Hidden Smoke and Polished Mirrors

By Steve Auger

Editor's note:  This post was originally published October 7, 2008.   While there are still concept cars and demos (buses in particular),  the conclusions I reached 1 year ago are becoming evident - we won't be seeing hydrogen fuel cell automobiles for quite some time, if ever.

Will hydrogen fuel cells propel us into the future? Or is the technology simply smoke and mirrors? A critical examination is presented in this final BlogOnSmog post on fuel cell technology as applied to automobiles.

Hydrogen Fuel Cell - Background

This is the third and final post in the BlogOnSmog fuel cell automobile series.  In previous posts, I provided a brief history of fuel cells and their usage.   I would like to start by briefly digressing to my childhood. When I was a young lad, my father, an engineer by profession, would give me talks on various scientific topics.  He often told stories about attending lectures by Einstein's understudies, the big bang theory and many other interesting subjects in physics and mathematics.  

When I was 10 years old, my father explained to me that the hydrogen fuel cell would never be commercially viable.   Back then, I didn't know what a fuel cell was, but I did know my father - an industrial engineer, an independent thinker with a high I.Q.  So he must be right.

Now, 40 years later, I still read about fuel cells being the answer to our future energy needs.  And I still hear the same counter-arguments.  Nothing has changed in the last 40 years.  The same arguments apply today as they did 40 years ago.  The technologies have improved but the fundamentals have not.  In this post I hope to do some justice to the following questions that have been in the back of my mind for quite some time:

• How practical is a hydrogen-based economy?
• How close are fuel cells to mass-production?
• Will the average American be able to afford a hydrogen-based car?
• Who is behind the push for the hydrogen economy? 

Hydrogen Economy - The Promised Land

The year 2003 was a period when America was still in shock over the tragedy of 9/11.  America wanted answers, not only for the unspeakable crimes but also for the security of the nation.  In 2003,  President Bush announced that America's future rested with a hydrogen-based economy.  The hydrogen economy provided some answers.  America would end its' dependence on fossil fuels.  Terrorists would not be able to affect America by targeting foreign oil and gas supplies. 

Seems logical BUT ... Even in 2003, it was clear (to me) that a hydrogen-based future was not practical. Was President Bush mis-informed? Were his advisors incompetent? Or was Mr. Bush involved in political manipulation, similar to his rationale for invading Iraq? Certainly Bush and Cheney have strong ties to the oil industry.  Were oil companies pulling the strings?  We may never know but it is (or should be) clear  that a hydrogen-based economy is out of the question, for now and perhaps forever.

"I have not seen a viable, affordable plan to convert an economy to hydrogen," Greg Frenette, Ford's lead engineer on the technology, said in an interview last week in East Haddam, Conn. "It could well take until 2030."

Hydrogen Powered Cars - Available Now!???

Only a couple of years ago I was left with the impression that fuel cell technology was several decades away.  Major discoveries were required on multiple fronts to make this technology practical. Honda, a fuel cell leader, indicated that fuel cell cars would come with a $1 Million price tag.  Now I see fuel cell cars rolling off the show room floor. Demos, field trials, leases ... most manufacturers have something to offer. Is the technology really here?  Or is this smoke and mirrors?

"Employees and management at Ballard are mobilized around a single mission … to accelerate fuel cell product adoption."

Within the last year or two, car companies have accelerated their schedules. Now it is clear that fuel cell technology has a couple of major discoveries left before it reaches commercially viability. Platinum electrodes ($$$) are required.  Platinum is not only expensive but there is a limited supply.  The efficiency of pure hydrogen generation, transportation and storage are of major concern.  There are also issues with low temperature performance, fuel cell longevity/durability, infrastructure. The list goes on...

"the General has a 2010 target to design a fuel-cell vehicle that could be cost effective in high-volume production."

So how can car companies accelerate their schedules?  Can revolutionary discoveries be scheduled?  What is the motivation for accelerating the development of this technology?  

"If someone can make an electric vehicle with reasonable range, that may kill fuel cells," Duleep said in an interview  from Arlington, Va

One of the major factors driving the fuel cell industry is the rapid advance of lithium-ion battery technology.  Lithium-ion batteries are more environmentally friendly than NiCad or lead batteries and increases the energy density, making plug-in hybrids more attractive to the average driver.   Lithium-Ion batteries have been a major shot in the arm for hybrid plug-ins. And there are other technologies coming to fruition such as air compression technology . So the accelerated fuel cell schedules are likely due to pressure exerted by competing technical solutions. Imagine the VHS/Betamax and Blu-ray/HD-DVD wars but on a grander scale. The bottom line is that the car companies need to show some working hydrogen fuel cell technology NOW or be left on the starting block.

"A spokesman for GM recently predicted that 4 out of 5 cars sold in the year 2020 will be fuel efficient hybrids as a result of increasingly tougher emissions standards."

They not only need to show working hardware but provide the image of a technology that is nearly production-ready. But what is the motivation?  Most automobile companies offer hybrids, alternative fuel options, and are working on plug-in hybrids, etc.  They have their bases covered.  What is the motivation for fuel cell cars? 

Let's think about this.  As long as the American politicians buy in to the hydrogen economy the oil companies will have decades to shift their business models. And the oil distributors will ultimately be best positioned to offer a new hydrogen infrastructure.  Not only that, but the hydrogen economy really doesn't eliminate the requirement for fossil fuels.  Hydrogen production is so inefficient that it may actually increase the demand for fossil fuels.  But along comes those annoying hybrid plug-ins, ready for mass production.  Infrastructure? Well - we already have an electrical grid. 

This technology not only threatens the future of the hydrogen fuel cell but also the future of the oil companies.   Is it possible that Bush and Cheney's buddies, the oil companies, are running scared?   And the car companies would love to sell their gas guzzlers for as long as possible.  Why not stretch this out a couple more decades?

Honda Clarity FCX - Stepping Up to the Plate

Honda is first out of the gate with their next generation fuel cell - smaller, more power, more efficient...  Not only is this the most practical fuel cell design to date, Honda has started a limited production run of 200 Honda Clarity FCX's.

 

"the Clarity's fuel-cell stack is located under the driver's right arm, is 65 percent smaller by volume, packs 17 percent more power (100 kW or 136 horses), and it can start at temperatures as low as -22 degrees F (owed to its vertical, gravity-drain water path). Combined with its co-axial and compact motor/gearbox up front, lithium battery pack under the rear seat, and single, 5000psi storage tank behind the rear passengers, the Clarity is brilliantly laid out."

The 200 Clarity FCXs are being leased to select individuals at a cost of $600 per month over three years in Los Angeles, where some of the existing hydrogen fuel stations are located.  What is not evident is the retail cost of the automobile, expected life time, re-fueling cost and expected maintenance costs.  When asked about the lease cost, a Honda representative indicated that they were targeting the ultimate user, individuals making $150,000 and up.  When the Clarity FCX makes it's way to into production (if ever),  the Honda Clarity FCX car will not be priced for the average American.

General Motors, the biggest U.S. automaker, is testing roughly 100 fuel cell vehicles in three U.S. cities with regular consumers with the intent of starting production as early as 2012.

"General Motors is tooling up to start producing fuel cell cars, announcing today that it's moving more than 500 fuel cell engineers from research into development...  The transition is aimed at expediting the company's efforts to produce vehicles that displace petroleum through energy diversity.  "This says, 'Not only have we done it in a lab, we're ready to do it for real,'" Larry Burns, GM's vice president for research and development told the Detroit News."

Toyota is also jumping onto the bandwagon by announcing a version of fuel cell car based on a hybrid concept (fuel cell + electric motor) similar to the very successful Toyota Prius concept.

"Toyota last week announced it, too, will begin leasing a new hydrogen-powered, emissions-free fuel cell car. The FCHV-adv will be available later this year in Japan"

In all of these public announcements none of the auto manufacturer's  are addressing the real world issues - hydrogen infrastructure, car retail price, cost of hydrogen fuel, maintenance (including mechanic training), reliability/durability, etc. 

Up and Coming or Swan Song?

It is possible that some auto manufacturers have sunk a great deal of money into fuel cell development and are in too deep.  The remainder have their fingers in the pie just in case the fuel cell turns out to be the technology of choice.  One never knows with American politics.  In any case the jury is out as to whether the hydrogen economy is up and coming or this is the final swan song.  But let's consider some facts.

1. Fuel cell vehicles are powered by an electric motor.  Hydrogen is used as an electrical storage medium, not as fuel.   Comparing apples to apples, one has to compare the efficiency of hydrogen as a storage medium versus lithium-ion batteries and other available storage mediums.  To isolate hydrogen from water yields about one-third the usable energy that the electricity could provide if stored in a simple battery and used in an electric car.  Then the hydrogen must be compressed into a liquid fuel to provide a practical range.
2. The cost of hydrogen converted to equivalent gas price is $10.00 per gallon.
   
3. Hydrogen cars are no “greener” than the energy required to provide the hydrogen.  Therefore a fuel cell car is much less environmentally friendly than a totally electric car.  This assumes you ignore the disposal of the batteries of course.
4. The fuel cell output - water vapor - is the most abundant greenhouse gas.  This is neglected by most if not all media reports.
   
5. Hydrogen fuel cells do nothing to eliminate America's dependence on fossil fuels.  If anything this technology will increase the dependency on fossil fuels.
6. Hydrogen fuel cells do not work in overly cold, humid or dry conditions.
7. Retail price puts the technology out of reach for the average consumer.
8. The hydrogen infrastructure is decades (or maybe a century) away.
   

So I will let the reader be the judge.  The smoke is still there - but it has been transferred from the engine to the utility company.  The mirrors are very polished, shiny enough to make believers out of the uneducated public.

Fuel Cell Theory and Application

By Steve Auger
Part II:  Fuel cell theory, applications and different types available.

Fuel Cell Theory

Fuel cells generate electricity by means of a chemical reaction.  The reaction takes place at two electrodes similar to a battery with one positive electrode (anode) and one negative (cathode). The electrodes are separated by an electrolyte membrane.  In a hydrogen fuel cell, hydrogen gas is passed over the anode and reacts to a catalyst resulting in negatively charged electrons (e-) and positively charged ions (H+).  The electrons are used as electrical energy outside the fuel cell.  The hydrogen ions pass through the membrane to the cathode where they combine with oxygen to produce water. 

Some cells require pure fuel as input such as pure hydrogen for example.  If a source of pure hydrogen is not available then a “reformer” is used to purify the fuel.  Some fuel cells can handle a certain amount of impurities.  In this case the electrolyte is generally operated at higher temperatures to maintain efficiency.

Fuel Cell Applications

Scientists have developed many different types of fuel cell, hydrogen being only one.  All fuel cells have in common an anode, cathode, catalysts and an electrolyte. The electrode design, materials and technical details are generally constrained by the choice of electrolyte.  The main types of electrolyte used today are alkaline, molten carbonate, phosphoric acid, proton exchange membrane (PEM) and solid oxide.   A single fuel cell generates only a small amount of electricity and applications generally require a stack of cells to be useful.

The five main types of fuel cell, their properties and typical application are summarized in the table below.  Each type of fuel cell has advantages and drawbacks.  In general,  either the fuel cell has to be operated at high temperature to allow impure fuels or operate at lower temperatures with pure fuel only and precious metal (platinum) catalysts.   The platinum catalyst makes the fuel cell more expensive than some markets can tolerate (automobile market for example).  The high temperature fuel cells tend to have slow start-up, a higher corrosion rate and faster breakdown of cell components. 

Fuel cells have either liquid or solid electrolytes.  The liquid electrolytes generally require pumps or more complex electrolyte management whereas the solid electrolytes have less corrosion and do not suffer the same management problems as liquid electrolytes.

Type	Electrolyte	Catalyst	Fuel	Oper. Temp.	Cell Output	Typical Application
Alkaline	Potassium hydroxide (liquid)	Platinum	Compressed hydrogen and oxygen	150 - 200OC	Electricity 300W- 5kW, drinking water	NASA Apollo and Gemini spacecraft
Molten Carbonate (MCFC)	Sodium or magnesium Carbonate (liquid)	Nickel	Hydrogen, carbon monoxide, natural gas, propane, ...	650OC	Electricity 10 kW - 2 MW, waste heat is recycled	Electric utility applications
Phosphoric Acid (PAFC)	Phosphoric acid (liquid)	Platinum	Impure hydrogen, gasoline (ex-sulpher)	150 - 200OC	Electricity 200 kW - 20 MW, steam used for cogeneration	Emergency back-up power in hospitals, nursing homes, businesses, ...
Proton Exchange Membrane (PEM)	Polymer (solid)	Platinum	Pure hydrogen, oxygen	80OC	Electricity 50 watts to 75 kW, water vapor	Light vehicles, buildings
Solid Oxide (SOFC)	Calcium or zirconium oxide (solid)	Variety	Impure hydrogen	1,000OC	Electricity up to 100 kW, waste heat is recycled	Stationary applications, auxiliary power units

Other Types of Fuel Cells

Some other types of fuel cell in development are:

• Direct Methanol - liquid methanol is input to the fuel cell and no reformer is necessary.  This type of fuel cell is attractive for small applications such as cell phones and laptop computers.
• Regenerative - This is a closed loop system whereby water is electrolyzed into hydrogen and oxygen using solar power.  The hydrogen and oxygen are fed into the fuel cell, where electricity and water are produced.  The water is fed back to the electrolyzer.
• Zinc Air - From a user perspective this fuel cell operates similar to a battery.  Oxygen and zinc are input to the fuel cell which produces electricity and zinc oxide.  Once the fuel is spent, the system is connected to the grid and the process is reversed, leaving zinc.  The advantage over batteries is the high energy density and fast reversal time.
• Protonic Ceramic - designed to be operated with fossil fuels directly this fuel cell operates at elevated temperatures.
• Microbial - Uses microorganisms such as bacteria to convert organic material into fuel at room temperature.  Potential applications could be medical devices fueled by blood glucose, or water treatment plants.

Part III will cover the current state of fuel cell technology as applied to vehicles.

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Hydrogen Cell - Fuel of the Future?

by Steve Auger
Technorati: 3bex7sy9nj

Part 1:  This is the first post in a series on hydrogen fuel cells and their use in automobiles.  This post was originally published Sept 28.2008.

When it comes to next-generation vehicles, the hydrogen fuel cell is one of the most controversial topics.  The technology promises zero emissions (water vapor) and may potentially eliminate our dependence on fossil fuels.  There is an abundance of hydrogen and can be used far into the future.  BUT ... and this is a big BUT ... hydrogen is one of the least efficient fuel alternatives, the recurring production fuel cell cost will be high and the infrastructure will not available for years or perhaps decades.

What is a Hydrogen Fuel Cell?

A hydrogen fuel cell essentially produces the opposite of electrolysis.  Electrolysis separates hydrogen and oxygen from water by the application of electricity.  A hydrogen fuel cell requires hydrogen and oxygen as inputs and produces electricity and heat.  Some fuel cells can use air instead of oxygen as input.

The operation of a fuel cell is somewhat akin to a battery.  But a fuel cell does not require recharging so long as fuel (hydrogen and oxygen) is supplied.

Hydrogen Fuel Cell History

The hydrogen fuel cell can be traced as far back as 1839 when Sir William Robert Grove mixed oxygen and hydrogen and produced electricity and water, the opposite of electrolysis.  Although the experiment produced electricity, it wasn't enough to be useful.  It wasn't until the late 1950s that the fuel cell became a reality.  In 1959 Francis T Bacon demonstrated a 5KWatt fuel cell, known as the "Bacon Cell", and was capable of powering a welding machine.  The same year, Chalmers Manufacturing Co. demonstrated a 20hp tractor, the first vehicle ever powered by a fuel cell.

NASA got into the act in the 1960s.  Nuclear power was deemed to be too risky and batteries were too large and bulky.  Fuel cell technology seemed ideal for the Gemini and Apollo space capsules. General Electric was contracted to produce the hydrogen cell to fuel the electrical power system for these space vehicles.  The same fuel cells provided the drinking water for the crew.

Part II:  The next post will cover hydrogen cell theory, fuel cell applications and the different types available.

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