Progress in Materials Development and Production
for Zero Emissions Powertrains
Dr Peter Gray
24 February, 2016
© 2016 Johnson Matthey Fuel Cells Ltd
Overview
01 Johnson Matthey Plc
02 JM Activities in Low and Zero Emissions Vehicles
03 Fuel Cell Vehicles Technology Status
04 Progress in Materials Development and Production for Fuel Cell Vehicles
05 Summary
© 2016 Johnson Matthey Fuel Cells Ltd
01 Johnson Matthey Plc
02 JM Activities in Low and Zero Emissions Vehicles
03 Fuel Cell Vehicles Technology Status
04 Progress in Materials Development and Production for Fuel Cell Vehicles
05 Summary
© 2016 Johnson Matthey Fuel Cells Ltd
Johnson Matthey Plc
In >30 Countries
High Investment Levels
• R&D spend £169.9m (2014-2015)
• Group Technology Centres in UK, USA and South Africa
• Capital investment of ~£909m in the last 5 years
• 19th century origins as high-quality, reliable refiner of gold & silver
• 20th century expansion in platinum group metal refining & products
• 21st century expansion into base metal catalysis, other environmental and process technologies, other pharmaceutical and fine chemical products
Numerous
Queen’s Awards
for Enterprise
Well Established Company
• Established 1817
• Floated in 1952
• FTSE 100 since 2002
• Leading global positions in all of its major businesses
• Award-winning commitment to sustainability
• Regularly voted one of Britain’s most admired companies
Large Cap Business of
the Year 2011
MacRobert Award
for Engineering in
1980 and 2000 Best Annual Report & Sustainability
& Stakeholder Disclosure 2012
• Market capitalisation £6.5bn • Sales excluding precious metals £3.12bn • Underlying profit before tax* £440.1m • Return on invested capital 18.8% • Employees – worldwide 13,000 • Sales excluding precious metals analysed:
Key Metrics (2015)
Emission Control
Technologies 53%
Precious Metals
Products 16%
Process Technologies
19%
Fine Chemicals
10%
New Businesses
1%
By Division
Europe 33%
China 10%
NA 34%
Rest of Asia 11%
ROW 12%
By Destination * Restated for IAS 19
© 2016 Johnson Matthey Fuel Cells Ltd
01 Johnson Matthey Plc
02 JM Activities in Low and Zero Emissions Vehicles
03 Fuel Cell Vehicles Technology Status
04 Progress in Materials Development and Production for Fuel Cell Vehicles
05 Summary
© 2016 Johnson Matthey Fuel Cells Ltd
Emission Control
Technologies
Process
Technologies
Precious Metal
Products
Fine
Chemicals
New
Businesses
Chemicals • Chemical Technologies • Syngas • Chemical Catalysts
Oil and Gas • Refineries • Purification • Tracerco
Services • Platinum Marketing
and Distribution • Refining and recycling
Manufacturing • Platinum products • Glasses and enamels • Precious metal powders
Pharmaceutical • Active Pharmaceutical
Ingredients (API)
Battery Technologies • Battery Electric, Plug-in Hybrid,
mild and micro hybrid vehicles • Advanced Battery Materials • Lithium ion batteries • Developer and assembly of
advanced automotive battery systems
Water • Purification, metal scavenging
Fuel Cells • Automotive, portable and
stationary power sectors • Membrane electrode
assemblies & sub-components • Fuel cell catalysts • Reforming and gas processing
catalysts
Emission Control Systems • Light Duty Gasoline and
Diesel Catalysts • Diesel particulate filters • Selective catalytic
reduction • Heavy Duty Diesel and
non-road applications • Stationary Emissions
Control
JM Activities in Low and Zero Emissions Vehicles
Increasing focus on environmental technologies:
> 50% of profit derives from products that directly
benefit the environment
© 2016 Johnson Matthey Fuel Cells Ltd
Global Drivers Continue to Provide Opportunities for
Powertrain Technology
Evolving
Technology
Population Growth
Urbanisation
Increasing Wealth
Natural Resource
Constraints
Environmental Factors
Climate Change Regulation
Health & Nutrition
Ageing Population
Increased demand
for mobility, focus
on emissions
Focus on air
quality to improve
public health
Tighter emission
regulations, low
CO2, zero emissions
Improved fuel
efficiency,
alternative fuels,
sustainable
energy generation
© 2016 Johnson Matthey Fuel Cells Ltd
Johnson Matthey Battery Technologies and Johnson Matthey Fuel Cells
► Johnson Matthey Fuel Cells develops and manufactures Cell components
► Membrane electrode assemblies (MEAs) and MEA sub-components and catalysts
► Range of automotive, stationary and portable fuel cell applications.
► Johnson Matthey Battery Technologies spans the battery value chain
► Acquisition of Axeon Group 2012. Acquisition of A123 assets & Clariant. Expanded internal R&D and product
development programs. Further acquisitions being pursued.
© 2016 Johnson Matthey Fuel Cells Ltd
Johnson Matthey Fuel Cells - Products
JMFC’s key product is the MEA (membrane
electrode assembly) - a complex laminate of carbon
fibre based gas diffusion layers, catalysed electrode
layers and a proton conducting polymeric
membrane.
Producing high quality MEAs requires skills in
materials science, chemistry, physics, catalysis,
production engineering and quality control.
The cell is completed by two conducting plates that
distribute gas uniformly over the outer surfaces of
the MEA sandwich.
In automotive fuel cell engines the cells are stacked
in a bipolar arrangement to provide the total power
and I-V characteristics required for the electric
powertrain.
© 2016 Johnson Matthey Fuel Cells Ltd
01 Johnson Matthey Plc
02 JM Activities in Low and Zero Emissions Vehicles
03 Fuel Cell Vehicles Technology Status
04 Progress in Materials Development and Production for Fuel Cell Vehicles
05 Summary
© 2016 Johnson Matthey Fuel Cells Ltd
Largest single long term market for fuel
cells.
Fuel cell car programmes influence
materials costs across the industry.
Drivers behind electric drivetrains are
strong.
Legislation and climate change.
Decarbonisation of transport and power
generation.
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Fuel Cell Vehicles
Consensus (OEMs, utilities, oil companies) that the
future will see a mixture of technologies:
• All sorts of hybrids
• Small city cars as pure battery electric vehicles (BEV)
• Larger, longer range fuel cell vehicles (FCV)
© 2016 Johnson Matthey Fuel Cells Ltd
Technology Status
Performance and durability have been demonstrated to meet specified requirements.
Development work is focussed on reliability and resilience in real world conditions.
The achievement of cost targets continues to be a challenge with focus on:
► Materials
► Volume manufacturing
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© 2016 Johnson Matthey Fuel Cells Ltd
01 Johnson Matthey Plc
02 JM Activities in Low and Zero Emissions Vehicles
03 Fuel Cell Vehicles Technology Status
04 Progress in Materials Development and Production for Fuel Cell Vehicles
05 Summary
© 2016 Johnson Matthey Fuel Cells Ltd
Real world - Cold starts
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© 2016 Johnson Matthey Fuel Cells Ltd
Real world - Hot hill climb
15
© 2016 Johnson Matthey Fuel Cells Ltd
Real world – Multiple stop/starts
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© 2016 Johnson Matthey Fuel Cells Ltd
Real world – Cell Reversal damage
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© 2016 Johnson Matthey Fuel Cells Ltd
Hydrogen starvation
18
H+ H+ H2 → 2H+ + 2 e- 2H+ + ½O2 + 2e- → H2O
H2 O2
0 V 0.7 V
Normal operation – single cell
© 2016 Johnson Matthey Fuel Cells Ltd
Hydrogen starvation
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H+ H+ 2H+ + ½O2 + 2e- → H2O
O2
X
X
X
X
½C + H2O → ½CO2 + 2H+ 2e-
e-
+1.7 V +0.7 V
- 1 V
Hydrogen starvation – single cell
© 2016 Johnson Matthey Fuel Cells Ltd
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Corrosion resistant carbons [0.9 V30sec – 1.4 V30sec]
Voltage at 500 mA/cm2
Voltage at 1000 mA/cm2
Improved carbon supports
corrosion without loss in
performance
• Tolerance to oxidative
potentials; SU / SD
• Require high carbon surface
area to ensure Pt dispersion
• Voltage cycling test
Cathode /Carbon #3 = best
combination of
• Corrosion resistance
• Pt ECA and stability
• ECA retention
© 2016 Johnson Matthey Fuel Cells Ltd
Cell reversal protection
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Oxygen evolution reaction (OER) catalyst
© 2016 Johnson Matthey Fuel Cells Ltd
Cell reversal protection
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Oxygen evolution reaction (OER) catalyst
© 2016 Johnson Matthey Fuel Cells Ltd
Hydrogen starvation
23
H+ H+ 2H+ + ½O2 + 2e- → H2O
O2
X
X
X
X
½C + H2O → ½CO2 + 2H+ 2e-
e-
+1.4 to 1.6 V
H2O → ½O2 + 2H+ 2e-
+0.7 V
- 0.7 to - 0.9 V
Hydrogen starvation – with Oxygen evolution reaction (OER) catalyst
© 2016 Johnson Matthey Fuel Cells Ltd
Membrane durability
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© 2016 Johnson Matthey Fuel Cells Ltd
Volume manufacture – the next challenge
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Thousands of MEAs
10s of thousands of MEAs
Millions of MEAs
10x millions of MEAs
2015-2017
100s of cars
2013-14
10s of cars
2018-2022
x10k of cars
2025
100 k cars
© 2016 Johnson Matthey Fuel Cells Ltd
JMFC Investment – High Volume Manufacturing
Catalyst layer deposition has evolved
► Originally screen printing
► Now continuous roll-to-roll coating
► Discrete images
► Class 1000 cleanroom
MEA assembly
► Originally discrete part assembly
► Now automated roll assembly
► Class 1000 cleanroom
In-Line Quality Control
► XRF, thickness, defects, part traceability
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© 2016 Johnson Matthey Fuel Cells Ltd
01 Johnson Matthey Plc
02 JM Activities in Low and Zero Emissions Vehicles
03 Fuel Cell Vehicles Technology Status
04 Progress in Materials Development and Production for Fuel Cell Vehicles
05 Summary
© 2016 Johnson Matthey Fuel Cells Ltd
Summary
28
Global Drivers continue to provide opportunities for powertrain technology evolution –
increasing focus of Johnson Matthey on environmental technologies for Low and
Zero Emissions Vehicles.
Increasing product portfolio for Zero Emissions Vehicles – Johnson Matthey Battery
Technologies and Fuel Cells. Recent acquisitions in Johnson Matthey Battery
Technologies spanning the battery value chain.
Performance and durability of existing PEM Fuel Cell MEA technology has been
demonstrated to meet requirements to allow introduction of fuel cell vehicles.
Development work is now focussed on successfully improving the reliability and
resilience of Fuel Cell materials in real world (mass market) conditions, with cost
reduction and quality control achieved through volume manufacturing methods.
© 2016 Johnson Matthey Fuel Cells Ltd
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