7th April 2011 © Proton Motor 2011 11© Proton Motor 2009 1

Proton Motor Fuel Cell GmbHBenzstraße 7D-82178 Puchheim

phone: +49 89-1276265-0fax: +49 89-1276265-99

... more than just fuel cells... more than just fuel cells

e-mail: sales@proton-motor.deweb: www.proton-motor.de

Proton Motor Fuel Cell GmbH

FUEL CELL DRIVEN PASSENGER SHIP IN COMMERCIAL SERVICE

...more than just fuel cells

7th April 2011 © Proton Motor 2011 22

Company Overview

© Proton Motor 2009

Ground Area 5,700 m²

Area Offices & Production 3,500 m²

Employees 51

7th April 2011 © Proton Motor 2011 33

Development of the fuel cell started 1994Proton Motor was founded1998 as spin-off of Magnet-Motor

Holding, founded 2006Listing in London 31.10.2006100% owner of Proton Motor

We offer Fuel Cell Hybrid Solutions for „back to base“ commercial vehicles and for stationary applications.

Company Overview

© Proton Motor 2009

7th April 2011 © Proton Motor 2011 4

PM Scope and Product Range

PM Stack

Maritim

Mobile

StationaryPM Kit

PM Module

PM Basic

PM Package

PM Cube

PM Turnkey

PM Customer Support

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7th April 2011 © Proton Motor 2011 5

ZEM-Ships becomes FCS Alsterwasser

ZEMSHIPS project:– Zero Emission Fuel Cell Ship– Fuel: Hydrogen– Ca. 100 passengers – Operating on the rivers Alster and Elbe, operator: ATG (local public ferry services)– Commissioned in Summer 2008– Proton Motor is responsible for the complete ships drive system– ZEMSHIPS project partner: ATG, Linde, Germanischer Lloyd, City of Hamburg, etc.

Proton Motor is the only manufacturer of fuel cell systems commercially available for marine vessels of this class and size.

7th April 2011 © Proton Motor 2011 6

Ship realisation

SSBSpezialschiffbau Oortkaten

Ship Design FC Hybrid System Ship Building

Customer / Operator

Subcontractors:• Ship Yard (SSB)• Electrical Ship Engineer• Ship Wiring Company• Piping Company• Battery Supplier• Supplier H2 Assembly

Subcontractors:• Ship Designer (Buchloh)• Electrical Ship Engineer• Ship Wiring Company• Piping Company

Safety&

Certification

7th April 2011 © Proton Motor 2011 7

Planing / Manufacturing

Power Demand System Concept Packaging Manufacturing

Safety & Certification

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Integration / Commissioning

Ship Building FC Integration Commissioning Certification

Safety & Certification

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Operating Phase 1 + 2

2008 Sept. – Dec.Demo & Test Drives

2009 Jan. – Mar. Season Stop at ATG

2009 Apr. – Dec. Normal Operation

2010 Jan. – Mar. Season Stop at ATG

Operating Ph. 1 Planing Upgrade Integration Upgrade Operating Ph. 2

Service

29th Aug. 2008Ship Christening • Final ZEM-Ship

Conference• New battery supplier

selected by ATG• Shipping PM Basic

M50 to Hamburg• FAT of FC System• Initial commissioning

FC System at PM’s• Mounting of

upgraded FC system• Desing of FC system

upgrade• Adopting PI, wiring

and power schemes

• Integration of Battery

• Integration FC System

• Wiring and piping of upgraded FC system

• Commissioning FC hybrid System

• HAT and certification of ship

• Fire incident• Presentation at

WHEC

7th April 2011 © Proton Motor 2011 10

Assemblies FC System

H2 Storage

FC Power pack

N2 Storage

H2 Refill

Double Block and Bleed H2 Refill Line

Double Block and Bleed H2 Midpressure Line

7th April 2011 © Proton Motor 2011 11

Components Electric Power System

DC/DC Converter:

• Input Voltage Range: 10 to 730 V

• Max. Input Current: 350 A

• Voltage Range DC Link: up to 750 VDC

• Cooling: Liquid Cooled

Traction / Buffer Battery:

• Closed Battery, Gel Lead Acid

• 7 Battery Blocks, 40 Cells Each

• Total of 280 Cells

• Voltage DC Link: 7 x 80 VDC = 560 VDC

Man-Machine Interface:

• System information for Captain

• Emergency Button

• Battery Information (SOC, Temp, Voltage)

• FC Information (FC Power, Failure Notice, System Status)

• Gas Storage Information (Gas contained in Tank)

7th April 2011 © Proton Motor 2011 12

Ship Layout

Propulsion motor100 kW

Buffer BatteryLead-Gel, 560 V, 360 Ah

12 Hydrogen tanks350 bar, In total 50 kg H2

2 Fuel Cell Systems„PM Basic A 50 maritime“48 kW peak power each

Power electronics

Bow thruster20 kW

CAD drawing: Schiffstechnik Buchloh

7th April 2011 © Proton Motor 2011 13

Safety Concept

PRD‘sSafety CircuitControlMicro Controller and CVMU‘s

• Keep System in normal parameters

• Normal shut down if first level switching points are reached

• Prevent system from getting damaged

• Prevent hydrogen from leaving the system

Hard wired safety circuit• Switches for temperature,

pressure and flow

• Emergency Shut Down if switching points are reached

• Preventing system from getting damaged

• Preventing hydrogen from leaving the system

Pressure Relief Devices• Safety valves

• Melting fuses

• Preventing the system from getting damaged

• Releasing hydrogen to surrounding if set pressure points or temperatures of melting fuse are reached

Packaging and System LayoutAvoiding H2 Leakage

• Welding instead of screwing

• Depressurizing high and mid pressure pipes if not in use

• Inerting mid and low pressure pipes if not in use

• Double-walled pipes

Ex-Zone Concept• Sectional classification in ship

• Forced air ventilation of areas with possibility of H2 leakage

• Monitoring gas concentration

7th April 2011 © Proton Motor 2011 14

Safety Concept Packaging

7th April 2011 © Proton Motor 2011 15

Fire Incident on Alsterwasser

What happened:• Test drive in basin of ship yard

• Cover of battery compartment remaind open because of test drive

• Fire in battery compartment

• Detection and automatically emergency shut down

NO EXPLOSION RISK AT ANY TIME

SAFETYCONCEPT PROOFED IT’S RELIABILITY

Messages:• Fuel cell systems on marine applications are safe

• Operator ATG clings to fuel cell systems on ships

• Alsterwasser shall be restored as soon as cause of incident is evident

7th April 2011 © Proton Motor 2011 16

Real World – System Data

• Energy demand from the FCS “Alsterwasser”: 222 kWh

• Average Energy demand from 25 kW

• Hydrogen consumption calculated from the pressure difference– Start: 304 bar– End: 199 bar

• Energy from the fuel cell: 218 kWh

• Efficiency at Fuel Cell output: 45 %

7th April 2011 © Proton Motor 2011 17

Real World - Service

• Service concept included– Free service hotline– Accessibility: 7 days a week from 8am to 8pm– On Workdays: After notification within 24h on board

• No permanent service technician in Hamburg necessary

• In average two or three service units a month

• Most failures were fixed within 24h– Damaged air compressor– Errors on some sensors

• Remote data monitoring system installed

7th April 2011 © Proton Motor 2011 18

Operator Statements

7th April 2011 © Proton Motor 2011 19

Operator Statements

7th April 2011 © Proton Motor 2011 20

Operator Statements

7th April 2011 © Proton Motor 2011 21

Operator Statements

7th April 2011 © Proton Motor 2011 2222© Proton Motor 2009 22

Proton Motor Fuel Cell GmbHBenzstraße 7D-82178 Puchheim

phone: +49 89-1276265-0fax: +49 89-1276265-99

... more than just fuel cells... more than just fuel cells

e-mail: sales@proton-motor.deweb: www.proton-motor.de

Proton Motor Fuel Cell GmbH

Thank you for your attention!

...more than just fuel cells