Demand on the MEA - vtt.fi · Demand on the MEA from a stack manufacturer point of view 2010-06-21 Felix Haberl, Development Engineer Andreas Bodén, Manager Fuel Cell Development

Demand on the MEAfrom a stack manufacturer point of view

2010-06-21

Felix Haberl, Development Engineer

Andreas Bodén, Manager Fuel Cell Development

16 juni 2010 PowerCell Sweden AB Confidential Information 1

Outline

• PowerCell company presentation

• Stack specification for different applications

• Stack/system problem solving with membrane

• Stack/system problem solving with electrodes

• Demand on GDL

• Different MEA layouts

• Assembly issues• Assembly issues

• Summary

Disclaimer:

This presentation only covers the MEA aspects for PEMFC application, except portable and automotive propulsion.


PowerCell Sweden ABBringing the future to you


Owner structure

Midroc New Technology AB is a Swedish Private Equity Company focusing on ground-braking, clean technologies with an emerged window of opportunity.The company is part of Midroc Europe. Midroc Europe is wholly-owned by sheik Mohammed H. Al AmoudiCorporate Venture Capital company founded in 1983

VTT main focus:

• Bring the Volvo group closer to new technologies or new

services by investing in companies and projects of high

technical and commercial interests.

• Support the development of businesses based on Volvo

technology with a business potential outside the Volvo

Group.

• Support the development of entrepreneurship

FININDUS

sheik Mohammed H. Al AmoudiGovernmental Venture Capital

Company founded in 2008

FourierTransform Mission:

• To contribute in strengthening of the

competitiveness and vitalization of the Swedish

Automotive Cluster. OCAS Venture is a seed and early stage venture fund investing in high-potential ideas and innovations from the material world to build outstanding businesses

• Support the development of entrepreneurship


2010 Q3: Laboratory for APU and Fuelcell testing

2010: Production line for Fuel Cell assembly

2012: Production line for APU assembly

2015: Full scale product ion in total 5000 m2

Company Global Footprint

16 juni 2010 PowerCell Sweden AB Confidential Information

Powercell HQ/R&D Center/Production

Powercell Sales office and local engineering

support (2010-11)

0

20

40

60

80

100

120

2009/Q1 2009/Q3 2010 2011 2012 2013

5

PowerCell Fuel Cell Product Strategy

Main Focus

o Innovation & Reliability

� Providing customers with solutions that meet their needs and

surpasses their expectations.

o Communication & Understandingo Communication & Understanding

� By understanding the needs of OEM's and system integrators as

well as end users our products are adapted to meet the customers

specific quality and performance requirements.

o Flexibility & Scalability

� Unique platform design provides products that are scalable, cost

effective and applicable both for reformate and hydrogen gas.


Unique and patented technologyRuns on both reformate and hydrogen

High power density (kW/l)

High tolerance to CO (50ppm) contamination in the fuel

Robust design

Mechanical (designed for automotive applications)

PowerCell Fuel Celladvantages


Mechanical (designed for automotive applications)

To different operation conditions, e.g. pressure temperature etc.

Low pressure drop ═> higher system efficiency

7

PowerCell Fuel Converter

• Fuel flexible

• Ethanol, DME, biodiesel, diesel, gasoline

• Fuel infrastructure neutral

• High scalability

• Low environmental impact

• Patent design


• Patent design

8

PowerCell Fuel ConvertorTechnology 2009

• Efficiency (> 85%)

• Load changes

(turn down ratio 1-5)

• Outlet CO < 50 ppm and

no NMHC slip during steady


no NMHC slip during steady

state and transient conditions

• Pressure drop < 200 mbar

• Start-up time < 12 min

9

Power Generator Unit

Features:

•5 kW Power Generators

•Developed for robust applications

PowerCell PowerPacthe environmental friendly power generator


•Developed for robust applications

•Operates on conventional fuels

Advantages:

•Zero emission of NOx, CO, SOx

•Low noise and vibration levels

•Low thermal signature

•High fuel efficiency

10

Prioritized market segments

MarineAPU for boats

and yachts

Cars

TruckAPU for Trucks

Peace


CarsRange Extender

Mobile applicationsMotor homes,

Transport

refrigeration

Peace

keepingAPU for

portable power

StationaryHousehold,

Telecom,

Traffic system

11

Industrial applicationsForklifts

PowerCell Truck Concept

Typical area of use

Provides sleeper air conditioning

Powers household accessories

Charges the truck batteries

Warms the truck engine

Provides sleeper heating

Using existing fuel infrastructure

Legislation

Eliminate idle operation of the diesel

main engine

Lower emissions of NOx and HC

Cost efficiency

Decrease the fuel cost


Provides sleeper heating

Replacing

Conventional ICE-generator sets

Decrease the fuel cost

Compact and reliable Power Systems

Enhanced comfort

Reduced noise and vibration

12

PowerCell Marine Concept

Typical area of use

Power demand when shore power is

not available

APU part of the Power Management

System

Replacing

Electrical power supply

Off shore and in harbor areas

Increase on-board comfort level

Reduced noise levels and vibrations

Reduced smell

Compact size saves space

Cost efficiency and environmental care Conventional ICE generator sets


Cost efficiency and environmental care

Increased reliability & durability

Fuel efficient

Minimized emissions

Stack specificationsfor some applications and the effect on MEA


Target Target Target Target Market/ Market/ Market/ Market/ CriteriaCriteriaCriteriaCriteria

Marine Trucks Range extenders

Forklifts /Material handling

Telecom mCHP Traffic systems UPS

Power output [kW] 5-30 2-5 5-10 3-5 / 10-15 1-3

/ 5-10 1-2 / 5-10 1-3 5-60Lifetime [hrs] 5000 15000 5000 15000 7000 40’-80’ 1000 5000

Environm. Temp. [°C] 0-45 -40<+85 -40<+55 -30<+40 -35<+55 0-45 0-45 0-55

Fuel Diesel, Petrol, LPG Diesel Hydrogen Hydrogen Hydrogen,

methanolNatural-gas,

LPGHydrogen,

LPG, natural-gas

Hydrogen, methanol

LPG

Market technology requirements

15

Startup time relevance

High (5 min)

High (5 min)

Low (due to

battery pack)

High (20000

start/stop)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)






Power output [kW] 5-30 2-5 5-10 3-5 / 10-15 1-3

/ 5-10 1-2 / 5-10 1-3 5-60Lifetime [hrs] 5000 15000 5000 15000 7000 40’-80’ 1000 5000

Environm. Temp. [°C] 0-45 -40<+85 -40<+55 -30<+40 -35<+55 0-45 0-45 0-55



LPGHydrogen,

LPG, natural-gas

Hydrogen, methanol

LPG

Product requirements effect on Stack

16


High (5 min)

High (5 min)

Low (due to

battery pack)

High (20000

start/stop)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)

Load profile Back-up Back-up Automotive Automotive Back-up Stationary Back-up Back-up

Anode condition Reformate Reformate Hydrogen Hydrogen Hydrogen

/Reformate Reformate Hydrogen//Reformate

Hydrogen//Reformate

Cathode condition Dry-Wet Dry-Wet Dry-Wet Dry-Wet Dry-Wet Wet Dry-Wet Dry-Wet

Cold start No No Yes Yes Yes No No No






Power output [kW] 5-30 2-5 5-10 3-5 / 10-15 1-3

/ 5-10 1-2 / 5-10 1-3 5-60Lifetime [hrs] 5000 15000 5000 15000 7000 40’-80’ 1000 5000

Environm. Temp. [°C] 0-45 -40<+85 -40<+55 -30<+40 -35<+55 0-45 0-45 0-55



LPGHydrogen,

LPG, natural-gas

Hydrogen, methanol

LPG

Product requirements difficult demand

17


High (5 min)

High (5 min)

Low (due to

battery pack)

High (20000

start/stop)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)




Hydrogen//Reformate








Power output [kW] 5-30 2-5 5-10 3-5 / 10-15 1-3

/ 5-10 1-2 / 5-10 1-3 5-60Lifetime [hrs] 5000 15000 5000 15000 7000 40’-80’ 1000 5000

Environm. Temp. [°C] 0-45 -40<+85 -40<+55 -30<+40 -35<+55 0-45 0-45 0-55



LPGHydrogen,

LPG, natural-gas

Hydrogen, methanol

LPG


18


High (5 min)

High (5 min)

Low (due to

battery pack)

High (20000

start/stop)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)




Hydrogen//Reformate




Load-profile effects on MEA

• Back-up

Application demand on system

� Many start and stop depending on grid stability.

� Can have a smooth start up and shut down due to balancing with batteries

� The power demand is constant gives low voltage variation

System demand on MEA

� Low demand on load-cycling

� The MEA can be stressed by dry/wet cycling due to on/off

� No need for high current density

� Relative low mechanical stress caused by pressure swings



• Automotive


� Many start and stop depending driver behavior.


� The power demand is not constant


� High demand on load-cycling

� The MEA can be stressed by dry/wet cycling due to on/off

� Need for high current density

� Might have high mechanical stress due to pressure swings



• Stationary


� Low number of start/stop


or balancing with grid

� The power demand are constant gives low voltage variation� The power demand are constant gives low voltage variation

� High system efficiency demand

� Long life-time requirement due to cost sensitivity


� Very-low demand on load-cycling

� Low mechanical stress

� Need for high efficiency i.e. low current/high voltage

� Low voltage decay on steady-state operation






Power output [kW] 5-30 2-5 5-10 3-5 / 10-15 1-3

/ 5-10 1-2 / 5-10 1-3 5-60Lifetime [hrs] 5000 15000 5000 15000 7000 40’-80’ 1000 5000

Environm. Temp. [°C] 0-45 -40<+85 -40<+55 -30<+40 -35<+55 0-45 0-45 0-55



LPGHydrogen,

LPG, natural-gas

Hydrogen, methanol

LPG


22


High (5 min)

High (5 min)

Low (due to

battery pack)

High (20000

start/stop)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)




Hydrogen//Reformate

Cathode condition Dry-Wet Dry-Wet Dry Dry Dry-Wet Wet Dry-Wet Dry-Wet



Anode condition effects on MEA

• Hydrogen:


� High fuel utilization

� Dry gas due to bottling




� Low stochiometry or re-circulation causing dilution with Nitrogen

� Low Pt-loading

Anode condition effects on MEA

• Reformate


� High fuel utilization

� Low cost




� High CO tolerance to avoid expensive PrOx-reactors

� Gives relative wet conditions due to reformate, i.e. no need of recirculation

or humidifier.

� Risk of peroxide formation due to need of air-bleed support at higher current

densities





Power output [kW] 5-30 2-5 5-10 3-5 / 10-15 1-3

/ 5-10 1-2 / 5-10 1-3 5-60Lifetime [hrs] 5000 15000 5000 15000 7000 40’-80’ 1000 5000

Environm. Temp. [°C] 0-45 -40<+85 -40<+55 -30<+40 -35<+55 0-45 0-45 0-55



LPGHydrogen,

LPG, natural-gas

Hydrogen, methanol

LPG


25


High (5 min)

High (5 min)

Low (due to

battery pack)

High (20000

start/stop)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)




Hydrogen//Reformate




Cathode condition effects on MEA

• Dry


� Low cost solution motivates downsized humidifier


� Low crossover rate of gases� Low crossover rate of gases

� Need of peroxide defense due to cross-over

� Good performance at even at dry conditions



• Wet


� Need of long life time

� High efficiency

System demand on MEASystem demand on MEA

� To be able to handle two phase conditions



• Dry-Wet


� Systems that are shut-down often but operated fairly constant, will have a

varying humidification over a “drive”-cycle

� Large variety in load


� Good performance at both dry and wet conditions to give stable system

� Handle membrane swell/shrinking cycling

� Minimizing crossover at dry conditions

� Need to withstand peroxide formation caused by the crossover






Power output [kW] 5-30 2-5 5-10 3-5 / 10-15 1-3

/ 5-10 1-2 / 5-10 1-3 5-60Lifetime [hrs] 5000 15000 5000 15000 7000 40’-80’ 1000 5000

Environm. Temp. [°C] 0-45 -40<+85 -40<+55 -30<+40 -35<+55 0-45 0-45 0-55



LPGHydrogen,

LPG, natural-gas

Hydrogen, methanol

LPG


29


High (5 min)

High (5 min)

Low (due to

battery pack)

High (20000

start/stop)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)

Low (due to

battery pack)




Hydrogen//Reformate




Cold start demand effects on MEA

• No-cold start


� Either the system is operated in non-freezing environment or has a heating

solution when it is in shut down


� No need to dry, gives less mechanical stress


Cold start demand effects on MEA

• Cold start


� The system need to be able to be frozen


� Need to handle dry condition at start-up and shut-down� Need to handle dry condition at start-up and shut-down

� Polarization reversal might occur at start-up


Stack/system problem solving with membranewith membrane


Why solve a problem with membrane?

By choosing different membrane types

• system control might be easier and more stable

• more stable performance at a larger variety of operating parameters

• reduce number of system components


What can be done and what is the effect

Things to manipulate:

Ionomer

• increase conductivity (higher power density, more cost competitive)

• increased H2O2 resistance (increased life time)

• better performance at dry condition operation (reduce system complexity)

• reduced H -crossover (increased life time) • reduced H2-crossover (increased life time)

• resistance to higher temperature (decrease system cost)

Reinforcement

• reduces H2-crossover (increased life time)

• increased stability towards shrinking and swelling (increased mechanical

stability)



Things to manipulate:

Thickness

• thin gives improved performance (higher power density and better

performance at dryer condition)

• thicker decreases crossover rate and increases lifetime (regular good for

stationary applications where current density is low)stationary applications where current density is low)

Additive

• defense against H2O2 , i.e. increased chemical stability (increase life time)


Stack/system problem solving with electrodeselectrodes



Anode

Reduced Loading

• Reducing the anode loading gives less carbon corrosion at start and stop

• Cost is reduced

Increased CO-toleranceIncreased CO-tolerance

• Possible to use carbon monoxide richer reformate without increasing the

air-bleed amount. Less H2O2 formation, i.e. less degradation higher system

efficacy. Gives less need of optimized PrOx.

Decreased stochiometry need

• Increased system efficiency

• More robust stack





Cathode

Stability / carbon corrosion

• Increase the number of start and stops

Change of loading

• Cost reduction• Cost reduction

Alloying

• Reduced voltage drop at low current densities good for stationary

applications

Decreased stochiometry need

• Improved robustness of stack

• Higher system efficiency, less air-supply power-loss and improved system

water balance


Demand on GDL



GDL

Contact resistance

• Improved performance

Thru/in plane resistance

• Better performance• Better performance

• Reduces uneven potential distribution

Water management in Wet/Dry condition

• Stack robustness under wet condition

• Properties of transporting water




http://www.sglgroup.com/cms/international/products/product-groups/su/fuel-cell-components/index.html?__locale=en

Different MEA layouts


Different MEA part options

3-layer without sub gasket

Only membrane with two electrodes

Cheapest to buy, difficult to handle, need own knowledge on sub gasket and

GDL assembly

3-layer with sub gasket

Cheep to buy, easy to handle, difficulty is to assembly the GDLCheep to buy, easy to handle, difficulty is to assembly the GDL

5-layer with sub gasket

Normally offered product, easy handling due to stiffening with GDL

Best product if the cell design is proper for putting the sealing onto the BPP

5-layer with sub gasket and sealing

An attempting product for the future, depending on cell design

Normally not offered today due to high risk of scrap


Assembly issues


Assembly issues

With/Without sub-gasket

• A MEA without sub-gasket can be handle as a roll material difficult to

handle, high automation level

• A MEA with sub-gasket is a discrete part and robust to handle but less

automated

GDL thickness tolerancesGDL thickness tolerances

• Behavior of individual cells might differ, life time

Sealing solution

• How easy it is to assembly in a stack.


Summary


Summary

Stack specification for different applications

• Reformate/Hydrogen

• Dry /wet

• # start/stop

• Freeze capability

Stack/system problem solving with membraneStack/system problem solving with membrane

• Increased performance

• Power density at dry condition

• Life time

Stack/system problem solving with electrodes

• CO tolerance

• Low stochiometry

• Low voltage decay due to start and stop


Summary

Demand on GDL

• Support MEA at dry/wet operating conditions

• Minimize resistance

Different MEA layouts

• 3-7 layer configurations depending on need

Assembly issues

• Production tolerance

• Sealing solution


Thank you for your attention!

PowerCell Sweden AB

Address:Ruskvädersgatan 12SE-418 34 Göteborg

Sweden

www.powercell.se

23 juni 2010 PowerCell Sweden AB 50

Documents

Demand on the MEA - vtt.fi · Demand on the MEA from a stack manufacturer point of view 2010-06-21 Felix Haberl, Development Engineer Andreas Bodén, Manager Fuel Cell Development