Materials for Proton Exchange Membranes and Membrane Electrode Assemblies for PEM Fuel Cells

Publication Date	January 2006
Publisher	BCC Research
Product Type	Report
Pages	216
ISBN Number	not applicable
Product Code	BCC00052

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Summary

Fuel cells are viewed as potential candidates for auxiliary power, mobile power, stationary distributed, or central power for the global market as well as the power source for the transportation industry. Advances in the technology are made, but sometimes these advances reveal even more challenges to be met. Slowly there is the realization that total dependency on hydrocarbon fuels is not a viable economic option. PEM fuel cells have a part in securing energy security for the country, improving the environment, greatly reducing urban pollution, and creating jobs in manufacturing as the technology advances.

This study analyzes components of the PEM fuel cell, a technology offering the promise of greatly reduced environmental impact and excellent - fuel efficiency. Hydrogen feed fuel cells are based on the electrochemical reaction between hydrogen and oxygen. This electrochemical process does not pollute the environment with hydrocarbons, particulates or any sulfur or nitrogen oxides. The study identifies the opportunities and technological requirements of the proton exchange membrane fuel cell and the MEA and the bipolar plates for the PEM fuel cell. When several units of the membrane electrode assembly are capped off with a bipolar plate and properly assembled, the arrangement is referred to as a stack.

Questions to be answered include determining when the PEM fuel cell will become a reality across the broad spectrum of all its potential commercial applications, and what types of membranes are needed to make this possible. There will eventually be a consolidation of the industry, but it is not yet clear when this will take place. The pace and path of various proton exchange membranes in development will impact the development of other types of fuel cells, and become a key factor in the maturation of the industry as a whole. The commercialization of fuel cells will create demand for new products and services from many diverse industries, which will in turn likely create a positive impact on the U.S. and, eventually, the global, economy.

Scope Of Study

This report:

Focuses on the electrolytes of polymer membranes; the heart of the proton exchange membrane (PEM) fuel cell.
Examines the advancing technology of these membranes, the membrane electrode assembly (MEA) and the bipolar plates.
Reviews the companies involved in these developments, the current and projected incentives, and the projected markets for such technologies.
Identifies the applications of the PEM fuel cell as a power source for transportation, stationary distributive power, and small-scale applications such as portable electronic devices.
Identifies how researchers are solving the search for better membranes that have greater tolerances to poisoning, greater durability, and lower costs.
Underlines the fact that commercialization of fuel cells is not solely influenced by engineers and scientists working on stacks and reformers, but how the major cost issue of the catalyst component is addressed.

Report Highlights

The components for PEM fuel cells market in North America is expected to rise at an average annual growth rate of 25.1% to $929 million in 2011.
The membrane for PEM fuel cells market is estimated at $334 million in 2011.
By 2011, it is expected that the functionalized hydrocarbons will be over 36% of the value of membranes for PEM fuel cells.
The bipolar plates, the gaseous diffusion layers and the catalyst ink market is estimated to reach $595 million in 2011, with average annual growth estimated at 24.7%.

Content

Introduction
- Study Goal And Objectives
- Reasons For Doing The Study
- Contribution Of The Study And For Whom
- Scope And Format
- Methodology And Information Sources
- Analysts' Credentials
- Related BCC Research Work Credentials
- BCC Online Services
- Disclaimer
Summary
- Materials For Proton Exchange Membranes And Membrane Electrode Assemblies For Pem Fuel Cells
- Summary Table: Forecast Of Defined Components For Pem Fuel Cells In North America, Through 2011 ($ Millions)
- Summary Figure: Forecast Of Defined Components For Pem Fuel Cells In North America, 2000-2011 ($ Millions)
Overview
- Market Environment
  - Environmental Issues
  - Advances
  - Innovation Driver
  - Regulatory Issues And Government Involvement
    - Department Of Energy
    - Office Of Science
  - National Hydrogen Association
    - How Much Hydrogen Is Needed?
- National Science Foundation
  - Department Of Defense
    - Army Research Laboratory
    - Usaf Research Laboratory
    - Naval Research Laboratory
  - National Aeronautics And Space Administration (Nasa)
    - Jet Propulsion Laboratory
- Academic Institutions' Involvement In Fuel Cell Development
  - Other
- Issues
  - Barriers
- Criteria For Commercially Viable Fuel Cells
- Conduction In Proton Exchange Membrane Fuel Cells
- Market Drivers
  - Pricing
    - Status Pem Fuel Cell Cost
    - Life-Cycle Costs
- Fundamentals Of Proton Exchange Membrane Fuel Cell
  - Legacy Technology
    - Direct Methanol Fuel Cells
- Regenerative Or Reversible Fuel Cells
  - Fuel Cell Characteristics
  - Fuel Processing
    - Improved Hydrogen Separation
    - Filtering Hydrogen And Oxygen
  - Brief Overview Of Membranes
- Membrane Processes
- Price
  - Value Of U.S. Membrane Market
  - Electrochemical Membrane Market Sectors
- Wrapping Up
Proton Exchange Membranes For Fuel Cells
- Proton Exchange Membranes For Fuel Cells
- Technology Challenges
- Choosing New Membranes
  - High Temperature Membranes
  - Other Options
    - Functionalized Membrane
    - Alternative Organic Fuels
    - Pretreatment Of Membrane
- Water Transport Processes
  - Protonated Water Clusters
  - Freezing Temperature Issues
- Fabrication Of Membranes
  - Casting Solvent
    - Ethylene Glycol As Solvent
  - Impact Of Membrane Thickness
- Approaches To Ionomer Synthesis
- Evolution Of Materials For Pems
  - Durability Of Membranes
- Functionalized Hydrocarbons
  - Polyfuel Hydrocarbon Membrane
  - Toray's Hydrocarbon Membrane
  - Jsr Multilayered Structure
  - Bam Membranes
  - Modified Polystyrene Sulfonated Membranes
  - Polyetherether Ketone (Peek)
  - Hoku Scientific's Sek Membrane
  - Tosoh's Poly(Arylene Ether Sulfone)
  - Sulfonated Poly(Arylene Ether) Sulfones
    - Direct Synthesis
    - Reduced Electro-Osmotic Drag
    - Conductivity
  - Argonne's Dendritic Sulfonated Polyaryl Ether
  - Sulfonation Of Styrene Containing Block Copolymers
    - Ethylene Styrene Interpolymers
    - Polystyrene Sulfonic Acid/Polyvinyl Alcohol Blend
    - Gas Technology Institute Membrane
- Perfluorocarbonsulfonic Acid Ionomers
  - Nafion Pfsa Membranes
  - Gore Select
  - Aciplex
  - Flemion
- Heterocyclic And Polybenimidizole (Pbi) Membranes
  - Pemeas And Celtec
  - Texas Variations Of Pbi Membrane
  - Plug Power And Doe And Pbi
  - Renssalaer's Chain-Transfer (Raft) Polymerization
  - Samsung's Polyimide Derivative
  - Sulfonated Perfluorocyclobutane
    - Other Modifications Of Pbi
  - Sulfonated Polyimides
    - Tailored Imides
  - Poly(Bisbenzoxazole) [Pbo]
  - University Of Massachusetts Co-Polymers
- Composites
  - Aciplex And Titanias
  - Inorganic-Organic Composite
  - Modified Siloxane (Ormosil)
  - Organic/Heteropolyacids And Nafion
  - Aniline And Perfluorosulfonic Acid Polymer
  - Random Fibers And Perfluorinated Membranes
  - Ionic Gel Fill
  - Zirconium Phosphonate Fill
- Others
  - Georgia Tech Triazole Booster
    - Dow Xus 13204.1
    - Altergy Freedom Power
  - Acid Functional Fluoropolymers Membrane
  - Novel Ion Selective Membranes
    - Glass Membrane
    - Glass Layer Improves Humidity
    - Pem Converted To Microfiber
    - Metallized Bio-Cellulosics
- Direct Methanol Fuel Cells
  - Dmfc Anode Problems
    - Toshiba Approach
  - Gen Iv
  - Medis' Conductive Polymer
  - Generics' Cmr
  - Energy Ventures Research
  - Polyfuel
  - Smart Fuel Cell
  - Additional Innovations
    - Gillette Co.
    - Sony Corp.
    - Los Alamos National Laboratory
    - California Institute Of Technology
    - University Of Connecticut
    - Direct Methanol Fuel Cell Corp.
    - Gore Dmfc
    - Maxdem Technologies
    - Russian Academy Of Sciences
    - Ube Industries, Ltd.
- Global Dmfc Summary
- Value Of Proton Exchange Membranes For Fuel Cells
  - Way Forward
Structure Of The Membranes For Pem Fuel Cell Industry
- Background
  - Ion-Selective Membrane Producers
  - Pem Materials Market Share
  - Market Share Of Pem Companies In North America
- Global Involvement In Pem Fuel Cells
- Company Profiles
  - Asahi Glass Co., Ltd.
  - Asahi Kasei Chemicals Corp.
  - Ballard Power Systems
    - U.S. Offices
    - Ballard Material Products
  - Dais Analytic Corp.
  - Dupont Fuel Cells
    - Nafion Membranes And Solutions
    - Direct Methanol Fuel Cell Development
  - Giner Electrochemical Systems, Llc
  - Golden Energy Fuel Cell Co., Ltd.
  - Gore Fuel Cell Technologies
  - Hoku Scientific, Inc.
  - Hydrogenics Corp.
  - Idatech, Llc
  - Jsr Corp.
  - Maxdem, Unc.
  - Medis El
    - Medis Technologies, Ltd.
  - Millenium Cell
  - Mti Micro/Mechanical Technology
  - Pemeas Gmbh
  - Plug Power
  - Polyfuel
  - Pure Energy Visions Corp.
  - Relion
  - Toray Industries, Inc.
  - United Technology Corp. Fuel Cells
  - Others
Mea, Gaseous Diffusion Layers, And Bipolar Plates
- Mea Configuration
- Steps In Assembly Of The Mea
  - Manufacturing
- Performance Goals For Meas
  - Cost Goals
- Functioning Stacks
  - Electrochemistry
  - Carbon Corrosion
- Graphites
  - Asbury Graphite Mills Approach
  - Crystal Graphite Approach
  - Timcal Synthetic Grapite Approach
- Gas Diffusion Layer
  - Attributes Of Gas Diffusion Layers
  - Gdl Manufacturing Techniques
  - Gdl Advancements
    - Developments At Graftech International
    - Developments At Umicore Ag
    - Developments At Ballard Material Products
    - Developments At Johnson Matthey
    - Developments At Lydall, Inc.
    - Developments At Mitsubishi Rayon
    - Developments At Sgl Carbon Group
    - Developments At Toray/Mitsui
    - Developments At Zoltek
    - Other Developments
  - Index Of Specialty Carbon Suppliers
  - Value Of Gdl And Carbons For Pem Fuel Cells
- Bipolar Plates And Membrane Electrode Assembly
  - Design Considerations For Bipolar Plates
    - Corrosion Protection Of Metallic Plates
    - Ballard Powers' Bipolar Metal Plate
    - Surface Modification
    - Tech-Etch Metal Plates
    - Ecpower/Sorapec Approach
    - Entegris Approach
    - Generics Porous Plates Approach
    - T8 Series
    - Idatech Layered Bipolar Plate Assembly
    - Use Of Thermoplastic
    - Intelligent Energy's Proprietary Design
    - Nisshinbo Approach
    - Pem Plates Approach
    - Plug Power Assembly
    - Porvair Approach
    - Sgl Technologies Approach
    - Improved Gasket Approach
    - Sumitomo Metal Approach
  - Index To Bipolar Plate Companies
    - Ancillary Factors
  - Value Of Bipolar Plate/ Collectors For Pem Fuel Cells
  - Meas Companies' Focus
    - 3m Innovative Properties Co. Approach
    - Dupont Approach
    - Gm Approach
    - Hoku Scientific Approach
    - Pemeas/E-Tek Approach
    - Palcan Power Systems Approach
    - Relion/Avista Approach
    - Gore Approach
    - Other Innovations
- Structure Of The Mea Industry
  - Mea Company Profiles
    - 3m
    - Ballard Power Systems
    - Ballard Material Products, Inc.
    - Dupont Fuel Cell
    - Electrochem, Inc.
    - General Electric
    - General Motors, Corp.
    - Gore Fuel Cell Technologies
    - W.L. Gore & Assoc., Inc.
    - Hoku Scientific, Inc.
    - Hydrogenics Corp.
    - Johnson Matthey
    - Lynntech Industries, Inc.
    - Manhattan Scientifics, Inc.
    - Research Headquarters
    - Materials And Electrochemical Research Corp.
    - Nuvant Systems, Inc.
    - Nuvera Fuel Cells
    - Nuvera Fuel Cells Europe
    - Palcan Fuel Cells Ltd.
    - Pemeas/E-Tek
    - Plug Power/H Power
    - Relion/Avista Corp.
    - Utc Power
  - Value Of Membrane Electrode Assemblies
Catalysts And Inks
- Background
- Market Dynamics
  - Cost Is An Issue
  - Doe Goals
- Catalyst Durability
  - Catalyst Particle Size
- Platinum And Platinum Group Metals
  - Platinum Markets And Consumption
  - U.S. Production
  - Catalytic Converters
  - Cost Of Platinum Group Metals
  - Producer And Consumer Conflicts
- Catalyst Coated Membranes
  - Dupont Method
  - Polyfuel Method
  - Aerogel Composite's Method
  - Ramot Method
  - Lower Catalyst Loadings
  - Stack Design
- Combinatorial Techniques
- Innovative Materials And Nanomaterials
  - Alloys Of Platinum
    - Anode Durability
  - Nanoparticles
    - Why Nano?
    - Nanofibers
    - Nanolevel Platinum/Carbon Electrocatalyst For Cathode
    - Nanowires
  - Transition Metal Nanosized Catalysts
- Catalyst Ink Compositions
  - Applied Research & Development Israel Formulation
  - Other Formulations
    - Progress By Sw Research And Gore
    - Progress At Utc Fuel Cells
    - Progress At Jet Propulsion Laboratory
    - Progress At Samsung Electronics
- Carbon Composite Electrocatalyst Powders
  - Superior Micropowders
- Value Of The Pem Catalyst/Inks Mea Market
- Important Pgm Players
  - Acta Spa
  - Anglo Platinum
  - Aquarius Platinum Pty Ltd.
  - Basf Corp.
    - Basf Ag
  - Englehard Corp.
    - Englehard Clal
  - Inco Limited
  - Impala Platinum Holding Ltd. (Implats)
  - Johnson Matthey Fuel Cells
    - Johnson Matthey Fuel Cells Uk
  - Lonmin Platinum Plc
    - Lonmin South Africa
  - Norilsk Nickel
    - Stillwater Mining
  - Om Group, Inc.
  - Quantumsphere, Inc.
  - Tanaka Precious Metals
List Of Figures
- Summary Table: Forecast Of Defined Components For Pem Fuel Cells In North America, Through 2011 ($ Millions)
- Table 1 Focus Of The National Hydrogen Vision
- Table 2 Proposed Timeline For The Hydrogen Economy
- Table 3 Major Institutional Research Into Pem Fuel Cells
- Table 4 Advantages Of A Higher Temperature Membrane For A Pem Fuel Cell
- Table 5 Parameter Variables For New Electrolyte Membranes
- Table 6 Pem Electrolyte Issues
- Table 7 Membrane Fabrication Technique
- Table 8 Approaches To Fuel Cell Ionomer Synthesis
- Table 9 Virginia Tech Bps Membrane Properties Compared With Nafion 117
- Table 10 Fundamental Properties Of Nafion Pfsa Membranes
- Table 11 Conductance Comparisons
- Table 12 Companies Involved In Direct Methanol Fuel Cells
- Table 13 Forecast Of Proton Exchange Membranes For Fuel Cells In North America By Type, Through 2010 ($ Millions)
- Table 14 Companies Producing Ion Selective Membranes For Pem Fuel Cells
- Table 15 Proton Exchange Membrane Material By Type, 2006
- Table 16 Estimated Market Share Pem Companies In North America, 2006
- Table 17 Fuel Cell Mea Performance Goals
- Table 18 Attributes Needed For Gas Diffusion Layer Materials
- Table 19 Pros And Cons Of Gdl Manufacturing Techniques
- Table 20 Typical Properties Of Sigracet Gas Diffusion Layer
- Table 21 Index Of Specialty Carbon/Gdl Suppliers
- Table 22 Value Of Gdl And Carbons For Pem Fuel Cells Through 2011 ($ Millions)
- Table 23 Design Considerations For Bipolar Plates
- Table 24 Material Types For Bipolar Plates
- Table 25 Sgl Bipolar Plate Typical Properties
- Table 26 Index Of Bipolar Plate Suppliers
- Table 27 Value Of Bipolar Plates/Collectors For Meas Through 2011 ($ Millions)
- Table 28 Estimated Market Share Of Mea Companies In North America, 2006
- Table 29 Value Of Membrane Electrode Assemblies In North America, Through 2011 ($ Millions)
- Table 30 World Platinum Supply, 2005 (Thousand Ounces)
- Table 31 World Platinum Demand, 2005 (Thousand Ounces)
- Table 32 U.S. Statistics For Platinum
- Table 33 Value Of Catalyst Inks For Meas, Through 2011 ($ Millions)
List Of Figures
- Summary Figure: Forecast Of Defined Components For Pem Fuel Cells In North America, 2000-2011 ($ Millions)
- Figure 1 Oil Use By Light-Duty Vehicles
- Figure 2 Jpl Twelve-Cell Dmfc Stack
- Figure 3 Water Transport In A Pem Fuel Cell
- Figure 4 Representations Of Peek Variations
- Figure 5 Structure Of Bpsh-Xx
- Figure 6 Schematic Dais Ion-Selective Membrane Triblock Copolymer
- Figure 7 Generalized Structure Of Nafion
- Figure 8 Structural Unit Of Pbi
- Figure 9 Phosphoric Acid Doped Pbi Polymer Complex
- Figure 10 Dow Monomer
- Figure 11 Schematic Dmfc Chemistry
- Figure 12 Schematic Simple Mea
- Figure 13 Schematic For Conceptual Mea Creation
- Figure 14 Preparation Of Carbon Aerogel Supported Platinum