Faculty of Engineering & Technology

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Analysis of the environmental impact on the design of fuel cells
(2013-08-22) Sibiya, Petros Mandla; Pienaar, H. C. v Z
The air-breathing Direct Methanol Fuel Cell (DMFC) and Zinc Air Fuel Cell (ZAFC)were experimentally studied in a climate chamber in order to investigate the impact of climatic environmental parameters such as varying temperature and relative humidity conditions on their performance. The experimental results presented in the form of polarization curves and discharge characteristic curves indicated that these parameters have a significant effect on the performance of these fuel cells. The results showed that temperature levels below 0ºc are not suitable for the operation of these fuel cells. Instead, it was found that air-breathing DMFC is favored by high temperature conditions while both positive and negative effects were noticed for the air-breathing ZAFC. The results of the varying humidity conditions showed a negative impact on the air-breathing DMFC at a lower temperature level but a performance increase was noticed at a higher temperature level. For air-breathing ZAFC, the effect of humidity on the performance was also found to be influence by the operating temperature. Furthermore, common atmospheric air pollutants such as N20, S02, CO and N02 were experimentally investigated on the air-breathing DMFC and ZAFC. At the concentration of 20 ppm, these air contaminants showed to have a negative effect on the performance of both air-breathing DMFC and ZAFC. For both air-breathing DMFC and ZAFC, performance degradations were found to be irreversible. It is therefore evident from this research that the performance of the air-breathing fuel cell will be affected in an application situated in a highly air-polluted area such as Vaal Triangle or Southern Durban. It is recommended the air-breathing fuel cell design include air filters to counter the day-to-day variations in concentration of air pollutants.
Design and development of a 100 W Proton exchange membrane fuel cell uninterruptible power supply
(2006-01) Du Toit, Johannes Paulus; Pienaar, H. C. v Z.
This study presents the design of a proton exchange membrane fuel cell stack that can be used to replace conventional sources of electrical energy in an uninterruptible power supply system, specifically for use in the telecommunications industry. One of the major concerns regarding the widespread commercialization of fuel cells is the high cost associated with fuel cell components and their manufacturing. A fuel cell design is presented in which existing, low-cost, technologies are used in the manufacture of cell components. For example, printed circuit boards are used in the manufacturing of bipolar flow plates to significantly reduce the cost of fuel cells. The first objective was to design, construct and test a single fuel cell and small fuel cell stack in order to evaluate the use of printed circuit boards in bipolar plate manufacturing. Since the use of copper in a fuel cell environment was found to reduce the lifetime of the cells, the bipolar plates were coated with a protective layer of nickel and chrome. These coatings proved to increase the lifetime of the cells significantly. Power outputs of more than 4 W per cell were achieved. The second objective was to analyze a small fuel cell stack in order to obtain a model for predicting the performance of larger stacks. A mathematical model was developed which was then used to design an electronic circuit equivalent of a fuel cell stack. Both models were adapted to predict the performance of a fuel cell stack containing any number of cells. The models were proven to be able to accurately predict the performance of a fuel cell stack by comparing simulated results with practical performance data. Finally, the circuit equivalent of a fuel cell stack was used to evaluate the capability of a switch mode boost converter to maintain a constant voltage when driven by a fuel cell stack, even under varying load conditions. Simulation results showed the ability of the boost converter to maintain a constant output voltage. The use of supercapacitors as a replacement for batteries as a secondary energy source was also evaluated.
Design and development of a 200 W converter for phosphoric acid fuel cells
(2013-03) Kuyula, Christian Kinsala; Janse van Rensburg, J. F.
“If we think oil is a problem now, just wait 20 years. It’ll be a nightmare.” — Jeremy Rifkin, Foundation of Economic Trends, Washington, D.C., August 2003. This statement harmonises with the reality that human civilisation faces today. As a result, humankind has been forced to look for alternatives to fossil fuels. Among possible solutions, fuel cell (FC) technology has received a lot of attention because of its potential to generate clean energy. Fuel cells have the advantage that they can be used in remote telecommunication sites with no grid connectivity as the majority of telecommunication equipment operates from a DC voltage supply. Power plants based on phosphoric acid fuel cell (PAFC) have been installed worldwide supplying urban areas, shopping centres and medical facilities with electricity, heat and hot water. Although these are facts regarding large scale power plants for on-site use, portable units have been explored as well. Like any other fuel cell, the PAFC output power is highly unregulated leading to a drastic drop in the output voltage with changing load value. Therefore, various DC–DC converter topologies with a wide range of input voltages can be used to regulate the fuel cell voltage to a required DC load. An interleaved synchronous buck converter intended for efficiently stepping down the energy generated by a PAFC was designed and developed. The design is based on the National Semiconductor LM5119 IC. A LM5119 evaluation board was redesigned to meet the requirements for the application. The measurements were performed and it was found that the converter achieved the expectations. The results showed that the converter efficiently stepped down a wide range of input voltages (22 to 46 V) to a regulated 13.8 V while achieving a 93 percent efficiency. The conclusions reached and recommendations for future research are presented.
Design and development of a high performance zinc air fuel cell
(2006-06) Lourens, Dewald; Pienaar, H. C. v Z.
The demand for efficient and environmentally friendly power sources has become a major topic around the world. This research explores the capability of the zinc-air fuel cell to replace conventional power sources for various applications, more specifically telecommunication systems. The research consisted of a theoretical study of the zinc-air fuel cell and its components, as well as their performance characteristics. A zinc-air fuel ce.ll and test rig were built, and the system was tested under various conditions. It was found that the zinc-air fuel cell has an advantage over other fuel cells in that it does not require any expensive materials or noble metals, reducing the overall cost of such a system. The fuel cell showed the potential to power various applications, but problems persisted in the fueling process as well as constant leaking of the aqueous electrolyte.
Design and development of a phosphoric acid fuel cell
(2013-08-21) Pholo, Thapelo; Pienaar, H. C. v Z
Fuel cells are electrochemical devices that convert chemical energy of a fuel cell into electricity at high efficiency without combustion. They are viewed as viable power sources for many applications including automobiles, distributed power generation and portable electronics. This dissertation presents the design and development of a phosphoric acid fuel cell. It deals with the experimental studies on phosphoric acid fuel cells and possible integration in replacing the conventional sources of electrical energy in stand-by power supply systems, particularly for use in the telecommunications industry. The design of a DC-DC converter system is also incorporated into the system. The first objective was to establish performance parameters and past studies on phosphoric acid fuel cells and this research revealed that parameters that affect the system's performance include: reactant gas pressures, mass flow rates as well as the operating temperature. Mathematical models in the literature were studied and verified against the simulation models acquired. The second objective was to design and assemble a single cell in order to analyze the cell's performances as well as the operating parameters in order to obtain a model for predicting and simulating the performance of larger fuel cell stacks. The next objective was to analyse from a set of design equations and construct a small DC-DC converter. The converter was used to boost a small fuel cell voltage and regulate it at a higher voltage level. Finally, the performance characteristics of the developed fuel cell, mathematical and simulation models were evaluated and compared. Simulation results for the models and the converter showing a regulated output voltage are presented. Some recommendations for improved system performance and for further studies are suggested.
Design and development of a remote monitoring system for fuel cells
(2006-07) Komweru, Laetitia; Pienaar, H. C. v Z.
This dissertation presents the design and development of a remote monitoring system (RMS) for polymer electrolyte membrane fuel cells (PEMFC) to facilitate their efficient operation. The RMS consists of a data acquisition system built around the PIC 16F874 microcontroller that communicates with a personal computer (PC) by use of the RS232 serial communication standard, using a simple wired connection between the two. The design also consists of a human machine interface (HMI) developed in Visual Basic 6.0 to provide a platform for display of the monitored parameters in real time. The first objective was to establish performance variables and past studies on PEM fuel cells revealed that variables that affect the system's performance include: fuel and oxidant input pressure and mass flow rates as well as operation temperature and stack hydration. The next objective was to design and develop a data acquisition system (DAS) that could accurately measure the performance variables and convey the data to a PC. This consisted of sensors whose outputs were input into two microcontrollers that were programmed to process the data received and transfer it to the PC. A HMI was developed that provided graphical display of the data as well as options for storage and reviewing the data. The developed system was then tested on a 150Watt PEM fuel cell stack and the data acquisition system was found to reliably capture the fuel cell variables. The HMI provided a real-time display of the data, with alarms indicating when set minimums were exceeded and all data acquired was saved as a Microsoft Excel file. Some recommendations for improved system performance are suggested.
Optimisation of the hydrogen pressure control in a regenerative proton exchange membrane fuel cell
(2012-10-24) Burger, Melanie; Pienaar, H. C. v Z.
Industrial countries, such as South Africa, rely heavily on energy sources to function profitably in today’s economy. Based on the 2008 fossil fuel CO2 emissions South Africa was rated the 13th largest emitting country and also the largest emitting country on the continent of Africa, and is still increasing. It was found that fuel cells can be used to generate electricity and that hydrogen is a promising fuel source. A fuel cell is an energy generation device that uses pure hydrogen (99.999%) and oxygen as a fuel to produce electric power. A regenerative fuel cell is a fuel cell that runs in reverse mode, which consumes electricity and water to produce hydrogen. This research was aimed at designing and constructing an optimised control system to control the hydrogen pressure in a proton exchange membrane regenerative fuel cell. The hydrogen generated by the fuel cell must be stored in order to be used at a later stage to produce electricity. A control system has been designed and constructed to optimise the hydrogen pressure control in a regenerative proton exchange membrane fuel cell. An experiment that was done to optimise the hydrogen system included the effects that the cathode chamber pressure has on the production of hydrogen and the most effective method of supplying hydrogen to a storage tank. The experiment also included the effects of a hydrogen buffer tank on the output hydrogen pressure and if the system can accommodate different output pressures. It was found that the cathode chamber pressure doesn’t need to be controlled because it has no effect on the rate of hydrogen produced. The results also showed that the flow of hydrogen need not to be controlled to be stored in a hydrogen storage tank, the best method is to let the produced hydrogen flow freely into the tank. The hydrogen produced was also confirmed to be 99.999% pure. The system was also tested at different output pressures; the control system successfully regulated these different output pressures.
Optimisation of water, temperature and voltage management on a regenerative fuel cell
(2012-05-31) Van Tonder, Petrus Jacobus Malan; Pienaar, HCvZ
“Never before in peacetime have we faced such serious and widespread shortage of energy” according to John Emerson, an economist and power expert for Chase Manhattan Bank. Many analysts believe that the problem will be temporary, but others believe the energy gap will limit economic growth for years to come. A possible solution to this problem can be fuel cell technology. Fuel cells (FCs) are energy conversion devices that generate electricity from a fuel like hydrogen. The FC however, could also be used in the reverse or regenerative mode to produce hydrogen. The reversible fuel cell (RFC) can produce hydrogen and oxygen by introducing water to the anode electrode chamber, and applying a potential across the anode and cathode. This will cause the decomposition of the water to produce oxygen at the anode side and hydrogen at the cathode side. In order to make this process as efficient as possible several aspects need to be optimised, for example, the operation temperature of the RFC, water management inside the RFC and supply voltage to the RFC. A three cell RFC and its components were constructed. The three cell RFC was chosen owing to technical reasons. The design factors that were taken into consideration were the different types of membranes, electrocatalysts, bipolar plates and flow topologies. A water trap was also designed and constructed to eliminate the water from the hydrogen water mixture due to water crossover within the MEA. In order to optimise the operation of the RFC a number of experiments were done on the RFC. These experiments included the optimal operating voltage, the effect that the temperature has on the production rate of hydrogen, and the effect that the water flow through the RFC has on the production rate of hydrogen. It was found that there is no need to control the water flow through the RFC because it had no effect on the production rate of hydrogen. The results also showed that if the operating temperature of the RFC were increased, the energy it consumes to warm the RFC significantly decreases the efficiency of the whole system. Thus the RFC need not be heated because it consumes significantly more energy to heat the RFC compared to the energy available from the hydrogen produced for later use. The optimised operating voltage for the three cell RFC was found to be 5.05 V. If the voltage were to be increased or decreased the RFC efficiency would decrease.
Technology development of a maximum power point tracker for regenerative fuel cells
(2015-06) Jansen van Rensburg, Neil
Global warming is of increasing concern due to several greenhouse gases. The combustion of fossil fuels is the major contributor to the greenhouse effect. To minimalise this effect, alternative energy sources have to be considered. Alternative energy sources should not only be environmentally friendly, but also renewable and/or sustainable. Two such alternative energy sources are hydrogen and solar energy. The regenerative fuel cell, commonly known as a hydrogen generator, is used to produce hydrogen. The current solar/hydrogen system at the Vaal University of Technology’s Telkom Centre of Excellence makes use of PV array to supply power to an inverter and the inverter is connected to the hydrogen generator. The inverter provides the hydrogen generator with 220VAC. The hydrogen generator has its own power supply unit to convert the AC power back to DC power. This reduces the efficiency of the system because there will be power loss when converting DC power to AC power and back to DC power. The hydrogen generator, however, could be powered directly from a PV array. However, the hydrogen generator needs specific input parameters in order to operate. Three different input voltages with their own current rating are required by the hydrogen generator to operate properly. Thus, a DC-DC power supply unit needs to be designed to be able to output these parameters to the hydrogen generator. It is also important to note that current PV panel efficiency is very low; therefore, the DC-DC power supply unit also needs to extract the maximum available power from the PV array. In order for the DC-DC power supply unit to be able to extract this maximum power, a maximum power point tracking algorithm needs to be implemented into the design. The DC-DC power supply is designed as a switch mode power supply unit. The reason for this is that the efficiency of a switch mode power supply is higher than that of a linear power supply. To reach the objective the following methodology was followed. The first part of the research provided an introduction to PV energy, charge controllers and hydrogen generators. The problem statement is included as well as the purpose of this research and how this research was to be carried out. The second part is the literature review. This includes the background study of algorithms implemented in MPPT’s; it also explains in detail how to design the MPPT DC-DC SMPS. The third part was divided into two sections. The first section is the design, programming and manufacturing of the MPPT DC-DC SMPS. The second section is the simulation of the system as a whole which is the simulation of the PV array connected to the MPPT DC-DC SMPS and the hydrogen generator. The fourth part in the research compared the results obtained in the simulation and practical setup. The last part of the research provided a conclusion along with recommendation made for further research. The simulation results showed that the system works with an efficiency of 40,84%. This is lower than expected but the design can be optimised to increase efficiency. The practical results showed the efficiency to be 38%. The reason for the lower efficiency is the simulation used ideal components and parameters, whereas the practical design has power losses due to the components not being ideal. The design of the DC-DC switch mode power supply, however, indicated that the hydrogen generator could be powered from a PV array without using an inverter, with great success.

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