1

AVL‘s FUEL CELL ACTIVITIESIEA Advanced Fuel Cells Workshop

Erich RAMSCHAK, AVL List GmbH Phone: +43.316.787.3784 or mobile +43.664.8274135Email: erich.ramschak@avl.com

Graz, SEPT. 1st, 2010

2IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

AVL AT A GLANCE

AVL is the world's largest

privately owned company for

development, simulation and testing

technology of powertrains for

passenger cars, trucks and large

engines.

� Combustion engines

� Hybrid

� Transmission

� Electric drive

� Batteries

� Software

Involved in more than 1.500 engine

development projects

More than 4,000 engine test bed

installations

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1990 1995 2000 2005 2010

Turnover

1989: 74 Mio €

2009: 590 Mio €

Company-financed research

~12.5% of the turnover

Employees

1989: 940

2009: 4300

Founded: 1948

Chairman and CEO: Prof. Dr. h.c. Helmut List

HQ Graz, Austria

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3IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

AmericaArgentinaBrasiliaMexicoUSA

AsiaChinaIndiaIndonesiaJapan KoreaThailand

Australia

EuropeGermanyFranceUnited KingdomItalyAustria (HQ)PolandRomaniaRussiaSwedenSloveniaSpainCzech RepublicTurkeyHungary

Headquarter – fuel cell development centerEV, battery or fuel cell investigation

45 representations and affiliates

GLOBAL LOCATIONS

4IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

City University, LondonImperial College, London

NASA, Langley

Cornell University, New York

TU Delft

State University, Buffalo

University of Wisconsin, Madison

StanfordUniversity

Univ. Southampton

FH DresdenTU Dresden

TU Darmstadt Universität WienTU Wien

Montanuniversität Leoben

FH Joanneum GrazUniversität GrazTU Graz

Universität LinzUniversität Salzburg

ETH Zürich

Universität Stuttgart

Universität Karlsruhe (TH)RWTH Aachen

Semenov Institute, Moscow

University, Hiroshima

Chalmers University of TechnologyKTH StockholmUniversität

Hamburg

Universidad de Valencia

TU Berlin

UMIST, Manchester

Tongji University Shanghai

ENSMM BesanconUniversité Montpellier II

INTERNATIONAL RESEARCH NETWORK WITH UNIVERSITIES

underlined universities are in current R&D fuel cell projects with AVL

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5IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

� AVL intensified the effort on fuel cells in 2002

� For PEMFC applications AVL offers engineering services, tools and technologies for development, optimization, integration and validation of fuel cell components and systems

� In the SOFC area AVL offers highly efficient anti-idling technology (SOFC APU), Diesel reformer (for SOFC or aftertreatment) and engineering services.

OVERVIEW - FUEL CELLS AT AVL

1999

HyLightHyLight CFD CFD FireFire rH sensor air control PEMFC control THDA monitoring Load Matrix FCC – Vehicle

SOFCSOFC 1kW 1kW subsystemsubsystem Diesel Diesel reformerreformer 1st & 2nd Gen1st & 2nd Gen 10kW SOFC10kW SOFC reformerreformer 3rd.3rd. anodeanode recyclerrecycler SOFC APUSOFC APU

AFC HIL AFC HIL systemsystem

surveystudy

2002 2010

simulationsimulation

2005

Info: www.avl.com – fuel cell engineering

6IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

SELECTED ACTIVITIES IN THE PEMFC AREA

� STACK MONITORING THDA™

� ENGINEERING PROJECT EXAMPLES

• „HyLite“: FCV

• „AVL FCC“: EV with H2-FC range

extender

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7IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

150 200

AVL THDA™ - APPROACH FOR ONLINE FUEL CELL MONITORING

voltage driftdetection

determinationof causes in

case of failures

ageing/degradation measurement

AVL THDA™ technology:harmonic distortion analysis for detection of critical cell voltage drops� safe stack operation

THD & impedance characteristics: collection of criteria and classification into low media supply, liquid water droplets and (membrane) dry out� allows right counteraction

Online impedance spectroscopy:extraction of component values and assessment� maintenance information and training of lifetime models

long term effect

one common hardware approach –no cell voltage measuring necessary

but 2 channels measurement only (stack voltage & current)

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2

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THDA: AVL patent & TM

8IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

battery pack

signal analysis

THDA device

signal

source

de-

coupling

µµCC ≈≈≈≈≈≈≈≈

fuel cell system

MDC

AC

DC

DC

DC

DC

FC FC controlcontrol

iAC

stack voltage

CAN 2.0

inverters, converters, etc.

stack current

+12V

INSTRUMENTATION PRINCIPLE FOR STACK MONITORING WITHOUT CVM

1. Superimposition of a small alternating current signal burst during operation

2. (Spectral-)Analysis of signal response (= voltage) in terms of thd, impedance

and other statistical parameters

3. Assessment of collected parameter (critical cell condition, low media, water

isssues, long term degradation)

4. Results via CAN or RS232 interface to FC controller or GUI

output data

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9IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

EXAMPLE: ON-LINE DETECTION OF WATER, MEDIA SUPPLY & MEMBRANE ISSUES

Extended On-line Diagnosis "AVL-THDA"E.R., AVL List GmbH, Dec.08

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time [s]

inte

nsit

y o

f is

su

e [

-],

tem

pera

ture

[°C

]

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0.5

1.0

1.5

2.0

2.5

sto

ich

iom

etr

y

membrane issuecathode issuewater issuetemperatureair stoichiometry

temperature

increase

>> dryout

high air flow

>> dryout

too fast air reduction

>> blocking through

remaining water

continous air reduction

>> insufficient O2 supplyISSUES:

drying issueliquid waterair supply issue

3 separate output channels for determination of failure causes

10IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

PEMFC AEGING MEASUREMENT

� Online lifetime measurement

on basis of THDA/EIS

approach by extraction and

interpretation of certain

electrical impedance

parameters

� THDA with its classification

algorithm prevents

misinterpretation of data if they

are impacted by critical or

changing operating conditions

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-1

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x 10-3

age[%]

Real and Imaginary Fraction of Cell Impedance vs. Lifetime (dryout failure)

log(f) [Hz]

Ohm

AGE

real and complex fractions of stack impedanceover full life time cycle

Cooperative R&D project with partners

supported by

begin

of life

end

of life

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11IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

HyLite® - PEMFC VEHICLE

AVL Participation

� EV characterisation on test track and chassis

dynamometer:

� vehicle dynamics

� efficiency maps of electrical powertrain components

� pedal/torque map

� Estimation and assessment of powertrain

configurations for FC vehicle

� Development of vehicle controlling unit:

� acceleration and deceleration characteristics

� driving mode detection supporting the energy controlling unit

ASMASM

vehicle vehicle management management

unitunit

R D N PR D N P

battery packbattery packNiMH,10kWNiMH,10kW

PEMFC systemPEMFC system18kW net18kW net

energy energy management management

unitunit

GH2 tankGH2 tankDC DC

ACAC

DC DC

DCDC

ASMASMASMASM

vehicle vehicle management management

unitunit

R D N PR D N P

battery packbattery packNiMH,10kWNiMH,10kW

PEMFC systemPEMFC system18kW net18kW net

energy energy management management

unitunit

GH2 tankGH2 tankDC DC

ACAC

DC DC

DCDC

HyLite® was a cooperation project between the

German Aerospace Centre and 10 partners from the supplier industry (2002-2004).

The partners developed a Hydrogen fuelled

PEM fuel cell vehicle on platform of an existing electrical vehicle (“Hotzenblitz”)i.e. partners were able to develop and prove fuel cell components

12IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

HyLite® - CONCEPT OF PEMFC VEHICLE

ASMASM geargear

boxbox

DC DC

ACAC

vehicle management vehicle management

unitunit

R D N PR D N P

battery packbattery packNiMhNiMh, Li, Li--IonIon

PEMFC systemPEMFC system

energy management energy management

unitunit

DC DC

DCDC

GH2 tankGH2 tank

ANTRIEBSTROM-ERZEUGUNG & SPEICHERUNG

STEUERUNG

ASMASMASMASM geargear

boxbox

DC DC

ACAC

DC DC

ACAC

vehicle management vehicle management

unitunit

R D N PR D N P

battery packbattery packNiMhNiMh, Li, Li--IonIon

PEMFC systemPEMFC system

energy management energy management

unitunit

DC DC

DCDC

DC DC

DCDC

GH2 tankGH2 tank

ANTRIEBSTROM-ERZEUGUNG & SPEICHERUNG

STEUERUNG

energy unit powertrain

control

� 68% powertrain efficiency

from battery to wheel

� Regeneration energy

� 24% (city),

� 11% (NEDC),

� 6% (extra-urban),

� 4% (highway)

� 95%, 77% and 81% of deceleration

events covered only by electrical motor

(city, extra-urban, highway driving)

GH2

air

Summary of base vehicle (pure EV) characterisation:

Lead acid battery: 5.5kWh / 338kgvehicle weight: 990kg (with equipment)nominal el. power: 12kWtop speed: 104km/h

Vehicle details and contact: www.dlr.de

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13IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

“AVL FCC”: RANGE-EXTENDER WITH PEM FUEL CELL FOR NON-STOP VEHICLE OPERATION

� Base vehicle: 4-6 persons commuter in the 5kW power range for short intra-company

distances as used at airports, hotel plants, fairs and exhibitions

� Downsizing of existing batteries and generation of energy with PEMFC from

Hydrogen i.e. battery operates as transient power buffer

� Added value: Practically non-stop operation over whole day because of short tank

stops instead of 8-12 hrs stand-still for battery recharging

i.e. fairs, airports with larger fleets require only half vehicle numbers

“EVs are already environmental friendly and operate at highest efficiency”

Vehicle Presentation at Expo 2010 Shanghai China

Austria Tec Week (WKO): Mobility for Sustainable Cities Oct. 13th, 2010

14IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

“AVL FCC” CONCEPT

PEMFC~ 3kW

Pb-batteries

170Ah

power inverter

E-Motor

base vehicle Pb-batteries250Ah

H2tank34L/200bar

new configuration withFC/H2-tank and Pb-battery

original base configurationwith large Pb-batteries

•PEM fuel cell: (main-)energy provider; power output 3kW•Lead acid battery: smaller & w/o plug in use (i.e. energy comes from Hydrogen)

• battery catches and stores braking power• buffers peak power demands• power supply for on-board equipment• emergency run (limb-home)

• H2 tank: 200bar gas tank (0.6kg)• Stack monitoring: AVL THDA

THDATHDA

DC/DC

Cooperation with Tongji University

control

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15IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

SELECTED ACTIVITIES IN THE SOFC AREA

� SOFC APU

� Diesel Reformer Development

� 8kW Methanol Demonstrator

16IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

SOLID OXIDE FUEL CELL – AUXILIARY POWER UNITS

APU Development Program

� AVL initiated the development program together with Topsoe Fuel Cell (TOFC) in 2002

� primary focus first was the technical feasibility (1kW proof-of-concept system)

� after successful proof-of-concept the focus was shifted to the development of competitive end-customer products

� AVL development focus at the moment:

• System development (e.g. combined reformer-burner development)

• Development of metal-supported stack technology with partners

• Durability and reliability development

• Compressor development (air and anode recirculation)

• Diesel reformer development

• Control system development

Solution

� SOFC APU concept based on solid oxide fuel cell technology

� Fuel: onboard Diesel

� Functions: cabin climatisation, electrification, engine pre-heating, electrical net efficiency: 35%

Motivation: Reduction of heavy duty truck

idling costs and emissions

mock up

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17IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

650mm

300m

m

„EFFICIENT, QUIET AND ECO-FRIENDLY ELECTRICAL ENERGY“

STAND ALONE SOLID OXIDE FUEL CELL AUXILIARY POWER UNIT

Specifications:

� 3kW electrical power

� 10kW thermal power

� el. efficiency >35%

� Fuel: road Diesel (max15ppm sulfur)

� 60L/70kg

� < 55dB(A) noise

300m

m

Prototypes ready for tests in 2011!

Technology:

� Solid Oxide Fuel Cell

� metal-supported stacks

� anode recirculation

� auto thermal reforming

� highly efficient radial-blowers for media supply

� system internalregeneration approaches

18IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

3kW „Stand Alone“ SOFC APU PRODUCTION COSTS STUDY

(Lot size: 20.000 / year, Start of production: 2015)

Sum: 4.500 $

Costs are a big issuebut not a show-stopper

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19IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

AVL DIESEL REFORMER DEVELOPMENT PROGRAM

Autothermal Reformer

@ Reference Point P=1kWel

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0.72

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0.78

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0.82

0.84

0.86

0.88

0.9

ETA

refo

rmin

g e

ffic

ien

cy [

%]

GENERATION I

GENERATION II

GENERATION III

2006200620062006 2008200820082008 2010201020102010Generation IGeneration IGeneration IGeneration I Generation IIGeneration IIGeneration IIGeneration II Generation IIIGeneration IIIGeneration IIIGeneration III76% 76% 76% 76% EfficiencyEfficiencyEfficiencyEfficiency 83% 83% 83% 83% EfficiencyEfficiencyEfficiencyEfficiency 84% 84% 84% 84% EfficiencyEfficiencyEfficiencyEfficiency

20IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

BRIEF INTRODUCTION

C16H31 H2 + CO+ O2 + CO2 + H2OCatalyst

+ H2O

Approach:

� Autothermal reforming

� Low S/C Ratio (0.3), due to water restriction in an automotive environment

� Water comes from an anode recirculation loop with recycling ratio ~40%

� Reforming temperature ~800°C (Lambda ~0.4)

� Anode recirculation loop is simulated through the FC Test Bed

Challenges:

� Carbon formation

� High hydrocarbon conversion required for fuel cell

� Sulphur

� Catalyst degradation (thermal, poisoning)

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21IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

AVL AT Reformer GEN3

UMICORE Sample: 2008 02 23 / 1c1

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675 700 725 750 775 800 825 850 875

Reformer Temperature [°C]

mo

l%(w

et)

, m

g/m

3

Qch4_X

Qhc_X

Soot

AVL DIESEL REFORMER Generation 3

� Generation 3 autothermal diesel reformer

available & proved

� Reformer can be operated with/without anode recirculation and under partial oxidation

conditions

� Efficiency of 84% demonstrated (ATR w.

conv. diesel)

� Efficiency is between 75 and 84% for reasonable operating conditions

� Turn down ratio: 1:10 (500W-5kW FC el. power)

� Reformer controller for fully automated operation available

� Gas quality: no carbon detectedNMHC<100ppm, C2-C4: ~60ppm, C2H2 & C2H4 < 5ppm

Fuel InjectionVaporizationCatalystCarrier gas(Air, H2O,.. @~300°C)Product gas(H2, CO, CO2, N2, H2O,.. @~800°C) Diesel@5bar40cm

22IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

SOFC APU PROTOTYPE DEVELOPMENTREFERENCE PROJECT – DEMO METHANOL SYSTEM

� 8kW SOFC APU demonstrator

� Fuel: methanol

� Fully dynamic system

� 8 months project

� 40% electrical efficiency even at low

60% fuel utilization

� Totally automated system control:

• 6 basic states

• Heat-up in 1h

• Manual and transient load profile

operation

• Current drop off protection

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23IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

TESTING CAPABILITIES

� Flexible test environment for SOFC, PEM & HT-PEM systems and system components

� Test capacity up to 10 kWel (SOFC) and 16kWel (PEM)

� H2, CO, N2, H2S, CO2, CH4, Air, H2O, NG in adjustableconcentrations up to 800°C available on 2 gas paths

� Infrastructure for liquid fuels available

� Fully automated HiL („hardware-in-the-loop“) test environment

� Types of tests:

� performance tests

� longtime and durability tests

� load profile tests (fully automated)

� impurity tests (e.g. H2S, carbon, hyrdrocarbons,…)

� vibration tests (1D or 2D, stacks in operation, components or systems)

� fuel processing tests (FTIR, GC, MC, carbondetection available)

� noise and climate chamber testing (systems only)

SOFC Test Bench FTIR Gas Analyzer

Vibration Test Bench Carbon Analyzer

24IEA Workshop, Sept. 2010, AVL‘s Fuel Cell Activities

SUMMARY

� Long term experience in PEMFC and SOFC operation

� Profound knowledge in fuel cell monitoring and fuel cell instrumentation technologies

� Fuel cell vehicle demonstrators

� SOFC APU system development

� Fuel processing (Diesel reformer) competence

� Experienced in power generation prototype development

For full product information visit: www.avl.com