hydrogen and fuel cells for electromobility : the...

Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016

HYDROGEN AND FUEL CELLS FOR ELECTROMOBILITY : THE HY WAYDEMONSTRATION PROGRAM AND PROGRESS IN FC STACK DEVE LOPMENT

| 2HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016

SUMMARY

• Context • Hydrogen mobility in world • Hydrogen mobility in France

• HYWAY : program overview • Introduction • Working Method• FLEET data analysis• Beyond HYWAY

• Development of next generation Fuel cell System

• Perspectives


• Fuel cell vehicles • Electric vehicle including battery a least for the system

start-up• clean vehicle (only water produced)• low level of noise• High efficiency compared to conventional engines

• Use of fuel • Refuelling duration =3 min-5min (for optimised 700

bars refuelling station) • Range : approximatively 600 km and independent of

climatic conditions (Temperature) • Easy to monitor the energy level stored in tank

• Availability of hydrogen (need of hydrogen refuelling station)

• Cost of fuel cell system

ADVANTAGES AND DRAWBACKS OF FCEV

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OVERVIEW OF ACTUAL AND FUTURE PEMFC MARKETS

Overview of projected sales of individual fuel cell vehicles during 2015-2025

• Increase of number of system shipped during last year

• Increase of power installed• Mainly used for stationary

applications

• Increase of number of Fuel cell vehicles is planned during next years.

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Main worldwide automotive suppliers program

2015

2016

2015

2013

2020

1000 véhicules en2015




30 000 véhicules en2020

2015



2020

2015 2020

2015 2017


2020

2014 2017

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TOYOTA MIRAI EXAMPLE

https://youtu.be/oOUjqxec4bA

CaractéristiquesDimensions L x l x h 4,890 / 1,815 / 1,535 m

Empattement 2,780 mVolume du coffre 361 l

Poids à vide 1.850 kgMoteur

SystèmePile à combustible + moteur électrique +

batterie Ni-Mh de 1.6 kWhPuissance 154 ch immédiatement

Couple 335 Nm immédiatement0 à 100 km/h 9,6 sVitesse maxi 178 km/Autonomie 500 km (données constructeur)

Temps de recharge 3-5 minutes

Tarifs 66.000 euros HT

Available in Asia, in North America and in Europe when hydrogen refuelling station already exists (Deutschland, Denmark, United Kingdom and Belgium) ; Not in FRANCE

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HYDROGEN MOBILITY - FRANCE (OCTOBRE 2014)

Captive float to start infrastructure deployment before a g lobal coverage of

Clusters will be the base of future national infrastructure

Source : www.afhypac.org/images/documents/h2_mobilit_france_fr_final.pdf

Le Projet HYWAY

� Déploiement de 50 utilitaires

Kangoo ZE hybrides

batteries/hydrogène

� 2 stations de distribution

d’hydrogène à Lyon et

Grenoble

� Premiers véhicules en

circulation en 2015

Déploiement Manche

� Déploiement de 40 utilitaires

et bus

� 1 station de distribution

d’hydrogène à Saint-Lô

� 10 véhicules en circulation en

2015

2015: premiers déploiements

PRESENTATION OF HYWAY PROJECT


CONTEXT : OUR PARTNERS


CONTEXTPROJECT OBJECTIVES

• Deployment of a FCHEV captive fleet (50 vehicles) simultaneously with the installation of 2 Hydrogen Refueling Station (port of Lyon, Grenoble GEG)

• Multi users• Multi customers (La Poste, CETUP, DHL, etc…)• Analysis of Hydrogen Refueling Station /Vehicles usages• Validation of the economic deployment model HRS/Vehicles

ENJEU

HRS – Grenoble GEG

FCHEV Fleet (Kangoo ZE-H2)


CONTEXTTHE VEHICLE

• Renault Kangoo ZE MAXI + FC kit from Symbio• Type: serial hybrid• Battery pack: 22 kW.h• FC Stack: 5 kW• H2 Tank: 350 bar, 1,5 kg H2

ENJEU

Kangoo at HRS – Grenoble GEG

Kangoo ZE-H2


CONTEXTCEA OBJECTIVES

CONTEXTE ET POSITIONNEMENT PAR RAPPORT À LA STRATÉGIE INTERNE

� 1st large scale feedback on FC stack based on bipolar plate developed at CEA,

CEA activities in HYWAY:• Analysis of the fleet’s data (vehicle data, FC system data)• Optical and electrochemical analysis of the degradation MEA,• Replacing original MEA by MEA made in CEA,

Beyond HYWAY:• Specific test and characterization to capitalize data and feedback on

FC system in real usage

• CEA is involved in the preparation of Grenoble site for local H2 production (HYWAY 2)


WORKING METHOD

Understand

Measure

Analyze

ModelSimulate

Experiment

Apply

CharacterizeQuantify

Validate

Optimize

Deploy

IndustrialPartners


FLEET DATA ANALYSISDATA RECOVERY AND PROCESSING

Automatic data recovery

Processing line


FLEET DATA ANALYSISDIFFERENT LEVEL OF ANALYSIS

second, minute, hour day, month, year

Level 1:Temporal data analysis

Level 2:Periodic data analysis

Level 3:Global fleet data analysis

Inter-vehiclecomparison

Usage, performance group, etc.


FLEET DATA ANALYSISEXAMPLE OF RESULTS

Full hybrid

batterypredominant

Hydrogenpredominant

Low usage

Data acquisition still in progress


FLEET DATA ANALYSISEXAMPLE OF RESULTS

Data acquisition still in progress


BEYOND HYWAYSPECIFIC INSTRUMENTATION

• Use of FCMS (Fuel Cell Monitoring System) developed in CEA• Current • Voltage• Qair• …

� Knowledge of the real temporal operating point� Hydrogen balance, system efficiency, hybridization rate

On boardData logger

Current, Voltage sensorFCMS


BEYOND HYWAYSPECIFIC INSTRUMENTATION

� Following up of the operating point evolution� Statistical analyze of the data� Identification of degradations signature

In progress


BEYOND HYWAYSPECIFIC TESTS

• Periodic test on stack• Measurement of the performance evolution

Using polarisation curves Using Cyclic voltammetry



• Periodic samples water (from cathodic exhaust)

• Analysis of samples• Ion chromatography:

• F- Concentration

• ICP-MS• Catalyst: Pt, Co• Bipolar plate component: Fe, Cr, Ni, etc.

• Checking with data recorded on a single cell on test bench

Kangoo during water sampling



• Postmortem analysis• Identification of degradation occurring in the different components of

MEA and in bipolar plate


BEYOND HYWAYLINK WITH OTHER ACTIVITIES

Tech-Eco Studies on Hydrogen components

H2 Vehicles Monitoring

Specification

• Product definition• Manufacturing

process definition

Cost Database

• From suppliers’ quotations and literature

• Covers Rawmaterials, consumables, Production equipment and tools, Labour, Misc.

Cost Model

• Activity BasedCosting Method

Multiscale & multiphysics Modeling

H2 Station Monitoring


• CEA is following one of the biggest fleet of hydrogen vehicles in Europe• After 12 months of experiment:

• More than 190 000 km traveled• More than 1200 H2 refueling

• 1/3 of the vehicle in operation are intensively used• 1/3 of the fleet is moderately used• 1/3 of the fleet is poorly used• The global usage of the vehicle is increasing (user adaptation period to

this new technologies)• A lot of data are recorded at different scale to capitalize over the use of

PEMFC stack in real conditions.• These data will be used to optimise fuel cell system operation and to prepare

the next generation of fuel cell system

HYWAY PERSPECTIVES

IMPROVEMENT OF FUEL CELL SYSTEM FOR AUTOMOTIVE APPLICATIONS

HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016


• Fuel cell system needs to be improved before a mass ive deployment

IMPROVEMENT OF FUEL CELL SYSTEM FOR AUTOMOTIVE APPLICATIONS

1. Decrease of system cost 2. Increase the overall system efficiency 3. Increase the durability of fuel cell system and fuel cell stack

Sources : D.O.E. & EU FCH-JU road map


DECREASE OF COST FUEL CELL SYSTEM

~50%

50 % of stack cost is due to catalyst � Need to reduce catalyst loading and/or to

replace platinum by less expensive materials

� Increase of stack power density = decrease of number of components and as a consequence the cost of stack

50 % of system cost is due to stack

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COST : DECREASE OF PLATINUM LOADING

Mat

urity

leve

l

Optimisation of platinum utilisation: Structuration of platinum supported electrode by physical deposition and electrode formulation

Example: MEA with 0.2 mgPt/cm²total loading (vs 0,5 mg/cm² ref, loading)

� no significant degradation after more than 2500 hours of operation in representative transportation conditions

Non platinum catalyst • Nitrogen doped catalyst,

A. Morozan, et al., Energy Environ. 2011 ; A. Morozan et al., ChemSusChem 2012.

• Bio-inspired Ni catalyst,….

Nanos-structured platinum catalyst• Core-shell structure,Galbiati et al., Electrochemica Acta 2014, 125, 107-116.

• Platinum nanotubesLepesant M. thesis 2014

• Mettalic alloy (PtNi; PtNiAu,…)

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DECREASE OF COST :IMPROVEMENT OF STACK POWER

• Improvement of stack power is another key point to reduce the fuel cell stack cost and to facilitate s ystem integration. • Optimise water management at MEA scale• Optimise mass transport limitation through bipolar plates

optimisation and through electrode manufacturing

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STRUCTURATION OF MEAS FOR WATER MANAGEMENT OPTIMISATION

L. Jabbour et al., Feasibility of in-plane GDL structuration: Impact on current density distribution in large-area Proton Exchange Membrane Fuel Cells, Journal of Power Sources, 299, 380-390, (2015)

Classical MEA: Homogeneous hydrophilic properties within the surface

Low current densities due to membrane dryingDecrease of catalytic utilisation

Homogenisation of current within the surface

Optimisation of hydrophilic properties over the surface by adding a gradient

Increase of hydrophobic properties

Air in

H2 out

H2 in

H2 out

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STACK & BIPOLAR PLATE CONCEPTION

ACTIVE AREA DESIGN

QUALIFICATIONFLUIDIC MODELING

HOMOGENEITY OF FLOW DISTRIBUTION WITHIN THE

CHANNELSCHANNEL/RIB DESIGN MODELLING

BIPOLAR PLATE CAD

Material selection, gasket geometry, fluids inlet/outlet,

coating technology…

OUTPUTSPpile

Rendement pileUpile min/max

CourantSurface active

Pertes de charges

INPUTSPsystème

Rendement systUpile min/max

Densité de puissanceConditions opératoires

PRELIMINARY SIZING VS. SPECIFICATIONS

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EXAMPLE OF MODELLING COMBINED WITH EXPERIMENTAL VALIDATION

Electrochemical and Thermal modelling of PEMFC stack including all components and with simplified water transport model

Measurement of water distribution within stack in real operating conditions @ NIST

SIM

ULAT

ION

EX

PE

RIE

NC

E

• Good correlation between experimental and simulation results

• Water distribution mainly linked to temperature distribution within the MEA surface.

F. Nandjou et al., IJHE, 41 (2016) 15573-15584

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STACK DEVELOPMENTS

• Optimisation of MEA performances • Optimisation of bipolar plates performances • Decrease of the mass and volume of bipolar plates

ANR H2PAC GENEPAC

Industrial THERMOPAC

Program

Industrial NEIGE Program

Improvement of stack power density

> DOE & EU targets

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DURABILITY ISSUES

Improvement of stack durability:

� Understanding of degradation phenomena occurring in real operation (Hyway

feedback)

� Mitigate degradation by

� materials designing

� and by optimisation of system control

Improvement of stack durability:

� Understanding of degradation phenomena occurring in real operation (Hyway

feedback)

� Mitigate degradation by

� materials designing

� and by optimisation of system control

Sources : D.O.E. & EU FCH-JUroad map

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EVIDENCE OF HETEROGENEOUS DEGRADATION OF MEAAGED UNDER AUTOMOTIVE CONDITIONS

Laure Guétaz, Sylvie Escribano, Olivier Sicardy, Journal of Power Sources 212 (2012) 169-178

Aged MEAFresh MEA

XRD : 6 nmXRD : 3 nm

At air outlet (& H 2 inlet): high H 2O content induces classical Electrochemical Ostwald ripening

Aged MEAFresh MEA

XRD : 13 nmXRD : 3 nm

At air inlet (& H 2 outlet): fuel starvation induces reverse current mechanism

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Commercial

FGLs+MWCNTs

IMPROVEMENT OF MATERIALS DURABILITY : DECREASE OF CARBON CORROSION

• Carbon corrosion occurs in fuel cell due to • Oxidant atmosphere• Start/stop

• Carbon corrosion induces • Loss of platinum (decrease of platinum surface)• Loss of porosity

• More resistant carbon for fuel cell electrode manufacturing• Carbon nanotubes • Graphene layer

FGL

MWCNT

Increase of electrode stability

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EMS: OPTIMAL PREDICTIVE ENERGY MANAGEMENT FUNCTION OF FUEL CELL STATE OF HEALTH (SOH)

R. da Fonseca et al., Fundamental and Developments of Fuel Cell Conference (FDFC), Karlsruhe, 2013.

Modeling of degradation phenomena based on experimental studies:

Catalyst surface losses

10 5,02 % 11.9

5 4,95 % 12.1

1 4,3 % 13.3

( )% 0tSoH∆ kmHg2

As fuel cell is used in a hybrid configuration, we have one degree of liberty to manage the power between the fuel cell and batteryand maintain the fuel cell in targeted conditions

High potential: Ostwald ripening

High current: Starvation Hot point

Optimum durability

Pt d

egra

datio

nra

te (

m²/

s)

Stack power output (/W)

� Decrease of degradation using an optimised control command strategy

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CONCLUSION

PEMFC is mature technology for automotive applicati ons.- Beginning of commercialization by OEM

Main achievements after ten years of R&D : - Decrease of platinum content without performance losses (/3)- Lifetime (at least 2500 hours) - Pmax about 1W/cm2 at stack level (x2)- Stack power density :3,5 kW/L (x2.5)

� Technology ready for early deployment

� Further R&D needed to fulfill manufacturers targets - Cost decrease (low platinum /platinum free catalyst,…)- Life Cycle Analysis (LCA)- Improved durability (by X2 to X3) - Feedback from field testing to orientate accurately R&D

Commissariat à l’énergie atomique et aux énergies alternatives17 rue des Martyrs | 38054 Grenoble Cedexwww-liten.cea.fr

Établissement public à caractère industriel et commercial | RCS Paris B 775 685 019

Thanks to CEA team involved in PEMFCdevelopment Thank you for your attention

Contact: [email protected]é[email protected]

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