Electrochemical and chemical catalyst synthesis

Infrastructure for producing fuel cell components and catalysts for chemical and electrochemical processes. This includes the production of polymer electrolyte membranes and the application of electrodes to a carrier or the membrane, which enables the in-house manufacturing of complete membrane electrode assemblies (MEA).

The manufacturing of solid catalysts in small series is particularly relevant for innovative heterogeneous catalytic processes in hydrocarbon processing and hydrogen-related processes. Suitable samples are prepared wet-chemically and/or dry-chemically.

Equipment:

Hot press (Fontijne Vlaardingen Holland TP200)
Automatic Film Applicator (Elcometer 4340)
Spray coater (Sonotek ExactaCoat OP3)
Electro-spinning (Tongli-Tech TL-Pro)
Intensive mixer (Eirich EL1)
Planetary mill (Fritsch Pulverisette 6)
High temperature ovens (…)

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Elcometer 4340 Automatic Film Applicator and 3580 Casting Knife

Elcometer 4340 Automatic Film Applicator is an equipment for preparing a wide variety of product samples including film and membrane preparation. The casting speed can be controlled with various level. The film thickness can be adjusted in 10 micro steps from 0 to 6mm by means of two integrated micrometric screws on Elcometer 3580 Casting Knife.

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TL-Pro Electrospinning Machine

This equipment can use different polymers to prepare electrospun nanofibers. In Fuel Cells application, it can be used for membrane and electrode preparation.

TL-Pro Electrospinning machine is an equipped with:

both positive & negative high voltage supply devices (-20 to 40 kV)
2-channel syringe pump
various spinnerets (single needle, 5-needle, coaxial, side by side, V-shape spinnerets)
various collectors (plate, rotating drum, grooved drum, mandrel, disk collectors)

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Electrochemical catalyst characterization

Rotating-Disc-Electrode (RDE) for ex-situ characterization as well as half-and single cell tests for in-situ characterization of catalysts for electrochemical cells. In detail Long-term properties or degradation effects are characterized in appropriate setups at different operating points.

Equipment:

RDE/RRDE test stands (Gamry / Autolab)
Multichannel single-cell test stand (BaSyTec)
Electrochemical characterization (Zahner IM6ex plus PP240)
Electric loads (Chroma 63306A, Zahner EL300)

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Fuel cell testing/ Automotive test stand for polymer electrolyte fuel cells (Keytech4EV)

Electrochemical characterization and long-term testing:

single fuel cells
short stacks
segmented cells.

Polarization curve measurements, cyclic voltammetry (CV) and linear sweep voltammetry (LSV) are applied for determination of:

the performance of a fuel cell or stack
the electrochemical active surface area
hydrogen crossover
parasitic currents through the membrane

Electrochemical impedance spectroscopy (EIS) is applied to identify certain degradation phenomena and total harmonic distortion analysis (THDA) is applied as a fast in-situ online monitoring technique.
Off-gas CO₂-monitoring and waste water analysis (fluoride/fluorine emission analysis) characterize carbon corrosion and membrane degradation.

Equipment:

Test stand for single cells and short stacks (1 W - 500 W, Greenlight Innovation)
Electrochemical characterization (Zahner Electric IM6ex plus PP240, Metrohm AUTOLAB PGSTAT302N, Gamry Instruments Interface 5000 und 1000)
Segmented cells (S++)
Electric loads (Chroma 63306A, Zahner EL300)
Fluoride ion selective electrode (Xylem Analytics F800)

The test stand for automotive polymer electrolyte fuel cells is designed to test single cells as well as short stacks. The test equipment is capable to conduct measurements with single cells with an active area up to 300 cm² and also short stacks with up to 10 cells. The main features are a load with a current range of up to 600 A, the electrochemical test station for in-situ characterization measurements like impedance spectroscopy and cyclic voltammetry over a wide range of frequencies and sweep rates.

The temperature of the fuel cell system is controlled by a liquid media temperature controller. All conditions like mass flows, humidity and pressure can be controlled. The switch box enables single cell voltage monitoring for short stacks as well as safety shut done procedures in case of undesired events. Remote control and external warning systems are included. The software includes beside a manual mode a process handler mode that provides the possibility to predefine thousands of consecutive process steps.

Therefore, this test stand is ideal for accelerate stress test measurements and can simulate automotive events like hundreds of startup and shut down cycles that normally take months or years in just some hours or days. Also load cycles tests like the ‘New European Driving Cycle’ (NEDC) can be conducted and that makes this test system superior for automotive fuel cell applications.

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PEM Fuel Cell Teststation (G60)

PEM fuel cell test station (type G60) by Greenlight Innovation GmbH for single PEM fuel cell testing including following specifications:

Anode flow: 2 MFCs: Hydrogen, Nitrogen (3 NLPM)
Cathode flow: 2 MFCs: Air/Oxygen switchable (3 NLPM)
Nitrogen purge rotameter
Humidification module (up to 90 °C)
Bypass permits delivery of gas directly to the cell
End-plate heater (2x 2 A max.)
Electrical reheat module (up to 110 °C)
Back pressure control (0-3 Barg)
650 W electronic load bank, up to 1.4 kW, air cooled
Zero volt compensation
Cell voltage monitoring (CVM), 5 channels
Emerald software

The performance of single PEM fuel cells is characterized on laboratory scale by means of electrochemical measurement methods:

polarization curves
cyclic voltammetry
electrochemical impedance spectroscopy

In addition, accelerated stress tests can be performed through rapid and simple modification of various operation parameters via the test station.

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Process gas analysis

Process gas and trace gas analytic systems for in-situ and ex-situ analysis of refinery-, hydrogen- and synthetic gases. Determination by micro gas chromatograph (µGC) or infrared spectrometer in the range of 1 ppm-100% for a wide range of common compounds:

H₂
CO
CO₂
CH₄
C₂-C₆
H₂S
SO₂
etc.

Equipment:

Micro gas chromatograph (Inficon MicroGC 3000A)
Micro gas chromatograph (Inficon Fusion)
Infrared spectrometer (ABB AO2000, LIMAS, URAS)

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Thermogravimetric analysis

Thermogravimetric analysis (TGA), differential scanning calorimetry (DSC) and differential thermal analysis (DTA) can be performed in the range between RT and 1250 °C on inorganic and organic samples. A steam furnace, allows the supply of steam in quantities of up to 10 g/h.

Possible applications are determination of:

decomposition temperatures
melting temperatures
evaporation temperatures
material stability tests
phase transition temperatures.

Equipment:

Thermogravimetric balance (Netzsch STA 449 C Jupiter) including:

TGA, DSC and DTA system
Steam generator (ADrop)

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High-temperature hydrogen and hydrocarbon process analysis

Small- and large-scale lab test benches for the evaluation of high-temperature hydrocarbon- and hydrogen-related processes (up to 1000 °C) from 10 W to 20 kW. Characterization and long-term lifetime testing of catalytic materials, thermal investigation of reactor designs and -materials as well as demonstration at an enlarged scale for process characterization and -development.

Equipment:

Test stands for high-temperature processes (10 W – 20 kW)
Product gas analysis (µGC, iR-spectroscopy)
Condensate analysis (GC/MS)

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Mercury porosimetry

Equipment for the evaluation of the porosity of solids. The analysis comprises of a low and a high pressure step to characterize the pore size distribution within the sample by forcing mercury into the pores. To allow meaningful analyses, the sample has to be resistant towards pressure of up to 400 MPa and needs to be stable in pure Hg. Samples of approx. 0.5g can be tested.

Equipment:

Mercury porosimeter (PASCAL 140/440) with semi-automatic filling station and characterization software

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