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Zentrum für BrennstoffzellenTechnik GmbH
Dr.-Ing. Jörg Karstedt, Coordinator Emobility
World of Energy Solutions,
Stuttgart, 6.10.2014
Development of a 300 cm² stack
for automotive applications
© by ZBT – all rights reserved. Confidential – no passing on to third parties 2
ZBT – Development of a 300cm² stack for automotive applications
Content
ZBT – a brief introduction
Powertrain configurations with battery and fuel cell
Development of a 300cm² stack for automotive applications
– Component benchmarking
– BPP design
– CFD simulation and flow measurements
– Flowfield benchmark
– BPP manufacturing
– Sealing
– Testing
Conclusion
© by ZBT – all rights reserved. Confidential – no passing on to third parties 3
ZBT – Development of a 300cm² stack for automotive applications
Content
ZBT – a brief introduction
Powertrain configurations with battery and fuel cell
Development of a 300cm² stack for automotive applications
– Component benchmarking
– BPP design
– CFD simulation and flow measurements
– Flowfield benchmark
– BPP manufacturing
– Sealing
– Testing
Conclusion
© by ZBT – all rights reserved. Confidential – no passing on to third parties 4
Zentrum für BrennstoffzellenTechnik GmbH
The fuel cell research center
The fuel cell research center :
Research and development of fuel cells, hydrogen
and battery technology
Focus on industry demand
Independent service provider
100 full time employees + 40 students
Infrastructure:
1200 m² laboratory
4 confidential laboratories with 220 m²
Flexible testbenches with advanced measurement and analytics
3 climatic chambers incl. vibration testing
First accredited testing laboratory for fuel cells
120 m² injection molding/compound laboratory
Prototype production line
© by ZBT – all rights reserved. Confidential – no passing on to third parties 5
ZBT – Development of a 300cm² stack for automotive applications
Content
ZBT – a brief introduction
Powertrain configurations with battery and fuel cell
Development of a 300cm² stack for automotive applications
– Component benchmarking
– BPP design
– CFD simulation and flow measurements
– Flowfield benchmark
– BPP manufacturing
– Sealing
– Testing
Conclusion
© by ZBT – all rights reserved. Confidential – no passing on to third parties 6
Powertrain configurations with battery and fuel cell
OEM commercialization plans
source: Linde 2013
© by ZBT – all rights reserved. Confidential – no passing on to third parties 7
Powertrain configurations with battery and fuel cell
BEVs, FCVs and Fuel Cell Plug-In Hybrids
Emission free
Low Noise
Energy Diversity
Advantages
Challenges
Applications
Design criteria
Battery
Fuel Cell System
Highest TTW efficiency
Low operating cost
Private charging
High density H2 infrastructure
Increased operating cost
Battery System
Fuel Cell System
High energy, > 15 kWh
-
High power, ~ 1.5 kWh
High performance, > 80 kW
State of the art range, comfort,
refuelling time
High continuous power
Limitations range, charging
time, comfort
Public charging
Range
-
Peak power
Performance
Urban traffic High performance long distance
(>120km/h, SUVs)
Battery Electric Vehicle Fuel Cell/Battery Hybrid
source: BMW source: Toyota
© by ZBT – all rights reserved. Confidential – no passing on to third parties 8
Powertrain configurations with battery and fuel cell
Operating experience DOE field trial
Program:
7 year duration
4 OEMs, 183 fuel cell vehicles
5.8 mio. km, 500.000 individual trips
System operation:
Low fuel cell power operation dominant
Fuel cell systems rarely operated at max. power
Fuel cell downsizing enables significant cost
reductions
source: National Fuel Cell Electric Vehicle Learning Demonstration Final Report, NREL 2012
> 90% below 40% max. fuel cell power
> 95% below 50% max. fuel cell power
Fuel cell system operating power
© by ZBT – all rights reserved. Confidential – no passing on to third parties 9
Powertrain configurations with battery and fuel cell
BEVs, FCVs and Fuel Cell Plug-In Hybrids
Emission free
Low Noise
Energy Diversity
Advantages
Challenges
Applications
Design criteria
Battery
Fuel Cell System
Highest TTW efficiency
Low operating cost
Private charging
High density H2 infrastructure
Increased operating cost
Battery System
Fuel Cell System
High energy, > 15 kWh
-
High power, ~ 1.5 kWh
High performance, > 80 kW
State of the art range, comfort,
refuelling time
High continuous power
Limitations range, charging
time, comfort
Public charging
Range
-
Peak power
Performance
Urban traffic High performance long distance
(>120km/h, SUVs)
Battery Electric Vehicle Fuel Cell/Battery Hybrid
High energy, ~ 10 kWh
Low cost, ~ 30 kW
State of the art range, comfort,
refuelling time
Low operating cost
Private charging
Medium density H2
infrastructure
Limited continuous power
Optimized TCO
Average power demand
Low-cost, emission free long
distance emobility
Fuel Cell Plug-In Hybrid
source: FEV source: BMW source: Toyota
© by ZBT – all rights reserved. Confidential – no passing on to third parties 10
Powertrain configurations with battery and fuel cell
The case for Fuel Cell Plug-In Hybrids
Optimal degree of hybridization of fuel cell vehicles depends on cost development of
battery and fuel cell
Fuel Cell Plug-In Hybrid focuses on low-cost fuel cell system
Fuel cell system must provide average vehicle power demand to ensure unlimited long-
distance emobility
Battery electric operation covers short-distance
driving w/ highest efficiencies, lowest operating
cost
High value fuel hydrogen is used for long-
distance emission free mobility
source: FEV
© by ZBT – all rights reserved. Confidential – no passing on to third parties 11
Powertrain configurations with battery and fuel cell
BREEZE: Stack development for automotive applications
Project Partners: With financial support from:
Zero emissions during fuel cell operation
Significant NVH advantages compared to ICE
High efficiency
Heat available for cabin heating
Reduction of battery capacity
Re-fueling possible in approx. 3 min. source: FEV
© by ZBT – all rights reserved. Confidential – no passing on to third parties 12
Powertrain configurations with battery and fuel cell
Packaging of BREEZE fuel cell system within demo vehicle
Hydrogen Tank Fuel Cell System
source: FEV
© by ZBT – all rights reserved. Confidential – no passing on to third parties 13
Powertrain configurations with battery and fuel cell
BREEZE fuel cell stack and system specification
System:
Dimensions: 750x520x400 mm
Weight: 80-100 kg
Fuel: Hydrogen 700 bar
Refuelling time: 3 min.
Boost converter to battery voltage
Water/glycol coolant loop with automotive components
Electrically driven automotive radial compressor
Stack:
Stack power output: 33 kW, 325 A, 100 V (nom. Load)
Operating temperature: 80
C
Operating pressure: 2 bar(a)
Cell pitch: 1,2 mm
Metallic bipolar plates
No cathode humidification
Cast aluminum endplate with integrated balance of plant
components
source: FEV
© by ZBT – all rights reserved. Confidential – no passing on to third parties 14
ZBT – Development of a 300cm² stack for automotive applications
Content
ZBT – a brief introduction
Powertrain configurations with battery and fuel cell
Development of a 300cm² stack for automotive applications
– Component benchmarking
– BPP design
– CFD simulation and flow measurements
– Flowfield benchmark
– BPP manufacturing
– Sealing
– Testing
Conclusion
© by ZBT – all rights reserved. Confidential – no passing on to third parties 15
MEA Benchmark
Characterization of MEAs for specified operating conditions
– Temperature
– Pressure
– Humidity
– Stoichiometries
High performance ZBT testcell based on Baltic qcf technology
Gradient free ZBT testcell
Coating Benchmark
Extensive BPP/Coating characterization technologies available at ZBT
– Mechanical: Tensile/Flexural
– Electrical: Conductivity and contact resistance
– Corrosion current
– Hydrogen permeation
– Thermal conductivity
– Weight/Density
– In-situ durability tests
Stack development for automotive applications
Benchmarking of MEAs and coatings
© by ZBT – all rights reserved. Confidential – no passing on to third parties 16
Close cooperation between stack developers and BPP
manufacturers
Optimized implementation of stack requirements
regarding the bipolar plate design and the
manufacturability of the bipolar plates
– Flowfield layout
– Gas distribution zones
– Port dimensioning
– Sealing design
– Cooling design
Output: Initial CAD design of bipolar plate
Stack development for automotive applications
Design development bipolar plates
© by ZBT – all rights reserved. Confidential – no passing on to third parties 17
Optimization of flowfield, gas distributors and ports with CFD-
simulation
– Pressure losses
– Flow velocities
– Flow distribution
In-house flow lab at ZBT: Comparison of simulation and
measurements
– µ-PIV analysis to determine flow in the channels of the
bipolar plates
– Validation and optimization of CFD-simulations
Stack development for automotive applications
CFD flowfield optimization and µ-PIV flow measurements
© by ZBT – all rights reserved. Confidential – no passing on to third parties 18
In-house manufacturing of sample flowfield geometries by
micro-milling
1:1 reproduction of typical stamping/hydroforming flowfield
geometries (tolerances down to 2µm)
Evaluation of flowfield performance in standardized testcells
Design changes can be validated „online“
– Reduction of development time
– Elimination of tooling cost
Stack development for automotive applications
Online flowfield performance evaluation: Flowfield benchmark
© by ZBT – all rights reserved. Confidential – no passing on to third parties 19
Stack development for automotive applications
Results flowfield benchmark
70
C
2 bara
Cathode dry
Anode 50% RH
© by ZBT – all rights reserved. Confidential – no passing on to third parties 20
Stack development for automotive applications
Bipolar plate production process
Hydroforming Semi-shell plate, uncutted Laser cutting
Cut semi-shell
Laser welding
Metallic Bipolar Plates
Production process
© by ZBT – all rights reserved. Confidential – no passing on to third parties 21
Stack development for automotive applications
Sealing application at ZBT
Automated application of dispensed seals for prototypes
and small numbers of stacks
High design flexibility
High tolerance compensation
No tooling cost
Iterative sealing development
Parameter optimization dispenser
– Needle speed
– Needle height
– Flowrate
Inhouse 3D surface metrology
– Sealing height and tolerance
– Sealing width and tolerance
– Quality of sealing in radii, starting-points etc.
Development of screen printing for volume production
© by ZBT – all rights reserved. Confidential – no passing on to third parties 22
Stack development for automotive applications
In-situ testing of stacks
Characterization/Mapping of operating
parameters
Optimization of operating strategies
Durability tests/Ageing investigations and
accelerated stress tests
Cyclic operation
Contamination investigations
Climatic tests
© by ZBT – all rights reserved. Confidential – no passing on to third parties 23
Stack development for automotive applications
Performance testing of 300cm² stack
80
C / 2 bara
87
C / 3 bara
Cathode dry
Anode recirculation
© by ZBT – all rights reserved. Confidential – no passing on to third parties 24
Stack development for automotive applications
Performance testing of 300cm² stack
80
C / 2 bara
87
C / 3 bara
Cathode dry
Anode recirculation
© by ZBT – all rights reserved. Confidential – no passing on to third parties 25
ZBT – Development of a 300cm² stack for automotive applications
Content
ZBT – a brief introduction
Powertrain configurations with battery and fuel cell
Development of a 300cm² stack for automotive applications
– Component benchmarking
– BPP design
– CFD simulation and flow measurements
– Flowfield benchmark
– BPP manufacturing
– Sealing
– Testing
Conclusion
© by ZBT – all rights reserved. Confidential – no passing on to third parties 26
To achieve significant CO2 reductions in the transport sector, a portfolio of powertrain
technologies is required
ZBT – Development of a 300cm² stack for automotive applications
Conclusion
Emobility enables the utilization of different primary energy carriers, the integration of
renewable energy in the transport sector as well as local emission free, low-noise driving
Fuel cells increase the range and reduce the refuelling time of electric vehicles and can
increase their market acceptance, especially for long-distance emission free driving
Fuel Cell Plug-In Hybrids complement „Full-Power“ FCVs with a focus on operating cost
and available hydrogen infrastructure
ZBT offers engineering services for emobility and fuel cell powertrains in cooperation
with industrial partners
Thank you for your attention!
Contact:
www.zbt-duisburg.de
Zentrum für BrennstoffzellenTechnik GmbH
Dr.-Ing. Jörg Karstedt
+49 (0)203/7598-1178
Hall 2 - E23