Periodic Reporting for period 2 - MORELife (Material, Operating strategy and REliability optimisation for LIFEtime improvements in heavy duty trucks)
Okres sprawozdawczy: 2023-03-01 do 2025-02-28
Overall, the MORELife project aims to understand cause-and-effect relationships in heavy-duty (HD) stacks, implement innovative modeling approaches, and determine specifications for next-generation membrane electrode assemblies (MEAs) for HD applications.
Objective 1: Develop a multi-pronged approach using baseline technology to understand and mitigate durability and degradation issues of HD stack components. This includes small-scale testing and mechanistic modeling, with protocols and models for catalyst degradation. The synthesis and optimization of catalysts with reduced platinum loading, particularly the Gen 3c catalyst, led to promising performance and durability improvements. Extensive tests and post-mortem analyses were conducted to understand degradation processes. Advanced methods for real-time diagnostics and simulation of real-world driving conditions were developed.
Objective 2: Advanced experimental analyses of baseline technologies using detailed analysis, single-cell testing of small-active-area MEAs, short stack testing for systematic screening of beyond baseline MEAs, and in/ex situ characterization methods. An Accelerated Stress Test (AST) protocol was developed to test material properties, targeting copper leaching and enabling rapid durability screening. Several models, including a spatially resolved performance model for LT-PEMFC, a 1D platinum catalyst degradation model, and a bimetallic catalyst degradation model, were developed, parameterized, and validated. MEB conducted 30 syntheses of catalysts to optimize composition and size of metallic particles. The best catalysts were integrated into MEAs and tested for performance and durability. SEM and TEM images documented structural changes. Tests showed that baseline materials meet MORELife goals, while the Gen 3c catalyst showed promising results with reduced platinum loading.
Objective 3: Analyze real-world data from HD vehicles to identify predominant degradation stimuli and failure modes based on stack operation conditions and transients. Material-specific ASTs were developed to provide critical data for a global degradation model for baseline MEAs. These protocols enable rapid durability screening and improve material durability. Analysis of real vehicle data provided insights into degradation stimuli and failure modes, which were used to develop AST protocols. Results were integrated into the global degradation model to enhance understanding of degradation processes and improve material durability.
Objective 4: Design a beyond-baseline MEA tailored for HD applications, featuring innovative core-shell catalysts, advanced gas diffusion layers (GDLs), and reinforced membranes with tailored thickness and chemical stabilization. MEB conducted extensive synthesis and optimization of catalysts, focusing on core-shell structures to enhance performance and durability. Advanced GDLs were developed using novel hydrophobization methods without fluorinated polymers, improving system morphology and stability. Reinforced membranes were designed with tailored thickness and chemical stabilization to withstand harsh conditions. Integration of these components into MEAs was tested for performance and durability, showing promising results with reduced platinum loading and improved stability. This comprehensive approach contributed to a highly durable and efficient MEA for HD applications.
Objective 1: Develop a multi-pronged approach using baseline technology to understand and mitigate durability and degradation issues of HD stack components. This includes small-scale testing and mechanistic modeling, with protocols and models for catalyst degradation. The synthesis and optimization of catalysts with reduced platinum loading, particularly the Gen 3c catalyst, led to promising performance and durability improvements. Extensive tests and post-mortem analyses were conducted to understand degradation processes. Advanced methods for real-time diagnostics and simulation of real-world driving conditions were developed.
Objective 2: Advanced experimental analyses of baseline technologies using detailed analysis, single-cell testing of small-active-area MEAs, short stack testing for systematic screening of beyond baseline MEAs, and in/ex situ characterization methods. An Accelerated Stress Test (AST) protocol was developed to test material properties, targeting copper leaching and enabling rapid durability screening. Several models, including a spatially resolved performance model for LT-PEMFC, a 1D platinum catalyst degradation model, and a bimetallic catalyst degradation model, were developed, parameterized, and validated. MEB conducted 30 syntheses of catalysts to optimize composition and size of metallic particles. The best catalysts were integrated into MEAs and tested for performance and durability. SEM and TEM images documented structural changes. Tests showed that baseline materials meet MORELife goals, while the Gen 3c catalyst showed promising results with reduced platinum loading.
Objective 3: Analyze real-world data from HD vehicles to identify predominant degradation stimuli and failure modes based on stack operation conditions and transients. Material-specific ASTs were developed to provide critical data for a global degradation model for baseline MEAs. These protocols enable rapid durability screening and improve material durability. Analysis of real vehicle data provided insights into degradation stimuli and failure modes, which were used to develop AST protocols. Results were integrated into the global degradation model to enhance understanding of degradation processes and improve material durability.
Objective 4: Design a beyond-baseline MEA tailored for HD applications, featuring innovative core-shell catalysts, advanced gas diffusion layers (GDLs), and reinforced membranes with tailored thickness and chemical stabilization. MEB conducted extensive synthesis and optimization of catalysts, focusing on core-shell structures to enhance performance and durability. Advanced GDLs were developed using novel hydrophobization methods without fluorinated polymers, improving system morphology and stability. Reinforced membranes were designed with tailored thickness and chemical stabilization to withstand harsh conditions. Integration of these components into MEAs was tested for performance and durability, showing promising results with reduced platinum loading and improved stability. This comprehensive approach contributed to a highly durable and efficient MEA for HD applications.
A voltage cycling AST protocol was developed to trigger extensive Cu leaching for fast durability screening. Models for LT-PEMFC performance, 1D Platinum catalyst degradation, membrane degradation, and bimetallic catalyst degradation were created and parametrized. These models estimated ECSA loss due to heavy-duty load cycles and investigated Cu leaching in MORELife PtCux catalysts, highlighting the importance of Pt shell thickness and catalyst particle size. Efforts aimed to enhance MEA durability and efficiency for HD fuel cell systems through innovative materials, optimized strategies, and new manufacturing processes. This included synthesizing PtCu alloy catalysts, conducting stress tests, developing numerical models for MEA degradation, exploring fluorine-free hydrophobic treatments for gas diffusion layers, and using inkjet printing for precise catalyst layer deposition. Key findings included reduced platinum usage while maintaining performance and improved chemical stability of new membranes. Thirty catalyst syntheses optimized gel precursor composition, annealing process parameters, and post-synthesis Cu leaching, with data stored in a repository. Generations of ORR catalysts with varying Pt content were reported. CCMs with active areas of 25 cm² and 50 cm² were prepared for single cell tests. Efforts replaced fluorinated materials in GDLs and MPLs with organosilicon- and hydrocarbon-based alternatives, achieving hydrophobicity without morphology changes and comparable performance. ASTs were applied on baseline material and catalysts, with ex-situ analysis. AST membrane testing and heavy-duty ADT were conducted on a short stack with baseline material. Development and validation of a short stack with advanced catalyst materials faced challenges, but comparative testing outlined implications based on single cell measurements. An online diagnostics methodology was developed to evaluate fuel cell durability, creating a digital twin of the fuel cell stack and a virtual vehicle model, integrating advanced diagnostic tools for real-time simulation and long test cycles, optimizing conditions to improve efficiency and reduce cell voltage spread. Vehicle-level optimization refined control strategies to balance performance and durability, providing insights for system integrators
The MORELife project has significantly impacted the hydrogen industry and society through various exploitation activities. Mebius expanded its production capabilities from 67 m² to 515 m², focusing on reducing MEA production costs by addressing key cost drivers. They plan to produce 30,000 Catalyst Coated Membranes (CCMs) per year using advanced technologies. AVL integrated a multi-scale modeling framework into its diagnostic toolchain, enhancing fuel cell data analysis. EKPO accelerated product development for heavy-duty vehicles, aiming to optimize operational strategies and reduce time to market. TU/e and TUM advanced research on fuel cell degradation, supervised students, and submitted a patent for a PFAS-free Gas Diffusion Layer, with plans to publish findings. UL developed a multi-scale modeling framework for transient fuel cell analysis, aimed at improving system reliability, lifetime, and performance, with applications in various sectors. UL plans for commercial licensing, consulting services, and training modules. These activities contribute to significant market opportunities, infrastructure expansion, and the sustainable development of the hydrogen-powered transportation sector, positioning the partners to lead the transition towards a hydrogen-powered future. The project’s innovations will support decarbonization, improve air quality, and drive the market forward, with government incentives and growing demand for clean energy solutions playing a crucial role.