Periodic Reporting for period 1 - RealHyFC (reliable durable high power hydrogen fueled PEM Fuel Cell stack)
Período documentado: 2023-06-01 hasta 2024-11-30
RealHyFC aims to reach required performance targets with proton exchange membrane fuel cells (PEMFC) stacks towards cost-competitive exploitation for heavy-duty transport.
This will be done relying on key improvements: i) new stable stack design, taking advantage of the two consolidated technologies with carbon and metal bipolar plates (BPPs) (from respectively stationary and light duty applications), coupled to ii) improved balance of stack (BoS), to hinder irreversible degradation of components, and iii) optimized operational monitoring options precluding evitable performance losses.
In line with the goals of the Clean Hydrogen SRIA, the solutions proposed will demonstrate expected KPIs in terms of efficiency, performance (>1W/cm² at 0.675V) and durability (projected more than 20,000 hrs with less than 10% losses), assessed in both representative conditions and scale (based on HD use-cases with at least 280 cm² cells in stacks of 3 to 10 kW), thus eventually bringing to TRL5 the technical objects and tools developed at stack level and at stack / system interface.
RealHyFC will deliver evidence-based insights and models characterizing the escalation of reversible and non-reversible losses attributed to critical characteristics of the HD case:
-enhanced physical degradation of the core components of the unit cell (leading to non-reversible losses) with significant risk of actual corrosion due to longer and harsher usage;
-increased local issues due to appreciable heterogeneities associated to the required large surface area for the high power demand and coupled to driving cycles;
-more challenging control of operating conditions at stack / system interface within acceptable boundaries for preventing faults and sustaining ultra-low requirements for degradation rates.
The investigations and further developments will be started using metallic BPP, and going towards carbon based BPP.
Preventing the stack components local degradations as well as better controlling the stack operation to hinder conditions promoting reversible or non-reversible losses are selected predominant means to improve stacks lifetime. While primarily enabling HDV-specific improvements aiming at selected use-cases, RealHyFC Research and Innovation activities will also give rise to generic ideas and will provide versatile solutions, enabling the PEMFC stack as a building-block foreseen for all HD transport. This will be achieved by including an open-design approach and understanding-based-developments.
Specific objectives defined to build the project actions toward final goal are the following:
Objective 1 - Identify, for the metal and carbon stack platforms defined as reference, the performance and durability issues for heavy duty transport applications.
Objective 2 - Development of model-based new diagnostics and monitoring tools towards optimized hybridization and operating strategies
Objective 3 - Improve two key complementary items of the stack itself: best suited bipolar plates to prevent corrosion risks and optimized mechanical assembling to overcome heterogeneities issues to further enhance stack durability.
Objective 4 - Demonstrate performance and durability improvements in representative conditions at stack scale.
Objective 5 - Lower the risk related to the industrial empowerment on RealHyFC results, identify pain points, how RealHyFC addresses them and ensure the industrial exploitation. Accelerate awareness on H2 for HD applications in all relevant scopes (industries, regulatory bodies, policy makers, citizens).
This will be done relying on key improvements: i) new stable stack design, taking advantage of the two consolidated technologies with carbon and metal bipolar plates (BPPs) (from respectively stationary and light duty applications), coupled to ii) improved balance of stack (BoS), to hinder irreversible degradation of components, and iii) optimized operational monitoring options precluding evitable performance losses.
In line with the goals of the Clean Hydrogen SRIA, the solutions proposed will demonstrate expected KPIs in terms of efficiency, performance (>1W/cm² at 0.675V) and durability (projected more than 20,000 hrs with less than 10% losses), assessed in both representative conditions and scale (based on HD use-cases with at least 280 cm² cells in stacks of 3 to 10 kW), thus eventually bringing to TRL5 the technical objects and tools developed at stack level and at stack / system interface.
RealHyFC will deliver evidence-based insights and models characterizing the escalation of reversible and non-reversible losses attributed to critical characteristics of the HD case:
-enhanced physical degradation of the core components of the unit cell (leading to non-reversible losses) with significant risk of actual corrosion due to longer and harsher usage;
-increased local issues due to appreciable heterogeneities associated to the required large surface area for the high power demand and coupled to driving cycles;
-more challenging control of operating conditions at stack / system interface within acceptable boundaries for preventing faults and sustaining ultra-low requirements for degradation rates.
The investigations and further developments will be started using metallic BPP, and going towards carbon based BPP.
Preventing the stack components local degradations as well as better controlling the stack operation to hinder conditions promoting reversible or non-reversible losses are selected predominant means to improve stacks lifetime. While primarily enabling HDV-specific improvements aiming at selected use-cases, RealHyFC Research and Innovation activities will also give rise to generic ideas and will provide versatile solutions, enabling the PEMFC stack as a building-block foreseen for all HD transport. This will be achieved by including an open-design approach and understanding-based-developments.
Specific objectives defined to build the project actions toward final goal are the following:
Objective 1 - Identify, for the metal and carbon stack platforms defined as reference, the performance and durability issues for heavy duty transport applications.
Objective 2 - Development of model-based new diagnostics and monitoring tools towards optimized hybridization and operating strategies
Objective 3 - Improve two key complementary items of the stack itself: best suited bipolar plates to prevent corrosion risks and optimized mechanical assembling to overcome heterogeneities issues to further enhance stack durability.
Objective 4 - Demonstrate performance and durability improvements in representative conditions at stack scale.
Objective 5 - Lower the risk related to the industrial empowerment on RealHyFC results, identify pain points, how RealHyFC addresses them and ensure the industrial exploitation. Accelerate awareness on H2 for HD applications in all relevant scopes (industries, regulatory bodies, policy makers, citizens).
PEMFC reference metallic stacks and a new graphite composite stack have been defined and manufactured. One common suitable project-specific MEA was defined for all the stack platforms identified for the investigations and technical solutions developments: Commercial Design Metal (CDM), Open Design Metal (ODM) and Open Design Carbon (ODC).
Relevant test protocols for the quantification of performance and durability testing, were defined including a heavy-duty cycle relevant for the application. One particularly remarkable initial result is the very good similarity of performance for the two metallic stack platforms, also showing a very good reproducibility of tests conducted at three partners. This result allowed to confirm the right level of performance of the newly tested open-design, compared to the state-of-the-art design and to get confidence in the data base to be used for the further developments. The study and impact of heterogeneities within the stacks started with first simulations and measurements on the ODM stack.
An extension of catalyst degradation modelling framework to accommodate bimetallic nanoparticles was performed, along with the introduction of a model reduction strategy to optimize simulation performance. Additionally, the metal BPP corrosion model was enhanced, enabling more accurate predictions. Machine learning techniques were implemented to estimate Remaining Useful Life (RUL) and State of Health (SoH), with comparisons conducted across multiple approaches. To improve computational efficiency in energy management systems (EMS), Reduced Order Models (ROMs) were created, and a spatially resolved operational condition observer was developed to provide real-time insights. Furthermore, advanced models and test systems were utilized to simulate real-world conditions, integrating virtual sensors and digital twin models for real-time operational condition assessments.
Regarding best-suited BPP, an open design for graphite composite was devised based on and with best achievable comparability to the open metal design of the project. This graphite composite open design will enable first direct valuable comparison between metal and graphite composite technology. Furthermore, this reference carbon composite design will form the basis for the development of an optimized stack featuring improved BoS components and BPPs to enhance homogeneity and durability. Significant progress on the characterization of the mechanical properties of the components and modelling of constraints within large stacks is enabling better understanding of issues related to the inhomogeneity and to prepare improvements mitigating the latter.
Our communication and dissemination activities are done to raise awareness around the H2 market and the PEMFC developments realised during the project. Significant communication activities through social media as well as a first successful workshop dedicated to industry stakeholders, in parallel to active synergies with sister projects allowed to pave the way towards our eventual objective of supporting future industrial empowerment on RealHyFC results.
Relevant test protocols for the quantification of performance and durability testing, were defined including a heavy-duty cycle relevant for the application. One particularly remarkable initial result is the very good similarity of performance for the two metallic stack platforms, also showing a very good reproducibility of tests conducted at three partners. This result allowed to confirm the right level of performance of the newly tested open-design, compared to the state-of-the-art design and to get confidence in the data base to be used for the further developments. The study and impact of heterogeneities within the stacks started with first simulations and measurements on the ODM stack.
An extension of catalyst degradation modelling framework to accommodate bimetallic nanoparticles was performed, along with the introduction of a model reduction strategy to optimize simulation performance. Additionally, the metal BPP corrosion model was enhanced, enabling more accurate predictions. Machine learning techniques were implemented to estimate Remaining Useful Life (RUL) and State of Health (SoH), with comparisons conducted across multiple approaches. To improve computational efficiency in energy management systems (EMS), Reduced Order Models (ROMs) were created, and a spatially resolved operational condition observer was developed to provide real-time insights. Furthermore, advanced models and test systems were utilized to simulate real-world conditions, integrating virtual sensors and digital twin models for real-time operational condition assessments.
Regarding best-suited BPP, an open design for graphite composite was devised based on and with best achievable comparability to the open metal design of the project. This graphite composite open design will enable first direct valuable comparison between metal and graphite composite technology. Furthermore, this reference carbon composite design will form the basis for the development of an optimized stack featuring improved BoS components and BPPs to enhance homogeneity and durability. Significant progress on the characterization of the mechanical properties of the components and modelling of constraints within large stacks is enabling better understanding of issues related to the inhomogeneity and to prepare improvements mitigating the latter.
Our communication and dissemination activities are done to raise awareness around the H2 market and the PEMFC developments realised during the project. Significant communication activities through social media as well as a first successful workshop dedicated to industry stakeholders, in parallel to active synergies with sister projects allowed to pave the way towards our eventual objective of supporting future industrial empowerment on RealHyFC results.
Expected results with high potential impact to be considered for further exploitation are the following:
Stacks with higher durability (lower degradation rates) and reliability.
New carbon-composite open design BPPs and fuel cell stacks, with optimized BoS, combining advantages of both metal and carbon designs.
Validated open development platforms (ODC designs will be made fully available as Open Access).
New mechanical model implemented in multi-physics simulation models.
New monitoring and control tools (thanks to physically based degradation models, virtual state observers and algorithms of optimization)
New characterization methods, simulation and testing protocols.
Exploitation roadmap for HD industries.
Stacks with higher durability (lower degradation rates) and reliability.
New carbon-composite open design BPPs and fuel cell stacks, with optimized BoS, combining advantages of both metal and carbon designs.
Validated open development platforms (ODC designs will be made fully available as Open Access).
New mechanical model implemented in multi-physics simulation models.
New monitoring and control tools (thanks to physically based degradation models, virtual state observers and algorithms of optimization)
New characterization methods, simulation and testing protocols.
Exploitation roadmap for HD industries.