AFCC Research Needs Analysis for Generation 4 Vehicles FRM5101460 Fuel Cell Roadmap - The Path to Commercialization Passenger Cars Bus Generation 1 Lead application 2004 Technology Demonstration Generation 2 Customer Acceptance Generation 1 Technology Demonstration F-Cell Generation 2 2010 2013 Future Generations Customer Acceptance B-Class F-Cell Sprinter Generation 1 Technology Demonstration Generation 2 Customer Acceptance Generation 3 Cost Reduction I Future Generations Generation 4 201x 202y Market Introduction Cost Reduction II Generation 5 High Volume Series Production Fuel cell passenger cars will drive the volume 2 FRM5101460 Status of Fuel Cell Technology Performance Safety Comfort Freeze start Range Reliability Longevity Package/weight Cost Generation 3 Cars will demonstrate competitive capabilities. Cost remains the challenge! 3 FRM5101460 5 Basic Strategies For Cost Reduction Detailed examination of all 5 areas will indicate the best paths for further improvement. Investment of development dollars 4 FRM5101460 Mining For Cost Reduction Given multiple options a good miner: • Drills new test holes. • Explores a few high risk/high gain paths. • Exploits the known paths fully in order of their value. • Saves some lower value ore bodies for later exploration. • Knows when a ore body is exhausted. 5 FRM5101460 Distillation Stack Cost 6 Technology Area Driver Catalyst Catalyst Catalyst Catalyst Catalyst Coating Technology Catalyst Primary Process Catalyst Recycling Process Freeze tolerant Catalyst Structure Size Dura 0.1 0.2 1 Catalyst Catalyst Catalyst Catalyst Catalyst Cell Design Cell Design Cell Design Cell Design Cell Design Cell Design Cell Design Cell Design Cell Design Cell Design FCS FCS FCS FCS FCS FCS FCS ( vehicle) Technology Area GDL GDL GDL GDL GDL GDL GDL GDL GDL GDL GDL GDL Membrane Membrane Membrane Membrane Membrane Membrane Membrane Membrane Membrane Membrane Technology Area Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Carbon supported Pt 9 9 9 9 9 High Low Technoloy at Limit New High Activity Catalyst Less Platinum Non Carbon Catalyst Support Materials Pt Dissolution Resistant Catalyst Better Mechanical Integration Higher Stack Peak T Low Force Seals Low Pressure Drop Anode FFs Minimize Port Areas Minimize transition areas 9 1 9 9 9 9 0 3 3 3 9 9 3 3 9 9 3 9 3 9 3 3 3 3 9 8.2 3.9 6.3 2.1 4.5 1.5 3 1.5 1.5 Low High Low Med Med High High High High High High Med High Med Med Med Low Med Low Low High Priority Research High Priority Research High Priority Research High Priority Research Engineering Engineering Technoloy at Limit Engineering Technoloy at Limit Technoloy at Limit Near Dead Ended Cells Robustness of design to MFG tols Self Hydrating Cell Smaller Seal Foot Print Ability to Boost Voltage from Stack Efficient Air Compressor Technology Higher Temperature Humidifiers Less Expensive Humidifiers Less Expensive H2 pump Less Expensive Intercooler Less Gross Power Driver 3 1 3 1 3 3 3 3 9 3 3 3 3 9 3 9 3 Improved GDL Pore Structure Freeze tolerant GDL Structure GDL Additive Materials GDL Additive Processes GDL Degradation GDL low Cost Substrate Materials GDL Microporous Layer Process GDL Substrate Mfg Process Improved Water Mgmt in GDL Maximize GDL Stiffness Minimize GDL Thickness More Conductive GDL Conductivity @ <20% RH Conductivity @ >80% RH Conductivity @ 20% to 80% RH Fundamentally less expensive polymers Less expensive PFSA precursors Low H2 Cross Over Membrane Low N2 Cross over membrane Manufacturing Process Membrane Loss ( degradation) Minimize Membrane Thickness Driver Increased Plate Conductivity Precise Plate Mfg Tolerances Carbon plate Cycle Time Carbon raw materials Processing Facile Liquid Water Removal Improved Plate Formability Increased Plate Strength Metal Coating materials/process Metal or Carbon Joining Method Metal Plate Substrate Alloy Minimize Plate Web Thickness Plate Corrosion Resistance ( metal only) Fuel Econ 0.3 3 3 9 3 9 3 3 3 3 Size 9 1 3 3 9 3 1 3 3 3 Dura 3 3 1 1 3 3 3 3 3 3 3 1 Size 1 9 3 Dura 3 1 3 1 3 3 3 3 1 3 3 3 3 9 9 3 9 Fuel Econ 1 1 1 3 1 1 1 9 3 3 3 9 9 3 Fuel Econ 1 9 3 Durability Fuel Economy Cost Criticality Understa Opportun Classification nding ity 0.4 3 2.3 Med Med Engineering 3 1.2 Low High Research 1 0.4 Low High Research 1 1 Med Med Research 3 3 Med Med Research 1 2 High Low Technoloy at Limit 3 4.2 High Low Technoloy at Limit 3 1.3 High Low Engineering 9 3.9 High High Engineering 9 7.2 High Med High Priority Research 3 1.2 Low High Research 3 6 Med High High Priority Research 3 2.7 Med Med Engineering 1 0.4 High Low Technoloy at Limit 9 6.6 High High Engineering Cost Criticality Understa Opportun Classification nding ity 9 5.4 Med High High Priority Research 3 1.9 Med Med Research 1 0.9 High Med Engineering 1 0.9 Med Med Engineering 0.6 Med Med Engineering 9 5.4 Med Med Engineering 1 0.7 Med High Engineering 3 1.2 Med Med Engineering 9 4.8 Med High Research 9 5.4 Med Low Engineering 1 1.3 High Low Technoloy at Limit 3 1.3 Med Low Engineering 9 6.6 High Low Technoloy at Limit 3 2.4 High Med Research 3 2.4 High Med Research 9 5.1 Low High High Priority Research 3 1.2 High Med Engineering 3 4.5 Med Low Research 9 6.3 Med Low High Priority Research 3 1.4 High Med Engineering 1 2.2 Med Med Engineering 3 2.8 High Low Technoloy at Limit Cost Crit Under. Opp Classification 3 3 3 3 3 9 9 9 3 3 3 1.8 1.9 1.2 1.2 4.6 5 0.9 3.9 4.2 1.8 1.5 3 High High Med Med High High High Low Med High High Low Low Low High Med Med Med Low Med Med Med Low Med Technoloy at Limit Technoloy at Limit Engineering Engineering High Priority Research High Priority Research Technoloy at Limit High Priority Research Engineering Engineering Technoloy at Limit High Priority Research Strategic Filter Technology Area Catalyst Catalyst Catalyst FCS FCS ( vehicle) Membrane Catalyst Membrane FCS GDL GDL GDL Membrane Plate Driver Carbon supported Pt New High Activity Catalyst Less Platinum Efficient Air Compressor Technology Less Gross Power Conductivity @ <20% RH Pt Dissolution Resistant Catalyst Low N2 Cross over membrane Less Expensive Humidifiers Improved GDL Pore Structure GDL low Cost Substrate Materials Maximize GDL Stiffness Fundamentally less expensive polymers Improved Plate Formability Criticality Understanding Opportunity 9 9 8.2 7.2 6.6 6.6 6.3 6.3 6 5.4 5.4 5.4 5.1 5 High Low High High High High Med Med Med Med Med Med Low High Low High Med Med High Low Med Low High High Med Low High Med Critical Research Needs FRM5101460 Strategic Filter 1. Criticality • The criticality is the sum of the magnitudes of all the effects (good or bad) of using a technology path. 2. Understanding • A measure of how much we know about a technology option • Advantages, failure modes and trade-offs 3. Remaining Opportunity Improvement Technology Limit Opportunity Status • How much improvement remains to be made along each technology path. • If a path is fully mature we reach the “Technology Limit” and further improvement will require a “breakthrough” or the exploitation of a different path. Effort 7 FRM5101460 Map of the Technology Mine (Cost) •High Priority Research Focus of academic and corporate research •Development Engineering Focus of in house and supplier engineering •Research Lower urgency research •Technology At Limit Exploit in present design: diminishing returns 8 FRM5101460 The Biggest Driver for Materials •High Priority Research Focus of academic and corporate research •Development Engineering Focus of in house and supplier engineering •Research Lower urgency research •Technology At Limit Exploit in present design: diminishing returns 9 FRM5101460 Some Statistics Opportunity Criticality Criticality Low 45% low 32% med 46% Criticality Med Criticality High 23% 32% high 22% Understanding Medium 38% Low 13% High 49% Classification Technology at Limit 23% Engineering 38% Research 17% 1. We should focus on the 23% that are most critical. 2. Overall understanding of the opportunities is good. 3. There are many good opportunities for cost reduction High Priority Research 22% 10 FRM5101460 The Most Critical Research 1 1 1 2 2 2 1 2 2 3 4 3 4 3 Technology Area Catalyst Catalyst Catalyst FCS FCS ( vehicle) Membrane Catalyst Membrane FCS GDL GDL GDL Membrane Plate Driver Carbon supported Pt New High Activity Catalyst Less Platinum Efficient Air Compressor Technology Less Gross Power Conductivity @ <20% RH Pt Dissolution Resistant Catalyst Low N2 Cross over membrane Less Expensive Humidifiers Improved GDL Pore Structure GDL low Cost Substrate Materials Maximize GDL Stiffness Fundamentally less expensive polymers Improved Plate Formability Criticality Understanding Opportunity 9 9 8.2 7.2 6.6 6.6 6.3 6.3 6 5.4 5.4 5.4 5.1 5 High Low High High High High Med Med Med Med Med Med Low High Low High Med Med High Low Med Low High High Med Low High Med These areas of research and development need to be the focus. 1 2 3 4 11 New durable high activity catalysts. Enable low cost system Enable high current density via plate and GDL Lower cost cell materials FRM5101460 The Mature Technologies Technology Area Catalyst Cell Design Cell Design Cell Design Cell Design Cell Design FCS GDL Membrane Membrane Plate Plate Plate Plate Driver Carbon supported Pt Self Hydrating Cell Robustness of design to MFG tols Minimize Port Areas Minimize transition areas Low Force Seals Less Expensive Intercooler Minimize GDL Thickness Conductivity @ <20% RH Minimize Membrane Thickness Precise Plate Mfg Tolerances Increased Plate Conductivity Minimize Plate Web Thickness Increased Plate Strength Criticality Understanding Opportunity 9 4.2 2 1.5 1.5 1.5 0.4 1.3 6.6 2.8 1.9 1.8 1.5 0.9 High High High High High High High High High High High High High High Low Low Low Low Low Low Low Low Low Low Low Low Low Low These technologies have reached their maximum capability. • Gen 4 stack will utilize them at their maximum. • It’s time to look for alternative paths or breakthroughs. 12 FRM5101460 Examples and Targets FRM5101460 Catalyst Technology Area Catalyst Catalyst Catalyst Catalyst Driver Cost 9 9 9 9 Fuel Econ 9 9 9 3 Catalyst Non carbon catalyst support materials 9 3 3 3.9 Low High High Priority Research Catalyst Catalyst Catalyst Catalyst Catalyst coating technology Catalyst primary process Freeze tolerant catalyst structure Catalyst recycling process 1 3 3 3 1 1 2.3 1.2 1 0.4 Med Low Med Low Med High Med High Engineering Research Research Research Carbon supported Pt New high activity catalyst Less platinum Pt dissolution resistant catalyst Size Dura 9 9 1 3 9 9 9 9 Criticalit Understa Opportun Classification y nding ity 9 High Low Technology at Limit 9 Low High High Priority Research 8.2 High Med High Priority Research 6.3 Med Med High Priority Research Carbon Supports - High surface area carbon supported Platinum catalysts have been the main technology in automotive PEM for the generation 1,2 and likely 3 stacks however they have essentially reached the limits of performance and durability and new path need to be explored for generation 4. Activity vs Durability - For Pt based structures mass activity can be enhanced by increasing the surface area or by altering the electronic structure of the surface. Both options need to be pursued but the impact on durability is critical. Processing - During the development of new catalyst systems we need to simultaneously develop the processes to synthesize them at low cost and possibly to deposit them directly onto MEA with as few intermediate steps as possible to ensure high material yields. 14 FRM5101460 Cathode Catalyst Pathways Work Streams Proprietary Process Stabilized Platinum Alloys Support Structures CatalystSupport Interaction (Non-Carbon) Pseudo Bulk Catalyst Non Precious Metal Catalyst 15 High Surface Area Metal oxides Core Shell Catalysts Thin film Pt-alloy Structures Various Materials Create stable alloys that retain high performance Improve activity w/ more robust support materials High activity & stability Replace platinum with w/ cheap catalytic materials FRM5101460 Mass Activity/ Specific Activity Ex-situ Activity Summary normalized to Pt baseline 4x Mass Activity Target Specific Activity 25 23.8 Specific Activity ( x Pt baseline) 20 10 2.6 1 5 3.9 2.1 1.9 ???? 4 3 10.3 2 4.5 1 1.6 1.4 1.0 de el l /C H ig h Su rfa Ad ce v C Ar ea or e O xi Sh de Pt -M et al O xi O /C "B " y Pt /M et al St a lo y Pt -a l Al lo ed bi liz "A " lo y Pt -a l Pt SC H in e ba se l xid e 0 HS C 0 Pt /C 6 5 3.4 Mass Activity ( x Pt baseline) 15 ???? Specific Mass Activity 30 C=Carbon; HSC=High Surface Area Carbon 16 FRM5101460 Membrane Membrane Membrane Membrane Membrane Membrane Membrane Membrane Membrane Membrane Membrane Conductivity @ <20% RH Conductivity @ >80% RH Conductivity @ 20% to 80% RH Fundamentally less expensive polymers Less expensive PFSA precursors Low H2 Cross Over Membrane Low N2 Cross over membrane Manufacturing Process Membrane Loss ( degradation) Minimize Membrane Thickness 3 3 3 3 3 1 1 9 3 9 3 3 3 9 9 3 9 3 3 9 3 3 9 3 1 3 6.6 2.4 2.4 5.1 1.2 4.5 6.3 1.4 2.2 2.8 High High High Low High Med Med High Med High Low Med Med High Med Low Low Med Med Low Technoloy at Limit Research High Priority Research High Priority Research Engineering Research High Priority Research Engineering Engineering Technoloy at Limit Driver PFSA membranes are quite mature and it is becoming apparent that further improvements will be limited. They are however quite capable and are expected to be viable in future generations when the cost of producing them is reduced significantly. Cross-over - In order to enable cost reduction in the fuel cell support systems a large reduction in the Nitrogen cross over is needed. Unless a change in the basic polymer is used to achieve this thinner membranes may not be practical. Hydration - A great deal of effort has been put into reducing the resistance of membranes at low RH however this has increased the basic cost of the materials. Fundamental studies have shown that zero RH conduction cannot occur for sulphonic acid based membranes. 17 FRM5101460 Membrane Pathways Work Streams Low cost SSC PFSA Low cost PFSA membranes Hydrocarbon membranes Additive Technology 18 Reinforcement Low cost LSC PFSA Block Co-polymer Homo polymer Free Radical Scavengers Water Retention Additives Lower membrane cost, improve performance & durability. Cost and better gas cross over. Improve membranes by adding special function materials. FRM5101460 Dry Conduction Progress Membrane resistances for different RH's 1 Supplier A Supplier B Supplier C Target 0.9 Resistance (Ohm.cm2) 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 20 40 60 80 100 Membrane RH (%) 19 FRM5101460 Dry Conduction Progress II Log Scale Membrane resistances for different RH's Resistance (Ohm.cm2) 1 0.1 0.01 Data from materials reported in the 2008 DOE Hydrogen program review 0.001 0 10 20 30 40 50 60 70 80 90 100 Membrane RH (%) • Improved materials all have the same sensitivity to RH. • Overall resistance at all RHs improved • Without a change in conduction physics target at <30% RH unlikely to be met 20 FRM5101460 Proton dissociation –Needs Water RSO3H : (H2O)n RSO3-+ H+(H2O)n Based on these models for the equilibrium: RSO3H : (H2O)n RSO3-+ H+(H2O)n When n>3, the ion pair structure, RSO3-+ H+(H2O)n is more stable than the neutral complex (H2O)n. Ionization could happen. Vassiliki-Alexandra Glezakou, et.al. Phys. Chem. Chem. Phys., 2007, 9, 5752–5760 n=2 n=3 • High proton transport rate in PFSA membranes requires a high degree ionization • At RH <30%, the number of molecules in a typical PFSA n 3. water • Insufficient water in the membrane can cause a low proton conductivity and poor durability 21 FRM5101460 N2 Cross Over Effect on Parasitic Load Normalized H2 Pump Power The amount of gas that needs to be pumped back into the stack inlet is proportional to the nitrogen cross over rate. % of Maximum 120% 100% 80% 60% 40% The power required to pump this nitrogen is waste and requires extra cells to produce it. 20% 0% 0 0.2 0.4 0.6 0.8 1 Nitrogen Mole Fraction Nitrogen Cross Over 7 Normalized to Target 6 The recycle circuit is typically purged to get rid of the accumulated nitrogen which inevitably wastes hydrogen. 5 Incremental improvements in nitrogen crossover directly benefit the cost and fuel economy of Fuel Cell Vehicles. 4 3 2 1 0 Target 22 HC Block CoPolymer PFSA 1 (~25 um) FRM5101460 Cost-Performance Gaps Gas inlet: Ambient atmosphere , T 95 C Gas inlet RH 30%, T 95 C 100 lower cost 80 60 40 20 100Random HC polymer Random HC polymer lower cost Block HC polymer+ reinforcement Block HC polymer+ reinforcement im prove perform nac e Membrane performance & durability 120 improve performnac e Membrane perform ance & durability 120 LSC PFSA+reinforcement 80LSC PFSA+reinforcement LSC PFSA LSC PFSA 60low cost SSC PFSA+reinforcement low cost SSC PFSA+reinforcement SSC PFSA from Supplier C SSC PFSA from Supplier C 40SSC PFSA from Supplier D SSC PFSA from Supplier D HY5 target HY5 target 20 0 0 0 20 40 60 80 100 0 120 20 40 60 80 100 120 Cost US$/m2 (volum 850k m2 per year) Cost US$/m2 (volum 850k m2 per year) Gas inlet RH 80% , T 85 C Membrane performance & durability 120 100 Random HC polymer Block HC polymer+ reinforcement lower cost 80 LSC PFSA+reinforcement LSC PFSA low cost SSC PFSA+reinforcement 60 SSC PFSA from Supplier C SSC PFSA from Supplier D 40 HY5 target 20 0 0 20 40 60 80 100 120 Cost US$/m2 (volum 850k m2 per year) 23 FRM5101460 Bipolar Plates Technology Area Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Driver Increased Plate Conductivity Precise Plate Mfg Tolerances Carbon plate Cycle Time Carbon raw materials Processing Facile Liquid Water Removal Improved Plate Formability Increased Plate Strength Metal Coating materials/process Metal or Carbon Joining Method Metal Plate Substrate Alloy Minimize Plate Web Thickness Plate Corrosion Resistance ( metal only) Size Dura 3 1 3 1 3 3 3 3 1 3 Fuel Econ 1 9 3 3 3 3 9 Driver Cost Crit Under. Opp Classification 3 3 3 3 3 9 1.8 1.9 1.2 1.2 4.6 5 0.9 3.9 4.2 1.8 1.5 3 High High Med Med High High High Low Med High High Low Low Low High Med Med Med Low Med Med Med Low Med Technoloy at Limit Technoloy at Limit Engineering Engineering High Priority Research High Priority Research Technoloy at Limit High Priority Research Engineering Engineering Technoloy at Limit High Priority Research 9 9 3 3 3 Plate technology is quite mature due to significant investment by researchers and a competitive environment with the suppliers. Plate assemblies can be made with good quality and strength at thicknesses well below 2mm and it is now the flow field and not plate material that limits further reductions. Cost - While several suppliers are predicting cost which approach the targets, a significant gap remains with respect to joining/sealing methods, as well as corrosion protection coating technology and production cycle times. Water Management - At high current densities much higher gas and liquid water fluxes must move through the channels. Water remains a big driver for flow resistance and poor flow distribution. 24 FRM5101460 Carbon or Metal: No Clear Winner Inherent Advantages • Inherently corrosion resistant. Carbon Composite • Conductive surface. • 200 um web thickness. • Better FF, seal, and backside geometry possible. • High Strength/Toughness Coated Metal 25 • 100 um web thickness Needed Improvements • Strength/toughness • Process cycle time • Raw material costs • Low cost joining method • Coating Cost/Process • Welding/joining cost • Inexpensive forming process • Surface contact resistance plate to plate • Inexpensive substrate • Available formed shapes. FRM5101460 Pressure Drop Vs Water L V2 P f D 2 Re VD ( f Re) L V P 2 D2 f 64 For a smooth wall Re circular pipe Effect of Water on Pressure Drop and Apparent Friction Factor 134 124 f*Re 114 104 94 Dry f*Re Wet f*Re ~ 10 to 30 % more liquid water Advanced Flow Field #1 Wet Advanced Flow Field #2 Wet 84 74 64 0 50 100 150 200 250 300 350 400 450 500 550 Reynolds Number Vapour Included (Re) Gen 4 flow field advancements reduce pressure drop of advanced cells by ~30 % 26 FRM5101460 Power Density Progress Stack Power Density and Cell Pitch 4 Power Density (volumetric) Cell Pitch 2000 3 1500 2 1000 Cell Pitch (mm) Stack Volumetric Power Density (kW/L) 2500 1 500 0 1990 0 1995 2000 2005 2010 2015 Year Current density and cell pitch Mk5 27 Mk7 Mk8 Mk901 Generation 1 Current density Generation 2 Generation 3 Generation 4 FRM5101460 Conclusions • There are many open paths to make further progress on Fuel Cell System costs. • There has been a great deal of progress in many key areas: o Our understanding of the options is good. o There are quite a few mature technologies that can be exploited in the generation 4 cars. And thus: o Resources will be focussed onto paths with the most remaining opportunity and highest impact on cost. • This focussed research and engineering effort will enable us to meet commercial fuel cell targets 28 FRM5101460