Next-Generation Fuel Cells

Introduction
A fuel cell is a power generation device that converts chemical energy into electricity with very high efficiency. The fuel cell has the potential to serve a wide range of applications, including stationary power, automotive power, a well as a power source for portable electronics. The worldwide market for fuel cells is estimated to reach $11 billion by 2013, with the automotive application particularly promising as a new, high-efficiency and clean power source. As a potential substitute for the internal combustion engine, fuel cells have already demonstrated the ability to convert chemically stored energy directly into electricity with two to three times greater efficiency than the traditional combustion pathway. Furthermore, a fuel cell running on hydrogen and air creates water as the only byproduct (the hydrogen and oxygen molecules combine to provide the electricity). Internal combustion engines operate at an efficiency of 20-30%, while fuel cells have a practical operating efficiency of 50-60%. Furthermore, next-generation fuel cells will have the ability to run on cleaner fuels such as methanol, ethanol or natural gas without any penalties on gas mileage and maintenance costs.

Challenge
One of the keys to making a fuel cell work is a catalyst, the active material which facilitates electrochemical reaction of hydrogen and oxygen/air. The most common catalyst is platinum, but it is expensive and limited in supply. Currently, the amount of platinum catalyst required per kilowatt to power a fuel cell engine is about 0.5 to 0.8 grams, or .018 to .028 ounces. At a cost of about $1,000 per ounce, the platinum catalyst alone would cost between $1,500 to $2,500 to operate a small, 100-kilowatt mid-sized, light duty vehicle - a significant cost given that an entire 100-kilowatt gasoline combustion engine costs about $2,000-3,000. To make the transition to fuel cell-powered vehicles possible, the automobile industry needs a catalyst which is better and less expensive.

Solution
QSI's catalyst solution is to use lower cost metals, engineered at the nano scale to replace platinum. Palladium is one example, as it resembles platinum chemically, is extracted from copper-nickel ore, and is already used as a catalyst material in the catalytic converters of automobiles. It is 75% less expensive than platinum, and when used at the nano scale in direct methanol fuel cells, palladium has demonstrated an increased power density of 45%. This power enhancement is due to the improved selectivity of the palladium catalyst and the additional surface area in nano scale materials, translating to a dramatic efficiency improvement of the catalytic reaction. Thus, using nano scale palladium is both less expensive and leads to better performance. Additionally, work underway with cobalt and nickel has also shown promising results, which can further lower costs.

QSI is among a handful of leading companies that can currently manufacture commercial quantities of high purity, narrow distribution, nano metals and alloys used as catalyst materials in fuel cell membrane electrode assemblies (MEA). QSI's patented manufacturing process is proven, automated, and scalable to meet industry needs today and in the future. In addition to palladium, QSI manufactures iron, cobalt, nickel, manganese and other metals and alloys at the nano scale that can be used in a variety of other catalytic applications. Using QSI nano metals in fuel cell electrodes significantly increases catalytic surface area, enhances durability, extends life cycles, and leads to a reduction in device size. Thus, QSI's nano materials are fundamental to enabling next generation fuel cell technology.

QSI is also working on compact high-temperature fuel cells, capable of reforming of hydrocarbons like methanol, ethanol and natural gas to hydrogen in situ, for use in fuel cells for power production, under a recent U.S. Army grant. In this project for next-generation fuel cells, QSI is developing a Unitized Reformed Hydrocarbon Fuel Cell, operating at 300oC, with proprietary development of membranes and bi-functional anodes, the latter capable of functioning as both a fuel reforming catalyzed membrane support and a high-temperature hydrogen anode for the fuel cell.