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