freudenberg sealing technologies
Post on 19-Oct-2021
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FREUDENBERG
SEALING TECHNOLOGIES
Dr. Manfred StefenerLead Center Fuel Cell Systems
Technical expertise meets the power to industrialize
No disclosure to third parties!
The Freudenberg Group: A globally leading technology company since 1849
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100 %
Family
Ownership
Global presence
in more than 60
countries worldwide
~ €8.8bnSales 2020
1849
Founded by Carl Johann
Freudenberg in ~48,000employees
5,0% R&D Ratio
Moody‘s
Rating A3~€3.0 BillionSales with products
≤ 4 years
No disclosure to third parties!
Freudenberg & Fuel Cell: A success story of product innovation since 1995
The company committed itself to Fuel Cells as sustainable and forward-looking
technology at an early stage
Freudenberg
Performance Materials
Freudenberg
Sealing Technologies
Freudenberg
Filtration Technologies
No major FC sold in market today without significant Freudenberg content.
Complete transfer of this long-term expertise to our FC systems for heavy duty applications.
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No disclosure to third parties!
Focus of BFC business is exclusively on heavy duty markets with highest life, quality and durability needs
Lead Center Battery Systems Lead Center Fuel Cell Systems
Division Battery & Fuel Cell Systems (BFC)
XALT LLC Freudenberg FST GmbH
BFC systems business initiated to further participate in global electrification trend
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No disclosure to third parties!
Overview Freudenberg Battery & FC Systems Business
Battery Cell &
Pack Production(Midland, MI)
Option: Future local manufacturing of
FC systems
Battery & Fuel Cell
R&D Center(Auburn Hills, MI)
Focus: Battery cell & system
development / validation, software /
electronics development / testing &
FC-Battery hybrid configuration
Fuel Cell System
Test Center(Plymouth, MI)
Focus: Local testing & validation
Battery Engineering, Standard
Compliance & Maritime Center(Weinheim, GER)
Fuel Cell Systems R&D Center(Munich I, GER)
Focus: Heavy-Duty Mobility
FC Development Center
Fuel Cell Systems Production /
Test Center(Munich II, GER)
Focus: Production & assembly of MEA & Stack up to 500 MW/a,
> 4 MW test capabilities for H2 & reformate systems,
validation FC-Battery hybrids
High in-house value-add and
system responsibility but
full customer flexibility regarding required supply
High volume FC production SOP 2024 initial site in EU (300 MW,
scaling to 3 GW per 2027)
All offers are designed exclusively for heavy duty market needs
Offerings covers in-house designed BMS and in future EMS in accordance with ISO26262
China / Asia expansion committed – likely timing 2022 for first local activities
6 sitesin NA & EU
>1000vehiclesin field
>10.000.000miles driven
Active programs on5 continents
~600employees
> 8.5MWhon single vessel
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Holistic fuel cell hybrid approach by high value creation, strategy of identical parts, modularity & full HD market coverage by LTPEM
City Bus >40 kW
System-Configuration Application Requirement
Delivery >40 kW
Truck >100 kW Rail >100 kW
Mega Yacht ~20 MW Cruise ~60 MW
>40 kW
1 x
>100 kW
Fuel Cell Racks
X x
Balance of Plant Battery
Balance of Plant Battery
BoP + Reformer Battery
Modular scalable
Stack
BPP
Leverage of several segments results in maximum economies of scale & competitive cost
structure in all segments - Ability to meet future cost targets for upscaled industry
illustrative images / internet
Integrated MEA
1-3
x
Potential scope of supply Freudenberg - extractions possible
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No disclosure to third parties!
20
100
1510
40
15
Freudenberg has highest share in the value chain of fuel cell systems with a strong focus on electrochemistry
Competitor Y
Competitor X
VALUE OF THE PRODUCT
20%
Catalyst,
Electrode
15%
Integrated
MEA
10%
BPP, Stack(true heavy-duty)
40%
FC System
incl. BoP
15%
Electronics
Value of FC
System
to customer
Manufacturing of low
loaded platinum
catalyst & CCM
Manufacturing of
integrated high
lifetime MEA with
gasket
Manufacturing of
long-lasting Heavy-
Duty BPP & Stack
Design of System,
BoP & Safety +
System certification
Design of Power
Electronic Controls,
Software &
Telematics
Majority of industry focuses on FC design and stack assembly, but in-house value creation
and industrialization ability in electrochemistry will drive future competition
Majority of fuel cell
companies are more a
kind of FC assembler
as real manufacturer
=> high dependency
from sub-suppliers
(pricing, quality,
technical performance)
Main
activities
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Example Freudenberg USP: Freudenberg relies already for prototypes on integrated MEGA1 (= MEA 7) concept
Freudenberg view: Integrated components are key step in the industrialization process for fuel cell systems and to meet target cost
Ability to manufacture integrated electrochemical core components leads the way towards this path paired with proprietary seal designs & compounds
In current MEGA generation, electrochemical active core element is permanently attached to the frame/sealing element in an integrated, highly automated process flow
Allows an easy, failure-proof handling in the successive stack assembly and avoids contamination/quality risksReliable protection and integration of all layers
GDL: Gas Diffusion Layer,
MPL: Micro Porous Layer, CL: Catalyst / Electrode Layer,
PEM: Proton Exchange Membrane
1. MEGA = Membrane Electrode Gasket Assembly; MEA7 with integrated sealing systems
High in-house value creation @ MEA drives technical efficiency,
product quality and cost level
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No disclosure to third parties!
Pre-fabricated container solutions with highest thermal integration of reformer unit
and fuel cell modules to realize maximum efficiencies and installation flexibility
Modular, scalable
Heavy-Duty FC stack
Modular, scalable FC-System (incl. BoP)
with integrated fuel reforming module + pure
Hydrogen
(example Aidanova / Methanol)
HD Bipolar plate (BPP)Graphite bipolar plate with advanced flow field design for
homogenous temperature profile and homogenous gas distribution
HD Membrane Electrode Assembly (MEA)Fully integrated MEA with patented concept for advanced
assembly characteristics
High in-house value creation of the modular pre-fabricated container solutions enables highest lifetimes & max efficiencies
Single Cell of a Heavy-Duty Fuel Cell Stack
1
2
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No disclosure to third parties!
Cruise industry values our holistic approach for high life-times supported by in-house value creation
“Meyer Werft and Freudenberg Sealing Technologies plan to equip next-gen cruise ships with fuel cell propulsion” (press release October, 10th 2019)
• Project consortium - includes Luerssen Werft, Carnival Maritime and DNV.GL -
will jointly develop a new generation of fuel cell technology with integrated
methanol reforming process
• Fuel cells with integrated fuel reforming offers excellent properties in terms of
storage volumes, easy fuel handling and enables maximum shipping ranges
• Hybridization of fuel cell system with XALT‘s modular battery portfolio will be
the next step
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One Example - Cruise
Freudenberg’s maritime portfolio is in line with all existing IMO rules / IGF codes
Maritime safety certification achieved
-
Start of integration @ cruise ship in Q4/2021
Also outside of maritime sector, we see strong interest in oursolution
“Fuel cells for long-distance bus transport / FlixBus and Freudenberg join forces to power up sustainable transportation solutions” (press release September, 1st 2019)
• Collaboration on a future-oriented project for sustainable, CO2-free
mobility with Europe’s largest operator of long-distance bus travel
• Development of the first long-distance bus with fuel cell drive
including hybridization platform; operation strategy, software, controls
& safety infrastructure (Battery & FC)
• Implementation on several European bus routes for proper system
validation – finally 50 vehicle test fleet targted (Munich Vienna,
Berlin Hamburg, Stockholm Copenhagen, etc.)
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FC Hybrid – the rightsizing of battery and fuel cell system within a parallel hybrid architecture fits perfectly the application requirements for the segment Truck & Bus
One Example - Bus
Activities connected with national funding / Will start soon
No disclosure to third parties!
Thank you for your attention!
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