Understanding Impacts of Catalyst-Layer Thickness on Fuel-Cell Performance via Mathematical Modeling

Abstract

In this article, a two-dimensional, multiphase, transient model is introduced and used to explore the impact of catalyst-layer thickness on performance. In particular, the tradeoffs between water production and removal through transport or evaporation are highlighted, with a focus on low-temperature performance. For the latter, a case study of an ultra-thin catalyst layer is undergone to explore how various material properties alter the steady-state and startup performance of a cell. The findings provide understanding and guidance to optimize fuel-cell performance with thin electrodes. Polymer-electrolyte fuel cells (PEFCs) have emerged as a promising zero-emission technology for energy conversion due to their thermodynamic efficiency and high energy density.1,2 However, to reduce cost, the amount of precious metal catalyst needs to be lowered. The most common strategy for such catalyst thrifting is to fabricate thinner catalyst layers. The prototypical example of this approach is the nanostructured thin-film (NSTF) electrode, which has several advantages compared to standard carbon-supported Pt electrodes.2 These stateof-the art electrodes have demonstrated improved chemical stability, durability and desired specific power and activity, at the same time having high Pt mass activities. 2,3 Common to these and other lowloaded electrodes are the issues associated with water management in thinner electrodes. Typically, thinner electrodes are susceptible to severe flooding due to their inherently low water capacity and perhaps lack of hydrophobic zones. Such phenomena are particularly pronounced when PEFCs operate at lower temperatures or during startup.Recently, several studies reported water-management mitigation strategies for thinner electrodes including modification of operating conditions and/or component morphologies to ensure successful startup and operation at low temperatures. For example, for NSTF electrodes, Steinbach et al.4,5 reported a novel water-management scheme of increasing the pressure on the cathode to drive water to the anode; coupled with a different anode design, the limiting current density at low temperatures increased by a factor of four. Kongkanand et al. 6,7 demonstrated that water removal and storage capacity of the NSTF electrode can be significantly enhanced by placing an additional Pt/C layer between the electrode and microporous layer. The various empirical findings of NSTF as well as traditional supported thin electrodes 8 can be much better understood by examining the various tradeoffs engendered and complications arising from the use of thin catalyst layers.Currently, the transport mechanisms of water removal behind possible mitigation strategies for thin electrodes are not well understood. In terms of modeling, both pore-scale and continuum models have been generated, although only the latter are germane to understanding cell water and thermal management. 9 Examples of continuum models include bilayer models, such as the one developed by Sinha et al. 10 with a membrane and wat...

A Mixed Wettability Pore Size Distribution Based Mathematical Model for Analyzing Two-Phase Flow in Porous Electrodes

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