The main objective of the project is the development of an innovative fuel cell system based on a PEM (Proton Exchange Membrane) stack with an emphasis placed on cost reduction for on board application in electric vehicles. System integration is studied for final demonstration in a fuel cell powered monospace electric car with high energy efficiency, environmentally compatible (ZEV).
Part of this project will be the industrialisation of the bipolar plate technology, in order to make available a fuel cell mass production, with a unit power in the range of 30 kW demonstrating cost reduction possibilities as low as 200 ECU/kW.
The re-design of the power module will result in weight/volume reduction by a factor of 2 to 3 with respect to presently developed applications (EQHHPP FC BUS). The integration of this power module with one of the most advanced traction system will result in a highly integrated, high efficiency fuel cell vehicle.
The project will develop along three main lines of activity: Development of the fuel cell technology, intended as a step forward from existing technology (FEVER Project) using improved innovative components (bipolar plates, electrodes and membranes) studied for low cost application.
Re-design of the fuel cell system (power module), i.e. all auxiliary components and subsystems needed for operating the fuel cells, in order to improve efficiency and significantly reduce weight and volume occupancy. Particular attention will be paid to the air compression system, responsible for over 90 % of auxiliary energy consumption.
Development of a high pressure, low weight storage system for gaseous hydrogen storage. The particular design and materials selection will allow to reach energy densities similar to those of liquid hydrogen.
The products of these activities will be integrated into an advanced traction system using a battery as energy buffer. Although significant modifications to the vehicle chassis and body will be necessary to accommodate the power module and the hydrogen storage, it is foreseen that the complete propulsion system will only occupy a small useful (payload) space on board.
Expected Achievements and Exploitation
Fuel Cell Stack Power = 30 kW for EV application with improved components
weight < 4 kg/kW volume < 3.5 l/kW cost 200 ECU/kW
High efficiency air compressor (working at 1.5 bars)
Improved DC/DC Convertor
High pressure gaseous Hydrogen Storage tanks allowing 6 % energy content with potential application for other gas
Development of a technological know-how for the integration on board of an electrical vehicle
Monospace electric vehicle with the integration of the different components as a demonstrator
Funding SchemeCSC - Cost-sharing contracts