Environmental assessment of end-of-life processes for PEM fuel cells

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Poster Number:  29 

Main Presenter:    Katja Metzler 

Co-Authors:   Nico Lüdtke     Nikolas Dilger      Sabrina Zellmer      Christoph Herrmann                              

Proton exchange membrane fuel cells (PEMFCs) hold a transformative role in accelerating the shift to clean energy systems and are characterized by their ability to convert the chemical energy of hydrogen and oxygen into electrical energy with high efficiency, producing only water and heat as by-products. Operating at relatively low temperatures (50–90 °C), PEMFCs rely on a proton-conducting polymer membrane, and are suited for applications such as transport, stationary energy systems, and decentralized power generation. However, despite their environmental advantages during operation, the production of PEMFCs relies on critical raw materials such as platinum and hydrofluorocarbons, raising ecological and economic concerns alongside potential health risks. To address these challenges, eco-friendly design and circular economy principles must guide the sustainable use of PEMFCs. Recycling strategies, encompassing mechanical, chemical, or thermal processes, provide viable solutions for the
efficient end-of-life (EoL) treatment of PEMFC components.
This study applies Life Cycle Assessment (LCA) according to ISO 14040/44 to systematically evaluate the environmental impact of EoL pathways for PEMFCs, utilizing measurement data from pilot-scale recycling experiments. The goal of the study is to identify processes and materials that are associated with high environmental impacts to derive recommendations for resource-efficient process design, taking into account the technological scale of the examined processes and their scalability potential. By benchmarking recycling pathways against primary PEM production materials, the study evaluates environmental criticality of PEMFC materials and quantifies potential environmental benefits of incorporating examined EoL treatment. Methodological challenges in LCA modelling, including allocation choices, multi-material EoL flows, data gaps, and scaling effects are addressed and uncertainties due to the quality of the given data are examined. This ensures a critical evaluation and transparent
communication of the results.
The study is expected to identify environmental hotspots and to provide preliminary estimates of environmental gains from recycling relative to primary-material production. Outcomes will inform design and process optimization for resource-efficient, scalable EoL management of PEMFCs and highlight priorities for data improvements and future research.

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