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An air-breathing stack for a direct formic acid fuel cell (DFAFC) was designed, fabricated and evaluated. The DFAFC stack consisted of six cells arranged in a hexagonal arrangement and each single cell contained a pair of stainless steel current collectors, a membrane electrode assembly (MEA) and a cathode end-plate. A fuel reservoir was located at the center which supplied formic acid supply to the anode of each cell. The effects of fuel concentration, palladium (Pd) loading at the anode and activation on DFAFC performance and long term operation were evaluated. DFAFC stack performance increased with increasing fuel concentration and a stable power up to 200 mW at 2.4 V was achieved for passive and ambient conditions at a 7 M fuel concentration. Catalyst loading had a slight effect on DFAFC performance, where 4 mg cm Pd loading was best for 7 M fuel operation. During long-term operation, the DFAFC stack could be operated for 27 hours without adding more fuel and less than a 20 % reduction in performance during operation. MEA reactivation with deionized water technique was required for immediate recovery of stack performance.

EFFECTS OF FUEL CONCENTRATIONS, CATALYST LOADINGS AND ACTIVATION ON THE PERFORMANCE OF DIRECT FORMIC ACID FUEL CELL (DFAFC) STACK