How A Fuel Cell Works
A fuel cell is an electrochemical device that combines hydrogen fuel and oxygen from the air to produce electricity, heat and water. Fuel cells operate without combustion, so they are virtually pollution free. Since the fuel is converted directly to electricity and heat, a fuel cell’s total system efficiency can be much higher than internal combustion engines, extracting more energy from the same amount of fuel. The fuel cell itself has no moving parts, making it a quiet and reliable source of power.
A fuel cell system typically comprises of three distinct parts, i.e. a Fuel Processor (Reformer), a Fuel Cell Stack & a Power Conditioner.
The Fuel Processor reforms the fuel (natural gas) to hydrogen gas to feed the Fuel Cell Stack. Note that the fuel cell can utilize hydrogen from a number of hydrocarbon fuels including natural gas, methanol, propane, biomass, and gasoline. In principle, any hydrogen compound will do. The emissions from reforming these various hydrocarbon fuels would still be cleaner than those from a combustion process. It is also possible to obtain hydrogen by separating water in an electrolyzer, or by extracting it from a compound that contains no carbon, such as ammonia or boron compounds.
Inside the Fuel Cell Stack, hydrogen gas and air are combined in an electrochemical process that produces Direct Current (DC) power, pure water and heat. The by product water is utilized in the operation of the power plant. The usable heat is available for meeting other facility energy requirements (e.g. hot water, space heating, air conditioning and cooling).
The Power Conditioner takes the DC power provided by the Fuel Cell Stack and conditions it to provide high quality Alternating Current (AC) power output.
Inside The Fuel Cell
The fuel cell is composed of an anode (a negative electrode that provides electrons), an electrolyte in the centre, and a cathode (a positive electrode that accepts electrons).
As hydrogen flows into the fuel cell anode, a catalyst layer on the anode helps to separate the hydrogen atoms into protons (hydrogen ions) and electrons.
The electrolyte in the centre allows only the protons to pass through the electrolyte to the cathode side of the fuel cell.
The electrons cannot pass through this electrolyte and therefore must flow through an external circuit in the form of an electric current. This current can power an electric load.
As oxygen flows into the fuel cell cathode, another catalyst layer helps the oxygen, protons and electrons combine to produce pure water and heat.
Individual fuel cells can be combined into a Fuel Cell “Stack” to increase the total electrical output.

Fuel Cell Types
Fuel cells are a family of technologies. Fuel cell types are characterized by their electrolytes and temperature of operation. Though there are many other types of fuel cells being developed, the following list seeks to identify the better known types of fuel cells currently available. With this wide array of technologies and applications possibilities, fuel cells are poised to revolutionize the way use energy today and in the future.
Proton Exchange Membrane fuel cell (PEM) – These fuel cells have a solid polymer membrane as an electrolyte. They operate at relatively low temperatures (60 -100°C), but new developments have produced higher temperature PEMs (up to 200°C). As platinum is the most chemically active substance for low temperature hydrogen separation, it is used as the catalyst. Hydrogen fuel is supplied as hydrogen gas or is reformed from methanol, ethanol, natural gas or liquefied petroleum gas and then fed into the fuel cell. The power range of existing PEMs is about 50W to 150KW with up to 50% electrical efficiency for the fuel cell itself and over 85% total efficiency when waste heat is captured for small scale space and water heating (combined heat and power or CHP).
PEM fuel cells have low weight and volume with good power-to-weight ratios, low temperature operation and quick start with full power available in minutes. These advantages make PEMs well suited for use in buildings, light duty specialty vehicle applications and potentially for much smaller applications such as replacements for rechargeable batteries. Quick-starting PEMs can also provide back-up power to telecommunications and other sites requiring uninterrupted power supplies (UPS).
Several challenges face PEMs. This type of fuel cell is also sensitive to fuel impurities and platinum catalysts are expensive and also subject to CO poisoning from hydrocarbon fuels, so membranes more resistant to chemical impurities, catalyst improvements, non-precious metal catalysts and other alternatives are also being developed.
Phosphoric Acid fuel cell (PAFC) - Phosphoric acid fuel cells are commercially available today. PAFCs are typically used for medium to large-scale stationary power generation and hundreds of fuel cell systems have been installed in several countries – in hospitals, nursing homes, hotels, office buildings, schools, utility power plants, airports, landfills and waste water treatment plants.
PAFCs use liquid phosphoric acid as an electrolyte with a platinum catalyst. Anode and cathode reactions are similar to PEMs, but operating temperatures are slightly higher (150 – 200°C) making them more tolerant to reforming impurities. PAFCs use hydrocarbon sources such as natural gas, propane or waste methane. It also has the added advantage in that it can use impure hydrogen as fuel and can tolerate a CO concentration of about 1.5%, therefore broadening the choice of fuels that can be used. The power range of existing PAFCs is 25KW to 250KW with up to 45% electrical efficiency and 85% total efficiency with co-generation of electricity and heat. However, if several units are linked together, PAFCs can achieve a combined power output greater than 1 MW (an 11 MW PAFC power plant is currently operating in Japan).
Direct Methanol fuel cell (DMFC) – These cells are similar to the PEM cells in that they both use a polymer membrane as the electrolyte. However, with DMFCs, the anode catalyst itself draws the hydrogen from unreformed liquid methanol rather than hydrogen, therefore eliminating the need for a fuel reformer. DMFCs operate at slightly higher temperatures than PEMs (120 – 190°C) and achieve around 40% electrical efficiency. DMFCs are directed toward small mobile power applications such as laptops and cell phones, using replaceable methanol cartridges with power ranges of 1-50 W.
Molten Carbonate fuel cell (MCFC) – Molten carbonate fuel cells use an electrolyte composed of a molten carbonate salt mixture suspended in a porous, chemically inert matrix, and operate at high temperatures (600 – 750°C). They require carbon dioxide and oxygen to be delivered to the cathode. The power range of existing MCFCs is 75KW to 250KW with up to 60% electrical efficiency and 85% total efficiency with co-generation of electricity and heat.
To date, MCFCs have been operated on a variety of fuels including hydrogen, carbon monoxide, natural gas, propane, landfill gas, marine diesel, and simulated coal gasification products. MCFCs are primarily targeted to electric utility applications.
Solid Oxide fuel cell (SOFC) – Solid oxide fuel cells use a hard, non-porous ceramic compound as the electrolyte, and operate at very high temperatures (800 – 1000°C). High temperature operation eliminates the need for precious metal catalysts and can reduce cost by recycling thee waste heat from internal steam reformation of hydrocarbon fuels. SOFCs are tolerant to CO poisoning, allowing CO derived from coal gas to also be employed as source of fuel. SOFCs produce a power output of 2KW to 100KW and can attain 200KW to 300KW when used in a SOFC/gas turbine hybrid system. Electrical efficiency is approximately 50% with total efficiencies of 85% with cogeneration of waste heat.
SOFCs are well-suited for medium-to-large scale, on-site power generation or CHP (hospitals, hotels, universities), and are also being marketed for telecommunications back up and as auxiliary power units (APUs) for military vehicle on-board equipment.
The challenges to both SOFC and MCFC development include slower start up when compared to other fuel cell types, requirements for strong thermal shielding, and the difficulties in developing durable materials for the higher operating temperatures.
Alkaline fuel cell (AFC) – Alkaline fuel cells use potassium hydroxide as the electrolyte and can use a variety of non-precious metal catalysts at operating temperatures slightly higher temperatures than PEMs (23 – 250°C). Fueled by hydrogen gas, AFCs have a high chemical reaction rate and offer an electrical efficiency of up to 70%. However, they are very susceptible to carbon contamination, so require pure hydrogen and oxygen.
Long used by NASA on space missions, alkaline fuel cells have been used to provide both electricity and drinking water for astronauts since the 1960s. AFCs used in the Space Shuttle missions produce 12KW of power.
Zinc Air fuel cell (ZAFC) – In a typical zinc/air fuel cell, there is a gas diffusion electrode (GDE), a zinc anode separated by electrolyte, and some form of mechanical separators. The GDE is a permeable membrane that allows atmospheric oxygen to pass through. After the oxygen has converted into hydroxyl ions and water, the hydroxyl ions will travel through an electrolyte, and reaches the zinc anode. Here, it reacts with the zinc, and forms zinc oxide. This process creates an electrical potential; when a set of ZAFCs are connected, the combined electrical potential of these cells can be used as a source of electric power. This electrochemical process is very similar to that of a PEM fuel cell, but the refueling is very different and shares characteristics with batteries. ZAFCs contain a zinc “fuel tank” and a zinc refrigerator that automatically and silently regenerates the fuel. In this closed-loop system, electricity is created as zinc and oxygen are mixed in the presence of an electrolyte (like a PEMFC), creating zinc oxide. Once fuel is used up, the system is connected to the grid and the process is reversed, leaving once again pure zinc fuel pellets. The key is that this reversing process takes only about 5 minutes to complete, so the battery recharging time hang up is not an issue. The chief advantage zinc-air technology has over other battery technologies is its high specific energy, which is a key factor that determines the running duration of a battery relative to its weight.
Protonic Ceramic fuel cell (PCFC) – This new type of fuel cell is based on a ceramic electrolyte material that exhibits high protonic conductivity at elevated temperatures. PCFCs share the thermal and kinetic advantages of high temperature operation at 700°C with MCFC and SOFCs, while exhibiting all of the intrinsic benefits of proton conduction in PEMs and PAFCs. The high operating temperature is necessary to achieve high electrical fuel efficiency with hydrocarbon fuels. PCFCs can operate at high temperatures and electrochemically oxidize fossil fuels directly to the anode. This eliminates the intermediate step of producing hydrogen through the costly reforming process. Gaseous molecules of the hydrocarbon fuel are absorbed on the surface of the anode in the presence of water vapor, and hydrogen atoms are efficiently stripped off to be absorbed into the electrolyte, with carbon dioxide as the primary reaction product. Additionally, PCFCs have a solid electrolyte so the membrane cannot dry out as with PEM fuel cells, or liquid can’t leak out as with PAFCs.
Microbial fuel cell (MFC) – Microbial fuel cells use the catalytic reaction of micro organisms such as bacteria to convert virtually any organic material into fuel. Some common compounds include glucose, acetate, and wastewater. Enclosed in oxygen-free anodes, the organic compounds are consumed (oxidized) by the bacteria or other microbes. As part of the digestive process, electrons are pulled from the compound and conducted into a circuit with the help of an inorganic mediator. MFCs operate at relatively low temperatures (20 – 40°C) when compared to other types of fuel cells. MFCs could be capable of an electrical efficiency as high as 50%.
MFCs are potentially suitable for small scale applications such as medical devices fueled by glucose in the blood, or larger applications such as water treatment plants or breweries producing organic waste that could then be used to fuel the MFCs.
Regenerative fuel cell – Regenerative fuel cells are attractive as a closed-loop form of power generation. Water is separated into hydrogen and oxygen by a solar-powered electrolyzer. The hydrogen and oxygen are fed into the fuel cell which generates electricity, heat and water. The water is then re-circulated back to the solar-powered electrolyzer and the process begins again. These types of fuel cells are currently being researched by NASA and others worldwide.