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Ballard Power Systems
Ballard Power Systems
Fuel Cells – Current Status and Prospects for the Future
David Musil, P. Eng.Project Engineer, Advanced Automotive Development
March 30, 2006
2 March 30, 2006
Outline
1. Background on Ballard Power Systemsa. Brief Historyb. Technical Progress to Date
2. Current Status and Benefitsa. Benefits of Fleet Programs to Fuel Cell Developmentb. Remaining Challenges
3. Future Developmenta. Ballard’s Next Generation Fuel Cell Stackb. Future Development of Fuel Cellsc. Path to Commercialization
4. Conclusions
3 March 30, 2006
Outline
1. Background on Ballard Power Systemsa. Brief Historyb. Technical Progress to Date
2. Current Status and Benefitsa. Benefits of Fleet Programs to Fuel Cell Developmentb. Remaining Challenges
3. Future Developmenta. Ballard’s Next Generation Fuel Cell Stackb. Future Development of Fuel Cellsc. Path to Commercialization
4. Conclusions
4 March 30, 2006
History of Ballard Power Systems
Founded in 1979 under the name Ballard Research Inc. to conduct research and development in high-energy lithium batteries.
In 1983, Ballard began developing proton exchange membrane (PEM) fuel cells.
Proof-of-concept fuel cells followed beginning in 1989.
From 1992 to 1994, sub-scale and full-scale prototype systems were developed to demonstrate the technology.
To date, Ballard has supplied fuel cells for over 130 fuel cell vehicles in 24 cities worldwide, including the CUTE, STEP, China, and California fleet bus programs, and Daimler Chrysler, Ford, and Honda automotive fleets.
Ballard also builds fuel cells for non-automotive and stationary applications.
5 March 30, 2006
Ballard’s Fuel Cell Progress
Power Density [W/L] of Ballard's Fuel Cell Products
1133.31109.01096.5
360.3
771.7
0.0
200.0
400.0
600.0
800.0
1000.0
1200.0
1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002
Time [Years]
Pow
er D
ensi
ty [W
/L]
Mk 901 Mk 902Mk 8
Mk 7
Mk 5
6 March 30, 2006
Mk902 LD and HD Stacks
Based on Light Duty (LD) automotive stack architecture
Cell active area and terminal voltage sized for automotive application.
Modular design designed for ease of repair.
MK902 Light Duty (LD)
Mk 902 LD Mk 902 HD
4 cell row 6 cell row
440 Cell 960 Cell
85kW/300A 150kW/240A
MK902 Heavy Duty (HD)
7 March 30, 2006
Outline
1. Background on Ballard Power Systemsa. Brief Historyb. Technical Progress to Date
2. Current Status and Benefitsa. Benefits of Fleet Programs to Fuel Cell Developmentb. Remaining Challenges
3. Future Developmenta. Ballard’s Next Generation Fuel Cell Stackb. Future Development of Fuel Cellsc. Path to Commercialization
4. Conclusions
8 March 30, 2006
Fuel Cell Vehicle Design Cycle
Fuel Cell Vehicle
Design Iteration
Specifications Development
Concept Development <CR Phase>
Implementation Readiness
<IR Phase>
Design Verification
<DV Phase>
Job 1
Research and Development
3 years
2 -3 years
1-2 years1 year
1 year
9 March 30, 2006
Bus Cell Row Lifetime Status (Data to end of 2005)
0
10
20
30
40
50
60
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000+
Cell Row Operating Hours (Hrs)
Nu
mbe
r of
CR
's
CR Operational
CR Failed
Early Life Failures
(0 – 1000 Hours)
Mid-Life Failures
(1000 – 2000 Hours)
Long Life Failures
(2000+ Hours)
10 March 30, 2006
Number of Bus Failure Modes (Mk 902 – Data to end of Dec 2005)
Bus Stack Module Failure Mode Resolution Progress
-15
-10
-5
0
5
10
Sep-02
Dec-02
Mar-03
Jun-0
3
Sep-03
Dec-03
Mar-04
Jun-0
4
Sep-04
Dec-04
Mar-05
Jun-0
5
Sep-05
Dec-05
Time
Num
ber o
f Act
ive
Failu
re M
odes
Require Further Investigation
Resolution Planned
Failure Mode Resolved
Supplier Defects, Manufacturing Issues, Stack/System Interface Issues, and Random Failures of Relatively High Frequency
Random Failures of Relatively Low Frequency, Wearout, Robustness, and Materials Development/Durability
11 March 30, 2006
Mk902 – Failure Modes
Principle failure mechanisms of the Mk902
LeaksChemical attack of membraneContaminants in platesFatigue
Performance LossCorrosionCatalyst damage
Low CellsRandom failure modes leading to localized damage (usually
repairable)
12 March 30, 2006
Benefits of Fleet Programs to Fuel Cell Development
Generation of “real-world” data not available from labs.
Large data set helps identify and eliminate short, medium, and long-life failure modes.
World-wide exposure of fleets enables fuel cells to operate in numerous driving and environmental conditions. This leads to improved fuel cell designs and more realistic driving simulations in the laboratories.
Development of support industry and training of maintenance and support workers.
13 March 30, 2006
Benefits of Fleet Programs to Fuel Cell Development
Fleet programs provide validation of environmental regulation implementation schedules.
Data gathered from fleet vehicles allows for advances and changes in codes and standards for safety and certification (ex. Hydrogen emission standards - SAE J2578).
Operating conditions, specifications, and test methods can be applied to other automotive and non-automotive fuel cell applications.
14 March 30, 2006
Mk902 – Remaining Challenges
Desirable features lacking in Mk902
High temperature operationHigh temperature enables smaller fuel cells, lower cost, smallerradiator
Low catalyst loading and high power densityPrinciple material cost drivers
Low relative humidityComplicated reactant gas humidification system drives cost and volume
FreezableMk902 series is not freezable. Requires additional support equipment to permit outside storage.
15 March 30, 2006
Outline
1. Background on Ballard Power Systemsa. Brief Historyb. Technical Progress to Date
2. Current Status and Benefitsa. Benefits of Fleet Programs to Fuel Cell Developmentb. Remaining Challenges
3. Future Developmenta. Ballard’s Next Generation Fuel Cell Stackb. Future Development of Fuel Cellsc. Path to Commercialization
4. Conclusions
16 March 30, 2006
Next Generation Improvements
1. Power Density ImprovementsImproved catalystsLower cell pitchHigher cell performance
2. Improved DurabilityMembrane improvementsCatalyst improvementsSeal material improvements
3. Freeze start capability
4. Higher temperature operation
5. Lower relative humidity operation
6. Lower costHigher cell performance requires less materialLower cost materials
17 March 30, 2006
Technology Roadmap
…in one fuel cell design
REDUCING COST
INCREASING DURABILITY
INCREASING POWER DENSITY
IMPROVING FREEZE START
Ballard will demonstrate commercially
viable automotive
technology by 2010
Based on U.S. Department of Energy (DOE) Requirements.
Ballard publishes the technology updates yearly.
Forms the basis of “must meet” requirements internally.
Roadmap requirements are cascaded to component and stack roadmaps, and the technology routemap.
18 March 30, 2006
Stack Power Density
19 March 30, 2006
Durability
20 March 30, 2006
Freeze Start
21 March 30, 2006
Cost
22 March 30, 2006
Fuel Cell Vehicle Adoption
Today - 2007 2008 - 2012 2012 - 2014
CARB target: 25,000 fuel cell vehicles
Initial limited production
More fueling stations
CARB target: 2,500 fuel cell vehicles
Controlled central fleet demonstrations
100s of vehicles
Customer demonstration programs
50% plus powered by Ballard
DEVELOPING TECHNOLOGY FOR LIMITED COMMERCIAL INTRODUCTION
PROVING THE TECHNOLOGYON THE ROAD
MANUFACTURING FOR COMMERCIAL INTRODUCTION
23 March 30, 2006
FCV Commercialization Scenarios
Note: Based on Hybrid experienceSource: Office for the Study of Automotive Transportation (UMTRI), JD Power, Monitor Analysis
0
250
500
750
1,000
1,250
1,500
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023
OptimisticBaselinePessimistic
Units
(000s)
Potential FCV Market Adoption Curves (Based on Hybrid Experience)
Pre-Commercial Activities
Variable 2: FCV Adoption RatesOptimistic: 250k in 6yrs; 500k in 6yrsBaseline: 250k in 6yrs; 500k in 7yrs
Pessimistic: 250k in 6yrs; 500k in 9yrs
Variable 2: FCV Adoption RatesOptimistic: 250k in 6yrs; 500k in 6yrsBaseline: 250k in 6yrs; 500k in 7yrs
Pessimistic: 250k in 6yrs; 500k in 9yrs
Variable 1: Commercial Launch DateOptimistic: 2012Baseline: 2013
Pessimistic: 2015
Variable 1: Commercial Launch DateOptimistic: 2012Baseline: 2013
Pessimistic: 2015
24 March 30, 2006
Outline
1. Background on Ballard Power Systemsa. Brief Historyb. Technical Progress to Date
2. Current Status and Benefitsa. Benefits of Fleet Programs to Fuel Cell Developmentb. Remaining Challenges
3. Future Developmenta. Ballard’s Next Generation Fuel Cell Stackb. Future Development of Fuel Cellsc. Path to Commercialization
4. Conclusions
25 March 30, 2006
Concluding Remarks
1. Background on Ballard Power SystemsBallard has been developing PEM fuel cells since 1983.Ballard fuel cells have made huge gains in power density since 1993.
2. Current Status and Benefits
Fleet programs generate data that enables learning which can be applied to future fuel cell designs. The current design shows many advances, but is not optimal.
3. Future Development
Ballard's next generation fuel cell has progressive technology improvements aligned with long term targets established by governments and industry.Achieving the long term targets will demonstrate a commercially viable automotive fuel cell design in 2010.
26 March 30, 2006
Concluding Remarks
1. Background on Ballard Power SystemsBallard has been developing PEM fuel cells since 1983.Ballard fuel cells have made huge gains in power density since 1993.
2. Current Status and Benefits
Fleet programs generate data that enables learning which can be applied to future fuel cell designs. The current design shows many advances, but is not optimal.
3. Future Development
Ballard's next generation fuel cell has progressive technology improvements aligned with long term targets established by governments and industry.Achieving the long term targets will demonstrate a commercially viable automotive fuel cell design in 2010.
27 March 30, 2006
Concluding Remarks
1. Background on Ballard Power SystemsBallard has been developing PEM fuel cells since 1983.Ballard fuel cells have made huge gains in power density since 1993.
2. Current Status and Benefits
Fleet programs generate data that enables learning which can be applied to future fuel cell designs. The current design shows many advances, but is not optimal.
3. Future Development
Ballard's next generation fuel cell has progressive technology improvements aligned with long term targets established by governments and industry.Achieving the long term targets will demonstrate a commercially viable automotive fuel cell design in 2010.