Page 1
Fuel Cell Stack
Value Proposition
Page 2
Overview
• Advantages of PEM fuel cell technology
• Ballard’s fuel cell stack portfolio
• Competitive advantages
• Ballard proof points
Page 3
Advantages of PEM Fuel Cell Technology
Page 4
PEM Fuel Cell Applications
High
600°C‐1200°C
SOFC (Bloom Energy)
Increasing heat management requirements MCFC (Fuel Cell Energy)
PAFC (Doosan Fuel Cell America)
Low
60°C‐120°C
Temperature
Fuel Cell Comparison
PEMFC
1KW
10KW
100KW
Backup Power
1MW
10MW
Distributed Generation
Material Handling
Bus & Light Tram
PEM fuel cells have the greatest flexibility across all power ranges
Page 5
Why PEM?
• Scalable
o Only PEM fuel cells can be used in applications ranging from mobile phones to power stations
• Efficient
o PEM fuel cells are compact and lightweight, offering powerful electric current relative to size and 40‐60% efficiency
• Reliable
o Reliable and durable; deployed with minimal service requirements in a range of environments
• Responsive
o Faster start‐up and rapid response to changes in power demand
Page 6
Ballard’s Stack Product Portfolio
Page 7
Ballard’s Fuel Cell Stack Portfolio
AIR‐COOLED
COMMERCIAL
• Primarily used in backup power & material handling applications
• Primarily used in motive (material handling & bus) applications • 400W to 3kW
• 3.8kW to 22kW
• ~4‐10,000 hour lifetime • ~10,000 hour lifetime
(application dependent)
DEVELOPMENT STAGE
LIQUID‐COOLED
• Primarily used in portable power applications
• 40W
• ~1,600 hour lifetime
Page 8
Ballard Competitive Advantage
• Ballard's fuel cell stack products offer a number of important advantages relative to the competition: 1. Proprietary MEA
•
Over 30 years of product development, •
Ballard has refined the membrane electrode assembly, a core component of our fuel cell stack products
2. Purpose Built Designs
•
A choice of air‐cooled or liquid‐cooled fuel cell stacks ensures purpose‐built designs optimized to suit your power application
3. Volume Manufacturing
•
4. Proven Durability
Automated and continuous manufacturing processes ensure high quality, low cost production to meet customer demand
Ballard’s commercial fuel cell stacks are fully validated, with more than 250MW of products deployed with customers around the world
5. System Integration Support
•
Our Applications Engineering team is available to ensure customer success through the entire system design and integration process
6. Tier 1 Customers
•
Our extensive collaborations with Tier 1 auto OEMs has driven enhanced product durability and performance while rapidly reduced product costs
Page 9
1. Key Technical Strengths
Page 10
Product Development
•
Ballard in a leader in all aspects of product design & research ranging from components through to prototype fuel cell stacks and complete systems
•
Utilize automotive robust engineering design practices
o Apply rigor of a Tier 1 automotive supplier
•
Prototype light‐weight, low‐power air‐cooled fuel cell stack concept Key technology advancements
o Unique system control strategies for start/stop and voltage clipping
o Continuous innovations related to flow field plate with flow guide
o Component technologies enabling low RH, low catalyst loaded MEAs
o Advanced sealing designs for extended lifetime operation
o ‘Freeze’ technology, enabling rapid start‐up at low temperature
o Unique water management, eliminates need for humidifiers and enables 5,000+ operational hours in certain designs
Bi‐polar plate designs
Page 11
Patent Portfolio & Know‐How
•
Ballard’s IP portfolio consists of ~200 patents/applications with access to ~1,500 patents/applications
o System, stack, and component‐level design
o Membrane, electrode, catalyst, and materials
o System and stack operation and control
•
Trade secrets and know‐how are centered on predictive design methods, accelerated test methods, catalyst coated membrane and MEA manufacturing processes
Ballard’s unparalleled depth of technical knowledge and experience translates into world leading fuel cell stack technology
Page 12
2. Air‐Cooled and Liquid‐Cooled Fuel Cell Stacks
Page 13
Fuel Cell Stack Development
•
Ballard has completed >10 application‐specific stack designs for a range of applications:
o Several watts to multi‐MW
o Stationary and motive applications
o Pure hydrogen and reformate fuel stacks
•
Current product lines primarily divided into air‐
cooled and liquid‐cooled categories
Page 14
Product Differentiation
Air‐Cooled versus Liquid‐Cooled
• Recommended BOP
•
DC energy storage .………..
Power Electronics
•
•
√ √
√
√
√
√
√
√
√
√
√
√
Regulated DC power .……..
Controls
•
Start/Stop, hybridization ..
Ballard 9SSL
√
√
Coolant pump ………………..
Radiator ……………………….
Battery or Ultra‐Capacitors
•
•
Fuel storage …………………..
Pressure regulator .………..
Supply valve ………………….
Purge valve ……………………
Anode recirculation blower
√ Coolant Subsystem
•
•
•
Fan, intake filter, ducting ..
Compressor …..……………..
Humidifier ..…………………..
Fuel Supply Subsystem
•
•
•
•
•
•
liquid‐cooled
Air Supply Subsystem
•
•
•
•
air‐cooled
√
√
√
√
√ √
In general, air‐cooled is better for <5kW and liquid‐cooled is better for >5kW
Page 15
FCgen®‐1020ACS Fuel Cell Stack
Air‐Cooled
•
Low cost design, delivering robust and reliable operation and incorporating advanced open cathode technology and self‐humidifying MEA to simplify system integration
•
Key Attributes:
o Scalable power output from 400W to 3kW (~41.1W per cell)
o Open‐cathode stack eliminates humidifier, coolant pump & radiator o Produces clean DC power
o 4‐10,000+ hour operating lifetime
o robust and reliable performance
o Fuelled with hydrogen
o Manufacturing capacity of 6,000 units @ 3kW per year (expandable)
•
Customers:
o Widely deployed through integration into Ballard’s ElectraGen™ direct hydrogen‐
and methanol‐fuelled backup power systems
o Also powers Plug Power’s line of GenDrive® fuel cell systems for electric lift trucks
Page 16
FCgen®‐micro
Air‐Cooled
•
Low power fuel cell stack prototype, designed for integration into portable applications
•
Key Attributes:
o Rated power of 40W
o Compact stack design
o Open‐cathode stack eliminates humidifier, coolant pump & radiator o Produces clean DC power
o ~1,600 hour lifetime
o Fuelled with hydrogen
•
Customers:
o Has been integrated into a specialized wearable fuel cell power system prototype to be used by soldiers to power a variety of devices and carry more mission‐
specific equipment, without limiting mobility
Page 17
FCvelocity®‐9SSL
Liquid‐Cooled
•
Designed to meet the requirements of motive power applications with demanding drive cycles
•
Key Attributes:
o
o
o
o
o
o
o
o
•
Scalable power output from 3.8kW to 22kW (~192W per cell)
A derivative of Ballard’s work in automotive fuel cell technology
Liquid cooled system enables high durability
Designed to withstand rugged operating conditions Features fast, dynamic response
10,000+ hour operational lifetime
Fuelled with hydrogen
Manufacturing capacity of 3,500 units @ 20kW per year (expandable)
Customers:
o Widely deployed in Plug Power’s line of GenDrive® fuel cell systems for electric lift trucks
o Also integrated into Ballard’s FCvelocity®‐HD motive module to power transit buses and light rail vehicles
Page 18
3. Manufacturing Capability
Page 19
World Class Product Development & Manufacturing Capability
•
High‐volume PEM fuel cell manufacturing facility in Burnaby, Canada
o Automated manufacturing techniques replace discrete, labor intensive processes in 110,000‐square foot facility o Robotics, liquid injection molding and roll‐to‐roll processing
o On‐site stack assembly and quality testing
o Sufficient near‐term capacity, with capability to scale‐up production
o kW‐scale fuel cell system production
•
Flexible, low‐cost manufacturing in facilities located in Hobro, Denmark and Tijuana, Mexico
•
Performed contract manufacturing for Ford and Daimler for the HW2/3 car fleets
Automated and continuous manufacturing processes ensure high quality, low cost production to meet customer demand
Page 20
4. Proven Durability Page 21
Performance Proof Points
•
Ballard’s products deliver on performance promises in the field, as demonstrated by the following proof points:
o Ballard has shipped over 250MW of PEM fuel cell stacks
• Ballard has produced over 2.4 million MEAs • Ballard produced and assembled 6,600 fuel cell stacks in 2014
o Durable, reliable real‐world performance
• Technology recognized and selected by major automotive OEM’s
• Ballard’s lead customer, Plug Power, has more than 10,000 GenDrive units deployed with material handling customers
• Ballard powered buses have travelled more than 8 million kilometers worldwide
Ballard’s extensive list of deployments provide proof of ability to deliver application solutions to the most demanding customers
Page 22
Fuel Cell Testing
•
Product development is supported by state‐of‐the‐
art fuel cell testing facility
o Collect 400,000+ hours annually o 24/7 operation, simulate real duty cycles o Test station capacity < 100 W to 333 kW
•
60+ automated test stations and specialized test tools
o Environmental: 10 temperature and humidity chambers
o Stack diagnostics: Current mapping, reference electrodes, water management, freeze protocols, SEM
o Accelerated stress tests (AST): Membrane durability, cell reversal tolerance, voltage cycling, start‐
up/shutdown, ice tolerance
Test Facility
Extensive testing systems support dedication to quality
Page 23
5. System Integration Support
Page 24
System Integration Support
•
Ballard’s Applications Engineering team is available to ensure customer success through the entire system design and integration process
o The team has helped customers successfully integrate fuel cell stacks into thousands of telecom backup systems, forklift trucks and other applications around the world
o We have supported the integration of more than 100 fuel cell buses, and numerous fuel cell cars
•
Guidance for product selection and system design through remote and on‐
site support
•
Services range from 4‐hour introductory calls to extensive system development programs
Page 25
Engineering Reference Systems
• Reference systems to accelerate system integration and development
o Includes fuel cell engine with key BOP components
o Suitable for hybridization with capacitor and/or battery
Controls
Stack
Hydrogen Recirculation
Humidification
Air Supply
Coolant Flow and Temperature Control
Page 26
6. Tier 1 Customers
Page 27
Blue‐Chip Partners & End‐Users
Telecom Backup Power
Material Handling
Plug Power Customers
Bus
Technology Solutions
Page 28
Experienced Automotive Fuel Cell Supplier
• Ballard has supplied >500 fuel cell products and 1,000s of engineering hours providing Technology Solutions to 8 of the top automotive companies – the most demanding customers
Page 29
Case Study: Volkswagen
• Ongoing, multi‐year engineering services contract involves the design and manufacture of next‐generation fuel cell stacks for use in the demonstration car program
• Ballard engineers are leading critical areas of fuel cell product design – including the membrane electrode assembly (MEA), plate and stack components – along with testing and integration work
Page 30
Case Study: Plug Power
• Ballard is a leading supplier of fuel cell stacks for Plug Power’s GenDrive® systems
o FCgen™‐1020ACS air‐cooled stacks used in GenDrive® systems to power Class 3 pallet jacks
o FCvelocity™‐9SSL liquid‐cooled stacks used in systems to power Class 2 reach trucks and Class 1 counterbalanced lift trucks
o Ballard’s lead customer, Plug Power, has more than 10,000 GenDrive units deployed with material handling customers Page 31
Conclusion
Page 32
Why Ballard?
• Expertise
o Team with decades spent in the industry and unparalleled depth of technical knowledge and experience • System Integration Capability
o Extensive stack and system integration capabilities which enable development of complete solutions that meet or exceed customer specifications
• Scope
o Breadth of product and solutions portfolio
• Flexibility
o Only PEM company to offer multiple cooling options and fuel flexible solutions with reformate capabilities
• Proven
o Ballard’s extensive list of deployments provide proof of ability to deliver application solutions to the most demanding customers
Page 33
Ballard Proof Points
Corporate Stability
• Publicly listed company (TSX: BLD, NASDAQ: BLDP)
• Transparent reporting of financial resources
Industry Pioneer
• Over 30 years of expertise in PEM fuel cell technology
Extensive IP Portfolio
• PEM fuel cell industry leading position, with access to ~1,700 patents and patent applications • More than $1 billion invested in technology development
PEM Stack Leadership
Customer References
Integrator Support
• Over 250MW of fuel cell products shipped and 2 million membrane electrode assembles produced
• Major automotive OEMs have chosen Ballard technology to support their fuel cell programs, including Volkswagen, Daimler, Ford, Honda, Toyota, Nissan and Audi
• Ballard’s lead customer, Plug Power, has more than 10,000 GenDrive units deployed with material handling customers
• Dedicated group to support customers’ fuel cell development and commercialization programs
• ISO 9001 & ISO 140001 registered company
Focus on Quality
• State of the art fuel cell testing facility, collecting 400,000+ hours of test data annually
Local and Global Presence
• Direct commercial presence in Europe, South Africa, Malaysia, USA, Canada
• Direct support & service presence in USA, Canada, Europe, Malaysia
• Global network of channel and service partners
Page 34
Fuel Cell Stack
Value Proposition