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PowerCell Sweden AB · Property of Powercell Sweden AB Powercell Company overview Located in...
Transcript of PowerCell Sweden AB · Property of Powercell Sweden AB Powercell Company overview Located in...
Per Ekdunge, PowerCell Sweden AB
21 May 2019, Lund University
Fuel Cells -
PowerCell AB
Property of Powercell Sweden AB
Powercell Company overview
Located in Gothenburg, Sweden
Building on a 15 year heritage of technology, know-how and IP developed within Volvo Group,
Independent company since 2009
Listed on NASDAQ during 2014
A high competence team of about >60 FTEs
Unique, patented fuel cell and reformer technologies
Northern Europe’s largest state-of-the-art fuel cell and reformer laboratories
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Fuel cell benefits
Highly efficient energy conversion
▪ reduced greenhouse gas emissions
▪ reduced oil consumption
Reduced air pollution
Fuel flexibility (use of diverse, domestic fuels, including clean and renewable fuels)
Expanded use of renewable power (through use of hydrogen for energy storage and transmission)
Modularity
Good partial load characteristics
Dynamic response
Quiet operation
Low maintenance needs
High reliability
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The Fuel Cell History
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Type of fuel cell technologies
Fuel cell PEMFCProton Exchange
Membrane Fuel Cell
AFCAlkaline Fuel Cell
PAFCPhosphoric Acid
Fuel Cell
MCFCMolten Carbonate
Fuel Cell
SOFCSolid Oxide Fuel
Cell
Electrolyte Solid organic
polymer
Potassium
hydroxide
Phosphoric Acid Molten carbonate Solid zirconium
oxide
Operating
Temperature
60-100 C 90-100 C 175-200 C 600-1000 C 600-1000 C
System
Efficiency
50-60% (H2)
35-45% (NG)
60-70% (H2) 38-42% (NG) 50-60% (NG) 50-60% (NG)
Application Backup Power
Portable Power
Dist. Generation
Transportation
Military, Space Dist. Generation Electric Utility,
Dist. Generation
Electric Utility,
Dist. Generation
Advantages Quick start-up,
simple construction
Low temperature
High efficiency Generate heat
and power
Cheap catalyst
fuel flexible
Cheap catalyst
fuel flexible
Dis-
advantages
Expensive catalyst
sensitive to fuel
impurities
Removal of CO2
from air and fuel
required
Pt catalyst
Large size weight
Corrosion
Material stability
Material stability
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Fuel cells serve a wide range of distributed power applications
Telecom
Genset Thermo transport
Household mCHP
Industrial
Power plantLaptopMobile devices Material handling
1W 1kW 1MW1mW
Vehicle APU
Car propulsion
Bus propulsion
10kW 100 kW
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Marine
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Fuel Cell System Efficiency
PEFC (H2)
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Fuel Cell Technology Challenges (1)
Cost and durability are the major challenges to fuel cell commercialization. However, hurdles vary according to the application in which the technology is employed. Size, weight, and thermal and water management are barriers to the commercialization of fuel cell technology. In transportation applications, these technologies face more stringent cost and durability hurdles. In stationary power applications, where cogeneration of heat and power is desired, use of PEM fuel cells would benefit from raising operating temperatures to increase performance. The key challenges include:
Cost. The cost of fuel cell power systems must be reduced before they can be competitive with conventional technologies. For transportation applications, a fuel cell system needs to cost $30/kW for the technology to be competitive. For stationary systems, the acceptable price point is considerably higher ($400-$750/kW for widespread commercialization.
Durability and Reliability. For transportation applications, fuel cell power systems will be required to achieve the same level of durability and reliability of current automotive engines, i.e., 5,000 hour lifespan (150,000 miles equivalent) for cars and >20000 h for commercial vehicels, and the ability to function over the full range of vehicle operating conditions (- 40°C to 80°C). For stationary applications, more than >40,000 hours of reliable operation will be required for market acceptance.
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Fuel Cell Technology Challenges (2)
System Size. The size and weight of current fuel cell systems must be further reduced to meet the packaging requirements for automobiles. This applies not only to the fuel cell stack, but also to the ancillary components and major subsystems (e.g., compressor/expander, and sensors) making up the balance of power system.
Air, Thermal, and Water Management. Air management for fuel cell systems is a challenge because today's compressor technologies are not suitable for automotive fuel cell applications. In addition, thermal and water management for fuel cells are issues because the small difference between the operating and ambient temperatures necessitates large heat exchangers.
Hydrogen infrastructure Cost efficiency• Availability• Coverage • Efficiency
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Conflicting Objectives of the Stack Design
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0
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10
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45
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Cost
Durability
EfficiencyOperationcondtions
Fuel
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Technology
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The Principles of Fuel Cells
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The fuel cell stack
The fuel cells are serially connected into a fuel cell stack
▪ Stack Voltage = (No. of Cells) x (Average Cell Voltage)
▪ Stack Current = Cell Current
The same current goes though all cells, i.e. if one cell malfunctions the whole stack will malfunction
▪ A Cell Voltage Monitoring (CVM) device is therefore used that monitors all cell voltages
▪ The CVM will have to communicate with the control system
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GDL• Purpose is to conduct
electricity, transport reactants and product water and to distribute compression forces
• Porous carbon based paper or wowen material
• Wetproofed with PTFE• Total thickness of 100-300 µm
Gas diffusion layer (GDL)
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Copyright © 2012 PowerCell Sweden AB. All rights reserved
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PEM Fuel Cell
WaterAcid
H2
Carbone
H+ Pt-particle
e-
Nafion
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The Membrane
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Fuel Cells Bulletin, Vol.2002, issue 11, November 2002, Pages 9–12
10 µm
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Electrodes
Electrodes • Platinum or platinum alloy nanoparticles
• High surface area carbon support material
• Thickness 5-10 µm
• Pt/C is mixed with ionomer to create the eletctrode structure
Durability of the electrodes is a key challenge for PEMFCs• Carbon corrosion
• Platinum dissolution/aglomeration
Oh et al., Journal of Hydrogen Energy, 35 (2), 2010
New materials
Ne
w m
ate
ria
ls
Core-shell catalyst
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Oliver Gröger et al. J. Electrochem. Soc. 2015;162:A2605-A2622
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Fluorinated Ionomer Membranes
Phase separation
• Hydrophobic
• Hydrophillic
8-50 µm
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Fuel cell component
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Bipolar plate (cathode side)
Diffusion medium (cathode side)
Membrane electrode assembly
Diffusion medium (anode side)
Bipolar plate (anode side)
Coolant inlets
Fuel Cell Components
Gas inlets
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Bipolar Plate
- Low Stoichiometry Operation- Di-Electric Coolant Development- Conductivity (composite plastics)- Corrosion (metal plates)- Freeze & Cold Performance
Gas inlets
Coolant inlets
Fuel Cell Components Key Issues
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Gas Diffusion Medium- Water Management- Electrical Conductivity
Gas inlets
Coolant inlets
Fuel Cell Components Key Issues
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Membrane Electrode Assembly
- Zero External Humidification- Higher Temperature Operation- Lower Pressure Performance- CO Tolerance- Catalyst Loading
Gas inlets
Coolant inlets
Fuel Cell Components Key Issues
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Efficiency
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Fuel cell versus Carnot Efficiency
Heat EngineCarnot Cycle
Fuel CellHE
T T
T
−1 2
1
Where T1 is the temperature at
which the heat is supplied and T2 is
the temperature at which the heat is
rejected.
EE
G
HT
S
H = −
1
The maximal work that can be done by
a fuel cell is given by the change in
Gibbs free energy, -G, for the
reaction of the fuel with the oxidant.
The energy content of the fuel is
expressed in terms of its heat value,
which is the change in enthalpy, H.
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Versus Carnot efficiency
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10
20
30
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50
60
70
80
90
100
300 500 700 900
Temperature/K
Eff
icie
nc
y/%
Fuel cell
Carnot cycle
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Fuel Cell Efficiency
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20
40
60
80
100
0 20 40 60 80
Eff
icie
nc
y/%
Current
Activation overpotential
Ohmic losses
Mass transport losses
Theoretical
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Efficiency in application
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30
40
50
60
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0 20 40 60 80 100 120
Verk
nin
gsg
rad
/%
Last/%
Fuel Cell
Otto
Diesel
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Fueling the fuel cell
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Fuels for the Fuel Cell
Energy Crops
WindOrganic
residuals Wood Sun NG
Electric grid
OilCool
Fermentation
Anaer. Digestion
Electrolysis Gasification Reforming Refinery
Nuclear
Ethanol MethanolBiogas hydrogen NGGasoline/
Diesel
Thermo-chemical
Fuel Cell
Hydrogen
Useful energy
Final Fuel
Fuel
Reformer Reformer ReformerReformerReformer
Primary
Energy
Electricity
Heat
Renewable Fossil
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Impacts of Fuel Constitutes
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Choice of Fuel
Hydrogen▪ Liquid
▪ Compressed
Methanol
Ethanol
Natural Gas
Biogas
Diesel
Other
On-site/On-board reforming
Needed
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Fuel cell system with hydrocarbon fuels
Fuel
Fuel cell
stack
AC Power output Inverter
AC Power output
Heat recovery
HeatFuel processor heating
Fuel Reformer
Hydrogen rich gas
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H2 (gas or liq.)
Steam or auto-thermal
reformerMeOH + H2O -> CO2 + 3H2
MeOH + ½O2 -> CO2 + 2H2
Methanol
CO cleanupCO + ½O2 -> CO2
FC
stack
POX reformerCnH2n+2 + n/2 O2 ->
n CO + (n+1) H2
Hydrocarbon
fuels
CO cleanupCO + ½O2 -> CO2
FC
stack
LT & HT shiftCO + H2O -> CO2 + H2
FC
stack
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Fuel cell system
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Powercell Reformer System for APU
ATR technology was chosen in order to be self sustained by heat and have
good load following with as high efficiency as possible.
CxHy + H2O + O2 → H2 + CO2 + CO
Water Gas Shift + Preferential Oxidation was chosen to reduce CO level
CO + H2O → H2 + CO2
CO + ½ O2 → CO2
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V = 15 mresp. ~ 1,3 kgH2
V = 15 mresp. ~ 1,3 kgH2
vehicle requirement:~ 4 - 8 kg
EYE PRESS/AP „GAS THIEVES in Puheng “
Hydrogen storage
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23 kg 4,6 kg 4,6 kg
26 L 68 L 120 L
Fuel Fuel Fuel
Diesel Liquid Hydrogen Compressed Hydrogen 700 bar
32 L 120 L 200 L
30 kg 90 kg 95 kg
System System System
23 kg 4.6 kg 4.6 kg
26 L 68 L 120 L
Fuel Fuel Fuel
Diesel Liquid Hydrogen Compressed Hydrogen 700 bars
Range: 400 km
Car Tank System Weight and Volume
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Elevated TemperatureT > 80°C
Cryogenic Temperature- 200°C < T < -150°C
Storage Technologies
Conventional Technology
LH2
CGH2
Solid State Materials
Absorption Adsorption on Inner Surface
High SurfaceMaterials
ChemicalHydrides
MetalHydrides
Hydrogen Storage Technology Options
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Fuel Cell Market and applications
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Fuel Cell Global Shipment - Trends
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Fuel Cell Global Shipment – Trends -2
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Applications transportation
Motive Power
▪ Specialty Vehicles, Light-duty Vehicles, Buses, and Trucks
Transportation
▪ Trucks, Aircraft, Rail, and Ships
L. Gaines and C. Hartman, “Energy Use and Emissions Comparison of Idling Reduction Options for Heavy-Duty Diesel Trucks,” Center for
Transportation Research, Argonne National Laboratory, November 2008;
The use of auxiliary power units (APUs) for Class 7–8 heavy trucks in US to avoid overnight idling of diesel engines could save up to 1000 million l of fuel per year and avoid more than 92,000 tons of NOx and 3 million tons CO2 emissions.
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Distributed Energy Applications and CHP Systems
Eliminating of transmission and distribution losses, low emissions, increased reliability, and high efficiency
Backup Power Fuel cells are emerging for providing backup power, particularly for telecommunications towers, data centers, hospitals, and communications facilities for emergency services.
Storage and Transmission of Renewable Energy
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Stationary Applications
60 MW MCFC installation POSCO KoreaPEMFC installation ReliOn USASOFC installation Bloom Energy USA
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mCHP development in Japan
35000 €
25000 €
16000 €
5300 €3500 €
Biggest fuel cell program (number of systems) is ENA-FARM mCHP in Japan
>300 000 system has been deployed
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BEV and FCEV
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Key components
▪ Fuel cell stack
▪ Air compressor
▪ Humidifier
▪ Hydrogen tank
▪ Hydrogen re-circulation system
▪ Power electronics
▪ Electric driveline
Hybridization
▪ Increases overall efficiency, supports durability and optimizes driving behavior
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Automotive fuel cell system layout
Illustration reproduced with permission from AUDI AG
Battery electric and hybrid combustion engine vehicles pave the way for fuel cells. The same or similar components are used.
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Fuel Cell system
Fuel Cell Stack
Application adapted
fuel cell systemFuel Cell Module
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Schematic of direct-hydrogen pressurized FCS
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Schematic of electric drive train for FCHEV
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Critical factors for a broad FCVs market introduction - Technology
Automotive fuel cell technology readiness level
Key technical findings which have paved the way for fuel cells in transport
▪ Low noble metal loading electrodes (1990’s)
▪ Reinforcement (1990’s) and doping (2000’s) of membranes
▪ Understanding of degradation mechanisms with respect to start/stop and fuel starvation (2000’s)
▪ Robust (low cost) metal bipolar plate sealing solutions and metal stamping / coating processes (2010’s)
▪ Cost and weight efficient on-board fuel storages (2010’s)
Photo: Daimler / Mercedez-Benz. Reproduced with permission.
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Critical factors for a broad FCVs market introduction - Technology
We are competing with combustion technology which has been developed for more than 100 years, i.e. we are still experiencing a steep learning curve!
Some selected official statements on OEM technical FCV advances
Toyota Advances 2008-2015 (Source Toyota)
▪ Fuel cell stack current density increase x 2.4
▪ Tank storage density increase by 20 % (now 5.7 w%) while reducing cost
Daimler advances 2010-2017 (Source Daimler)
▪ Test fleet FC B-class: 8.000.000 km driven, 36.000 refueling occasions (2.8 min average)
▪ Fuel cell engine size reduction by 30 %
▪ Platinum amount reduction by 90 %
▪ Increase of driving range by 30 %
Honda advances new Clarity vs previous model (Source Honda)
▪ Fuel cell stack 30 % more power with 33 % less volume
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Critical factors for a broad FCVs market introduction – Customer acceptance
Reasonable price to end user (ultimate DOE system production cost target 27 € / kWnet)
Convenience, user behavior
Environmental impact, local and global
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1000 10 000 30 000 80 000 100 000 500 000
PR
OD
UC
TIO
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OST
EU
RO
ANNUAL PRODUCTION VOLUME
PRODUCTION COST ESTIMATION DOE 2015 BASED ON TODAY’S TECHNOLOGY
System Cost (€/kWnet)
Stack Cost (€/kWnet)
Source: DOE: "Fuel Cell System Cost - 2015" Ahluwalia et al.
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Release dates for fuel cell cars
▪ Hyundai ix35 fuel cell: 2014
▪ Toyota Mirai: 2015
▪ Honda Clarity: 2017
▪ Mercedes-Benz GLC F-Cell: 2018
Photo: Daimler / Mercedez-Benz. Reproduced with permission.
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Manufacturer Honda Mercedes
Production 2016–present 2017
Class Mid-size compact SUV
Electric drive Fuel cell powered 130 kWFuel cell plug in hybrid with9 kWh Li-Ion battery
Range 589 km (EPA) 500 km (NEDC).
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Production optimization and investments
Technology and production development
Where are we now production cost wise?
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Prototype development
Proof of concept Test fleets
Early adopters
Broad market introduction
Pro
du
cti
on
Co
st
Tre
nd
Time
2018202X
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Power density, Pt-reduction and durability need balancing
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o Loading of < 0.3 mg/cm2 is used in the context of optimized operation conditions
o Lower Pt-loading establish conflicts of objective with regards of performance, durability and stack power density.
o Increase of area specific power density delivers an equally effective tool for cost reduction.
o Further optimization potential is ties with the OEM system requirements
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acceleration=> H2 depletion deceleration
=> high ∆P
between A / C
low power, stack stop=> Carbon corrosion
Extended stop
=> O2 ingressPotential cycling
=> catalyst corrosion
Durability - Stress factors in a “real” drive cycle
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Powercell Fuel Cell Stacks & Systems
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PowerCell fuel cell stacks and system
PowerCell S320-100 kW (prototype)
PowerCell S25-25 kW
PowerCell S1 1-5 kW
PowerCell PS-51-5kW
PowerCell MS-100100kW (prototype)
PowerCell MS-2020kW (prototype)
PowerCell PS-51-5kW
PowerCell PowerPac3kW (prototype)
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Fuel Cell Platforms Serving a Wide Range of Applications
Fuel Cell stack PowerCell S2 (in production)
▪ 2-35 kW power
▪ Runs on pure hydrogen or reformate
▪ Suitable for continuous power or back-up solutions
▪ Can be operated in multiples for larger systems (MW)
Fuel Cell stack S3 (in prototype production)
▪ 20-125 kW power
▪ Runs on pure hydrogen
▪ Suitable for propulsion or industrial systems
▪ Can be operated in multiples for larger systems (MW)
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S2 Designed with Fuel Flexibility & Used in Multiple Applications
MethanolHydrogen LPG DieselNatural Gas Biogas
Smart
Homes
Micro-CHP Telecom Range Extender
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PowerCell S3 – Establishes Best-in-Class Power Density
S3
Powered by hydrogen gas
High-quality fuel cell stack primarily for powering vehicles
20-100 kW power range
Designed in accordance with automotive cost targets
The design is exclusively based on industrial components and materials
Goal: Superior quality and performance to meet the requirements from the automotive industry!!
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Outstanding Power Density Addresses Packaging and Cost
Improved active to passive ratio
Lower cell pitch
Improved material usage
Lower cost materials
More rugged design
CVM integrated in stack housing
Prototype tooling for housing components
Specifications Unit EVO3 Target EVO1 Outcome EVO2 Outlook
Outer dimensions (lenght x width x height) dm 6.5 x 4.3 x 1.55 5 x 4.14 x 1.656 4.9 x 4.15 x 1.49
Volume of the stack exterior dm3 < 41 34.3 ~ 27,7
Weight without fluids and fully humidified membranes (net weight) kg < 44 46,3 ~ 33,1
Change Evo 1 vs. Evo 2 Active/passive ratio +13%
Cell pitch mm -17%
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Industrial and research partners have joined forces in the AutostackIndustrie project
The project addresses a critical gap in the German value chain
The project uses the results from AutostackCore as starting point for industrialization of the technology
The objective is to develop best- in-class automotive stack technology with strong focus on production technology
The stack platform concept enables additional vehicle and stationary applications
The design is exclusively based on industrial components and materials
Target is automotive stack production in Europe from 2021
Project budget: 60 M€
Partners: 11
Duration: 48 months
AutoStack Industrie Consortium
Automotive OEMs
Component and System Suppliers
Research Institute
Example of costumer projects
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PowerPac: A Complete System for Clean Power Generation
Unique diesel reformerDiesel based 3kW
fuel cell system(prototypes avalible)
Fuel Cell stack designed for H2 or
reformate gas
PowerCell addresses the market with cost effective power supply solutions using current fuel infrastructure
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Reliable Power Supply for Vodacom & TeliaSonera
One million telecom towers are outside of reliable electrical grids and another
200,000 are expected to be added by 2020 (GSMA)
Traditional alternative is a diesel power unit, but global players are under strong pressure to find environment-friendly renewable alternatives
Currently testing together with Vodacom in South Africa and Telia in Sweden
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PowerPac: Freezer and Refrigerated Transport
Field test of PowerCell PowerPac B-prototype during 2016
Up to 90% reduction in fuel consumption (ca 1,800 liters per year)
Up to 90% reduction of CO2 emissions (ca 5 tons per year)
CO, NOx and particulates eliminated
Opens the door to up new opportunities for PowerPac
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Customer Case:
Decentralized Smart Houses - ”Off Grid”
Summer: Production of Hydrogen from Photovoltaic
Winter: Fuel Cells Producing Heat and Electricity from Stored
Hydrogen
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Energy system solution
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Inverters
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Fuel Cell System and Longterm storage
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12 Mounth Energy data from the House
10,500 kWh sun energy converted to 210 Kg Hydrogen from March thruOctober, Electrolyser run time 1190 hrs.
210 Kg Hydrogen converted with PS-1.5 to 6.000 kWh electricity and thermal heat from November thru February.
Total electricity consumption 12,400 kWh including 3.000 kWh by the fuel cell.
Total thermal heat consumption 14800 kWh including 2.900 kWh by the fuel cell.
Electric Vehicle charging consumption 3.500 kWh
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Off-grid houses: Skellefteå Kraft
Sunlight: Production of hydrogen from solar panelsDarkness: Heat and electricity from stored hydrogen
The Zero Sun Project
Nilsson Energy
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▪ 30kW peak power
▪ Complet Fuel Cell System
• PowerCell S2 Stack 35kW peak power
• Hydrogen loop
• Air loop
• Coolant loop (no radiator)
• Control and safety system
• DC/DC
▪ Easy to integrate
▪ 10 000 h life time expected at 20kW
▪ Compact
PowerCell MS-30 (prototype)
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PowerCell MS-30 (prototype)
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Fuel Cell System based on PowerCell S2
Middle sized Forklift for SSAB
Test until 2018
Material Handling: Kalmar and SSAB
PowerCell S2
Kalmar 18 ton electric forklift
PowerCell provides complete energy solution
▪ 2 units of MS-30
▪ 120 kW Li-batteries
▪ 3 H2 cylinders 700bar
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INN-BALANCE
100 kW Fuel cell system will be installed in vehicle from Volvo
Main technical objectives of project are:
▪ develop highly efficient and reliable fuel cell BoP components
▪ reduce costs of current market products in fuel cell systems
▪ achieve high technology readiness levels (TRL7 or higher) in all the tackled developments
▪ improve and tailor development tools for design, modelling and testing innovative components in fuel cell based vehicles.
Project consortium:
Brose Fahrzeugteile GmbH & Co
AVL LIST GMBH
VOLVO PERSONVAGNAR AB
Powercell Sweden AB
DEUTSCHES ZENTRUM FUER LUFT - UND
RAUMFAHRT EV
UNIVERSITAT POLITECNICA DE CATALUNYA
STEINBEIS INNOVATION GGMBH
CELEROTON AG
EU funding 5.0 M€, 6.1 M€ total
budget
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COOP Switzerland presents world first fuel cell truck with trailer
34 ton truck with a daily route of about 400 km
Powercell S3 fuel cell in 100 kW fuel cell system
35 kg of hydrogen
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100 kW Fuel Cell Power System (prototype)
FC system technical data SHA-100-E
Number of cells 455
Max. continuous net power 100 kW
DC net out at max. cont. power 332 V; 300 A
System pressure (at full load) 2.6 barabs
Voltage range (Peak Power EOL .. OCV BOL) 250 .. 500 V
Coolant flow (pump integrated) 150 l/min
Coolant outlet temperature 80 °C
Waste Heat 92 kW
System Efficiency (LHV H2 in to DC stack out) 52 %
Dimensions (H x W x D) 1) 750 x 750 x 520 mm
Weight 2) 98 kg
Durability (depending on usage profile) > 5000 h1) Not included: brackets, covers, heat shields, coolant reservoir
2) All included (but Radiator and DC/DC converter not within system
content)
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Best in class performance
Easy to integrate
Suitable for mass since based on industrial components
Life time 20 000 h (expected)
Price competitive
Nikola Fuel Cell Truck
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Marine application of a new fuel cell powertrain validated
in demanding arctic conditions
165 kW (2 x 82.5 kW AC) fuel cell powertrain based on
S3 fuel cell stack
Powers research vessel Aranda's electrical equipment
and dynamic positioning during measurements
18-month marine field testing including extreme cold
and saline conditions (mostly Baltic and North Sea)
MARANDA project
Project consortium:
VTT Technical Research Centre of Finland Ltd
Powercell Sweden AB
ABB Oy
OMB Saleri SPA
PersEE
The Finnish Environment Institute (SYKE)
Swiss Hydrogen SA
EU funding 2.9 M€, 3.7 M€ total budget
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Siemens MoU on Marine Applications
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Thank You for Your Attention!
Powercell Sweden AB (publ) noterat på Nasdaq First NorthRuskvädersgatan 12, 418 34 Göteborg
+46 31 [email protected]
PowerCell, a Leading Fuel Cell Company
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