progress in materials development and production for … · 01 johnson matthey plc 02 jm activities...

Progress in Materials Development and Production

for Zero Emissions Powertrains

Dr Peter Gray

24 February, 2016

© 2016 Johnson Matthey Fuel Cells Ltd

Overview

01 Johnson Matthey Plc

02 JM Activities in Low and Zero Emissions Vehicles

03 Fuel Cell Vehicles Technology Status

04 Progress in Materials Development and Production for Fuel Cell Vehicles

05 Summary






05 Summary


Johnson Matthey Plc

In >30 Countries

High Investment Levels

• R&D spend £169.9m (2014-2015)

• Group Technology Centres in UK, USA and South Africa

• Capital investment of ~£909m in the last 5 years

• 19th century origins as high-quality, reliable refiner of gold & silver

• 20th century expansion in platinum group metal refining & products

• 21st century expansion into base metal catalysis, other environmental and process technologies, other pharmaceutical and fine chemical products

Numerous

Queen’s Awards

for Enterprise

Well Established Company

• Established 1817

• Floated in 1952

• FTSE 100 since 2002

• Leading global positions in all of its major businesses

• Award-winning commitment to sustainability

• Regularly voted one of Britain’s most admired companies

Large Cap Business of

the Year 2011

MacRobert Award

for Engineering in

1980 and 2000 Best Annual Report & Sustainability

& Stakeholder Disclosure 2012

• Market capitalisation £6.5bn • Sales excluding precious metals £3.12bn • Underlying profit before tax* £440.1m • Return on invested capital 18.8% • Employees – worldwide 13,000 • Sales excluding precious metals analysed:

Key Metrics (2015)

Emission Control

Technologies 53%

Precious Metals

Products 16%

Process Technologies

19%

Fine Chemicals

10%

New Businesses

1%

By Division

Europe 33%

China 10%

NA 34%

Rest of Asia 11%

ROW 12%

By Destination * Restated for IAS 19


http://www.coutts.com/





05 Summary


Emission Control

Technologies

Process

Technologies

Precious Metal

Products

Fine

Chemicals

New

Businesses

Chemicals • Chemical Technologies • Syngas • Chemical Catalysts

Oil and Gas • Refineries • Purification • Tracerco

Services • Platinum Marketing

and Distribution • Refining and recycling

Manufacturing • Platinum products • Glasses and enamels • Precious metal powders

Pharmaceutical • Active Pharmaceutical

Ingredients (API)

Battery Technologies • Battery Electric, Plug-in Hybrid,

mild and micro hybrid vehicles • Advanced Battery Materials • Lithium ion batteries • Developer and assembly of

advanced automotive battery systems

Water • Purification, metal scavenging

Fuel Cells • Automotive, portable and

stationary power sectors • Membrane electrode

assemblies & sub-components • Fuel cell catalysts • Reforming and gas processing

catalysts

Emission Control Systems • Light Duty Gasoline and

Diesel Catalysts • Diesel particulate filters • Selective catalytic

reduction • Heavy Duty Diesel and

non-road applications • Stationary Emissions

Control

JM Activities in Low and Zero Emissions Vehicles

Increasing focus on environmental technologies:

> 50% of profit derives from products that directly

benefit the environment


Global Drivers Continue to Provide Opportunities for

Powertrain Technology

Evolving

Technology

Population Growth

Urbanisation

Increasing Wealth

Natural Resource

Constraints

Environmental Factors

Climate Change Regulation

Health & Nutrition

Ageing Population

Increased demand

for mobility, focus

on emissions

Focus on air

quality to improve

public health

Tighter emission

regulations, low

CO2, zero emissions

Improved fuel

efficiency,

alternative fuels,

sustainable

energy generation


Johnson Matthey Battery Technologies and Johnson Matthey Fuel Cells

► Johnson Matthey Fuel Cells develops and manufactures Cell components

► Membrane electrode assemblies (MEAs) and MEA sub-components and catalysts

► Range of automotive, stationary and portable fuel cell applications.

► Johnson Matthey Battery Technologies spans the battery value chain

► Acquisition of Axeon Group 2012. Acquisition of A123 assets & Clariant. Expanded internal R&D and product

development programs. Further acquisitions being pursued.


Johnson Matthey Fuel Cells - Products

JMFC’s key product is the MEA (membrane

electrode assembly) - a complex laminate of carbon

fibre based gas diffusion layers, catalysed electrode

layers and a proton conducting polymeric

membrane.

Producing high quality MEAs requires skills in

materials science, chemistry, physics, catalysis,

production engineering and quality control.

The cell is completed by two conducting plates that

distribute gas uniformly over the outer surfaces of

the MEA sandwich.

In automotive fuel cell engines the cells are stacked

in a bipolar arrangement to provide the total power

and I-V characteristics required for the electric

powertrain.






05 Summary


Largest single long term market for fuel

cells.

Fuel cell car programmes influence

materials costs across the industry.

Drivers behind electric drivetrains are

strong.

Legislation and climate change.

Decarbonisation of transport and power

generation.

11

Fuel Cell Vehicles

Consensus (OEMs, utilities, oil companies) that the

future will see a mixture of technologies:

• All sorts of hybrids

• Small city cars as pure battery electric vehicles (BEV)

• Larger, longer range fuel cell vehicles (FCV)


Technology Status

Performance and durability have been demonstrated to meet specified requirements.

Development work is focussed on reliability and resilience in real world conditions.

The achievement of cost targets continues to be a challenge with focus on:

► Materials

► Volume manufacturing

12






05 Summary


Real world - Cold starts

14


Real world - Hot hill climb

15


Real world – Multiple stop/starts

16


Real world – Cell Reversal damage

17


Hydrogen starvation

18

H+ H+ H2 → 2H+ + 2 e- 2H+ + ½O2 + 2e- → H2O

H2 O2

0 V 0.7 V

Normal operation – single cell


Hydrogen starvation

19

H+ H+ 2H+ + ½O2 + 2e- → H2O

O2

X

X

X

X

½C + H2O → ½CO2 + 2H+ 2e-

e-

+1.7 V +0.7 V

- 1 V

Hydrogen starvation – single cell


20

Corrosion resistant carbons [0.9 V30sec – 1.4 V30sec]

Voltage at 500 mA/cm2

Voltage at 1000 mA/cm2

Improved carbon supports

corrosion without loss in

performance

• Tolerance to oxidative

potentials; SU / SD

• Require high carbon surface

area to ensure Pt dispersion

• Voltage cycling test

Cathode /Carbon #3 = best

combination of

• Corrosion resistance

• Pt ECA and stability

• ECA retention


Cell reversal protection

21

Oxygen evolution reaction (OER) catalyst


Cell reversal protection

22

Oxygen evolution reaction (OER) catalyst


Hydrogen starvation

23

H+ H+ 2H+ + ½O2 + 2e- → H2O

O2

X

X

X

X

½C + H2O → ½CO2 + 2H+ 2e-

e-

+1.4 to 1.6 V

H2O → ½O2 + 2H+ 2e-

+0.7 V

- 0.7 to - 0.9 V

Hydrogen starvation – with Oxygen evolution reaction (OER) catalyst


Membrane durability

24


Volume manufacture – the next challenge

25

Thousands of MEAs

10s of thousands of MEAs

Millions of MEAs

10x millions of MEAs

2015-2017

100s of cars

2013-14

10s of cars

2018-2022

x10k of cars

2025

100 k cars


JMFC Investment – High Volume Manufacturing

Catalyst layer deposition has evolved

► Originally screen printing

► Now continuous roll-to-roll coating

► Discrete images

► Class 1000 cleanroom

MEA assembly

► Originally discrete part assembly

► Now automated roll assembly

► Class 1000 cleanroom

In-Line Quality Control

► XRF, thickness, defects, part traceability

26






05 Summary


Summary

28

Global Drivers continue to provide opportunities for powertrain technology evolution –

increasing focus of Johnson Matthey on environmental technologies for Low and

Zero Emissions Vehicles.

Increasing product portfolio for Zero Emissions Vehicles – Johnson Matthey Battery

Technologies and Fuel Cells. Recent acquisitions in Johnson Matthey Battery

Technologies spanning the battery value chain.

Performance and durability of existing PEM Fuel Cell MEA technology has been

demonstrated to meet requirements to allow introduction of fuel cell vehicles.

Development work is now focussed on successfully improving the reliability and

resilience of Fuel Cell materials in real world (mass market) conditions, with cost

reduction and quality control achieved through volume manufacturing methods.


progress in materials development and production for … · 01 johnson matthey plc 02 jm activities...

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