Final Report Summary - EURECA (Efficient use of resources in energy converting applications)
Executive Summary:
The EURECA team develops the next generation of µ-CHP systems based on advanced PEM stack technology. The idea is to overcome the disadvantages of complex gas purification, gas humidification and the small temperature gradient for the heat exchangers in a heating system. In the EURECA project we will develop a new stack generation based on PEM technology with operating temperatures of 90°C to 120°C. Thus results in a less complicated and therefore in a more robust µ-CHP system with reduced costs. The development of a new stack generation includes various parallel working packages and tasks. During the EURECA project duration we will optimize materials to operate in that temperature range – including membrane and bipolar plate materials. Also the catalyst will be improved including a lower platinum load – with a design target of below 0.2 g/kW. The stack design and the flow field of the bipolar plates will be optimized for the intended operating conditions. All development steps will be supported by state-of-the-art modeling. As the final step the developed stack will be integrated in an adapted µ-CHP system to achieve proof-of-concept in the target application. Important part of the project is the validation of the design targets. The µ-CHP system – including the reformer – is expected to operate at an electrical efficiency of 40%. Lifetime tests with defined test procedures on single cells and short stacks will indicate a stack lifetime of approx. 12.000 h. In all development processes the partners have agreed to a design-to-cost approach. This includes the producibility in scalable production processes. A cost assessment will indicate the cost saving potential by the less complicated system. The consortium is well balanced along the supply chain. Component suppliers and system designers are backed by research institutions. The consortium agreed at the beginning of EURECA on specific quality and management procedures – including contingency planning and fall back solutions.
The overall dissemination and exploitation strategies of the EURECA project will be declared within this report. This report will show the already received dissemination and exploitation results of the project as well as the further planned activities. The aim is to:
• Have a close collaboration with related EU/FCH JU projects
to support their dissemination and spread the results
• Provide a homepage with the latest results and publications within the project
• Involve national/international experts to support and judge the results of the project e.g. within an EURECA project workshop
• Provide the results to the scientific community on national or international conferences, publication of journal articles, attending of other workshops, etc.
• Show the results to Industry and customers on e.g. technical fairs
• Prepare and take care to make the project results market ready
Within the project runtime changes in the realisation and implementation may appear, new possibilities might be available and adjustment is required. Therefore, a regularly update of the dissemination and exploitation plan is necessary.
Project Context and Objectives:
EURECA develops the next generation of µ-CHP systems based on advanced PEM stack technology. The idea is to overcome the disadvantages of complex gas purification, gas humidification and the low temperature gradient for the heat exchangers in a heating system. EURECA will develop a new stack generation based on PEM technology with operating temperatures of 90°C to 120°C. Thus results in a less complicated and therefore in a more robust µ-CHP system with reduced costs. The development of a new stack generation includes various parallel working tasks. EURECA will optimize materials to operate in that temperature range – including membrane and bipolar plate materials. Also the catalyst will be improved with a lower platinum loading – design target < 0.2g/kW. The stack design and the flow field of the bipolar plates will be optimized for the operating conditions. All development steps will be supported by state-of-the-art modeling. As the final step the developed stack will be integrated in an adapted µ-CHP system to achieve proof-of-concept in the target application. Important part of the project is the validation of the design targets. The µ-CHP system – including the reformer – is expected to operate at an electrical efficiency of 40%. Lifetime tests with defined test procedures on single cells and short stacks will indicate a stack lifetime of approx. 12.000 h. In all development processes the partners have agreed to a design-to-cost approach. This includes the producibility in series production processes. A cost assessment will indicate the cost savings by the less complicated system. The consortium is well balanced along the supply chain. Component suppliers and system designers are backed by research institutions. High quality of the development process is of top priority to all partners. Therefore the consortium will agree at the beginning of EURECA on specific quality and management procedures – including contingency planning measurements. The purpose of the project is to develop a µ-CHP system with reduced complexity. Therefore, a proof-of-concept and a higher electrical efficiency are among the objectives of EURECA. The development of new membrane material, catalyst material and higher performance at lower humidification and higher temperatures are further targets. The project is divided in five RTD work package: WP2 – Membrane Electrode Assembly (MEA), WP3 – Bipolar Plate (BPP) and Gaskets, WP4 – Stack and WP5 – System. All WPs are accompanied by simulation for different scenarios. Figure 1 gives an overview of the EURECA content.
The main objective of the Work Package 2 was to develop and produce new anode catalyst showing high tolerance to CO, new membrane with improved conductivity and mechanical properties, and finally MEAs designed for the operation of a PEMFC in the medium temperature (MT) range (90 to 120 °C) for a µ-CHP system supplied with hydrogen rich gas coming from the reforming of natural gas.
In parallel to these technological developments, extensive studies have been conducted thanks to dedicated and advanced experiments and modelling in order to understand the operation and durability of MT PEM.
n the project EURECA graphite composite based bipolar plates and gaskets for MT-PEM (up to 120 °C) fuel cells have been developed, manufactured and implemented in the EURECA stack and fuel cell system. Regarding the bipolar plate, state of the art where the project started was a consistent manufacturing process for LT-PEM materials with polypropylene binder and a successful proof of concept for MT-PEM bipolar plates based in the fluoro-polymer PVDF (polyvinylidene-fluoride) as a binder. Within the first half of the project, the partners developed PVDF bonded bipolar plates and characterized them with respect to electrical conductivity and mechanical stability at the anticipated temperatures.
The goal of WP4 was the development of a MT-PEM fuel cell stack based on the cell and stack design from the INHOUSE LT-PEM fuel cell stack. This development was guided by modelling data of flow rate and concentration distribution of the reactants and fluids made by FORTH and in addition by investigations using a segmented single cell made by FRAUNHOFER ISE. This new developed stack design was approved in performance and degradation tests of several short stacks with cell quantity of 5 to 8 cells (active area ~200 cm² per cell, Figure 14, right) equipped with 3 generations of MEA developed in WP2. At the end a full scale stack with 83 cells was realized (Figure 12, right) and used for the MT-PEM system integration done in WP5.
The goal of EURECA WP5 was the development of a MT-PEM µ-CHP system based on the system platform of inhouse. The main tasks were related to design issues and components developments to operate at MT-PEM Stack conditions. The work package also incorporated performance testing and degradation measurement. The adaption was guided by simulating system performance with a specific static model and intense pre-testing of developed balance of plant concepts and components. These preliminary works lead to the development, construction and testing of a MT-PEM System with the MT-PEM Full Stack from WP4.
n a first step, the EURECA partners analysed cost structure of the current system and evaluated the cost reduction potential for this specific type of fuel cell. A summary of the components has been set up and all project partners contributed with cost information, such as material, fabrication charges and available cost-volume information. As described in the section above there are considerable dependencies between different components within the fuel cell system. Consequently, not every cost saving of a single part contributes to overall cost reduction. The partners identified the most important interactions and identified critical cost parameters. Target of EURECA system design is a low overall cost of the fuel cell system. As starting point, cost structure of the current system without improvements from EURECA was analysed.
Within the first half of the EURECA project the partners analysed cost structures and collected data to determine further cost reduction in the case of technical improvements from EURECA and for a production volume of 1000 fuel cell systems per year. The coordinator collected cost information of all partners, in particular industrial partners, and summarized them. For confidentiality reasons these cost details were structured by the coordinator into the sections stack, MEA, Pt, reformer, BoP and others and then circulated to all partners.
The current cost information of the EURECA system for 1000 pcs/a is considered as an extrapolation. It shall be updated based on the technical results achieved in EURECA and possible changes in cost/volume information regarding components. Changes in price/volume data for components and precious metal prices on world market will be taken into account.
Project Results:
Please see attached publishable summary
Potential Impact:
See ExploitationPlan (confidential)
List of Websites:
www.project-eureca.com
The EURECA team develops the next generation of µ-CHP systems based on advanced PEM stack technology. The idea is to overcome the disadvantages of complex gas purification, gas humidification and the small temperature gradient for the heat exchangers in a heating system. In the EURECA project we will develop a new stack generation based on PEM technology with operating temperatures of 90°C to 120°C. Thus results in a less complicated and therefore in a more robust µ-CHP system with reduced costs. The development of a new stack generation includes various parallel working packages and tasks. During the EURECA project duration we will optimize materials to operate in that temperature range – including membrane and bipolar plate materials. Also the catalyst will be improved including a lower platinum load – with a design target of below 0.2 g/kW. The stack design and the flow field of the bipolar plates will be optimized for the intended operating conditions. All development steps will be supported by state-of-the-art modeling. As the final step the developed stack will be integrated in an adapted µ-CHP system to achieve proof-of-concept in the target application. Important part of the project is the validation of the design targets. The µ-CHP system – including the reformer – is expected to operate at an electrical efficiency of 40%. Lifetime tests with defined test procedures on single cells and short stacks will indicate a stack lifetime of approx. 12.000 h. In all development processes the partners have agreed to a design-to-cost approach. This includes the producibility in scalable production processes. A cost assessment will indicate the cost saving potential by the less complicated system. The consortium is well balanced along the supply chain. Component suppliers and system designers are backed by research institutions. The consortium agreed at the beginning of EURECA on specific quality and management procedures – including contingency planning and fall back solutions.
The overall dissemination and exploitation strategies of the EURECA project will be declared within this report. This report will show the already received dissemination and exploitation results of the project as well as the further planned activities. The aim is to:
• Have a close collaboration with related EU/FCH JU projects
to support their dissemination and spread the results
• Provide a homepage with the latest results and publications within the project
• Involve national/international experts to support and judge the results of the project e.g. within an EURECA project workshop
• Provide the results to the scientific community on national or international conferences, publication of journal articles, attending of other workshops, etc.
• Show the results to Industry and customers on e.g. technical fairs
• Prepare and take care to make the project results market ready
Within the project runtime changes in the realisation and implementation may appear, new possibilities might be available and adjustment is required. Therefore, a regularly update of the dissemination and exploitation plan is necessary.
Project Context and Objectives:
EURECA develops the next generation of µ-CHP systems based on advanced PEM stack technology. The idea is to overcome the disadvantages of complex gas purification, gas humidification and the low temperature gradient for the heat exchangers in a heating system. EURECA will develop a new stack generation based on PEM technology with operating temperatures of 90°C to 120°C. Thus results in a less complicated and therefore in a more robust µ-CHP system with reduced costs. The development of a new stack generation includes various parallel working tasks. EURECA will optimize materials to operate in that temperature range – including membrane and bipolar plate materials. Also the catalyst will be improved with a lower platinum loading – design target < 0.2g/kW. The stack design and the flow field of the bipolar plates will be optimized for the operating conditions. All development steps will be supported by state-of-the-art modeling. As the final step the developed stack will be integrated in an adapted µ-CHP system to achieve proof-of-concept in the target application. Important part of the project is the validation of the design targets. The µ-CHP system – including the reformer – is expected to operate at an electrical efficiency of 40%. Lifetime tests with defined test procedures on single cells and short stacks will indicate a stack lifetime of approx. 12.000 h. In all development processes the partners have agreed to a design-to-cost approach. This includes the producibility in series production processes. A cost assessment will indicate the cost savings by the less complicated system. The consortium is well balanced along the supply chain. Component suppliers and system designers are backed by research institutions. High quality of the development process is of top priority to all partners. Therefore the consortium will agree at the beginning of EURECA on specific quality and management procedures – including contingency planning measurements. The purpose of the project is to develop a µ-CHP system with reduced complexity. Therefore, a proof-of-concept and a higher electrical efficiency are among the objectives of EURECA. The development of new membrane material, catalyst material and higher performance at lower humidification and higher temperatures are further targets. The project is divided in five RTD work package: WP2 – Membrane Electrode Assembly (MEA), WP3 – Bipolar Plate (BPP) and Gaskets, WP4 – Stack and WP5 – System. All WPs are accompanied by simulation for different scenarios. Figure 1 gives an overview of the EURECA content.
The main objective of the Work Package 2 was to develop and produce new anode catalyst showing high tolerance to CO, new membrane with improved conductivity and mechanical properties, and finally MEAs designed for the operation of a PEMFC in the medium temperature (MT) range (90 to 120 °C) for a µ-CHP system supplied with hydrogen rich gas coming from the reforming of natural gas.
In parallel to these technological developments, extensive studies have been conducted thanks to dedicated and advanced experiments and modelling in order to understand the operation and durability of MT PEM.
n the project EURECA graphite composite based bipolar plates and gaskets for MT-PEM (up to 120 °C) fuel cells have been developed, manufactured and implemented in the EURECA stack and fuel cell system. Regarding the bipolar plate, state of the art where the project started was a consistent manufacturing process for LT-PEM materials with polypropylene binder and a successful proof of concept for MT-PEM bipolar plates based in the fluoro-polymer PVDF (polyvinylidene-fluoride) as a binder. Within the first half of the project, the partners developed PVDF bonded bipolar plates and characterized them with respect to electrical conductivity and mechanical stability at the anticipated temperatures.
The goal of WP4 was the development of a MT-PEM fuel cell stack based on the cell and stack design from the INHOUSE LT-PEM fuel cell stack. This development was guided by modelling data of flow rate and concentration distribution of the reactants and fluids made by FORTH and in addition by investigations using a segmented single cell made by FRAUNHOFER ISE. This new developed stack design was approved in performance and degradation tests of several short stacks with cell quantity of 5 to 8 cells (active area ~200 cm² per cell, Figure 14, right) equipped with 3 generations of MEA developed in WP2. At the end a full scale stack with 83 cells was realized (Figure 12, right) and used for the MT-PEM system integration done in WP5.
The goal of EURECA WP5 was the development of a MT-PEM µ-CHP system based on the system platform of inhouse. The main tasks were related to design issues and components developments to operate at MT-PEM Stack conditions. The work package also incorporated performance testing and degradation measurement. The adaption was guided by simulating system performance with a specific static model and intense pre-testing of developed balance of plant concepts and components. These preliminary works lead to the development, construction and testing of a MT-PEM System with the MT-PEM Full Stack from WP4.
n a first step, the EURECA partners analysed cost structure of the current system and evaluated the cost reduction potential for this specific type of fuel cell. A summary of the components has been set up and all project partners contributed with cost information, such as material, fabrication charges and available cost-volume information. As described in the section above there are considerable dependencies between different components within the fuel cell system. Consequently, not every cost saving of a single part contributes to overall cost reduction. The partners identified the most important interactions and identified critical cost parameters. Target of EURECA system design is a low overall cost of the fuel cell system. As starting point, cost structure of the current system without improvements from EURECA was analysed.
Within the first half of the EURECA project the partners analysed cost structures and collected data to determine further cost reduction in the case of technical improvements from EURECA and for a production volume of 1000 fuel cell systems per year. The coordinator collected cost information of all partners, in particular industrial partners, and summarized them. For confidentiality reasons these cost details were structured by the coordinator into the sections stack, MEA, Pt, reformer, BoP and others and then circulated to all partners.
The current cost information of the EURECA system for 1000 pcs/a is considered as an extrapolation. It shall be updated based on the technical results achieved in EURECA and possible changes in cost/volume information regarding components. Changes in price/volume data for components and precious metal prices on world market will be taken into account.
Project Results:
Please see attached publishable summary
Potential Impact:
See ExploitationPlan (confidential)
List of Websites:
www.project-eureca.com
