This presentation will discuss PEMScale1.5, which is a DLR project involving nine DLR institutes from the areas of energy, transport and aviation in order to develop a concept of a generic, integrated fuel cell system with an output of 1.5 megawatts including electric drive. The goal of the PEMScale1.5 project is to identify specific requirements for the fuel cell systems and power trains of the individual applications. Moreover, a concept of a generic fuel cell system with a power of up to 1500 kW is proposed.

From factory to production, this presentation addresses the latest developments in production methods of Fuel Cells and Electrolysers and how to scale impact of design features on production methods.

This presentation will discuss the dynamics of the Electrolyser market and the important considerations to scale Electrolyser manufacturing on a global scale.

The presentation will report about the usage of hydrogen fuel cells for large stationary power plant. Andrea will review the status of the engineering activates at Intelligent Energy to deliver a 10 MW power plant based on hydrogen fuel cell that will be in operation in Korea in 2025.

The APC will present a comparison of installed powertrain costs for a hydrogen fuel cell system, NMC and LFP batteries used in large premium SUVs and vans. This analysis is novel because it links detailed future battery and fuel cell cost projections within a modular electrified platform concept, where OEMs can produce fuel cell and battery electric powertrains on the same vehicle production line.

This panel will address the pros and cons of both fuel cells and batteries, and how these can be complimentary rather than opposing technologies. The panel will also highlight how this might differ between different industries, with a particular focus being on the transport sector.

Fuel cells are a promising but challenging technology for achieving zero-emission heavy-duty commercial vehicles. AVL has developed a modular 156 kW fuel cell system and based on it an optimized fuel cell powertrain for a long-haul semitrailer tractor that meets the industry requirements of lifetime, driving performance, fuel consumption, driving range as well as the costs for acquisition and operation. Driven by climate change and corresponding new legislation emission-free transport becomes increasingly important. Especially, the long-haul truck is considered to be a key application, as this vehicle category contributes most to the emissions within the on-road transport sector. First battery-powered commercial vehicles (e.g., Mercedes eActros) and fuel cell-powered commercial vehicles (e.g., Hyundai Xcient) indicate the ongoing shift toward emission-free transportation on the market. We will elaborate on the methods and tools we used to optimize the Fuel Cell System, battery, e-Axle and all other relevant auxiliaries to develop a class leading solution for the 40ton truck.

Degradation is one of the remaining big challenges for the PEM fuel cell technology to become a main stream mass product at high quantities. The presentation explains why degradation is such a big challenge and lines out AVL's innovative, new and open fuel cell degradation R&D platform.

Nowadays, achieving a zero emission goal is paramount. To do so, hydrogen is becoming one of the key enablers and fuel cells the way to promote the adoption of sustainable mobility worldwide. However, to achieve mass diffusion, the manufacturing process must definitely scale up. In fact, this will reduce costs by up to 20% and increase uptake. To permit the realization of such volumes, automation is the answer. Not only, to be sure automation can release its full potential, the fuel cell design has to be manufacturing and automation-oriented. The goal of automation companies, especially the ones that have led the automotive scale up at the current incredible level of high-speed automation, is to guide fuel cell development to enable a comparable expansion.

Within the project "BReCycle", experts from Fraunhofer IWKS, Electrocycling, Mairec, Proton Motor and KLEIN Anlagenbau developed a sustainable process for the reprocessing of fuel cells, generating high-quality material fractions, in particular from the electrode coating and the polymer membrane. In this presentation, a verified recycling approach comprising of mechanical pre-treatment and chemical separation processes is introduced that ensures a high degree of recovery of the raw materials used and which is superior in terms of environmental compatibility and economic efficiency.

Increasing demand for green hydrogen needs a significant increase of water electrolysis capacity. Here, PEM electrolysis will cover a significant share of the planned GW installations to reach the ambitious H2 generation goals. However, all electrolysis technologies and particularly PEM electrolysis is dealing with critical raw materials, for the latter precious metals. On the other hand, precious metals also show highest efficiencies in activity and in recyclability which makes them not only a chance but a pivotal element of the hydrogen economy. Their application beyond water electrolysis shows especially in in fuel cells, gas purification and conversion into other compounds for transport, e.g. ammonia, a big opportunity. With material development and recycling strategies as well as the best fitting metal management tools, it can be avoided that those critical raw materials become a critical factor for the hydrogen economy.

Water management of fuel cells is essential for efficient usage and optimal performance. Simulation approaches for water transport analysis vary between simple and fast 1D models up to computational expensive 3D resolved transient models. Users have to decide between simplicity versus complexity in model set-up, quick versus time-consuming solutions, global versus detailed resolutions ending up in decisions between short development cycles, high investment costs and accurate modelling results. Our presentation will show an industrial useable approach with a good accuracy/time/cost ratio using an efficient VOF model which can be coupled with further sophisticated models for transport in gas-diffusion layers and membranes. We will show results of water transport in industrial fuel cell designs as well as possible optimization strategies using various model levels.

The European Critical Raw Materials Act (CRMA) is set to secure Europe's competitive edge and produce 40% of its own clean tech by 2030. The EU plans to produce 10Mtons of renewable hydrogen, requiring 100 GW of electrolyser capacity. This panel discussion aims to highlight how the CRMA will impact fuel cell and electrolyser producers throughout the value chain.

This presentation covers various PVD coating materials, including titanium, platinum, and diamond-like carbon, and their effects on the properties of fuel cell and electrolyzer components, such as corrosion resistance, electrical conductivity, and catalytic activity. We also discuss the challenges associated with PVD coating, such as cost and scalability, and potential solutions to overcome these obstacles.

The presentation explains the principle and the setup of the calibration system. By increasing the system pressure, higher mass flow rates can be achieved at the same volume flow. Thermal stability is mandatory for calibrations and measures needed to be taken for that. Pressure drop and fluctuations have been investigated and have been optimized. With the system it is now possible to perform high flow real gas (hydrogen) calibrations.

This presentation will be about the EKPO NM12 stack module and its performance characteristics. The level of integration of the BOP-components and how we ensure a high quality over lifetime with our design verification plan

Christian Vinther will give an insight into how Ballard received the world’s first DNV Type Approval, what a Type Approval process involves and ultimately what this means for the marine market. In addition, Christian will also present several vessel projects which in 2023 will embark on their maiden voyages powered by Ballard’s fuel cells -showcasing how zero-emission operation can be made possible here and now. This includes the presentation of the Norwegian MF Hydra ferry, which is the world’s first ferry to be powered by PEM fuel cells running on liquid hydrogen. In November 2022 Ballard installed two 200kW FCwaveTM fuel cell modules on board the ferry, and in March 2023 the project reached a huge milestone, when ferry owner Norled announced that the ferry was put into official operation.

It is imperative to develop breakthrough solutions to retrofit the existing fleets and allow maritime transport industry to meet the environmental challenges with investments that do not compromise their businesses nor waterborne transport industry. Therefore, the availability of cost-effective and easy-to-integrate PEM fuel cell systems type-approved for maritime applications and the use of green hydrogen as zero emission fuel will significantly contribute to the decarbonization of the shipping industry.

This panel will focus on recent breakthroughs in fuel cells and stack design, focussing on topics such as performance and durability, the latest developments in bipolar plates, simulation techniques and cost reduction strategies. The panel will conclude the discussion with future directions and challenges facing the industry.

Ths session will highlight the role of cathode air filter and its influence on the performance and durability of the fuel cell.

Fuel Cells represent an integral part of the future energy sector, i.e. in heavy-duty mobility or stationary power generation. However, its production is characterized by complex processes, the utilization of sensitive materials and niche knowledge due to its novelty regarding the series production. One main process chain represents the production of the membrane electrode assembly (MEA) where the electrochemical processes in the fuel cell take place. Hence, this component is primarily responsible for the overall fuel cell performance. By having a more profound insight into its production process it comes up, that improving material handling and product quality due the thin membrane, huge consumption of carrier material and high production cost remain major challenges in MEA production. As part of the project Fuel Cell Performance Production (FCPP), an innovative process concept is developed to address the above-mentioned challenges and propose a process solution for future fuel cell production systems. Within the concept, a re-coatable transfer belt is used as a continuous decal to enable a roll-to-roll coating of the membrane. In a following process step, the membrane is assembled with a subgasket and gas diffusion layer (GDL) to the MEA. To gain knowledge about relevant parts of the new concept, e.g. transfer belt coating and catalyst transfer to the membrane, first tests need to be conducted to understand relevant interdependencies of the materials, their handling and process parameters to enable a state-of-the-art MEA production. Thus, a holistic hands-on experience of the whole process chain of the MEA production is explained. Next to the applied materials, a prototypical manually MEA production line is described and integral process parameters as well as the impact of their deviation are shown. Finally, requirements to an automated and industrialized MEA production are derived.

Fuel cell stacks and bipolar plates are key components of any mobile or stationary fuel cell application. In addition to the safe operation of hydrogen-containing compounds, cost-effective processes with short cycle times are the main objectives when selecting leak testing methods for these components. Taking the requirements of mono plates, bipolar plates and complete stacks as examples, we present the selection process for the respective leak test method and discuss the advantages and disadvantages of the individual procedures.

The German Fuel Cell Cooperation will present the key elements of their concept of an integrated bipolar plate production and the parameters that enable a robust, efficient and scalable production that the industry demands. In an emerging market, it’s not only about the equipment but also about the technologies being used, which the German Fuel Cell Cooperation addresses as well.

In the previous BOSAL publication A1609 from EFCF2020, the modelling and advanced characterization of the thin foil counterflow heat exchanger elements were discussed and how they function optimally as quantum manager to achieve a quasi-reversible functionality. These quantum managers are a necessity to reach in SOFC and SOEC high electrical efficiencies. In such a way, they are crucial building blocks to achieve the desired conditions of the flows towards the fuel cell stack. Temperature and gas composition must be provided in the required windows, so the stack can function and perform as desired. Composing the quantum managers together results in a Hot-Balance of Plant (H-BoP) system. BOSAL realized already since 2008 SOFC H-BoP systems. Specifications regarding space, heat transfer and quantum management in combination with pressure drop (backpressure as it is called), are essential parameters to consider by finding the desired trade-off between CAPEX and OPEX. BOSAL has configured over the last years for multiple customers a variety of SOFC and SOEC systems based on the specific approach and P&ID of the customer, resulting in optimal designs and optimization for each approach. By doing so, a learning curve was generated, resulting in lessons learned which are taken in the process development for serial production. Very often small details make at the end the difference. Thermal management is key. Such experiences are shared in the paper to prepare and help the SOFC or SOEC system developer better in the multiple choices he has to make to generate a P&ID including the lay-out, the number of components and their position, which are very often the key to success. Practice showed that the best compromises deliver much better results compared to the theoretical best choices. Reason is that in reality, materials reach with their properties their limits in these applications, not speaking about the cost complications that sometime pushes the application in the direction of very exotic and costly material selections. Examples are discussed. Nowadays, multiple customers work on fast heat-up within minutes instead of hours for SOFC and SOEC components. There is the experience in the BOSAL-group coming from automotive exhaust systems to minimize the design and concept loops to achieve a functional and endured concept. Finetuning in the virtual environment happens before going into high production volumes by using Thermal Mechanical Fatigue (TMF), validated with thermal cycling tests with burners and heaters to control risks when going into high production volume. On request of multiple customers, BOSAL is realizing the industrialization of several heat exchanger footprints production up to the fully integrated H-BoP systems up to TRL 8.

Hydrogen, generated with renewable energy, is the promising energy storage type of the future. The challenges in the hydrogen value chain, from hydrogen generation to storage and transportation as well as end use, are numerous and especially materials used for these purposes have to be adapted to tough conditions. Not only materials are very sensitive to hydrogen influences but also special requirements need to be fulfilled to reach a higher product efficiency and longer service life. ZwickRoell would like to give an overview of the relevant material testing solutions regarding to the hydrogen fuel cell/electrolyzer.