Prior to the development of this FOA, the DOE issued a Request for Information (RFI) regarding possible topics and held two pre-solicitation workshops (one for Fuel Cell R&D and one for Molten Carbonate Fuel Cells (MCFC) and Phosphoric Acid Fuel Cells (PAFC)).

With this FOA, DOE is seeking applications in seven technical areas of interest: balance-of-plant components; fuel processors; high-temperature stack component research; proton exchange membrane fuel cell membrane electrode assembly integration (PEMFC MEA); catalyst/electrodes; membranes; and innovative concepts.

The cost analysis funding opportunity will help to determine the economic viability and technical progress of fuel cell and hydrogen technologies for stationary, transportation, and emerging market applications, including light duty vehicles, forklifts, buses and stationary power plants, as well as hydrogen storage systems.

Under the program, the grantees will be expected to conduct life cycle cost analyses for different manufacturing volumes to help gauge the near-term, low-volume market viability for these technologies, along with their long-term potential.

Topic 1: Balance-of-Plant Components

Successful development of low-cost, high-performance, durable BOP components that are qualified for stationary or transportation duty cycles is critical if overall system cost, durability, and performance goals are to be achieved. DOE notes that the majority of fuel cell system failures and forced outages (~90% in automotive systems and ~ 90% in micro CHP systems ) are the result of non-fuel cell stack balance-of-plant events. Also, the cost of the non-stack subsystems has been estimated to be about 50% in automotive fuel cell propulsion systems and in stationary backup power systems.

To overcome these limitations, DOE is seeking low-cost, durable, high performance BOP components in four main areas: sensors and blowers for BOP for stationary applications; and air management systems and humidifier technologies for BOP for transportation applications. Power electronics are not included in this FOA for either stationary or transportation applications.

Topic 2: Fuel Processors

Fuel processors (FPs) for stationary fuel cell systems convert raw fuel into hydrogen-rich streams suitable for use in fuel cells. The FP sub-systems include but are not limited to:

• raw fuel pre-treatment to remove constituents deleterious to the fuel processor catalysts and fuel cell components (e.g., desulfurization);
• reactors to convert the raw fuel into a hydrogen-rich stream (e.g., reformers);
• reactors to reduce CO and increase H₂ content (e.g., water-gas-shift); and
• separators and/or polishers to enrich and further clean the hydrogen stream (e.g., pressure-swing adsorption (PSA) and preferential oxidation (PROX)).

Raw fuels considered for this FOA are natural gas, LPG, and renewable fuels such as digester gas, landfill gas, biodiesel, alcohols, etc. Military logistic fuels such as JP8 are not considered responsive and are covered by Department of Defense funding.

DOE is seeking technologies that offer significant improvements in one or more of the following areas for FP systems:

• fuel flexibility;
• durability;
• cost;
• fuel clean-up;
• impurity tolerance;
• thermal and physical integration; and
• cold start-up time.

Topic 3: High Temperature Stack Component Research

DOE is seeking research to improve performance and reduce cost of high temperature fuel cells, including molten carbonate fuel cells (MCFC), phosphoric acid fuel cells (PAFC), small scale (≤10kW) solid oxide fuel cells (SOFC), polybenzimidazole (PBI) -phosphoric acid, other polymer-phosphoric acid, and similar temperature range fuel cells through development of better stack components.

DOE considers alkaline fuel cell-based applications non-responsive to this specific topic, as it is covered in Topic 7 (Innovative concepts). In addition, SOFC activities that are similar to work being performed under DOE’s Solid State Energy Conversion Alliance (SECA) Program are considered non-responsive to this Topic.

The higher operating temperature of these fuel cell systems offers advantages compared to PEMFCs, especially in terms of Combined Heat and Power (CHP) applications. However, advances are required to reduce the cost of these fuel cell systems. Research interests include, but are not limited to: improved anodes, cathodes, electrode structures, matrix structures, and electrolytes. Research should be directed at improving performance and durability while decreasing cost.

Applications should address any pertinent risks or known problems with the respective technology. Examples include, but are not limited to: poor catalyst utilization due to electrolyte intrusion into the catalyst layer; platinum agglomeration; high catalyst loading required due to poor durability; phosphoric acid coordination to the catalyst; poor membrane mechanical properties (PBI-phosphoric acid); electrolyte loss (in phosphoric acid, PBI-phosphoric acid and molten carbonate systems); degradation of the electrolyte support (in molten carbonate systems), and nickel oxide dissolution from the cathode and its deposition as nickel metal in the electrolyte matrix. Upper temperature limits and the suitability of waste heat for CHP applications should also be addressed.

Topic 4: PEMFC MEA Integration

DOE is soliciting research to improve performance of polymer electrolyte membrane electrode assemblies (MEAs) through a better understanding of the interactions between and integration of MEA components.

In particular, DOE is soliciting research to integrate state-of-the-art catalysts with state-of-the-art membranes and gas diffusion layers (GDLs) into MEAs that can meet DOE 2015 performance targets for their respective application (transportation and/or stationary applications, including CHP).

The majority of the effort for this Topic should be on MEA integration with minimal component level research. MEA integration issues and risks, along with risk mitigation strategies, should be described. Applications should address any known mass transport issues that may arise (e.g., flooding issues that decrease access to catalysts at low temperature). MEAs for transportation applications should address cold-start and freeze-start, while those for stationary applications should address upper temperature limits and the suitability of waste heat for CHP applications. MEA cost and durability should also be addressed. Accelerated lifetime tests to determine the long-term durability of the MEA under realistic conditions are required.

Topic 5: Catalysts/Electrodes

Catalysts are key cost components for both stationary and transportation PEM fuel cells. The focus of this Topic is catalyst/electrode research that will improve catalyst activity and durability while decreasing catalyst cost. Of particular interest are studies that result in decreased platinum group metals (PGM) in the fuel cell.

These studies include research of low PGM loading catalysts (meeting or exceeding the 2015 target of 0.125 mg PGM/cm²) and non-PGM catalysts. This Topic is intended for cathode catalysts only and excludes work on anode catalysts.

Low PGM studies may be directed at development of new PGM alloys, approaches that increase activity of current PGM and PGM alloy catalysts, approaches that increase the utilization of PGM in the catalysts, approaches that tailor catalyst particle size or structures, and/or other novel approaches. The applicant should clearly state the status of the applicant’s current catalyst technology as it relates to the state-of-the-art and provide sufficient justification that the approach can reduce total platinum content to ≤0.125 g PGM/kW (the DOE 2015 target) and any potential for improvements beyond the 2015 targets. Teaming is encouraged with an MEA and/or stack integrator/developer to ensure relevant materials are investigated.

For non-PGM catalysts, the DOE seeks development of durable catalysts with an open circuit voltage (OCV) of 0.9V (or higher) under H₂/air conditions. Cathode catalysts capable of 300 A/cm³ at > 800 mVIR-free (based on the volume of the supported catalyst) are sought. Non-PGM anode catalysts are excluded from this Topic.

The work should address mass transport limitations and provide for the development of viable supports that would allow an increase in loading and/or thickness for non-PGM catalysts if needed.

Topic 6: Membranes

New low-cost durable proton-conducting PEMs (including PBI-type membranes) are sought to improve performance and reduce the cost of fuel cells. The emphasis for this Topic is on decreasing cost while improving durability. While temperature requirements vary for stationary and transportation applications (up to 95°C for near-term transportation, up to 120°C for longer-term transportation systems, and up to 200°C for stationary CHP), cost and durability must be improved in both cases.

Membranes must have low area specific proton resistance (< 0.02 ohm cm²) at the operating temperature of interest, with good mechanical and chemical durability. Conductivity at low relative humidity (RH) (e.g., 25-50%) has been identified as beneficial for reducing fuel cell system costs.

Performance under conditions of lower RH (25-50%) and at elevated temperatures (95-120°C for transportation, up to 200°C for stationary applications) should be emphasized. The application should encompass work up to and including MEA testing at a size of 50 cm² or larger. The work plan should include a discussion of durability testing of sufficient duration to show viability.

Topic 7: Innovative Concepts

This Topic covers novel ideas that do not fall under any of the other research Topic areas. The proposed concept must be innovative. The primary thrust is new materials, new architectures, or new modes of operation for fuel cells. New structures and/or morphologies for existing materials will be considered if a strong case is made for their benefits.

Areas of research interest include but are not limited to: low-cost, durable materials, components, or subsystems suitable for longer-term use in the fuel cell system environment. Stationary, automotive, and portable applications are acceptable. Possible areas of interest include alkaline fuel cells, liquid-fueled (non-hydrogen) fuel cells, and regenerative or reversible fuel cells.

The final deliverable in this Topic is appropriate hardware (e.g., single cell with active area ≥50 cm² or component based on the material developed) that will be made available for independent testing and evaluation at a DOE-approved location.

Applications for the $65 million research and development program are due by 3 March 2011. Applications for the cost analysis solicitation are due on 18 February 2011. Funding for both programs are subject to congressional appropriations.