According to the UK’s Department for Energy Security & Net Zero, “Hydrogen has a critical role in helping to achieve our Clean Energy Superpower Mission. It can provide flexible low carbon power generation, meaning we can use hydrogen to produce electricity during extended periods of low renewable output.”
How Hydrogen Cells Work
Fuel cells operate similarly to batteries, but they have a distinct advantage: they do not run down or require recharging if fuel is available. The fundamental structure of a fuel cell consists of two electrodes—a negative electrode (or anode) and a positive electrode (or cathode)—separated by an electrolyte. This setup facilitates an ongoing chemical reaction as long as hydrogen fuel is supplied.
In a hydrogen fuel cell, hydrogen is fed to the anode while oxygen from the air is fed to the cathode. A catalyst at the anode triggers the splitting of hydrogen molecules into protons and electrons. This separation is crucial; the electrons take a route through an external circuit, generating electricity, while the protons move through the electrolyte to the cathode. Here, they reunite with the electrons and oxygen to produce water vapor and heat. The synergy of these processes underscores the efficiency and environmental benefits of hydrogen fuel cells. “It’s an intrinsically simple system, but highly efficient and extremely green, producing only water vapor out of the exhaust pipe, so to speak, and doesn’t rely on electricity from the National Grid,” explains Oliver Jackson, a senior research engineer at Intelligent Energy, the UK’s leader in hydrogen fuel cell technology.
Innovations in Using Electric Energy
The versatility of hydrogen fuel cells extends across multiple sectors, including the aerospace industry. The potential to replace fossil fuel-powered jet engines with electrically powered alternatives is not just a distant dream; it’s becoming increasingly realistic. “It’s really exciting stuff,” Jackson notes.
Intelligent Energy has a rich history, having emerged as a spin-off from Loughborough University in 2001, where its first fuel cell project started in 1988. Fast forward over two decades, and through collaborations with prominent names like Suzuki, Airbus, Boeing, and BMW, the company has grown to employ around 250 people and serves clients globally. Their hydrogen fuel cell products are making waves in various industries—automotive, aerospace, power generation, telecoms, marine, rail, UAV, and materials handling.
An interesting historical note from Jackson emphasizes the evolution of hydrogen technology: “The first hydrogen fuel cell was developed by Welshman William Grove in 1838, with the modern electric battery invented by Alessandro Volta some forty-two years earlier.” This historical context highlights just how far hydrogen technology has come in recent decades.
“Hydrogen fuel cell technology has progressed significantly in just the last 35 years,” Jackson adds. “Our collaborations with major global companies have been instrumental in this evolution. Reaching net zero is the primary goal, along with driving down costs. However, the industry faces challenges in developing lighter, cheaper, and more efficient fuel cells to meet these targets.”
Testing for More than Just Quality Control
The innovation landscape necessitates rigorous materials testing, making it a key focus in research and development. If lighter or more cost-effective materials can be proven to perform just as well after a robust testing program, they can be integrated into manufacturing processes, promoting better cost-effectiveness and viability.
Intelligent Energy’s in-house research team extensively employs Tinius Olsen equipment to assess materials for mechanical attributes such as tensile, compressive, and bending strength. Jackson elaborates, “If we’re on a mission to create a lighter, fine material, we must ensure it’s strong and durable for its intended applications.”
The testing regime is comprehensive; it includes assessing electrical resistance, coatings, and even the transport properties of materials such as the carbon papers used for gas diffusion. The team must apply different pressures to understand how material properties change under various conditions.
In addition, they conduct extensive tests on gaskets and seals while collaborating with other departments, including mechanical design teams, to evaluate new designs and prototypes. The data collected on material properties significantly impacts modeling, quality assurance, and production efforts, critically informing batch variability and defect analysis.
Materials Testing Moves the Industry Forward
Jackson highlights the importance of thorough testing: “Our partnership with Tinius Olsen is fundamental to what we do, as their support is on the front lines of our development process. This ensures confidence in both the materials used and the final products delivered to customers.”
“Customers can only be as confident in your products as you are. The more testing we conduct, the greater our trust in our work, and the more willing we are to supply customers without worrying about product performance. A product not up to specification can lead to returns and increased support needs to correct issues.” Jackson emphasizes the goal of getting it right the first time while continuously improving systems for better customer outcomes.
As Intelligent Energy progresses rapidly in hydrogen fuel cell technology development, it remains poised at the forefront of innovation. With major automotive players like BMW and Toyota investing heavily in hydrogen-powered vehicles, the work being done today could lead to a technology that rivals, or even surpasses, current battery-powered systems.