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Auto-Stack
HFC-JU Project No.: 245142
- 3 -
Agenda 19 January 2011
Topic Venue
Auto-Stack Grenoble
Workshop on Intermediate Results Date
08.02.2011
Start
10:00End
15:30Convener Telefon-Nr. Minutes taken by Telefon-Nr. Agenda from
Jörissen +49-731-9530-605 17.01.2011
Public Distribution Consortium Members
Belenos
CEA
CRF
DANA
Daimler
FFCCT
JRC-ie
PSI
Powercell Sweden
SNECMA
Solvay
Solvicore
Umicore
Volkswagen
ZSW Discussion / Result Remark / Action
Agenda
TOP 1. Summary of System and Stack Requirements
TOP 2. Status of Stack Platform concept and -specification
TOP 3. Stakeholder Inventory and Supply Chain Analysis
TOP 4. Identification and Classification of Research Needs
TOP 5. Lunch
TOP 6. Draft of Stack technology Roadmap
TOP 7. Status of Business Model
TOP 8. Discussion
TOP 9. End of Meeting
Autostack: Workshop on Intermediate Results: Grenoble, February 8th 2011
Name Organisation E-Mail
Gauthier Wime Alphea Hydrogene Forbach [email protected]
Uwe Hannesen Belenos [email protected]
Secondo Sibona C.R.F. [email protected]
Pars Mukish CEA [email protected]
Isabelle Noirot CEA Grenoble [email protected]
Thierry Priem CEA Grenoble [email protected]
Raimund Ströbel Dana [email protected]
Torsten Knöri DLR [email protected]
Timo Bednarek elringKlinger AG [email protected]
Carlos Navas FCH [email protected]
Carsten Cremers Fraunhofer ICT [email protected]
Volker Banhardt Freudenberg FCCT [email protected]
Frank Erbach Harro Hoefliger GmbH [email protected]
Bruno Cocheteux Harro Hoefliger GmbH [email protected]
Jean-Marc le Canut INEVA/CNRT Belfort [email protected]
Georgios Tsotridis JRC [email protected]
Nicolas Bailly Lepmi/Ademe [email protected]
Stefan Kreitmeier PSI [email protected]
Come Loevenbruck Snecma [email protected]
Ludwig Jörissen ZSW [email protected]
Andre Martin ZSW [email protected]
Daimler AG
Workshop on Automotive Stack Design Options, Platform Concept, and Cost Targets
AUTOSTACK Workshop
Feb8th 2011, Grenoble
F. Finsterwalder
1
Content
1. Introduction
2. Summary of system requirements and stack specification
3. Conclusions for design options and platform concept
4. Critical trade-offs - Power density vs. Pt-loading
2
Autostack: The Objectives
• Analyze– vehicle requirements
– supply industry
– Cost and cost drivers
• Identify– synergy potential
– Research needs
• Propose– Consitent dvelopment road map
– Business model
3
Combining Expertise
3
Automotive
OEMsResearchInstitutes
Component and System Suppliers
Autostack Consortium
4
Tackling the Issue
OEM-System Reqirements
Stack Platform Definition
Detailed Stack Specifications
Component Requirements
Supplier Survey
Component Performance
Stack Specifications
„Top-Down“
„Bottom-Up“
Virtual Stack Design
55
Project Workflow
WP1 OEM System RequirementsWP1 OEM System Requirements
WP2 Supply Chain & ResearchWP2 Supply Chain & Research
WP4 Business ModelWP4 Business Model
WP3 Road MapWP3 Road Map
01.01.2010
30.06.2011
7
Micro-Kompakt
Klein-laster
B-EV
FC-EV
SchwererLKW
MittlererLKW
Überland-Bus
City-BusLuxus- &
Familien-FzgeMittel-Klasse
Kompakt-Klasse
possible Possible with restrictions Today not possible
Suitability of Battery / Fuel Cell Drive Train for Various Vehicles
E-Drive-Portfolio – Opportunities and Limitations
Long Distance Interurban Urban
Fuel Cell
Battery Drive
Combustion Engine
Hybridization
Plug-In/Range Extender
8
FC System Concept:Basic Requirements to Observe
• Power / gravimetric / volumetric Power Density
• Cost
• Durability
• (Freeze)-Start-up time
• Efficiency superior to any (hybrid)-ICE
• One Fuel on Board (H2)
These requirements strongly reduce the number of system options…
comparable to ICE
9
Automotive System Architecture
M
anode
cathode
coolant
MM
humidifier
radiator
MM
H2-blower
M
anode
cathode
coolant
MM
humidifier
radiator
MM
Simplified schematic
Features:• Air compressor without
expander• Gas-to-gas humidifier
(cathode out cathode in)
• High power density stack• An active / passive
H2 recirculation pumpp = 1 .. 2 bar abs
T = 55 .. 95°C max (outlet)
Rh cathode @ max power = 50%
14
Conclusion
• FC-systems designers have to respect many ambitious requirements. The number of concepts able to fulfill these requirements is small
• OEMs participating in AUTOSTACK have agreed commonly on a system concept of choice
• Other promising system concepts exist, are however not broadly accepted within the automotive industry. Still, they should be further considered, in particular for the earlier markets.
17
Components Considered Part of the Stack
• Bipolar plates, MEA, Seals• Current Collectors + end plates• Stack compression kit• Casing / Housing (also for EMC*)• Flanges (quick connectors)• HV-Contactors + interlock• Vehicle mounts (brackets)• End cell heaters (PTCs) integrated in the stack enclosure – may be used for
stack discharge• Sensors (also for diagnostic purposes - may be removed at a later stage):
– Pressure: Coolant in- and outlet, Fuel in- and out, Oxidant in- and out– Temperature: Coolant in- and outlet; Fuel in- and out; Oxidant in- and out, End Cells– RH-sensors in the header (manifold part)
• Cell Voltage Monitoring Unit: – This will be required during development phase - Aim is to remove CVM– Already today, control strategy must be developed without the need for individual cell
voltage monitoring!
*electromagnetic compatibility
19
High Level Stack Requirements
Stack nominal power (gross, continuous) 95 kW (requirement)(System power 80 kW)
Stack Open Circuit Voltage <430 V (requirement)(limit set by power electronics – consider OCV > 1V @ freeze T)
Minimum stack voltage >200 V (guidance)(limit depending on E-motor and DC/DC converter characteristics)
Weight <60 kg
Volume <50 l
Operating Temperature min -25°C (start capability)max +95°C (outlet temp.)
Interface parameters at nominal powerPressure 2 baraAir Stiochiometry 1,6 Humidification 50%
20
Plate Design
Area Power density 95 kW, 1 W/cm2
Cell voltage at nominal power 0,67 VCurrent density at nominal power 1,5 A/cm2
Active area of stack 9.5 m2
Number of cells (1-row stack is a requirement) 300 .. 380 (stack height!)
Active are area per cell (projected) 317 cm2
Plate Area (a.a. = 60% of plate area) 528 cm2
Cell pitch 1,5 mm
Ci
Ao
Ai
Co
Wi Wo
Active Area (aspect ratio 1:3)Port
Region Transition
Region
Preliminary Plate Design (1 Path parallel Flow Field)
30,8 cm
10,3 cm
Plate Dimensions:
11,3 x 46,8 cm2
22
Degradation Targets
• Throughout its lifetime the stack is allowed to degrade by 10% in max. power output, i.e. 1 W/cm2 0.9 W/cm2
• The max power is limited by the cooling power
• Therefore, the stack will be operated at maximum waste heat during its life
• As the stack degrades, the max power point will move to lower voltage and – in order to keep the waste heat constant – to lower current density, i.e. max power point moves along the “iso-waste heat” curve
24
Operating Strategy and Turn-Down Ratio
• The stack can be operated efficiently and stable within certain limits (highest power/lowest power = turn-down ratio)
• This results from the conflict of flow homogeneity vs. pressure dropknown in fluid dynamics
• Very low and very high power demands will be covered by the battery Hybridization
• This implies a start/stop strategy for the stack
• The stack will be switched of between5% and 10% of its nominal power,i.e. 5 kW .. 10 kW (= the required size of the battery. This corresponding to a TDR of 1:10 .. 1:20)
Pre
ssur
e dr
op
in s
tack
Current density / volumetric flow / load
pmax
pmin
p high
p low
Efficiency lossesStable operation
Stable+efficientoperating regime (determines the turn down ratio)
27
acceleration H2 depletion
deceleration high p
between A / C
low power stack stop extended stop O2
ingressPotential cycling
catalyst corrosion?
Drive Cycle Analysis
Stress Factors in a “Real” Drive Cycle
31
Conflicting Targets / Major Gaps
Power Density / Efficiency
Pt loading Durability
1 W/cm2 / 0.8 V @ 0.2 A/cm2
0,16 mg/cm2 5000 hrs, >20,000 starts
33
Gap Power Density / Pt LoadingFuel efficiency targets might even be more challenging
relevant for fuel efficiency relevant for top speed
36
Optimize the €/kW Parameter- with a given catalyst layer technology
Save Membrane?high Pt loading, small membrane area
Save Platinum?low Pt loading, large membrane
area
Pt Ptmembrane
Finding the best compromise between Pt loading and power density
39
Pt Loading Variation (logarithmic fit)and Resulting Stack Power Costs
41
Summary & Conclusion
• The cost optimized Pt loading is influenced by:- the costs of membrane, GDL, BIP vs. Pt- the power density characteristics of the MEA
• With today’s MEA technology and price structure do not address low Pt loading at the expense of power density
• Power density is paramount target.High power density allows standardization, thus cost reduction
42
Standardization & Economies of Scale
higher power density higher degree of freedom (packaging)
standardizationeconomies of scale (1)
Pt reduction economies of scale (2)
Addressing ultimate cost targets
Addressing product design targets
market volume
43
Thank you very much for your kind attention
Seite 1
Stakeholder Inventory and Supply Chain Analysis
Paul Scherrer Institut
Stefan Kreitmeier, Philipp Dietrich, Felix Büchi
8th Feb. 2011, Grenoble / CEA
2. März 2011PSI,
Autostack workshop on intermediate results
Seite 2
Analysis of the Supply Chain
1. Generate an inventory of the European stack component supply industry
2. Analyze status of present and future products
Objectives
3. Identify gap between goals and state of the art
Component properties Component cost
Seite 3
Inventory of the stack component industry
Seite 4
Inventory of the stack component industry
ca. 60 European companies are active in PEFC componentsand/or advertise „fuel cell“ in their port-folio
Seite 5
Analysis of the Supply Chain
1. Generate an inventory of the European stack component supply industry
2. Analyze status of present and future products
Objectives
3. Identify gap between goals and state of the art
Component properties Component cost
Seite 6
• limited to European suppliers
• includes data collection of product properties and cost
• for preliminary mass production(250-25.000 stacks/year)
• Timeframe 2010-2020
• for stack specification requestedby the consortium
Not all data statistically evaluable
• 350 cm2 active area
• 1 W/cm2 power density
• 0% rH at anode, < 50% rH at cathode
• …
Study for the purpose of Autostack project
Data analysis
Seite 7
Methodology
Step 1: Short questionnaire (Sept. 2010) to all European PEFC component supplier
Two step approach
Seite 8
Example: Cost range
( < 1 < < 2 < < 5 < < 10 < €/unit for… )reply rate: 34% (n=24)
Methodology
Seite 9
Methodology
Step 1: short questionnaire (Sept. 2010) to allEuropean PEFC component supplier
Step 2: NDA; extended questionnairesand interviews (Nov. 2010)
Two step approach
Data anonymisation based on averaging(a minimum of 3 replies required)
Seite 10
Reply rate: 46%
Filled questionnaires: 24 (34%)
Short questionnaires sent: 65
Interest in ext. Stakeholder group: 16
Extended questionnaires / interviews: 16
Reply rate: 74%
Methodology - Summary
Seite 11
Analysis of the Supply Chain
1. Generate an inventory of the European stack component supply industry
2. Analyze status of present and future products
Objectives
3. Identify gap between goals and state of the art
Component properties Component cost
Seite 12
Cost evaluation
Input Cost range Detailed cost
Cost Lowcost
Highcost
DTI (US) cost estimation
Seite 13
DTI study on cost estimation
B. D. James, J. A. Kalinoski, K. N. Baum, DTI, Contract Nr. DE-AC36-08GO28308, Virginia, USA, 2010.
Metallic BPP
Composite BPP
Seite 14
Stack components
Membrane
Catalyst
GDL
Material
Process
Material
Process
MEA
BPP
Sealing
Metallic
Composite
Seite 15
State of the Art - MEA
Required power density is only achievablewith a higher PGM loading
If roll good is desirable, development is necessary
Low PGM loading is in principle not an issue
Seite 16
State of the Art - Membrane
Membrane swelling needs further improvement
Durability is still critical and may not be sufficiently analyzed
Proton conductivity at required rH is still critical
Seite 17
State of the Art - metal BPP
The desired cell pitch is with an average sheet thickness of 0.065 mm feasible
Additional coating and integrated sealing can mostly be provided (->properties of coating?)
Durability may not be sufficiently analyzed
Seite 18
State of the Art - carbon BPP
The cost are critical
The thickness of carbon BPP is highly critical
Additional treatment and sealing are partly provided
Seite 192. März 2011PSI,PSI, Seite 19
Thank you very much for your kind attention
WP 2.3 : Identification and classification of research needs
AutoStack Workshop on Intermediate Results8 February 2011, Grenoble
Georgios Tsotridis
1
Research Needs – Objectives & contributors
• Objectives:
• To identify and classify further research needs for automotive fuel cell stacks and associated system aspects
• To define their priorities to close existing R&D gaps between ultimate development goals and identified state-of-the-art materials and components, and today’s stack technologies
• To support preparation of FCJ JU AIP call for proposals (2011, 2012 and beyond) and contribute to MAIP revision
• Contributors:
• JRC (task leader), CEA, ZSW, SC, SY, UC, PSI, DANA, FFCCT
2
Prerequisites for Market Introduction of automotive Fuel Cell Systems
• Performance and range similar to present vehicles powered by ICE– Available power and fuel efficiency are crucial
– Lifetime (operation and overall)
• No purpose design vehicle– Front packaging of the fuel cell power system
• Cost– Only moderate extra cost might be acceptable
3
Enablers for the Key Challenges in Automotive Fuel Cell Systems
• System net power 80 kW in a front packaging– High power density (1 W/cm2)– Low cell pitch (< 1.5 mm)
• High fuel efficiency– High average single cell voltage (> 670 mV)
• Cost– High power density (1 W/cm2)– Low noble metal loading (<1.5 mg/cm2)
• Potential conflict of interest
• Robustness: Operation under highly dynamic load including soak times at high single cell voltage– Corrosion resistant catalysts and structural materials– Resistant to frequent fuel cell power system startup and shutdown– Temperature excursions to 95°C acceptable while– Operating at low or no external humidification (<50% RH)
4
A Successful Research Agenda Needs to Address the Challenges
• Demonstrate technical feasibility– Simultaneous fulfillment of all requirements
• Power density• Cell pitch• Average single cell voltage• Operating temperature• Humidification requirements• Noble metal loading
• Development of tools for in depths understanding– Water management– Modeling to assist component, stack, and system design
• Engineering models including analysis of power flow on a system basis• Fundamental (molecular scale based) models• Cost models
• Improved components and system architecture
5
Research Needs – Assumptions
1. Automotive fuel cell stack specification based on identified OEMsystem requirements and on assessed materials and components available from European supply industry
2. Development of 1st generation stack hardware based on state-of-the-art (as of 2011) components validated against technical automotive performance requirements (volume, weight, dimension, power)
3. Development of 2nd generation stack hardware based on advanced components (AIP call 2012 and beyond) meeting additional automotive performance requirements (wide operation window: low RH, temperature; low PGM content) and cost targets for market introduction
4. Ready for market
6
Research Needs – Anticipated development evolution schematic for a European full size automotive stack
Specifications Generation 1 Generation 2 Market
State of the Art ComponentsMEA, BPP
AdvancedComponentsMEA, BPP
AIP2010
AIP2011
ff
R&D-Results
Supply Industry
2011 2013 2015 2018
7
Research Needs - Scope, R&D priorities and time frame
Short-term research needs (2011 - 2014):
• Integration of full size automotive stack– High– Development, design and validation of a competitive European automotive
stack based on the specification and technology roadmap developed in the AutoStack project
• Development of optimum power streams in fuel cell systems– High– Modelling, assessment and validation of optimum power streams between
fuel cell and energy storage devices to identify best hybridization concepts and operating strategies, determine viable start-stop concepts and appropriate stack and system design parameters based on OEM requirements
• Development of industry wide uniform performance test schemes –High
– Development and validation of commonly accepted test protocols for the reliable and consistent assessment of performance, durability and cold start of stack and system, including accelerated test cycles based on OEM requirements
8
Research Needs - Scope, R&D priorities and time frame
Medium-term research needs (from 2012 - …):
• Development of advanced MEA (membrane electrode assemblies) with increased power density, lower humidification requirements and elevated operating temperatures – High– Concerted development of advanced membranes, GDL (gas
diffusion layers), catalysts and MEA with improved durability, very high power density, low or no humidification requirements in an extended operating temperature range from -25°C up to 130°C, including validation testing according to OEM requirements
• Development of advanced low-cost bipolar plates – High– Concerted development of low cost advanced corrosion resistant,
highly conductive and gas tight bi-polar plates including appropriate sealing structures allowing cell pitch < 1 mm suitable for operation at elevated temperatures up to 130°C according to OEM requirements
9
Research Needs - Scope, R&D priorities and time frame
Medium-term research needs (from 2012 - …):
• Development of cell modelling for accelerated stack design –Medium– Development of realistic cell modelling for the assessment and
experimental verification of stack materials, components and design with particular focus on critical operating parameters for accelerated development cycles
• Development of characterization techniques for water management and state of health – High– Development of a common European tool and techniques for in-situ
(non-destructive), ex-situ (non-intrusive) and real-time characterization of water management capabilities at cell and stack level, including state-of-health monitoring
10
Research Needs - Scope, R&D priorities and time frame
Long-term research needs (post 2012):
• Material research on non noble catalyst materials – Medium– Identification and validation of suitable non noble metal catalysts to
replacement of platinum as major cost driver of fuel cells in the long term while maintaining activity comparable to Pt-based catalysts
• Development of modelling tool for MEA performance – Medium– Development and experimental verification of multi-scale modelling
tools for best understanding of the different reaction, transport and ageing phenomena of MEA
• Development of simplified system architectures and improvement of scale effects– Assessment and experimental validation of different system
concepts, including key components based on optimized energy flows for further simplification of system architectures and improved communalities
Technology Roadmap
Autostack
Workshop Intermediate results
February 8, 2011
CEA Grenoble
Per Ekdunge
PowerCell Sweden AB
8 February 2011
WP 3 Overall Objectives & Participants
• Participants– Powercell, CEA, Daimler, DANA, Freudenberg , JRC, PSI,
Solvicore, Umicore, VW, ZSW
• Objectives– Setting up a structured and consistent technology roadmap for
stack development– Check of alignment with running or required research projects– Provide a master plan
• Start: Month 10• End: Month 15• Final deliverables
– Roadmap for stack development– Masterplan for commercialization– Needed research results and insertion points
8 February 2011
Technology Road map
2
Stack State of
Art
Plattform Definition
Status of Material and Component
s
Cost Model
Research need
Technology Road Map to CommercialFuel Cell Stack for Automotive Mass Market
Trade Offs with Other Application
s
Work Package 1 Work Package 2
8 February 2011
WP 3 Timing
I II III IV V VI
Task 3.1Stack development
plan
Task 3.2Research projects
and insertion
Task 3.3Masteplan and
Milestones
WP 4: Business Model
WP1: Stack platform concept Synergies with other applications
WP2: Research needsStack cost model
8 February 2011
Stack Development plan, 1st generation stack.
• Assumptions– Fuel cell stack development begin in 2011
• The stack will be based on today's stat of art materials and components
– Fuel cell stacks needed to support fleet programs in 2015
– The fuel cell stack will have a OEM market of about 1000 units
– A trade of with other applications is possible• Total volume >10000 units
4
A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M JPhases Pre Study Concept Study Development Design Industrialisation
Engineering
2012 2013 2014 20152011
A-release B-release
B stage verification C stage verification
SP-start
P-releaseC-release
A stage verification
Stack certification
P-startProductionInvestm.
P stage verification
Start field testing
Start build
Define concept &Select Dev.Supplier
Buisniss plan estabilchment
Specification and plattform definition
Pre study
ProductionInvestm.
DRAFT
8 February 2011
Stack Development plan, 2nd generation stack.
5
• Assumptions– Fuel cell stack development begin in 2014/2015
• The stack will be based on advanced materials and components
– Fuel cell stacks needed to support mass market ramp up around 2020
– The fuel cell stack will be able to meet all the OEM requirements (from WP1) including cost targets.
– The OEM market is big enough for justify all investment and development cost
A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M JPhases Pre Study Concept Study Development Design Industrialisation
Engineering
2015 2016 2017 2018
A-release B-release
B stage verification C stage verification
SP-start
D-releaseC-release
A stage verification
Stack certification
P-startProductionInvestm.
D stage verification
Start field testing
Start build
Define concept &Select Dev.Supplier
Specification definition
Pre study ProductionInvestm.
DRAFT
WP 3.2: Research projects and insertion points
Autostack
Workshop Intermediate results
February 8, 2011
CEA Grenoble
Dr. Volker Banhardt
Freudenberg FCCT
8 February 2011 7
Task 3.2: Research Projects and Insertion Points
• Objectives– Alignment of ongoing research projects with the stack development
plan
– Insertion points of research results into the stack roadmap and the corresponding fuel cell application
• Contributors– FFCCT (leader), CEA, PSI, JRC, DANA, ZSW, SC, UC
• Description of Work– Define research needs based on topics identified in WP2.3 and
propose insertion points
• Input from: Task 2.3, Task 3.1
• Output to: Task 4.2
8 February 2011 8
Task 3.2: Subtasks
• Analysis of output from WP 2.3, 3,1
• Analyze research needs for FC stack components and align with milestones of WP3.1
• Define milestones
• Work package report
8 February 2011
Task 3.2 Research Projects and Insertion Points
• Status– Report of WP2.2 on research needs and classification
available and analysed
– FFCCT provided questionaire worked out in WP3 to AUTOSTACK partners
– provided questionaire suggests research areas
– all returned information has been collected
– insertion points are currently aligned to proposed stack development plan for generation 1 and generation 2
DRAFT
8 February 2011
Task 3.2 Research Projects and Insertion Points
• Since more input is needed to sumarize on research needs current status is open for discussion
• Questionaire for– BPP
– MEA
– GDL
– Seal
– Current collector
– Stack assembly
DRAFT
8 February 2011
Task 3.2 Research Projects and Insertion Points
• Bipolar plate
No Subtopic Requirements Developm. priority
Begin End
1 Plate material inexpensive, formable and corrosion resistant
High Q1-2012 Q3-2014
2 Plate surface coating Conductive, adhesion to plate, corrosion resistance
High Q3-2011 Q3-2014
3 Plate design (generation 1) optimized flowfield High Q3-2011 Q4-2012
4 Plate design (generation 1) optimized feed region High Q3-2011 Q4-2012
5 Plate design (generation 2) optimized flowfield medium 2013 2014
6 Plate design (generation 2) optimized feed region medium 2013 2014
DRAFT
8 February 2011
Task 3.2 Research Projects and Insertion Points
• Further components still to be included– end plates
– cell voltage monitoring
– housing
DRAFT
WP 3.3 : Master Plan and Milestones
Dr. Raimund Stroebel
DANA-Reinz
Autostack
Workshop Intermediate results
February 8, 2011
CEA Grenoble
8 February 2011 14
Task 3.3 Master Plan and Milestones
• Objectives– Master plan for automotive FC commercialization including non-
classic/emerging vehicle concepts and related application
• Contributors– DANA (leader), CEA, FFCCT, ZSW, VOLVO, DAI, VW, CRF
• Description of Work– Develop a master plan for automotive fuel cells which takes into
account the addition vehicle concepts, e.g. urban (fleet) and service vehicles, plug-in hybrids, range extenders, public transport vehicles, light traction vehicles and related applications.
– Break down the big step towards an automotive FC mass market into several smaller steps.
• Input from: Task 3.1, Task 3.2, Task 4.2
• Output to: Task 4.2.
8 February 2011 15
Task 3.3: Subtasks
• Analysis of output from WP 2.2, 3,1, 4.1, 4.2
• Analyze related FC vehicle applications
• Assess other fuel cell stack related application
• Define milestones
• Compile master plan
• Preparation of milestone report
8 February 2011 16
Task 3.3: Master plan
Performance Specification
Packaging Specification
Production Volumes
TargetApplications
Cost Goal
Define priority list of
requirements
Find Stack definition based on compromise
Unified Stack specification
8 February 2011 17
Task 3.3: Master plan
Performance Specification
Packaging Specification
Production Volumes
TargetApplication
Cost Goal
Temperature range
EOL expectations
Load spreadingMax powerMin Power
Dynamic requirements
Pressure drop
Fuel requirements
DC level, max and min Voltage, Current
8 February 2011 18
Task 3.3: Master plan
Performance Specification
Packaging Specification
Production Volumes
TargetApplication
Cost Goal
3D size, space requirements
Connection to subsystem
Main orientation
Serviceability, maintenance
Recycling
Robustness
Assembly
8 February 2011 19
Task 3.3: Master plan
Performance Specification
Packaging Specification
Production Volumes
TargetApplication
Cost Goal
Identify potential applications
Automotive range extender
Automotive traction
Industrial mobility
Other mobility; Boat …
Back up power
Electrolyser
8 February 2011 20
Task 3.3: Master plan
Plate design
Soft good selection
End hardware and assembly design
Component evaluation
and benchmark
Component specification
Unified Stack specification
Testing Production
8 February 2011 21
Task 3.3: Milestones
• Fix specifications, applications, targets and goals• Priorities technical and commercial parameter list • Fix compromise on priorities • Define unified stack specification• Evaluate extended application potential• Generate component specification• Design and select components• Benchmark and evaluate components• Stack evaluation and testing• Stack production
8 February 2011 22
Task 3.3: Applications
Application Stack size
• Automotive FC traction 50 to 100 kW
• Automotive FC range extender 5 to 30 kW
• Bus FC traction / range extender 50 to 200 kW• Boat, Ship FC traction / range extender / APU 2 to 100 kW• Truck APU 5 to 10 kW• Fork Lifts, Industrial vehicles 2 to 10 kW• UPS; Back up 2 to 100 KW?• Fuel Hydrogen, Reformate• Electrolyser
8. February 2011Dr. Raimund Stroebel
Status of Business Model
By André Martin
Auto-Stack - Workshop – Feb 8, 2011
Grenoble
WP 4 Objectives
Overall Objectives
• Compile the technical expertise needed to form a stack integrator
• Compile the financial resources needed to form a stack integrator
• Work out a business plan
• Assess options for ventures and potential candidates
1
Contents
A. Product and Markets
B. Cooperation model
C. Technology Roadmap
D. Expertise and resources
E. Implementation
2
A. Product and Markets
3
Implementing the mission
4
Common OEM Platform
Fuel Cell Stack
Two way approach to establish platform
OEM-System Requirements
Stack Platform Definition
Detailed Stack Specifications
Component Requirements
Supplier Survey
Component Performance
Stack Specifications
„Top-Down“
„Bottom-Up“
Virtual Stack Design
6
High power density is enabler for different platforms
Source: GM Equinox – next gen
95 kW gross powerScalable 5 – 95 kW220 – 430 V SCV @ 675 mVMax. 2 baraOT max. 95°C≤ 50 l / 60 kg40 € /kW@100000
The benchmark
Several applications can be supported
Transport Stationary Portable
Compact cars UPS Telecom, IT Generators
City-Buses Back-up power
Light Trucks
Special vehicles
Boats, Ferries
7
B. Cooperation Model
8
Combining expertise
9
Automotive
OEMsResearchInstitutes
Component and System Suppliers
Autostack Consortium
Facilitating commercial launch
10
Critical learning curve
€ 40
Reducing constraints for early commercialization
Cooperation enables economies of scale
Assumed production rates:1 000 vehicles / year10 000 vehicles / year50 000 vehicles / year
100 000 vehicles / year500 000 vehicles / year
Accumulating volumes of several OEMsSharing of investment burden and risksAllowing superior economies for other apps
Cost control to achieve commercial targets
CEA’s model on MEA
Cost Assessment
Tool
InputsInputs OutputOutput
MEA production cost
Bipolar Plates production cost
End Plates, current Collectors, BoPproduction cost
Data from other assessments
Genericstack
Design
C. Technology roadmap
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Business Plan Generation 1 Generation 2 Market
State-of-the-Art ComponentsMEA, BPP
2018201520132011
Technology Roadmap
AdvancedComponentsMEA, BPP
Critical targetsPower densityEfficiencyScalability Robustness@ target cost
Consistent long-term roadmap
D. Expertise and resources
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Focus on core activities
Stack -Integrator
Strategic Supply ChainManagement
Integration & Assembly
Validation Testing
Quality Management
System
Stack concept &
Specification
> Determine financial & personnel resources> Identify potential candidates for integrator role> Establish financing concept & action plan
E. Implementation
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Executing the plan
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Common OEM specification and platform is close to completion
Initial supply chain analysis is available and will be further
completed
Cost tool is established and will be fed with data
Proposals for research agenda were submitted to the FCH JU
Technology roadmap and business plan are in preparation
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You are welcome @
http://autostack.zsw-bw.de/
Thank you!
