This 4 months feasibility project between ACAL Energy Ltd (AE), with its globally innovative fuel cell technology, FlowCath® & TATA Steel (TS), major UK supplier and innovator in added value on steel products, is to explore the opportunity for the use of steel or steel coated materials in FlowCath® which may enable a step change in manufacturing cost whilst improving the quality & perfromance of the technology; thereby accelerating the delivery of the weight and volume developments needed to meet automotive applications specifications. It will focus on completing an initial assessment of material compatibility between steel products with AE’s novel catalysts in general; then specifically explore the feasibility for perfromance improvements using advanced coated material options in AE’s spoecific components & the options for the manufacturing routes for production of tailor made low cost steel parts.

This project has delivered the world's first fully functioning and field- tested 1kW stand alone PEM fuel cell powered system for the pumps in an environmental monitoring outflow plant at Solvay Interox’s Warrington site, using ACAL Energy's novel low cost platinum free cathode technology, FlowCath®. The project has built a deep understanding of the design & engineering requirements of the integrated 1kW system, as well undertaking detailed research into the unique fluid flows and stack designs for ACAL Energy's novel approach, including researching MEAs and materials to ensure durability and performance. Integral to the project has been the work to meet the challenging safety requirements of the installation on the chemical plant as well implementation from the outset of remote management capability of the system. The project has been led by ACAL Energy, who built and researched the stack configurations as well leading the field trial; Southampton University, developed simulation tools & fluid modelling; Johnson Matthey Fuel Cells, world leading catalyst and MEA specialists, provided the MEA for project; Solvay Interox hosted the field system and UPS Systems plc installed & configure the integrated system. The grant enabled the consortium of high-calibre, experienced groups with funding that balanced the high risk as well accelerated the deployment of this UK invented technology.

This 4 months feasibility project between ACAL Energy (innovative fuel cell technology) & Thomas Swan (major UK supplier of sub contract chemicals) will make an assessment of options for a feasible, economic scale up route for AE’s new catalyst system, designed to deliver the performance requirements for the automotive fuel application. It will initially make an assessment of the alternative synthesis routes, complete the pre-production process steps to the manufacturing steps and deliver a report on the scaled up cost implications of the chemistry for mass market application. If successful this project not only enables Thomas Swan to apply their chemical manufacturing capability to provide a step change in volume & cost of production routes for this new chemistry, it will also develop the UK based supply chain for what will be a critical, strategic component in this novel fuel cell technology approach.

Abstracts are not currently available in GtR for all funded research. This is normally because the abstract was not required at the time of proposal submission, but may be because it included sensitive information such as personal details.

Abstracts are not currently available in GtR for all funded research. This is normally because the abstract was not required at the time of proposal submission, but may be because it included sensitive information such as personal details.