Lesson 3 - Battery and Fuel Cell Technologies: Concepts

1
Lesson 3 Battery and Fuel Cell Technologies

Concepts
1.
There is a need for alternative fuels to supplement or replace fossil fuels, which are
a limited resource and cause pollution.
2.
Battery electric and fuel cell cars both rely on an electric motor to convert electricity
to mechanical energy to propel the car. Electrochemical reactions are the basis for
both types of automobiles.
3.
Hydrogen gas has been proposed as a potential alternative fuel. Hydrogen is an

energy carrier, it is not a primary energy source the way we consider gasoline.
4.
Fuel cells require hydrogen and oxygen as fuel to produce electricity and water.
5.
Hydrogen does not exist free in nature, and must be isolated in order to use it for
energy production.
6.
Electricity can be used to produce H2 from water in an electrochemical reaction. This

is an inefficient process that requires energy.
7.
Although the use of hydrogen in fuel cells is clean and efficient, the creation of
hydrogen from electricity or fossil fuels is less so.
8.
Fuel cell design affects efficiency.
9.
Fuel cell stacks for transportation or electricity generation often contain hundreds or
thousands of individual cells to get more power out of fuel cells. Cells connected in
series add up their voltages, while cells connected in parallel keep the same
potential (voltage) but can transfer more electrons at a time.
10.
Voltage is a measure of electric potential.
11.
Power, measured in watts or kilowatts (kW), is equal to the product of voltage and
current (amps).
12.
Energy is measured in watt-hours or kilowatt-hours (kW-h), and is a measure of how

much power is produced over a certain period of time (power x time). Our electric
bills are calculated in terms of kW-h.
13.
Efficiency is a measure of the amount of power delivered by a system relative to the

amount of power provided to the system ((power out/power in) x 100%).
Relationship to Guiding Question

Students need to develop an understanding of how a fuel cell operates in order to
evaluate if the technology is a worthwhile component of our transportation energy
future. The activities in this section are designed to give students hands-on experience
with the technical aspects of fuel cell operation.
Copyright 2009 Clarkson University, Office of Educational Partnerships
revised 08/09
www.clarkson.edu/k12
Key Questions
1. What happens in a fuel cell?
2. What happens during electrolysis?
3. What advantage does a fuel cell have over a traditional battery?
4. What are the environmental benefits of a hydrogen fuel cell car, relative to a
fossil fuel combustion engine?
5. How can we determine the efficiency of our fuel cell?
6. How can we improve the performance of our fuel cell?
Student Learning Objectives

Objectives
Standards
Students will be able identify the basic components of a

fuel cell.
Students will be able to describe how a fuel cell operates
and the chemical reactions that take place during
operation.
Students will demonstrate an understanding of the
environmental benefits of hydrogen fuel cells over fossil
fuel combustion systems for transportation energy.
Students will be able to describe 3 applications of
hydrogen fuel cells.
Students will be able to describe some challenges to the
wide-spread application of fuel cells for meeting our
nations energy needs.
Students will be able to analyze their original fuel cell
design and make improvements based on performance.
Students will be able to measure the amount of power
supplied by their model fuel cell.
Students will be able to calculate the efficiency of their
model fuel cell.
Students will be able to describe the chemical reactions
that take place during the electrolysis of water, identifying
which reaction occurs at the cathode and which at the
anode.
Students will be able to state whether electrolysis
produces or consumes energy.
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Students will be able to state the reasons why one would
consider using electrolysis to produce hydrogen.
Students will be able to describe the relationship
between what happens during electrolysis and what
takes place during the operation of a fuel cell.
Background
The main purpose of this lesson is to help students gain a conceptual understanding
of the technical aspects of electric motor cars (batteries or fuel cell to generate
electricity) (components, structure, chemical reactions that take place) and hydrogen
production.
A fuel cell is a device that converts chemical energy into electrical energy. It works
like a battery, but is continually fed with a fuel usually hydrogen. The output
voltage of a fuel cell can be increased by adding cells in series, called stacking.
Fuel cells have many benefits such as higher energy efficiency, less emission of
pollutants and greenhouse gases, and have combined heat and power capabilities.
Some applications of fuel cells include transportation, space missions, stationary
power generation to buildings and remote areas, portable applications such as back
batteries for laptops etc. However, currently the cost, fuel storage, and fuel delivery
have been the main challenges that face fuel cells and are preventing their widescale use.
Electrochemistry Basics
There are a few useful tricks to try to remember the complexities of
electrochemical reactions:
LEO the GERM

o Loss of electrons oxidation
o Gain of electrons reduction
Oxidation the atom goes from a lower oxidation state to a

higher oxidation state. For example, hydrogen gas has a
zero oxidation state, H+ has a +1 oxidation state: 2H2
4H+ + 4e-
Reduction the atom goes to a lower oxidation state. For

example, O2 has a zero oxidation state and the oxygen atom
in water has a -2 oxidation state.
O2 + 4H+ + 4e- 2 H2O
Cathode = a negatively charged electrode that is the source

of electrons entering an electrical device. For the electrolysis
of water, the hydrogen gas is produced at the cathode.
4H2O + 4e- 2H2 + 4OH-
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How does it work?
O2
e-
eeElectric circuit
eH2
Fuel
O2
eH+
H2
From air
e-
H+
Anode
catalyst
H+
H+
H+
O2
O2
H+
Polymer
Electrode
membrane
Cathode
catalyst
H2O
Exhaust
In a typical fuel cell, gas (hydrogen) is fed continuously to the anode (negative
electrode) compartment and an oxidant (e.g. oxygen from the air) is fed continuously
to the cathode (positive electrode) compartment. Electrochemical reactions take
place at the electrodes to produce electric current.
Two key components

Electrodes that catalyze the electrochemical reactions
Electrolyte that facilitates the transfer of hydrogen ions from the anode to
the cathode. In this case the electrolyte is a PEM polymer electrode
membrane. It allows the passage of protons, but not electrons.
Hydrogen enters the fuel cell at the anode (negative electrode) where it is oxidized
into two H+ ions (protons) and 2 electrons for every hydrogen molecule. This is
called an electrochemical reaction. That just means it requires the transfer of
electrons.
2H2 4H+ + 4eThe protons pass through the PEM (electrolyte) to the cathode side of the fuel cell.
The electrons cant pass through the PEM, so instead they pass through the
electrical circuit and through the electric load (e.g., the electric motor on an
automobile) before reaching the cathode (positive electrode). Oxygen enters the
fuel cell at the cathode and combines with the hydrogen ions and the electrons in a
reduction reaction to produce water:
O2 + 4H+ + 4e- 2 H2O
Oxygen is the oxidant in this reaction, it is reduced.
Overall hydrogen and oxygen molecules are the reactants and H2O is the product:
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2H2 + O2 2 H2O
+/ee-
H2
e-
Fuel
Cell
9v
O2
H2
Electrolysis
Cell
O2
(H2O)
H 2O
Anode
e-
Cathode
Anode
Fuel cell: Hydrogen and

oxygen gases flow into the
cell producing water and
electricity.
Cathode
Electrolysis cell: Hydrogen

and oxygen gases produced
when electricity flows through
an electrolyte containing
water.
The fuel cell is the physical structure that makes these electrochemical reactions
happen and captures and utilizes the current generated by electrons as well. This
rapid combination of elements also creates heat (e.g., the process is not 100%
efficient). A PEM fuel cell has an average operating temperature of about 80C
(176F).
A fuel cell differs from a traditional battery because it continues to operate as long as
the fuel and oxidant are supplied to the electrodes. The transfer of ions is the
fundamental chemical process that creates the electrical energy within the fuel cell.
The PEM fuel cell uses hydrogen fuel and oxygen from the air and gives off water as
a waste product. The theoretically maximum voltage that can be produced from the
fuel cell is 1.23 volts. This voltage is the theoretical electrochemical potential of the
reduction half-cell reaction which occurs at the cathode. However, this is impossible
to achieve because of internal resistance, diffusion losses, and voltage losses
manifested as heat.
To define the efficiency of a fuel cell, the 2nd law efficiency is used that relates the
power produced in a fuel cell to the maximum theoretical power produced by
oxidizing the same amount of hydrogen:
% efficiency = 100%
power out
max . power
Assuming that the current is constant, we can use P=IV, to simplify this formula to:
% efficiency = 100%
voltage out
%
max . voltage
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The maximum voltage is 1.23 volts and the actual voltage can be measured with a
multimeter. A typical fuel cell can generate 0.6 0.7v. Thus, the efficiency is
approximately 50-55%.
But driving an automobile requires hundreds of volts, and a single fuel cell can only
produce ~1v. An engineering design question arises - How can fuel cells be
designed to provide the voltage, and therefore power, required to drive a vehicle? A
collection of fuel cells connected together is known as a stack. In order to increase
the voltage available, cells are connected in series. Several hundred fuel cells can
be connected in a stack to provide over two hundred volts in a typical automobile
fuel cell. The newest Honda fuel cell design provides 100kW of power (about 134
hp) to drive their FCX Clarity, the latest H2 car design.
Another possibility for connecting several fuel cells together is a parallel connection.
This type of connection is essentially the same as creating one large cell, so the
voltage would remain at the 0.6-0.7v range, but there would be more surface area
available for the chemical reactions and so there would be the potential for more
electrons to flow, which would provide more current at that voltage. There are
limitations to the size of a single fuel cell. For example, if there is not enough
pressure or volume of H2 flow, the entire area of the fuel cell may not act effectively.
The cell size factor must be considered in design of fuel cell stacks to optimize
efficiency.
Hydrogen Production
Hydrogen is the most abundant element in the universe. Its a component in a wide
variety of compounds (CH4, H2O etc.), but is rarely found in our natural world as H2
the form we need for a FC. Thus, we need to make hydrogen to supply the H2 fuel
required for a FC vehicle. How hydrogen is produced is very important to overall
efficiency and environmental impact of the hydrogen based energy system.
Electrolysis
Electrolysis is one method for producing hydrogen. This is basically the reverse of
what happens in a fuel cell electrolysis uses an electric current passed through an
electrolyte to split H2O into hydrogen and oxygen. (remember a fuel cell combines
hydrogen and oxygen ions to produce an electric current). In our electrolysis
experiment, the electrolyte is a solution of water and salt (sodium chloride or sodium
acetate). When we apply an electrical current to the electrolyte solution we supply
electrons to the system. This electrical energy causes the water (H2O) to
decompose. Hydrogen forms at the anode (negative electrode) and oxygen forms at
the cathode (the positive electrode).
The overall chemical equation for electrolysis is:
energy (electricity) + 2 H2O O2 + 2 H2
At the anode, the water molecules split up into positively charged hydrogen ions
(H+) and oxygen. The electrons are produced at the anode by this oxidation reaction
help to create the external circuit:
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2H2O O2 + 4H+ + 4eAt the cathode, there is an electrical pressure to push electrons from the external
circuit into the water where the water is reduced into hydrogen gas:
4H2O + 4e- 2H2 + 4OHIn the solution, the extra hydrogen ions from the anode and hydroxide ions from the
cathode react to form water. Overall, for the transfer of 4 electrons through the
circuit, 2 molecules of hydrogen gas are created and one molecule of oxygen gas is
created. When doing an electrolysis experiment, it is easy to tell which electrode is
the cathode because twice as much gas (hydrogen) is produced there.
2H2O O2 + 2H2
Electrolysis was the main method for hydrogen production in the U.S. until the
1950s, but currently is not a very widely used method for producing hydrogen
because it is relatively inefficient and can be expensive, depending on the cost of
electricity (only about 4% of all H2 is produced by electrolysis). However, developing
this technology in combination with a renewable energy source (solar, wind, hydro)
offers the chance for a green (environmentally friendly) hydrogen economy and a
true Zero Emission Vehicle (ZEV).
It is important to realize that the process that happens in a fuel cell is similar to but
the reverse of what happens during electrolysis. Hydrogen and oxygen are supplied
to the fuel cell. The elements combine within the fuel cell and produce free
electrons, which leave the anode side and travel through an electric circuit to power
an electrical device before returning to the fuel cell at the cathode side. Thus, while
the electrolysis process uses electrical energy to separate water molecules into
hydrogen and oxygen gases, the fuel cell creates electrical energy by combining
hydrogen and oxygen to form water molecules.
Reforming of Hydrocarbons
Hydrogen can also be produced from hydrocarbons such as methane or gasoline
through a process called reforming. This process has approximately an 80%
efficiency. Worldwide, 48% of hydrogen is produced from natural gas, 30% from oil
(mostly consumed in refineries), 18% from coal, and the remaining (4%) via water
electrolysis.
Commercial bulk hydrogen is usually produced by the steam reforming of natural
gas. High temperature steam (H2O) reacts with methane (CH4) to yield syngas.
CH4 + H2O CO + 3 H2
Additional hydrogen can be recovered through a lower-temperature reaction with the
carbon monoxide:
CO + H2O CO2 + H2
Essentially, the oxygen atom is stripped from the water (steam) to oxidize the
carbon, liberating the hydrogen formerly bound to the carbon and oxygen. Overall,
one molecule of carbon dioxide is formed for every molecule of methane consumed
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in this series of reactions. Thus, the same amount of fossil carbon is produced in this
reaction as is produced by directly combusting the methane.
Hydrogen production can be centralized, distributed or a mixture of both. While
generating hydrogen at centralized energy plants promises higher hydrogen
production efficiency, difficulties in high-volume, long range hydrogen transportation
(due to factors such as hydrogen damage and the ease of hydrogen diffusion
through solid materials) makes electrical energy distribution attractive within a
hydrogen economy. In such a scenario, small regional plants or even local filling
stations could generate hydrogen using energy provided through the electrical
distribution grid or on-site wind or solar power. While hydrogen generation efficiency
is likely to be lower than for centralized hydrogen generation, losses in hydrogen
transport can make such a scheme more efficient in terms of the primary energy
used per kilogram of hydrogen delivered to the end user. The proper balance
between hydrogen distribution and long-distance electrical distribution is one of the
primary questions that arises in the hydrogen economy.
Historical Context:
The fuel cell technology is not as new as you might think! It was initially observed in
1839 by Sir William Grove while he was experimenting with the electrolysis of water.
He reversed the electrolysis process, reacting oxygen with hydrogen to produce
electricity. Ludwig Mond and Charles Langer tried to build the first practical device
in 1889 using air and industrial coal gas. Francis Bacon made improvements to that
model and invented the first successful fuel cell device in 1932. It was a 20horsepower fuel cell-powered tractor. In the late 1950s, NASA explored the use of
fuel cell technology to develop a power source for space travel and, ultimately, in the
space shuttle program and space stations.
Key Terms
Anode: a positively charged electrode by which electrons leave an electrical
device; the electrode at which oxidation occurs.
Catalyst: substance that speeds up the chemical process by lowering the
amount of energy needed to cause the reaction.
Cathode: a negatively charged electrode that is the source of electrons entering
an electrical device; the electrode at which reduction occurs.
Efficiency: a measure of how energy is delivered per unit of energy input to a
system (efficiency = energy out/energy in x 100% OR
efficiency = energy out/max. theoretical energy produced).
Electricity: the flow of electrons in a circuit.
Electrochemical reaction: a reaction that involves the transfer of electrons
among ions and molecules to convert chemical energy to electrical energy (or
vice versus).
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Electrodes: typically metal rods that catalyze the electrochemical reactions. (Al,
Pd, Pt, Cu etc.)
Electrolyte: solution that allows the flow of ions required in the electrochemical
reactions. In a fuel cell, the electrolyte is a PEM polymer electrode membrane
that facilitates the diffusion of the hydrogen ions from the anode to the cathode.
Fuel Cell: the physical structure that facilitates electrochemical reactions to
create electrical energy from chemical energy.
Hydrogen: chemical fuel of a fuel cell flowing through the anode.
Membrane: substance that allows hydrogen and oxygen to pass through while
preventing the diffusion of other molecules or electrons.
Operating temperature: temperature needed for the chemical reactions to occur
(this will depend on the fuel cell type).
Oxidation: change in chemical composition to a higher oxidation state.
Oxygen: chemical fuel of a fuel cell flowing through the cathode.
PEM: proton exchange membrane.
Prototype: small scale model of a real system.
Reduction: an electrochemical reaction that causes a molecule or ion to change
to a lower oxidation state.
Stacking: method of adding fuel cells in series to increase voltage.
Voltage: measure of electric potential of an electrical circuit or device.
ZEV: zero emissions vehicle. A vehicle fueled by an energy source that does
not produce any tailpipe emissions.
Activities:
This series of classes is comprised of 4 basic activities designed to help students
understand 1) how batteries work; 2) how a fuel cell works (two activities); and, 3) how
hydrogen is produced. Students will build and test a battery and two different fuel cell
prototypes. They will calculate the efficiency of their model and then change their
design to try to make improvements and increase the power production. Students will
also perform a short electrolysis experiment to observe what happens as electricity is
used to split water into hydrogen and oxygen gases which is one method of hydrogen
production. The total time for these activities will be about one week.
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Introduction general concepts (1 1.5 days)
Briefly recap from previous activities ask students, based on what theyve
learned so far, do they think electric vehicle (EV) or fuel cell cars are a good
idea? Why or why not? (Weve talked a lot about the need for a change the
problems associated with fossil fuel combustion but what about the batteries or
fuel cells? How reliable are they? How do they work?) Do we need to know
something about how an EV fuel cell operates, in order to decide if its better than
an internal combustion engine? (yes). Over the next week were going to spend
some time now learning about how EVs and fuel cells work.
Provide demonstrations to give basic idea Battery connected to Lego car (built
by instructor), H-Tec fuel cell model car. Key concepts:
o Both have an electric motor that converts electrical energy to
mechanical energy that provides power to the drive train.
Fuel
cell
Electric
energy
H2O
electric
motor (mechanical energy)
Battery
Storage
Electric
energy
Electricity
H2
electric
motor (mechanical energy)
o The electricity sent to the electric motor is generated in the battery of

fuel cell through electrochemical reactions:
Battery from chemical energy stored in chemicals within the

battery (often lead and sulphuric acid). The chemical energy
stored in the battery can be depleted, reducing the power output
of the battery over time. Batteries are recharged by plugging the
batteries into an electric power source.
Fuel cell hydrogen fuel continuously supplied. The fuel cell

can provide power as long as fuel supplied. Hydrogen has to be
provided as fuel at regular intervals (like refilling the vehicle with
gasoline)
o Neither vehicle has any tailpipe emissions of concern.
Introduce basic electrical and electrochemical concepts

o An electrical current is caused by moving free electrons. Free
electrons can move through a conductor but not through an
insulator. Ask the class if they can name some conductors and
insulators. (ex. Conductors: silver, gold, iron, copper. Insulators: glass,
plastic, rubber, wood).
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o Certain materials are less conductive than others. For example, the
human body conducts electricity but copper conducts electricity better.
The human body has more resistance to electrical current than copper
does. Resistance is the opposite of conductance. To prove that the
human body conducts electricity, bring in the touch circuit.
o Have the students pretend that their hand is an electron. Have them
open their hand and move it up and down. Tell them that since their
hand is now a moving electron, they are modeling an electrical current.
Now tell them to put a book on their hand and move it at the same
speed. By putting the book on their hand, they are adding resistance.
In which case did they use more force, with our without the added
resistance? Lead them to the conclusion that if you add more
resistance, you use more force. Electrical force is called voltage.
o Define that most appliances are rated in terms of power, with units of
Watts. How are all of these things related? Give them the following
equations for future reference:
voltage= resistance x current, (V = I x R)
power = voltage x current (P = I x V = V2/R)(R=resistance)
o A common way of generating electricity is by turning a magnet in a coil
(A Lego generator with a Lego LED are a good way to illustrate this
(need a axle on the generator to spin rapidly by hand to spin the
magnets within the generator)). This is how hydro-electric plants,
steam turbines in a coal-fired power plant and wind turbines work.
Demo (or brief activities to do in smaller groups) to show electric circuit using a
battery to supply electric energy
o materials: battery, LED bulb, glass of water (distilled best), copper
wire, and some salt.
Connect anode of the LED to the negative side of the battery
and the cathode to the positive to show that the bulb lights up.
The circuit is completed.
Change the wire to the cathode - submerge the cathode wire of
the LED in the glass of water (you may need to attach longer
wire leads. Run an additional wire from the positive side of the
battery into the water. Observe that the circuit is not completed;
the bulb is not lit. Turn of the lights and have a volunteer start
the shake some salt into the water. The class will see the LED
bulb start to light up and become brighter as more salt is added.
Now explain what is happening.
Distilled (and most tap) water doesnt conduct electricity. When
you dissolve table salt in water, the salt dissolves into positive
sodium ions and negative chorine ions. The more salt you add,
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the more the water conducts. This salt-water is acting as an
electrolyte.
o If you put two dissimilar (differently charged) metals into the electrolyte,
the positive ions will migrate towards one metal and the negative ions
will migrate towards the other metal. If the metals are connected by a
good conductor, a current will flow through the conductor. Show the
potato clock. This is a wet-cell battery because the electrolyte is a
liquid. Another example of a wet-cell battery is a normal car battery. 9
volt, AA, AAA, D, and C batteries are all dry-cell batteries because
the electrolyte is a paste.
o Write on the board these general definitions:
A battery stores electrical energy and is made up of an

electrolyte, a conductor, and two oppositely charged metals. A
battery can be recharged but degrades with each charge. A
used battery is hard to dispose of.
A fuel cell is made up of an electrolyte, a conductor, and two

oppositely charged fluids (liquids or gases). A fuel cell does not
store energy because the fluids need to be constantly fed into
the electrolyte in order to produce electricity. Fuel cells produce
no harmful waste products and indefinitely reparable.
Tell the class that a fuel cell will be described in greater detail later and
tomorrow they each will be building a salt-water battery using dimes
and tin-foil as the dissimilar metals and paper-clips for the conductors.
Batteries for EVs (0.5 - 1 day)
o Complete the Saltwater Battery Activity
Split the class into their groups and hand out the materials
Let them just start to build their batteries, but walk around and make
sure that they arent shorting out the battery by filling the ice-trays too
high. Also make sure the paper clips are making connections to the
dimes and foil.
At the end of class, go over discussion questions and, if theres time,

try stacking all the batteries and see how much voltage they produce.
Be sure to have them try running the motor off the battery. It probably
wont work. This will just add some perspective when motor does end
up working off the fuel cell.
Fuel Cell Basics (1 day)
VERY BRIEFLY Show fuel cell model car again and refresh major components of
car. (use a transparency or powerpoint for this figure)
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sun
electricity
HO
2
HO
2
Electrolysis
Fuel
cell
electricity
Solar cell
motor
Mechanical
energy
Our goal is to understand how the fuel cell works and how we can generate
hydrogen to use as a fuel. Lets look at the fuel cell:
o There is an electric motor in this car so the fuel cell must make
electricity.
o What do we need to move to create the current necessary for
electricity? (We need to move electrons).
o So a Fuel cell must separate electrons from our fuel to create
electricity.
o What is our fuel? Hydrogen.
Use board work and/or fuel cell powerpoint.ppt to explain operation and
electrochemical reactions in a fuel cell at a class-specific level
Show students an example of the fuel cell that they will be building from their kits
show the parts and also the finished fuel cell.
o Pass out activity sheets and fuel cell kits. Have students carefully explore the
kit contents as you go over what the materials are - define the materials used
in the FC and what role each of these materials play (show each material as
you describe what it is):
Membrane electrode assembly (MEA) a combination of a Proton

Exchange Membrane (PEM) and a catalyst (usually platinum). These
are the small black squares in the center of our cell
Proton Exchange Membrane (PEM) electrolyte material (such as

DuPont Nafion) that promotes the passage of protons but blocks
electrons from passing through.
Catalyst A material (such as platinum) that promotes the splitting of

Hydrogen into its component electron and proton.
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Graphite Plates Serve to direct the flow of Hydrogen gas, air, and
exhaust, as well as conduct electricity from the surface of the MEA to
the copper-clad plates.
Copper-clad plates Sturdy, conducting casing for the cell. It protects

the delicate graphite inside while efficiently conducting charge from the
interior of the cell to the terminals (where wires would be hooked)
Silicon gasket (part of MEA assembly) Serves to electrically insulate

the anode from the cathode and prevent leakage of Hydrogen gas from
the grooves in the graphite plate
Anode electrode where the H2 is oxidized to H+ ions and electrons
Cathode electrode where electrons consumed to reduce oxygen to

create water
Demonstrate the layers (order) that the students need to assemble the FC.
Show students the diagram at the back of their activity packet.
Finish assembling the graphite plate fuel cells and test with hydrogen generated
with electrolyzer (Activity PEM Fuel Cells). Total time will depend greatly on the
extent of preparation and preassembly completed by the instructor before class.
Based on experience with students not following instructions closely, it is best to
have the components preassembles layered and one bolt holding layers
together.
Discuss low voltage output (would be 0.6-0.7v in commercial FC). Calculate the
actual efficiency of the fuel cell from measured voltage and theoretical maximum.
Fuel cell testing (1 day)
Review fuel cell components
Discuss results of graphite plate fuel cells. Define specific issues:

o Which side is anode/cathode
o Low power output from fuel cell
o Not a lot of surface area where grooves for gas flow, contributes to low
efficiency of a homemade fuel cell
Discuss - How can a car be powered by fuel cells?
o Single fuel cell no more than 1.23V (1.16 from fueleconomy.gov),
typically 0.6-0.7
o Honda FCX powered by a fuel cell stack
>200V
Several hundred cells together in a stack
Newest design has vertical orientation water drainage.
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80-100 kW (1kW = 1.34 horsepower)
Introduce todays lab test better fuel cells and determine how to best maximize
power from a set of fuel cells rather than just one.
o Show fuel cells and observe to define important component parts and
how they work.
o Introduce concept of maximum voltage per fuel cell, but the need of
much higher voltages for car motors.
o Therefore need to stack fuel cells
Review Ohms law as required and basic series vs. parallel circuits
o P=IV
o Need higher current or voltage or both to increase power
o Circuits in series voltage added, current same through all
o Circuits in parallel current added, voltage drop across each fuel cell
the same
Series circuit
Parallel circuit
LOAD
LOAD
- +
- +
- +
- +
- +
- +
Do activity. Encourage students to explore as much as possible different

combinations of series and parallel configurations to try to maximize power.
o Debrief how well did students do? What was best combination to
maximize power? (draw pictures and review Ohms law).
o Calculate the fuel cell efficiency with the class. How does it compare
to the efficiency of the graphite plate FC? What is the efficiency of the
whole system from Hydrogen production to Fuel Cell output?
In this case, efficiency will be defined as actual energy

output / theoretical maximum (the approximation as a ratio of
voltages does to account for variable current expected in
stacked FCs.
Actual energy = Power x time (time of hydrogen injection);

where P = V2/R (V and R measured with the multimeter)
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Theoretical energy - The energy content of hydrogen being

oxidized is 10.92 J/ml [1]. Multiple this energy content by the
volume of H2 injected.
Debrief key concepts

o Hydrogen fuel into FC
o Power output of the FC can be calculated from measured voltage and
resistance.
o Voltage or current, and therefore power, can be increased with stacked
fuel cells (series circuit voltage added; parallel circuit current
additive)
o Efficiency is determined as a ratio of voltage (in simple systems) or
energy output divided by theoretical maximum.
Where does Hydrogen come from? (1 day)
Discussion - Lets look at the bigger picture look again at the car (show slide):
we are putting hydrogen and oxygen into this system. Where do we get these?
Oxygen, obviously, comes from the air. Where does the hydrogen come from?
o Hydrogen is the most abundant element in the universe. Its a component
in a wide variety of compounds (CH4, H2O etc.), but is rarely found in our
natural world as H2 the form we need for a FC. Thus, we need to make
hydrogen to supply the H2 fuel required for a FC vehicle. How hydrogen is
produced is very important to overall efficiency and environmental impact
of the hydrogen based energy system.
o Show FC model car again ask students to recall how H2 is provided for
the FC car (show schematic transparency if required; the model car uses
a solar panel to generate hydrogen by electrolysis).
Explain basics and importance of electrolysis (save specific equations until after
the activity).
o electrolysis is one method for producing hydrogen (definition). Explain to
the students that electrolysis is basically the reverse of what happens in a
fuel cell electrolysis uses an electric current to split H2O into hydrogen
and oxygen. (remember a fuel cell combines hydrogen and oxygen ions
to produce an electric current).
o Interesting tidbits
In fact, the fuel cell was discovered accidentally in 1839 by Sir

William Grove, when he was experimenting with electrolysis (see
background).
Electrolysis was the main method for hydrogen production in the

U.S. until the 1950s
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17
Currently, it is not a very widely used method for producing

hydrogen because it is relatively inefficient and can be expensive,
depending on the cost of electricity (only about 4% of all H2 is
produced by electrolysis).
Electrolysis demonstration
o Have a working electrolysis setup as a demonstration in the front of the
room, running off of a solar cell (could be the model car). Ask:
where is the electricity coming from to generate hydrogen in this

system? (answer: solar cell).
So, what is the net effect on the environment? (no emissions

produced). In reality, though, we are getting power from the grid to
fuel this system (because we are using a light in the classroom)
and that power is generated from --- what?
Does anyone know the primary energy source for most of our
electricity? (Coal! (U.S.) Actually in NY state we also have a lot of
hydro and nuclear power plants). So, if we look at the whole fuel
cell system and include the production of hydrogen, are we
producing any emissions? YES (through combustion of coal).
This demonstrates that the method for producing the hydrogen

makes a big difference in our overall environmental impact.
Do electrolysis activity.
o Show students the electrolyzer they will construct. Explain the goals of
this part of the activity to actually generate hydrogen from an external
electricity source in this case a battery. NOTE once they get started,
this activity is done on their own in an inquiry mode explain to the
students that you want them to figure out what is happening.
o Probing Questions to ask as students perform activity:
Whats happening at the wires in the water? What do you call the
wires? What do you call the salt solution? What are the bubbles
composed of?
What do you notice about the volumes of the gases produced at

each electrode? Which gas is which?
What is happening to the electrodes? (corrosion) (Note: if it seems

that very little oxygen gas is generated then it is being consumed
at the electrode to oxidize the metal (corrosion). Depending on the
electrode used, you can get rust (Fe(OH)3), Al(OH) 3, or CuO.
Show electrolysis.ppt or use board to better explain the specifics of

electrochemical reaction.
Go through discussion questions on activity sheet.
Revisit project statement
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18
OPTIONAL see hydrogen infrastructure lesson and activity for additional 1-2 day
discussion of what is required to enable the wide spread use of hydrogen fuel cell
vehicles.
Resources
For more information on the different types of fuel cells and operating temperatures visit
the following websites:
http://www.eere.energy.gov/hydrogenandfuelcells/fuelcells/
http://www.fuelcells.org
http://www.epa.gov/fuelcell/basicinfo.htm
For more information about fuel cell and fuel cell activities for the classroom, visit:
http://www.eere.energy.gov/hydrogenandfuelcells/education/classroom.html
Supply list
Graphite Fuel Cells
(see materials list)
Fuel cells
(h-tec Fuel Cell Mini Kit:
http://www.htec.com/html/web/education/english/sub_produkte/brennstoff_brennstoffzellen.asp?id=2
131 (left photo)
Multimeter
Electrolysis Apparatus http://www.htec.com/html/web/education/english/sub_produkte/brennstoff_elektrolyseure.asp?id=21
32 (right photo)
Fresh batteries
Small electronic device such as fan, clock *with voltage low enough so it can be
powered by the homemade fuel cell (need to test beforehand)
Supply of hydrogen with fixtures and flow meter
Resource Files
Activity Saltwater Battery
Activity Electrolytes and Chemical Power (optional)
Activity Building a Fuel Cell.doc
Activity Testing a Fuel Cell.doc
Activity Electrolysis.doc
Powerpoint slides for this lesson: Fuel Cell Powerpoint.ppt; Electrolysis.ppt
FC materials list
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Activity Saltwater Battery

Purpose
In this experiment you will build a multi-cell battery that will be able to power a
calculator. You will plot the battery voltage as a function of battery cells.
Background
Electrical power is (current) x (voltage). Battery cells and fuels can either be stacked
(connected in series) or bundled (connected in parallel). Below is a diagram of
both configurations.
Series: As you stack cells, the voltage increases and the current
remains the same.
-
Parallel: As you bundle cells, the voltage stays the same and the
current increases.
Many appliances need a minimum voltage to run. In this activity we will only be
measuring voltage. The batteries shown above are dry-cell batteries with a paste for
an electrolyte. We will be building a wet-cell battery, with a liquid for an electrolyte
(saltwater). Remember, a battery needs 2 dissimilar metals, an electrolyte, and a
conductor to operate.
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Equipment (per group)
Ice tray
2 cups of tap water
2 tablespoons of salt
15 U.S. dimes
1 foot of Aluminum foil
An inexpensive solar LCD calculator, with the solar panel removed.
15 paper clips
DMM (Digital Multi-Meter) w/ leads
Scotch tape (or any tape thats available)
An empty container
Procedure
1. Fill the empty container with 2 cups of tap water and mix with 2 tablespoons of
salt. Bring this back to your group.
2. Tape the dimes to the inside of each ice tray compartment as shown in the
picture below. Use tape loops so that the tape is only between the dimes and
the ice tray. The dimes are the anodes because they contain 92% copper
which acts as the negative metal. (10 yen pieces work even better)
3. Fold up small squares of tin foil and tape them (with tape loops) to the opposite
sides of the dividers as the dimes. The foil pieces are the cathodes because
they contain aluminum which acts as the positive metal.
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4. You now need to connect your two dissimilar metals (the dime and the foil) with
a conductor. We will use paper clips. You want to make sure that the paper clip
touches both metals. Suggestion: Deform the paper clip in the steps shown
below. Squeeze the deformed paper clip onto the ice-tray divider, making a
tight connection between the dime and the foil.
5. Pour the saltwater slowly into each cell of the ice-tray. You want the water to
touch the dime and/or foil in each cell, but you dont want to fill it to the top.
You dont want water from one cell flowing into another cell.
6. You now have your battery! One cell is saltwater-dime-paperclip-foil-saltwater
(electrolyte-metal#1-conductor-metal#2-electrolyte). How many cells are in
your battery?
________________ cells
7. Draw a schematic below of how the cells in your battery are connected?
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8. Lets test the battery. Set the multi-meter to DC volts and measure the
voltage of the battery. Put the black lead into the saltwater on the negative side
of the battery (anode) and the red lead into the saltwater on the positive side of
the battery (cathode) as shown below.
9.
How much voltage does the battery produce? __________V
10. Is it enough to power the calculator? (try it out)
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Data sheet:
Measure the voltage for just one cell, then two cells, and so on.
Plot the voltage vs. # of cells. Be sure to label each axis.
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Observations
1. What is the minimum voltage needed to power the calculator?
3. Based on the graph, are the cells connected in series or parallel?
4. Bonus: Try connecting your ice-tray battery to another groups ice-tray battery
and see how much voltage you get.
Discussion Questions
5. What are some problems you can see associated with this battery? What are
some problems with batteries in general?
6. What do you think the battery might look like in a few days? What might it look
like in a few weeks?
7. Why is it called an ice-tray battery and not an ice-tray fuel cell?
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Activity Assemble and Test a Fuel Cell

Purpose
Fuel cells are highly efficient and they produce no harmful emissions, making them a
cleaner fuel alternative than the combustion of fossil fuels. When electric energy is
needed to supply power, hydrogen and oxygen are fed to the fuel cell producing
electricity. In order to make good choices about fuel cells, we need to understand the
basics of how they operate by assembling and testing a simple fuel cell.
Equipment
Partially assembled graphite plate fuel cell
Screw fasteners and wing nuts with shrink tube coating
Electrolyzer or H2 gas cylinder for H2 supply
Procedure
1. To save time, the fuel cell has already been assembled for you and we have
discussed how we made these fuel cells. Three screws have been removed so that you
can slide the pieces around and examine the structure of the cell. Please do so and
make observations about the structure of the fuel cell in the space below.
2. Align the pieces by sliding them together to form a cube and attach your binding
posts, screws, washers, and wing nuts. Tighten the screws until they are snug but
dont overdo it. Make sure washers are on the OUTSIDE of the plates, not the interior.
Identify the oxygen and hydrogen entry points.
3. Does it work? Connect it to a hydrogen supply and observe the reading on your
voltmeter. If youre not getting a reading, you may have to adjust the screws a bit.
They should be tight enough to prevent any gas leaks but loose enough to allow air
flow.
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1. What are the basic parts of a fuel cell?
2. How does a fuel cell work?
3. What gases did we use to feed the fuel cell to produce electricity?
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4. Can you name any by-products that may have been produced?
5. Discuss some ways in which hydrogen fuel cells are more environmentally sound
than typical fossil fuel engines. Does this mean that utilizing power derived from
hydrogen fuel cells is harmless to the environment?
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20041206
Fuel Cell Activity Materials List
Double or single-sided copper clad circuit board

Radio Shack part 276-1499. double-sided board 4 x 6 3/8, One piece is
sufficient for making the two endplates (1 per fuel cell)
Graphite sheets
McMaster-Carr part 95715K63. 12x12 graphite sheet (~4 fuel cells) Website:
http://www.mcmaster.com
Silicone rubber sheet
McMaster-Carr part 86435K35. 12x12 and 0.020 thick, with 35A durometer
rating (~4 fuel cells)
Insulated binding posts with banana jacks
Radio Shack part 274-661. (2 per fuel cell)
MEA (Membrane electrode assembly)
Element 1 Power Systems 1.25x1.25 1 watt raw PEMembrane (1 per fuel cell)
Website: http://e1ps.tripod.com/E1PSwebsite/
Screw fasteners, wing-nuts, fiber washers
Local hardware store 10-24 x 1 socket head cap screws, 10-24 wing nuts, fitting
insulating fiber washers (4 of each needed per fuel cell)
Shrink Tubing
Radio Shack or hardware store (~5 in. per fuel cell)
Hose connectors (1/8 diameter)
Small Parts, Inc. Item number SVD-02-01. In-line shutoff valve 1/8 (2 per fuel
cell) Website: http://www.smallparts.com
Silicone rubber adhesive
Local hardware store (~1 tube per class)
Scraping instrument
Small knitting needles
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Activity Testing Fuel Cells

Purpose
In this experiment you will build a mini PEM (Proton Exchange Membrane)
fuel cell and calculate the 2nd law efficiency of the cell. You will connect
the fuel cells as a class in series (and perhaps also in parallel) and test the
voltage to understand the effect of connecting more than one fuel cell. We
may also power a small motor or light with the cells and observe the
reaction to one or more fuel cell(s).
Background
The PEM fuel cell uses Hydrogen and Oxygen (from the air) as fuel and
gives off water as a waste product. The maximum voltage that can be
produced from the fuel cell is 1.23 volts. However, this is almost
impossible to achieve because of internal resistance, diffusion losses, and
voltage losses manifested as heat.
Because the hydrogen (if combusted) usually has a much higher power
than the fuel cell needs, we will not compare power in to power out.
Instead, we will use 2nd law efficiency:
% efficiency =
Power out
100%
max . Power
We can use P=IV, and assume the current, I, stays the same. This
simplifies our formula to:
% efficiency =
Voltage out
100%
max . Voltage
and we know the Max. Voltage is 1.23 volts.
Equipment
h-tec Fuel Cell Mini Kit

multi-meter
syringe
hydrogen (supplied by instructor)
small motor
jumper wire
breadboard (shared as a class for connecting the
fuel cells)
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Procedure
1. Build the Fuel Cell, following the instructions (in English or German, whichever
you prefer). These are sensitive and expensive, so treat delicately!
2. Fill your syringe with Hydrogen from the electrolyzer.
3. Set your multi-meter to measure volts and hold the meter leads to the fuel cell
terminals. Someone else should hold the meter itself, another person should
record the highest voltage, and another person should slowly feed the
hydrogen into one of the small holes on the fuel cell.
4. Try this three times and record your voltages. Do you notice any condensation
on the fuel cell? Where do you think the condensation could come from?
Trial
Voltage
1
2
3
Average
5. Now try connecting your small motor to the fuel cell. Make observations and
record them below.
Fuel Cell Stacking

Now we will try Stacking our fuel cells - The Triple Fuel Cell Stack
Record data and observations in the table provided on the back of this page.
1. Work with two other groups to stack (connect) the fuel cells in series using the
connectors and the solderless breadboard provided. Try two cells first. The
teacher will have prepared syringes with hydrogen. Use the syringes and
coordinate to inject hydrogen into the connected fuel cells at the same time and
at the same slow rate. Make sure to have the multimeter ready to measure the
voltage of your fuel cell stack.
2. Now try connecting three fuel cells in series. Inject hydrogen simultaneously at
the same slow rate. Record the voltage measured in each of three trials.
3. Now connect two fuel cells in parallel. Again, inject hydrogen into the fuel cells
simultaneously using the syringes and record the voltage obtained in three trials.
4. Now three fuel cells in parallel.
5. Connect the stacks a load (such as a motor or light) in order to measure the
current. To measure current, we must connect the load between the multimeter
and the stack, forming one circuit and set the meter to measure milliamps (mA).
Measure the current from both series-connected stack and parallel-connected
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3
stack. Record the readings from three trials below. Also, make observations
about how the load functions (e.g. if the load is a light, is it brighter or dimmer
with the different types of connections).
6. Connect ALL of the groups fuel cells in series. Have them predict how much
total voltage will be produced. When they are ready, someone needs to countdown so that each group is injecting the hydrogen at the same time and at the
same (slow) speed into each fuel cell. Make sure also that everyone starts with
the same volume of hydrogen.
Discussion Questions for Lab Report
1. What is the second-law efficiency of your fuel cell? Use the average value from
the three trials.
2. Discuss the difference between fuel cells connected in series and fuel cells
connected in parallel. Be sure to talk about how the voltage changed with
different circuit configurations, and, if the cells were connected to a load, what
observations you made.
3. Is one type of circuit better than the other? Why or why not?
4. Would it be possible to just make one big fuel cell, instead of stacking many little
ones? What would be the advantage or disadvantage of this approach?
5. Why do we use the theoretical maximum voltage of 1.23V? How do you think
this is determined? What are some reasons why our little PEM fuel cells cannot
achieve this voltage? Hint: think about the type of chemical reactions are
occurring within the fuel cell.
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4
For this activity, you are required to write and hand in a lab report. The report should
look professional and be acceptable as a college (freshman) level report. The format
can be of your own design, but should include the following sections (some are
mandatory).
Introduction (must be included) Briefly describe what the activity is about.
Hypothesis (optional) This is where you would describe your expected outcome.
Procedure (must be included) Describe the steps you took in your investigation
Results (must be included) What you found during your investigation.
Discussion (must be included) Address the discussion questions on the previous
page. The discussion should be written in an essay-like form, not just answers to the
questions. Talk about what you learned, using the questions as a guide. If you have
questions of your own, feel free to include them.
Conclusion (optional, but easy) Summarize the activity, similar to introduction, but
include important points from results and discussion also. Make suggestions for future
investigation.
You are not expected to stress-out about lab reports, which helps no one. You
are expected to spend some time on and invest effort in the assignment. A little
additional research on your own may help in providing a full discussion. If you cant
answer all the questions, its OK, but at least give them all a try.
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5
Data Table
Trial
Series
2 cells
Parallel
3 cells
2 cells
3 cells
1
Voltage V
2
3
Average
1
Current I
(with load)
2
3
Average
Series Stack
Parallel Stack
(bundle)
Observations
(of load, if
connected)
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Activity Hydrogen Production by

Electrolysis
Purpose
With the increased interest in fuel cells as a power source, there has been a related
interest in various methods to produce H2. The production of H2 is a critical component
of the overall fuel cell system. It may impact our ability to develop fuel cell systems for
energy needs.
Electrolysis is one way to generate the hydrogen fuel required for fuel cells. In this
electrochemical reaction, H2O water molecules are split into hydrogen gas (H2) and
oxygen gas (O2) molecules. This activity shows how we can produce hydrogen gas
from water using electricity.
Equipment
1 600 milliliter (mL) beaker
warm water
salt (pinch; adjust as needed)
Direct current (DC) power supply (6 or 9 volt battery)
Solar Cell
2 insulated copper wires with alligator clips (insulation stripped from ends)
2 small plastic graduated cylinders or narrow test tubes
Safety Glasses
Procedure
1) Mix water warm water and salt. Make sure salt is mixed in completely
2) Fill beaker with warm salt water.
3) Fill each graduated cylinder (or test tube) with warm water salt to the brim.
4) Place a finger over each graduated cylinder, flip over and insert the ends
underwater in the beaker.
5) Remove fingers from cylinder ends. The cylinders should have no air in them. If
air gets into them, simply repeat this procedure until there is no air in them.
6) Connect one alligator clip to each terminal of the power source.
7) Bend the exposed ends of the wire into a U shape and insert the ends into the
graduated cylinders (one wire end to each cylinder). MAKE SURE METAL
ENDS DO NOT TOUCH.
8) Observe what happens at the ends of the wires and note the gas collected in the
cylinders
9) Explore variables that affect the rate of hydrogen production. Try changing your
system to make use of the following (remember to formulate a hypothesis about
the change you expect in the H2 production rate).
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2
a. Use a different electricity source (higher voltage battery, batteries in series,
solar cell)
b. Add more salt to the water
10) Answer the concluding questions.
Sketch a diagram of your set-up. Label each wire end as the anode or the cathode.
Describe what you see happening at each wire end when it is submerged in the salt
water. Is there a difference in what is happening, or are they both the same (look
carefully!).
What was the ratio of volumes of the gases you observed the graduated cylinders?
Which gas do you think is which and why?
Write the chemical equations for what is happening at the two different wire ends:
The anode:
The cathode:
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If 20 molecules of water are split, how many molecules of hydrogen and how many
molecules of oxygen will be produced?
Why did you put the salt in the water? What happens when we add more salt?
What if we used a stronger or weaker (higher or lower voltage) battery? Would you
see more or less bubbles being produced compared to the unit powered by this
power source? Explain why they were different.
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Lesson Plan Hydrogen Infrastructure

Background
So far in our systems analysis we have considered the methods used to produce the
hydrogen fuel, as well as the technology of the hydrogen fuel cell car itself. Students
will now look at other issues surrounding the feasibility of the fuel cell car, including
those associated with hydrogen delivery and refueling options, safety issues, consumer
convenience, and so on.
One thing that must be considered is the number and location of hydrogen filling
stations. The current hydrogen fuel cell car can carry enough hydrogen to travel about
300 miles. Thus, the consumer must be constantly aware of his fuel level and the
location of the nearest filling station. In rural areas, fuel must be available within
reasonable distances so that people will not have to drive excessive distances out of
their way just to refuel.
Another issue is how much hydrogen needs to be available. This clearly depends on
how many hydrogen fuel cell cars are in operation. There are currently studies being
done that are based on certain percentages of the U.S. vehicle fleet being converted to
hydrogen fuel cells. One estimate is that even in the early stages of implementation,
nearly 300 hydrogen stations will be required along the U.S. interstate highway system
(http://www1.eere.energy.gov/hydrogenandfuelcells/). Ultimately, hydrogen stations
must be located throughout cities and rural areas, similar to todays gasoline stations.
Decisions about hydrogen infrastructure including: hydrogen production technology,
the use of large, centralized production facilities vs. small, on-site production, and if
centralized production, the method for delivering the hydrogen from the production
facility to the filling station include many tradeoffs. In terms of lower production costs
and higher efficiency (hence lower energy requirements), large scale, centralized
hydrogen production facilities may offer a better choice than smaller, on-site production.
However, once it is produced, the hydrogen gas must be delivered to the refueling
station. Hydrogen is a bulky gas, and it is not nearly as easy to work with as gasoline.
Compressing the gas requires huge amounts of energy, and compressed hydrogen
contains far less energy than the same volume of gasoline. (This presents problems not
only with getting the fuel to the filling station, but also with carrying the fuel in the
vehicle.) Once compressed, either to a compressed gas stage or to liquid hydrogen,
the hydrogen must be delivered to the consumer, either by pipeline or by tanker truck.
These processes also require energy and expense.
The following information on hydrogen delivery systems is taken from
http://www.fe.doe.gov/programs/fuels/hydrogen/Hydrogen_Delivery_R%26D.html:
Currently, hydrogen delivery systems exist only for the small merchant hydrogen market
in the chemical and refining industries. This limited system lacks the scope or scale to
deliver hydrogen outside geographically limited areas. It is insufficient by orders of
revised 08/09
2
magnitude from being capable of supplying the hydrogen fuel needs of the Hydrogen
Initiative announced in 2003 by President Bush.
Hydrogen has physical properties that may cause embrittlement of some high-strength
steel piping materials and components such as compressors and valves that are
commonly used today to transport natural gas. Even if these problems could be
overcome, today's natural gas pipelines may not be available or capable of handling the
additional volumes of hydrogen projected. Therefore, it is likely that significant capital
investments in a dedicated hydrogen delivery infrastructure will be required before a
hydrogen economy is practicable.
To begin studying possible hydrogen delivery alternatives, DOE will use computational
techniques and analyses to determine the most attractive "carriers" of hydrogen. These
studies could include investigations of new chemical process routes and reaction
catalysts. Trade-offs will be studied between the massive capital investments in new
delivery systems associated with central location hydrogen plants and the use of today's
liquid and natural gas transportation systems to deliver fuels from which hydrogen can be
extracted at end-use locations. Concepts for small-scale, on-site reforming will be
evaluated against the large capital costs of a dedicated hydrogen infrastructure.
For a very thorough, easy to understand background on things to consider with respect
to hydrogen fuel cell infrastructure, see the fact sheet: How Much Will Hydrogen
Infrastructure Cost?
http://www.energyindependencenow.org/pdf/fs/EIN-HowMuchWillHydrogenInfr.pdf
the DOE website:
http://www.eere.energy.gov/hydrogenandfuelcells/delivery/current_technology.html .
Concepts
1. Choices we make as consumers have environmental, economic, and societal
impacts.
2. Developers need to consider trade-offs of different alternatives, and be able to
defend their choices when they propose development plans.
3. A support system, or infrastructure, needs to be in place for hydrogen delivery
before consumers will be willing to purchase hydrogen fuel cell vehicles.
4. An appropriate system for hydrogen delivery will be based on a thorough
analysis of how the hydrogen is produced, where it is produced, and how it gets
from the production facility to the point of consumption.
Relationship to Guiding Question

Students continue to gather information about the whole system of the fuel cell car,
now considering issues that relate to actually using the car in todays world how to
refuel the car, how much will the fuel cost, how do we create the infrastructure of the
hydrogen fuel cell economy.
Key Questions
1.
2.
3.
4.
What is infrastructure?
How many hydrogen filling stations would we need in our area?
What can we expect to pay for the hydrogen fuel?
What are some benefits of small, on-site hydrogen production?
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3
5. What are some benefits of large, centralized hydrogen production?
6. What methods are available to transport hydrogen from the production facility to
the filling station?
7. How is hydrogen provided to the hydrogen fuel cell cars and buses now in
operation?
8. How safe is hydrogen to the consumer?
9. With current and emerging technologies, how can we positively impact our
consumption of renewable energy sources?
Student Learning Objectives
Standards
Students will be able to identify the complexity of factors

involved in developing a workable appropriate hydrogen
infrastructure.
Students will be able to analyze several alternatives with
respect to hydrogen delivery systems and propose a best
alternative.
Students will be able to defend their decision with facts.
Students will be able to describe how hydrogen is now
provided to the few hydrogen fuel cell cars and buses
currently in operation.
Key Terms
Pipeline: a network of pipes used to deliver a commodity, such as natural gas or
hydrogen.
Delivery system: combination of methods used to bring hydrogen from the site
of production to the location where it is available to the consumer (pipelines,
trucks, tankers, etc.)
Infrastructure: The basic facilities, services, and installations needed for the
functioning of a society or a component of that society. With respect to
hydrogen, infrastructure includes production and delivery systems.
Activities:
The Hydrogen Infrastructure Activity is a relatively unstructured research activity where
students independently research the topic of developing a hydrogen infrastructure in St.
Lawrence County. Students are given a time period to conduct their research, and
ultimately are required to propose a plan for their system.
Activity: Hydrogen Infrastructure (2 days)
Introduction remind students of overall goal to evaluate the potential for future
reliance on hydrogen use with a fuel cell car. Weve been gathering all this
information and learning a lot about fuel cell technologies and hydrogen
production, but one big question remains:
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4
Once somebody buys their fuel cell car, how will they fill up?
Relate this to the situation that happened at the turn of the century, when the
gasoline engines were first developed same thing. Many people doubted the
success of the gasoline powered vehicle because there was no method in place
for delivering fuel, and investors were hesitant to put money into the
infrastructure because of the risk that nobody would buy the cars and use the
infrastructure.
This is a classic chicken and egg problem. (see information below about the
introduction of gasoline and internal combustion engine)
Review options for Hydrogen production. This will help to illustrate the need to
consider transporting hydrogen long distances (e.g., if made in a centralized
steam reforming facility) versus the possibility of making hydrogen locally via
electrolysis and a distributed (solar, wind, hydro) electricity generation system.
o Natural Gas (Steam) Reforming
Typically used to produce large quantities of fuel so as to make
use of economies of scale.
Use of fossil fuels as feedstock as well as energy source
Product requires further refining, hydrogen not 100% pure
Show chemistry of CH4 + 2H20 + ENERGY -> 4H2 + CO2
o Electrolysis
A lot less energy efficient per unit of hydrogen produced than
natural gas reforming
Easy to do at a smaller scale
Only feedstock required is water
Very pure product
Requires a source of electricity (coal, nuclear, renewable)
Show chemistry of 2H2O + ELECTRIC ENERGY -> 2H2 + O2
What is infrastructure?
o Infrastructure is the basic facilities, services, and installations needed
for the functioning of a society or a component of that society. With
respect to hydrogen, infrastructure includes production and delivery
systems.
o Whos going to build hydrogen fueling stations if there are no hydrogen
cars? Who wants a hydrogen car if there are no fueling stations?
What would be needed to create a hydrogen infrastructure? Here ask

leading questions to get the students to be aware of the necessity of the
following pieces of infrastructure, which will lead into the activity.
o Fueling stations
o H2 production
o H2 transport
revised 08/09
Provide a limited amount of background just to let students know that scientists
(mostly DOE) are working on developing plans for hydrogen delivery systems.
Discuss what currently happens in California (see background information for
description). Describe some of the trade-offs with respect to large, centralized
production and delivery vs. small, on-site production.
Tell them that to enable someone here to buy a fuel cell car, they need to have a
plan in place for how people will fill up their tanks. For the next few days they will
be putting together that plan they will have access to computer documents and
can also search the web (search hydrogen fuel cell infrastructure for example).
Show a large map of St. Lawrence (or what ever is local) County. Tell them that
their task will be to identify their proposed locations for hydrogen filling stations
with color-coded pins on this map, and describe their proposed method of
hydrogen production and delivery. They will need to defend their choices to the
rest of the class.
Pass out activity sheets. Emphasize that the critical questions are basically their
task all relate to their proposal. The other questions on the sheet are meant to
help them search particular types of information that might help them make their
decisions they do not need to answer each question!
Spend the remaining class period and the next day on this activity. Allow each
group 5 minutes to present their proposal.
Wrap up. Revisit problem solving and how this relates to overall issue of
recommending a vehicle. Discuss issues related to other vehicle types (Is there
enough power and electric grid infrastructure to support battery electric vehicles?
How much land mass would be required for ethanol production?)
Resources
http://people.howstuffworks.com/hydrogen-economy4.htm
http://www1.eere.energy.gov/hydrogenandfuelcells/
revised 08/09
6
From the American Congressional Record of 1875:
"A new source of power, which burns a distillate of kerosene called gasoline, has been produced
by a Boston engineer. Instead of burning the fuel under a boiler, it is exploded inside the cylinder
of an engine. This so-called internal combustion engine may be used under certain conditions to
supplement steam engines. Experiments are under way to use an engine to propel a vehicle.
This discovery begins a new era in the history of civilization. It may some day prove to
be more revolutionary in the development of human society than the invention of the wheel, the
use of metals, or the steam engine. Never in history has society been confronted with a power so
full of potential danger and at the same time so full of promise for the future of man and for the
peace of the world.
The dangers are obvious. Stores of gasoline in the hands of the people interested
primarily in profit would constitute a fire and explosive hazard of the first rank. Horseless
carriages propelled by gasoline engines might attain speeds of 14 or even 20 miles per hour. The
menace to our people of vehicles of this type hurtling through our streets and along our roads and
poisoning the atmosphere would call for prompt legislative action even if the military and
economic implications were not so overwhelming. The Secretary of War has testified before us
and has pointed out the destructive effects of the use of such vehicles in battle, Furthermore, the
cost of producing it is far beyond the financial capacity of private industry, yet the safety of the
nation demands than an adequate supply should be produced. In addition, the development of
this new power may displace the use of horses, which would wreck our agriculture. The
discovery with which we are dealing involves forces of a nature too dangerous to fit into any of
our usual concepts.
revised 08/09

Lesson 3 - Battery and Fuel Cell Technologies: Concepts

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Lesson 3 Battery and Fuel Cell Technologies

Hydrogen gas has been proposed as a potential alternative fuel. Hydrogen is an

Electricity can be used to produce H2 from water in an electrochemical reaction. This

Fuel cell design affects efficiency.

Voltage is a measure of electric potential.

Energy is measured in watt-hours or kilowatt-hours (kW-h), and is a measure of how

Efficiency is a measure of the amount of power delivered by a system relative to the

Relationship to Guiding Question

Copyright 2009 Clarkson University, Office of Educational Partnerships

Student Learning Objectives

Students will be able identify the basic components of a

Copyright 2009 Clarkson University, Office of Educational Partnerships

LEO the GERM

Oxidation the atom goes from a lower oxidation state to a

Reduction the atom goes to a lower oxidation state. For

Cathode = a negatively charged electrode that is the source

Copyright 2009 Clarkson University, Office of Educational Partnerships

How does it work?

Two key components

Fuel cell: Hydrogen and

Electrolysis cell: Hydrogen

Copyright 2009 Clarkson University, Office of Educational Partnerships

Copyright 2009 Clarkson University, Office of Educational Partnerships

Copyright 2009 Clarkson University, Office of Educational Partnerships

o The electricity sent to the electric motor is generated in the battery of

Battery from chemical energy stored in chemicals within the

Fuel cell hydrogen fuel continuously supplied. The fuel cell

o Neither vehicle has any tailpipe emissions of concern.

Introduce basic electrical and electrochemical concepts

Copyright 2009 Clarkson University, Office of Educational Partnerships

Copyright 2009 Clarkson University, Office of Educational Partnerships

A battery stores electrical energy and is made up of an

A fuel cell is made up of an electrolyte, a conductor, and two

At the end of class, go over discussion questions and, if theres time,

Fuel Cell Basics (1 day)

Copyright 2009 Clarkson University, Office of Educational Partnerships

Membrane electrode assembly (MEA) a combination of a Proton

Proton Exchange Membrane (PEM) electrolyte material (such as

Catalyst A material (such as platinum) that promotes the splitting of

Copyright 2009 Clarkson University, Office of Educational Partnerships

Copper-clad plates Sturdy, conducting casing for the cell. It protects

Silicon gasket (part of MEA assembly) Serves to electrically insulate

Anode electrode where the H2 is oxidized to H+ ions and electrons

Cathode electrode where electrons consumed to reduce oxygen to

Fuel cell testing (1 day)

Review fuel cell components

Discuss results of graphite plate fuel cells. Define specific issues:

Several hundred cells together in a stack

Newest design has vertical orientation water drainage.

Copyright 2009 Clarkson University, Office of Educational Partnerships

80-100 kW (1kW = 1.34 horsepower)

Do activity. Encourage students to explore as much as possible different

In this case, efficiency will be defined as actual energy

Actual energy = Power x time (time of hydrogen injection);

Copyright 2009 Clarkson University, Office of Educational Partnerships

Theoretical energy - The energy content of hydrogen being

Debrief key concepts

Where does Hydrogen come from? (1 day)