ROBUST PEMFC MEA DERIVED FROM MODEL-BASED UNDERSTANDING OF DURABILITY LIMITATIONS FOR HEAVY DUTY APPLICATIONS

Project Information

PEMTASTIC

Grant agreement ID: 101101433

DOI

10.3030/101101433

EC signature date 16 January 2023

Start date 1 February 2023

End date 30 November 2026

Funded under

• Climate, Energy and Mobility

Total cost

€ 2 748 608,75

EU contribution

€ 2 748 608,50

Coordinated by

DEUTSCHES ZENTRUM FUR LUFT - UND RAUMFAHRT EV
Germany

Periodic Reporting for period 1 - PEMTASTIC (ROBUST PEMFC MEA DERIVED FROM MODEL-BASED UNDERSTANDING OF DURABILITY LIMITATIONS FOR HEAVY DUTY APPLICATIONS)

Reporting period: 2023-02-01 to 2024-07-31

Summary of the context and overall objectives of the project

To overcome durability hurdle of polymer electrolyte membrane fuel cells (PEMFC) for heavy duty applications and in line with the Strategic Research and Innovation Agenda (SRIA) of the Clean Hydrogen Joint Undertaking, new application-tailored component materials, cell designs and operating strategies must be developed.
The purpose of the PEMSTATIC project which aims at bringing to technology readiness level (TRL) 4 the highly innovative concept of durable heavy-duty membrane electrode assembly (MEA) derived from enhanced degradation models and addressing the different sub-components of the catalyst coated membrane (CCM) and their interactions.
Specifically, PEMTASTIC aims to meet the key technical challenges to increase durability of membrane-electrode assembly (MEA) for heavy-duty applications. These challenges are approached with a combination of model-based design and the development of a durable catalyst coated membrane using innovative materials tailored for heavy duty operation at high temperature (105°C). The quantitative targets correspond to a durability of 20,000 hours maintaining a state-of the art power density of 1.2 W/cm2@0.65 V at a Pt loading of 0.30 g/kW.
The individual objectives of the project are:
Objective 1: Define fuel cell operation protocols and cycling tests for heavy duty application and propose operation strategy for high fuel efficiency.
Objective 2: Parameterisation of degradation models to predict MEA lifetime and identify specific improvements of the CCM and its components.
Objective 3: Development of robust catalyst support and deposition process for catalysts.
Objective 4: Development of membrane and ionomer for operation at increased temperature
Objective 5: Catalyst layers and CCM with increased durability and state-of-the art performance tailored for heavy duty operation
Objective 6: Ensure the dissemination of the project results and the promotion of the project, through ad-hoc strategies through target groups and key stakeholders and define the exploitation strategy of the PEMTASTIC outcome.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

During the first period, protocols for testing of materials as well as single cells and stacks were defined. They are available as a public report and have been shared with other CleanH2 projects related to MEA or stack development. In-situ and ex-situ tests to parametrize degradation models were extensively discussed between modelers and experimentalists. A multiscale modelling approach is being developed which describes cell performance and degradation processes from the mesoscale up to the single cell. Mesoscale models of the cathode catalyst layer have been developed. This is to consider local degradation reactions on the carbon support and the platinum catalyst nanoparticles. The micro-kinetics of the oxygen reduction reaction, carbon corrosion, and hydrogen peroxide formation are accounted. Moreover, a microstructure-resolved model of the catalyst layer degradation due to Ostwald ripening has been developed to link the material properties of the catalyst layer with the degradation rate. A continuum-scale catalyst layer degradation model was implemented to simulate the degradation-related change in platinum particle size distribution, the associated change in electrochemical surface area. Additionally, the dynamics of chemical membrane degradation was studied involving radical attack of the membrane. These degradation models will be coupled with the continuum-scale performance models to simulate their impact on performance. New testing protocols have been implemented into testbenches and validated and revised to achieve reproducibility among testing partners. A commercial MEA from IRD was used to realize first durability tests up to 1,500 h using the developed PEMTATIC HD-load cycle along with in-situ characterization protocols and ex-situ material analysis. Based on these tests the reproducibility was assessed. Eventually, issues were solved and good reproducibility was achieved. To develop heavy duty tailored MEAs, innovative materials from IMERYS, Heraeus and Chemours were used to design the first generation of project MEAs (Gen1 MEA). Moreover, promising candidate materials for Gen2 MEA were identified and fixed to start production of Gen2 MEA. Tests with Gen1 MEA will be used to improve degradation models. Model-based input will be used during implementation of adaptation when going from Gen2 to Gen3 MEA.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Expected outcomes beyond state of the art:
• FCs suitable for HDV: increase of MEA lifetime to >20,000 h at operation temperature >100°C
• Model-based development to become integral part of MEA development in Europe, allowing speeding-up market penetration of FC technologies in on-road (trucks) and off-road mobility (ships, trains, planes).
• Model-based MEA health-monitoring in HDVs: the durability and availability of HDV systems will be enhanced by identification of failures of the MEA and by adaption of the fuel cell control logic.
• Recommendations on system components & operation strategy to achieve high fuel efficiency.
• Protocols harmonization at EU level: common FC testing (through exchanges with other networks activities) protocols and ASTs will be established
Expected results:
• Achievement of SRIA KPIs Nr. 3, 5, and 6 for HDV FC building blocks (2024 targets / Low TRL)
• Model-guided innovation (digitalization) on CCM components with durability of >20'000 h for HDVs
• Establish strong link between ex-situ characterisation of MEAs, the modelling of degradation under HD operating conditions and MEA properties adaptation
• Parametrisation of MEA degradation models to reflect CCM material degradation properties
• Validated micro-/meso-/ and continuum scale MEA performance and degradation models.
• Definition of accelerated cycling and stress test protocols for HD cycles applications
• HDV FC system operation strategy driven by fuel efficiency and durability
Potential economic impacts:
• Market MEAs for upcoming future sectors of hydrogen mobility, not just on-road but also off-road (e.g. rail, maritime, etc.).
• Raise EU market shares of CCM components, analysis tools and MEAs for HDV applications.
• Raise of market share of analysis tools and computational solution via spin-off companies.
Potential societal impact:
• Decarbonisation of HDVs: Expected 17% of new truck sales in 2030 will be powered by PEMFCs leading to at least 25 Mt CO2 savings per year
• Jobs creation: doubled for MEAs value chain by 2030
Potential scientific / technological impact
• Uptake of the open-source MEA modelling approach by the scientific community and extension to account for lower-scale MEA material properties.
• Transfer multi-scale modelling approach to other fields of applications
• R&D project transferring PEMTASTIC results to other high-power applications

Project objectives and methodology

Model based approach of CCM development

Value chain and partners involved