The thesis aims at designing a modular system of zinc-air fuel cell (3 cells) for generating electricity, powering electric vehicles, development of smart grid. This study continues the system architecture of the previous students with new protoype and high performance, using zinc particle and the flowing electrolyte. Zinc-air fuel cell is an auspicious energy storage technologies thanks to its huge advantages, which can be the solution to environmental problems. We analyzed and examined the factors affecting the cell performance to find out the best parameters of single cells and then develop cell module. Polarization curves have been used as the criteria to determine whether the performance is good or bad. The influence of operating parameters on performance of single cells including the gap between two electrodes (anode and cathode), the concentration and temperature of the electrolyte (KOH), was investigated. The modular system design was created and modified several times in order to improve the performance. Nevertheless, their wide application is still confronted with challenges, which are from complex configuration, advanced materials,… Herein, the focus is on the scientific understandings of the working principle, fundamental design of the modular system and their chemistries, operating parameters in relation to the cell performance. On the whole, the thesis focuses on the design, modification, optimization and optimal working conditions. SolidWorks, FCTester and Microsoft Excel have been used in experimental design and data processing. Currently, the maximum current density of single cell is 688.64mA/cm2; the power density is 386.45mW/cm2, the corresponding voltage to the highest point of power density is 0.62V, and the maximum power of the single cell is 9.27W. Although the development of zinc-air fuel cell still face significant challenges, great efforts of scientists throughout the world, together with the advancement of technology in general, materials, structures and characterization methods in particular, will surely accelerate commercialization.

The thesis aims at designing a modular system of zinc-air fuel cell (3 cells) for generating electricity, powering electric vehicles, development of smart grid. This study continues the system architecture of the previous students with new protoype and high performance, using zinc particle and the flowing electrolyte. Zinc-air fuel cell is an auspicious energy storage technologies thanks to its huge advantages, which can be the solution to environmental problems. We analyzed and examined the factors affecting the cell performance to find out the best parameters of single cells and then develop cell module. Polarization curves have been used as the criteria to determine whether the performance is good or bad. The influence of operating parameters on performance of single cells including the gap between two electrodes (anode and cathode), the concentration and temperature of the electrolyte (KOH), was investigated. The modular system design was created and modified several times in order to improve the performance. Nevertheless, their wide application is still confronted with challenges, which are from complex configuration, advanced materials,… Herein, the focus is on the scientific understandings of the working principle, fundamental design of the modular system and their chemistries, operating parameters in relation to the cell performance. On the whole, the thesis focuses on the design, modification, optimization and optimal working conditions. SolidWorks, FCTester and Microsoft Excel have been used in experimental design and data processing. Currently, the maximum current density of single cell is 688.64mA/cm2; the power density is 386.45mW/cm2, the corresponding voltage to the highest point of power density is 0.62V, and the maximum power of the single cell is 9.27W. Although the development of zinc-air fuel cell still face significant challenges, great efforts of scientists throughout the world, together with the advancement of technology in general, materials, structures and characterization methods in particular, will surely accelerate commercialization.

ABSTRACT i
ACKNOWLEDGMENT iii
CONTENTS iv
LIST OF FIGURES vi
LIST OF TABLES ix
Chapter 1 INTRODUCTION 1
1.1 Overview 1
1.2 Research motivation 4
1.3 Research objectives 5
1.4 Outline of thesis 5
Chapter 2 LITERATURE REVIEW 6
2.1 Fuel cell technology 6
2.2 Primary zinc-air batteries 9
2.2.1 Portable primary zinc-air batteries 10
2.2.2 Industrial primary zinc-air batteries 12
2.3 Mechanically rechargeable zinc-air batteries 13
2.4 Electrically rechargeable zinc-air batteries 14
2.5 Zinc-air fuel cell 16
Chapter 3 EXPERIMENTAL METHOD AND SYSTEM DESIGN 22
3.1 Working principle 22
3.1.1 Activation polarization 25
3.1.2 Ohmic polarization 26
3.1.3 Concentration polarization 27
3.2 System architecture and materials 28
3.3 Experimental system platform 33
3.4 Experimental method 35
3.4.1 Experimental method 35
3.4.2 AC impedance analysis 37
3.4.2.1 Basic principle of AC impedance analysis 37
3.4.2.2 Equivalent circuit elements 40
3.4.2.3 Graphical analysis 42
3.4.2.4 Bode Plot 44
3.4.2.5 Warburg Impedance 45
3.4.2.6 AC impedance analysis 47
3.5 Experimental preparation and parameters 48
Chapter 4 RESULTS AND DISCUSSION 52
4.1 Zinc-air fuel cell leakage detection and design optimization 52
4.2 Performance of different electrode gap 54
4.3 Performance of different electrolyte concentration and temperatures 55
4.4 Performance of three-cell module 61
Chapter 5 CONCLUSIONS 63
5.1 Conclusions 63
5.2 Future perspectives 64
REFERENCES 65

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