110208 Agenda Intermediate results Pub · 2018-10-22 · Torsten Knöri DLR torsten.knoeri@dlr.de...

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Transcript of 110208 Agenda Intermediate results Pub · 2018-10-22 · Torsten Knöri DLR torsten.knoeri@dlr.de...

Auto-Stack

HFC-JU Project No.: 245142

- 3 -

Agenda 19 January 2011

Topic Venue

Auto-Stack Grenoble

Workshop on Intermediate Results Date

08.02.2011

Start

10:00End

15:30Convener Telefon-Nr. Minutes taken by Telefon-Nr. Agenda from

Jörissen +49-731-9530-605 17.01.2011

Public Distribution Consortium Members

Belenos

CEA

CRF

DANA

Daimler

FFCCT

JRC-ie

PSI

Powercell Sweden

SNECMA

Solvay

Solvicore

Umicore

Volkswagen

ZSW Discussion / Result Remark / Action

Agenda

TOP 1. Summary of System and Stack Requirements

TOP 2. Status of Stack Platform concept and -specification

TOP 3. Stakeholder Inventory and Supply Chain Analysis

TOP 4. Identification and Classification of Research Needs

TOP 5. Lunch

TOP 6. Draft of Stack technology Roadmap

TOP 7. Status of Business Model

TOP 8. Discussion

TOP 9. End of Meeting

Autostack: Workshop on Intermediate Results: Grenoble, February 8th 2011

Name Organisation E-Mail

Gauthier Wime Alphea Hydrogene Forbach gauthier.wime@alphea.com

Uwe Hannesen Belenos uwe.hannesen@belenoscleanpower.com

Secondo Sibona C.R.F. secondo.sibona@fptpowertrain.erf.it

Pars Mukish CEA pars.mukish@cea.fr

Isabelle Noirot CEA Grenoble isabelle.noirot@cea.fr

Thierry Priem CEA Grenoble thierry.priem@cea.fr

Raimund Ströbel Dana raimund.stroebel@dana.com

Torsten Knöri DLR torsten.knoeri@dlr.de

Timo Bednarek elringKlinger AG timo.bednarek@elringklinger.com

Carlos Navas FCH carlos.navas@fch.europa.eu

Carsten Cremers Fraunhofer ICT carsten.cremers@ict.fraunhofer.de

Volker Banhardt Freudenberg FCCT volker.banhardt@freudenberg.de

Frank Erbach Harro Hoefliger GmbH frank.erbach@hoeflinger.de

Bruno Cocheteux Harro Hoefliger GmbH bruno.cocheteux@hoeflinger.com

Jean-Marc le Canut INEVA/CNRT Belfort jean-marc.le-canut@utbm.fr

Georgios Tsotridis JRC georgios.tsotridis@jrc.nl

Nicolas Bailly Lepmi/Ademe nicolas.bailly@lepmi.grenoble-inp.fr

Stefan Kreitmeier PSI stefan.kreitmeier@psi.ch

Come Loevenbruck Snecma come.lovenbruck@snecma.fr

Ludwig Jörissen ZSW ludwig.joerissen@zsw-bw.de

Andre Martin ZSW andre.martin-nc@t-online.de

Daimler AG

Workshop on Automotive Stack Design Options, Platform Concept, and Cost Targets

AUTOSTACK Workshop

Feb8th 2011, Grenoble

F. Finsterwalder

1

Content

1. Introduction

2. Summary of system requirements and stack specification

3. Conclusions for design options and platform concept

4. Critical trade-offs - Power density vs. Pt-loading

2

Autostack: The Objectives

• Analyze– vehicle requirements

– supply industry

– Cost and cost drivers

• Identify– synergy potential

– Research needs

• Propose– Consitent dvelopment road map

– Business model

3

Combining Expertise

3

Automotive

OEMsResearchInstitutes

Component and System Suppliers

Autostack Consortium

4

Tackling the Issue

OEM-System Reqirements

Stack Platform Definition

Detailed Stack Specifications

Component Requirements

Supplier Survey

Component Performance

Stack Specifications

„Top-Down“

„Bottom-Up“

Virtual Stack Design

55

Project Workflow

WP1 OEM System RequirementsWP1 OEM System Requirements

WP2 Supply Chain & ResearchWP2 Supply Chain & Research

WP4 Business ModelWP4 Business Model

WP3 Road MapWP3 Road Map

01.01.2010

30.06.2011

7

Micro-Kompakt

Klein-laster

B-EV

FC-EV

SchwererLKW

MittlererLKW

Überland-Bus

City-BusLuxus- &

Familien-FzgeMittel-Klasse

Kompakt-Klasse

possible Possible with restrictions Today not possible

Suitability of Battery / Fuel Cell Drive Train for Various Vehicles

E-Drive-Portfolio – Opportunities and Limitations

Long Distance Interurban Urban

Fuel Cell

Battery Drive

Combustion Engine

Hybridization

Plug-In/Range Extender

8

FC System Concept:Basic Requirements to Observe

• Power / gravimetric / volumetric Power Density

• Cost

• Durability

• (Freeze)-Start-up time

• Efficiency superior to any (hybrid)-ICE

• One Fuel on Board (H2)

These requirements strongly reduce the number of system options…

comparable to ICE

9

Automotive System Architecture

M

anode

cathode

coolant

MM

humidifier

radiator

MM

H2-blower

M

anode

cathode

coolant

MM

humidifier

radiator

MM

Simplified schematic

Features:• Air compressor without

expander• Gas-to-gas humidifier

(cathode out cathode in)

• High power density stack• An active / passive

H2 recirculation pumpp = 1 .. 2 bar abs

T = 55 .. 95°C max (outlet)

Rh cathode @ max power = 50%

14

Conclusion

• FC-systems designers have to respect many ambitious requirements. The number of concepts able to fulfill these requirements is small

• OEMs participating in AUTOSTACK have agreed commonly on a system concept of choice

• Other promising system concepts exist, are however not broadly accepted within the automotive industry. Still, they should be further considered, in particular for the earlier markets.

17

Components Considered Part of the Stack

• Bipolar plates, MEA, Seals• Current Collectors + end plates• Stack compression kit• Casing / Housing (also for EMC*)• Flanges (quick connectors)• HV-Contactors + interlock• Vehicle mounts (brackets)• End cell heaters (PTCs) integrated in the stack enclosure – may be used for

stack discharge• Sensors (also for diagnostic purposes - may be removed at a later stage):

– Pressure: Coolant in- and outlet, Fuel in- and out, Oxidant in- and out– Temperature: Coolant in- and outlet; Fuel in- and out; Oxidant in- and out, End Cells– RH-sensors in the header (manifold part)

• Cell Voltage Monitoring Unit: – This will be required during development phase - Aim is to remove CVM– Already today, control strategy must be developed without the need for individual cell

voltage monitoring!

*electromagnetic compatibility

19

High Level Stack Requirements

Stack nominal power (gross, continuous) 95 kW (requirement)(System power 80 kW)

Stack Open Circuit Voltage <430 V (requirement)(limit set by power electronics – consider OCV > 1V @ freeze T)

Minimum stack voltage >200 V (guidance)(limit depending on E-motor and DC/DC converter characteristics)

Weight <60 kg

Volume <50 l

Operating Temperature min -25°C (start capability)max +95°C (outlet temp.)

Interface parameters at nominal powerPressure 2 baraAir Stiochiometry 1,6 Humidification 50%

20

Plate Design

Area Power density 95 kW, 1 W/cm2

Cell voltage at nominal power 0,67 VCurrent density at nominal power 1,5 A/cm2

Active area of stack 9.5 m2

Number of cells (1-row stack is a requirement) 300 .. 380 (stack height!)

Active are area per cell (projected) 317 cm2

Plate Area (a.a. = 60% of plate area) 528 cm2

Cell pitch 1,5 mm

Ci

Ao

Ai

Co

Wi Wo

Active Area (aspect ratio 1:3)Port

Region Transition

Region

Preliminary Plate Design (1 Path parallel Flow Field)

30,8 cm

10,3 cm

Plate Dimensions:

11,3 x 46,8 cm2

22

Degradation Targets

• Throughout its lifetime the stack is allowed to degrade by 10% in max. power output, i.e. 1 W/cm2 0.9 W/cm2

• The max power is limited by the cooling power

• Therefore, the stack will be operated at maximum waste heat during its life

• As the stack degrades, the max power point will move to lower voltage and – in order to keep the waste heat constant – to lower current density, i.e. max power point moves along the “iso-waste heat” curve

24

Operating Strategy and Turn-Down Ratio

• The stack can be operated efficiently and stable within certain limits (highest power/lowest power = turn-down ratio)

• This results from the conflict of flow homogeneity vs. pressure dropknown in fluid dynamics

• Very low and very high power demands will be covered by the battery Hybridization

• This implies a start/stop strategy for the stack

• The stack will be switched of between5% and 10% of its nominal power,i.e. 5 kW .. 10 kW (= the required size of the battery. This corresponding to a TDR of 1:10 .. 1:20)

Pre

ssur

e dr

op

in s

tack

Current density / volumetric flow / load

pmax

pmin

p high

p low

Efficiency lossesStable operation

Stable+efficientoperating regime (determines the turn down ratio)

27

acceleration H2 depletion

deceleration high p

between A / C

low power stack stop extended stop O2

ingressPotential cycling

catalyst corrosion?

Drive Cycle Analysis

Stress Factors in a “Real” Drive Cycle

31

Conflicting Targets / Major Gaps

Power Density / Efficiency

Pt loading Durability

1 W/cm2 / 0.8 V @ 0.2 A/cm2

0,16 mg/cm2 5000 hrs, >20,000 starts

33

Gap Power Density / Pt LoadingFuel efficiency targets might even be more challenging

relevant for fuel efficiency relevant for top speed

36

Optimize the €/kW Parameter- with a given catalyst layer technology

Save Membrane?high Pt loading, small membrane area

Save Platinum?low Pt loading, large membrane

area

Pt Ptmembrane

Finding the best compromise between Pt loading and power density

39

Pt Loading Variation (logarithmic fit)and Resulting Stack Power Costs

41

Summary & Conclusion

• The cost optimized Pt loading is influenced by:- the costs of membrane, GDL, BIP vs. Pt- the power density characteristics of the MEA

• With today’s MEA technology and price structure do not address low Pt loading at the expense of power density

• Power density is paramount target.High power density allows standardization, thus cost reduction

42

Standardization & Economies of Scale

higher power density higher degree of freedom (packaging)

standardizationeconomies of scale (1)

Pt reduction economies of scale (2)

Addressing ultimate cost targets

Addressing product design targets

market volume

43

Thank you very much for your kind attention

Seite 1

Stakeholder Inventory and Supply Chain Analysis

Paul Scherrer Institut

Stefan Kreitmeier, Philipp Dietrich, Felix Büchi

8th Feb. 2011, Grenoble / CEA

2. März 2011PSI,

Autostack workshop on intermediate results

Seite 2

Analysis of the Supply Chain

1. Generate an inventory of the European stack component supply industry

2. Analyze status of present and future products

Objectives

3. Identify gap between goals and state of the art

Component properties Component cost

Seite 3

Inventory of the stack component industry

Seite 4

Inventory of the stack component industry

ca. 60 European companies are active in PEFC componentsand/or advertise „fuel cell“ in their port-folio

Seite 5

Analysis of the Supply Chain

1. Generate an inventory of the European stack component supply industry

2. Analyze status of present and future products

Objectives

3. Identify gap between goals and state of the art

Component properties Component cost

Seite 6

• limited to European suppliers

• includes data collection of product properties and cost

• for preliminary mass production(250-25.000 stacks/year)

• Timeframe 2010-2020

• for stack specification requestedby the consortium

Not all data statistically evaluable

• 350 cm2 active area

• 1 W/cm2 power density

• 0% rH at anode, < 50% rH at cathode

• …

Study for the purpose of Autostack project

Data analysis

Seite 7

Methodology

Step 1: Short questionnaire (Sept. 2010) to all European PEFC component supplier

Two step approach

Seite 8

Example: Cost range

( < 1 < < 2 < < 5 < < 10 < €/unit for… )reply rate: 34% (n=24)

Methodology

Seite 9

Methodology

Step 1: short questionnaire (Sept. 2010) to allEuropean PEFC component supplier

Step 2: NDA; extended questionnairesand interviews (Nov. 2010)

Two step approach

Data anonymisation based on averaging(a minimum of 3 replies required)

Seite 10

Reply rate: 46%

Filled questionnaires: 24 (34%)

Short questionnaires sent: 65

Interest in ext. Stakeholder group: 16

Extended questionnaires / interviews: 16

Reply rate: 74%

Methodology - Summary

Seite 11

Analysis of the Supply Chain

1. Generate an inventory of the European stack component supply industry

2. Analyze status of present and future products

Objectives

3. Identify gap between goals and state of the art

Component properties Component cost

Seite 12

Cost evaluation

Input Cost range Detailed cost

Cost Lowcost

Highcost

DTI (US) cost estimation

Seite 13

DTI study on cost estimation

B. D. James, J. A. Kalinoski, K. N. Baum, DTI, Contract Nr. DE-AC36-08GO28308, Virginia, USA, 2010.

Metallic BPP

Composite BPP

Seite 14

Stack components

Membrane

Catalyst

GDL

Material

Process

Material

Process

MEA

BPP

Sealing

Metallic

Composite

Seite 15

State of the Art - MEA

Required power density is only achievablewith a higher PGM loading

If roll good is desirable, development is necessary

Low PGM loading is in principle not an issue

Seite 16

State of the Art - Membrane

Membrane swelling needs further improvement

Durability is still critical and may not be sufficiently analyzed

Proton conductivity at required rH is still critical

Seite 17

State of the Art - metal BPP

The desired cell pitch is with an average sheet thickness of 0.065 mm feasible

Additional coating and integrated sealing can mostly be provided (->properties of coating?)

Durability may not be sufficiently analyzed

Seite 18

State of the Art - carbon BPP

The cost are critical

The thickness of carbon BPP is highly critical

Additional treatment and sealing are partly provided

Seite 192. März 2011PSI,PSI, Seite 19

Thank you very much for your kind attention

WP 2.3 : Identification and classification of research needs

AutoStack Workshop on Intermediate Results8 February 2011, Grenoble

Georgios Tsotridis

1

Research Needs – Objectives & contributors

• Objectives:

• To identify and classify further research needs for automotive fuel cell stacks and associated system aspects

• To define their priorities to close existing R&D gaps between ultimate development goals and identified state-of-the-art materials and components, and today’s stack technologies

• To support preparation of FCJ JU AIP call for proposals (2011, 2012 and beyond) and contribute to MAIP revision

• Contributors:

• JRC (task leader), CEA, ZSW, SC, SY, UC, PSI, DANA, FFCCT

2

Prerequisites for Market Introduction of automotive Fuel Cell Systems

• Performance and range similar to present vehicles powered by ICE– Available power and fuel efficiency are crucial

– Lifetime (operation and overall)

• No purpose design vehicle– Front packaging of the fuel cell power system

• Cost– Only moderate extra cost might be acceptable

3

Enablers for the Key Challenges in Automotive Fuel Cell Systems

• System net power 80 kW in a front packaging– High power density (1 W/cm2)– Low cell pitch (< 1.5 mm)

• High fuel efficiency– High average single cell voltage (> 670 mV)

• Cost– High power density (1 W/cm2)– Low noble metal loading (<1.5 mg/cm2)

• Potential conflict of interest

• Robustness: Operation under highly dynamic load including soak times at high single cell voltage– Corrosion resistant catalysts and structural materials– Resistant to frequent fuel cell power system startup and shutdown– Temperature excursions to 95°C acceptable while– Operating at low or no external humidification (<50% RH)

4

A Successful Research Agenda Needs to Address the Challenges

• Demonstrate technical feasibility– Simultaneous fulfillment of all requirements

• Power density• Cell pitch• Average single cell voltage• Operating temperature• Humidification requirements• Noble metal loading

• Development of tools for in depths understanding– Water management– Modeling to assist component, stack, and system design

• Engineering models including analysis of power flow on a system basis• Fundamental (molecular scale based) models• Cost models

• Improved components and system architecture

5

Research Needs – Assumptions

1. Automotive fuel cell stack specification based on identified OEMsystem requirements and on assessed materials and components available from European supply industry

2. Development of 1st generation stack hardware based on state-of-the-art (as of 2011) components validated against technical automotive performance requirements (volume, weight, dimension, power)

3. Development of 2nd generation stack hardware based on advanced components (AIP call 2012 and beyond) meeting additional automotive performance requirements (wide operation window: low RH, temperature; low PGM content) and cost targets for market introduction

4. Ready for market

6

Research Needs – Anticipated development evolution schematic for a European full size automotive stack

Specifications Generation 1 Generation 2 Market

State of the Art ComponentsMEA, BPP

AdvancedComponentsMEA, BPP

AIP2010

AIP2011

ff

R&D-Results

Supply Industry

2011 2013 2015 2018

7

Research Needs - Scope, R&D priorities and time frame

Short-term research needs (2011 - 2014):

• Integration of full size automotive stack– High– Development, design and validation of a competitive European automotive

stack based on the specification and technology roadmap developed in the AutoStack project

• Development of optimum power streams in fuel cell systems– High– Modelling, assessment and validation of optimum power streams between

fuel cell and energy storage devices to identify best hybridization concepts and operating strategies, determine viable start-stop concepts and appropriate stack and system design parameters based on OEM requirements

• Development of industry wide uniform performance test schemes –High

– Development and validation of commonly accepted test protocols for the reliable and consistent assessment of performance, durability and cold start of stack and system, including accelerated test cycles based on OEM requirements

8

Research Needs - Scope, R&D priorities and time frame

Medium-term research needs (from 2012 - …):

• Development of advanced MEA (membrane electrode assemblies) with increased power density, lower humidification requirements and elevated operating temperatures – High– Concerted development of advanced membranes, GDL (gas

diffusion layers), catalysts and MEA with improved durability, very high power density, low or no humidification requirements in an extended operating temperature range from -25°C up to 130°C, including validation testing according to OEM requirements

• Development of advanced low-cost bipolar plates – High– Concerted development of low cost advanced corrosion resistant,

highly conductive and gas tight bi-polar plates including appropriate sealing structures allowing cell pitch < 1 mm suitable for operation at elevated temperatures up to 130°C according to OEM requirements

9

Research Needs - Scope, R&D priorities and time frame

Medium-term research needs (from 2012 - …):

• Development of cell modelling for accelerated stack design –Medium– Development of realistic cell modelling for the assessment and

experimental verification of stack materials, components and design with particular focus on critical operating parameters for accelerated development cycles

• Development of characterization techniques for water management and state of health – High– Development of a common European tool and techniques for in-situ

(non-destructive), ex-situ (non-intrusive) and real-time characterization of water management capabilities at cell and stack level, including state-of-health monitoring

10

Research Needs - Scope, R&D priorities and time frame

Long-term research needs (post 2012):

• Material research on non noble catalyst materials – Medium– Identification and validation of suitable non noble metal catalysts to

replacement of platinum as major cost driver of fuel cells in the long term while maintaining activity comparable to Pt-based catalysts

• Development of modelling tool for MEA performance – Medium– Development and experimental verification of multi-scale modelling

tools for best understanding of the different reaction, transport and ageing phenomena of MEA

• Development of simplified system architectures and improvement of scale effects– Assessment and experimental validation of different system

concepts, including key components based on optimized energy flows for further simplification of system architectures and improved communalities

Technology Roadmap

Autostack

Workshop Intermediate results

February 8, 2011

CEA Grenoble

Per Ekdunge

PowerCell Sweden AB

8 February 2011

WP 3 Overall Objectives & Participants

• Participants– Powercell, CEA, Daimler, DANA, Freudenberg , JRC, PSI,

Solvicore, Umicore, VW, ZSW

• Objectives– Setting up a structured and consistent technology roadmap for

stack development– Check of alignment with running or required research projects– Provide a master plan

• Start: Month 10• End: Month 15• Final deliverables

– Roadmap for stack development– Masterplan for commercialization– Needed research results and insertion points

8 February 2011

Technology Road map

2

Stack State of

Art

Plattform Definition

Status of Material and Component

s

Cost Model

Research need

Technology Road Map to CommercialFuel Cell Stack for Automotive Mass Market

Trade Offs with Other Application

s

Work Package 1 Work Package 2

8 February 2011

WP 3 Timing

I II III IV V VI

Task 3.1Stack development

plan

Task 3.2Research projects

and insertion

Task 3.3Masteplan and

Milestones

WP 4: Business Model

WP1: Stack platform concept Synergies with other applications

WP2: Research needsStack cost model

8 February 2011

Stack Development plan, 1st generation stack.

• Assumptions– Fuel cell stack development begin in 2011

• The stack will be based on today's stat of art materials and components

– Fuel cell stacks needed to support fleet programs in 2015

– The fuel cell stack will have a OEM market of about 1000 units

– A trade of with other applications is possible• Total volume >10000 units

4

A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M JPhases Pre Study Concept Study Development Design Industrialisation

Engineering

2012 2013 2014 20152011

A-release B-release

B stage verification C stage verification

SP-start

P-releaseC-release

A stage verification

Stack certification

P-startProductionInvestm.

P stage verification

Start field testing

Start build

Define concept &Select Dev.Supplier

Buisniss plan estabilchment

Specification and plattform definition

Pre study

ProductionInvestm.

DRAFT

8 February 2011

Stack Development plan, 2nd generation stack.

5

• Assumptions– Fuel cell stack development begin in 2014/2015

• The stack will be based on advanced materials and components

– Fuel cell stacks needed to support mass market ramp up around 2020

– The fuel cell stack will be able to meet all the OEM requirements (from WP1) including cost targets.

– The OEM market is big enough for justify all investment and development cost

A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M JPhases Pre Study Concept Study Development Design Industrialisation

Engineering

2015 2016 2017 2018

A-release B-release

B stage verification C stage verification

SP-start

D-releaseC-release

A stage verification

Stack certification

P-startProductionInvestm.

D stage verification

Start field testing

Start build

Define concept &Select Dev.Supplier

Specification definition

Pre study ProductionInvestm.

DRAFT

WP 3.2: Research projects and insertion points

Autostack

Workshop Intermediate results

February 8, 2011

CEA Grenoble

Dr. Volker Banhardt

Freudenberg FCCT

8 February 2011 7

Task 3.2: Research Projects and Insertion Points

• Objectives– Alignment of ongoing research projects with the stack development

plan

– Insertion points of research results into the stack roadmap and the corresponding fuel cell application

• Contributors– FFCCT (leader), CEA, PSI, JRC, DANA, ZSW, SC, UC

• Description of Work– Define research needs based on topics identified in WP2.3 and

propose insertion points

• Input from: Task 2.3, Task 3.1

• Output to: Task 4.2

8 February 2011 8

Task 3.2: Subtasks

• Analysis of output from WP 2.3, 3,1

• Analyze research needs for FC stack components and align with milestones of WP3.1

• Define milestones

• Work package report

8 February 2011

Task 3.2 Research Projects and Insertion Points

• Status– Report of WP2.2 on research needs and classification

available and analysed

– FFCCT provided questionaire worked out in WP3 to AUTOSTACK partners

– provided questionaire suggests research areas

– all returned information has been collected

– insertion points are currently aligned to proposed stack development plan for generation 1 and generation 2

DRAFT

8 February 2011

Task 3.2 Research Projects and Insertion Points

• Since more input is needed to sumarize on research needs current status is open for discussion

• Questionaire for– BPP

– MEA

– GDL

– Seal

– Current collector

– Stack assembly

DRAFT

8 February 2011

Task 3.2 Research Projects and Insertion Points

• Bipolar plate

No Subtopic Requirements Developm. priority

Begin End

1 Plate material inexpensive, formable and corrosion resistant

High Q1-2012 Q3-2014

2 Plate surface coating Conductive, adhesion to plate, corrosion resistance

High Q3-2011 Q3-2014

3 Plate design (generation 1) optimized flowfield High Q3-2011 Q4-2012

4 Plate design (generation 1) optimized feed region High Q3-2011 Q4-2012

5 Plate design (generation 2) optimized flowfield medium 2013 2014

6 Plate design (generation 2) optimized feed region medium 2013 2014

DRAFT

8 February 2011

Task 3.2 Research Projects and Insertion Points

• Further components still to be included– end plates

– cell voltage monitoring

– housing

DRAFT

WP 3.3 : Master Plan and Milestones

Dr. Raimund Stroebel

DANA-Reinz

Autostack

Workshop Intermediate results

February 8, 2011

CEA Grenoble

8 February 2011 14

Task 3.3 Master Plan and Milestones

• Objectives– Master plan for automotive FC commercialization including non-

classic/emerging vehicle concepts and related application

• Contributors– DANA (leader), CEA, FFCCT, ZSW, VOLVO, DAI, VW, CRF

• Description of Work– Develop a master plan for automotive fuel cells which takes into

account the addition vehicle concepts, e.g. urban (fleet) and service vehicles, plug-in hybrids, range extenders, public transport vehicles, light traction vehicles and related applications.

– Break down the big step towards an automotive FC mass market into several smaller steps.

• Input from: Task 3.1, Task 3.2, Task 4.2

• Output to: Task 4.2.

8 February 2011 15

Task 3.3: Subtasks

• Analysis of output from WP 2.2, 3,1, 4.1, 4.2

• Analyze related FC vehicle applications

• Assess other fuel cell stack related application

• Define milestones

• Compile master plan

• Preparation of milestone report

8 February 2011 16

Task 3.3: Master plan

Performance Specification

Packaging Specification

Production Volumes

TargetApplications

Cost Goal

Define priority list of

requirements

Find Stack definition based on compromise

Unified Stack specification

8 February 2011 17

Task 3.3: Master plan

Performance Specification

Packaging Specification

Production Volumes

TargetApplication

Cost Goal

Temperature range

EOL expectations

Load spreadingMax powerMin Power

Dynamic requirements

Pressure drop

Fuel requirements

DC level, max and min Voltage, Current

8 February 2011 18

Task 3.3: Master plan

Performance Specification

Packaging Specification

Production Volumes

TargetApplication

Cost Goal

3D size, space requirements

Connection to subsystem

Main orientation

Serviceability, maintenance

Recycling

Robustness

Assembly

8 February 2011 19

Task 3.3: Master plan

Performance Specification

Packaging Specification

Production Volumes

TargetApplication

Cost Goal

Identify potential applications

Automotive range extender

Automotive traction

Industrial mobility

Other mobility; Boat …

Back up power

Electrolyser

8 February 2011 20

Task 3.3: Master plan

Plate design

Soft good selection

End hardware and assembly design

Component evaluation

and benchmark

Component specification

Unified Stack specification

Testing Production

8 February 2011 21

Task 3.3: Milestones

• Fix specifications, applications, targets and goals• Priorities technical and commercial parameter list • Fix compromise on priorities • Define unified stack specification• Evaluate extended application potential• Generate component specification• Design and select components• Benchmark and evaluate components• Stack evaluation and testing• Stack production

8 February 2011 22

Task 3.3: Applications

Application Stack size

• Automotive FC traction 50 to 100 kW

• Automotive FC range extender 5 to 30 kW

• Bus FC traction / range extender 50 to 200 kW• Boat, Ship FC traction / range extender / APU 2 to 100 kW• Truck APU 5 to 10 kW• Fork Lifts, Industrial vehicles 2 to 10 kW• UPS; Back up 2 to 100 KW?• Fuel Hydrogen, Reformate• Electrolyser

8. February 2011Dr. Raimund Stroebel

Status of Business Model

By André Martin

Auto-Stack - Workshop – Feb 8, 2011

Grenoble

WP 4 Objectives

Overall Objectives

• Compile the technical expertise needed to form a stack integrator

• Compile the financial resources needed to form a stack integrator

• Work out a business plan

• Assess options for ventures and potential candidates

1

Contents

A. Product and Markets

B. Cooperation model

C. Technology Roadmap

D. Expertise and resources

E. Implementation

2

A. Product and Markets

3

Implementing the mission

4

Common OEM Platform

Fuel Cell Stack

Two way approach to establish platform

OEM-System Requirements

Stack Platform Definition

Detailed Stack Specifications

Component Requirements

Supplier Survey

Component Performance

Stack Specifications

„Top-Down“

„Bottom-Up“

Virtual Stack Design

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High power density is enabler for different platforms

Source: GM Equinox – next gen

95 kW gross powerScalable 5 – 95 kW220 – 430 V SCV @ 675 mVMax. 2 baraOT max. 95°C≤ 50 l / 60 kg40 € /kW@100000

The benchmark

Several applications can be supported

Transport Stationary Portable

Compact cars UPS Telecom, IT Generators

City-Buses Back-up power

Light Trucks

Special vehicles

Boats, Ferries

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B. Cooperation Model

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Combining expertise

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Automotive

OEMsResearchInstitutes

Component and System Suppliers

Autostack Consortium

Facilitating commercial launch

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Critical learning curve

€ 40

Reducing constraints for early commercialization

Cooperation enables economies of scale

Assumed production rates:1 000 vehicles / year10 000 vehicles / year50 000 vehicles / year

100 000 vehicles / year500 000 vehicles / year

Accumulating volumes of several OEMsSharing of investment burden and risksAllowing superior economies for other apps

Cost control to achieve commercial targets

CEA’s model on MEA

Cost Assessment

Tool

InputsInputs OutputOutput

MEA production cost

Bipolar Plates production cost

End Plates, current Collectors, BoPproduction cost

Data from other assessments

Genericstack

Design

C. Technology roadmap

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Business Plan Generation 1 Generation 2 Market

State-of-the-Art ComponentsMEA, BPP

2018201520132011

Technology Roadmap

AdvancedComponentsMEA, BPP

Critical targetsPower densityEfficiencyScalability Robustness@ target cost

Consistent long-term roadmap

D. Expertise and resources

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Focus on core activities

Stack -Integrator

Strategic Supply ChainManagement

Integration & Assembly

Validation Testing

Quality Management

System

Stack concept &

Specification

> Determine financial & personnel resources> Identify potential candidates for integrator role> Establish financing concept & action plan

E. Implementation

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Executing the plan

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Common OEM specification and platform is close to completion

Initial supply chain analysis is available and will be further

completed

Cost tool is established and will be fed with data

Proposals for research agenda were submitted to the FCH JU

Technology roadmap and business plan are in preparation

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You are welcome @

http://autostack.zsw-bw.de/

Thank you!