Concept and demonstration of a mechanism for the automated disassembly of PEMFC stacks

To enhance sustainability and reduce the carbon footprint in the transport sector, hydrogen technologies are essential. Hydrogen systems present a viable pathway for heavy-duty applications, potentially enabling zero emissions. Fuel cell technologies, particularly Proton Exchange Membrane Fuel Cells (PEMFC), convert sustainably produced hydrogen into water and electricity, making them integral to hydrogen-based decarbonization strategies. However, the anticipated increase in PEMFC stack usage necessitates scalable manufacturing technologies and a focus on End-of-Life (EoL) considerations, as these stacks contain valuable resources like platin, steel and polymers. This research investigates automated disassembly as a means to promote efficient reuse, remanufacturing, and recycling processes. A novel disassembly mechanism is developed to extract key PEMFC stack components: Bipolar Plates (BPP) and Membrane Electrode Assembly (MEA). The study includes three distinct disassembly concepts, which are compared systematically, resulting in the selection of one mechanism for prototypical evaluation. The investigations demonstrate the potential of using cutting wires to detach BPPs and MEAs with minimal damage. Finally, tensile tests assess the necessary forces, establishing a basis for further automated solutions. Overall, the findings highlight the technological possibilities and limitations of automated disassembly for PEMFC stacks, paving the way for new industrialized systems and contributing to sustainable material circularity in heavy-duty fuel cell applications.