Periodic Reporting for period 2 - FC-eCompressor (Commercialisation of a Novel and Efficient Air Compressor to Improve the Economic Viability of Hydrogen Fuel Cells)
Periodo di rendicontazione: 2021-01-01 al 2021-12-31
Ongoing environmental and health concerns associated with the use of fossil fuels is driving demand for clean energy sources. For example, countries including China, the UK, Germany, India and France intend to ban new internal combustion vehicles within ~20 years. Battery powered electric vehicles have an important role to play, but they continue to be limited by range and charging time, so there is increasing interest in alternatives such as hydrogen fuel cells. It is predicted that by 2032, over 22 million fuel cells will be in operation. Fuel cells consume stored hydrogen and oxygen (from air) to produce electricity. Heat and water are the only by products, so the technology is non-polluting at the point of use. However, fuel cells are still relatively expensive and a key way to reduce their cost is to supply air at higher pressure, using a compressor. This increases power output, allowing them to be made smaller and cheaper, but compressors can consume up to 40% of the energy produced by the fuel cell, so their efficiency is critical. Aeristech’s compressors operate much more efficiently, requiring 10-20% less power than competitive products. They are also up to 20% smaller and will operate continuously at high power for 4,000 hours without servicing. These unique advantages are creating enormous commercial interest. Our solution, FC-eCompressor, has been developed to prototype stage (TRL6) and we now need to optimise the technology for production and gain approvals for commercial supply. To achieve this, we must produce sample units that are manufactured using high-volume production techniques, but this is expensive and time-consuming. By overcoming this barrier, we will open-up market opportunities that will create new jobs and generate over €65 million in cumulative revenue by 2025.
In summary, we believe we have been successful in achieving important milestones during the project, not just for the project but also for the business. These milestones include the following:
1) Development of Aeristech’s first eCompressor utilizing oil free air bearing technology.
2) Successful 1000hour durability test.
3) 9 prototypes built, delivery of 4 prototypes to customers.
4) Further evolution of prototype development resulting in 30% BOM size reduction and optimisation for manufacturing.
5) Installation of pilot production equipment (including 5 axis grinding machine, and assembly cells.)
6) Implementation of key assembly processes (including rotor assembly.)
7) Pre-compliance testing carried out on prototype controller for EMC requirements against CISPR-25 and ECE-R10.
8) Achieved ISO 9001 Quality status.
9) Rapid growth of Aeristech from 30 to 60 employees over the duration of the project.
Outside of H2020 we will continue to develop the products further, and exploit learnings across other projects.
1) Development of Aeristech’s first eCompressor utilizing oil free air bearing technology.
2) Successful 1000hour durability test.
3) 9 prototypes built, delivery of 4 prototypes to customers.
4) Further evolution of prototype development resulting in 30% BOM size reduction and optimisation for manufacturing.
5) Installation of pilot production equipment (including 5 axis grinding machine, and assembly cells.)
6) Implementation of key assembly processes (including rotor assembly.)
7) Pre-compliance testing carried out on prototype controller for EMC requirements against CISPR-25 and ECE-R10.
8) Achieved ISO 9001 Quality status.
9) Rapid growth of Aeristech from 30 to 60 employees over the duration of the project.
Outside of H2020 we will continue to develop the products further, and exploit learnings across other projects.
Objectives: We expect to achieve at least 5 more integration based objectives between now and project end, with the remaining commercial objectives expected post project.
Impact:
The demand for fuel cells is still growing and has been increasing since we applied for Horizon 2020. For example, since the start of the Horizon 2020 project, Aeristech are now key partners of 3 UK government backed fuel cell projects; 2 of which are major Aerospace fuel cell programmes called H2Gear with lead partner GKN and Hyflyer2 with lead partner Zero Avia (both kicked off in December 2020) and an automotive programme with lead partner Cummins called Trident (due to kick off in January 2021.) Due to the infancy of the market, the specifications required by the end user change and vary due to their own learning of fuel cell technology, so between these programmes and Horizon 2020, there will be an opportunity for spill over and knowledge sharing. Aeristech prides itself on being agile so we can adapt according to the user’s needs as not to be caught out and left behind. Hence the business decision to amend the specification of our 2 products early in the project. Aeristech uniquely addresses market needs through a combination of efficient motor and controller technology, compact size and reduced cost. By amending the products from a replaceable bearing system to an exceptionally durable air bearing solution we will meet operational lifetime requirements without the need for replacement and maintenance tasks during the life of the product. Secondly, unlike traditional bearings, air bearings do not require any grease and oil for operation and whilst some studies had been carried out by Aeristech to measure for oil contamination from a greased bearing which resulted in a pass, the feedback from customers and the market showed a strong demand for air bearing as to completely remove the risk of contamination to the fuel cell stack which grease and oil pose. This is a significant improvement to what we had proposed previously thus providing a greater impact to the market. The knowledge, successes and lessons learned (including air bearings) obtained through Horizon 2020 will be applied to these 3 major programmes and others beyond.
Impact:
The demand for fuel cells is still growing and has been increasing since we applied for Horizon 2020. For example, since the start of the Horizon 2020 project, Aeristech are now key partners of 3 UK government backed fuel cell projects; 2 of which are major Aerospace fuel cell programmes called H2Gear with lead partner GKN and Hyflyer2 with lead partner Zero Avia (both kicked off in December 2020) and an automotive programme with lead partner Cummins called Trident (due to kick off in January 2021.) Due to the infancy of the market, the specifications required by the end user change and vary due to their own learning of fuel cell technology, so between these programmes and Horizon 2020, there will be an opportunity for spill over and knowledge sharing. Aeristech prides itself on being agile so we can adapt according to the user’s needs as not to be caught out and left behind. Hence the business decision to amend the specification of our 2 products early in the project. Aeristech uniquely addresses market needs through a combination of efficient motor and controller technology, compact size and reduced cost. By amending the products from a replaceable bearing system to an exceptionally durable air bearing solution we will meet operational lifetime requirements without the need for replacement and maintenance tasks during the life of the product. Secondly, unlike traditional bearings, air bearings do not require any grease and oil for operation and whilst some studies had been carried out by Aeristech to measure for oil contamination from a greased bearing which resulted in a pass, the feedback from customers and the market showed a strong demand for air bearing as to completely remove the risk of contamination to the fuel cell stack which grease and oil pose. This is a significant improvement to what we had proposed previously thus providing a greater impact to the market. The knowledge, successes and lessons learned (including air bearings) obtained through Horizon 2020 will be applied to these 3 major programmes and others beyond.