The R&D activities on Phosphoric Acid Fuel Cell (PAFC) technology at t
he Energy Research Institute, KACST, have progressed successfully duri
ng the past 3 years. The development of components with ''in-house'' k
now-how of half cells, mono cells, 100W, and 250W stacks has been quit
e successful. The 0.25 kW PAFC stack is the first prototype developed
in the Gulf countries (GCC) with ''in-house'' know-how for the prepara
tion of the large size porous carbon electrodes (anodes/cathodes), ele
ctrolyte matrices, graphite bi-polar plates, external aluminum gas man
ifolds, and other components necessary for constructing the PAFC stack
s. In this paper, details of the preparation of the porous carbon elec
trodes, electrolyte matrices, design and fabrication technique of grap
hite bi-polar plates are given. The assembly and the experimental test
results of the half cells, mono cells, 100 W, and 0.25 kW PAFC stacks
are reported.