Vapor-feed direct methanol fuel cells using pure methanol

• Vapor-feed DMFCs driven by pure methanol and ambient air. • Methanol crossover rates measured by a CO 2 sensor. • Implementation of water management strategies to improve the energy density. • The achievement of an energy density of 867.73 Wh kg −1 during a 14-hour test. This work optimizes the performance of the direct methanol fuel cell (DMFC) to increase its efficiency and strengthen its validity in portable power generation. Specifically, this work focuses on optimizing vapor-feed supply techniques and incorporating water management layers (WMLs) to analyze their effect on methanol crossover. The significance of the vapor-feed supply technique is to enhance the reaction kinetics of the methanol oxidation reaction (MOR) and enable the use of pure methanol (MeOH) as a fuel. Pure methanol is the ideal fuel for the DMFC as it has the highest possible energy density compared to dilute concentrations. However, use of pure methanol is hindered by methanol crossover, which is regarded as the largest technical barrier to commercializing DMFCs. This study measured methanol crossover through a CO 2 sensor attached to the cathode outlet and added hydrophobic WMLs to the cathode to alleviate the methanol crossover. The hydrophobic WMLs increased the mass transfer resistance to generate a pressure gradient that encourages water backflow for use in both the proton exchange membrane (PEM) and anode reactions. The influence of vapor flow rate and fuel concentration will also be explored to show their impact on performance and methanol crossover. Likewise, long-term consumption and durability tests were conducted with and without a WML to dictate the WML’s superior fuel efficiency, total efficiency, energy density, and reduced methanol crossover using pure methanol. The addition of the WML increased the energy density of the vapor feed DMFC, using pure methanol, from 705.9 Wh kg MeOH -1 to 867.7 Wh kg MeOH -1 and lowered the crossover current density by 14.8 % when discharged at a constant 200 mA cm −2 .