Researchers at Washington University in St. Louis have made significant strides in hydrogen fuel technology by developing a method to stabilize iron catalysts for use in fuel cells. This breakthrough aims to cut the manufacturing costs of fuel-cell vehicles, which currently average around $70,000, compared to approximately $30,000 for gasoline-powered cars.
The high expense of fuel-cell vehicles largely stems from the reliance on platinum catalysts, which account for nearly 45% of the total cost of a fuel cell stack. As demand for fuel-cell systems rises, the price of platinum—being a precious metal—has also increased, thus limiting the technology’s scalability. By utilizing iron as a substitute, the research team hopes to create a more cost-competitive alternative for hydrogen-powered transportation, which can rival both battery-electric and internal combustion engines.
Hydrogen fuel cells exhibit remarkable efficiency, extracting over 60% of their fuel’s energy, a stark contrast to internal combustion engines that recover less than 20% of the energy in gasoline. The researchers assert that this efficiency can soar to 85% when the heat generated by the fuel cells is also used to produce electricity.
Advancing Hydrogen Fuel Technology
Led by Gang Wu, a professor at the McKelvey School of Engineering, the team focused on stabilizing iron for use in proton exchange membrane fuel cells (PEMFCs), which are particularly suited for heavy-duty vehicles such as transport trucks, buses, and construction equipment. These vehicles often operate from centralized locations, simplifying the logistical aspects of hydrogen refueling.
In contrast to passenger electric vehicles that can be charged at home, hydrogen vehicles require dedicated refueling stations. The implementation of this technology in heavy-duty fleets will create a manageable infrastructure as it scales. “Hydrogen fuel cells work to generate electricity with zero emissions via hydrogen and oxygen, two constituent parts of water,” the researchers explained in a press release.
Historically, iron has been an attractive alternative due to its abundance and low cost. Yet, it has faced stability issues when used in the acidic environment of PEMFCs. The research team addressed this challenge by developing a chemical vapor method that stabilizes iron during thermal activation, significantly enhancing catalyst stability while maintaining optimal activity within the fuel cells.
Future Steps and Broader Implications
Professor Wu highlighted that the next phase of their research will focus on refining the stabilization process to further improve catalyst performance. The goal is to develop iron-based catalysts that can match the effectiveness of precious metals. Transitioning away from platinum is viewed as a crucial step towards the wider adoption of hydrogen as a clean energy source across various sectors, including manufacturing and transport.
The ongoing research not only presents a potential cost reduction for fuel-cell vehicles but also opens up new possibilities for sectors requiring high energy density and reliable power sources, such as low-altitude aviation and artificial intelligence data centers. These fields stand to benefit significantly from the high energy density of hydrogen systems.
By resolving the stability issues associated with iron catalysts, the research team at Washington University positions hydrogen fuel cells as a viable and sustainable alternative to traditional energy sources, paving the way for a greener future in transportation and beyond.
