Track 02 | Agenda 2021 

Fuel Cell Design, Development, & Manufacturing

Day1: September 27, 2023

Networking breakfast
8:00 am - 8:50 am
Scaling up Fuel Cells and Electrolysers
9:00 am - 12:30 pm

9:00 am

Moderator Opening Remarks
Dr Carsten Pohlmann
Business Development Director
Bramble Energy
Bramble logo
 

9:05 am

Challenges for PEMFC for high power applications: scaling up and durability
Dr. Pawel Gazdzicki
Team Leader Low Temperature Fuel Cell & Electrolysis
DLR e.V. – German Aerospace Center
This presentation will discuss PEMScale1.5, which is a DLR project involving nine DLR institutes from the areas of energy, transport and aviation in order to develop a concept of a generic, integrated fuel cell system with an output of 1.5 megawatts including electric drive. The goal of the PEMScale1.5 project is to identify specific requirements for the fuel cell systems and power trains of the individual applications. Moreover, a concept of a generic fuel cell system with a power of up to 1500 kW is proposed.
 

9:30 am

How to get my production of Fuel Cells and Electrolysers done
Thomas Kuschel
Head of fuel Cell
thyssenkrupp Automation Engineering GmbH
From factory to production, this presentation addresses the latest developments in production methods of Fuel Cells and Electrolysers and how to scale impact of design features on production methods.
 

9:55 am

Electrolyser Manufacturing Dynamics and Accelerating Scale-up
Adam Cooper
Business Development Manager
Wood plc
This presentation will discuss the dynamics of the Electrolyser market and the important considerations to scale Electrolyser manufacturing on a global scale. Wood is actively engaged in the global Electrolyser market, helping OEM’s to scale their manufacturing facilities and drive down cost through deployment of fully automated robotic assembly and automation system.
 

10:20 am

Hydrogen fuel cells for large-scale power generation plant
Andrea Trevisan
Head of Sales
Intelligent Energy
The presentation will report about the usage of hydrogen fuel cells for large stationary power plant. Andrea will review the status of the engineering activates at Intelligent Energy to deliver a 10 MW power plant based on hydrogen fuel cell that will be in operation in Korea in 2025.
 
Break
10:45 am - 11:15 am

11:15 am

A modular platform approach to future BEV & FCEV production
Chris Jones
Strategic Trends Manager
Advanced Propulsion Centre UK
The APC will present a comparison of installed powertrain costs for a hydrogen fuel cell system, NMC and LFP batteries used in large premium SUVs and vans. This analysis is novel because it links detailed future battery and fuel cell cost projections within a modular electrified platform concept, where OEMs can produce fuel cell and battery electric powertrains on the same vehicle production line.
 

11:40 am

Panel Discussion- Are Fuel Cells and Batteries Competing Technologies?
Chris Jones
Strategic Trends Manager
Advanced Propulsion Centre UK
Prof Katja Rösler
Professor for Automotive Engineering
University of Applied Science Ruhrwest
Jeremy Bowman
CTO
Hypermotive
Francisco Javier Sánchez Castañeda
Researcher
Tecnalia Research & Innovation
This panel will address the pros and cons of both fuel cells and batteries, and how these can be complimentary rather than opposing technologies. The panel will also highlight how this might differ between different industries, with a particular focus being on the transport sector.
 
Lunch
12:20 pm - 1:20 pm
Automation and Raw Materials
1:20 pm - 5:00 pm

1:20 pm

Moderator
Dr Stephan Wagner
Technical Lead Hydrogen Systems
Segula Technologies

1:20 pm

High Power Density Fuel Cell Systems for Commercial Vehicles
Falko Berg
Manager & Technical Product Responsible PEM Systems
AVL List
AVL has developed a modular 156 kW fuel cell system and based on it an optimized fuel cell powertrain for a long-haul semitrailer tractor that meets the industry requirements of lifetime, driving performance, fuel consumption, driving range as well as the costs for acquisition and operation. This presentation will elaborate on the methods and tools we used to optimize the Fuel Cell System, battery, e-Axle and all other relevant auxiliaries to develop a class leading solution for the 40ton truck.

1:45 pm

Innovative PEM fuel cell R&D tool platform to enable informed trade-offs on designs, strategies and calibrations by factoring in degradation
Tomas Dehne
Chief Engineer Fuel Cell Testing Technology
AVL
The presentation explains why degradation is such a big challenge and outlines AVL's innovative, new and open fuel cell degradation R&D platform. The tool is fully embedded into an holistic approach and enables normalized stress and failure fingerprint indication throughout the whole development process.

2:10 pm

Design for automation in next-gen fuel cells
Lucrezia Morabito
Strategic Marketing responsible for Automation in Renewables
Comau S.p.A.
Hydrogen is becoming one of the key enablers in achieving net-zero, and fuel cells are the way to promote the adoption of sustainable mobility worldwide. However, to achieve mass diffusion, the manufacturing process must definitely scale up. To permit the realization of such volumes, automation is the answer.
Break
2:35 pm - 3:05 pm

3:05 pm

Recovery of raw materials from end-of-life fuel cells - consequences for the product design
Dr Sven Grieger
Head of Innovation Transfer Office
Fraunhofer IWKS
Fuel cell systems become more and more competitive as an alternative to mineral oil-based propulsions at applications such as independent power supplies as well as trains, ships, ferries, or vehicles. Sooner or later, electronics recycling facilities will be one of the main destinations of end-of-life fuel cell systems or related components such as fuel cell stacks. In this presentation, a verified recycling approach comprising of mechanical pre-treatment and chemical separation processes is introduced that ensures a high degree of recovery of the raw materials used and which is superior in terms of environmental compatibility and economic efficiency.

3:30 pm

Precious Metals – Indispensable Elements for Green Hydrogen! What needs to happen to secure the supply during the hydrogen ramp-up?
Dr Christian Gebauer
Head of R&D
Heraeus Precious Metals GmbH
Increasing demand for green hydrogen needs a significant increase of water electrolysis capacity. Here, PEM electrolysis will cover a significant share of the planned GW installations to reach the ambitious H2 generation goals. However, all electrolysis technologies and particularly PEM electrolysis is dealing with critical raw materials, for the latter precious metals. On the other hand, precious metals also show highest efficiencies in activity and in recyclability which makes them not only a chance but a pivotal element of the hydrogen economy. Their application beyond water electrolysis shows especially in in fuel cells, gas purification and conversion into other compounds for transport, e.g. ammonia, a big opportunity

3:55 pm

Industrial-useable simulation approach for water management analysis in fuel cells
Dirk Ortlieb
Managing Director
Simerics GmbH
Water management of fuel cells is essential for efficient usage and optimal performance. This presentation will show an industrial useable approach with a good accuracy/time/cost ratio using an efficient VOF model which can be coupled with further sophisticated models for transport in gas-diffusion layers and membranes. It will also show results of water transport in industrial fuel cell designs as well as possible optimization strategies using various model levels.

4:20 pm

PANEL DISCUSSION: European Critical Raw Materials Act: How this will impact fuel cell and electrolyser production
Dr Stephan Wagner
Technical Lead Hydrogen Systems
Segula Technologies
Thomas Kuschel
Head of fuel Cell
thyssenkrupp Automation Engineering GmbH
Dr Christian Gebauer
Head of R&D
Heraeus Precious Metals GmbH
Falko Berg
Manager & Technical Product Responsible PEM Systems
AVL List
The European Critical Raw Materials Act (CRMA) is set to secure Europe's competitive edge and produce 40% of its own clean tech by 2030. The EU plans to produce 10Mtons of renewable hydrogen, requiring 100 GW of electrolyser capacity. This panel discussion aims to highlight how the CRMA will impact fuel cell and electrolyser producers throughout the value chain.

Day2: September 28, 2023

Design, Development and Application
9:00 am - 12:15 pm

9:00 am

Opening Remarks
Christina Houlihan
Co-founder & CEO
bspkl.
 

9:05 am

Review and future of PVD coating for fuel cell and electrolyzer
Anthony Chavanne
Global Product Manager PVD PECVD Technologies
HEF Groupe
Physical Vapor Deposition (PVD) coating has shown great potential in improving the performance and durability of fuel cells and electrolyzers. In this review, we present an overview of the current state of research on PVD coating for fuel cell and electrolyzer components, and discuss future directions for this technology.
 

9:30 am

Loop Calibration System enabling high hydrogen mass flow calibration
Peter Brouwer
Market Developer Renewable Energy
Bronkhorst High-Tech B.V
Bronkhorst High-Tech has developed a calibration system for mass flow meters in which the calibration gas circulates through a pump in a closed loop circulation system. The presentation explains the principle and the setup of the calibration system. By increasing the system pressure, higher mass flow rates can be achieved at the same volume flow. Thermal stability is mandatory for calibrations and measures needed to be taken for that. Pressure drop and fluctuations have been investigated and have been optimized. With the system it is now possible to perform high flow real gas (hydrogen) calibrations.
 

9:55 am

The EKPO NM12 stack module - high performance platform for heavy duty applications
Pascal Gaus
R&D Engineer Development Stack Operation
EKPO
This presentation will be about the EKPO NM12 stack module and its performance characteristics. The level of integration of the BOP-components and how we ensure a high quality over lifetime with our design verification plan.
 
Break
10:20 am - 10:50 am

10:50 am

How Ballard achieved DNV Type Approval and what it means for marine
Christian Vinther
Account Manager Marine
Ballard Power Systems
Christian Vinther give an insight into how Ballard received the world’s first DNV Type Approval, what a Type Approval process involves and ultimately what this means for the marine market. In addition, Christian will also present several vessel projects which in 2023 will embark on their maiden voyages powered by Ballard’s fuel cells- showcasing how zero-emission operation can be made possible here and now.
 

11:15 am

PEM Fuel Cells Solutions for the Marine Industry
Mathias Enger
Operations Manager
TECO 2030
It is imperative to develop breakthrough solutions to retrofit the existing fleets and allow maritime transport industry to meet the environmental challenges with investments that do not compromise their businesses nor waterborne transport industry. Therefore, the availability of cost-effective and easy-to-integrate PEM fuel cell systems type-approved for maritime applications and the use of green hydrogen as zero emission fuel will significantly contribute to the decarbonization of the shipping industry.
 

11:40 am

PANEL DISCUSSION- Technological Innovations in Fuel Cell Materials and Stack Design
Christina Houlihan
Co-founder & CEO
bspkl.
Giampaolo Sibilia
Director of EU Operations
Nuvera
NUVERA logo
Christian Altenhofen
Team Lead - Reactive Flow Applications
Gamma Technologies
Fabian Kapp
Managing Director
Graebener Bipolar Plate Technologies
This panel will focus on recent breakthroughs in fuel cells and stack design, focussing on topics such as performance and durability, the latest developments in bipolar plates, simulation techniques and cost reduction strategies. The panel will conclude the discussion with future directions and challenges facing the industry.
 
Lunch
12:20 pm - 1:20 pm
Design and Development
1:20 pm - 5:00 pm

1:20 pm

Opening Remarks
Chris Robertson
Director, Sales and Marketing
AvCarb
AvCarb logo

1:20 pm

Filtration and membrane around H2 Fuel Cells
Dr. Korneel De Rudder
Product Manager Alternative Power
Donaldson
The role of cathode air filter and its influence on the performance and durability of the fuel cell.

1:45 pm

Fuel Cell MEA Production Industrialization: From Prototyping to Process development
Dr Sebastian Kohsakowski
Head of Research and Development
Laufenberg GmbH
Niels Hinrichs
Research Associate Fuel Cell
Chair of Production Engineering of E-Mobility Components
Fuel Cells represent an integral part of the future energy sector, i.e. in heavy-duty mobility or stationary power generation. However, its production is characterized by complex processes, the utilization of sensitive materials and niche knowledge due to its novelty regarding the series production. One main process chain represents the production of the membrane electrode assembly (MEA) where the electrochemical processes in the fuel cell take place. Hence, this component is primarily responsible for the overall fuel cell performance. By having a more profound insight into its production process it comes up, that improving material handling and product quality due the thin membrane, huge consumption of carrier material and high production cost remain major challenges in MEA production. As part of the project Fuel Cell Performance Production (FCPP), an innovative process concept is developed to address the above-mentioned challenges and propose a process solution for future fuel cell production systems. Within the concept, a re-coatable transfer belt is used as a continuous decal to enable a roll-to-roll coating of the membrane. In a following process step, the membrane is assembled with a subgasket and gas diffusion layer (GDL) to the MEA. To gain knowledge about relevant parts of the new concept, e.g. transfer belt coating and catalyst transfer to the membrane, first tests need to be conducted to understand relevant interdependencies of the materials, their handling and process parameters to enable a state-of-the-art MEA production. Thus, a holistic hands-on experience of the whole process chain of the MEA production is explained. Next to the applied materials, a prototypical manually MEA production line is described and integral process parameters as well as the impact of their deviation are shown. Finally, requirements to an automated and industrialized MEA production are derived.

2:10 pm

Leak testing accompanying production from mono plate to fuel cell stack
Dr. Philipp Schurig
Market Manager Industrial Leak Testing
Pfeiffer Vacuum GmbH
Fuel cell stacks and bipolar plates are key components of any mobile or stationary fuel cell application. In addition to the safe operation of hydrogen-containing compounds, cost-effective processes with short cycle times are the main objectives when selecting leak testing methods for these components. Taking the requirements of mono plates, bipolar plates and complete stacks as examples, we present the selection process for the respective leak test method and discuss the advantages and disadvantages of the individual procedures.
Break
2:35 pm - 3:05 pm

3:05 pm

German Fuel Cell Cooperation: Efficient and Scalable Production Equipment for Bipolar Plates
Anthony Nobel
Head of Strategic Sales
Zeltwanger
The German Fuel Cell Cooperation will present the key elements of their concept of an integrated bipolar plate production and the parameters that enable a robust, efficient and scalable production that the industry demands. In an emerging market, it’s not only about the equipment but also about the technologies being used, which the German Fuel Cell Cooperation addresses as well.

3:30 pm

From prototype, prove of concepts, towards reliable serial design and robust production processes for SOFC and SOEC Hot Balance of Plant systems
Ted Straten
VP Strategy & New Business
BOSAL
In the previous BOSAL publication A1609 from EFCF2020, the modelling and advanced characterization of the thin foil counterflow heat exchanger elements were discussed and how they function optimally as quantum manager to achieve a quasi-reversible functionality. These quantum managers are a necessity to reach in SOFC and SOEC high electrical efficiencies. In such a way, they are crucial building blocks to achieve the desired conditions of the flows towards the fuel cell stack. Temperature and gas composition must be provided in the required windows, so the stack can function and perform as desired. Composing the quantum managers together results in a Hot-Balance of Plant (H-BoP) system. BOSAL realized already since 2008 SOFC H-BoP systems. Specifications regarding space, heat transfer and quantum management in combination with pressure drop (backpressure as it is called), are essential parameters to consider by finding the desired trade-off between CAPEX and OPEX. BOSAL has configured over the last years for multiple customers a variety of SOFC and SOEC systems based on the specific approach and P&ID of the customer, resulting in optimal designs and optimization for each approach. By doing so, a learning curve was generated, resulting in lessons learned which are taken in the process development for serial production. Very often small details make at the end the difference. Thermal management is key. Such experiences are shared in the paper to prepare and help the SOFC or SOEC system developer better in the multiple choices he has to make to generate a P&ID including the lay-out, the number of components and their position, which are very often the key to success. Practice showed that the best compromises deliver much better results compared to the theoretical best choices. Reason is that in reality, materials reach with their properties their limits in these applications, not speaking about the cost complications that sometime pushes the application in the direction of very exotic and costly material selections. Examples are discussed. Nowadays, multiple customers work on fast heat-up within minutes instead of hours for SOFC and SOEC components. There is the experience in the BOSAL-group coming from automotive exhaust systems to minimize the design and concept loops to achieve a functional and endured concept. Finetuning in the virtual environment happens before going into high production volumes by using Thermal Mechanical Fatigue (TMF), validated with thermal cycling tests with burners and heaters to control risks when going into high production volume. On request of multiple customers, BOSAL is realizing the industrialization of several heat exchanger footprints production up to the fully integrated H-BoP systems up to TRL 8.

3:55 pm

Materials Testing in Hydrogen Fuel Cell/Electrolyzer– Challenges, Requirements, Solutions
Dr Chen Cao
Global Industry Manager
ZwickRoell GmbH & Co. KG
Hydrogen, generated with renewable energy, is the promising energy storage type of the future. The challenges in the hydrogen value chain, from hydrogen generation to storage and transportation as well as end use, are numerous and especially materials used for these purposes have to be adapted to tough conditions. Not only materials are very sensitive to hydrogen influences but also special requirements need to be fulfilled to reach a higher product efficiency and longer service life. ZwickRoell would like to give an overview of the relevant material testing solutions regarding to the hydrogen fuel cell/electrolyzer.

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