to showcase zero exhaust emission vehicles during the 2012 London Olympics.

The taxi has been put together by Lotus, a UK company more famous for its Formula 1 team and for making sports cars such as the Elise.

Long-range electric motoring

From the outside, the taxi looks like any other black cab and it weighs as much too – a whopping 2.6 tonnes.

But driving it at the Lotus test track in Norfolk feels completely different as it accelerates from 0-60mph (0-100km/h) in 15.5 seconds – slow compared with most cars, but a full seven seconds quicker than an ordinary black cab.

Under the taxi’s familiar exterior – within its generous bulk – the truly special bits are hidden.

The back wheels of the taxi are powered by two electric motors – though it is not an electric car in the conventional sense of the term.

Yes, the taxi has a lithium polymer battery that delivers electricity to the electric motors, but this is not its main source of power.

The cab also has a stack of fuel cells that convert energy from hydrogen, which is stored in a tank under the car’s bonnet, into electricity.

The electric motors can be powered by either the fuel cell system, or by the battery, or by a combination of the two.

During braking the battery, which is located in the middle of the taxi under the floor of the cabin, is recharged by two sources:

• surplus electricity created by the fuel cells is sent to the battery
• kinetic energy captured during braking is sent to the battery from the back wheels, via the electric motor.

With two different power sources – fuel cell system and battery – the taxi could be described as a hybrid vehicle, but again, not in the conventional sense of the term, which usually refers to petrol-electric hybrids.

Read Entire Article Here

Hydrogen is considered the fuel of the future. Yet this lightest of the chemical elements can embrittle the metals used in vehicle engineering. The result: components suddenly malfunction and break. A new special laboratory is aiding researchers’ search for hydrogen-compatible metals.

Most likely, there is hardly a soul that cannot recall K.I.T.T. – the legendary talking supercar from the US television series “Knight Rider”. A hydrogen turbo motor fuels the fantasy vehicle and propels it on the chase for the bad guys at over 300 miles an hour. In the future, cars may be equipped with hydrogen propulsion not just in the movies, but in real life as well. In the transportation and energy sectors, hydrogen is viewed as an eventual alternative to the raw materials of fossil-fuel power, such as coal, petroleum and natural gas.

However, for metals like steel, aluminum and magnesium – which are commonly used in automotive and energy technology – hydrogen is not quite ideal. It can make these metals brittle; the ductility of the metal becomes reduced. Its durability deteriorates. This can lead to sudden failure of parts and components. Beside the fuel tank itself, or parts of the fuel cell, but ordinary components like ball bearings could also be affected. These are found not only in the car, but also in almost all industrial machinery.

This lightest of the chemical elements permeates the raw materials of which the vehicle is made not only when fi lling the tank, but also through various manufacturing processes. Hydrogen can infi ltrate the metal lattice through corrosion, or during chromium-plating of car parts. Infi ltration may likewise occur during welding, milling or pressing. The result is always the same: the material may tear or break without warning. Costly repairs are the consequence.

To prevent cracks and breakage in the future, the researchers at the Fraunhofer Institute for Mechanics of Materials IWM in Freiburg are studying hydrogen-induced embrittlement. Their objective: to fi nd materials and manufacturing processes that are compatible with hydrogen. “With our new special laboratory, we are investigating how and at which speed hydrogen migrates through a metal. We are able to detect the points at which the element accumulates in the material, and where it doesn’t,” says Nicholas Winzer, researcher at IWM.

Since the risk potential mostly emanates from the diffusible, and therefore mobile, portion of the hydrogen, it is necessary to separate this from the entire hydrogen content. Researchers can release and simultaneously measure the movable part of the hydrogen by heat treatment, where samples are continuously heated up. In addition, the experts can measure the rate that hydrogen is transported through the metal while simultaneously applying stress to the material samples mechanically. They can determine how the hydrogen in the metal behaves when tension is increased. For this purpose, the scientists use special tensile test equipment that permit simultaneous mechanical loading and infi ltration with hydrogen. Next, they determine how resis- tant the material is.

“In industry, components have to withstand the combined forces of temperature, mechanical stress and hydrogen. With the new special laboratory, we can provide the necessary analytical procedures,” as Winzer explains the special feature of the simultaneous tests.

The researchers use the results from the laboratory tests for computer simulation, with which they calculate the hydrogen embrittlement in the metals. In doing so, they enlist atomic and FEM simulation to investigate the interaction between hydrogen and metal both on an atomic and a macroscopic scale. “Through the combination of special laboratory and simulation tools, we have found out which materials are suitable for hydrogen, and how manufacturing processes can be improved. With this knowledge, we can support companies from the industry,” says Dr. Wulf Pfeiffer, head of the process and materials analysis business unit at IWM.

From last June Aragon (Spain) has a new hydrogen filling station in the region which opens the first hydrogen motorway in the spanish country. Now the motorway from Zaragoza to Huesca (75Km) can be done with an hydrogen vehicle thanks to the new hydrogen station located in Huesca, at Aragon Hydrogen Foundation facilities in Walqa Technology Park. This station added to Expo Hydrogen Filling Station situated in Zaragoza since 2008, when was created for the International Expo “Water and Sustainable Development”, allows to travel between both cities with a fuel cell vehicle.

On 22^nd of June Mr. Nick Reilly, president of GM Europe and Mr. Arturo Aliaga, Regional Industry Minister of Government of Aragon, had driven for the first time this hydrogen motorway on board of a GM HidroGen4 car before they inaugurated the Walqa hydrogen filling station officially at the launch event.

This new Walqa hydrogen filling station belongs to Aragon Hydrogen Foundation who has designed the installation too.  The Aragon Hydrogen Foundation, whose has the direct support of the Government of Aragon, aims to promote hydrogen as energy carrier in general, and in particular, it works to promote new projects based on hydrogen technologies.  

BOTHELL, WA– NEAH Power Systems, Inc., (OTCBB: NPWZ), www.neahpower.com, the Company developing fuel cell based renewable energy, announced today that it is collaborating with a major US Defense Supplier to explore development of unique power solutions for potential customers. The Defense Supplier is a technology and innovation leader specializing in defense, homeland security and other government markets throughout the world. With a history of innovation, the Defense Supplier provides state-of-the-art electronics, mission systems integration and other capabilities in the areas of sensing; effects; and command, control, communications and intelligence systems, as well as a broad range of mission support services. 

“This is further validation of our technology, and we are honored and privileged to work with such an industry leader. The team at NEAH looks forward to providing patented, differentiated power solutions for defense, homeland security, and other applications,” said Dr. Chris D’Couto, President and CEO of NEAH Power Systems.

“We produce a number of systems and components, which could potentially benefit from NEAH Power Systems’ anaerobic fuel cell technology. We would like to work together to explore how NEAH Power Systems’ technology may be applied to complement our solutions for enhanced operation of equipment for our customers,” commented the Vice President of Advanced Technologies for the Defense Supplier.

About NEAH Power
NEAH Power Systems, Inc. (NPWZ) is developing long-lasting, efficient and safe power solutions for the military and for portable electronic devices and off the grid power solutions. NEAH uses a unique, patented, silicon-based design for its micro fuel cells that enable higher power densities, lower cost and compact form-factors.

Further company information can be found at www.neahpower.com.

ITHACA, N.Y. — In the quest for efficient, cost-effective and commercially viable fuel cells, scientists at Cornell University’s Energy Materials Center have discovered a catalyst and catalyst-support combination that could make fuel cells more stable, conk-out free, inexpensive and more resistant to carbon monoxide poisoning. (Journal of the American Chemical Society, July 12, 2010.)

The research, “Highly Stable and CO-Tolerant Pt/Ti0.7W0.3O2 Electrocatalyst for Proton-Exchange Membrane Fuel Cells,” led by Héctor D. Abruña, Cornell professor of Chemistry and Chemical Biology and director of the Energy Materials Center at Cornell (emc2); Francis J. DiSalvo, Cornell professor Chemistry and Chemical Biology; Deli Wang, post doctoral researcher; Chinmayee V. Subban, graduate student; Hongsen Wang, research associate; and Eric Rus, graduate student. Hydrogen fuel cells offer an appealing alternative to gasoline-burning cars: They have the potential to power vehicles for long distances using hydrogen as fuel, mitigate carbon dioxide production and emit only water vapor.

However, fuel cells generally require very pure hydrogen to work. That means that conventional fuels must be stripped of carbon monoxide – a process that is too expensive to make fuel cells commercially viable.

Fuel cells work by electrochemically decomposing fuel instead of burning it, converting energy directly into electricity.

The problem is that platinum and platinum/ruthenium alloys, which are often used as catalysts in PEM (proton exchange membrane) fuel cells, are expensive and easily rendered ineffective by exposure to even low levels of carbon monoxide.

To create a catalyst system that can tolerate more carbon monoxide, Abruña, DiSalvo and colleagues deposited platinum nanoparticles on a support material of titanium oxide with added tungsten to increase its electrical conductivity. Their research shows that the new material works with fuel that contains as much as 2 percent carbon monoxide – a level that is about 2000 times that which typically poisons pure platinum. Also, the material is more stable and less expensive than pure platinum. With the new catalyst, said Abruña, “you can use much less-clean hydrogen, and that’s more cost-effective because hydrogen derived from petroleum has a very high content of carbon monoxide. You need to scrub off the carbon monoxide and it’s very expensive to do that.”

The researchers are now preparing to put the catalyst to the test in real fuel cells. “So far, indications are very good,” Abruña said. In preliminary experiments comparing the new material’s performance with pure platinum, he added, the platinum cell was readily poisoned by carbon monoxide and conked out early. Said Abruña: “But ours was still running like a champ.”

The research was supported by the U.S. Department of Energy and by the Energy Materials Center at Cornell, an Energy Frontier Research Center funded by the Department of Energy.

It was part of a Southern Legislative Conference presentation highlighting the progress and the challenges of hydrogen-fuel research.

Hydrogen fuel is expanding into more niche markets, and South Carolina has a network of experts poised to translate that into more state jobs, according to S.C. Hydrogen & Fuel Cell Alliance Executive Director Shannon Baxter-Clemmons.

The alliance is a public-private partnership that includes more than a dozen companies and schools, including the University of South Carolina, Clemson University and South Carolina State University. The group, which also includes the Savannah River National Laboratory and the South Carolina Research Authority, is collaborating to advance the commercialization of hydrogen and fuel cell technologies.

State taxpayers have chipped in more than $12 million for hydrogen fuel cell efforts, while federal, municipal and private sources have invested an additional $115 million in South Carolina.

The Silverado was an early demonstration model, brought out almost three years ago. Hydrogen fuels a modified internal-combustion engine. The major manufacturers have been experimenting with cars that use hydrogen fuel cells and run like electric cars.

Researcher Scott Greenway of Columbia was standing by the truck Monday, explaining to bystanders how hydrogen is more energy-efficient than gasoline and emits only water vapor.

Mike Sandbrink, a tall, burly Kentucky state trooper who reconstructs accidents, stepped up with a question.

“What happens if this thing gets slammed in the rear end?” Sandbrink asked.

The carbon-fiber tanks have been slammed, dropped, even shot with guns without breaking, Greenway said. They have a valve that lets out the gas when severely bumped, and the hydrogen dissipates in the air in about five minutes.

“We have permission to park this under the Capitol in Columbia,” he said.

Roy Brandon, a downtown tour guide, stepped up and started taking pictures.

“I just like the fact that it’s clean out of the exhaust,” he said.

The hydrogen in the tanks was made from natural gas, a process that emits carbon dioxide, although only half as much as a gasoline engine. Researchers are developing ways to get hydrogen from other sources that don’t pollute, Greenway said.

For example, a solar panel can produce hydrogen that can be stored for power. To demonstrate, Greenway is rigging up solar panels and hydrogen cells at Fort Sumter. When the conversion is complete, probably by the end of the year, the Civil War landmark will run entirely on the sun and hydrogen.

Critics say hydrogen fuel cells are too expensive, are not energy-efficient and that other technologies may offer better solutions. Other obstacles include the storage and distribution of hydrogen.

Still, in a nation looking for alternatives to fossil fuels, hydrogen also is making inroads as backup power for cell-phone towers and for forklifts in manufacturing plants, Greenway said.

“Are the investments we’re making in hydrogen worth it?” he asked. “They’re starting to pay off for us.”

Trulite President Ron Seftick was demonstrating a backup generator that uses hydrogen fuel cells. For example, hospitals will use it to keep ventilators and other machinery running when the electricity goes out. Trulite opened a plant in Columbia this spring. The operation could mean 1,000 direct and spinoff jobs, company and development officials said when the plant was announced several months ago.

The 20-pound KH4 generator runs on a hydrocell about the size of a liter bottle. The hydrocell contains sodium borohydride, a powder that releases hydrogen when water is poured in.

In the quest for efficient, cost-effective and commercially viable fuel cells, scientists at Cornell University’s Energy Materials Center have discovered a catalyst and catalyst-support combination that could make fuel cells more stable, conk-out free, inexpensive and more resistant to carbon monoxide poisoning. (Journal of the American Chemical Society, July 12, 2010.)

The research, “Highly Stable and CO-Tolerant Pt/Ti0.7W0.3O2 Electrocatalyst for Proton-Exchange Membrane Fuel Cells,” led by Héctor D. Abruña, Cornell professor of Chemistry and Chemical Biology and director of the Energy Materials Center at Cornell (emc2); Francis J. DiSalvo, Cornell professor Chemistry and Chemical Biology; Deli Wang, post doctoral researcher; Chinmayee V. Subban, graduate student; Hongsen Wang, research associate; and Eric Rus, graduate student.

Hydrogen fuel cells offer an appealing alternative to gasoline-burning cars: They have the potential to power vehicles for long distances using hydrogen as fuel, mitigate carbon dioxide production and emit only water vapor.

However, fuel cells generally require very pure hydrogen to work. That means that conventional fuels must be stripped of carbon monoxide – a process that is too expensive to make fuel cells commercially viable.

Fuel cells work by electrochemically decomposing fuel instead of burning it, converting energy directly into electricity.

The problem is that platinum and platinum/ruthenium alloys, which are often used as catalysts in PEM (proton exchange membrane) fuel cells, are expensive and easily rendered ineffective by exposure to even low levels of carbon monoxide.

To create a catalyst system that can tolerate more carbon monoxide, Abruña, DiSalvo and colleagues deposited platinum nanoparticles on a support material of titanium oxide with added tungsten to increase its electrical conductivity.

Their research shows that the new material works with fuel that contains as much as 2 percent carbon monoxide – a level that is about 2000 times that which typically poisons pure platinum. Also, the material is more stable and less expensive than pure platinum. With the new catalyst, said Abruña, “you can use much less-clean hydrogen, and that’s more cost-effective because hydrogen derived from petroleum has a very high content of carbon monoxide. You need to scrub off the carbon monoxide and it’s very expensive to do that.”

The researchers are now preparing to put the catalyst to the test in real fuel cells. “So far, indications are very good,” Abruña said.

In preliminary experiments comparing the new material’s performance with pure platinum, he added, the platinum cell was readily poisoned by carbon monoxide and conked out early. Said Abruña: “But ours was still running like a champ.”

The research was supported by the U.S. Department of Energy and by the Energy Materials Center at Cornell, an Energy Frontier Research Center funded by the Department of Energy.

AC Transit fuel cell bus fills up at its onsite hydrogen fueling facility.

The U.S. Department of Energy (DOE) National Renewable Energy Laboratory (NREL) first began evaluating hydrogen-fueled transit buses in 2000 as part of its extensive technology validation efforts. These evaluations are funded by DOE and the U.S. Department of Transportation’s Federal Transit Administration. Over the years, NREL has collected and analyzed data on nine early generation fuel cell buses operated by four transit agencies in the United States.

“The transit industry provides an excellent test-bed for developing and optimizing advanced transportation technologies,” said Leslie Eudy of NREL’s Hydrogen Technologies and Systems Center. “These vehicles log thousands of miles every month, generating lots of data very quickly.”

In 2007, one of the manufacturers replaced the early generation fuel cell power systems in five of the buses with newer systems that featured improvements based on lessons learned during prior operation. According to NREL’s evaluation, these current generation systems show significant improvements in durability and reliability.

“Reliability increased by 21% after the installation of the new fuel cell systems,” Eudy said.

One measure of reliability and durability for the transit industry is “miles between roadcalls.” A roadcall is the failure of an in-service bus that requires it to be replaced on route or causes a significant scheduling delay. NREL data show a substantial increase in fuel cell-related “miles between roadcalls” after the installation of the new fuel cell systems.

As of June 2010, two of the fuel cell systems have accumulated a record number of hours without requiring repair or replacement of single fuel cells or cell stacks—one bus accrued more than 7,000 hours, and another more than 6,000. And, the fuel cells continue to operate at rated power.

“These impressive results demonstrate that fuel cell technologies are indeed proving themselves in real-world applications, offering great promise for our nation’s portfolio of advanced transportation options,” Eudy said.

How does a fuel cell work? 
A fuel cell uses the chemical energy of hydrogen to cleanly and efficiently produce electricity with water and heat as byproducts. To see this process in action, view the fuel cell animation.

Fuel cells are unique in terms of the variety of their potential applications; they can provide energy for systems as large as a utility power station and as small as a laptop computer. A single fuel cell produces approximately 1 volt or less—barely enough electricity for even the smallest applications. To increase the amount of electricity generated, individual fuel cells are combined in series to form a stack. Depending on the application, a fuel cell stack may contain only a few or as many as hundreds of individual cells layered together. This “scalability” makes fuel cells ideal for a wide variety of applications, from laptop computers (50-100 Watts) to homes (1-5 kW), vehicles (50-125 kW), and central power generation (1-200 MW or more).