Membrane Requirements for Stationary Applications€¦ · Stationary Power 4.4kW – 19.3kW 75kW &...

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COPYRIGHT © 2009 USED WITH PERMISSION OF BALLARD POWER SYSTEMS, INC. Membrane Requirements for Stationary Applications Ballard Power Systems High Temperature Membrane Working Group Meeting November 16, 2009

Transcript of Membrane Requirements for Stationary Applications€¦ · Stationary Power 4.4kW – 19.3kW 75kW &...

Page 1: Membrane Requirements for Stationary Applications€¦ · Stationary Power 4.4kW – 19.3kW 75kW & 150kW 10,000 hrs 6,000 hrs Material handling applications Bus & oth er h avy-duty

COPYRIGHT © 2009 USED WITH PERMISSION OF BALLARD POWER SYSTEMS, INC.

Membrane Requirementsfor Stationary Applications

Ballard Power Systems

High Temperature Membrane Working Group MeetingNovember 16, 2009

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Outline

Introduction to Ballard and its Market Focus

Comparison of Stationary and Automotive Requirements

Membrane Testing Methodology

Results & Summary

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About Ballard

CLEAN ENERGY FUEL CELL PRODUCTS…OUR COMPANY

• Approximately 335 employees

• World-leading R&D & manufacturing facilities

• Locations in Vancouver, Canada (HQ) & Lowell, MA

OUR BUSINESS

• Design, manufacture, sale & service of hydrogen fuel cell products

OUR CUSTOMERS

• System integrators and OEM’s addressing end-user needs: materials handling, telecom backup power, residential cogeneration, and transit buses

OUR FOUNDATION

• Technology Leadership – 350+ Patents and patent applications

• Production Expertise – Shipped over 100MW fuel Cell Products

• Expanding Go-to-Market Capabilities – Powered over 1,000 stationary installations and over 200 heavy and light duty vehicles

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Lines of Business

Clean Energy Fuel Cell Products

Motive Power Stationary Power

Contract Automotive Services – contract technical

& manufacturing servicesMaterial Products -

Carbon fiber products & gas diffusion layer materials

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Fuel Cell Growth Markets

Fuel Cell Growth Markets

Motive PowerStationary Power

Material Handling

Backup Power

Heavy Duty

Distributed Power Generation

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Leading Fuel Cell Products Portfolio

PRODUCTSPower Level (gross)

LifeProduct

Positioning

Stationary Power

4.4kW –19.3kW

75kW & 150kW

10,000 hrs

6,000 hrs

Material handling applications

Bus & other heavy-duty applications

0.3 – 3.4kW 4,000 hrs

10,000 hrs

Telecom backup power

Motive Power

Telecom backup power

2.3 – 11kW

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Market Focus: Backup Power

Market Opportunity• Initial focus on replacing batteries in wireless

telecommunications

• In areas with a highly reliable electrical grid

• Addressable market: ~$350M

Drivers

• Extended runtime• Highly durable, even at extreme temperatures• Minimal annual maintenance

• Regulatory requirements for extended runtime (e.g. TETRA)

Channels

• System integrators – key relationship with Dantherm/Motorola (123 stacks delivered)

• Network equipment providers

• Power equipment OEMs

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Market Focus: Supplemental Power

Market Opportunity

Drivers

• Initial focus on replacing diesel generators and batteries in wireless telecommunications

• In areas where the electrical grid is unreliable, e.g. developing countries

• Addressable market: ~$1bn

• Lower maintenance costs due fewer moving parts• Lower noise and reduced emissions• Broader fuelling options• Lower fuel costs due increased efficiency

Channels• System integrators – key relationship with

ACME/IdaTech (~620 stacks delivered)

• Network equipment providers

• Power equipment OEMs

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Market Focus: Distributed Generation

Market Opportunity• Utility peak load management

• Megawatt-scale applications where there is byproduct hydrogen available and a feed-in tariff program in place to underpin demand

Drivers• Supportive feed-in tariff policies (Korea, Germany,

California, etc.)

• Increased utility focus on clean energy generation

Channels

• Direct with chemical company or utility

• Demonstration program with FirstEnergy

•Portable 1 MW peak load management solution

•Delivery scheduled in Dec/09

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Market Focus: Material Handling

Market Opportunity• Addressable market: Plug Power indicates ~380k trucks

of an installed base of 1.7M trucks in North America

•Market potential > $1.5bn

• Reference sites in place, full-facility implementations beginning

• Initial focus on battery replacement in high volume distribution centers in North America

Productivity gains from:

• Increased lift truck uptime

• Consistent power

• More productive warehouse floor space

Drivers

Channels• Ballard is exclusive supplier of fuel cell stacks for Plug

Power’s GenDriveTM product line of fuel cell battery emulators through December 31, 2010

• Over 850 systems deployed to date with key customers, such as Wal-Mart, Sysco, Bridgestone, Central Grocers

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Market Focus: Bus

Market Opportunity• Zero-emission public transit

• Government supported programs in countries throughout the world (e.g. Canada, UK, Brazil, Germany)

Drivers• Government subsidies

• Reduction in GHG emissions & elimination of SOX / NOX

Channels

• Bus OEM’s and Systems Integrators

• ISE/New Flyer (BC Transit 2010 Olympic Fleet – 20 buses for the largest fuel cell bus fleet worldwide)

• FC buses have transported +8M passengers in revenue service in 15 cities worldwide

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Durability Requirements

30,000+

(up to 120,000)Distributed Power Generation

20,000

5,000*

40,000*-80,000

4,000 -24,000

10,000

Hours

Automotive (bus)

Automotive (light duty)

Residential cogeneration

Backup power

Materials handling

Application

*DOE ‘11-15 targets

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Product Development CapabilitiesDurability as a Function of the Operating Condition Dynamics

Same Stack Technology….•Meets needs of many applications•Durability is dependent on operating conditions

Mark9 SSLTM

Forklifts

Mark 902Light Duty

Transportation

Pressure: 3 bara

Duty cycle: Fast Dynamic

Durability: ~1,000 hr

Pressure: 2 bara

Duty cycle: Slow Dynamic

Durability*: ~10,000 hr

* Based on limited product test data

4 - 21 kW85 kW

Pressure: 3 bara

Duty cycle: MediumDynamic

Durability: ~3,000 hr

Mark 902 Heavy Duty

Transportation

180 kW

Mark1030 V3Cogeneration

Pressure: 1 bara

Duty cycle: Slower Dynamic

Durability*: >40,000 hr

* Based on ASTs

1 kW

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Lifetime Requirements

Required lifetimes must be achieved over a range of operational conditions, both expected and “out-of-spec”.

Other key system attributes must be simultaneously satisfied.

CostPower density

Safety Lifetime

Customer expectations

Fuel cell system design • Stack and balance of plant

Temperature

Pressure

Humidification Peak load (I)

Rate of I/V transients

Reactant feed composition

Reactant flows Start-up/shut-down conditionsOperating

voltage

Turn-down ratio

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Requirements Comparison

Stressor Stationary Automotive

Efficiency Fuel efficiency critical, drives V to ~0.7 or higher

Peak operating point generally <0.7V

Temperature Fairly steady operation, high temperature maintained over duty cycle, depends on co-gen requirement.

Higher temperature required, but generally only at peak power.

Humidification Drive to reduce humidification, simplify control systems

Lower cost materials

Increased contamination levels

Freeze-start Less critical, freeze-thaw generally okay.

Required.

Transient operation Very slow dynamics, fairly steady state

Can be very rapid dynamics

Fuel Reformate (CO, airbleed) Hydrogen

Accelerated testing requirements

40,000h+ requires predictive capability

5000h allows screening accelerated tests only

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Temperature has a Strong Impact on Membrane Degradation

Arrhenius Plot for Membrane Degradation

R2 = 0.97

-2

-1.5

-1

-0.5

0

0.5

1

1.5

0.0027 0.0028 0.0029 0.003 0.0031 0.0032 0.0033 0.0034

1/T (1/K)

Ln (F

rele

ase/

F re

leas

e 70

C)

F=Fbaseline*A*e(-Ea/(RT))

In-situ operational data

Temperature Range90°C 30°C

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Air Bleed Effect

Effect of Air Bleed on Fluoride Washout

y = 0.0042x + 0.1469R2 = 0.8728

1.4E-01

1.6E-01

1.8E-01

2.0E-01

2.2E-01

0 2 4 6 8 10 12Air Bleed (%)

Fluo

ride

Was

hout

Rat

e ( µ

g/s)

Increased AB results in increased local temperatures

Oxygen on anode creates peroxides

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Effect of Operational Stressors on Predicted Membrane Lifetime

Operating Voltage

Relative Humidity

Temperature

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Membrane Testing Methodology

Accelerated stress test (AST) for screening purposes

COCV and OCV tests

A “hammer” test to screen components efficiently for relative durability comparisons

Accelerated durability test (ADT) with predictive capability

Test failures are correlated to field failures

Lifetime testsTested by programs at BPS or customer sites

Provides validation to accelerated durability tests

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Membrane AST

Internal Transfer Development – Peroxide Radical Attack on Perfluoroionomers

Thinning Rupture

FAILURE ANALYSIS

1. Peroxide generation in fuel cell

2. Peroxide radical production through reaction with Fenton’s catalysts, such as iron (Fe2+)

3. Attack of membrane by radicals resulting in loss of material (thinning) and loss of mechanical strength

4. Rupture of membrane due to mechanical stresses

Perfluorinated Polymer

Backbone

Side Chain

Susceptible Groups

FUNDAMENTAL UNDERSTANDING

OBSERVATION OF FAILURE MODE

Inte

rnal Leak R

ate

Hours of Operation

ACCELERATED STRESS TESTS

0

2000

4000

0 500 1000 1500

Aut

omot

ive

Dut

y C

ycle

Life

time

(h)

6000

Transfer Initiation

New Material Implemented

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Membrane AST (cont.)

Mechanical Stressor Sensitivities

0

0.5

1

1.5

2

2.5

3

3.5

0 25 50 75 100Dry Phase RH

Nor

mal

ized

AS

T Li

fetim

e

0

0.5

1

1.5

2

2.5

3

3.5

50 75 100 125 150 175 200 225 250Wet Phase RH

Nor

mal

ized

AS

T Li

fetim

eUnder wet-dry cycling, humidity transients to even 50% RH reduced the AST lifetime by 50% while larger transients show little additional effect.

Over-saturated RH transients also reduced lifetime, but to a lesser extent than did the dry-phase.

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Membrane ADT Development

ObjectiveTo accelerate membrane failures by a factor of 20 to 40 times, so that 40k hours can be tested in 1k to 2k hours.

Approach

Fundamental understanding from R&D

• Understand membrane degradation mechanisms

• Understand stressors that accelerate membrane degradation

Identify stressors due to system operation

• Temperature, RH, air bleed, wet-dry cycles

Characterization of failure finger print

• Failure analysis of membrane from field return stacks

• Characterize membrane thinning, divots, tears

Develop accelerated tests to replicate failure finger print

• Tune stress levels until test failure finger print matches with field return

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Cogeneration Product Lifetime

Stack Design

ADT (hours)

Actual Lifetime (hours) Acceleration Factor

25

Predicted Lifetime (hours)

AP2a 300 7500

AP2b 1600 20,000+ (no failure) 40,000

V3 >1600 20,000+ (no failure) > 40,000

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Stack Lifetime DataMembrane Thickness

No membrane thinning observed up to 15,000 hours

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Stack Lifetime DataLeak Rate

No external leaks observed up to 20,000 hours

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Durability Progress - Automotive

Chiem, B. et al., “The Development And Demonstration Of Technology On The Path To Commercially Viable PEM Fuel Cell Stacks”, ECS Conference, October, 2008

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EDH 156.02 - Operating at 0.163 A/cm2

June 29, 2001 - Apr. 24, 2006

Average Cell Voltage = 756 mV - 0.23 µV/cell/h

200

300

400

500

600

700

800

900

1000

0

5,00

0

10,0

00

15,0

00

20,0

00

25,0

00

30,0

00

Elapsed Time [hours]

Cel

l Vol

tage

[mV]

Stationary Power Laboratory Testing>30,000 hours Lifetime Achieved

20-cell stack1.3 mg/cm2 supported Pt50 micron membraneStationary power operating conditions

Test

term

inate

d

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FCgenTM-1020ACS Lifetime

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Summary

Air Cooled Liquid CooledCost ($/m2 @ 5000 m2/year) ~100 ~100Lifetime (hrs) 20000 > 15000Voltage (V) 0.5 to 1.2 0.7Turn down ratio 20 5Temperature ( °C) 85 >70Peak Temperature at outlet ( °C) 90 80Relative humidity at inlet (%) 0 60 -100RH cycles (% range) 0 - 100% 50 - 100Reactant gas pressures (Bar a) 0 to 1.5 1.05Pressure differential across membrane (Bar a) 0.5 < 0.5Freez-thaw (°C) -40 n/a

Ballard is global fuel cell product leader offering a leading clean energy alternatives

Significant advances in fuel cell durability have been achieved in recent years

Stationary applications provide further technical challenges for fuel cell membrane development

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Acknowledgements

The following Ballard employees should be recognized for contributing to the content of this presentation

Bien Chiem

Shanna Knights

Mike Lauritzen

Yeng Lim

Building a Clean Energy Growth Company