11.30 vortrag mr hannovermesse 2012.ppt · pdf fileproton motor fuel cell gmbh...

Challenges in Fuel Cell Stack Development

Dr. Mathias ReumSenior Manager R&D

Phone

Fax

+49 (0) 89 1276265‐66

+49 (0) 89 1276265 99

Challenges in Fuel Cell Stack Development

Senior Manager R&D

Proton Motor Fuel Cell GmbHBenzstraße 7, D‐82178 Puchheim

Fax

email

Web

+49 (0) 89 1276265‐99

m.reum@proton‐motor.de

www.proton‐motor.de

Company Structurep y

Proton Motor Fuel Cell GmbH, Headquarters Puchheim,

d ti l t l b & ffi 6000 2

PEFC d l t i 1994 (M t M t )

production plant, labs & offices on 6000m2.

PEFC‐development since 1994 (Magnet Motor),PM founded 1998, today 57 employees.Proton Motor is a subsidiary of:

Proton Power Systems PLCHolding founded 2006Holding, founded 2006,Listed in London since 31.10.2006.

© Proton Motor 201226.04.2012 m.reum@proton‐motor.de

Fuel Cells for industrial applications

Stack products

ll d fl f ld l

pp

System products

l f f‐ Cell design: flow field layout & simulation of fuel cell performance

‐ Stack design: construction & design of

‐ Development of components for BoP (incl. control system) in cooperations

‐ Development and production of PEFC stack components, material testing

‐ Evaluation and certification of the Proton Motor stack products

systems in different levels of integration

‐ Development and assembly of fuel cell based prototype turnkey applications


Proton Motor Stack History

PM Stack Development Timeline:

y

28x7 prototype

1994 1998 2002 2006 2010

t l dG‐series

PM600 seriesair cooled

water cooled


PM200 series

air cooled


active area ca 200 cm2

1994: The 28x7 Prototype

y

active area: ca. 200 cm2

usage: prototype only, proof of principleproof of principle

attribute: metal mesh as gas diffusiongas diffusion medium



1998: The G‐series

y

active area ca 450 cm2active area: ca. 450 cm2

usage: prototype system module with SGLmodule with SGL, prototype car E2G(VW Golf II: 30 kW)



2002: The PM600 series

y

active area 525 cm2active area: 525 cm2

usage: 20kW and 50kW multi stack vehiclemulti‐stack vehicle propulsion systems (Maritime, Busses)



2006: The PM200 Series

y

active area 155 cm2active area: 155 cm2

usage: stack product, single stack andsingle‐stack and multi‐stack systems for stationary and mobile applicationsmobile applications (Module S5, PM‐Basic50, PM‐REX)


PEFC-Stacks PM200 / PM400/

Since 2010: Product State PM200 Prototype State PM400

2 kW – 8 kW continuous power (24, 48, 96 cells) FC‐Systems of 2 – 50 kW net power TÜV‐certificate according to EEC 62282‐2

9 kW – 20 kW continuous power (only 96 cells) FC‐Systems of 10 – 200 kW net power commercially available in 2013

Focus on low cost technology and components suitable for mass production:• concept for fast hand manufacturing, as well as semi‐ and fully automated manufacturing. • good servicability cells can be quickly and easily replaced• good servicability cells can be quickly and easily replaced.• operating on low cost components from mass production.


PEFC-Stack PM200 Specificationsp

Voltage and Performance


PEFC-Stack PM200 Specificationsp

Air pressure and stoichiometry,temperature Adaption dry gases


Conflicts in Stack developmentp

Stack specifications forStack specifications for fulfillment of market requirements moving in tension field.

Performance

nominal‐ & peak power

servicability

manufacturability

p p

operating parameters

Cost

y

recyclability gas impurity tolerance

size, weight & volume

voltage degradation

part reduction

reliability

Lifetime

Any worthwhile balance has to be appli ation spe ifi !


Lifetimeapplication‐specific!

Performance - related issues

The choice of material and design denominates performance losses in PEFC!




mass transport losses(reactant supply)(reactant supply)




ohmic losses(current flux)(current flux)




activation losses(catalysis reactant crossover)(catalysis, reactant crossover)



As a Stack Developer:Flow Field Design is most obvious aspect of performance‐related engineeringFlow Field Design is most obvious aspect of performance related engineering



The impact of flow field design on stack performance:

decrease of channel dimension is limited by reactant pressure drop. increase of channel dimension is limited by electric contact and mechanical support.

increase of rib dimension is limited by reactant transport losses increase of rib dimension is limited by reactant transport losses. decrease of rib dimension is limited by ohmic resistance and manufacturability.



The impact of flow field design on stack performance:

percentage of rib coverage is significant!


Lifetime - related issues

St k D iS t D i Stack DesignSystem Design

choice of cell material cell compression

load dynamics start/stop cycles start/stop cycles p

flow field design operating conditions

sta t/stop cyc es freeze/thaw cycles reactant impurities …

flow field design/ p y

FC lifetime



Physico‐Chemical Membrane Degradation (Start‐Stop‐Problem): an issue inflicted by the operational conditions of the application System Designan issue inflicted by the operational conditions of the application System Design

0.64 A/cm2 in UPS‐systemincreasing the number of

ynumber of starts/hour by factor of 3

ca. 0.7 Starts/h 8.2 V/h

degradationincreases by

ca. 2 Starts/h 73.3 V/h

increases byfactor of 8!



Mechanical Membrane Degradation: an issue inflicted by shortcomings in flow field geometry Stack Designan issue inflicted by shortcomings in flow field geometry Stack Design

design‐relatedcurrent peaks orcurrent peaks orlocal starvation /local drying

membrane damage atair inlet „bottle neck“

membrane failure afterfailure after a specific time!


Cost - related issues

Low Fuel Cell Performance

Low Fuel Cell Life Time

service expenses total cost of ownership

system/stack size ffi i

Higher

total cost of ownership efficiency

Higher Cost

Pricing ofCell Material

Production Process



bipolar platecatalyst coated membrane (w/o Pt)

The PM200 cost cake:

50.38%

y ( )Platinum (trade price)gas diffusion layer + sealingend plate + restraintmedia connectors

3.04%

miscellaneous

21.00%

2.52%19 43%


3.58%19.43%

0.05%


Prognosis of cost degression for the fuel cell stack


Summaryy

‐ PEM Fuel Cell stack development is a tension field between Fuel Cell Performance, Lifetime and Cost.

‐ Performance issues are dominated by the chemical engineering of the‐ Performance issues are dominated by the chemical engineering of the heterogenous catalysis, for performance optimization stack manufacturers have to resort on flow field design and the choice of material. a lot of things can be done wrong! a lot of things can be done wrong!

‐ Lifetime is strongly impacted by both, system design and stack design. longevity is a product of material, design and application!

‐ Approximately 80% of possible Cost‐Down to the incremental costs isApproximately 80% of possible Cost Down to the incremental costs is achieved by volume degression, only ca. 20% of cost gap can be filled by design‐to‐cost techniques with today´s state of the art fuel cells. sales seem to count more than sufficient engineering!


sales seem to count more than sufficient engineering!

11.30 vortrag mr hannovermesse 2012.ppt · pdf fileproton motor fuel cell gmbh...

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