Examples Projects PDF

Electrochemical Car
Daniell Cell Car

Joshua Addis
Ramasamy Palaniappan
Mahesh Biradar

ChE-555 Analysis Of Electrochemical Systems

December 07, 2006
2 Ohio University - Institute for Corrosion and Multiphase Technology
y
x
Description of Electrochemical
Reaction/Power Source
The Daniell Cell
The Daniell Cell
Anodic:

Electrochemical reaction:
Overall reaction:
2 2 2
C H O CO H + ! +
Cathodic:

Electrochemistry
E
0
= 0.763 V vs.
SHE
E
0
= 0.340 V vs.
SHE
Zn
(s)
! Zn
2+
(aq)
+ 2e
-

Cu
2+
(aq)
+ 2e
-
! Cu
(s)

Zn
(s)
+ Cu
2+
(aq)
! Zn
2+
(aq)
+ Cu
(s)

E
0
= 1.103 V vs.
SHE
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Environmental/Safety
Features

Design Flaws
Cell Set-Up
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Daniell Cell with a Porous Filter
Image Source: http://quiz2.chem.arizona.edu/preproom/demo%20Files/cu-zn_battery.htm
Cell Set-Up
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Daniell Cell with a Porous Cup
Image Source: http://quiz2.chem.arizona.edu/preproom/demo%20Files/cu-zn_battery.htm
y
x
Testing the Daniell Cell
Optimizing the Electrolyte Solution
Effect of Electrolyte and Concentration
Electrolyte Lower Concentration
(0.5 M)
Higher Concentration
(1.0 M)
Voltage
(V)
Current
(A)
Voltage (V) Current
(A)
CuSO
4
1.01 0.210 1.01 0.280
ZnSO
4
1 0.005 - -
CuSO
4
+
ZnSO
4
1.01 0.200 - -
HCl
0.792 0.098 0.79 0.126
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
(0.5 M HCl)
(1.0 M HCl)
Voltage
(V)
Current
(A)
Voltage
(V)
Current
(A)
CuSO
4
(0.5 M)
0.75 0.250 0.80 0.290
CuSO
4
(1 M)
0.75 0.250 0.80 0.290
CuSO
4
(0.5 M)
+
ZnSO
4
(0.5M)

0.87

0.370

0.90

0.383
Effect of Hydrochloric Acid in the Electrolyte
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
(0.5 M)
(1.0 M)
Voltage
(V)
Current
(A)
Voltage
(V)
Current
(A)
CuSO
4
0.74 0.310 0.80 0.260
ZnSO
4
- - - -
CuSO
4
+
ZnSO
4

0.875

0.230

-

-
HCl
0.71 0.105 0.73 0.135
CuSO
4
(0.5 M)
+
ZnSO
4
(0.5M)
+
HCl (0.5M)

0.150

0.085

-

-
Effect of Saturated Salt in the Electrolyte
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Conclusion from Electrolyte Testing
Using hydrochloric acid
! Eats away too much zinc
! Bubbles form
Copper Sulfate + Zinc Sulfate
! No significant change in current or voltage
Copper Sulfate + Zinc Sulfate + Hydrochloric Acid
! Significantly increased current
! Acid eats away zinc

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Conclusion from Electrolyte Testing
Pure copper sulfate chosen as electrolyte
! No significant difference between pure copper
sulfate and other electrolytes
! HCl does help but eats away at zinc
Was going to be used as braking mechanism

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Proposed Braking Mechanism (1)
Zinc gets plated by copper sulfate
Reaction stops after a certain time
Zinc surface area will get completely covered
! Some current lost due to this reaction

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Proposed Braking Mechanism (2)
Wires used Time Taken (minutes)
HCl (3 M) HCl (6 M)
Thick wire
(0.091)
24 4
Flattened
wire
17 <1
Electrochemical Fuse: Cu and Zinc wire
in contact in an HCl Solution. Zinc acts
as the anode and is Corroded. Copper
acts as the Cathode.
y
x
Optimizing Power Output

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Series/Parallel Connection
Series Connection
! Increases voltage
! Voltages are additive
Parallel Connection
! Increases current
! Currents are additive


Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Series Connection
+ ! + !
Voltage = 2 V
Current = 1 A
Voltage = 1 V
Current = 1 A

Voltage = 1 V
Current = 1 A


Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Parallel Connection
+ !
+ !
Voltage = 1 V
Current = 2 A
Voltage = 1 V
Current = 1 A

Voltage = 1 V
Current = 1 A

Electrolyte One Cell Two in Series
Connection
1 Molar Voltage
(V)
Current
(A)
Voltage (V) Current
(A)
CuSO
4
0.91 0.210 1.80 .217
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Electrolyte One Cell Two in Parallel
Connection
1 Molar Voltage
(V)
Current
(A)
Voltage (V) Current
(A)
CuSO
4
0.91 0.210 0.89 0.389
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
y
x
Unique Features/Design Creativity

1. Three wheel design
Lighter
Compact

2. Plexiglas wheels
Decrease friction
More rpm than using heavier wheels

3. No gears, gear shaft
Wheel attached directly to motor shaft
4. Made from Legos
Easy construction
Lightweight
Allows disassembly and repair
Design flexibility

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
y
x
Environmental/Safety Features

Wear protective goggles
Wear protective gloves
Use concentrated HCl in fume hood
Clean spills immediately
If chemical contact with skin, wash
immediately and flush with water

General Safety
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws

Copper Sulfate Pentahydrate (CuSO
4
5H
2
O)
Harmful if swallowed
Digestive and repiratory tract irritation with
possible burns
Eye and skin irritation
Mutagen
Possible sensitizer
Target Organs
Blood, kidney, liver
Chemical Safety
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws

Zinc Sulfate Heptahydrate (ZnSO
4
7H
2
O)
Harmful if swallowed
Digestive and respiratory tract irritation
Eye and skin irritation
Target Organs
None
Chemical Safety
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws

Hydrochloric Acid (HCl)
Corrosive
Skin and eye burns
Respiratory and digestive tract irritation
with possible burns
Possible sensitizer
Target Organs
Teeth
Circulatory system
Chemical Safety
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws

Chemicals are in covered container
Bottles covered with parafilm
Exposed electrical contacts
Low voltage and current
No concern

Safety Features Concerning Car Operation
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
y
x
Design Flaws
Design Flaws

Motor will spin with supplied current and
voltage from wet cell
Vehicle will not move when wheels contact
ground
Mechanical problems
AAA battery will supply enough power to
move the car
Not getting enough power from the wet cell

Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Design Flaws

Two Cells in Series
Voltage = 1.8 V
Current = 0.217 A
Power = V x I = 0.39 W

Two Cells in Parallel
Voltage = 0.89 V
Current = 0.389 A
Power = V x I = 0.35 W
Power Calculation
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Design Flaws

Not enough power to move car
Could increase voltage or current
Increasing current
More surface area of electrodes
Parallel connection
Increasing voltage
Different materials (Aluminum, Carbon)
Series connection
Weight considerations with more cells
Power Calculation
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Design Flaws

At first the design used wide, gripping tires
Too much friction
Changed to lighter plexiglas wheels
Less friction
Wheels tended to spin out
With AAA battery supplying current
Tried to use tape to get more grip
Wheel design
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Design Flaws

Need more power
Increased voltage and/or current
Car would move with AAA battery
Shows sufficient car design
Battery needs to be optimized
Not enough cells to generate power
Not enough room to add more cells
Porous cup would help increase current
Current is lost due to copper plating on zinc
Conclusions
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
Design Flaws

Conclusions
Car needs to be bigger to accommodate more
cells
Bigger motor to get more torque
Plexiglas tires will work if car is heavier
More down force to increase traction
Description of
Electrochemical
Reaction/Power
Source

Unique Features/
Design Creativity

Features

Design Flaws
y
x
Questions, Comments, Concerns
Electro-Chem-E-Car
Swamp Thang
Ben Hanna
Dan Hauser
Dezra Hinkson
Bill Hurder
David McCandlish

Initial Design
Swamp Thang
Unique Features of the Vehicle
! Fuel Cell Chamber
! Use of NaBH
4
gives higher power output
! One molecule of NaBH
4
gives 8 electrons
! Inexpensive design
! Disassembles to fit required size limits
! Light weight materials for greater efficiency
! State of the art stopping mechanism
! Durable rubber tires
Problems encountered
with alcohol fuel
! Use of Ethanol gave rise to problems
! Inconsistent results due to poisoning of
electrodes from Carbon Monoxide
! Two fuel cells in series were needed to run
vehicle
! Less voltage output than NaBH
4

Voltage output
Current,
mA
Voltage with
NaBH
4
fuel,
V
Voltage with
alcohol fuel,
V
0 0.90 0.7
50 0.80 0.5
100 0.76 0.3
200 0.69 -
500 0.47 -
Fuel Cell Design
FUEL:
KOH + NaBH4
Cell Schematic
V
Anode
Cathode
-
+
e-
Current
Galvanic Cell Schematic
Electrochemical Reactions
! Anode:
(1) NaBH
4
+ 8 OH
-
" NaBO
2
+ 6 H
2
O + 8e
-
E
o
=

1.2V
(2) NaBH
4
+ 2 H
2
O " NaBO
2
+ 4 H
2

H
2
+ 2 OH
-
" 2 H
2
O + 2e
-

! Cathode:
O
2
+ 2 H
2
O + 4e
-
" 4 OH
-
E
o
= 0.401 V

! Net Reaction:
NaBH
4
+ 2 O
2
O" NaBO
2
+ 2 H
2
O E
o
= 1.60V
Stopping Mechanism
! Breaking the circuit by reacting away a strip of
Al wire with 6N HCl:
2 Al + 6 HCl " 2 AlCl
3
+ 3 H
2
! Al wire is pretreated in acid for 1 minute and 20
seconds
! The time taken for the complete reaction of Al
is approximately 2 minutes and 15 seconds

Problems encountered with stopping
mechanism
! Inconsistent results
! Different sizes of Aluminum tested
! Slight differences in concentrations of acid due to
AlCl
3
buildup from previous trials
! Calibration correlations with the cell, which was
found to be slightly inconsistent
Time ran vs. Distance Traveled
y = 0.2046x
R
2
= 0.9347
0
5
10
15
20
25
30
35
0 50 100 150 200
Time(seconds)
D
i
s
t
a
n
c
e
(
f
e
e
t
)
Vehicle Control
Safety/Environmental
Considerations
! H
2
gas evolution:
! H
2
is extremely flammable.
! Limit the amount of reactant used to avoid
exceeding flammability limit
! NaBH
4
:
! Toxic substance
! Handle with care. Use gloves.
! Dispose in proper waste container

Safety/Environmental
Considerations Cont.
! KOH:
! Corrosive, harmful if inhaled or ingested.
! Handle with care. Use gloves and proper eye
protection.
! Hydrochloric Acid:
! Corrosive, harmful if inhaled or ingested.
! Handle with care. Use gloves and proper eye
protection.
! Flush down drain with running water.
LeClanch Trike
Bryan Boggs, Dammy Daramola, and
Channa De Silva

ChE 555 ~ Analysis of Electrochemical
Systems Chem-E-Car Project
2
Electrochemical Device
Dry cell battery that uses a Zinc container as the anode,
Manganese(IV) Oxide as the cathode, and a Carbon rod as
the current collector [1].
LeClanche! Cell
Courtesy of Wikipedia [1]
Electrochemical
Reaction
Unique Features Design Creativity Safety & Environ. Vehicle Calibration
3
Georges LeClanche! is
famous for inventing the
LeClanche! cell which was
a precursor to the modern
day dry cell.
He was a French electrical
engineer (1839-1882)[2]
LeClanche! Himself
Electrochemical
Reaction
Courtesy of Google Images
4
Cell Design ~ Zn|Zn
+2
|| ZnCl
2
||Mn
2
O
3
|MnO
2
Anode:
Zinc Container
Cathode:
Manganese(IV) Oxide
Electrolyte:
Zinc Chloride
*Carbon powder improves conductivity and provides moisture
retention
Separator:
Felted Paper
Electrochemical
Reaction
Current Collector:
Carbon Rod
5
! +
+ " e aq Zn s Zn 2 ) ( ) (
2
) ( ) ( 2 ) ( 2 ) ( 2
2 3 2 2
l O H s O Mn e aq H s MnO + ! + +
" +
Mechanism (E
0
vs. SHE) [3,4]
Anode: Oxidation of Zinc (E
0
= 0.763 V)
Cathode: Reduction of Manganese Dioxide (E
0
= 1.081V)
Overall (E
0
= 1.844 V) :
) ( ) ( ) ( ) ( 2 ) ( 2 ) (
2 3 2
2
2
l O H s O Mn aq Zn aq H s MnO s Zn + + ! + +
+ +
Electrochemical
Reaction
Anode
(-)
Cathode
(+)
e e
i
1.84 V
6
Cathode Mix
Component % / wt.
Manganese(IV) Oxide 56.0 %
Acetylene Black 9.0 %
Zinc Oxide 0.3 %
Zinc Chloride 9.0 %
Water 25.7 %
Electrochemical
Reaction
7
Theoretical Capacity Zn/MnO
2
[1]
Electrochemical
Reaction
e
e
M g eq
hr A
C
1
8 . 26
!
!
=
e
C
e
M where theoretical capacity and is
equivalent weight
g eq
g
M
mol
g
MW
Zn e
Zn
!
=
=
75 . 32
49 . 65
,
g eq
g
M
mol
g
MW
MnO e
MnO
!
=
=
47 . 43
93 . 86
2
2
,
g
hr mA
C
Zn
e
!
= 818
,
g
hr mA
C
MnO
e
!
= 617
2
,
8
LeClanche! Trike
Schematic
Materials
1. Acrylic chassis and
wheels
2. DC-geared motor
3. Zinc/MnO
2
Build-
A-Battery Kit
4. Reversible PEMFC
5. Aluminum bearings
6. Aluminum axle
7. Nylon shaft collars
Electrochemical
Reaction
9
LeClanche! Trike
Budget
Order # Materials Cost
1 Acrylic $13.65
2 Shaft Collars $8.44
3 Rev. PEMFC $139.00
4 Bearings $21.64
5 DC Motor $2.99
6 Aluminum Axle $3.05
7 Wires/Switches $12.27
8 Screws & Nuts $3.22
9 Battery Materials $11.88
Total $216.14
Electrochemical
Reaction
10
The Batterys Job
H
2
O Electrolysis/PEMFC [5]
Electrochemical
Reaction
Unique Features Design Creativity Safety & Environ.
Vehicle Calibration
Electrolyzer
Zn/MnO
2
11
The Batterys Job
H
2
O Electrolyzer [5]
Electrochemical
Reaction
Vehicle Calibration
Electrolyzer Operation
Normal working voltage:
1.5 - 1.8 V
Current: 0-500 mA
Storage capacity of H
2
and
O
2
: 15 mL

12
Zn/MnO
2
Single Cell ~ Charging PEMFC
Electrochemical
Reaction
Vehicle Calibration
+
-
Zn/MnO
2
-
+
0.72 V
0.35A
13
Zn/MnO
2
Electrochemical
Reaction
Vehicle Calibration
Parallel
Zn/MnO
2
Zn/MnO
2
+
-
-
+
1.41 V
0.36 A
PEMFC Charging (Parallel vs. Series)
Series
Zn/MnO
2
Zn/MnO
2
+
-
-
+
1.61 V
0.34 A
14
Zn/MnO
2
Electrochemical
Reaction
Vehicle Calibration
Single/Parallel/Series Characterization
15
Zn/MnO
2
Electrochemical
Reaction
Vehicle Calibration
Possible Discharge Reactions Single Cell
16
LeClanche! Trike
Equipment Layout
Electrochemical
Reaction
17
Safety & The Environments
Safety Concerns
1. In 1995, there were reports of exploding
flashlights. This occurred because H
2
gas is
produced naturally from the corrosion of Zn in
the aqueous electrolyte.
2. Electrolyte (ZnCl
2
) is corrosive and causes
irritation
3. Have proven to cause sparks resulting in fires
4. Water and electricity present!can cause
shock
Electrochemical
Reaction
18
Safety and The Environment
1. Since Zinc is oxidized, the Zinc container
becomes thinner and thinner over time. As a
result, materials found in the cathode mix, in
particular ZnCl
2
, will leak.
2. Are not hazardous under U.S. Federal Law
3. Zn-C batteries are not rechargeable!build
up of batteries in waste dumps
4. Battery industries have demonstrated
recycling batteries via furnace
Environmental Concerns
Electrochemical
Reaction
19
0.5-1.5 V Solar DC-Geared Motor
Power Consumption (76 1 mW)
Electrochemical
Reaction
20
Reversible PEMFC
Voltage vs. Time (Power Generation 80 1 mW)
Electrochemical
Reaction
21
Vehicle Control
Calibration based on volume of hydrogen vs. distance the car
travels. A wide range was tested to obtain a curve that can be
interpolated.

A curve for both 50 and 100 g of water were prepared.

An Arbin potentiostat was used to electrolyze the water until
pre-determined volumes of hydrogen were reached in an effort
not to waste the batteries.

Matrix
Electrochemical
Reaction
22
Vehicle Control
Electrochemical
Reaction
Calibration Curves
23
References
[1] www.Wikipedia.org
[2] http://www.geocities.com/bioelectrochemistry/leclanche.htm
[3] Linden, D. Handbook of Batteries and Fuel Cells. McGraw
Hill. 1984, New York.
[4] Prentice, G. Electrochemical Engineering Principles.
Prentice Hall. 1991, Upper Saddle River, NJ.
[5] Heliocentris. Hydrogen Fuel Cell Model Car hydro-Genius
Operation Guide. 3
rd
ed. 2005, Berlin.

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Electrochemical Car

Daniell Cell Car

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