This study presents for the first time the results of a test bench evaluation of a 78 kWel Honda fuel cell module, originally designed for mobile applications, in a stationary combined heat and power (CHP) configuration. The module’s performance was assessed at various return temperatures (40, 50, and, 60°C) and power setpoints. Notably, the results show very efficient operation across the temperatures and power setpoints. The module achieved thermal and electrical efficiencies of over 54% and 50%, respectively, with a total efficiency of up to 97.1% with respect to the high heating value (HHV) of hydrogen. Furthermore, the hydrogen content in the exhaust gas was analyzed and the results show almost no hydrogen in the stream. These findings suggest that the Honda fuel cell module has significant potential as a highly efficient stationary power source, offering improved performance compared to commercially available hydrogen engine CHP systems, e.g. hydrogen internal combustion engines.
Battery technologies are essential for achieving net-zero carbon dioxide emissions, but their large-scale production and recycling cause notable environmental burdens. Life cycle assessment (LCA) is therefore crucial for evaluating the environmental performance of battery technologies. While conventional LCAs mainly address mature systems, emerging battery technologies are often assessed at laboratory scale and thus require methodological upscaling to estimate industrial scale impacts. Our structured literature search identifies 28 peerreviewed studies published between 2014 and 2025. Since electrode materials are typically developed and optimized at laboratory scale, environmental assessments must address both process scaling and transfer to commercially relevant cell formats, including prismatic, pouch, and cylindrical cells. Product scaling can be supported by battery-specific tools such as BatPaC and CellEst 3.0, which enable representative bills of materials. Across the reviewed studies, five main approaches were identified for scaling material and energy flows from laboratory to industrial production. Battery cell manufacturing can also be upscaled using literature-based inventories or dedicated battery modeling tools. However, uncertainty remains insufficiently addressed, and process-related scaling parameters are rarely considered. Overall, the review underscores the need to integrate sustainability assessment and industrial scaling perspectives at early stages of battery development to support targeted improvements while implementation remains feasible.
Commercial off-the-shelf (COTS) Li ion cells offer an attractive and rechargeable power source for spacecraft applications. However, since these cells are typically designed for charging above 0°C, challenging sub-zero temperatures could inflict irreversible degradation and safety hazards during in-flight operation. To address these challenges, this work explores strategies affecting their low-temperature performance. Specifically, we investigate the Li plating behavior of the COTS LG Chem 18650 HG2 cell during galvanostatic cycling at −20°C and its dependence on prior high-temperature preconditioning protocols, involving either two-week galvanostatic cycling or storage at 30°C, as well as a reference case without preconditioning, i.e., direct cycling at −20°C. Experimental cycling tests reveal distinct differences in Li metal deposition between cells subjected to these conditions. To identify the origin of these discrepancies, we combine computed tomography of the electrode microstructure with three-dimensional, spatially resolved cell modeling and analyze the simulation results.
We derive a recursive transmission line model (TLM) for the cathode catalyst layer impedance in a working PEM fuel cell. The TLM results from the approximate solution of the macro-homogeneous model equations for impedance of the CCL with fast oxygen transport and a finite proton transport rate. The classic de Levie TLM requires two orders of magnitude more "stairs" to achieve the same impedance accuracy as the recursive TLM. The recursive TLM is suitable for any mixed-conducting electrode with high conductivity of one type of charged species and fast transport of feed molecules.
