Fuel Cells and Hydrogen Joint Undertaking
Programme Review 2012 Final Report Fuel Cells and Hydrogen Joint Undertaking Email: [email protected] www.fch-ju.eu
Publication: March 2013, in Belgium
Legal notice
Neither the FCH JU nor any person acting on behalf of the FCH JU is responsible for the use which might be made of the following information. The views expressed in this publication, based on independent reviewers’ reports, are the sole responsibility of the authors and do not necessarily reflect the views of the FCH JU members.
EUROPE DIRECT is a service to help you find answers to your questions about the European Union Freephone number (*): 00 800 6 7 8 9 10 11 (*) Certain mobile telephone operators do not allow access to 00 800 numbers or these calls may be billed
More information on the European Union is available on the Internet (http://europa.eu).
Cataloguing data can be found at the end of this publication.
Luxembourg: Publications Office of the European Union, 2013
ISBN 978-92-79-29158-6 doi 10.2777/79943
© FCH JU Reproduction is authorised provided the source is acknowledged
Printed in Luxembourg
Printed on elemental chlorine-free bleached paper (ecf) Fuel Cells and Hydrogen Joint Undertaking
Programme Review 2012
Final Report 2 Fuel Cells and Hydrogen Joint Undertaking TABLE OF CONTENTS
List of acronyms 7
Executive summary 8
Introduction 10
FCH JU project portfolio analysis 13 Transportation and refuelling infrastructure 14 Hydrogen Production, Storage and Distribution 17 Stationary power generation and CHP 22 Early Markets 29 Cross-Cutting activities 32
Conclusion and recommendations 35 List of reviewers 37
FCH JU Projects 39
Transport and refuelling infrastructure CHIC, Clean Hydrogen in European Cities 40 DESTA, Demonstration of 1st European SOFC Truck APU 42 FCGEN, Fuel Cell Based On-board Power Generation 44 H2moves Scandinavia, Lighthouse Project for the Demonstration of Hydrogen Fuel Cell Vehicles and Refuelling Infrastructure in Scandinavia 46 High V.LO City, Cities speeding up the integration of hydrogen buses in public fleets 48 HyTEC, Hydrogen Transport in European Cities 50 PEMICAN, PEM with Innovative low cost Core for Automotive applicatioN 52
Hydrogen production and storage ADEL, Advanced Electrolyser for Hydrogen Production with Renewable Energy Sources 54 ARTIPHYCTION, Fully artificial photo-electrochemical device for low temperature hydrogen production 56 Bor4Store, Fast, reliable and cost effective boron hydride based high capacity solid state hydrogen storage materials 58 CoMETHy, Compact Multifuel-Energy to Hydrogen converter 60 DeliverHy, Optimisation of Transport Solutions for Compressed Hydrogen 62 ELECTROHYPEM, Enhanced Performance and Cost-Effective Materials for Long-Term Operation of PEM Water Electrolysers Coupled to Renewable Power Sources 64
ELYGRID, Improvements to Integrate High Pressure Alkaline Electrolysers for Electricity/H2 production from Renewable Energies to Balance the GRID 66 HY2SEPS-2, Hybrid Membrane - Pressure Swing Adsorption (Psa) Hydrogen Purification Systems 68 HYDROSOL 3D, Scale up of thermochemical hydrogen production in a solar monolithic reactor: a 3rd generation design study 70 HyTIME, Low temperature hydrogen production from 2nd generation biomass 72 HyUnder, Assessment of the potential, the actors and relevant business cases for large scale and seasonal storage of renewable electricity by hydrogen underground storage in Europe 74 IDEALHY, Integrated Design for Efficient Advanced Liquefaction of Hydrogen 76 NEMESIS2+, New Method for Superior Integrated Hydrogen Generation System 2+ 78 NEXPEL, Next Generation PEM Electrolyser for Sustainable Hydrogen Production 80 PrimoLyzer, Pressurised PEM Electrolyzer stack 82 RESelyser, Hydrogen From RES: Pressurised Alkaline Electrolyser with High Efficiency and Wide Operating Range 84 SSH2S, Fuel Cell Coupled Solid State Hydrogen Storage Tank 86
Programme Review 2012 - Final Report 3 Stationary power generation and Combined Heat and Power ASSENT, Anode Sub-System Development & Optimisation for SOFC systems 88 ASTERIX III, ASsessment of SOFC CHP systems build on the Technology of htceRamIX 3 90 CATION, Cathode Subsystem Development and Optimisation 92 CLEARgen Demo, The Integration and Demonstration of Large Stationary Fuel Cell Systems for Distributed Generation 94 D-CODE, DC/DC COnverter-based Diagnostics for PEM systems 96 DEMMEA, rstanding the Degradation Mechanisms of Membrane- Electrode-Assembly for High Temperature PEMFCs and Optimization of the Individual Components 98 Design, Degradation Signature Identification for Stack Operation Diagnostic 100 ene.field,European-wide field trials for residential fuel cell micro-CHP 102 EURECA, Efficient use of resources in energy converting applications 104 FluMaBack, Fluid management component improvement for back up fuel cell systems 106 GENIUS, Generic diagnosis instrument for SOFC systems 108 KeePEMalive, Knowledge to Enhance the Endurance of PEM fuel cells by Accelerated LIfetime Verification Experiments 110 LASER-CELL, Innovative Cell and Stack Design for Stationary Industrial Applications Using Novel Laser Processing Techniques 112 LoLiPEM, Long-life PEM-FCH &CHP systems at temperatures ≥100°C 114 LOTUS, Low Temperature Solid Oxide Fuel Cells for micro-CHP Applications 116 MAESTRO, MembrAnEs for STationary application with RObust mechanical properties 118 MCFC-CONTEX, Molten Carbonate Fuel Cell catalyst and stack component degradation and lifetime: Fuel Gas CONTaminant effects and EXtraction strategies 120 METPROCELL, Innovative fabrication routes and materials for METal and anode supported PROton conducting fuel CELLs 122 METSAPP, Metal Supported Sofc Technology for Stationary and Mobile Application 124 MMLCR, Working towards Mass Manufactured, Low Cost and Robust SOFC stacks 126 PREMIUM ACT, PREdictive Modelling for Innovative Unit Management and ACcelerated Testing procedures of PEFC 128 RAMSES, Robust Advanced Materials for Metal Supported SOFC 130 ReforCELL, Advanced multi-fuel Reformer for CHP-fuel CELL systems 132 ROBANODE, Understanding and minimizing anode degradation in hydrogen and natural gas fuelled SOFCs 134 SCOTAS-SOFC, Sulphur, Carbon, and re-Oxidation Tolerant Anodes and Anode Supports for Solid Oxide Fuel Cells 136 SOFC-Life, Solid Oxide Fuel Cells – Integrating Degradation Effects into Lifetime Prediction Models 138 SOFCOM, SOFC CCHP with poly-fuel: operation and management 140 SOFT-PACT, Solid Oxide Fuel Cell micro-CHP Field Trials 142 STAYERS, STAtionary PEM fuel cells with lifetimes beyond five YEaRS 144
Early markets DURAMET, Improved durability and cost-effective components for new generation solid polymer electrolyte direct methanol fuel cells 146 FCpoweredRBS, Demonstration Project for Power Supply to Telecom Stations through FC technology 148 FITUP, Fuel cell field test demonstration of economic and environmental viability for portable generators, backup and UPS power system applications 150 HyLIFT-DEMO, European demonstration of hydrogen powered fuel cell material handling vehicles 152 IRAFC, Development of an Internal Reforming Alcohol High Temperature PEM Fuel Cell Stack 154
ISH2SUP, In situ H2 supply technology for micro fuel cells powering mobile electronics appliances 156 MobyPost, Mobility with hydrogen for postal delivery 158 SHEL, Sustainable Hydrogen Evaluation in Logistics 160 SUAV, Microtubular Solid Oxide Fuel Cell Power System development and integration into a Mini-UAV 162
4 Fuel Cells and Hydrogen Joint Undertaking Cross-cutting issues FC-EuroGrid, Evaluating the Performance of Fuel Cells in European Energy Supply Grids 164 FC-HyGuide, Guidance document for performing LCAs on Hydrogen and Fuel Cell Technologies 166 HyCOMP, Enhanced Design Requirements and Testing Procedures for Composite Cylinders intended for the Safe Storage of Hydrogen 168 HyFacts, Identification, Preparation and Dissemination of Hydrogen Safety Facts to Regulators and Public Safety Officials 170 Hyindoor, Pre Normative Research on the in-door use of fuel cells and hydrogen systems 172 HYPROFESSIONALS, Development of educational programmes and training initiatives related to hydrogen technologies and fuel cells in Europe 174 HyQ, drogen fuel Quality requirements for transportation and other energy applications 176 TEMONAS, TEchnology MONitoring and ASsessment 178 TrainHy, uilding Training Programmes for Young Professionals in the Hydrogen and Fuel Cell Field 180
Programme Review 2012 - Final Report 5 6 Fuel Cells and Hydrogen Joint Undertaking List of acronyms
AA Application Area
AIP Annual Implementation Plan
APU Auxiliary Power Unit
CHP Combined Heat and Power (generation)
CCS Carbon Capture and Storage
DoE US Department of Energy, US
EIB European Investment Bank
FP7 7th Research and Development Framework Programme of the EU (2007-2013)
GHG Greenhouse Gases
IG Industry Grouping
IPHE International Partnership for Hydrogen in the Economy
ISO International Organization for Standardization
JU Joint Undertaking
LCA Life Cycle Assessment
MAIP Multi-Annual Implementation Plan
MCFC Molten Carbonate Fuel Cells
OEM Original Equipment Manufacturer
PEMFC Proton Exchange Membrane Fuel Cells
PNR Pre-Normative Research
RCS Regulations, Codes and Standards
RG Research Grouping
SET-Plan Strategic Energy Technology Plan
SME Small and Medium Enterprises
SOFC Solid Oxide Fuel Cells
SRA Strategic Research Agenda
TRL Technology Readiness Levels
UPS Uninterruptible Power Supply
Programme Review 2012 - Final Report 7 Executive summary
The Fuel Cells and Hydrogen Joint Undertaking (FCH JU) is a The Transportation and Refuelling infrastructure application unique industry-led Public-Private Partnership, established in area has grown to include both an extension of demonstration 2008 between the European Commission, Industry and the activities with a large bus project, HighV.LO City, following Research Community. It brings public and private interests from up the CHIC project and projects strengthening technology across Europe together, with the objective of accelerating the development, such as DESTA, HyTEC and FCGEN. Improved vehicle development of fuel cells and hydrogen technologies in Europe performance, durability, and the development of a cost-efficient to enable their commercial deployment between 2010 and 2020. initial Hydrogen Refuelling Infrastructure are clear indicators of progress. There is an opportunity to extend demonstrations The FCH JU defines and implements, together with its members, across the Member States and the regions, with the benefit a targeted multi-annual research and development programme of enhancing the Europe wide hydrogen refuelling stations for these innovative energy technologies. This is supported with infrastructure. Work also needs to continue on standardisation a ring-fenced budget of nearly € one billion between 2008 and to ensure that the challenges of fuel metering and fuel quality 2013 contributed jointly and on a 50/50 basis by private and are addressed appropriately. Volume-building towards mass public actors. commercialisation remains, however, a challenging target, although it is clear that the multi-annual strategic ambition goes Annual research agendas are designed to deliver the strategic well beyond the remit of this program’s scope and budget. direction and the multi-annual plan across five applications areas (AA): Transportation and Refuelling infrastructure, Hydrogen Hydrogen Production, Storage and Distribution activities continue Production, Storage and Distribution, Stationary Power to address the production challenge, especially the production Generation & CHP (combined heat and power), Early Markets and of green hydrogen, with a mix of mature and developing Cross Cutting activities. technologies, such as water electrolysis (Elygrid and RESelyser projects), biomass gasification, fermentation (Hytime project) A periodic independent assessment of the portfolio of projects and solar technology (ArtipHyction project). Strengthened is a valuable instrument to steer the management of the efforts on storage to complement renewable production programme and identify relevant adjustments where needed, pathways (HYunder project), improve solid stage hydrogen while preparing for the next phase of the programme under storage (SSH2S, Bor4store projects) and on distribution of Horizon 2020. hydrogen (IDEALHY, DeliverHy projects), are valued. The potential to use hydrogen for large scale storage of energy from Initiated in 2011, the 2012 programme review edition covered 71 intermittent renewable energy sources still generates a lot of ‘live’ projects from the 2008, 2009 and 2010 calls for proposals, interest. together with some projects from the 2011 call. Total funding for these projects stands at close to € 450 million, 50% of which The Stationary Power Generation and Combined Heat and Power comes from FCH JU financial contributions and 50% of which application area has significantly developed with an increase of comes from industry and research in-kind contributions. demonstration projects able to provide valuable experience and learning for Europe. Targets on volume and costs for 2015, are 23 independent reviewers from Europe, Japan and the USA being achieved: demonstration of more than 1000 1-2 kW systems with expertise and experience in the Fuel Cell and Hydrogen (project ene.field) from 9 manufacturers supported by 24 utilities technology field reviewed these projects based on both written in 12 Member States, is complemented by a 1MW commercial and presentation material provided by the projects themselves system H2-based in Hungary targetting more than 20,000 hours and the FCH JU. The portfolio of projects was assessed against a operation, electrical efficiency of 48% and a cost of system 2.5 range of criteria, with rapporteurs providing an overview of the mill Euro/MW (equivalent of 2500 Euro/kW) (project ClearGen five Application Areas, as detailed further. Demo). In terms of technical targets, electrical efficiencies of more than 60% will also be demonstrated (project SOFT-PACT) The 2012 Programme review confirms the FCH JU has continued through demonstration of an additional 100 micro-CHP units in to make progress against its principle objectives as set out in Germany, UK, Italy and Benelux. In terms of research needs, the the Multi-Annual Implementation Plan (MAIP), notably vehicles opportunity to develop road-mapping, in close collaboration and materials performance, durability, and costs reduction for with industry, has been emphasized. both components and systems. A significative extension of the demonstration projects in all application areas is welcome and matched by a sustained industry involvement in the portfolio, 50% of which are SMEs.
8 Fuel Cells and Hydrogen Joint Undertaking Regarding Early Markets, the portfolio continues to be well The Fuel cells and hydrogen sector reported that on average, its aligned with strategic objectives: three flagship projects HyLIFT- annual turnover has increased by 10% (on a 2012 total of € 0.5 DEMO, Shel and Mobypost focus on forklifts, postal delivery billion), R&D expenditures were up by 8% (on a 2012 total of € vehicles as well as trucks for airport usage. Back-up power 1.8 billion) and market deployment expenditures rose 6% (on a systems are addressed with two large projects, FCPoweredRBS 2012 total of € 0.6 billon), confirming the leverage effect FCH JU and FITUP, focused on back-up systems for telecommunication investments had across the whole sector. Further with a 16% per applications. These latter projects are paving the way for annum rise in patents granted in the EU to European businesses, deployment with some of the manufacturers optimizing their the sector has also outpaced the rest of the industry (1,5 % production lines for larger commercialisation. Innovative average annual growth for all EU industries). personal power solutions, and unmanned flying vehicles, are also explored as part of the portable and micro-fuel cells for personal power solutions.
Finally the strategic role of the cross-cutting activities for the whole programme is acknowledged, with notably the new socio- economic tool on technology assessment and progress (Temonas project). Further work to address market obstacles arising from variability of regulations, standards and permit procedures, now timely, would be welcome. Achievements in education and training, reaffirmed as a priority, is to be maintained with appropriate consideration on follow-up and updating beyond the life of the projects, because challenges in this area will only increase as fuel cells and hydrogen technologies move closer to deployment.
The 2012 Review concluded that some quantitative targets would be worth revisiting or complementing with application- specific or commercially relevant targets, to better account for technology improvements and priorities.
Shared learning between projects and across the portfolio, could be further explored, through exchanges of information, data banks or workshops. In particular, where synergies are free from IPR issues and commercial interest, the FCH JU portfolio would also benefit from collaborations on safety issues.
To enable more flexibility and interaction between the application areas, consideration might be given to simplifying the current programme structure for a second phase of the FCH JU programme under Horizon 2020.
Enhanced cooperation with national and regional programmes could be considered for demonstration activities, by nature budget intensive, while international cooperation remains key to understand and align with the state-of- the art.
The European fuel cells and hydrogen sector1 acknowledged in a survey conducted in 2012, the key role the FCH JU partnership has had in providing medium to long-term stability for R&D public funding for the sector as well as long-term commitment to the industry. In challenging economic times, the Joint Undertaking’s contribution to European competitiveness, in uniting the various stakeholders in the European FCH community behind deployment whilst supporting nascent technologies is highly valued.
1 Study on the trends in investments, jobs and turnover in the Fuel cells and Hydrogen sector. Way forward for European support, published February 2013 by the FCH JU.
Programme Review 2012 - Final Report 9 Introduction
Europe is committed to change of the energy paradigm toward The FCH JU supports RTD developments and demonstrations a more self-sufficient, cost-effective and decarbonized energy through a series of projects that cover the entire RTD range of system. Only by supporting innovative energy production, activities from basic and breakthrough research through applied infrastructure build-up, including storage, while promoting research (RTD) to demonstrations of fuel cell and hydrogen efficiency - friendly measures, can Europe respond to its technologies. These are complemented and supported by cross- environmental and energy challenges whilst also delivering cutting activities e.g. Regulations, Codes and Standards, Pre- economic growth. The energy transition agenda will require Normative Research, socio-economic analysis, life cycle analysis, more integration between transport and energy systems and market support, public awareness, education and training. an increased ability to manage intermittent renewable energy systems. The projects are funded on a 50/50 basis by both private (in-kind contributions) and public sectors (in-cash contributions), the FCH Fuel cell and hydrogen technologies will be part of the solutions JU contribution being awarded as grants through annual open currently being developed to facilitate this transition and have a and competitive calls for proposals. clear potential to achieve Europe’s climate change, energy and environmental objectives, whilst also bringing about economic Such a multi-annual commitment provides a safe sanctuary for growth. Hydrogen is recognized as one of the very few near-zero- technological innovation and a stable environment to enable emissions energy carriers that could be a significant part of the stakeholders to make long-term investment plans. EU’s future low-carbon energy and transport sectors. The activities are guided by a long-term strategy document, International developments show that fuel cell and hydrogen the Multi-Annual Implementation Plan (see figure 1), which technologies are also being considered as promising future tools, outlines the scope and details the planning for research and and in countries such as Japan, Korea, US, Canada and China demonstration in the long term as well as defining a tentative preparations are being made for the broader deployment of budget breakdown for the full period 2008-2013 by application these technologies. area (see Figure 2) and by action category (see Figure 3).
Recognising the potential for European growth and competitiveness, the Fuel Cell and Hydrogen Joint Undertaking Early markets (FCH JU), a unique Public Private Partnership between (12-14 %) the European Commission and the industry and research communities, was established in 2008 through the Council Regulation (EC) 521/2008.
As the first public-private instrument established under the European Strategic Energy Technology Plan (SET-Plan), with a budget of nearly one € billion between 2008 and 2013, the FCH JU brings public and private interests from across Europe together, with the aim of speeding up the development of fuel cells and hydrogen technologies in Europe to enable their commercial deployment in the years to 2020.
The partnership aims to define and implement an industry-driven integrated RTD programme carried out by and in cooperation with its stakeholders: industry including SMEs, research centres and universities, together with the Member States and Europe’s regions and municipalities.
10 Fuel Cells and Hydrogen Joint Undertaking Fig. 1 Multi-annual implementation plan (MAIP) 2008-2013
Cross cutting activities Support Actions Long-term and Transport and refuelling (5-6 %) (9-11 %) Breakthrough Research infrastructure (32-36 %) (13-15 %) Early markets (12-14 %)
Hydrogen Stationary power production and Demonstration Research and Technological generation and combined storage (10-12 %) (41-46 %) Development heat and power (34-37 %) (31-35 %)
Fig.2 Budget breakdown by application area Fig.3 Budget breakdown by activity type
The Multi-Annual Implementation Plan (MAIP) is divided into five The strategy and objectives set out in the MAIP are translated main application areas: into Annual Implementation Plans (AIP). These AIPs issue Calls for • Transport and refuelling infrastructure Proposals which set out the research and demonstration topics • Hydrogen production and distribution for which each AA is seeking proposals. • Stationary power generation and combined heat and power • Early markets Six calls for proposals have been published: 2008, 2009, 2010, • Cross-cutting activities such as regulations, codes and 2011 2012 and 2013. The calls from 2008 to 2011 have resulted standards, pre-normative research, socio-economic research, in over 100 projects, which are currently being managed by the technology and life-cycle assessments, market support, public Programme office. In total, over 700 research organisations and/ awareness, and education. or industry, a quarter of the latter being SMEs, have benefited from the FCH JU’s support between 2008 and 2011. Figure 4 provides a breakdown of these funds by country.
Programme Review 2012 - Final Report 11 Fig 4. Programme participation per country (2008-2011) A team of 23 independent reviewers from Europe, Japan and USA2, assessed the portfolio of projects, remotely and during As part of its strategic programme management, as the review days. One rapporteur by session aligned the views of recommended in its first interim evaluation, the FCH JU began all corresponding reviewers for that session, while rapporteurs an annual review of its projects’ portfolio in 2011. This aims to further consolidated sessions’ assessments per application area, assess the progress of the FCH JU program in relation to the which provided the basis for this final report. achievement of the targets of its Multi-Annual Implementation Plan (MAIP), the Annual Implementation Plans, as well as the At a time when the current programme, which is due to evolution versus international developments. complete its first funding phase in 2013, is reflecting on its achievements and preparing for Horizon 2020 ambitions, Following the 2011 exercise the second edition of the annual the impact assessment of the FCH JU programme is gaining Program Review Days took place on 28 and 29 November 2012. momentum. The Fuel Cells and Hydrogen sector has invested These covered the entire portfolio of on-going FCH JU funded- considerably in research and demonstration and is planning projects from the 2008, 2009, 2010 calls and some projects from larger and broader deployment plans for the seven years to the 2011 call, in total 71 projects. 2020.
Infrastructure investments, new research needs, regulatory support are considered key for the next seven years. Industry and research players are fully committed to supporting the sector’s development, and are calling for enhanced support from the public authorities.
2 C. List of reviewers p. 37.
12 Fuel Cells and Hydrogen Joint Undertaking FCH JU Project portfolio analysis
Transport and refuelling infrastructure 14
Hydrogen production and storage 17
Stationary power generation and Combined Heat and Power 22
Early markets 29
Cross-Cutting activities 32
Programme Review 2012 - Final Report 13 FCH JU project portfolio analysis Transportation and refuelling infrastructure
Strategic priorities 109 M€ have been allocated from the budget 2008-2011 to support 21 projects so far, covering mainly demonstrations (66% The main objective of the Transportation Application Area of the budget being in line with MAIP targets of 65,4%). Overall, strategy is the testing and development of competitive this AA accounts for about 36% of the FCH JU operational budget, hydrogen-fuelled road vehicles and corresponding refuelling which is at the upper boundary of the 32-36% range foreseen in infrastructure, together with full supporting elements for market the MAIP. deployment and increased industrial capacity. The emphasis is on large scale fleet demonstrations, including cars and The portfolio of projects is composed of 3 bus projects (total of 49 buses, plus a number of refuelling stations Europe wide. Such units) and 3 car projects (total of 37 passenger cars + 95 minicars demonstrations are to test for durability, robustness, reliability, with range extenders) for the demonstration projects, while 2 efficiency and sustainability of vehicles and infrastructures for projects are developing APU for trucks, one with SOFC and one everyday use. The original global market objectives were for with PEM technology. Several projects deal with components- thousands of vehicles by 2015 and mass production from 2020. level R&D activities. One project (HYQ) covers fuel quality and one project deals with hydrogen storage (HyCOMP, addressed The application area has also sought to support activities focused here under cross cutting activities). Two support projects which on developing a credible European leadership in stack research have been concluded are not part of this programme review. and development, working with OEMs, the supply industry and research institutes; undertake research and technology The portfolio of Transport and Refuelling infrastructure projects development to improve PEMFC for transport use, for example has grown to include both an expansion of demonstration stable and long life membranes, stable and low cost catalysts, activities, with the HighV.LO City bus demonstration project corrosion resistance and low weight, cost and volume bipolar complementing the CHIC activity, and projects focused on plates; and finally to support heavy duty transport applications technology development, DESTA, HyTEC and FCGEN. The with the common goal of reducing C02 emissions and local addition of work on APUs for trucks strengthens the AA’s pollution and increasing the efficiency of on-board power coverage of transport applications. The reviewers noted that the generation. It sees opportunities to co-ordinate activities with projects aligned with the MAIP and there were opportunities for the other AAs. demonstration projects to work together and share learning.
14 Fuel Cells and Hydrogen Joint Undertaking Demonstrations Technology R&D
Good progress has been made by demonstration projects both The reviewers emphasized the need for the FCH JU programme in terms of extending vehicle performance, including durability, to support basic and applied R&D for the AA, to improve and in the development of an initial Hydrogen Refuelling Station performance of components and systems, and also to reduce (HRS) infrastructure. Looking towards the future the opportunity cost, for example for bus drive trains. Further basic R&D was exists for extending these demonstration activities to further required for longer term developments, whilst frequent cities and regions in the Member States, with the benefit of reassessment of R&D needs were necessary to maximise extending the HRS infrastructure and in enhancing hydrogen relevance of R&D for transport applications in addition. mobility between regions and Member States. More specific comments related to APUs for trucks, with reviewers The reviewers held the view that demonstrations should target noting that the market opportunity in Europe was unclear more ‘early customers’ both for fuel cell cars and buses to improve being influenced by the level of future truck hybridisation, and understanding of user acceptance issues. Early customers for as such recommended that developments should await the fuel cell cars could be incentivised with daily use and rental recently initiated technology assessment. Finally, efforts in the schemes, whilst bus drivers and depot operators could also be area of low cost platinum catalysts need to be part of more involved in acceptance assessments. Part of the latter challenge comprehensive European action for development of new low was to increase bus availability from 85% levels to match real cost, high performance stack components. Future AIPs issued by service demands, and enable assessment of performance in FCH JU should address this issue. daily service. In general, reviewers identified some grounds for adjustments, Further comments on bus demonstrations focused on the need to especially on the 2015 targets for vehicles and Hydrogen look towards a second phase from 2015-16 which would involve Refuelling Stations which will be difficult to achieve, even more cities testing fuel cell buses. Reviewers noted that rules and though good progress has been made in vehicle performance funding rates for this phase were as yet unknown, but also that bus and durability, and with HRS infrastructure. Volumes and interest OEMs had yet to confirm the readiness or availability of second have increased, though not to the levels required for mass generation fuel cell buses. commercialisation. For buses, the objective of realising 500 fuel-cell powered units in operation by 2015 is still out of range, Regarding hydrogen refuelling stations, cost targets have despite purchasing prices coming closer to the 1M€ range target. been achieved as most are in the price range of 1-2 M€ for MAIP targets could also be expanded to include reference to 50-200 kg/day capacity; volumes however still need progress. system lifecycle and well-to-wheel emissions for example. Furthermore, the HRS activities still require development to ensure that standards are harmonized so that the challenges Reviewers also emphasized the linkages between the Transport of fuel metering and fuel quality can be addressed. Safety and and Hydrogen Production and Distribution AA, noting that work permitting issues would benefit from a holistic, industry rather in the latter area must address the issues of production of lean than a customized approach. or no carbon hydrogen, preferably utilising renewable energy sources, whilst also considering synergies from competing Progress was thus evident in the demonstration projects, but energy carriers and competing technologies. reviewers noted that further basic research was required, even if it were not on the critical path for products moving towards deployment in the markets.
Programme Review 2012 - Final Report 15
Project name Type Description Coordinator EC Funding (M€)
H2 Moves Demonstration European project H2moves Scandinavia sets Ludwig-Bölkow- 7.8 Scandinavia car fleet and out to gain customer acceptance for electric Systemtechnik station vehicles with fuel cells in Scandinavia. GmbH,
CHIC Demonstration Partnerships between cities which have Daimler 25.8 bus fleet previously gained experience with hydrogen powered buses and 14 new cities and regions in Europe which are considering moving into the field. These partnerships will facilitate the effective and smooth introduction and expansion of the new systems now and into the future.
High V.LO City Demonstration Implement a fleet of 14 2H hybrid FC Van Hool 13.49 bus fleet commercial public buses in 3 regions across Europe as well as establish and enhance three hydrogen production and refuelling facilities, linked to economical and sustainable hydrogen production plants.
HyTEC Demonstration Demonstration of up to 30 new hydrogen Air Products 12 vehicles in the hands of real customers in Denmark and UK, in three vehicles classes: taxis, passenger cars and scooters. These will be supported by new hydrogen refuelling facilities, which combine with existing deployments to create two new city based networks for hydrogen fuelling.
PEMICAN New material The objective of PEMICAN is to develop and Commissariat à 1.8 of automotive manufacture MEA (membrane Electrode l’énergie atomique PEMFC Assembly) with reduced Platinum cost. (CEA), France
FCGEN Demonstration To develop and demonstrate a proof-of- Volvo 4.34 on-board concept complete fuel cell auxiliary unit in a power real application, on-board a truck. generation
DESTA Demonstration demonstration of the first European Solid AVL 3.87 of Auxiliary Oxide Fuel Cell (SOFC) Auxiliary Power Unit power unit (APU) for trucks.
16 Fuel Cells and Hydrogen Joint Undertaking Hydrogen Production, Storage and Distribution
Strategic priorities Hydrogen Production
This Application Area aims to develop and where possible, fully Natural gas reforming (SMR), coal gasification and water implement a portfolio of sustainable hydrogen production, electrolysis are proven technologies that can be applied at storage and distribution processes which can meet 10% - 20% an industrial scale. For the next 15-20 years, SMR and water of the hydrogen demand for energy applications from carbon- electrolysis are likely to be the main sources of hydrogen, free or carbon-lean energy sources by 2015, complemented whereas only the latter will be able to provide CO2 free or lean with preparatory work to enable the wide spread introduction of hydrogen without additional Carbon Capture and Storage (CCS). hydrogen infrastructure beyond 2020. Water electrolysis may be coupled to renewable energy sources Given the range of processes with differing degrees of maturity, (RES) and has potential to support grid stabilization. Energy production capacity and sustainability, the emphasis is on storage issues arising from the increasing Hydrogen production R&D for mature production and storage technologies, whilst via biomass gasification, fermentation and solar (-thermal/ also supporting longer term, fully sustainable production and electrochemical) technology are other methods with high supply pathways. Mature technologies include: i) reforming potential in the long term. SMR of biogas is another possible bio-fuels plus conventional fuels; ii) cost-efficient low- source of green hydrogen. temperature electrolysers adapted for large scale use of carbon free electricity; iii) biomass gasification. The various projects are focused on sustainable hydrogen production via water electrolysis or developing innovative Longer term technologies include water splitting together with technologies such as water splitting via solar energy thermo-chemical processes based on solar, nuclear or waste (ArtipHyction) or biological hydrogen production through heat plus development of low temperature, low cost biological fermentation (Hytime). hydrogen and photo-electrochemical processes for direct hydrogen production. The PrimoLyzer project developed and tested a cost-minimised, highly efficient and durable PEM-Electrolyser stack for integration Production methods are allied to storage options to include with domestic μCHPs, with a hydrogen outlet pressure of 5-10 high volumes e.g. underground and liquefaction, plus long term MPa. Results show that the best performing MEAs managed to breakthrough solid and liquid materials storage. exceed the project objective with even less than the targeted catalyst loading. Costs could be brought down to less than 5,000 The programme recognises the variety of technologies under €/Nm3/h if the stack production is up-scaled to 100 units. development and their varying maturities by identifying a mid- term need for carbon lean hydrogen (supply up to 50% of the The FCH JU’s Hydrogen Production and Distribution projects anticipated hydrogen energy demand from renewable energy have expanded significantly within the past year: more mature sources by 2020), and longer term requirement for sustainably electrolysis production technologies have seen the addition of produced hydrogen, with a zero carbon foot print. It has projects developing alkaline based technologies, Elygrid and sought to support a range of mature and developing hydrogen RESelyser, as well as a further PEM focused activity Electro- production technologies, with further developments in the area HyPEM; more innovative technologies are supported through of storage and distribution. CoMETHy, ArtipHyction and HYTIME, together with HYSEPS-2 and NEMESIS2+, the latter continuing the work of previous projects; As of now, over 35 M€ have been allocated from the budget whilst storage and distribution is being addressed in HyUnder, 2008-2011 to support 21 projects in this area, which is in line with IDEALHY, DeliverHy, Bor4Store. These and the existing projects the MAIP target of 10-12%. contribute to the MAIP’s major aims and topics, and there is little evidence of overlaps.
Programme Review 2012 - Final Report 17 Reviewers found that the balance between mature and Hydrogen Distribution and Storage innovative hydrogen production technologies was good, but there was a need to ensure that the latter continue to be For hydrogen to be a useful future fuel, it has to be conveyed to supported by the FCH JU. Electrolysis based projects were the point of use and stored. well represented, with a mixture of PEM, alkaline and SOFC technologies. Innovative, longer term projects were represented, Distribution of hydrogen includes transmission and distribution but further support is required for technologies incorporating pipelines, compressors, pressure-regulating equipment, and biomass integration. Overall there is a need to maintain effort above- and below ground storage facilities near fuel markets. on alternative lower-cost sustainable hydrogen production technologies, and the FCH JU should support a plurality of Hydrogen storage is a critical issue that still needs to be addressed technologies with future promise. in order to establish a hydrogen economy. The constraints for the
storage of H2 are highest for road transport, with compressed gas Technology progress appeared clearly in some projects, for cylinders being the most likely option. example in projects which were continuing the work of previous European FP6 and 7 activities. However reviewers would have Storage of hydrogen for stationary applications will likely be favoured, for a better identification of real innovation, more linked to coupling with RES. The potential of hydrogen for large reference to state-of-the-art and competing technologies and scale storage of energy from intermittent renewable energy more attention to the need to understand other energy and sources is currently generating a lot of interest, but outside the storage technologies both from the perspective of competition, current scope of the Application Area’s objectives. but also possible synergies. Storage technologies are being developed in order to Areas for concern relate to the emphasis of projects on basic complement renewable production pathways and help and applied R&D rather than demonstrations, although this had establish the supply chain for hydrogen (SSH2S, Bor4store) been partly addressed already with the project Don Quichote on improving solid state hydrogen storage. Options for (not part of the 2012 review) which is the extensive demonstration distributing hydrogen are also studied. IDEALHY is an of hydrogen production by renewable electricity, compression, enabling project to develop an economically viable hydrogen storage and end use of hydrogen in transport applications or for liquefaction capacity for Europe. This will help in accelerating grid balancing. By storing excess renewable electricity in large rational infrastructure investment and enabling the rapid quantities in hydrogen, otherwise unused renewable energy can spread of hydrogen refuelling stations across the continent. be used to power transport and other applications. IDEALHY will investigate the different steps in the liquefaction process in detail, using innovations and greater integration Additionally whilst work on materials and component in an effort to reduce specific energy consumption by 50% development is seen as necessary, there is lack of systems compared to the state of the art, and simultaneously to reduce development work. The FCH JU needs to show that its activities investment cost. are leading to possible solutions to hydrogen production, especially sustainable hydrogen production. As noted above The growing portfolio of storage and distribution projects linkages of projects with renewable energy sources was deemed is welcomed by the reviewers: HyUnder was deemed to be to have been strengthened. especially significant as part of the solution to the storage of excess power from intermittent renewable sources. However, more work in the area of integration of fuel cell and hydrogen technologies with renewables is required.
The work on solid state storage continues activity funded under FP6 and FP7 frameworks, but reviewers recognised an opportunity to support further low temperature or hybrid system developments, eg cryo-compressed or low temperature high pressure solid state storage. Reviewers felt that in addition regenerative liquid materials for hydrogen storage had not received the attention it deserves.
Generally the programme and the projects need to integrate the state-of-the-art globally to ensure that lessons learned from other regions are incorporated into the MAIP and the projects themselves. According to the reviewers, this applied especially to solid state storage technologies, where work in the USA for example, has been more advanced than within Europe.
18 Fuel Cells and Hydrogen Joint Undertaking Reviewers welcome the expansion of the portfolio, but highlight weaknesses: the scale of the projects tends to be limited in terms of size and funding, there is for example only one storage project with ambitions of more than a MW, and therefore suitable for grid balancing duties. Targets regarding the total production capacity from renewables are not likely to be met with the current portfolio, partly because there is no project focused on centralised large scale production of hydrogen via water electrolysis.
In general, reviewers noted that the current MAIP uses a number of limited technical targets, with a preference for techno-economic ones; these are not seen as sufficient to steer breakthroughs of quick growth non-mature technologies and more detailed application specific targets are deemed necessary. In addition defining application specific requirements will assist in understanding commercial opportunities and targets, for example achieving a balance between capital costs and process efficiencies.
Since integration of hydrogen with renewable power is an essential objective of the FCH JU’s activities, more emphasis on the genuine integration of renewables into projects is critical if fuel cell and hydrogen technologies are to contribute to meeting
Europe’s energy challenges. The well to tank C02 intensity of all the production technologies is not adequately considered and should be part of the techno-economic assessment of all projects.
As part of this any future FCH JU programme might consider simplifying the AA structure to enable more flexibility and interaction between Hydrogen Production and Distribution, and Transport, Stationary and Early Market applications.
Opportunities for shared learning between projects and across the FCH JU portfolio have been identified. For hydrogen production and distribution this includes joint learning on HAZOP issues, where projects would benefit from an exchange of information and hard data. Additionally where learning is free from IPR issues and commercial interest projects should collaborate in the safety field. The proposed workshop on solid state storage solutions is a good starting point. A dedicated Cross-cutting project to make publicly available a range of safety analyses, data, risk assessment methods and guidelines would allow benefits to be spread to other FCH JU projects.
In terms of cooperation at national level, reviewers recommend enhanced co-ordination between National and regional programmes activities and FCH JU, notably for demonstrations projects which tend to be expensive and consume significant parts of FCH JU budget. International co-operation beyond Europe FCH JU is also recommended, with benefits to be gained from actively engaging with programmes in the USA, Canada, Japan, Australia, China, South Korea.
Programme Review 2012 - Final Report 19
Project name Type Description Coordinator EC Funding (M€)
HYDROSOL-3D Sustainable H2 Demonstration of a C02-free hydrogen Center for Research 1 production production and provision process and related and Technology, technology, using two-step thermochemical Greece water splitting cycles harnessing concentrated solar radiation.
ArtipHyction Sustainable Development of improved and novel nano Hysystech 2
H2 production structured materials for photo-activated and solid state processes as well as chemical systems for highly storage efficient low temperature water splitting using solar radiation.
Hytime Sustainable Construction of a prototype process based SDLO 1.6
H2 production on fermentation of biomass for delivering and solid state 1-10 kg hydrogen per day and to develop a storage biohydrogen production system as a stepping stone to pre-commercial application.
Bor4Store Sustainable Development of novel cost-efficient boron Helmholtz-Zentrum 2.27
H2 production hydride based hydrogen high capacity storage GmbH and solid state materials. storage
DeliverHy Sustainable The project will assess the effects that can be LBST 0.71
H2 production achieved by the introduction of high capacity and trailers composed of composite tanks with distribution respect to weight, safety, energy efficiency and greenhouse gas emissions.
IDEALHY Sustainable Development of a generic process design and Shell 1.29
H2 production plan for a prospective large scale demonstration and of efficient hydrogen liquefaction in the range liquefaction of up to 200 tonnes per day.
ELECTROHYPEM Sustainable H2 Development of cost-effective components for CNR 1.35 production PEM electrolysers with enhanced activity and stability in order to reduce stack and system costs and to improve efficiency, performance and durability.
ELYGRID Sustainable H2 Contribution to the reduction of the total Foundation for 2.1 production cost of hydrogen produced via electrolysis Hydrogen in Aragon coupled to renewable energy sources, mainly wind turbines, and focusing on megawatt size electrolyzers (from 0,5 MW and up).
20 Fuel Cells and Hydrogen Joint Undertaking
Project name Type Description Coordinator EC Funding (M€)
Reselyser Sustainable H2 Development of high pressure, highly efficient, DLR 1.48 production low cost alkaline water electrolysers that can be integrated with renewable energy power sources (RES) using an advanced membrane concept, highly efficient electrodes and a new cell design.
SSH2S H2 storage Development of a full tank-FC integrated system University of Turin, 1.6 and to demonstrate its application on a real Italy system.
NEXPEL New Demonstration of an efficient PEM electrolyser Sintef, Norway 1.3 electrolysers integrated with Renewable Energy Sources.
ADEL New Development of a new steam electrolyser Htceramix, 2 electrolysers concept aimed at optimizing the electrolyser life Switzerland time by decreasing its operating temperature whilst maintaining satisfactory performance level and high energy efficiency.
Primolyzer New Development, construction and test of cost- IRD, Denmark 1.2 electrolysers minimised highly efficient and durable PEM- Electrolyzer stack aimed for integration with domestic µCHPs.
CoMETHY Hydrogen Intensification of hydrogen production ENEA 2.48 production processes, developing an innovative and compact and modular steam reformer to purification convert reformable fuels (natural gas, biogas, activities bioethanol, etc.) to pure hydrogen, adaptable to several heat sources (solar, biomass, fossil, etc.) depending on the locally available energy mix.
NEMESIS2+ Hydrogen Development of a small-scale hydrogen DLR 1.61 production generation prototype capable of producing and 50 Nm³ per hour from diesel and biodiesel at purification refuelling stations. activities
Hy2Sep_2 Hydrogen Design and testing of hybrid separation ICEHT 0.82 production schemes that combine Membrane and Pressure and Swing Adsorption (PSA) technology for the
purification purification of H2 from a reformate stream that
activities also contains CO2, CO, CH4, and N2.
Programme Review 2012 - Final Report 21 Stationary power generation and CHP
Strategic priorities The portfolio of projects has expanded since the last review exercise, the primary improvement being the development of The strategy for the Stationary Power Generation and CHP area demonstration projects. With the portfolio of projects supported in the MAIP is to improve the technology for fuel cell stacks and so far, it can be said that progress is being made towards the balance of plant components to the level required to enable most important targets on volume and costs for the medium- products to bridge the gap between laboratory and pre- term, 2015 set up by the MAIP document: demonstration of commercial systems for power or power and heat. This AA has more than 1000 units 1-2 kW systems (project ene.field) from 9 sought to provide a pathway supporting necessary basic and manufacturers supported by 24 utilities in 12 Member States, breakthrough research at one end of the research spectrum, 1MW commercial system H2-based in Hungary for more than through applied research including proof-of-concept, to 20000 hours operation, electrical efficiency of 48% and a cost of technology validation and field demonstrations at the other end. system 2.5 mill €/MW (equivalent of 2500 €/kW) (project ClearGen Demo). In terms of technical targets, electrical efficiencies of more Further development of the main fuel cell technologies (SOFC, than 60% will also be demonstrated (target being more than MCFC and PEMFC) in order to improve performance, durability, 45%) (project SOFT-PACT) through demonstration of additional reliability, robustness and costs is targeted. The FCH JU has 100 micro-CHP units in Germany, UK, Italy and Benelux. focused therefore on the one side on a better understanding of degradation and lifetime fundamentals, development of novel cell and stack architectures, reliable control and diagnostic tools Degradation and New Materials and balance of plant, and on the other side on demonstrating proof-of-concept, validation and demonstration activities, The Stationary portfolio has a range of projects addressing the latter to include full integration into existing fuel and grid the needs for a better understanding of degradation and for infrastructures. It also recognises the opportunity to co-ordinate assessing new materials. R&D with other AAs. 14% of the budget is dedicated to degradation and lifetime The overall objective of this application area is to improve the fundamentals in all technologies, combined with additional 10% technology for fuel cell stack and balance of plant components on materials aspects and another 10% on next generation of cell to the level required by the stationary power generation and CHP and stacks. Different teams in Europe are currently addressing markets by bridging the gap between laboratory prototypes and the development of accelerated stress tests (AST) protocols for pre-commercial systems. cells/stack in H2/air and reformate/air (average voltage decay rate of 1.5μV/h within the 26,000 hours of a three years project), In this respect, 100 € mill have been allocated from the budget followed by predictive modeling for system lifetime in case 2008-2011 to support 35 projects so far, covering the whole value of low temperature PEM technology (project KEEPEMALIVE) chain from long-term and breakthrough orientated research or a degradation rate less than 5 μV/h at 200 mA/cm² for high (degradation and lifetime fundamentals related to materials temperature PEM technology (project DEMMEA). and typical operation environments for relevant power ranges) to technology validation (proof-of-concept fuel cell systems and In case of SOFC, emphasis was put on understanding of Ni-based their interactions with supply & demand interfaces i.e. other (state-of-the-art) SOFC anode degradation (project ROBANODE) power generation devices, cooling/heating systems, and with while also looking at new designs for the anode and anode the infrastructure i.e. grid interface, fuel supply and local power support layer based on strontium titanates (operating 750-920 output) and market capacity building across all applications (full °C) (project SCOTAS-SOFC) or developing new Metal Supported scale field demonstrations of proven systems in real end user Cell using a gas-permeable porous metallic substrate for both environment). planar and tubular cells (operating 600°C) (project RAMSES).
Following on from 2011 Review which found that there was an imbalance between PEMFC and other fuel Cell types, further work needs to be done to encourage more SOFC degradation projects for example. In addition further development of accelerated test procedures is sought.
22 Fuel Cells and Hydrogen Joint Undertaking The reviewers also recommend that given the scale of the Proof of Concept (PoC) and Demonstrations challenge in the basic research area efforts the FCH JU should support and encourage those projects that demonstrate real About 10%of funds are also dedicated in supporting different progress. proof-of-concept projects, especially in the SOFC technology either for a Low Temperature SOFC system prototype which can Conversely more work on radical new materials for cell and operate at 650°C with reduce down time by integrating mass stacks is not perceived as offering sufficient added value for produced Gas Air Delivery, electrical system efficiency of minimal the FCH JU, given that these projects will take a very long time 45% and total system efficiency of minimal 80% (project LOTUS) to come to fruition, if at all. By way of example the reviewers or for a fully automated and integrated SOFC CHP system with stated that projects with the objective of taking new materials an electric power output of 770W gross on the stack, electrical through to system integration in three years are extra-ordinarily efficiency of more than 35% , total efficiency of the system up to ambitious, unrealistic and should be discouraged. This view 78% in facilities and performance degradation of the fuel cell unit points to a need to ensure that the selection process used by the around 10%/1000h operation (project Asterix3). FCH JU should be more rigorous in seeking to support projects with realistic and achievable goals. The greatest share, 41%, of the budget was spent in demonstration activities, especially in small CHP-residential applications, involving both PEM and SOFC technologies. Diagnostics Project SOFT-PACT, through the leader E.ON intends to deploy 100 micro-CHP units (Gennex SOFC based provided by Ceramic Another 10% of the budget is dedicated to BoP components Fuel Cell Limited company) in Germany, UK, Italy and Benelux improvement, sustained by additional 5% on operation and to demonstrate an electrical efficiency of at least 60% diagnostics tools. Support was provided to activities on and address the most important commercial challenges by development of anode and cathode side SOFC subsystems developing the whole supply chain, mass manufacturing and individual components (scalable stack modules, air side aspects and European housing stock availability, ultimately fluid, thermal management and mechanical solutions) - for addressing the certification schemes in the different Member future 10 to 250 kWe atmospheric SOFC systems (projects States, Standard Assessment procedures and Grid connection ASSENT and CATION). A GENERIC tool to diagnose the health standards. of a SOFC system (no more than 1 maintenance/year, detect at least 60% of degradations with a rate > 0.5%/1000hrs, etc) has In addition, the Ene-field project, a major demonstrator which been developed under project GENIUS, while a solution based has just started in 2012, aims at testing about 1,000 micro-CHP on on-line electrochemical impedance spectroscopy (EIS) as an units from 9 European manufacturers (both PEM and SOFC effective diagnostic tool - implemented on-board with a new DC/ based), supported by 24 utilities across 12 Member States of the DC converter is currently explored by project D-CODE. EU. As regards industrial applications, 1 MW CHP system (PEM based) will be demonstrated in Hungary by project ClearGen The 2011 Review highlighted the issue of the appropriateness Demo using by-product hydrogen (industrial waste hydrogen) of some projects focusing on the development of generic from a chlor-alkali plant. This big system will try to achieve a cost tools, given the variability of systems and technologies being reduction to 2.5 mill Euro/MW and 48% electrical efficiency for at developed. The issue was raised again in 2012, with reviewers least 20,000 Hours operation in real conditions. noting that there was little evidence to suggest that the ‘plug in, diagnose and prevention of faults’ systems under development With the stationary portfolio being expanded and strengthened will work. Rather they concluded that system specific approaches with more PoC and Demonstration projects, the reviewers were were probably necessary and that industry should clearly specify keen to ensure that learning was maximised for the stationary what can realistically be implemented to achieve improvements community as a whole and that the learning from demonstration on the subject in the next five years. activities was fed back into R&D efforts. The dissemination efforts of some projects were felt to be insufficient, and that there was an opportunity to utilise independent assessment/reviews as a possible way to allow issues to be identified and relayed to the R&D base, perhaps adopting systems used in Government programmes in the USA. An additional point was that there appeared to be little appreciation amongst projects of state-of-the-art in the demonstration field, especially at the international level.
Programme Review 2012 - Final Report 23 Reviewers were concerned that some Demonstration projects A valuable addition to the FCH JU’s activity in this field would be were inappropriate given the relative immaturity of the the development of centralised data banks, where this is possible technology and high costs. There was doubt about the technology within the restrictions of Intellectual Property rights. There is also readiness of some systems, especially SOFC, where more work on a need for better interaction with the activities of Member States, stack reliability and maturity was deemed necessary. Additionally of which there are some good examples, but not enough. Finally reviewers questioned whether more work was required on international co-operation should be enhanced if only to enable component developments to achieve real breakthroughs rather a better understanding of state-of-the-art. than emphasizing yet more system development. The importance of technology readiness for demonstration is recognised in the Reviewers also identified an opportunity for the FCH JU to support MAIP and AIP: projects are required to demonstrate success in Cross-Cutting projects addressing the common issues affecting Proof of Concept and Validation activities before proceeding to all stationary demonstrations of the ‘obstacles’ encountered in Demonstration. A such if there are examples of inappropriate the variability of regulations, codes and standards, for example demonstration projects then there is reason to look at the proposal official building codes, siting permits and gas quality, across and selection processes. Europe’s Member States and even within the Member States.
Even given some of the issues identified above reviewers are keen to see manufacturing developments supported in the Stationary AA to ensure that costs and quality are effectively addressed. It is notable that the 2013 AIP Call has a specific manufacturing call, although reviewers do question whether the FCH JU is the right framework for this type of activity.
In general, reviewers considered that current targets need to be supplemented, with an emphasis on commercially relevant measures, including cost of ownership. There is also an opportunity to undertake more road mapping to better understand R&D needs to ensure that projects are focused on these critical areas. The FCH JU has indeed recognised the role of such activities, and plans for a combined review and road mapping exercise in the 2013 AIP. Industry is encourage to become a more active driving force especially in the fields of basic and applied research, so that market needs are fully addressed.
Regarding learning opportunities from the whole portfolio of projects, the role of workshops, and advisory boards has been identified.
24 Fuel Cells and Hydrogen Joint Undertaking
Project name Type Description Coordinator EC Funding (M€)
RAMSES New materials & The project aims at developing an innovative CEA, France 4.7 stacks high performance, robust, durable and cost- effective Solid Oxide Fuel Cell based on the Metal Supported Cell concept.
MAESTRO New materials & The objective of MAESTRO is to improve the CNRS, France 2.26 stacks mechanical properties of low equivalent weight state of the art perfluorosulfonic acid membranes using chemical and thermal processing and filler reinforcement methodologies.
SCOTAS-SOFC New materials & The project will demonstrate a new full ceramic Technical university, 4.4 stacks SOFC cell with superior robustness regarding Denmark sulphur tolerance, carbon deposition (coking) and re-oxidation (redox resistance). Such a cell mitigates three major failure mechanisms which today have to be addressed at the system level.
SOFC-Life New materials & This project is concerned with understanding Forschungszentrum 2.4 stacks the details of the major SOFC continuous Jülich, Germany degradation effects and developing models that will predict single degradation phenomena and their combined effect on SOFC cells and single repeating units.
D-CODE Degradation The D-CODE project aims to develop and University of Salerne, 1.1 issues implement on-line electrochemical impedance Italy spectroscopy (EIS) to have direct and meaningful information on the system status. The D-CODE project’s outcomes are expected to improve management and operational capabilities of both low and high temperature PEM fuel cells, to enhance monitoring capabilities, increase maintenance intervals with higher MTBF and reduce degradation rate, while optimizing system performance.
MCFC-CONTEX Degradation MCFC-CONTEX aims to tackle the degradation ENEA, Italy 1.8 issues of components by investigating poisoning mechanisms caused by alternative fuels and applications and determining precisely MCFC tolerance limits for long-term endurance and by optimizing fuel and gas cleaning to achieve tailored degrees of purification according to MCFC operating conditions and tolerance.
ROBANODE Degradation The ROBANODE project proposes an integrated Foundation for 1.5 issues strategy for understanding the mechanism Research and of processes which cause anode degradation Technology, Greece in hydrogen and natural gas fuelled SOFCs by combining robust theoretical modelling with experiments over an extended range of operating conditions, using a large number of modified state-of-the-art Ni-based anodes.
Programme Review 2012 - Final Report 25
Project name Type Description Coordinator EC Funding (M€)
KEEPEMALIVE Degradation KEEPEMALIVE aims to establish improved Stichting 1.2 issues understanding of degradation and failure Energieonderzoek mechanisms, accelerated stress test protocols, Centrum, sensitivity matrix and lifetime prediction Netherlands models for Low Temperature PEMFC to enable a lifetime of 40 000h at realistic operation conditions for stationary systems, in compliance with performance and costs targets.
DEMMEA Degradation The objective of the present proposal is to Advanced Energy 1.6 issues understand the functional operation and Technologies Greece degradation mechanisms of high temperature
H3PO4 PEM and its electrochemical interface.
PREMIUM ACT Degradation Project on the durability of PEFC (Polymer CEA-Liten, France 2.5 issues Electrolyte Fuel Cells), targeting one of the main hurdles still to be overcome before successful market development of stationary fuel cell systems.
LoLiPEM Degradation The main objective is to give a clear National council for 1.4 issues demonstration that long-life stationary Research, Italy power generation, CHP systems based on PEMFCHs operating above 100°C can now be developed on the basis of recent knowledge on the degradation mechanisms of ionomeric membranes and on innovative synthetic approaches recently disclosed by some participants of this project.
STAYERS Degradation Project STAYERS is dedicated to the goal of NEDSTACK, 1.9 issues obtaining 40,000 hours of PEM fuel cell lifetime Netherlands employing the best technological and scientific means.
GENIUS Operation The GENIUS project aims to develop a European Institute 2.07 diagnostics “GENERIC” tool that would only use process for Energy Research, values (normal measurements and system Germany control input parameters) to evaluate the state of health of any SOFC system.
DESIGN Operation The project proposes to study the influence of CEA, France 1.7 diagnostics slow acting damaging conditions on measures performed on the stack sub-components: the Cells and the Single Repeating Units (SRU) and on small stacks.
LOTUS Proof-of- The LOTUS project is to build and test a Low Hygear, Netherlands 1.6 concept Temperature SOFC system prototype based on and system new SOFC technology combined with low cost, component mass-produced, proven components. The use development of a modular concept and design practices from the heating appliances industry will reduce maintenance and repair downtime and costs of the system.
26 Fuel Cells and Hydrogen Joint Undertaking
Project name Type Description Coordinator EC Funding (M€)
ASTERIX3 Proof-of- The objective of the collaboration was to Dantherm, Denmark 1.3 concept evaluate HTceramix’s SOFC technology in and system perspective of development of a residential component micro-CHP application with a strong and well development defined market focus.
ASSENT Proof-of- This project is focused on the development VTT, Finland 2.0 concept of fuel and water management for SOFC and system systems. The fuel management, and especially component recirculation, is a key question in achieving high development electric efficiency and rejecting external water supply.
CATION Proof-of- This project is focused on the development Technical Research 2.6 concept of SOFC system’s air side fluid and thermal Centre, Finland and system management and mechanical solutions, i.e. component cathode subsystem and individual components. development
SOFT-PACT Demonstration Large scale field demonstration of Solid Oxide Eon 3.9 Fuel Cell (SOFC) generators that can be utilised in residential applications.
ClearGen Demo Demonstration Integration and demonstration of large Logan Energy 4.6 stationary fuel cell systems for distributed generation.
Ene-Field Demonstration European-wide field trials for residential fuel cell Cogen Europe 26 micro-CHP.
Reforcell Proof-of- Development of a new multi-fuel membrane Tecnalia 2.85 concept reformer for pure hydrogen production (5 and system Nm³/h) based on Catalytic Membrane Reactors component in order to intensify the process of hydrogen development production through the integration of reforming and purification in one single unit.
Flumaback Proof-of- Improvement of the performance, life time and Electro Power 2.98 concept cost of BOP components of back up fuel cell Systems and system systems specifically developed for emerging component countries where long black-outs occur and development difficult operative conditions are present.
SOFCOM Proof-of- Demonstration of the technical feasibility, Politecnico di Torino 2.9 concept the efficiency and environmental advantages and system of CCHP (a three product plant based on component cogeneration of cooling, heat and power) based development on SOFC (solid oxide fuel cell technology).
Programme Review 2012 - Final Report 27
Project name Type Description Coordinator EC Funding (M€)
EURECA New materials Development of the next generation of micro Next Energy 3.55 and stacks combined Heat-and-Power (µ-CHP) systems based on advanced PEM stack technology to overcome the disadvantages of complex gas purification, gas humidification and low temperature gradients for heat exchangers with operating temperatures of 90 to 120°C.
Metsapp New materials Development of novel cells and stacks based Topsoe 3.39 and stacks on a robust and reliable up-scale-able metal supported technology for stationary as well as mobile applications.
Metprocell New materials Development of innovative Proton Conducting Tecnalia 3.43 and stacks Fuel Cells (PCFCs) by using new electrolytes and electrode materials and implementing cost effective fabrication routes.
MMLCR+SOFC New materials Working towards mass manufactured, Low Cost Juelich 2.06 and stacks and robust SOFC stacks.
Laser-cell New materials Innovative cell and stack design for stationary AFC Energy 1.42 and stacks industrial applications using novel laser processing techniques.
28 Fuel Cells and Hydrogen Joint Undertaking Early Markets
Strategic priorities Taken as a whole, this portfolio covers the objectives of the MAIP, although the reviewers expressed concern that some of these With the objective to build up and sustain an early manufacturing projects were not progressing as well as had been initially planned. and supply base for fuel cells products and systems Early Markets Demonstration projects had experienced difficulties attracting aim to show technology readiness by focusing on demonstrations clients for demonstration activities, whilst others, without OEMs and ready-to-market products that are able to provide real world in the consortium appeared to have no clear route to market. operational experience to feed back into the RTD process. Some projects were affected by issues with the consortium or OEM suppliers, with at least one of the latter going bankrupt, Short term demonstrations cover mainly i) portable and micro- and the difficulty in attracting clients for demonstrations. With fuel cells, ii) portable generators, back-up power and UPS regard to the latter reviewers recommended that demonstration systems, iii) speciality vehicles, including hydrogen related projects should only start when end-users had been identified infrastructure, together with technology development projects and signed-up. with commonality with the Transportation and Stationary AAs. Main focus are on cost competitiveness, lifetime, reliability and However, perhaps the greatest concern of the reviewers is sustainability of devices and systems. whether or not the portfolio of projects were innovative or merely copying ideas and concepts already developed or under The Early Markets strategy has been to develop and deploy development elsewhere in the world. They questioned the value a range of fuel cell based products with near term market of the latter activities to the FCH JU, stating that it might be better potential. As such demonstrations are a substantive part of the supporting innovative concepts. Further they proposed that project portfolio, supported by specific R&D projects focused fewer demonstrations, and more basic and applied R&D projects on improving performance and achieving cost reductions of were supported. the key technologies. Projects fall into one of three categories: Material Handling vehicles, primarily fork lift trucks; portable and micro-fuel cells for personal power solutions; and back-up and Portable applications UPS power systems, especially for remote applications such as telecoms towers. The projects were deemed to be addressing the issues of the MAIP, but it was not clear how projects were ‘positioned’ against The portfolio of projects in this Application Area after three each other. Reviewers’ primary cause for concern was that the calls is well aligned with the overall strategy set up in the MAIP. portfolio comprised too much basic and applied R&D, and not With three flagship projects HyLIFT-Demo, SHEL and Mobypost enough demonstration activity. Many of them seemed to be covering material handling vehicles, over fifty vehicles should focused on cell and stack developments, rather than achieving be in the warehouses by 2013. These are not limited to forklifts, any of the demonstration activities. Furthermore the business but they include ten postal delivery vehicles and two trucks for cases, as presented, were felt to be weak. Reviewers therefore airport usage, including their fuel logistics. recommended that the portfolio required strengthening with projects focused on ‘real’ Early Markets and hence were more On the other identified early market, two important projects, advanced in terms of Technology Readiness Levels . The business FCPoweredRBS and FITUP have been launched to cover back- perspective of projects was further weakened by poor competing up and off-grid power supply. They are mainly focused on technology assessments. telecommunication applications such as radio based stations. Over 35 units will be installed in the field and some more Reviewers recommended undertaking a technology assessment used for assessment in specialized research laboratories. This to assist the FCH JU in identifying the real opportunities and is a real success story: following the first results, some of the needs in the portable space. manufacturers of the systems are optimizing their production lines and are close to fully commercial products.
In the portable application sector, new concepts are being explored for innovative solutions for fuel cells and the fuel logistics such as fuel cartridges that include reforming capabilities or reforming processes previous to the fuel cells, but integrated with them (DURAMET). Novel market opportunities such as unmanned flying vehicles and recreational boats are covered with different fuel cell concepts (SUAV).
Programme Review 2012 - Final Report 29 Back-up and off-grid applications In general, reviewers recommended that targets for Early Market applications be reviewed to define their relevance in what is a The two projects for this category appeared to address fast moving and highly variable sector. As part of this, reviews the AIP objectives and were broadly achieving progress of the technology requirements and market opportunities were in demonstrations. Performance targets were compatible recommended prior to commissioning of further demonstration with the AIP and MAIP, although there was some ambiguity activities. This was considered to be especially important for regarding definition of targets as they relate to back-up microFCs where competing technologies such as batteries and systems operating for only short periods of time in any one other fuel cell systems existed. Further work was required on year, as opposed to continuous operation. Further failure to performance metrics to ensure consistency of interpretation. present convincing competing technology assessments meant that there was uncertainty about whether targets in the MAIP It is believed there are considerable opportunities for interaction continued to be valid. between projects in the portfolio, for example safety, regulations and codes, as well as with European Member State programme. Reviewers were concerned that an emphasis on demonstrations Collaboration within the FCH JU portfolio and with Member was to the detriment of progress on cost reductions and States projects and programmes is evident in several cases, but technical problem resolution, and hence the improved systems currently under-developed by projects, which would be able to sought by MAIP. The reviewers argued that consideration should significantly benefit industry and allowing it to take advantage of be given to strengthening the portfolio to counter this apparent the FCH JU partnership. The FCH JU could assist through running weakness in technical development. The FCH JU has sought to technical thematic workshops to disseminate learning across address this issue with one project now on-going and another the FCH JU portfolio and those of the MS, eg linkages between being negotiated. Materials Handling and Refuelling Infrastructure.
Material Handling
The Material Handling projects have now been underway for more than a year. These are clearly aligned with the MAIP, but reviewers were concerned that maximum value added was unlikely to be achieved. Similarly they were convinced that the MAIP targets for vehicles would not be achieved.
Reviewers were especially critical of the mix of R&D and demonstrations, arguing that timing and resources meant that demonstrations were unlikely to be able to utilise any R&D advances within the timescale of the project. For example it would be preferable for demonstrations to use standardised HRS systems. They recommended that in the future projects should have a clear split between demonstrations and R&D in order that resources could be focused on one or the other objective. R&D was necessary to advance technologies in terms of performance and costs, but these should be separate from demonstrations.
Reviewers also expressed concern that projects were not able to present a good assessment of competing technologies, and as such requested that market and total cost of ownership assessments be undertaken to inform future Materials Handling demonstration projects. In addition there was a concern that for some projects there was no clear route to market for technologies, the consortia including technology developers and research, but not OEMs.
30 Fuel Cells and Hydrogen Joint Undertaking
Project name Type Description Coordinator EC Funding (M€)
Mobypost Demonstration of Low pressure storage solutions for hydrogen Institut Pierre 4.2 FC vehicles over two fleets of five vehicles on two different Vernier, France sites for postal mail delivery. Development of the vehicles and the associated refueling stations with due consideration of certification and public acceptance.
SHEL Demonstration of Demonstration of 10 units of 1.5-2.5 ton FCH Cidetec, Spain 2.44 forklifts FLTs and associated hydrogen refuelling infrastructure across 3 sites in Europe: UK, Spain and Turkey. The project also develops unified rapid product certification and infrastructure build approval procedures across the EU.
HyLIF-DEMO Demonstration of 2 year demonstration of 30 units of 2.5-3.5 tons LBST, Germany 2.88 forklifts forklifts with a fully integrated 3rd generation fuel cell system, as well as 2 year demonstration of hydrogen refuelling infrastructure at 3 end-user sites throughout Europe.
ISH2SUP H2 supply for Research and development of the cartridge Aalto University 1.0 micro-fuel cells technology and the electrical system.
IRAFC Development Development of an internal reforming alcohol Advanced 1.4 of PEM fuel cell high temperature PEM fuel cell. Energy stack Technologies
FITUP Demonstration Installation of 19 market-ready fuel cell systems Electro power 2.47 of back-up power from 2 suppliers as UPS/ backup power sources in systems systems selected sites across the EU. Real-world customers from the telecommunications and hotel industry will utilize these fuel cell-based systems, with power levels in the 1-10kW range, in their sites.
DURAMET Systems Development of direct methanol Fuel cells CNR 1.49 development components for application in auxiliary power units (APU) as well as for portable systems.
SUAV Systems Design, optimization and building of a 100- Hygear 2.1 development 200W mSOFC stack, and its integration into a hybrid power system comprising the mSOFC stack and a battery. All these components will be integrated into a mini Unmanned Aerial Vehicle platform like the CopterCity of SurveyCopter.
FCPowerdRBS Demonstration An EU-wide set of field trials that demonstrates Ericsson 4.22 the industrial readiness and market appeal of power generation systems for off-grid Radio Base Stations based on fuel cell technology and photovoltaic panels
Programme Review 2012 - Final Report 31 Cross-Cutting activities
Strategic priorities HyFacts is developing high quality and up-to-date training materials for regulators and public safety officials. A The Cross-cutting AA supports the fuel cell and hydrogen sector comprehensive map of existing educational and training activities in the other Application Areas with a range of projects activities in Europe has been produced, the target audience including those focused on socio-economic, environmental identified and a database with hundreds of contacts of public and energy impact of the FCH technologies, the development safety officials and other interested persons created. of processes to monitor the RTD programme, and support the European fuel cell and hydrogen sector to commercialise its The TrainHy project has developed an International Curriculum products. on fuel cell and hydrogen technologies for post-graduate students and young professionals. Two summer schools have In particular Regulation Codes and Standards (RCS) are identified been organised to verify and evaluate the applicability of the as a critical activity requiring support of the FCH JU to address curriculum concepts and develop a course and e-learning barriers associated with varying standards across Europe and the structure within which the educational programme can be developments to ensure harmonisation;socio-economic research organised. is seen as playing a role in providing data and information to educate and inform policy and decision makers, investors and The HyProfessionals project has developed an online course end users; Life Cycle Assessments enhance the understanding in order to train technicians and vocational training centres of the environmental and sustainability benefits and challenges (teachers and students) in electric vehicles, hydrogen and FCEVs. of FCH products; and training and general public education and They carried out a mapping of existing training initiatives, awareness are necessary to advance the general understanding materials and funding programs, made proposals for new of FCH technologies. initiatives by means of a gap analysis (current training offer vs. industry expectations) and have been implementing initiatives Cross-Cutting projects are both necessary and critical to through two pilot actions (200 person-week trained), and an realisation of the FCH JU’s overarching commercialisation E-library. objective. More information about the ‘actual outcomes’; indicators such as In this respect, over 8 €m have been allocated from the budget organisations contacted, training and assessment criteria by which 2008-2011 to support 9 projects so far, covering three distinct progress could be tracked for training projects. topics: training and education with three projects, TrainHy, HyProfessionals and HyFacts, all of which have either finished or The two Socio-economic studies cover two aspects of the MAIP are about to finish; Socio-economic studies with FC-EuroGrid and and meet the specific requirements of the MAIP. The reviewers the relatively newer Temonas; plus Pre-normative Research and noted that the value of both would be determined by the quality Life Cycle Analysis (PNR & LCA) projects, HyQ, HyComp, HyIndoor of targets and benchmarks in the case of FC-EuroGrid, and whether and FC-HyGuide. It is notable that only two projects, Temonas and and how the FCH JU could access data and other information to HyIndoor, had been added to the portfolio in the past year, which make use of the Temonas assessment tool. Both projects could is a concern given the importance of the Cross Crossing AA. potentially be used to inform the future development of the FCH JU, MAIP 2.0. Their primary concern was the extent to which the Reviewers state that the Education and Training projects are outputs of the projects would be used by industry and the FCH JU. adequately funded to meet their objectives, but also note that Interaction is critical for the former, and although there is evidence the efforts in this area should be continued and consideration that advisory boards are used, these appear to have had limited given to a budget increase given that the challenge will only involvement to date. Additionally international involvement could increase as fuel cell and hydrogen technologies move closer to be strengthened. early market deployment. Nonetheless,reviewers feel that an overall project assessing the requirements of the commercialisation in terms of objectives, benchmarks and assessment activities is required to ensure that future FCH JU activities are focused on the right areas.
32 Fuel Cells and Hydrogen Joint Undertaking PNR and LCA are sufficiently addressed by the four projects The legacy issue was noted in the question of how to keep currently underway. Furthermore the FCH JU is encouraging training materials up to date for example, and how to build on use of LCA as part of projects in the other AAs. With regard to these as fuel cell and hydrogen technologies were developed PNR and LCA projects reviewers stated a clear need for progress and demonstrated, and deployment progressed. Training of and achievements to be documented centrally to identify the trainers and regulators and public safety officials will become advances made and the gaps to be filled. increasingly important over next five plus years; these need to be prioritised. The reviewers noted that workshops with relevant More specifically the FCH JU and projects should devote more representatives are a valuable means of mapping out future, and time for planning for how the results of their work would be developing plans for education and training. utilised in the future, and to identify what future work was required. Reviewers were critical of the apparent lack of industry Reviewers also identified a need for much stronger interaction and end user involvement in the projects. Failure to involve these with projects within the portfolios of the other AAs. Possible groups meant that there was a failure to capture the views of the standardization of training programmes developed with other entire value chain, with the result that the projects were biased AAs was raised. Although there is evidence that this is taking by the nature of the consortia participants. Reviewers concluded place it is not widespread at present. Linkages with other EU that more involvement from across the value chain was required programmes, for example Marie Curie, were highlighted, as was to avoid niche viewpoints. As such AIPs should state that, for the need to operate in tandem with the activities of Member approval in the future, PNR and LCA projects needed to include States. However, projects themselves noted that education the entire value chain from developers through suppliers to end needs were largely met by Member States own activities, users as participants. This would enable a better understanding whereas harmonisation of regulator and public safety officials of the challenges and maximise the extent to which results are was European need. utilised by industry.
In general, reviewers believe that the current portfolio of nine projects provide adequate coverage of the key elements of the MAIP, but more effort on budget should be expended in the coming few years to ensure that the progress that has been made is maintained and enhanced through additional projects and adequate funding.
Reviewers considered that education and training should remain as a priority but a much clearer statement of intent was required to ensure that activities in the area continue beyond the life of the projects, and that these activities build on the momentum established to date, as already noted in the 2011 review.
Programme Review 2012 - Final Report 33
Project name Type Description Coordinator EC Funding (M€)
FC-Eurogrid Benchmark Evaluating the performance of fuel cells University of 0.58 in European Energy Supply Grids, by Birmingham, UK establishing technical and economic targets and benchmarks that allow the assessment of fuel cells in stationary power generation.
TRAINHY Training Building vocational training programmes for Forschungszentrum 0.26 post-graduate engineers and scientists, either Jülich, Germany at a Masters or PhD studies level of education or already employed by a company.
HyPROFESSIONALS Training Development of training initiatives for Foundation for 0.37 technical professionals aiming to secure the Hydrogen in Aragon required mid- and long-term availability of human resources for hydrogen technologies.
HY-FACTS Safety Identification, preparation and dissemination TÜV SÜD Akademie 1.04 of hydrogen safety facts to regulators and public safety officials.
HyCOMP PNR Currently, the most mature technology for Air Liquide 1.38 storing hydrogen is in compressed form in high-pressure cylinders. To improve volumetric and gravimetric performances, carbon fibre composite cylinders are currently being developed. However, current standards do not allow cylinder design to be optimized. The objective of HyCOMP is to produce improved type approval and batch testing protocols. The main outcome of the project will be a documentation of the real performance of composite cylinders to support Authorities and Industry in making enhanced RCS.
FC-HyGUIDE LCA The project FC-HyGuide aims to develop a PE International, 0.6 guidance manual for LCA of Fuel Cell and Germany Hydrogen based systems and related training materials and courses.
HyIndoor LCA Safe indoor use of H2; develop knowledge Air Liquide 1.5
base for safe handling of H2 indoor and issue safety guide and recommendations for RCS.
HyQ Pre-normative Hydrogen fuel quality requirements for CEA 1.37 research transportation and other energy applications.
TEMONAS Benchmark Standalone assessment tool aiming to enable Climt GmbH 1.13 the FCH JU to obtain an accurate assessment of progress both towards its objectives and its position within the global field of energy technologies.
34 Fuel Cells and Hydrogen Joint Undertaking Conclusion and recommendations
Clear achievements and progress are identified in this second Sustainable hydrogen production is confirmed as a priority, with programme review exercise, confirming the initial outcome of the various new projects coupling water electrolysis with renewable first review: the portfolio of some 70 projects arising from the first energy sources. Efforts towards the development of centralised four calls 2008-2011 is aligned with the strategy identified in the large scale production of hydrogen via water electrolysis are Multi-Annual Implementation Plan and structured to address the encouraged. Hydrogen storage, critical in establishing a hydrogen challenges identified along the value chain, from basic research, economy, is being addressed with the SSH2S, Bor4store projects through applied research to demonstrations. Gaps identified in on solid state storage, whereas HyUnder project is a welcome the last programme review are being filled by projects selected start to address the issue of energy storage of excess power from from the calls 2011 and 2012. intermittent renewable sources. The potential of hydrogen for large scale storage of energy from renewables would further Among these successes, the close integration between the justify enlarging the scope of work to allow for larger and more European Union, the research and industry communities, is ambitious projects. a valuable achievement. Over its five years of existence, the programme has structured the whole sector around ambitious, As project players get closer to the market, reviews of the shared goals. This programme has maintained a competitive technology readiness requirements and market opportunities support process fully open to all interested European industrial are considered valuable activities, as well as integration of end- and research entities, whilst achieving a high participation rate users, at an earlier stage of project development, in order to pave from innovative SMEs. a clearer way to market.
The industry-led public private partnership confirms its focus on With the current funding being only available till end of 2013, a commercialisation as the significant proportion of the budget next phase of the FCH JU under Horizon 2020 would provide a for demonstration activities illustrates. Ene-Field, SOFT-Pact and timely opportunity to further develop and improve the program’s ClearGen Demo stationary projects, and the CHIC, High V.LO city effectiveness and synergies. and FCGen transport projects are all excellent examples of this ambition. In particular, learning synergies and interaction between FCH JU projects, perhaps alongside national projects, would benefit the Regarding targets, technical and economic, adjustments are whole portfolio, especially should exchanges of information, required as the FCH JU moves towards another phase, and as centralised data banks or thematic worskshops be further technologies advance and markets develop. Current targets envisaged. would also benefit from additional commercially relevant measures and indicators such as cost of ownership. Volumes Technology transfer might also be enhanced through the use should be assessed against the actual scope of the Multi-annual of end–users groups established to spread benefits, although implementation plan, which goes beyond the remit of the FCH this needs to be done within the constraints of IPR ownership JU to encompass European activities as a whole. commercial sensitivities.
For Fuel Cell Electric Vehicles and Hydrogen Refuelling Stations, More strategically, any future FCH JU programme redesign although volumes and interest have increased, and good provides the opportunity to simplify the current application progress is being made on performance and durability or even area structure to facilitate interaction and synergies between purchasing prices as is the case for buses, the volumes required hydrogen fuel and usage applications, whilst also avoiding ‘silo’ for mass production remain challenging. Stationary technologies activities and projects. are achieving their objectives on volume and costs and the initial gap between prototypes and pre-commercial systems is being bridged.
Programme Review 2012 - Final Report 35 Collaboration with the activities of Member States and at the The nature of the challenges ahead – the level of investment international level, is further re-affirmed. Enhanced co- required in R&D to secure technology improvements and cost- ordination between National and regional programmes and the reductions, tackling barriers to market entry and EU-wide FCH JU is recommended, notably for demonstrations projects, consumer acceptance – calls for a step change in the operating which consume significant parts of FCH JU budget. International strategy of the FCH JU. A sharper focus on innovative collaborative co-operation beyond Europe FCH JU is also considered an asset, schemes, stronger integration with Member States, as well as if only to enable a better understanding of state-of-the-art with commensurate financial support for deployment to enable benefits to be gained from actively engaging with programmes returns on investment are avenues that need to be explored. in the USA, Canada, Japan, Australia, China, South Korea.
Cross-cutting activities, notably issues related to regulations, codes and standards, training and public awareness deserve attention with funds to match the ambitious objective to support implementation of the whole programme. These horizontal activities would also need to account appropriately for the achievements and ensure exploitation of results continue beyond the lifetime of the projects. Indeed training of trainers, regulators and public safety officials will become increasingly important as deployment progresses towards market commercialisation, and also raises the question of the legacy issue of how to keep training materials up to date.
Public awareness is increasingly important both to carefully manage expectations and prepare for consumer acceptance as fuel cells and hydrogen technologies reach a commercial reality.
36 Fuel Cells and Hydrogen Joint Undertaking List of reviewers
Alan ATKINSON, Member of the FCH JU Scientific Committee. Giuseppe ROVERA, Member of the FCH JU scientific committee.
Daniel CLEMENT, Deputy scientific director of ADEME (the Lars SJUNNESSON, Member of the FCH JU scientific committee. French agency for environment and energy), expert for the French ministries, the International Energy Agency and for the Tomohide SATOMI, General Manager for planning division in European Commission Fuel Cell commercialization Conference of Japan (FCCJ), Member of the technical advisory committee in NEDO, Japan. Andreas DORDA, Member of the FCH JU scientific committee. Michael SPIRIG, Advisor for the Swiss FCH Research Program Antonio GARCIA-CONDE, Director of the Department of and Swiss Research Program for Industrial Processes, Director Aerodynamics and Propulsion in INTA (the Spanish National Institute of the European Fuel Cell Forum AG and CEO of Fomenta AG. of Aerospace Technology), Executive Committee Chairman of the International Energy Agency Hydrogen Implementing Agreement Ulrich STIMMING, Member of the FCH JU scientific commlttee. (2008-2011). Marc STEEN, Head of unit Cleaner Energy at JRC Institute for Knut HARG, Chair of the FCH JU scientific committee. Energy and Transport, leading JRC research and innovation activities on hydrogen storage, sensing, safety and fuel cell Thorsten HERBERT, Program Manager for Transportation in technologies. NOW GmbH (German National Organization Hydrogen and Fuel Cell Technology). Thanos STUBOS, Research Director, Head of the Environmental Research Laboratory, at the National Research Center Helge HOLM-LARSEN, CEO of TEGnology, a company working “Demokritos” in Greece. with electricity generators based on thermo electrical materials and advisor and reviewer for Danish energy organizations. George SVERDRUP, President of GMS Consulting, since June 2012, previously Laboratory Program Manager at the U.S. John KOPASZ, Technical Advisor to the U.S. Department of National Renewable Energy Laboratory. Energy Fuel Cell Technologies Program in the areas of fuel cells and hydrogen storage, Manager at Argonne National Laboratory Daria VLADIKOVA, Member of the FCH JU scientific committee. for programs on materials related problems in energy production.
John LOUGHHEAD, Georg MENZEN, Head of division for Fuel Cells, Hydrogen, Energy Storage in the German Federal Ministry of Economics and Technology.
Pietro MORETTO, Director of the microstructural and analytical activities of the Institute for Energy and Transport of the Joint Research Center of the European Commission.
Stefan OBERHOLZER, Andreas PFRANG, Researcher in the fuel cell activities and responsible for micro- and nano-structural analysis at the Institute for Energy and Transport of the Joint Research Centre in Petten, Netherlands.
Walt PODOLSKI, Technical Advisor to the U.S. Department Of Energy Fuel Cell Technologies Program, Leader of the Electrochemical Projects Support Group in the Argonne National Laboratory Chemical Sciences and Engineering Division.
Programme Review 2012 - Final Report 37 38 Fuel Cells and Hydrogen Joint Undertaking Project funded by the FCH JU
Transport and refuelling infrastructure 40
Hydrogen production and storage 54
Stationary power generation and Combined Heat and Power 88
Early markets 146
Cross-cutting issues 164
Programme Review 2012 - Final Report 39 CHIC Clean Hydrogen in European Cities
Key Objectives Challenges addressed Technical approach and achievements
The CHIC-Project is the next essential 26 FC buses will operate in daily public The project aims to achieve certain step leading to the full market transport operations in five locations technical goals regarding the fuel cell commercialization of hydrogen across Europe: Aargau (Switzerland), bus operation and the H2 infrastructure. powered fuel cell (FC) buses. This Bolzano (Italy), London (UK), Milan The main technical goals for the installed project will provide results from a (Italy) and Oslo (Norway) . hydrogen infrastructures are to achieve: demonstration run of more than 55 The project is based on a staged • a capacity of 200kg H2 per day or fuel cell buses. The key objectives are: introduction and build-up of FC bus minimum 5 vehicles per hour with a • Operation of 26 fuel cell buses and fleets, the supporting hydrogen fueling minimum of 50 vehicles per day (to be the respective infrastructure in 5 stations and infrastructure in order to upgradeable to min 100 vehicles per major European regions (“Phase facilitate the smooth integration of the day) 1 cities”) for a period of 5 years FC buses into Europe’s public transport • an average availability of 98% (based • Collaboration and transfer of system. Furthermore, a sustainability on operation time)
key lessons learned from “Phase assessment of the use of the buses will Furthermore, the H2 OPEX costs are 0” cities (~30 fuel cell buses in be provided in order to analyse their planned to be less than 10 €/kg (excl. tax)
operation) to “Phase 1” cities impact on sustainability. Therefore, the and the production efficiency for the H2 • Assessment of the technology bus operation will be accompanied production will be between 50-70 %. with a focus on environment, by several studies analysing the The demonstration of the FC buses and
economy and society performance, environmental profile, hereby the use of H2 is supposed to • Dissemination to the general public as cost development and the social replace a minimum of 500.000l diesel fuel well as to cities and regions preparing acceptance of the operating buses. In throughout the project. for the technology in the next step and general, the project will identify the The main technical goals of the bus interested in setting up fuel cell bus advantages, improvement potential, operation focus on ecological and and hydrogen projects (“Phase 2” cities). complementarities and synergies of economical aspects such as low FC buses compared with conventional fuel consumption and a high rate of and alternative technologies and availability. Therefore, the main technical will help the technology on the goals during the project are to achieve way to commercialisation. • a fuel cell lifetime of >6000 h of operation • an average availability of all FC buses greater than 85% (based on operation time) • fuel consumption less than 13 kg/100 km (depending on drive cycle) • a minimum running distance of 2.75 Mio km and a minimum of 160,000 hours of operation of the deployed FC bus fleet. © chic
40 Fuel Cells and Hydrogen Joint Undertaking 2 Clean Hydrogen In European Cities www.chic-project.eu www.chic-project.eu Transport and Refuelling infrastructure
Expected socio and economic impact Partners London Bus Service Ltd UK Hydrogen and fuel cells play an EvoBus GmbH PE INTERNATIONAL AG important role in the reduction of Germany Germany local air pollutants, as well as in the decarbonisation of Europe’s transport Air Products Plc PLANET - Planungsgruppe Energie und system. Fuel cells use hydrogen to UK Technik GbR generate electricity while emitting Germany only water vapour. CHIC will reduce the Azienda Transporti Milanesi S.p.A. ‘time to market’ for the technology and Italy PostAuto Schweiz AG support ‘market lift off’ – two central Switzerland objectives of the Joint Undertaking. Berliner Verkehrsbetriebe A.ö.R. Germany SHELL DOWNSTREAM SERVICES INTERNATIONAL BV Project Information Element Energy Limited Netherlands UK Project reference: FCH JU Spilett new technologies GmbH Call for proposals: 2009 Euro Keys SPRL Germany Application Area: Transport Belgium Project type: Collaborative Suedtiroler Transportstrukturen AG Topic: Demonstration Air Liquide Hydrogen Energy Italy Contract type: Collaborative Project France Start date: 01/04/2010 TOTAL Deutschland GmbH End date: 31/12/2016 HyCologne - Wasserstoff Region Germany Duration: 81 months Rheinland e.V. Project total costs: € 81 894 400 Germany UNIVERSITAET STUTTGART Project funding: € 25 878 334 Germany European Regions and Municipalities Partnership on Hydrogen and Fuel Cells Vattenfall Europe Innovation GmbH Project Coordinator Belgium Germany
Dr. Helmut Warth Infraserv GmbH & Co. Höchst KG Ruter AS Daimler Buses – EvoBus GmbH Germany Norway Hanns-Martin-Schleyer-Straße 21-57 D-68301 Mannheim BC Transit Wrightbus Limited Germany Canada UK
Phone: +49 (0) 621 / 740 – 59 79 Linde AG hySOLUTIONS GmbH Fax: +49 (0) 621 / 740 – 42 50 Germany Germany [email protected]
Programme Review 2012 - Final Report 41 DESTA Demonstration of 1st European SOFC Truck APU
Key Objectives Summary/overview performed by the independent research institute Forschungszentrum Jülich. The result of this benchmark is an The main objective of DESTA is the On 1st of January 2012, the research optimized DESTA SOFC APU combining demonstration of the first European project DESTA started under the the superior features of the individual Solid Oxide Fuel Cell (SOFC) Auxiliary coordination of AVL List GmbH (Austria). systems. In parallel, Topsoe Fuel Cell will Power Unit (APU) for trucks: It is the goal of DESTA to demonstrate work on the SOFC stack optimization. • Maximum electrical power ≥3kW the first European Solid Oxide Fuel Cell The consortium is confident that the • Operation on conventional (SOFC) Auxiliary Power Unit (APU) on chosen technology is sufficiently mature road diesel fuel board of a heavy duty truck. By gathering to perform well in a truck demonstration • Long-term tests: ~ 300 thermal the project partners J. Eberspächer in 2014 and will be close to the start- cycles and ~ 3.000 operating hours GmbH (Germany), AVL List GmbH of-production in the coming years. • System electrical net (Austria), Volvo (Sweden), Topsoe Fuel efficiency around 35% Cell (Denmark) and Forschungszentrum • System volume and weight Jülich (Germany) into one consortium, Technical approach below 150 l and 120 kg a 100% European value chain for a and achievements
• CO2 reduction of 75% compared to SOFC APU is established. With an aim to engine idling of a heavy-duty truck reduce emissions, noise and costs, the After the project start in January 2012, • Start-up time of ~30min end product will have excellent export the requirement specifications for the • Noise level ~65dB(A) opportunities, creating new high & clean application of the SOFC APU on a Volvo • Truck integration. teach job opportunities in Europe. heavy-duty truck for the US market have been performed. This process was A significant advantage of the SOFC essential for the further development technology in contrast to other fuel of the project. JE and AVL continued cell technologies is its compatibility the optimization of their SOFC APU with conventional road fuels like diesel. systems with the support of TOFC in The DESTA partners Eberspächer and stack improvement and supply. In line AVL put a lot of effort in bringing the with the timeline, the project has started SOFC APU technology to the prototype the benchmark phase for which the level. For the market entry of this benchmark criteria have already been technology, the final breakthrough defined. The first 2 APU systems (one milestone is the demonstration of from AVL and one from JE) are already its functionality on a truck – the in operation. Otherwise, all deliverables major goal of the DESTA project. and milestones have been provided and The first phase of the project defines reached in time. the requirements for the application of a SOFC APU in a Volvo heavy-duty truck for the US market. Based on test results including production costs, controllability and the manufacturability of the existing systems from AVL and Eberspächer, a benchmark will be © desta
AVL SOFC APU Gen 1.0 (released for publication, JR, 27.01.2012, benchmark system)
42 Fuel Cells and Hydrogen Joint Undertaking www.desta-project.eu Transport and Refuelling infrastructure
Expected socio and economic impact Project Information Partners
Significant impact on society is expected Project reference: FCH JU 278899 J. Eberspächer GmbH & Co. KG, Esslingen through the fast market introduction Call for proposals: 2010 (JE) of SOFC APU products (estimated for Application Area: Automotive Germany 2015) with all positive effects such as Applications reduced emissions, noise and costs. With Project type: Demonstration Topsoe Fuel Cell A/S, Lyngby (TOFC) stack manufacturing (TOFC, Denmark), Topic: SP1-JTI-FCH.2010.1.5: Denmark system manufacturing (Eberspächer, Auxiliary Power Units for Germany) and vehicle manufacturing Transportation Applications Volvo Technology AB, Gothenburg (Volvo) (Volvo, Sweden), the product value Contract type: Collaborative project Sweden chain stays completely within the EU. Start date: 01/01/2012 The final product will enjoy excellent End date: 31/12/2014 Forschungszentrum Jülich GmbH, Jülich export opportunities to the US and Duration: 36 months (FZJ) other countries due to local anti- Project total costs: € 9.841.007 Germany idling legislations and the great cost Project funding: € 3.874.272 saving potential for truck operators. Project Coordinator
AVL List GmbH Austria
Contact Coordination: Mr Jürgen RECHBERGER [email protected]
Contact Communication: Ms Ingrid KUNDNER [email protected]
Programme Review 2012 - Final Report 43 FCGEN Fuel Cell Based On-board Power Generation
Key Objectives Complete APU system: The focus Project management: The focus in this was on identification of the most work package was on monitoring the important criteria for system design and progress of the project, maintain and The overall objectives of the FCGEN integration, providing a comprehensive update the project plan, administrate project are to develop and demonstrate description of the requirements for APU the project communication platform a proof-of-concept complete FC-APU control, integrating the components (Teamplace), keep track of the costs and in a real application and on-board a and sub-systems, and identifying the financial reporting, support the work truck to further develop the APU key limitations while further developing with project results dissemination and components that are expensive or still the existing BoP components. Work exploitation, interact with the European behind the required level of maturity. The has been carried out on system Commission and external parties concrete system targets are (i) to reduce design and packaging optimization and arrange work package leaders the system volume and mass to 300 l and to meet efficiency and size targets. and steering committee meetings. 125 kg respectively; (ii) to demonstrate a system of efficiency ~ 30% and (iii) to Fuel processor: A system design and reduce the system cost to ~1000 €/ kW. architecture was developed for the fuel Technical approach processor system, and system units were and achievements developed and manufactured focusing Summary/overview on requirements related to efficiency, So far the project team has managed to performance, compactness, and cost. develop a complete and compact system System integration and design and packaging model and define demonstration: The focus has been on Control system- electrical interface the final system architecture for the fuel defining vehicle specifications which and power conditioning: The focus in processor (FP) system. The FP reactors are necessary for the development of this work package was on defining the are developed and manufactured and the APU unit; and the creation of a data most optimal strategy plan for system most of the Balance of Plant components set and the physical signal interface control, both under the development (BOP) are identified or purchased. The necessary for APU communication phase and for the integrated APU specification for the vehicle integration with the vehicle. Additionally, we wish system alike. A preliminary design have been addressed and completed to define important aspects for APU based on the APU system control and the exchange data set necessary communication specifications and requirements and system control for APU controls and operation is implementations. In addition, an analysis needs was developed and functional available. A Control system concept and was carried out in order to identify connections necessary to manage the architecture with the intermediate use the profit of electrifying the most APU was defined to make the driver of standard controllers is developed and conventional auxiliaries in terms of fuel able to operate the APU system. the acquisition of basic EMC automotive saving during travelling and stop phases. standards and directives is carried out.
44 Fuel Cells and Hydrogen Joint Undertaking Transport and Refuelling infrastructure
Expected socio and economic impact Project Information Partners
The vision of the FCGEN project is to Project reference: FCH JU 277844 Powercell Sweden AB move the FC-based APU systems a Call for proposals: 2010 Sweden step further towards industrialization. Application Area: Transportation & The project is targeting several issues Refuelling Infrastructure Forschungszentrum Juelich GMBH which make this possible, including: Project type: research and (Juelich) system cost, improved system design Technological Germany for better performance, better efficiency Topic: SP1-JTI-FCH.1.5: Auxiliary Power and durability, reduced system size Units for Transportation Applications Institut Jozef Stefan (JSI) and weight. Efficient, durable and cost Contract type: Collaborative project Slovenia effective FC-based APU systems provide Start date: 01 November 2011 clean electricity and less noise in the End date: 31 October 2014 Centro Ricerche Fiat SCPA (CRF) driver’s cabin during stand still conditions, Duration: 36 months Italy compared to the condition when Project cost: €10 338 414 electricity is generated by engine idling. Project funding: € 4 342 854 Institut fuer Mikrotechnik Mainz GMBH (IMM) Germany Project Coordinator Johnson Matthey PLC. (JM) Jazaer Dawody UK Volvo Technology Corporation Sweden Modelon AB (Modelon) Sweden Contact: Jazaer Dawody [email protected]
Programme Review 2012 - Final Report 45 H2moves Scandinavia Lighthouse Project for the Demonstration of Hydrogen Fuel Cell Vehicles and Refuelling Infrastructure in Scandinavia
Key Objectives Challenges addressed Technical approach and achievements
The focus of this public-private Obviously fuel cell vehicle and Next to the daily operation of 17 fuel partnership is to accelerate the market hydrogen technologies have reached cell cars in Oslo (and 2 in Copenhagen) introduction of hydrogen powered fuel a state of development allowing their using an existing hydrogen refuelling cell electric cars. The projects ambition deployment in mass markets soon station network and one additional is to launch the latest “state-of-the-art” in central Europe. Also in harsher station conveniently located in Oslo hydrogen fuel cell vehicles and to European climates, such as in the North, accompanying activities study car and consolidate the existing hydrogen performance data need to be assessed station performance, asses today’s fuelling network in the south of Norway from everyday driving to understand in certification procedures in Scandinavia and in Denmark by adding a new how far vehicles and fuelling equipment and communicate about the project and refuelling station in Oslo and delivering are ready for commercialisation its achievements in the public. 19 fuel cell city and sedan cars in under these conditions. total (17 in Oslo, 2 in Copenhagen). To attain customer acceptance, the Accompanying activities shall accelerate In sharp contrast it is perceived hydrogen station in Oslo Gaustad was the commercialization of fuel cell vehicles that the technical and comfort publically opened in November 2011 and hydrogen refuelling infrastructure by advantages of fuel cell cars have not and a Road Tour across Europe is under understanding the status of certification yet been well communicated, such preparation in the summer of 2012. By and the needs to adapt them across as rapid refuelling as well as driving organising public events, such as test all of Scandinavia. Finally, the general range per refuelling and payloads drives, the public is informed about this public in Scandinavia shall be informed acceptable for the customer. Hence exciting technology – sustainable fuel and it should become obvious that communication activities should be should be seen in normal operation as fuel cell cars and hydrogen are about an important part of the project. alternative to fossil fuel. to enter the European market. Time consuming and expensive vehicle and refuelling station certification The experience from Nordic climate procedures are one burden to their conditions will yield additional insights accelerated market introduction across to ensure the vehicles are capable to Europe. A safety study will contribute perform within more extreme climatic to understand the current state-of- markets. play of legal procedures across all of Scandinavia and to derive best practices to reduce potential burdens.
Driving into the future with FIE. © h2moves scandinavia © h2moves
46 Fuel Cells and Hydrogen Joint Undertaking www.scandinavianhydrogen.org/h2moves Transport and Refuelling infrastructure
Expected socio and economic impact Project Information Partners
A widely visible launch event in Oslo Project reference: FCH JU, Grant Ludwig-Bölkow-Systemtechnik GmbH with live broadcasting on several TV Agreement 245101 Germany channels and a ride&drive event attached Call for proposals: 2008 to it have resulted in a sound echo in Application Area: Transportation and Daimler AG (Germany) with Bertel O. Oslo and Norway. This has contributed refuelling infrastructure Steen to a better understanding of the role of Project type: Demonstration Norway fuel cell vehicles as one type of electric Topic: SP1-JTI-FCH.1.1: Demonstration vehicle, characterised by the advantage of Hydrogen fuelled road vehicles and Hyundai Motor Europe GmbH of rapid refuelling, extended driving refuelling infrastructure Germany range per refuelling in combination Contract type: Collaborative Project, with zero emissions of hydrogen from Large-scale demonstration of road H2 Logic hydropower and noiseless driving with vehicles and refuelling infrastructure Denmark high vehicle acceleration potential. The Start date: 01/01/2010 project key messages of “here today – End date: 31/12/2012 Hydrogen Link Association everywhere tomorrow” and “fun to drive” Duration: 36 months Denmark were well and widely communicated. Project total costs: € 19.4 million With the European Road Tour, Project funding: € 7.8 million Hydrogen Sweden the consortium expects to widely Sweden demonstrate that the project fuel cell The project is nationally co-funded car fleet extended by cars from other by contributions from Transnova in SINTEF manufacturers can travel all across Europe Norway and EUDP in Denmark. Norway already today even though refuelling infrastructure is scarce. It will also be SP shown that fuel cell vehicles are reaching Project Coordinator Sweden the deserved attention in central as well as in Southern and Northern Europe. Dr. Ulrich Bünger TÜV SÜD c/o Ludwig-Bölkow-Systemtechnik Germany GmbH Daimlerstrasse 15 D-85521 Ottobrunn/Germany
Tel: +49(89) 608 110 – 42 Fax: +49(89) 609 97 31 [email protected]
Programme Review 2012 - Final Report 47 High V.LO City Cities speeding up the integration of hydrogen buses in public fleets
Key Objectives The project addresses the More specifically High V.LO City will: following key issues: - Build on the experience of Van Hool in the USA (21 buses 2005-2010) The overall objective of High V.LO-City A) Increase the energy efficiency - Link Liguria, Antwerp, and is to facilitate the rapid deployment of of the buses and reduce the Aberdeen with already existing the last generation FCH buses in public cost of ownership by: activities in the United Kingdom transport operations, by addressing - Taking hydrogen consumption (London), Netherlands (Amsterdam key environmental and operational down to 7–9 kg H2/100km and Arnhem), Germany concerns that transport authorities are - Integrating the latest drive train (Cologne, Hamburg, Berlin), facing today. Therefore, a fleet of 14 and battery technologies Spain (Madrid, Barcelona) and commercial FC buses and the required - Ensuring the availability of Italy (Bolzano and Milano). refueling infrastructure will be put 90% without the need for in place in 3 sites: San Remo (Italy), permanent support Antwerp (Belgium) and Aberdeen - Ensuring >12.000 hours warranty and Technical approach (Scotland). The infrastructure will support decreased additional warranty cost and achievements the creation of a network of ‘Clean - Increasing the lifetime of Hydrogen Bus Centers of Excellence’. key components as fuel At this moment, the demonstration cells and batteries infrastructure is being deployed. At Van - Taking down investment Hool, the 14 FC buses are in production Summary/overview cost <1,3 million euro and will become available in 2013. The first buses are planned to leave the Several European bus manufacturers B) Reduce the cost of factory at the end of March, with the last consider the hybrid fuel cell (FCH) bus hydrogen supply in: one departing in early 2014. All three as the most promising technology - Liguria: linking up with sites are initiating the construction of to facilitate the decarbonisation of renewable hydrogen sources the necessary infrastructure work in public transport. By leveraging the - Antwerp: using by-product order to have the Hydrogen Refuelling experiences of past fuel cell bus projects, hydrogen from industry Infrastructure ready once the buses implementing technical improvements - Aberdeen: making use of existing go into commercial service. This entire that are meant to increase efficiency hydrogen production and infrastructure (FCB and HRI) is equipped and reduce the costs of FCH buses, as distribution mechanisms and with a data logging system to evaluate well as introducing a modular approach eventually Scotland’s extensive the ‘Key Performance Indicators’ – a set to hydrogen refueling infrastructure wind energy resources of indicators that will demonstrate the build-up, the High V(Flanders).L(Liguria) achievements of both the buses and the O(ScOtland)-City project aims to C) Consolidate past, current and future refuelling infrastructure. significantly increasing the “velocity” fuel cell bus demonstration activities of integrating these buses on a larger by creating an active dissemination scale in European bus operations. network of Hydrogen Bus Centres of Excellence in collaboration with the Hydrogen Bus Alliance, Global Hydrogen Bus Platform, HyRaMP and JTI hydrogen bus demonstration projects.
48 Fuel Cells and Hydrogen Joint Undertaking www.highvlocity.eu Transport and Refuelling infrastructure
Expected socio and economic impact Project Information Partners
High V.LO-City intends to maximize Project reference: FCH JU 278192 Riviera Trasporti the effect of its actions at local level, Call for proposals: 2011 Italy considering regional development Application Area: as the key element to sustain the Project type: Demonstration Dantherm European FCH market takeup. Involving Topic: SP1-JTI-FCH.2010.1.1: Large scale Denmark in each demonstration site the entire demonstration of road vehicles and value chain of public and private refuelling infrastructure III Solvay stakeholders, the expected outcome Contract type: Collaborative project Belgium is to reach Regional & Urban Mobility Start date: 01 January 2012 Plans, committing these regions to built- End date: 31 December 2016 De Lijn up long-lasting integrated policies to Duration: 60 months Belgium support FCH market enhancement. Project cost: € 31.586 million To guarantee a wide impact of Project funding: € 13.491 million Waterstofnet the results, a clear Transferability Belgium model has been identified. Project Coordinator HyER Belgium Van Hool Belgium DITEN Italy Contact: Mr Paul JENNE [email protected] Regione Liguria Italy
FIT Italy
Aberdeen City Council UK
Ballast Nedam Netherlands © high v.lo city © high v.lo
Programme Review 2012 - Final Report 49 HyTEC Hydrogen Transport in European Cities
Key Objectives The results of the project will inform In addition, new networks for hydrogen future commercialisation and refuelling in each city will be developed, infrastructure rollout planning by including: The HyTEC project will expand the policy makers and industry players. A • A new publicly accessible London existing European network of hydrogen widespread dissemination campaign refuelling station. demonstration sites into two of the will be aimed at improving public • The start of a city-wide network for most promising early markets for awareness of the potential for hydrogen London with associated hydrogen hydrogen and fuel cells, Denmark vehicles as a future low carbon transport delivery logistics. This deployment will and the UK. The key objectives are: solution. This will be backed up by a represent a major step forwards in the • Demonstrate up to 30 new hydrogen more targeted campaign aiming at development of an integrated citywide vehicles in the hands of real industry players, opinion formers and refuelling infrastructure, designed for customers, in three vehicles classes: key policy makers across Europe. For the high hydrogen throughput required to taxis, passenger cars and scooters. first time, the project will create genuine begin a commercial-rollout. These will be supported by new links between the new and existing • A new publicly accessible Central- hydrogen refuelling facilities, which European hydrogen demonstration Copenhagen refuelling station network. combine with existing deployments projects, with a view to informing The city network is to be linked to create two new city based ongoing strategic planning for hydrogen with other major cities in Denmark, networks for hydrogen fuelling. rollout and also ensuring a ‘common contributing to the efforts of securing • Analyse the results of the project, voice’ towards the expansion of the a countrywide station network beyond with an expert pan-European research hydrogen vehicle fleet in Europe towards 2015. team considering full well-to-wheel life cycle impact, demonstrating An extensive research program will assess technical performance of the vehicles Technical approach the technical performance of the vehicles and uncovering non-technical and achievements over a two year demonstration period, barriers to wider implementation. a life cycle impact assessment of the • Plan for future commercialisation The project will involve a fleet of 30 state- vehicles will demonstrate the overall well of the vehicles. of-the-art hydrogen fuel cell vehicles to wheels impacts and social studies will • Disseminate the results of the operated for two years, in London and investigate the non-technical barriers. project widely to the public to Copenhagen, based on: improve hydrogen awareness. • A fleet of state-of-the-art hybrid hydrogen fuel cell LTI ‘black cab’ taxis in London, to be operated by a number of Challenges addressed end-users. • A fleet of state-of-the-art hybrid The project will implement stakeholder- hydrogen fuel cell Suzuki scooters in inclusive vehicle demonstration London, to be operated within the programmes that specifically address London municipal fleet. the challenge of transitioning hydrogen • A fleet of state-of-the-art hydrogen vehicles from running exemplars to fuel cell OEM passenger cars in fully certified vehicles utilised by end- Copenhagen, to be used by high profile users and moving along the pathway to public bodies in prominent roles, as providing competitive future products. well as vehicle dissemination tours around Denmark.
50 Fuel Cells and Hydrogen Joint Undertaking www.hy-tec.eu Transport and Refuelling infrastructure
Expected socio and economic impact Project Information CENEX – Centre of excellence for low carbon and fuel cell technologies The expected impacts are to: Project reference: FCH JU UK • Demonstrate a combined hydrogen Call for proposals: 2010 vehicle and fuelling system Application Area: Transportation & Greater London Authority for urban fleet operations. Refuelling Infrastructure UK • Create links between the new Project type: Demonstration and existing European hydrogen Topic: Large-scale demonstration hySOLUTIONS GmbH demonstration projects. of road vehicles and refuelling Germany • Improve public awareness of infrastructure III hydrogen fuel cell vehicles and their Contract type: Collaborative project MATGAS 2000 A.I.E. potential in tackling the problem Start date: 01/09/2011 Spain of emissions from transport. End date: 31/12/2014 • Raise the profile of alternative fuel Duration: 40 months Ludwig-Boelkow-Systemtechnik GmbH vehicles in the UK and Denmark Project total costs: € 29.5 million Germany beyond the current focus on Project funding: € 12 million battery electric vehicles. Copenhagen Hydrogen Network AS • Improve industry engagement with Denmark hydrogen fuel cell technology. Project Coordinator • Catalyse a partnership between Kobenhavns Kommune industry and Government in both Diana Raine Denmark countries, achieved through a European Business Manager new public-private partnership Air Products PLC, Hersham Place Foreningen Hydrogen Link Danmark which will report on the next Technology Park, Walton-on-Thames, Denmark steps to commercialisation. Surrey, KT12 4RZ, • Create two new lighthouse cities Intelligent Energy Ltd in Europe for large-scale vehicle [email protected] UK demonstration activities, reducing the burden of responsibility on Germany BAA Airports Ltd and catalysing future hydrogen Partners UK fuel cell vehicle markets beyond a single major European country. Air Products PLC London Bus Services Ltd UK UK
Element Energy Ltd Fraunhofer-Gesellschaft zur Foerderung UK der Angewandten Forschung E.V Germany European Regions and Municipalities Partnership on Hydrogen and Fuel Cells Belgium
LTI Limited UK © hytec
Programme Review 2012 - Final Report 51 PEMICAN PEM with Innovative low cost Core for Automotive applicatioN
Key Objectives Challenges addressed Technical approach and achievements
Reduction in the catalyst costs (gram The global aim of PEMICAN is to Three key Milestones are defined in the of catalyst per kW) should contribute manufacture active layers with reduced project. greatly to the industrialisation of catalyst loading but keeping the PEMFC for automotive applications. power density as high as possible. MEA Level 1 is planned at Month 12: To date much work has been carried For this to happen, the first issue reaching around 0.6 g Pt/kW and 350 out on the catalyst but much less consists in developing and introducing mW/cm². on other aspects of the active layers specific electrolyte and carbon black Focus will be on the improvement (structure, carbon and electrolyte) into the active layers. These new raw of ink formulation (electrolyte and even though they play a crucial role on materials should improve charge and carbon) on the cathode side and performance. PEMICAN proposes to gas transfers, increasing the electrical on the manufacturing of anodes by reduce the catalyst cost down to 0.15 current delivered and consequently Particle Vapour Deposition (PVD). gram per kW by a twofold approach: i) the power density. The other issue is to Performance models will be used to foster increase catalyst use and power density produce active layers with a reduced improvement of the active layers. by improving transport properties of catalyst loading by locating it where it is Air Liquid; ii) reduce catalyst loading most useful. Combination of both should MEA Level 2 is planned at Month 24: by controlling its distribution. allow reducing the catalyst loading with reaching around 0.4 g Pt/kW and 500 This technological approach is supported little influence on the power density. mW/cm². by a scientific one: i) numerical Another challenge is to improve Focus will be on gradients (electrolyte, models to help defining catalyst the existing numerical modelling to Carbon, Pt) on the cathode side and on improved distribution; ii) fundamental better link local properties of active the manufacturing of anodes by PVD or electrochemical experiments to layers to performance of the PEMFC. by Direct Electro Deposition. Performance improve the existing models. For this, specific new measurements models will be improved (better will be performed on fundamental characterization of transport properties, electrochemistry, charge and gas experimental validation) and used to help transfers and introduced into specific improvement of the active layers. models to improve the active layers. MEA Level 3 is planned at Month 36: reaching the final target at around 0.15 gPt/kW and 350-700 mW/cm². Focus will be on manufacturing active layers with precise Pt/Carbone/electrolyte localisation and properties. According to Autostack project’s outputs, if high power density is difficult to reach with such low catalyst loading, priority will be given to increasing the power density (up to ideally 1 W/cm²) even if higher catalyst loadings are necessary for this. © pemican
52 Fuel Cells and Hydrogen Joint Undertaking www.pemican.eu Transport and Refuelling infrastructure
Expected socio and economic impact Project Information Partners
PEMICAN will contribute to the cost Project reference: FCH JU 256798 CEA reduction in PEMFC and consequently Call for proposals: 2009 France to its mass market development for Application Area: Automotive automotive application. Whereas the application Opel project is focused on pure platinum Project type: Research and Germany its results will be useful also in the Technological Development future when efficient non pure Topic: SP1-JTI-FCH.2009.1.3 Solvay platinum is available to even reduce “Development and optimisation of Italy more the cost of PEMFC. Improved PEMFC electrodes and GDLs modelling developed in the project Contract type: Collaborative project Tecnalia could also be used in the future as a Start date: 01/04/2011 Spain baseline for design tools of PEMFC. End date: 31/03/2014 The project will contribute to the Duration: 36 months Timcal development of a low carbon driven Project cost: € 3.96 million Switzerland European Industry and is a good Project funding: € 1.86 million example of collaboration between Imperial College industry (manufacturers, end-users), UK research centers and universities. Project Coordinator
First results have been obtained: Commissariat à l’Energie Atomique • simulation has been used to et aux Energies Alternatives analyse first modifications of (CEA) cathodes to deduce the reduction France in catalyst loading with minor French Atomic and Alternative influence on performance Energies Commission • active layers with reduced catalyst loading and with new ink formulations Contact: Mr Joël PAUCHET (electrolyte, carbon black) have [email protected] been manufactured and tested • feasibility checks have been carried out on the manufacture of active layers with gradients.
Programme Review 2012 - Final Report 53 ADEL Advanced Electrolyser for Hydrogen Production with Renewable Energy Sources
Key Objectives Challenges addressed Technical approach and achievements
The ADEL project (ADvanced ELectrolyser The challenge of the ADEL project is The project targets the development of for Hydrogen Production with Renewable in the optimisation of materials for cost-competitive, high energy efficient Energy Sources) is developing a new intermediate temperature operation and sustainable hydrogen production steam electrolyser concept. This so- allowing for reduced costs while based on renewable energy sources. For called Intermediate Temperature Steam maintaining sufficient performances with such an ambitious target the project is Electrolysis (ITSE) aims at optimising the limited degradation. On the system level, built on a two scales parallel approach: electrolyser life time by decreasing its an appropriate thermal integration of the • At the stack level, the adaptation and operating temperature while maintaining overall devices with available electricity development of cell, interconnect/ satisfactory performance level and high and heat sources is another key point. The coating and sealing components energy efficiency at the level of the project combines experienced partners for ITSE operation conditions (T complete system including the heat and having recognized knowledge and skills down to 600°C) aims at increasing power source and the electrolyser unit. in separated fields. It particularly depends the electrolyser durability. on their implementation from laboratory • At the system level, the development The relevance of the ITSE is an increased scale to technological scale for producing of flow sheets to analyse and quantify coupling flexibility. Improved robustness intermediate research and development the coupling between the electrolyser and operability will be assessed both, at tools and on their integration into a unit and renewable heat and power the stack level based on performance laboratory prototype constituting the sources aims at identifying the and durability tests followed by in final outcome of the project. most energy efficient solutions. depth post test analysis, and at the system level based on flow sheets and The quantitative assessment of the global energy efficiency calculations. coupling relevance of the ITSE unit with renewable energy sources such as solar or wind or with nuclear and the preliminary dimensioning of a proof of concept technology demonstrator including an operating ITSE stack constitute the final outcomes of the project.
54 Fuel Cells and Hydrogen Joint Undertaking www.adel-energy.eu Hydrogen Production Storage and Distribution
Expected socio and economic impact Project Information Deutsches Zentrum für Luft und Raumfahrt e.V. The project will contribute in developing Project reference: FCH JU Germany a portfolio of sustainable hydrogen Call for proposals: 2009 production liable to meet 10% - 20% of the Application Area: Area SP1-JTI-FCH.2: European Institute for Energy Research hydrogen demand for energy applications Hydrogen Production & Distribution Germany from carbon-free or lean energy sources Project type: Research and by 2015. One of the outcomes of the Technological Development Eidgenössische Materialprüfungs- und project is a preliminary specification of a Topic: SP2-JTI-FCH.2.3: New generation Forschungsanstalt proof of concept demonstrator that will of high temperature electrolyser Switzerland pave the way to further demonstration Contract type: Collaborative Project and pre-commercialisation activities. Start date: 01/01/2011 Abengoa Hidrogeno End date: 01/01/2014 Spain The project gathers a pool of Duration: 36 months complementary industries to bring to Project total costs: € 4,373,548 HyGear B.V. the market a sustainable H2 production Project funding: max € 2,043,518.00 Netherlands plant based on Steam Electrolyser coupled to renewable energy sources. Fundacion IMDEA Energia Project Coordinator Spain The project will prepare the ground for future large investments. Olivier Bucheli JRC – Joint Research Centre – European So far, on the system side, a basis for HTceramix SA, 26 Avenue des Sports Commission understanding the different operation CH-1400 Belgium modes has been established and various Yverdon-les-Bains heat and electricity sources have been Switzerland SOFCpower SPA inventoried for further flow sheeting work. Italy System analysis has validated operating [email protected] temperatures from 600-800°C as relevant Topsoe Fuel Cell A/S for the electrolyser. On the electrochemical Denmark level, promising results have been Partners obtained at 700°C both in continuous and Empresarios Agrupados Internacional intermittent operation, opening the door HTceramix SA SA for grid-balancing operation of such units. Switzerland Spain
accelopment AG Switzerland
Commissariat à l’Energie Atomique et aux Energies Alternatives France
Programme Review 2012 - Final Report 55 ARTIPHYCTION Fully artificial photo-electrochemical device for low temperature hydrogen production
Key Objectives Summary/overview A tandem system of sensitizers will be developed at opposite sides of the membrane in order to capture light at
• Improved and novel nano structured Leaves can split water into O2 and H2 at different wavelengths so as to boost materials for photo-activated processes ambient conditions exploiting sun light. the electrons potential at the anode for
comprising photo catalysts, photo In photosynthesis, H2 is used to reduce water splitting purposes and to inject
anodes interfaced with liquid or new CO2 and give rise to the various organic electrons at a sufficiently high potential
polymer electrolytes compounds needed by the organisms for effective H2 evolution at the cathode. • Chemical systems for highly efficient or even oily compounds which can be Along with this, the achievement of low temperature water splitting using used as fuels. However, a specific enzyme, the highest transparence level of the solar radiation hydrogenase, may lead to non-negligible membrane and the electrodes will be
• Demonstration of solar to hydrogen H2 formation even within natural systems. a clear focus of the R&D work. A proof efficiency > 5% with a perspective of of concept prototype of about 100 W
>10.000 h lifetime Building on the pioneering work (3 g/h H2 equivalent) will be assembled • Small to medium scale applications performed in a FET project based on and tested by the end of the project ranging from 100 W for domestic use natural enzymes (www.solhydromics. for a projected lifetime of >10,000 h.
(ca. 3 g/h H2 equivalent) to 100 kW (ca. org) and the convergence of the work
3 kg/h H2 equivalent) for commercial of the physics, materials scientists, use. chemical engineers and chemists involved in the project, an artificial device will be developed to convert sun energy
into H2 with close to 10% efficiency by water splitting at ambient temperature, including: i) an electrode exposed to sunlight carrying a PSII-like chemical mimic deposited upon a suitable transparent electron-conductive porous electrode material (e.g. ITO, FTO); ii) a membrane enabling transport of protons via a pulsated thin water gap; iii) an external wire for electron conduction between electrodes; iv) a cathode carrying an hydrogenase-enzyme mimic over a porous electron-conducting support in order to recombine protons and electrons into pure molecular hydrogen at the opposite side of the membrane.
56 Fuel Cells and Hydrogen Joint Undertaking www.artiphyction.org Hydrogen Production Storage and Distribution
Expected socio and economic impact Project Information Partners
With a solar light to hydrogen conversion Project reference: FCH JU 123456 HySyTech srl efficiency of 10 % and a radiation input of Call for proposals: 2010 Italy 2 1000 kWh per m , one gets 3 kg of H2/y/ Application Area: Hydrogen m2. If a 7 €/kg cost of solar-electrolytic production Commissariat à L’Energie Atomique hydrogen is considered, each panel Project type: Research and France 2 will provide about 24 €/m /y of H2. Technology development Assuming a 20 years lifetime and a money Topic: SP1-JTI-FCH.2011.2.6: Low- Chemical Process Engineering Research capitalization of 5 %, one can afford temperature H2 production processes Institute costs up to 200 €/m2 of the Artiphyction Contract type: Collaborative project Greece panels including installation to ensure a Start date: 01 January 2010 widespread diffusion of the technology. End date: ongoing Solaronix SA Duration: 36 months Switzerland Project cost: € 4.0 million Project funding: € 2.0 million Lurederra Foundation for Technical and Social Development Spain Project Coordinator Tecnologia Navarra de Nanoproductos Prof. Guido Saracco SL Organisation: Politecnico di Torino Spain Dept. Of Applied Science and Technology Pyrogenesis SA Italy Greece
Contact: Prof. Guido Saracco [email protected]
Programme Review 2012 - Final Report 57 Bor4Store Fast, reliable and cost effective boron hydride based high capacity solid state hydrogen storage materials
Key Objectives Summary/overview • Enhance the cycling stability of the materials to several 1000 cycles Only boron hydride based hydrogen by suitable additives as well as by BOR4STORE will develop novel cost- storage materials exhibit the necessary scaffolding the storage material in efficient boron hydride based hydrogen high hydrogen storage capacities (more pore size optimized nanoporous 3 storage materials with capacities of more than 120 kg H2/m and up to 18 wt %). materials to tailor reaction pathways, 3 than 8 wt.% and 80 kg H2/m for specific It is highest among all known hydrogen prevent phase separation and fuel cell applications, including: storage materials suitable for gas phase retain a high storage density; (a) Synthesis and modification of boron loading and discharge inside the tank. To • Decrease material cost to reach the hydrides, either single or as Reactive overcome their current deficits (loading long term target of < 50 €/kg in large Hydride Composites and Eutectic and unloading times, cycling stability, cost), scale production, by (a) developing cost Mixtures; BOR4STORE will take the following steps: effective materials synthesis routes, (b) Systematic investigation of special and (b) systematically investigating catalysts and additives, and; • Synthesize novel boron hydride based the effects of impurities on storage (c) Adaptation of nanoporous scaffolding materials (e. g. bi- and tri-metal boron properties to enable the use of more to optimise performance. Moreover, an hydrides, anion substituted materials) cost effective raw materials with less integrated laboratory storage - SOFC and composites (e.g. Eutectically stringent requirements on purity, and; prototype will be set up, representing e.g. Melting Composites (EMC)) with high • Demonstrate the suitability, high stationary power supplies. hydrogen storage capacities >8 wt.% energy and cost efficiency of a boron 3 and >80 kg H2/m and evaluate their hydride based laboratory prototype suitability for practical application; tank and supply a small SOFC as a • Accelerate reaction kinetics and model for a continuous power supply adjust reaction temperatures for specific applications like net appropriately to supply a SOFC with independent telephone or weather sufficient hydrogen pressure and stations, UPS systems for lighting and flow at acceptable rehydrogenation control, CHP, potentially also being times of 1 hour or below; a model for APU’s for trains or ships and other portable applications. © bor4store
58 Fuel Cells and Hydrogen Joint Undertaking www.bor4store.eu Hydrogen Production Storage and Distribution
Expected socio and economic impact Project Information Partners
High capacity hydrogen storage at low Project reference: FCH JU 303428 Abengoa Hidrógeno S.A. pressure <10 MPa. High overall energy Call for proposals: 2011 Spain efficiency due to energetic integration with Application Area: SP1-JTI-FCH.2: fuel cell and low hydrogen compression. Hydrogen Production & Distribution Zoz GmbH. Cost target 500 €/kg of stored hydrogen Project type: Basic Research Germany by use of cost effective raw materials / Research and Technological and simple tank construction. Development Katchem spol. s r.o.
Topic: SP1-JTI-FCH.2011.2.4 Novel H2 Czech Republic storage materials for stationary and portable applications Aarhus Universitet Contract type: Collaborative project Denmark Start date: 01 April 2012 End date: ongoing Institutt for Energieteknikk Duration: 36 months Norway Project cost: € 4.07 million Project funding: € 2.27 million Università degli Studi di Torino Italy
Eidgenössische Materialprüfungs- und Project Coordinator Forschungsanstalt Switzerland Helmholtz-Zentrum Geesthacht Germany National Centre for Scientific Research “Demokritos” Contact: Dr. Klaus Taube Greece [email protected]
Programme Review 2012 - Final Report 59 CoMETHy Compact Multifuel-Energy to Hydrogen converter
Key Objectives First challenge is the development Technical approach of advanced low-temperature steam and achievements reforming catalysts and cost-effective CoMETHy aims at the intensification selective membranes in the reference During the 1st project year research has of hydrogen production processes, operational range (400-550°C, 1-10 bar). mainly been focused on the development developing an innovative compact Next technical challenge is targeted on of the two basic components and steam reformer to convert reformable the coupling of the membrane with the materials for the “low-temperature” fuels (natural gas, biogas, bioethanol, catalyst in a membrane reactor. Finally, steam reforming: the catalyst and the etc.) to pure hydrogen, adaptable to the project involves the integration of hydrogen selective membrane. several heat sources (solar, biomass, the developed membrane reformer in a Multi-fuel catalytic materials with fossil, etc.) depending on the locally molten salts loop for proof-of-concept at satisfactory performance (activity, stability available energy mix. Therefore, the the 2 Nm3/h hydrogen production scale, and selectivity) in steam reforming of system will highly flexible in terms of and the performance assessment of the methane and/or ethanol at 400-550°C either the feedstock that is converted to whole system. have been identified and characterized. hydrogen and the primary energy source. Moreover, a structured ceramic support The objective is to provide a CoMETHy work plan involves five has been identified to enhance heat reformer for decentralized hydrogen main RTD work packages (WPs 2 to transfer and minimize pressure drops. production (close to the end-user). 6) proceeding in parallel with project Development and characterization of management, coordination and high performance hydrogen selective dissemination of results (WP1). membranes is also in progress. Summary/overview Moreover, some integrated The 1st project year was mainly focused membrane reactor design concepts CoMETHy proposes a new “low- on the development of the two key have been conceived. temperature” steam reforming components, catalyst and membrane technology, where a molten salt (in WPs 2 and 3, respectively), to provide (molten nitrates mixture) at maximum basic recommendation about the catalyst temperatures of 550°C is used as the system and the membrane to be applied heat transfer fluid. This concept allows (Milestones 1 and 2, respectively). This recovery and supply of the process represents input to the reformer design heat to the reformer from different heat (Milestone 3) and validation (WP4) as sources like Concentrating Solar Power key activity during the 2nd project year. (CSP) plants. The produced hydrogen Finally, after construction of the 2 Nm3/h is separated and purified by means of pilot unit, the 3rd project year is mostly selective membranes. dedicated to the proof-of-concept (WP5, Milestones 5) and to optimization and evaluation of the whole system (WP6, Milestones 6 and 7, respectively). In the perspective of a multi-fuel application, the identification of specific catalysts for bioethanol steam reforming is required too (Milestone 4). © comethy
60 Fuel Cells and Hydrogen Joint Undertaking http://www.comethy.enea.it Hydrogen Production Storage and Distribution
Expected socio and economic impact Project Information Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten CoMETHy leads to potential benefits on Project reference: FCH JU 279075 Forschung E.V - Institute for Ceramic hydrogen production costs, operational Call for proposals: 2010 Technologies and Systems flexibility and environment impact. Application Area: Hydrogen Germany Materials cost is reduced by operating at production & distribution less than 550°C, and additional process Project type: Research and Università degli Studi di Salerno units (water-gas-shift reactor(s) and Technological Development Italy hydrogen purifiers) avoided by the Topic: SP1-JTI-FCH.2010.2.2: integration with membranes. Development of fuel processing Centre for Research and Technology The coupling with renewable sources catalyst, modules and systems Hellas, CPERI/CERTH (e.g. solar) makes production costs less Contract type: Collaborative project Greece sensible to the fossil fuel price and allows Start date: 1 December 2011
40-50% reduction of CO2 emissions, End date: ongoing Aristotelio Panepistimio Thessalonikis whereas the use of biofuels (biogas, Duration: 36 months - Aristotle University of Thessaloniki bioethanol, etc.) allows totally green Project cost: € 4.9 million Greece hydrogen production. Project funding: € 2.5 million Università degli Studi di Roma La Sapienza Project Coordinator Italy
Agenzia per le Nuove Tecnologie Stichting Energieonderzoek Centrum l’Energia e lo Sviluppo Economico Nederland - Energy Research Centre of Sostenibile, ENEA Netherlands, ECN Italy Netherlands
Contact: Dr. Alberto GIACONIA GKN Sinter Metals Engineering GmbH [email protected] Germany
Università Campus Bio Medico di Roma Partners Italy
Processi Innovativi Srl. Italy
Acktar Ltd. Israel
Technion - Israel Institute of Technology Israel
Programme Review 2012 - Final Report 61 DeliverHy Optimisation of Transport Solutions for Compressed Hydrogen
Key Objectives The analysis of regulatory requirements Expected socio and for the approval of hydrogen trailers economic impact arising from ADR has progressed and the Compressed hydrogen trailers are cost process has been widely understood, Compressed hydrogen trailers are cost efficient for near term distribution but with the first wave of recommendations efficient for near term distribution. due to the low pressure, they require disseminated. However, with the currently used 20 MPa multiple daily truck deliveries, which is trailers supply of larger refuelling stations not often acceptable. In order to increase (HRS) would result in multiple daily the transport quantities, lighter materials Technical approach deliveries, which often are not acceptable. and higher pressure must be facilitated. and achievements In order to increase the transported The effects that can be achieved by quantities, lighter materials and higher the introduction of high capacity The intended result of this project will be pressure must be adopted. The cost composite material tank trailers, an optimized high-pressure storage trailer increase by advanced hydrogen trailers allowing a payload increase from 350 to solution assisting in the optimisation of can be off-set by the distribution cost 1,000kg with respect to weight, safety, the entire supply chain regarding energy savings from increased truck capacity. This energy efficiency and greenhouse use, related emissions, product losses project will assess the effects achievable gas emissions will be assessed. and supply cost while ensuring EU-wide through the introduction of high capacity certification. This will simplify, harmonize composite materials tank trailers with and speed up the safe deployment respect to weight, safety, energy efficiency Challenges addressed of hydrogen supply to customers. and greenhouse gas emissions.
A significant increase in capacity can be DeliverHy intends to further develop this The transport of compressed hydrogen achieved, in comparison to state-of-the- line of argumentation which functions today is strictly regulated by international art pressure levels and steel technology. to support any changes needed in the and regional standards. New materials Delivery frequencies can be reduced by RCS framework relevant for hydrogen and product capacities available today a factor of 3, compared to steel trailers, transport, something which can in the have the potential to increase the while transport-related CO2 emissions can end, lead to harmonized requirements payload of a single trailer from about drop by 75%. and approval processes in Europe. 350kg of hydrogen to more than 1000 kg. Materialising this potential is of great The optimal trailer concept for a delivery importance for the efficient distribution strongly depends on the HRS size and the of hydrogen to HRS’s with high output. delivery distance.
The delivery costs of new CGH2 trailers are competitive with LH2 delivery costs of up to at least 250km.
© nexpel Steel Tube Trailer [Air Liquide]
62 Fuel Cells and Hydrogen Joint Undertaking www.deliverhy.eu Hydrogen Production Storage and Distribution
This will require changes to existing Regulations, Codes and Standards (RCS) Project Information Partners in particular for proof pressures higher than 65 MPa and tubes larger than 3000 Project reference: FCH JU 278796 Ludwig-Bolkow- litres. Adopting these changes is a time Call for proposals: 2010 Systemtechnik GmbH consuming process and will only happen Project type: Basic Research (LBST) if authorities are convinced that the Topic: SP1‐JTI‐FCH.2010.2.6: Feasibility Germany necessary safety precautions are taken of 400b+CGH2 distribution care of to achieve a level of safety at Contract type: Collaborative project Air Liquide Hydrogen Energy (AL) least as high as observed with today’s Start date: 01 January 2012 France distribution technologies for hydrogen. End date: ongoing Duration: 24 months CCS Global Group (CCS) The project will address these Project cost: € 1,247,773 UK challenges by means of Project funding: € 719,501 • a detailed assessment of safety, H2 Logic A/S (H2L) environmental and techno- Denmark economic impacts of the use Project Coordinator of higher capacity trailers, Raufoss Fuel Systems (HEX) • the development of a line of Ludwig-Bölkow-Systemtechnik Norway argumentation supporting the changes GmbH needed in the RCS framework, Germany Norwegian University of Science and • a preliminary action plan Technology (NTNU) leading to a Roadmap for the Contact: Mr. Reinhold WURSTER Norway required RCS amendments, [email protected] • communicating these needs to the authorities in charge • facilitating a widely accepted and harmonized set of requirements and approval processes in Europe.
Programme Review 2012 - Final Report 63 ELECTROHYPEM Enhanced Performance and Cost-Effective Materials for Long-Term Operation of PEM Water Electrolysers Coupled to Renewable Power Sources
Key Objectives The achievement of such performance The main impact concerns the enhanced is attributed to the enhanced proton performance and cost-effectiveness of conductivity of the novel membranes PEM electrolysers, obtained through the The overall objective of the and the high electrochemically active development of novel electrocatalyst ELECTROHYPEM project is to develop surface area electrocatalysts. Interesting and membrane formulations. cost-effective components for PEM performances have also been obtained electrolysers with enhanced activity and with fluorine-free low-cost hydrocarbon stability in order to reduce stack and membranes. High surface area oxide Summary/overview system costs and to improve efficiency, supports are under development to performance and durability. The focus of reduce the noble metal loading in the The overall objective of the the project is on low-cost electrocatalysts, MEA. ELECTROHYPEM project is to develop low-noble metal loading electrodes and cost-effective components for proton membrane development. The project conducting membrane electrolysers addresses the development of PEM Expected socio and with enhanced activity and stability in electrolysers based on such innovative economic impact order to reduce stack and system costs components for residential applications in and to improve efficiency, performance the perspective of a suitable integration The project deals with cost-effective and and durability. The focus of the project with renewable power sources. enhanced durability components for PEM is mainly concerned with low-cost electrolysers which are amenable to be electrocatalysts and membrane integrated with renewable energy sources. development. The project is addressing Technical approach The decentralised hydrogen production the validation of these materials in a PEM and achievements may represent an important option for electrolyser for residential applications in the future. This implies the use of small the presence of renewable power sources. Nanosized Pt and Ir oxide electrocatalysts systems directly coupled to wind/solar with enhanced mass activity have been sources for hydrogen generation and its developed respectively, for hydrogen storage at high pressure. The aim of the and oxygen evolution reactions in PEM project is to contribute to the road-map, electrolysers. These electrocatalysts, addressing the achievement of a large- in combination with short-side chain scale decentralised hydrogen production sulfonated perfluorosulphonic ionomer infrastructure in approaches clearly membranes performances of 2.8 A cm-2 at oriented towards long term innovation. 1.8 V with hydrogen, ae cross-over lower than 1 mA cm-2. © electrohypem
64 Fuel Cells and Hydrogen Joint Undertaking www.electrohypem.eu Hydrogen Production Storage and Distribution
The aim is to contribute to the road-map addressing the achievement of a wide Project Information Partners scale decentralised hydrogen production infrastructure. Polymer electrolytes Project reference: FCH JU 300081 JOINT RESEARCH CENTRE (JRC) developed in the project concerned with Call for proposals: 2011 EUROPEAN COMMISSION novel chemically stabilised ionomers and Application Area: SP1-JTI-FCH.2: Belgium sulphonated hydrocarbon membranes, Hydrogen Production & Distribution as well as their composites with inorganic Project type: Research and CENTRE NATIONAL DE LA RECHERCHE fillers, characterised by high conductivity technological development SCIENTIFIQUE and better resistance than conventional Topic: SP1-JTI-FCH.2011.2.7 : France
Nafion membranes to H2-O2 cross-over Innovative Materials and Components and mechanical degradation under for PEM electrolysers SOLVAY SPECIALTY POLYMERS ITALY high pressure operation. Low noble- Contract type: Collaborative project S.P.A. metal loading nanosized mixed-oxides Start date: 01 July 2011 Italy oxygen evolution electrocatalysts, highly End date: ongoing dispersed on high surface area conductive Duration: 36 months ITM POWER (TRADING) LIMITED doped-oxide or sub-oxides are developed Project cost: € 2,842,312.00 UK together with novel supported non- Project funding: € 1,352,771.00 precious oxygen evolution electrocatalysts TRE SPA TOZZI RENEWABLE ENERGY prepared by electrospinning. After Italy appropriate screening of active materials Project Coordinator (supports, catalyst, membranes, ionomers) and non-active stack hardware (bipolar CONSIGLIO NAZIONALE DELLE plates, coatings) in single cell and short RICERCHE CNR-ITAE stack, these components are validated Istituto di Tecnologie Avanzate per in a PEM electrolyser prototype. l’Energia “Nicola Giordano” The stack is integrated in a system and Via Salita S. Lucia sopra Contesse, 5 assessed in terms of durability under 98126 Messina steady-state operating conditions as Italy well as in the presence of current profiles simulating intermittent conditions. Dr. Antonino Salvatore Arico [email protected]
Programme Review 2012 - Final Report 65 ELYGRID Improvements to Integrate High Pressure Alkaline Electrolysers for Electricity/H2 production from Renewable Energies to Balance the GRID
Key Objectives New materials have been developed The expected results affect several and tested in order to assess the areas which constitute important goals feasibility of the membranes. Tests and which are central to the European The ELYGRID Project aims at contributing characterizations have been carried out in Union’s policies such as promoting to the reduction of the total cost of a membrane with a diameter of 130 mm. environmental protection and energy hydrogen produced via electrolysis as it As for power electronics, different saving, fighting climate change and is coupled to renewable energy sources, topologies are being assessed in order maximizing the use of renewable energy mainly wind turbines, and focusing on to decide the best technology available and the independence of fossil fuels. megawatt size electrolyzers (from 0,5 MW at the current time, in comparison to the and up). The objectives are to improve traditional power electronics design for a the efficiency related to the complete large electrolyser (MW). Expected socio and system by 20 and to reduce costs by 25%. economic impact The work will be structured in 3 different The project is also working on developing parts, namely: cell improvements, models in order to optimize BOP The ELYGRID project specifically addresses power electronics, and a balance of operation, improve manufacturing the coupling of high pressure and high plant (BOP). Two scalable prototype processes and assess the safety of current capacity alkaline electrolyzers with electrolyzers will be tested in facilities topology. wind energy. It is expected that the which allow feeding with renewable results from the ELYGRID project will energies (photovoltaic and wind). have a considerable impact beyond Technical approach the geographical and time scopes of and achievements the project, contributing to advances in Challenges addressed answers related to the new typologies The project activities will include an of electrolytic hydrogen that is adapted The project has just completed its first assessment of the potential commercial to ensure maximum penetration of year out of a total of three. Important possibilities and the participation of renewable energies, especially wind advances have already been completed industrial partners also will contribute energy. Application of the results should in terms of the development of new to the successful market exploitation not only benefit the EU, but could membranes, power electronics design of results. The planned dissemination specially contribute to soften serious and BOP optimization. activities, together with the commercial environmental problems emerging emphasis to get results to the market, from developing countries, which need will guarantee the impact of the new clean energy technologies to ELYGRID project on energy efficiency, supply the electricity demand, support the support of renewable energy their socio-economic development markets, and the contribution to and ensure that it is compatible with
the reduction of CO2 emissions. environmental preservation.
66 Fuel Cells and Hydrogen Joint Undertaking www.elygrid.com Hydrogen Production Storage and Distribution
Besides the negative impact of fossil fuels on global warming, the increasing Project Information Partners shortage of such energy resources will result in unstoppable increases in the costs Project reference: FCH-JU-2010-1 Fundación para el Desarollo de las of electricity from conventional sources. Call for proposals: 2010 Nuevas Technologias del Hidrógeno en ELYGRID will optimize the electrolytic Application Area: SP1-JTI-FCH.2: Aragon (FHa) green hydrogen costs and make sure that Hydrogen Production & Distribution Spain it is able to supply clean fuel based on Project type: Demonstration, Research the maximum use of available renewable and Technological development Industrie Haute Technologie (IHT) energies which can contribute to Topic: SP1-JTI-FCH.2010.2.1: Efficient Switzerland independence from traditional fossil fuels. alkaline Electrolysers Contract type: Collaborative project Eidgenossische Materialprufungs-und The ELYGRYD project has been Start date: 01/11/2011 Forschungsantalt undertaken by a well-balanced team End date: 01/11/2014 Switzerland of academic, research and industrial Duration: 36 months partners of renowned prestige with Project total costs: € 3.752.760,80 Helion S.A.S. important know-how and experience in Project funding: € 2.105.017,00 France renewable energies, electrolysis (more than 40 years), energy storage, materials Forschungszentrum Jülish GmbH (FZJ) development, demand management Project Coordinator Germany and weather forecast modeling. Based on this, considerable synergies Foundation for the Development Vlaamse Instelling voor Technologish will be generated, guaranteeing the of New Hydrogen Technologies in Onderzoek N.V. (VITO) fulfillment of the project’s objectives. Aragon Belgium
Walqa Technology Park. Ctra. Zaragoza Lapesa Grupo Empresarial N330A, km 566. 22197. Cuarte (Huesca) Spain Spain Instrumentacion y Componentes S.A. Luis Correas (INYCOM or I&C) [email protected] Spain
Contact for communication: Ingeteam Energy María Alamán Spain [email protected] Commissariat à l’énergie Atomique et aux Energies Alternatives (CEA) France
Programme Review 2012 - Final Report 67 HY2SEPS-2 Hybrid Membrane - Pressure Swing Adsorption (Psa) Hydrogen Purification Systems
Key Objectives Challenges addressed developed adsorbents for the PSA unit. At the same time, the study of membranes and adsorbents will generate transport The main project goal of HY2SEPS-2 is the Methane steam reforming is currently the & adsorption data, which will be used in design and testing of hybrid separation major route of hydrogen production. The the course of the project. Mathematical schemes combining Membrane and cost for hydrogen-derived units of energy models are employed in the conceptual Pressure Swing Adsorption (PSA) is higher than that of energy derived design and optimization of a membrane technology for H2 purification from from hydrocarbon fuels. One reason for – a PSA hybrid system with the goal to reformate streams. The project’s the increased production cost is the low maximize H2 recovery without sacrificing focus is on small-scale PSA units recovery rates at the PSA separation purity. Dynamic optimization of the operating at low feed pressures and unit, which is employed for hydrogen overall system will be carried out for being less flexible in operating modes separation and purification. selected flowsheet configurations. Design in order to maintain high H2 purity and control issues will be considered without sacrificing recovery. Various A hybrid process combining PSA with simultaneously. The performance of possible configurations of the hybrid membrane separation is expected to have optimized membranes will be evaluated system are envisioned, depending on lower operating costs and to increase the under actual industrial conditions. The membrane and adsorbent properties overall H2 recovery without sacrificing final stage of the project refers to the as well as on operating conditions. its purity, especially for small scale units. construction and testing of a membrane- Furthermore, it provides the means for PSA hybrid system at the scale of 1 Nm3 -1 co-producing a CO2 stream which can be H2 h . ready for capture and sequestration. The development of the hybrid separation process incorporates both Technical approach material development and process/ and achievements system modelling. In terms of material development, the main activity refers to New types of adsorbents for the PSA optimization of procedures for synthesis unit have been evaluated in order to of carbon membranes on ceramic tubular enhance performance. Adsorbents
supports tuned to being either H2 or with improved characteristics in terms
CO2-selective and highly permeable in of CO2 adsorption capacity have been order to keep membrane production identified. In the process, adoption of costs as low as possible. At the same these adsorbents needs to take into time, the adopted protocols should account their respective cost compared be easily transferable to scaled-up to the existing situation. Synthesis of
production. An additional activity refers carbon membranes with high H2/CO2 to the assessment of alternative, newly separation selectivity on ceramic supports
68 Fuel Cells and Hydrogen Joint Undertaking http://hy2seps2.iceht.forth.gr Hydrogen Production Storage and Distribution
is feasible only after a lengthy production procedure. Alternative approaches have Project Information Partners been identified and are proposed in order to prepare membranes with a low Project reference: FCH JU 123456 Universidade do Porto processing cost. A mathematical model of Call for proposals: 2008 Portugal the membrane unit has been developed Application Area: SP1-JTI-FCH.2 for steady state simulation and optimal Project type: Basic Research, Research Process Systems Enterprise Ltd design of the membrane module. & technological Development UK Topic: SP1-JTI-FCH.3.2: Component and system improvement for stationary Hygear B.V. Expected socio and Applications Netherlands economic impact Contract type: Collaborative project Start date: 01 November 2011 Ceramiques Techniques et Industrielles The expected impact of the project is End date: 31/10/2013 Sa in the field of “Hydrogen Production Duration: 24 months France & Distribution” by enabling the more Project cost: € 1,606,279.00 efficient clean hydrogen production in Project funding: € 825,321.00 small scale units through the design of an advanced hydrogen separation and purification system. The proposed hybrid Project Coordinator process should, in principle, also be able to produce hydrogen with almost no CO2 Foundation for Research and emissions if it is optimized appropriately Technology-Hellas, Institute of and, as a consequence, aims to improve, Chemical Engineering Sciences make more effective and reduce the cost (FORTH/ICE-HT) of the fossil fuel decarbonization process. Greece
Mr Theophilos IOANNIDES [email protected]
Programme Review 2012 - Final Report 69 HYDROSOL 3D Scale up of thermochemical hydrogen production in a solar monolithic reactor: a 3rd generation design study
Key Objectives Challenges addressed Technical approach and achievements
HYDROSOL-3D aims at the preparation of • Fine-tuning of materials composition The project started from fine-tuning a demonstration of a CO2-free hydrogen and reactor configurations developed the materials compositions and reactor production and provision process and within HYDROSOL & HYDROSOL-II, designs advanced through the Projects related technology, using two-step in order to ensure long-term, reliable HYDROSOL and HYDROSOL-II to thermochemical water splitting cycles by solar-aided H2 production. ensure long-term, reliable solar-aided concentrated solar radiation. This process • Design & development of a solar Hydrogen production. Emphasis was has been developed within two relevant H2 receiver/ reactor with enhanced placed on improving the solar reactor predecessor EU projects, HYDROSOL and transport, thermal and heat recovery performance by introducing designs HYDROSOL-II and through several steps properties. and concepts that will enhance the long of improvement has reached the status of • Development of control concepts and term thermal stability of materials and a pilot plant demonstration in a 100 kW procedures and pre-design of a specific the reduction of radiation losses among scale showing that hydrogen production process control system others. The project then developed via thermochemical water splitting is • Complete pre-design of alternative the control concepts, algorithms and possible on a solar tower under realistic plant scenario options (coupled procedures necessary for the operation conditions. HYDROSOL-3D focuses on the to existing and to new solar field/ of such a plant. Two alternative options next steps towards commercialisation tower facilities) and selection of most were analyzed: adapting the hydrogen carrying out all activities necessary to promising one for further in-detail production plant to already available solar prepare the erection of a 1 MW solar analysis facilities or developing a new, completely demonstration plant. The project • Development of operational strategies optimised hydrogen production/solar concerns the pre-design and design of the for specific phases of the process plant. The most promising option would whole plant including the solar hydrogen • Detailed design study of complete be analysed in detail, establishing the reactor and all necessary upstream and demonstration plant complete plant layout and defining downstream units needed to feed in the • Sizing and selection of all necessary and sizing all necessary components. reactants and separate the products and peripheral components Validation of pre-design components the calculation of the necessary plant • Simulation of core components and and process strategies by experiments erection and hydrogen supply costs. standard operation phases (in laboratory, solar simulator and solar • Simulation of controlling the process as tower facilities) and a detailed techno- a whole economic analysis covering market • Identification of investment and introduction complement the project. operational cost of a 1 MW demo plant
for 2-step solar H2 generation. • Calculation of the cost necessary to erect a 1 MW demonstration plant, as
well as H2 production & supply costs, in a 1 MW scale on a solar tower. • Techno-economic & market analysis to determine the feasibility of process scale-up to the MW scale.
70 Fuel Cells and Hydrogen Joint Undertaking www.hydrosol3d.org Hydrogen Production Storage and Distribution
Expected socio and economic impact Project Information Partners
HYDROSOL-3D responds to the necessity Project reference: FCH JU Deutsches Zentrum of developing hydrogen production Call for proposals: 2008 für Luft- und Raumfahrt e.V. (DLR) processes from carbon-free sources by Application Area: SP1-JTI-FCH.2: GERMANY 2015 and the need to demonstrate the Hydrogen Production & Distribution technical and economical feasibility of Project type: Research and Centro de Investigaciones Energéticas thermochemical decomposition of water Technological Development Medioambientales y Tecnológicas as a potential pathway for this goal. The Topic: SP1-JTI-FCH.2.3 Water (CIEMAT) Project aimed at improving the technical decomposition with solar heat sources SPAIN and economic industrial-size feasibility of Contract type: Collaborative Project such processes by enhancing materials’ Start date: 01/01/2010 Total SA (TOTAL) performance, by introducing, designing End date: 31/12/2012 FRANCE and simulating real-sized components Duration: 36 months like solar reactors with enhanced Project total costs: € 1,729,083.40 HyGear B.V. (HYG) efficiency and volumetric hydrogen Project funding: € 984,374.80 NETHERLANDS productivity, by implementing and validating efficient solar process control strategies and schemes and by coupling Project Coordinator of the above to hydrogen separation/ purification technologies. HYDROSOL- Dr. Athanasios G. 3D aims to be the first demonstration KONSTANDOPOULOS of solar chemistry-based hydrogen [email protected] production from water, with a future potential - when employed in combination Aerosol and Particle Technology with concentrated solar thermal power Laboratory / Center for Research and plants - to achieve a hydrogen cost Technology–Hellas/ Chemical Process competitive to that of non-sustainable, Engineering Research Institute
CO2-emitting, hydrogen production. (APTL/CERTH/CPERI) GREECE
Dr. Souzana LORENTZOU [email protected] © hydrosol-3d
Programme Review 2012 - Final Report 71 HyTIME Low temperature hydrogen production from 2nd generation biomass
Key Objectives Challenges addressed More specifically: for the production of biomass, road side grass, straw and over- date residues from supermarkets will The overall objective of ‘HyTIME’ is to • Optimal utilization of 2nd generation be studied in terms of availability and accelerate the implementation of an biomass from sustainable biomass suitability. Pretreatment and hydrolysis for industrial bioprocess for decentral supply chains (grass, straw, residues mobilisation of sugars will be optimized hydrogen production systems from food-industry) in tailor-made by developing procedures to decrease using 2nd generation biomass. pretreatment procedures energy demand, use of chemicals and The target of this project is to • developing large scale high rate enzymes, formation of inhibitors, and construct a prototype process based bioreactors for increased H2 to increase fermentability, keepability on the fermentation of biomass for productivity at low nutrient cost etc. The hydrolysates will be tested for delivering 1-10 kg hydrogen/d and to • combining high yield in H2 thermophilic fermentation and adjusted develop a biohydrogen production fermentation with increased quality of with required nutrients for optimum system as a stepping stone to biogas from anaerobic digestion yield. The increase in productivity pre-commercial applications. • stimulating production by recovering (kg H2/ time) will be addressed by
The objective of HyTIME is to expand dissolved H2 from the liquid phase increasing the concentration of the the unique strategy of thermophilic • optimizing the unit-operations for bacteria through immobilization on dark fermentation and to add an upgrading H2 at small scale, low carriers or by making bacterial flocs. The alternative approach in combining the pressure and low temperature approach will be using designed co- thermophilic dark fermentation with including the development of a process cultures of Caldicellulosiruptor species anaerobic digestion. HyTIME builds for monitoring and control devices and bacteria from the Thermotogales on previous results with a focus on • heat and energy integration for order in dedicated bioreactors based thermophilic fermentation to accelerate a increasing the overall energy efficiency on a combination of a moving bed and breakthrough of fermentative hydrogen • providing the design for a pre- trickle bed system. For the removal and production from 2nd generation commercial H2 production plant capture of hydrogen, the strategy is biomass including waste biomass. to enable medium term market twofold: upgrading hydrogen in the gas The acquired knowledge on biomass implementation. phase by Pressure Swing Adsorption availability, logistics and pretreatment or the application of a membrane and on gas upgrading technology contactor combining specific absorption will be fully exploited to develop Technical approach and separation. Besides, hydrogen dedicated systems for an easy to handle and achievements in the liquid phase will be removed biohydrogen production system. by a membrane unit in an internal The 9 participants, coming from small loop connected to the bioreactor. To and large industries, universities and a guarantee proper process control and research institutes are spread over HyTIME operation and, eventually, automation, and addresses the entire value chain dedicated measurement devices will be from biomass logistics and pretreatment, developed which will allow continuous thermophilic hydrogen production detection of hydrogen or contaminants
and gas upgrading technologies. The like H2S. Finally, the effluent of the integration of all these components of hydrogen bioreactor will be tested for the hydrogen production system is done methane production in an innovative in order to bring progress to HyTIME continuous anaerobic membrane reactor beyond the state-of-the-art of current operating at thermophilic conditions. fermentative hydrogen production.
72 Fuel Cells and Hydrogen Joint Undertaking www.hy-time.eu Hydrogen Production Storage and Distribution
All mass and energy balances and basic engineering data of the separate process Project Information Partners units will be integrated and used for modelling and simulation studies to Project reference: FCH JU Stichting Dienst Landbouwkundig design a hydrogen production unit with Call for proposals: 2011 Onderzoek maximum product output, minimum Application Area: Hydrogen Netherlands energy demand and low cost. production and storage Project type: RTD Awite Bioenergie GmbH Topic: SP1-JTI-FCH.2012.2.4. Low Germany Expected socio and temperature hydrogen production economic impact Contract type: Collaborative project Parco Scientifico e Tecnologico per Start date: 01/01/2012 L’ambiente – Environment Park SPA In the EU, 118-138 million tons of bio- End date: 01/01/2015 Italy waste (garden waste, food and kitchen Duration: 36 months waste and waste from food processing Project total costs: € 2.923.818.40 Heijmans Techniek & Mobiliteit B.V. plants) is currently produced on a yearly Project funding: € 1.609.026.00 Netherlands basis. This bio-waste could be used for methane production with a theoretical Rheinisch-Westfaelische Technische production of 2 million ton of methane. Project Coordinator Hochschule Aachen Using the same assumptions, the Germany theoretical hydrogen production would be Pieternel Claassen 0.34 million ton hydrogen with additional Stichting Dienst Landbouwkundig Technische Universitaet Wien 1.3 million ton methane when using the Onderzoek-Food & Biobased Research Austria technology of HyTIME. If only half of the Bornse Weilanden 9 theoretical amount of hydrogen would 6708 WG Wageningen, Wiedemann-Polska Projekt Spolka z be produced, a production 20 PJoule/year Netherlands Ograniczona Odpowiedzialnoscia would be the result. This would increase Poland because of the 10% increase in bio-waste [email protected] production foreseen in the EU and because HyGear B.V. the technology will grow from its infancy Netherlands to full maturity after 10 years following the start of HyTIME. The impact for the Veolia Environnement Recherche & EU is twofold: a significant contribution Innovation to the triple 20% by 2020’ objective with France green hydrogen and a contribution to improved bio-waste management.
Programme Review 2012 - Final Report 73 HyUnder Assessment of the potential, the actors and relevant business cases for large scale and seasonal storage of renewable electricity by hydrogen underground storage in Europe
Key Objectives Summary/overview The sequence of work follows a set of work packages. WP2 to WP5 are required Interest in the use of hydrogen as a to provide the fundamental knowledge The ambition of HyUnder is to develop universal energy carrier and storage to carry out the detailed Case Studies a European Implementation Plan, medium has been growing in recent years. (WP6), a feasibility study on the possible based on a detailed assessment of six This is based on the insight that our energy integration of hydrogen in each energy individual Case Studies of the hydrogen future, which will require the integration market is expected as an outcome of utilization options and salt cavern of increasing amounts of renewable the Case Studies. The final result will be storage potential across Europe. The main electricity generation, chemical methods the European Hydrogen Underground actions to be developed in each case offer one of the most promising options Storage Implementation Plan which will study will be: regional storage prototype for storing large amount of energy. top the comparison of results from the location analysis, economic scenario individual Case Studies. The following type assessment and the introduction In general, the project has individual work packages are foreseen: of hydrogen underground storage seven major milestones: into different markets. A comparative - WP1. Project coordination assessment of the individual case studies - M1 for the setup of a Document and administration is expected as an outcome at the end of Management System that is - WP2. Benchmarking of large scale the project. common for all partners; hydrogen underground storage - M2 for the development of a - WP3. Assessment of geologic options joint Communication Strategy at for hydrogen underground storage Technical approach the beginning of the project, - WP4. Geologic mapping of and achievements - M3 for the development of a joint European regions for underground Case Study methodology; storage of hydrogen In the administrative and communication - M4 for the development of a - WP5. Plant technologies side, the kick-off meeting and the Initial German Case Study serving as - WP6. Representative Case Studies Conference of HyUnder project were benchmark and providing the most with a focus on salt caverns storage held during first months of the project. A detailed insights available now; - WP7. Dissemination to improve website has been created to promote the - M5 to compile basic knowledge stakeholder awareness project progresses. on hydrogen energy storage; - WP8. Major conclusions. - M6 for the development of the other On the scientific and technological side: Case Studies and for comparison of the - A Methodology Approach for the individual Case Studies with each other; Case Studies has been developed. - M7 for the development of a European This methodology will be the base Hydrogen Underground Storage to evaluate the different case studies Implementation Plan all reviewed by of each region (Germany, Spain, UK, an external supporting partner group. France, Romania and Netherlands); - The toolkits to provide inputs for the case study development (WP2, WP3, WP4 and WP5) are in progress).
74 Fuel Cells and Hydrogen Joint Undertaking www.hyunder.eu Hydrogen Production Storage and Distribution
Expected socio and economic impact Project Information Partners
The Implementation Plan will be a concrete Project reference: FCH JU 303417 Ludwig-Bölkow – Systemtechnik (LBST) action plan to develop and move hydrogen Call for proposals: 2011 Germany storage from the current development Application Area: AA5 phase through the demonstration Project type: Support Action Hinicio and finally the deployment phase. Topic: SP1-JTI-FCH.2011.5.1: Belgium
The expected impact of HyUnder project Assessment of benefits of 2H for energy comprises of the following elements: storage and integration in energy KBB Underground Technologies (KBB) - Understand the feasibility, relevance, markets Germany timelines, chances and limitations of Contract type: Coordination and
H2 underground storage to facilitate Support Action National Center for Hydrogen & Fuel renewable electricity in Europe; Start date: 18 June 2012 Cells Romania (NHFCC) - Understand the different regional End date: ongoing (18 June 2014) Romania potentials, roles in energy Duration: 24 months systems and the commitment Project cost: € 1,766,516 DEEP Underground Technologies
of H2 underground storage; Project funding: € 1,193,273 (DEEP) - Understand the European Scope Germany
of H2 underground storage; - Understand the necessary next E.ON Gas Storage (EGS) steps, including the financing needs Project Coordinator Germany and required policy measures
of H2 underground storage Fundación para el Desarrollo de las Energy Research Centre of Netherlands towards commercialization. Nuevas Tecnologías del Hidrógeno (ECN) en Aragón(Foundation for Hydrogen Netherlands in Aragon - FHA) Spain Shell Global Solutions (Shell) Netherlands Dr Luis Correas [email protected] Centre of Excellence for Low Carbon and Fuel Cell Technologies (CENEX) UK
Solvay Chemicals (Solvay) Germany
Commissariat à l’énergie atomique et aux énergies alternatives (CEA) France
Programme Review 2012 - Final Report 75 IDEALHY Integrated Design for Efficient Advanced Liquefaction of Hydrogen
Key Objectives Technical approach Summary/overview and achievements
IDEALHY aims to develop a generic High energy consumption is the Hydrogen is expected to be an important process and plan for the demonstration main blocker for a liquid hydrogen future clean transport fuel. In the absence of efficient hydrogen liquefaction infrastructure. Removing this would of a pipeline network, liquid hydrogen is of up to 200 tons per day, whereby enable the following to happen: the most effective way to supply larger energy consumption is reduced by - An increased amount of hydrogen can refuelling stations. Without developing 50% compared to existing plants. be transported by a truck, reducing liquefaction capacity, it may be impossible The design is based on components the number of trucks on the road, to operate hydrogen stations of the that can be manufactured today and - The possibility of larger hydrogen same size as current liquid fuel stations. additionally, a proposal for a near future retail stations (>500 kg/d) because demonstration plant will be made. of the reduced truck deliveries, However, liquefaction of hydrogen is - The transport of energy over long expensive and energy intensive today. Moreover, the process and the liquid distances via ship and rail, enabling IDEALHY brings together world experts hydrogen pathway will be compared to remote energy resources (wind, to develop a generic process design and alternatives on greenhouse gas emissions, solar and stranded fossil resources) plan for a large-scale demonstration energy use and HSE implications. to be used and thus increasing of efficient hydrogen liquefaction. the security of energy supply. The principal objectives are to: - Reduce the specific energy consumption Challenges addressed of hydrogen liquefaction by optimising an improved generic process design A review of eight existing liquefaction - Prepare a strategic plan for plants and a similar number of literature demonstration of efficient concepts has been carried out, comparing hydrogen liquefaction at a scale these on the same basis and boundary of up to 200 tonnes per day. conditions. From the best concepts, with the expertise on cycles and components The project will carry out a detailed in the consortium, a single liquefaction investigation of different steps in concept was derived and is being the liquefaction process, bringing optimised. Discussions with equipment innovations and greater integration manufactures indicate that the IDEALHY in an effort to reduce specific energy efficiency target is achievable considering consumption by 50% compared to the available equipment. In addition, existing plants. The partners in IDEALHY lifecycle and HSE analyses have started believe this can be achieved by: to compare the liquid hydrogen chain - Increasing plant scale with alternatives like compressed - More efficient process design hydrogen. These show that further work is - Using more efficient components. needed before the introduction of liquid hydrogen at scale.
76 Fuel Cells and Hydrogen Joint Undertaking www.idealhy.eu Hydrogen Production Storage and Distribution
Furthermore, efficiency improvements are possible by integrating Project Information Partners liquefaction with other processes such as LNG re-gasification. Project reference: FCH JU 123456 Linde Kryotechnik AG Call for proposals: 2010 Switzerland IDEALHY will also perform a well-to- Application Area: AA2 end-user analysis of liquid hydrogen Project type: Research and SINTEF Energi AS in the energy chain, comparing it Technological Development Norway with appropriate fossil and renewable Topic: SP1-JTI-FCH.2010.2.5: alternatives. This will include techno- Preparation of demonstration of Loughborough University economic analyses and emissions efficient large-scale hydrogen UK calculations and will be combined with an liquefaction assessment of safety and risk mitigation. Contract type: Collaborative project Technische Universitaet Dresden Start date: 01 November 2011 Germany Finally, the project will develop a proposal End date: 21 October 2013 for a demonstration of the IDEALHY Duration: 24 months North Energy Associates Limited liquefaction technology in a subsequent Project cost: € 2.5 million UK phase. The strategic plan for a large scale Project funding: € 1.3 million demonstration will be based on the WEKA AG commercial partners’ plans for supplying Switzerland hydrogen for fuelling and will include Project Coordinator options for location of the planned demo, PLANET Planungsgruppe Energie und with a consideration of available hydrogen Shell Global Solutions International Technik GBR supplies and nearby customer markets. BV Germany Netherlands Kawasaki Heavy Industries An overview of the IDEALHY project Alice Elliott (not part of Grant Agreement) was published in “International [email protected] Japan Innovation, December 2012” by Research Media Ltd, pages 34-36. © idealhy
Programme Review 2012 - Final Report 77 NEMESIS2+ New Method for Superior Integrated Hydrogen Generation System 2+
Key Objectives Challenges addressed Summary/overview
The objective of this project is an on- A review of eight existing liquefaction Currently, large-scale methane steam site hydrogen production at refuelling plants and a similar number of literature reforming is the prevailing technology for stations from diesel and biodiesel. concepts has been carried out, comparing hydrogen production. In the transition The NEMESIS2+ consortium aims to these on the same basis and boundary towards a sustainable hydrogen economy develop a pre-commercial, small- conditions. From the best concepts, with with a fully functional infrastructure, scale hydrogen generator capable of the expertise on cycles and components decentralized hydrogen production at producing 50 Nm3 of hydrogen per hour in the consortium, a single liquefaction refuelling stations will accelerate the from diesel and biodiesel. By applying concept was derived and is being market introduction of hydrogen-powered pressurized steam reforming, using a optimised. Discussions with equipment vehicles. On-site hydrogen production “one-reformer”-concept and focusing on manufactures indicate that the IDEALHY at refuelling stations is economically liquid fuels only, hydrogen production efficiency target is achievable considering reasonable, especially in areas where costs of < 4 Euro per kg are targeted. the available equipment. In addition, hydrogen cannot be supplied by a central lifecycle and HSE analyses have started production plant in a cost-efficient to compare the liquid hydrogen chain manner. Such technology has not yet been with alternatives like compressed developed as a commercially available hydrogen. These show that further work is product fulfilling the requirements of the needed before the introduction of liquid market in terms of cost and efficiency. hydrogen at scale. The FCH JU Annual Implementation plan 2010, in which it is stated that the market introduction of hydrogen powered cars is expected within the next few years, envisions a market share between 10 and 20 % of sustainably produced hydrogen in 2015.
The NEMESIS 2+ consortium will contribute towards reaching this target by developing a pre-commercial and sustainable on-site hydrogen generator system capable of producing 50 Nm3/h
H2 from diesel and biodiesel (FAME).
78 Fuel Cells and Hydrogen Joint Undertaking www.nemesis-project.eu Hydrogen Production Storage and Distribution
Technical approach and achievements Project Information Partners
High energy consumption is the Project reference: FCH JU (GA 278138) HyGear B.V. main blocker for a liquid hydrogen Call for proposals: 2010 Netherlands infrastructure. Removing this would Application Area: SP1-JTI-FCH.2 enable the following to happen: “Hydrogen Production & Distribution” Johnson Matthey PLC. - An increased amount of hydrogen can Project type: Research and UK be transported by a truck, reducing Technological Development the number of trucks on the road, Topic: SP1-JTI-FCH.2010.2.2 Abengoa Hidrógeno, S.A. - The possibility of larger hydrogen “Development of fuel processing Spain retail stations (>500 kg/d) because catalysts, modules and systems” of the reduced truck deliveries, Contract type: Collaborative project Abengoa Bioenergía San Roque, S.A. - The transport of energy over long Start date: 01 January 2012 Spain distances via ship and rail, enabling End date: 31 December 2014 remote energy resources (wind, Duration: 36 months Centre for Research and Technology solar and stranded fossil resources) Project cost: € 3.393.062 million Hellas to be used and thus increasing Project funding: € 1.614.944 million Greece the security of energy supply. Instituto Superior Técnico Project Coordinator Portugal
Stefan Martin Deutsches Zentrum für Luft- und Raumfahrt Germany
Contact: Mr Stefan MARTIN [email protected]
Programme Review 2012 - Final Report 79 NEXPEL Next Generation PEM Electrolyser for Sustainable Hydrogen Production
Key Objectives Challenges addressed Technical approach and achievements
The main objective of the NEXPEL Centralized and decentralized sustainable NEXPEL will develop and demonstrate project is a successful demonstration H2 production using low temperature novel components that are of an efficient proton exchange electrolyser technology requires further essential for cost-competitive, high- membrane (PEM) electrolyser integrated improvement in performance and efficiency PEM electrolysis systems with Renewable Energy Sources. reduction of costs. In this context, the through five key concepts: The NEXPEL project consist of a top PEM technology particularly adapted for • lower capital costs of the main stack class European consortium which is applications in power levels up to 0.5 MW components; membrane, electrodes carefully balanced between leading will be considered, with a strong focus and bipolar plates / current collectors R&D organizations and major industrial on technology improvements to make • higher performance, in particular of the actors from 4 member states. The the technology fit for integration with membrane electrode assembly (MEA) partners are devoted to developing new renewable energies for electricity/ H2 • longer life time of the most materials and stack design concepts generation. crucial PEM components, to increase the efficiency and lifetime • highly efficient advanced of PEM electrolysers and at the same power electronics time cutting costs. The three main goals • novel stack design for high pressure for the NEXPEL project is to achieve operation and low assembly costs.
• Electrolyser efficiency greater than 75% Stack design simplification and cost • A stack life time of 40 000 h reduction through the use of more cost • A reduction in system costs to effective materials is vital to lowering € 5,000/Nm3 production capacity. capital costs. Apart from lowering the catalyst loading, a further concept The consortium is confident that the to reduce the system cost down dissemination and exploitation of to €5,000/Nm3h-1 is the use of less the project will create considerable expensive polymers for membranes impact especially in terms of and alternative materials for current Europe’s energy security, reducing collectors, bipolar plates and end plates greenhouse gas emission and increasing Europe’s competitiveness.
Statoils Energy Park at Herøya, Porsgrunn, Norway. The energy park consists of two 6 kW wind turbines and two 2.1kW solar panels and is equipped with a 70 kWh lead acid battery storage system, and water electrolysers from NEL Hydrogen (Earlier Hydrogen Technologies). © nexpel
80 Fuel Cells and Hydrogen Joint Undertaking www.nexpel.eu Hydrogen Production Storage and Distribution
Expected socio and economic impact Project Information Partners
The results obtained so far in NEXPEL Project reference: FCH JU 245262 Stiftelsen SINTEF are promising and demonstrate Call for proposals: FCH-JU-2008-1 Norway a high probability for achieving Application Area: SP1-JTI-FCH-2.1: improved performance and reduced Efficient PEM electrolysers The University of Reading cost of PEM water electrolysers. The Project type: RTD UK main expected outcomes from the Topic: SP1-JTI-FCH-2.1: technological developments are: Efficient PEM electrolysers FuMA-Tech GmbH Contract type: Collaborative Project Germany • A new generation of polyaromatic Start date: 01/01/2010 membranes for PEM electrolysers End date: 31/12/2012 CEA LITEN with a significant enhancement in Duration: 36 months France membrane lifetime and cost. Project total costs: € 3 353 549 • New oxygen evolution catalysts Project funding: € 1 256 286 Fraunhofer Gesellschaft zur Förderung with significant improvement in der angewandten Forschung e.V. catalytic activity and potential Germany for noble metal thrifting. Project Coordinator • Novel stack design, reducing Hélion - Hydrogen Power construction material costs Magnus Thomassen France and easing assembly. Senior Research Scientist, Dr.Ing StatoilHydro ASA In addition, performed market analyses SINTEF Materials & Chemistry Norway of the utilization of PEM electrolysers New Energy Solutions in different application areas (micro Postboks 4760 Sluppen, SINTEF Energiforskning AS wind & PV for telecom, green H2 NO-7465 TRONDHEIM, Norway stations and large scale H2 production Norway from renewable energy sources), Phone: +47 98243439 will give a better understanding of the role of PEM electrolysers in a future hydrogen economy.
Programme Review 2012 - Final Report 81 PrimoLyzer Pressurised PEM Electrolyzer stack
Key Objectives Challenges addressed Technical approach and achievements
The primary objective of PrimoLyzer is Stationary µCHPs based on fuel cells are in The PrimoLyzer key-targets are as follows: 3 to develop, construct, and test a cost- demonstration all over the world. Almost A) Stack capacity: 1 Nm H2/h minimised highly efficient and durable all these systems are fed with reformed B) PH2: 10 MPa 2 PEM-electrolyser stack with a hydrogen fossil fuel like natural gas. The FC-based C) UCell @ BoL: 1.62 V @ 1.2 A/cm 3 production capacity of 1 Nm /h aimed µCHPs are more efficient than the D) ΔUCell: <30 µV/h for integrated with domestic μCHPs. The technologies they replace, resulting in a E) Stack cost: <5,000€ in objectives will be reached through a substantial reduction in the CO2 emission, series production. combination of the following activities: calculated to be ≈1 tons CO2/year/’single Furthermore, the stack will be liquid 1. Specification done by the end- family house’ when fuelled with natural cooled to enhance durability and enable user [Abengoa Hidrógeno] gas. However, the emission reduction easy heat utilisation. This is important as a 2. Basic material R&D on catalyst & is five times higher when the µCHPs are PEM electrolyser operated with renewable membrane to increase durability fuelled with hydrogen produced with will run when the electricity is cheap and & efficiency while reducing cost excess renewable energy e.g. wind therefore not simultaneous with the μCHP. [FumaTech, VTT & Åbo Academy] power or photovoltaics. Hydrogen The project is scheduled to last 2.5 3. Process development to fabricate production by electrolysis of water is years. The technical work is divided into high performance MEAs [ECN & IRD] presently associated with substantial six (6) Work Packages. Nineteen (19) 4. Engineering of a durable, reliable, and energy losses. Furthermore, small deliverables and ten (10) milestones robust high pressure stack [IRD & ECN] electrolysers are prohibitively expensive are defined for the project to facilitate 5. Continuous test for 2,000 hours while larger electrolysers with a relative the completion of the ambitious together with a 1.5 kW μCHP [IRD] smaller plant investment cost require project targets and to enable an easy 6. An evaluation headed by additional hydrogen distribution grids. monitoring of the project progress. the end-user(s) [Abengoa The primary objective of the PrimoLyzer Hidrógeno, FumaTech & IRD] project is to develop, construct, and test The best performing MEAs are equipped PrimoLyzer is phase I in a two- a cost-minimised highly efficient and with a VTT OER catalyst consisting of step development, where phase durable PEM-electrolyser stack aimed for mixed Ir-Ru and a Fumatech PSFA-type II will comprise full integration integration with domestic µCHPs. membrane. The single cell IR-corrected of the electrolyser with a μCHP polarisations of the optimised MEAs followed by a field test. show a better performance than the project target [1.64 V @ 1.2 A/cm2] for MEAs with less than the targeted catalyst loadings [actual Anode/Cathode loading: 0.3/0.5 mg per cm2; target: Anode/ Cathode loading: 1.0/0.5 mg per cm2]. The observed degradation rate is <30 μV/h. A high-pressure stack was designed in accordance with the standard: IEC 62282-2(2005-3) FC technologies-Part 2 and successfully verified. The cost of one stack with a production capacity of 1 Nm3/h hydrogen is less than 5,000 € in production of 100 units, as targeted.
82 Fuel Cells and Hydrogen Joint Undertaking www.PrimoLyzer.ird.dk Hydrogen Production Storage and Distribution
Expected socio and economic impact Project Information Partners
The overall aim of PrimoLyzer is to develop Project reference: FCH JU 245228 VALTION a high efficiency electrolyser stack based Call for proposals: year 2009 TEKNILLINEN TUTKIMUSKESKUS on PEM technology. The project started Application Area: Advanced Materials with an analysis of solar and wind power Project type: Basic Research; Research Finland followed by a specification to ensure and Technological Development that the stack can be integrated with Topic: SP1-JTI-FCH.2.1: Efficient FumaTech -Tech Gesellschaft für Renewable Energy Sources. Experiences PEM Electrolyzers & SP1-JTI-FCH.3.2 funktionelle Membranen und from this project will contribute to solving Component and system improvement Anlagentechnologie mbH [FuMa] the future challenges in grid operation for stationary applications Germany with balancing issues due to higher Contract type: Collaborative Project, degree of distributed generation in the Small or medium-scale focused Abengoa Hidrógeno [AH] grid, high level of renewable energy research project Spain based on wind/solar power in the grid, Start date: 01/01/2010 and the need for fast response in the End date: 30/06/2012 Åbo Akademi University [AABO] activation of the distributed generation Duration: 30 months Inorganic Chemistry for grid balancing. The planned activities Project total costs: € 2,615,270 Finland include a 2,000 hours prototype testing Project funding: € 1,154,023 together with hydrogen fuelled dead-end STICHTING ENERGIEONDERZOEK µCHP system. The PrimoLyzer project CENTRUM NEDERLAND [ECN] will assist the European Union to reach Project Coordinator Netherlands their short- to medium term target on sustainable hydrogen production Laila Grahl-Madsen and supply chains demonstrated and Director of Science and Technology ready for commercialisation by 2013. IRD A/S Kullinggade 31 DK-5700 Svendborg Denmark
Programme Review 2012 - Final Report 83 RESelyser Hydrogen From RES: Pressurised Alkaline Electrolyser with High Efficiency and Wide Operating Range
Key Objectives Challenges addressed Summary/overview
The project RESelyser develops high First steps towards an alkaline water Alkaline water electrolysis for hydrogen pressure, highly efficient, low cost alkaline electrolyser that is better adapted to production is a technique that is well water electrolysers that can be integrated highly fluctuating current supply when established with electrolysers of a wide with renewable energy power sources connected to RES were taken. Membranes power range now commercially available. (RES) using an advanced membrane for a new concept were developed, Hydrogen production by electrolysis is concept, highly efficient electrodes and electrodes for higher efficiency were increasingly studied as a way to smooth a new cell design. The project is set to demonstrated and a new cell design is out the fluctuating power output of develop a prototype of an improved now available. renewable energy sources not correlating electrolyser, wherein high efficiency and with the electrical energy demand. low system costs will be demonstrated. “E-bypass separator” diaphragms However for this purpose, present Additionally, the stability of this efficiency with internal electrolyte bypass and electrolysers have to be improved for during long term operation in on/off properties for maximum benefit of the fluctuating power operation and the cycles will be demonstrated with an cell were developed with a total thickness system costs have to be decreased to extrapolation to a lifetime of 10 years. (including the internal electrolyte reach a low cost energy conversion. channel) between 1.4 and 3.4 mm at the size of a 300 cm2 electrolyser. A cell To address these challenges in the concept was also realised. Electrode project, RESelyser has a new separator coatings were demonstrated which membrane with internal electrolyte wound up reducing the overpotential of a circulation (“E-bypass separator”) and an nickel electrode. adapted design of the cell to improve mass transfer, especially gas evacuation, is investigated and demonstrated. Technical approach and achievements
The outcome of this project will be an electrolyser that suits the requirements of operation with significantly varying loads in order to help the integration of renewable energy sources in the electrical power grid in Europe. A major mar¬ket for this product is expected in the next years. Hydrogenics already produces and sells alkaline water electrolysers that are also operated when coupled to RES. However an im¬provement in costs, partial load operation, efficiency and life time will substantially increase the market possibilities.
84 Fuel Cells and Hydrogen Joint Undertaking www.reselyser.eu Hydrogen Production Storage and Distribution
Intermittent and varying load operation with RES is addressed by improved Project Information Partners electrode stability and a cell concept for increasing the gas purity of hydrogen and Project reference: FCH JU 278732 VLAAMSE INSTELLING VOOR oxygen, especially at low power operation Call for proposals: 2010 TECHNOLOGISCH ONDERZOEK N.V. as well as for very high pressure. Also, the Application Area: Hydrogen Belgium system architecture is optimized for the Production & Distribution intermittent operation of the electrolyser. Project type: Research and HYDROGENICS EUROPE NV To date “E-bypass separator” diaphragms Technological Development Belgium with internal electrolyte bypass and Topic: SP1-JTI-FCH.2010.2.1 Efficient properties for maximum benefit of the alkaline electrolysers DANMARKS TEKNISKE UNIVERSITET cell were developed with a total thickness Contract type: Collaborative project Denmark (including the internal electrolyte Start date: 01 November 2011 channel) between 1.4 and 3.4 mm at End date: 31 October 2014 the size of a 300 cm2 electrolyser. A cell Duration: 36 months concept was realised and electrode Project cost: € 2.89 million coatings were demonstrated, reducing Project funding: € 1.48 million the overpotential of a nickel electrode by 210 mV for the cathode and 161 mV for the anode, thus increasing the efficiency. Project Coordinator A stability of this efficiency during long term operation in on/off cycles, as DEUTSCHES ZENTRUM FUER LUFT - needed when operated with RES, will be UND RAUMFAHRT EV demonstrated with an extrapolation to Germany a lifetime of 10 years. At the same time, low costs for the system are the target: Contact: Ms. Regine Reissner System costs of 3.000 €/(Nm3/h) plant [email protected] capacity for the complete system.
Cross section (left and middle) and top view of the E-bypass separator membrane for a 300 cm2 electrolyser © reselyser
Programme Review 2012 - Final Report 85 SSH2S Fuel Cell Coupled Solid State Hydrogen Storage Tank
Key Objectives Challenges addressed Technical approach and achievements
In accordance with the requirements of Hydrogen storage for automotive is At the beginning of the project, the the call, the main objective of SSH2S is to currently achieved by means of high design and the synthesis, as well as the develop a solid state hydrogen storage pressure (about 700 atmpsphere) physico-chemical characterization, of tank fully integrated with a fuel cell and compressed gas. This approach has existing and novel materials for solid state to demonstrate its application on a real several efficiency and safety limitations, hydrogen storage will be undertaken. system. A well assessed hydrogen storage so that alternatives are necessary. Solid Ab-initio and thermodynamic calculations material (i.e. a mixed lithium amide/ state hydrogen storage has already will determine the selection of magnesium hydride system) will be been demonstrated as suitable for materials. In fact, the materials selected considered as the active material for the stationary applications, but it requires should be characterized by improved tank. A new class of material for hydrogen further scientific and technological capacity and efficiency, in terms of storage (i.e. mixed borohydrides) will improvements for use with mobile thermodynamic and kinetic properties, be also explored. The application of applications. The key challenge addressed resistance to cycling and thermal the hydrogen tank on a real system will by the project is the integration of a solid behaviour. The synthesis of materials be experimentally investigated with a state hydrogen storage tank with a HT- will be performed by ball milling. The 1 kW prototype on High Temperature PEM fuel cell. This system will act as an characterisation will be performed Polymer Electrolyte Membrane (HTPEM) Auxiliary Power Unit (APU) to be installed by a combination of structural and fuel cells. On the basis of the results in a Light Transport Vehicle (LTV). This will spectroscopic experimental techniques. obtained for the prototype system, an require the development of new materials Two fluido-dynamic modelling of ON/OFF milestone will be considered. with high gravimetric and volumetric different tank concepts, as well as the If suitable performances are obtained, energy density and with technically experimental validation of the models a scale-up of the tank will be applied relevant (i.e. close to ambient) sorption in a lab-scale tank will be addressed as to a 5 kW APU. The overall aim is clearly temperature and pressure. The loading well as the development of a prototype to demonstrate the applicability of time and the stability after several cycles tank optimized for use with the the proposed integrated system in will be crucial parameters with which to selected materials. The project and the real situations, also on the basis of a test the performances of the integrated development of the prototype tank will critical techno-economic evaluation. system. Finally, low cost should also be be undertaken by industrial partners. obtained. The results will be used to integrate the materials/tank systems with a low power HT-PEM Fuel Cell (1 kWel). To this end, on the basis of the properties and simulation results obtained, a suitable material composition will be defined for a scale-up production. The final goal of the project is application of the integrated system as a 5 kWel APU to be installed in a LTV. The decision about possible scale-up will be taken after a critical techno-economic evaluation.
86 Fuel Cells and Hydrogen Joint Undertaking www.ssh2s.eu Hydrogen Production Storage and Distribution
Expected socio and economic impact Project Information Partners
A material for a solid state hydrogen Project reference: FCH JU (GA n. UNITO - Università di Torino tank with capacities of up to 4.5 H2 256653) Italy wt%, fully reversible at 180 °C and with Call for proposals: 2009 high stability on cycling has never Application Area: Hydrogen Institute for Energy Technology (IFE) been developed in previous European production and storage Norway Projects. Moreover, new concepts on the Project type: Research and design and the coupling of solid state Development Karlsruhe Institute of Technology (KIT) hydrogen tank with HT-PEM fuel cells Topic: SP1-JTI-FCH.2009.2.4: Improved Germany will represent a significant achievement solid state H2 storage systems by the project. Finally, the development Contract type: Collaborative Project Deutsches Zentrum für Luft- und of a prototype 1 kW integrated system Start date: 01/02/2011 Raumfahrt e.V. (DLR) and the possible application to a 5 kW End date: 01/08/2014 Germany APU are real advances in the field. Duration: 42 months The results of the project may be of Project total costs: € 3 501 749,00 Tecnodelta s.r.l. (TD) significant economic impact for large Project funding: € 1 595 685,00 Italy industries, as well as for SMEs’ industrial partners. The possibility of coupling Serenergy A/S (SER) the HTPEM with a compact and safe Project Coordinator Denmark hydrogen storage system will greatly increase business opportunities for Prof. Marcello BARICCO Centro Ricerche Fiat (CRF) SER and TD partners. The availability of NIS Centre of Excellence Italy safe hydrogen tanks at low pressures Dipartimento di Chimica is expected to contribute to the social Università di Torino Joint Research Centre of European acceptance of hydrogen technologies. Via P.Giuria, 9 Commission (JRC) I-10125 TORINO (Italy) Belgium Tel. + 39 011 670 7569 Fax. + 39 011 670 7855
Programme Review 2012 - Final Report 87 ASSENT Anode Sub-System Development & Optimisation for SOFC systems
Key Objectives Challenges addressed Technical approach and achievements
The objective of this project is to find Whilst much effort and resources are The focus of this project is on evaluating optimal anode subsystem concepts that devoted to cell and stack issues, less different process approaches for fuel are validated for small-scale and large- attention has been paid to the balance of and water management in the case scale SOFC systems to be implementable plant, or components and sub-systems of natural gas and biogas. Possible into a real system to fulfil performance, required for an operational system. process approaches include e.g. fuel and lifetime and cost targets for stationary Components and sub-systems such recirculation management with a recycle applications. To find optimal anode as fuel processing, heat and thermal blower-based approach and/or an ejector- subsystems to be validated, conceptual management, humidification, fluid supply based approach, and water circulation analysis and evaluation of the feasibility and management, and power electronics with condensing from the anode off-gas/ of the different recycle solutions for are as fundamental to successful exhaust gas and evaporating back to the anode subsystem will be carried commercialisation of fuel cell systems as loop. Relevant process options are first out. In addition, sensing techniques are the cell and stack. This is the main reason evaluated on conceptual level and the tested, evaluated, and also developed, and basic idea which lead our consortium results are used as a basis for detailed where available techniques are not to propose this work. In this proposal feasibility evaluation. The aspects taken sufficient. Optimum components the development work specifically into account in the conceptual analysis should be viable for mass production. addresses SOFC technology but some are effects on electric efficiency and of the results might also support process simplicity implying easiness development of MCFC technology. of controllability, and requirements on diagnostics accuracy to provide insights into failure mode prevention. In detailed evaluation, the suitable approaches are analysed more thoroughly in terms of component availability and reliability, achievable diagnostics accuracy, controllability, effects on reformer, mechanical integration feasibility to whole system, safety control, failure mode prevention, cost effects etc.
88 Fuel Cells and Hydrogen Joint Undertaking http://assent.vtt.fi/ Stationary power production and CHP
Expected socio and economic impact Project Information Partners
SOFC technology is immature, but is Project reference: FCH JU Technical Research Centre of Finland seen as having more potential than other Call for proposals: 2008 Finland fuel cell technologies both in terms of Application Area: Stationary Power applications and efficiencies and costs. Generation & CHP HTceramix Based on lower cost ceramic materials Project type: Research and Switzerland SOFC technologies are believed to have Technological Development the greatest potential in becoming Topic: SP-JTI-FCH.3.2: Component and EBZ Entwicklungs- und cost competitive with incumbent system improvement for stationary Vertriebsgesellschaft Brennstoffzelle technologies. High electrical and CHP applications mbH efficiencies will directly impact fuel Contract type: Collaborative Project Germany supplies, whilst low or negligible NOx Start date: 1/1/2010 and SOx emissions and no particulate End date: 31/12/2012 Wärtsilä Finland Oy matter will contribute to cleaner air. Duration: 36 months Finland SOFC units can therefore improve fuel Project total costs: € 4 854 760 security, sustainability, competitiveness, Project funding: € 1 954 675 Hexis AG efficiency and flexibility, and lower Switzerland carbon emissions that will contribute to meeting the objectives of Europe’s Project Coordinator Forschungszentrum Jülich GmbH Energy Policy. Looking into the future Germany the fuel flexibility of SOFC systems Dr. Jari Kiviaho will allow units to transition from the Chief Research Scientist common hydro-carbon fuels of today VTT, Fuel Cells through to future potential fuels such Biologinkuja 5, Espoo as bio-fuels and hydrogen. The focus P.O.Box 1000, FI-02044 VTT will be on technologies for SOFC units Finland with the potential for costs less than Tel.+358207225298 1500-2000 €/kW or 3000-4000 €/kW GSM +358 50 5116778 for large- and small-scale applications Fax +358 20 722 7048 respectively, have 40 000 - 60 000 hours durability and efficiencies of 45-60% in power generation mode and 80% + for CHP mode.
Programme Review 2012 - Final Report 89 ASTERIX III ASsessment of SOFC CHP systems build on the Technology of htceRamIX 3
Key Objectives Challenges addressed Technical approach and achievements
The main objectives of this project are The residential µCHP system based on System simulations will be used to to further develop a micro combined SOFC technology has the potential to explore key Fuel cell system parameters heat and power (µCHP) system based produce both heat and power in a very and suggest optimized system on solid oxide fuel cells (SOFC). The efficient way. The heat and power is dimensions. This will be used in the important parameters to be in focus produced in the private home where design of two generations of the Proof are lifetime, reliability and robustness. used and hence, transmission loss can be of Concept system. Subsequently the This will include tolerance to thermal neglected. The units are fueled by natural project focuses on the optimization of cycling and improving quality of the gas. The high efficiency of the fuel cell the system components such as the individual components of the system will secure, that the µCHP system will SOFC subsystem, the heating system and an integrated automated control reduce the CO2 food print of the family and the inverter. The SOFC system will system. Also the system efficiency both installing the µCHP. The challenges of further be engineered and optimized thermal and electrical will be increased. the project are to develop the µCHP with an emphasis on the stack, the heat Achieving these objectives will enable SOFC fuel cell technology to achieve exchanger, the post-combustion and the us to demonstrate a residential µCHP proof-of-concept in order to make the insulation. Individual components will concept fulfilling market requirements, technology ready for demonstration in be improved with a constant attention and we can start working on the next step residential environments. The important on their assembly. Increased stack and towards commercialization; validation of issues addressed in the project are: system performances, wider operating fuel cell system readiness, field trials and • Lifetime of fuel cell stack range, and more robustness are aimed preparation for large scale production. • Electrical an thermal efficiency for the SOFC subsystem. For the heating • Cost reduction system, besides improvements on • Integration in residential environment the heat storage and the inverters, a significant innovation will be aimed with the integration of a heat pump as an auxiliary heater for the micro CHP system instead of an auxiliary burner.
Ultimately, the objective is to test and validate the Asterix3 micro-CHP appliance. As a first step an experimental program will be established to test the system in various conditions. The test program will be defined with respect to the testing procedures drafted in the upcoming International standard IEC
© asterix III © asterix 62282-3-2 (test methods for stationary
90 Fuel Cells and Hydrogen Joint Undertaking www.asterix3.eu Stationary power production and CHP
fuel cell systems), which is currently under development. The testing conditions will Project Information Partners be established to demonstrate extended continuous operation, thermal cycling, Project reference: FCH JU HTCeramix and normal and emergency shutdown Call for proposals: 2009 Switzerland conditions. Application Area: Research and Technology Development EIFER The objectives are to reach costs slightly Topic: R&D to achieve proof –of- Germany higher that a normal condensing boiler concept of µCHP fuel cell system and an electrical efficiency that is higher Contract type: Collaborative Project CNR-ITAE than to days typical large power plant. Start date: 01/01/2011 Italy End date: 31/12/2013 Duration: 36 months Expected socio and Project total costs: € 3.096.000 economic impact Project funding: € 1.361.000
The project takes a vital step towards the commercialization of the SOFC power Project Coordinator systems for application in private homes. The switch from traditional gas boilers Per Balslev to SOFC µCHP systems will heighten the Director Business Development efficiency and promote decentralizing Dantherm Power of power production. SOFC µCHP power A/S systems can provide energy security and independency of nuclear and large coal Majsmarken 1 fired power plants. The high efficiency DK 9500 of the SOFC CHP systems provide once Hobro reasonably priced, a massive incentive for Denmark switching from conventional centralized power generation to decentralized heat/ [email protected] cooling and power production. This will lead to reduction of distribution losses and thus lower CO2 missions.
Programme Review 2012 - Final Report 91 CATION Cathode Subsystem Development and Optimisation
Key Objectives Challenges addressed Technical approach and achievements
This project would bring improvements Whilst much effort and resources are This project will give a thorough to the current state-of-the-art cathode devoted to cell and stack degradation evaluation into alternatives for the side subsystem, thermal and fluid supply issues, less attention has been paid to SOFC system’s cathode side subsystems management of SOFC systems and may the balance of plant, or components and (fluid and thermal management and lead into the novel design solutions sub-systems required for an operational mechanical solutions including stack/ and optimized subsystems which will system. Cathode side subsystem including system interface) and one of them could significantly increase SOFC system stacks and system components such be implemented into new ~250 kWe efficiency, reliability, controllability and as high temperature heat exchangers, SOFC system demonstrations based lifetime, and will decrease overall cost. burners and blowers etc. can be on the development achieved in the With this novel cathode subsystem significant factors decreasing the electric proposed project. The optimization of solution the new stationary 250 kWe efficiency of the whole system. Relatively SOFC cathode subsystem also leads SOFC system should reach 55% electrical high mass flows and corresponding into significant reduction of piping and efficiency, and achieve 40000 hours of pressure drops together with non-optimal supporting structures. With layout-wise lifetime with over 90% availability. The components, sub-system solutions and optimized components and structural optimization of SOFC cathode subsystem the overall system layout can decrease and insulation solutions, major benefits also leads into significant reduction of the total electrical efficiency many can be achieved in compactness and piping and supporting structures. With percent points, and may drop the cost- weight of the unit and in cost of piping layout-wise optimized components and effectiveness of the whole system below and supporting structures. This project structural and insulation solutions, major commercial profitability. This can be would bring improvements to the current benefits can be achieved in compactness one of the main barriers preventing state-of-the-art cathode side subsystem, and weight of the unit and in cost of commercialization of a final fuel cell thermal and fluid supply management piping and supporting structures. system for stationary power production. of SOFC systems and may lead into the novel design solutions and optimized subsystems which will significantly increase SOFC system efficiency, reliability, controllability and lifetime, and will decrease overall cost. With this novel cathode subsystem solution the new 250 kWe SOFC system should reach 55% electrical efficiency, and achieve 40000 hours of lifetime with over 90% availability. © cation
92 Fuel Cells and Hydrogen Joint Undertaking http://cation.vtt.fi/ Stationary power production and CHP
Expected socio and economic impact Project Information Partners
Even if the SOFC technology is Project reference: FCH JU Technical Research Centre of Finland immature compared to MCFC and PEM Call for proposals: 2009 Finland technologies, it can be clearly seen Application Area: Stationary Power as having more potential than these Generation & CHP Wärtsilä Finland Oy other fuel cell technologies in terms Project type: Research and Finland of applications, efficiencies and cost. Technological Development Based on lower cost ceramic materials Topic: SP1-JTI-FCH.2009.3.4: AVL List GmbH SOFC technologies are believed to have Component and system improvement Austria the greatest potential in becoming for stationary applications cost competitive with conventional Contract type: Collaborative Project Topsoe Fuel Cells A/S technologies. Thus SOFC solutions Start date: 1/1/2011 Denmark with efficiencies above 60% in power End date: 31/12/2013 generation mode and 90% plus for CHP Duration: 36 months Bosal Research NV mode are possible for the medium to Project total costs: € 7 194 680 Belgium longer term. High electrical and CHP Project funding: € 2 625 680 efficiencies will directly impact fuel Centro per lo Sviluppo della supplies, whilst low or negligible NOx Sostenibilita dei Prodotti and SOx emissions and no particulate Project Coordinator Italy matter will contribute to cleaner air. SOFC units can therefore improve fuel Dr. Jari Kiviaho security, sustainability, competitiveness, Chief Research Scientist efficiency and flexibility, and lower VTT, Fuel Cells carbon emissions. This will contribute Biologinkuja 5, Espoo to meeting the objectives of Europe’s P.O.Box 1000, FI-02044 VTT Energy Policy. Looking into the future Finland the fuel flexibility of SOFC systems will Tel.+358207225298 allow units to move from the common GSM +358 50 5116778 hydro-carbon fuels of today, notably Fax +358 20 722 7048 natural gas, through to future potential fuels such as hydrogen and biofuels.
Programme Review 2012 - Final Report 93 CLEARgen Demo The Integration and Demonstration of Large Stationary Fuel Cell Systems for Distributed Generation
Key Objectives Technical approach Expected socio and and achievements economic impact
High Level Objectives: The project has begun development to • To reduce the volume of flared or • The development and construction accommodate the on-site conditions vented to atmosphere hydrogen of a large scale fuel cell system, and necessary implementation, however by 246.4 tonnes per annum. developed and purpose-built actual installation has not yet started. • Reduce carbon emission by offsetting for the European market. fossil fuel generated grid electricity • The validation of the technical and • Reduce demand for centrally economic readiness of the fuel generated electricity. cell system at megawatt scale. • The field demonstration and development of megawatt scale system at a European chemical production plant, running on by-product hydrogen. © cleargen demo © cleargen demo © cleargen
1MWe ClearGen unit installed at Toyota, Los Angeles © cleargen demo © cleargen
Proposed installation in Kazincbarcika, Hungary
94 Fuel Cells and Hydrogen Joint Undertaking Stationary power production and CHP
Expected socio and economic impact Project Information Partners
• Demonstrate the deployment of a Project reference: FCH JU 303458 Dantherm Power A.S 1MW PEM Fuel Cell, developed and Call for proposals: 2010 Denmark purpose-built for the European market, Application Area: Hungary running on hydrogen generated Project type: Demonstration Linde Gas (To be confirmed) as a surplus from a HyCo plant Topic: SP1-JTI-FCH.3.2: Component Hungary • Conduct a waste hydrogen scheme and system improvement for stationary and utilise it to generate no less than Applications Budapest University of 7884 MW hours of electricity for use Contract type: Collaborative project Technology & Economics on the site or return to the grid Start date: 01 January 2010 Hungary • The project will validate the technical End date: 31st December 2017 and economic readiness of fuel Duration: 36 months cell systems at megawatt scale Project cost: € 10.1 million • This project provides the site Project funding: € 4.6 million with a security of supply to the limit of the fuel cells capacity • The electricity produced by a fuel cell Project Coordinator is formed with a perfect sine wave Logan Energy Limited United Kingdom
Contact: Mr William Ireland [email protected]
Programme Review 2012 - Final Report 95 D-CODE DC/DC COnverter-based Diagnostics for PEM systems
Key Objectives Challenges addressed Technical approach and achievements
The D-CODE project aims at developing The D-CODE main challenge is the The approach focuses on the an innovative diagnostic procedure to on-line determination of the FCS state- experimental activity to characterise detect PEM fuel cell stack faults and of-the-health through the information both low temperature (LT) and high support stack degradation level analysis. provided by the impedance spectrum. temperature (HT) fuel cell systems and The stack electrochemical impedance Therefore, single information will to test diagnostic hardware and related spectrum (EIS) is used for on-line guarantee a holistic analysis of the stack. strategies. The hardware design and diagnosis during on-field operations. To achieve this goal several technological realization of the DC/DC power converter Thanks to both new DC/DC converter issues are addressed, among others: to perform EIS has to be achieved as well hardware and diagnosis algorithms, faults • Design and build an improved DC/ as the development of the algorithms for and potential failures associated with DC converter; the new DC/DC the diagnosis. Finally, the development electrochemical processes, components hardware improves interface between of the management system is needed faults (blower, power electronics, power generators and load/grid. in order to drive the DC/DC converter actuators) or having external origin • Implementation of power electronics for EIS purposes and to improve the FCS (erroneous control, critical load) can be controllers aimed at immunizing the control strategies taking advantage of detected on-line while system runs. stack from the load disturbance. the information gathered from EIS-based Main Objectives: • Implement EIS functions on- diagnosis. • Innovative FC stack monitoring board of the DC/DC converter. to change radically the concept • Develop EIS-based diagnostics for low of on-line diagnostic. and high temperature PEM fuel cells. Expected socio and • EIS-based diagnosis-oriented DC/DC • Embed the EIS-based diagnostic economic impact converter to be installed on low and tool in the electronic control unit. high temperature fuel cell systems. • Derive FC degradation/diagnostic Total performance during the life of • Transpose EIS from lab scale to on- information while the system runs. a PEM system plays a very important field for monitoring and diagnosis. • Analysis of EIS to diagnose role in the overall economics of the FC • Power stage and control strategy incipient failures caused by either system. Therefore, the system needs of a DC/DC converter to obtain faults or cell degradation. to operate in such a way as to limit the stack EIS on-board. or prevent degradation and highly • A set of indicators from the spectrum damaging failures. It is therefore very to evaluate differences between the important for the commercialisation of actual status and the nominal one. PEM system to develop good diagnosis tools that can be used on board when diagnosing systems failures.
96 Fuel Cells and Hydrogen Joint Undertaking http://www.d-code.unisa.it https://dcode.eifer.uni-karlsruhe.de/ Stationary power production and CHP
Diagnostics tools developed in D-CODE offer potential for instrumentation cost Project Information Partners reduction, thus significantly reducing the required investment cost for PEM Project reference: FCH JU University of Salerno (UNISA) systems. Additionally, system on- Call for proposals: 2009 Italy demand servicing becomes possible by Application Area: SP1-JTI-FCH.3: utilizing a diagnosis tool that monitors Stationary Power Generation & CHP European Institute for Energy Research and predicts PEM system and stack Project type: Research and (EIFER) failures. On-demand servicing can Technological Development Germany decrease the operation and maintenance Topic: SP1-JTI-FCH.2009.3.3: Operation costs of the PEM systems, as the diagnostics and control for stationary Université de Franche-Comté (UFC) components are serviced and replaced applications France just prior to their end-of-life date. Contract type: Collaborative Project The lifetime of the PEM stacks can be Start date: 1/3/2011 Dantherm Power A/S (DANTH) increased by means of a diagnosis tool End date: 28/2/2014 Denmark that indentifies degrading operating Duration: 36 months conditions and provides information Project total costs: € 2215767.40 CIRTEM (CIRTEM) on a stable operating window for the Project funding: € 1173818.00 France PEM system. This will decrease O&M costs as the time between servicing and Bitron S.p.a (BITRON) replacement of the stacks is extended. Project Coordinator Italy
Cesare Pianese inno TSD (INNO) Dept. of Industrial Engineeting – France University of Salerno, Via Ponte don Melillo, 1, 84084 – Fiaciano (SA) Italy
Programme Review 2012 - Final Report 97 DEMMEA Understanding the Degradation Mechanisms of Membrane- Electrode-Assembly for High Temperature PEMFCs and Optimization of the Individual Components
Key Objectives Challenges addressed Technical approach and achievements
The state of the art high temperature The goal of this project is to study and For the achievements of the project’s polymer electrolyte, PEM, fuel cell understand the physical origin of the goals, ex-situ and in-situ testing technology is based on H3PO4 degradation phenomena that take methodologies must be applied for the imbibed polymer electrolytes. The place during the operation of an MEA examination of the polymer electrolytes most challenging areas towards the of a high temperature PEM fuel cell. The (PEMs), the catalytic layers and MEAs. optimization of this technology are: ultimate milestone of the project is the • Two groups of HT PEMs are employed: (i) the development of stable long combined use of advanced experimental a) PBI and variants as control group and lasting polymer structures with high techniques that will lead to the design b) the advanced state of the art MEAs ionic conductivity and minimal cost and development of prediction tools based on aromatic polyethers bearing and (ii) the design and development for the MEA’s performance. Despite pyridine units. The polymer electrolytes of catalytic layers with novel structures conventional techniques, in-situ have been prepared and characterized and architectures aiming to reduced spectroscopy and locally resolved in terms of their chemical stability and Pt loadings and more active and stable measurements are developed and proton conductivity under various electrochemical interfaces with minimal adopted for the first time for this purpose. conditions. Pt corrosion. In this respect the objective The degradation mechanisms will be • Pt based electrocatalysts have been of the present proposal is to understand thoroughly studied. This will permit the prepared using new modified carbon the functional operation and degradation tailormade optimization of the MEA supports and characterized as to mechanisms of high temperature H3PO4 through the proposal of new materials their physicochemical properties imbibed PEM and its electrochemical (PEMs and catalysts) into a commercially and electrochemical performance. interface. The fundamental understanding reliable product for stack manufacturers. The objective is to achieve a stable of the failure mechanisms can be used electrocatalytic layer with full metal to guide the development of new electrocatalyst utilization at the materials and the development of system electrode/electrolyte interface in order approaches to mitigate these failures. to lower Pt loadings and increase durability. • MEAs preparation and combined in situ electrochemical and spectroscopic investigation techniques and ex-situ post mortem characterization are used in order to study thoroughly the degradation mechanisms aiming to the development of a series of diagnostic tests. MEAs are studied
© demmea and tested in single fuel cells with regards to their operating conditions’ effect on performance, their long term stability and the determination of Pt electrocatalytic utilization and durability. Innovative characterization methods have been developed and employed.
98 Fuel Cells and Hydrogen Joint Undertaking http://demmea.iceht.forth.gr/ Stationary power production and CHP
• The information of the aforementioned experimental methodologies are used Project Information Partners as a feedback for the development of a mathematical model intended as a Project reference: FCH-JU-2008-1 Advanced Energy Technologies predicting tool for the MEA’s long term Call for proposals: 2008 (ADVENT) and transient performance. Application Area: SP1-JTI-FCH.3: Greece Stationary Power Generation & CHP Project type: Research and Foundation for Research and Expected socio and Technological Development Technology Hellas-Institute of Chemical economic impact Topic: 3.3 Degradation and lifetime Engineering & High Temperature fundamentals Chemical Processes (FORTH) The main direct and indirect socio- Contract type: Collaborative Project Greece economic benefits from the DEMMEA Start date: 01 January 2010 project include cost reduction of the End date: ongoing Paul Scherrer Institute (PSI) MEA components and thus the overall Duration: 36 months Switzerland fuel cell, achievement of reliable and Project cost: € 3.1 M efficient operation and therefore Project funding: €1.6 M opening/broadening of the fuel cell Centre National de la Recherche market with the obvious economic Scientifique (CNRS) (employment, rural regions) and Project Coordinator France environmental beneficial impact. Advanced Energy Technologies FUMATECH GmbH Results to date: Certain failure Greece Germany mechanisms of the current technology MEAs have been identified. Novel Contact: Dr. Stylianos Neophytides Institute of Chemical Technology polymer electrolytes have been [email protected] Prague (ICTP) prepared aiming to stable structures Czech Republic at elevated temperature. The novel electrocatalytic systems with new Next Energy - EWE-Forschungszentrum architectures prepared so far seem to fur Energietechnologie e.V. overcome certain limitations of current Germany state of the art formulations towards the improvement of performance and Technical University of Darmstadt stability of the HT MEAs. The expected (8 TUD) outcome at the end of the project is Germany a commercially reliable product.
Programme Review 2012 - Final Report 99 Design Degradation Signature Identification for Stack Operation Diagnostic
Key Objectives Challenges addressed Technical approach and achievements
The overall objective of the DESIGN The main challenges addressed are the The DESIGN project follows the complete project is to provide a sound diagnostic identification of specific signatures at loop from an identified problem (i.e. the method for insidious phenomena that the local cell /SRU / small stack level and list of degradation phenomena studied), slowly accelerate the degradation at their transposition from local signatures set by a group of industry partners, to the commercial stack level, through to full stack with limited instrumentation. the development of a solution (core understanding of the local responses of study) and finally the assessment of sub-stack elements. The main outcome the resulting recommendations, again of the project will be the identification of with the implication of industry. After relevant signals monitored to diagnose the specification and prioritisation of full stack degradation phenomena. Data the different long-term degradation analysis methodology is to be applied to phenomena to be considered (Milestone measured signals; a set of characteristic M1), a test matrix and test protocols signatures for selected degradation to be used will be defined. 3 iterations phenomena such as high Fuel Utilisation are scheduled encompassing test at the local and stack level, to diagnose matrix definition, experiments and long-term degradation conditions; data analysis for the characterisation Recommendations for operation of separate phenomena and the fine- recovery, once a degradation condition is tuning the data analysis methods. Each identified at the cell, SRU or stack level. iteration is launched by a Milestone. Up- scaling of the diagnostic method from sub-components to stack diagnostic will conclude the project with some diagnostics developed in DESIGN, applied on commercial full-size stacks.
100 Fuel Cells and Hydrogen Joint Undertaking www.design-sofc-diagnosis.com Stationary power production and CHP
Expected socio and economic impact Project Information Partners
During the first half of the project, Project reference: FCH JU Commissariat à l’Energie Atomique et the Design partners have identified collaborative project GA 256693 aux Energies Alternatives - Grenoble and prioritized operating conditions Call for proposals: AIP 2009 (CEA) generating degradation to be Application Area: Stationary Power France investigated in the project with the Generation & Combined Heat and external participation of the Genius Power Europaisches Institute für consortium. Among the three main Project type: Applied Research; EnergieForschung mechanisms selected (1) Anode re- Topic: 3.3 Operation Diagnostics (EIFER) oxidation by locally increased fuel and Control for Stationary Power Germany utilizations, 2) Carbon deposition and 3) Application Small leakages at anode side) the project Contract type: Collaborative Project Universita Degli Studi di Salerno has focused on the first one. Specific Start date: 01/01/2011 (UNISA) test matrix and test protocols have been End date: 31/12/2013 Italy defined and implemented iteratively at Duration: 36 months cell, Single Repeating Unit, and short Project total costs: € 3,266,000 Ecole Polytechnique Fédérale de stack level allowing the identification of Project funding: € 1,746,000 Lausanne a high FU signal at all scales. On-going (EPFL) work aims at assessing this signature Switzerland and at validating it on large stacks. Such Project Coordinator a result, that has never been reported HyGear Fuel Cell Systems BV elsewhere, is considered for protection. Dr. Florence Lefebvre-Joud (HFCS) CEA – Grenoble /LITEN Netherlands 17 rue des martyrs, 38054 Grenoble Cedex 9 HTceramix SA France (HTC) Switzerland Tel: +33 438 78 40 40 Fax: +33 438 78 25 56 EBZ Entwicklungs und [email protected] Vertriebsgesellschaft Brennstoffzelle mbH (EBZ) Germany
Programme Review 2012 - Final Report 101 ene.field European-wide field trials for residential fuel cell micro-CHP
Key Objectives By learning the practicalities of installing Expected socio and and supporting a fleet of fuel cells with economic impact actual customers, ene.field partners The objectives of this project are will take one final step before they To provide a detailed fact base which to promote practical learning, the can begin commercial roll-out. An clearly demonstrates where in the demonstration of market potential, increase in volume deployment for the European housing stock FC micro-CHP segmentation, and the cost and manufacturers involved will stimulate cost can provide a tangible emission savings environmental benefits of micro FC- reduction of the technology by enabling and improvements in home energy bills. CHP while developing market-oriented a move from hand-built products Additionally, we hope to enable key product specifications and harmonised towards serial production and tooling. decision makers across Europe to codes and standards. Additionally, we The ene.field project also brings evaluate a final commitment to the seek to set up a more mature supply together over 30 utilities, housing commercialisation and widespread chain, ready for the deployment of providers and municipalities in order rollout of the technology and to micro FC-CHP in 12 Member States, to take the products to market and ensure the technology is rolled provide evidence base on a cost and explore different business models out where the economic and environmental analysis that can be for micro-CHP deployment. environmental benefits are greatest. used to accelerate policy support Lastly, we want to increase the scale from governments and a market The data produced by ene.field will be of deployment of FC micro-CHP adoption by several channels. used to provide a fact base for FC micro- and stimulate a cost reduction by CHP, including a definitive environmental allowing manufacturers to move to lifecycle assessment and cost assessment a series production process, with on a total cost of ownership basis. great attention to quality control. Summary/overview To inform clear national strategies Ene.field will deploy up to 1000 on micro-CHP within Member States, residential fuel cell Combined Heat and ene.field will establish the macro-
Power (micro-CHP) installations, across economics and CO2 savings of the 12 key Member States. This represents technologies in their target markets a change in the volume of fuel cell and make recommendations on the micro-CHP deployment in Europe most appropriate policy mechanisms and a meaningful step towards the to support the commercialisation of commercialisation of the technology. domestic micro-CHP across Europe. Finally The programme brings together ene.field will assess the socio-economic 9 mature European micro FC-CHP barriers to widespread deployment manufacturers into a common analysis of micro-CHP and disseminate clear framework in order to deliver trials position papers and advice for policy across all of the available fuel cell CHP makers to encourage further roll out. technologies. Fuel cell micro-CHP trials will be installed and actively monitored in dwellings across a range of European domestic heating markets, dwelling types and climatic zones, which will, in the end, lead to an invaluable dataset on domestic energy consumption and micro-CHP applicability across Europe.
102 Fuel Cells and Hydrogen Joint Undertaking www.enefield.eu Stationary power production and CHP
Project Information Dantherm Power A.S. Development Centre for Hydrogen Denmark Technologies (DCHT) Project reference: FCH JU 303462 Slovenia Call for proposals: 2011 Elcore Gmbh Application Area: Stationary power Germany Parco scientifico e tecnologico per production and CHP L’ambiente - ENVIRONMENT PARK SPA Project type: Demonstration Hexis AG Italy Topic: SP1-JTI-FCH.3.7: Field Switzerland Politecnico di Torino demonstration of small stationary Italy fuel cell systems for residential and Riesaer Brennstoffzellentechnik GmbH commercial applications Germany DBI Gastechnologische sInstitutg GmbH Contract type: Collaborative project Freiberg (DBI-GTI) Start date: 01 September 2011 SOFCpower S.p.A Germany End date: ongoing Italy Duration: 60 months Energy Saving Trust Project cost: € 53 million Vaillant GmbH UK Project funding: € 26 million Germany Gas- und Wärme-Institut Essen e.V (GWI) Dolomiti Energia SPA Germany Project Coordinator Italy Danmarks Tekniske Universitet The European Association for the British Gas Trading Limited Denmark promotion of Cogeneration UK Belgium European Institute for Energy Research (COGEN Europe) Element Energy Ltd Germany UK Contact: Fiona RIDDOCH DONG Energy Power A/S [email protected] GDF SUEZ Denmark France
Partners ITHO Daalderop Group BV Netherlands Baxi Innotech Gmbh Germany Hydrogen, Fuel Cells and Electro- mobility in European Regions (HyER) Bosch Thermotechnik Gmbh Belgium Germany Imperial College of Science, Ceres Power Limited Technology and Medicine UK UK
Programme Review 2012 - Final Report 103 EURECA Efficient use of resources in energy converting applications
Key Objectives Summary/overview Also, the catalyst will be improved with a lower platinum loading – design target EURECA develops the next generation < 0.2 g/kW. The stack design and the EURECA is developing the next of μ‐CHP systems based on advanced flow field of the bipolar plates will be generation of micro combined Heat- PEM stack technology. The idea is to optimized for the operating conditions. and-Power (µ-CHP) systems based on overcome the disadvantages of complex All development steps will be supported advanced PEM stack technology to gas purification, gas humidification and by modelling. As the final step, the overcome the disadvantages of complex the low temperature gradient for the heat developed stack will be integrated in gas purification, gas humidification exchangers in a heating system. EURECA an adapted μ‐CHP system to achieve and low temperature gradients for will develop a new stack generation proof‐of-concept in the target application heat exchangers with operating based on PEM technology with operating with validation of the design targets. The temperatures of 90 to 120°C. The temperatures of 90 to 120°C. This results μ‐CHP system – including the reformer main outcome is a less complicated, in a less complicated and therefore – is expected to operate at an electrical highly efficient, and therefore a robust more robust μ‐CHP system with reduced efficiency of above 40 %. Lifetime tests µ-CHP system with reduced cost, cost. The development of a new stack with defined test procedures on single meaning that the consortium is well generation includes various parallel cells and short stacks will indicate a balanced along the supply chain. working tasks. Inside the EURECA project stack lifetime of approx. 12.000 h. In all we will optimize materials to operate development processes the partners have in that temperature range – including agreed to a design‐to‐cost approach. Technical approach membrane and bipolar plate materials. and achievements
A public website has been designed and is available at: www.project-eureca.com. An internal website has been included and serves as an exchange server for documents. First technical meetings of the GA and in WP 2, 3, 4 have taken place to review the project’s progress and define test protocols. © eureca
104 Fuel Cells and Hydrogen Joint Undertaking www.project-eureca.com Stationary power production and CHP
A cost assessment will indicate the cost savings by the less complicated Project Information Partners system. The consortium is well balanced along the supply chain. Component Project reference: FCH JU 123456 Eisenhuth GmbH & Co. KG suppliers and system designer are Call for proposals: 2011 Germany backed by research institutions. Application Area: Next generation stack and cell design Univerzitet u beogradu Project type: Research and Serbia Expected socio and Technological Development economic impact Topic: SP1-JTI-FCH.2011.3.1: Efficient Commisariat à l’énergie atomique et use of resources in energy converting aux énergies alternatives We will simplify the design and applications France manufacturing of cells and stacks Contract type: Collaborative project and therefore we will search for new Start date: 01 July 2012 Foundation for research and architectures respectively and design End date: 30 June 2015 technology Hellas the specific application. Also, we will Duration: 36 months Greece improve the tolerance to contamination Project cost: € 6.314.505 and increase the performance Project funding: € 3.557.295 inhouse engineering GmbH power density efficiency reliability. Germany In the end, we will have a system with higher robustness to cycling. Project Coordinator Celaya a emparanza y galdos We support the system engineering internacional, S.A. with a design to cost approach. EWE‐Forschungszentrum für Spain Energietechnologie e.V. Germany Fundacion CIDETEC Spain Mr Alexander DYCK [email protected] Fraunhofer-Gesellschaft zur Förderung der Angewandten Forschung e.V. Germany
Programme Review 2012 - Final Report 105 FluMaBack Fluid management component improvement for back up fuel cell systems
Key Objectives Summary/overview The project is focused on the most critical BOP components with the largest The Back project aims to improve the potential for performance improvement The project aims to develop specific performance, life time and cost of BOP and cost reduction, including: components relative to fluid components of back up fuel cell systems - Air and fluid flow equipment, management that substantially affect specifically developed for emerging more specifically blowers electric efficiency and the total cost countries where long black-outs occur and recirculation pumps of a fuel cell system. This includes: and difficult operative conditions are - Humidifiers a) Blower present. The improvement of sub- - Heat exchangers. b) Recirculation pump system components addressed in the c) Humidifier project will benefit both back-up and Relevant research institutes and d) Heat exchanger. CHP applications. The project focuses universities support the industries in on new designs and improvement the development and evaluation Additionally, the project aims to: of BOP components, aimed at: of BoP components. 1. Improve performance, in terms - improving BOP components’ The project activity completely aligns of reliability and efficiency performance, in terms of reliability; with the call topic as it aims to improve 2. Improve lifetime singularly - improving the lifetime of BOP availability and the cost competitiveness and at a system level, components, both at component of balance of plant (BoP) components, 3. Reduce cost in a mass and at a system level; as well as their suitability for mass production perspective, - reducing cost in a mass production to meet performance and 4. Simplify manufacturing/ production perspective; lifetime targets (up to 10 years). assembly processes of the - simplifying the manufacturing/ As the industrial partners are entire fuel cell system. assembly process of the actively supplying the fuel cell entire fuel cell system. business, the project results can be implemented rapidly, enhancing The project consortium consists of the impact of the project. industries working together commercially and being able to identify the critical needs based on their daily experience. It represents a real opportunity for developing a strategic alliance of industrial actors. In the future, these actors can collaborate on fostering the technological evolution of the components towards more efficient and flexible BOP components that will allow the fuel cell industry to exploit the huge opportunities both for EU market and for emerging countries.
106 Fuel Cells and Hydrogen Joint Undertaking www.flumaback.eu Stationary power production and CHP
Expected socio and economic impact Project Information Partners
• Support the implementation of Project reference: FCH JU 123456 Domel the RTD priorities of the MAIP Call for proposals: 2010 Slovenia • Disseminate the technology Application Area: SP1-JTI-FCH.3: and its functional capabilities Stationary Power Generation & CHP Tubiflex against current technology Project type: Research and Italy • Launching of new and innovative Technological Development initiatives and products Topic: SP1-JTI-FCH.2011.3.3: Environment Park • Implementation of hydrogen and fuel Component Improvement for Italy cells as mainstream applications stationary power applications • Improved energy efficiency Contract type: Collaborative project Jozef Stefan Institute • Increased public and private Start date: 01 July 2012 Slovenia RTD investment in fuel cells End date: 30 June 2015 and hydrogen technologies Duration: 36 months Foundation for the Development of • Development of market applications Project cost: € 4.37 million New Hydrogen Technologies in Aragon and facilitation of additional industrial Project funding: € 2.98 million Spain efforts for development of fuel cell and hydrogen technologies. NedStack Fuel Cell Technology BV Project Coordinator Netherlands
Electro Power Systems, SpA Onda Italy Italy
Contact: Ms. Ilaria ROSSO University of Ljubljana - Faculty for [email protected] Mechanical Engineering Slovenia
Joint Research Centre Netherlands
Programme Review 2012 - Final Report 107 GENIUS Generic diagnosis instrument for SOFC systems
Key Objectives Challenges addressed Technical approach and achievements
In order to comply with the constraints of In order to compete with current The purpose of this project is to develop stationary generators during operation, boilers and entering the market, diagnostic tools that would be validated it is necessary to develop monitoring SOFC systems need to reach similar on real systems. For this, main faults and devices that could either be used as reliability, lifetime and costs level: failures that occur on a SOFC system On Board Diagnostic or as “off-line” • no inconvenience at the customer together with their impacting parameters diagnostic. In the former case, the tool place, limited cost for operation and were identified. On this basis, test plan sends an alarm in order to guarantee (at worst) yearly maintenance. were defined according to the specificities installation safety and the respect of • 40 000 hrs llifetime with a of each stack/system and on each test regulations. Once a fault identified, degradation rate < 0.5%/1000hrs. bench. A permanent loop is established counter measures could then be taken between testing, algorithm development by the control system and a recovery But, these systems’ state of health is and test plan definition, in order to strategy could be defined to limit currently difficult to evaluate, which create diagnostic algorithms that will degradations or performance drop. makes difficult to handle faults or be validated on three different µ-CHP In the latter case, the tool helps the degradation with an appropriate systems. maintenance operations or repairs. counter measure. As a consequence, The objective of GENIUS project is to abovementioned requirements cannot develop a “GENERIC” approach based on be achieved. That’s why state of different algorithms that would only use health diagnostic tools are needed. process values (normal measurements and system control input parameters) to diagnose the state of health of different SOFC systems. If the approach remains generic, the final tool will be adapted to the specificities of the different systems in which it will be integrated and validated.
108 Fuel Cells and Hydrogen Joint Undertaking https://genius.eifer.uni-karlsruhe.de/ Stationary power production and CHP
Expected socio and economic impact Project Information Ceramic Fuel Cells Limited (CFCL) UK GENIUS contributes directly to the Project reference: FCH JU 2008-1 commercialization of the SOFC power Call for proposals: 2008 EBZ GmbH (EBZ) systems. Indeed, along with costs, the Application Area: Stationary Germany reliability and lifetime of SOFC stacks Applications remain as barriers for the market Project type: Research and Université Technologique de Belfort- penetration of the SOFC power systems. Technological Development Montbéliard (FCLAB) Significant improvements in these Topic: SP1-JTI-FCH.3.1 Operation France aspects can be expected by utilizing diagnostics and control for stationary sophisticated diagnosis tools, that applications Université de Franche Comté (UFC) just use the normal measurements Contract type: Collaborative action (third party of FC LAB) and their control input parameters, Start date: 01/02/2010 France for the monitoring, the prediction End date: 31/01/2013 and the prevention of stack failures Duration: 36 months Hexis AG (Hexis) and degradation. In this way, counter Project total costs: € 3 928 509 Switzerland measures can be taken and degradation Project funding: € 2 067 785 minimized by appropriate operation HTCeramix (HTC) even in dynamic load conditions. Switzerland The implementation of such tools Project Coordinator in real systems could therefore be Topsoe Fuel Cell (TOFC) of great benefit for the technology Philippe MOÇOTÉGUY Denmark by increasing the trust of utilities. R&D Project Manager Distributed Energy Group University of Genoa (UNIGE) EIFER Italy Europäisches Institut für Energieforschung University of Salerno (UNISA) Institut européen de recherche sur Italy l’énergie European Institute for Energy Research Technical Research Center of Finland Emmy-Noether Strasse 11 (VTT) D-76131 Karlsruhe Finland Germany Tél : +49 721 6105 1337 Wärtsilä (WAR) Fax: +49 721 6105 1332 Finland
inno TSD (INNO) Partners France
European Institute for Energy Research (EIFER) Germany
Programme Review 2012 - Final Report 109 KeePEMalive Knowledge to Enhance the Endurance of PEM fuel cells by Accelerated LIfetime Verification Experiments
Key Objectives Challenges addressed Technical approach and achievements
KeePEMalive aims at establishing KeePEMalive particularly addresses The concept of this project contains the improved understanding of degradation the degradation challenge by following elements (also illustrated on and failure mechanisms, by developing focusing on the following issues: next page): and approving accelerated stress • Identify the relevant stressing • Systemizing and synthesising all test protocols, a sensitivity matrix conditions for μ-CHP by assessing available information on degradation and a lifetime prediction model for data from field operations as and failure mechanisms Low Temperature Proton Exchange well as laboratory tests. • Designing experiments and accelerated Membrane Fuel Cells (LT PEMFC) • Establish a robust and efficient stress test protocols to enable a lifetime of 40 000 h at methodology for identification and • Carrying out comprehensive cell and realistic operation conditions for quantification of the conditions stack testing utilising the latest and stationary systems, in compliance causing degradation and failure. most advanced in situ electrochemical with performance and costs targets. • Develop ex situ accelerated ageing tests as well as effluent analysis techniques for individual MEA component, and • Complementing the in situ tests by relate results to observed degradation post mortem characterising fuel cell rates for single cell and stacks. materials by ex situ techniques • Verify and validate proposed • Analysing the data utilising powerful materials’ improvements. statistical tools • Develop Accelerated Stress Test (AST) • Developing a model for prediction of protocols that enable quantification lifetime and failure. of the impact of selected stressors on single cells and stacks. The KeePEMalive -project is of an • Provide validated recommendations iterative nature, initially using state-of- for degradation mitigation strategies. the-art materials and stacks supplied • Establish a model that reliably predicts by European fuel cell manufacturers for lifetime on the basis of AST results. detailed analyses and characterisation. As the project progresses and the understanding of degradation and failure mechanisms is enhanced, recommendations for improved materials and stack components as well as degradation mitigation strategies will be provided.
110 Fuel Cells and Hydrogen Joint Undertaking http://www.sintef.no/Projectweb/KEEPEMALIVE/ Stationary power production and CHP
Expected socio and economic impact Project Information Partners
The KeePEMalive project contributes Project reference: FCH JU Stiftelsen SINTEF to achieve the principal technical Call for proposals: 2008 Norway and economic requirements needed Application Area: Stationary Power for PEMFCs to compete with existing Production and CHP IRD Fuel Cells A/S energy conversion technologies (e.g., Project type: Basic Research Denmark natural gas burners, resistive heating) or Research and Technology for stationary heat generation, and in Development Stichting Energieonderzoek Centrum addition provide electricity by efficient Topic: SP1-JTI-FCH.3.3: Degradation Nederland cogeneration of power. The project has and lifetime fundamentals Netherlands a strong link to the Danish Vestenskov Contract type: Collaborative Project stationary fuel cell demonstration Start date: 01/01/2010 Centre National de la Recherche project, where 35 PEMFC based µ-CHPs End date: 30/06/2013 Scientifique, Institut Charles Gerhardt will be placed in households, utilizing Duration: 42 months France hydrogen from wind in a weak grid. Project total costs: € 2,9 million Real-life operation data from this Project funding: € 1,3 million FuMA-Tech GmbH demonstration project feed into the Germany KeePEMalive project and forms, together with experimental laboratory test Project Coordinator EIfER – European Institute for Energy data, the basis for improving materials Research and developing a lifetime prediction Dr. Steffen Møller-Holst Germany model. The increased understanding Vice President Marketing of degradation mechanisms achieved Hydrogen & Fuel Cell Technologies Technische Universität Graz in the KeePEMalive-project will SINTEF Austria eventually contribute to develop mitigation strategies, thereby ensuring Postal Address: SEAS-NVE longer lifetimes for PEMFCs and hence SINTEF Materials and Chemistry Denmark lower cost of energy (electricity and Postboks 4760 Sluppen heat) compared to current state- NO-7465 TRONDHEIM European Commission Joint Research of-the-art stationary fuel cells. Norway Centre, Institute for Energy Belgium Results obtained from KeePEMalive Tel (direct line): +47 926 04534 will be of a generic nature and are thus Switch board: +47 4000 3730 highly relevant for all PEMFC systems, [email protected] including High Temperature PEMFC and PEMFCs for automotive applications, be it that the impact on the lifetime and failure will be different and that other mitigation strategies will be required.
Programme Review 2012 - Final Report 111 LASER-CELL Innovative Cell and Stack Design for Stationary Industrial Applications Using Novel Laser Processing Techniques
Key Objectives Technical approach Key parameters that will dictate fuel and achievements cell and stack design are; safety, reduced part count, ease of assembly, 1. Designing a novel AFC based on laser- Achievements to date fall in 4 main areas: durability, optimised performance, processed substrates with optimised 1. THEORETICAL MODELING recyclability and increased volumetric technical/commercial characteristics. Substrate model completed and power density in a way which achieves 2. Assessing and adapting laser successfully used to determine optimal a cost of under €1,000 per kW. manufacturing techniques and porosity of nickel substrates To realise this vision, proprietary cell incorporating their benefits 2. LASER DRILLING and stack features that have never in the fuel-cell design. Demonstrated drilling of 4000 holes per before been incorporated into an 3. Designing an innovative fuel- second with single laser-source. This AFC system will be employed and cell stack to operate in industrial achievement significantly improves deliver a flawlessly functioning stack. stationary settings, which delivers commercial viability of the laser drilling In order to achieve these ambitious safety, mass manufacture, ease of process objectives, the consortium comprises assembly, recyclability, serviceability 3. LASER SINTERING world leading specialists in the fields and optimal performance. Successful sintering of porous nickel of alkaline, polymer electrolyte and 4. Combining the above objectives samples achieved. Established that the use solid oxide fuel cells, advanced laser in order to establish the cost- of innovative optics provides significant processing technologies, conductive competitiveness of the AFC technology improvements in process speed nano composites, polymer production in comparison with all competing 4. NANOMATERIALS and large scale, stationary power plants. technologies – confirming for the first High CNT-content polymers A cell design tool, based on physical time the commercial viability of AFCs successfully produced using and cost models, will be produced. in large-scale stationary applications. compression moulding and sheet extrusion. This disseminated tool will provide First trials of combined nickel and design rational for material selection conductive polymer materials and geometric design and will, in successfully undertaken. principle, be applicable to all low- temperature fuel cells. Commercially viable porosity forming processes Challenges addressed developed in this project will enable organisations working with other fuel The alkaline fuel cell (AFC) is one of the cell types to re-evaluate the fabrication most efficient devices for converting and design of their core technologies. hydrogen into electricity. Project Impacts will also be felt in other sectors, LASER CELL will develop a novel, mass including; solar cells, aviation, medical producible AFC and stack design for and automotive industries, for whom the stationary, industrial applications utilising partners’ achievements are potentially the latest laser processing technology. This economically viable, sophisticated technology will enable design options, not previously possible, that will revolutionise the functionality and commercial viability of the AFC. © laser-cell
SEM image of a laser-drilled substrate sample produced in year one of project. This optimised process achieved a much higher hole density compared to what was previously possible.
112 Fuel Cells and Hydrogen Joint Undertaking www.laser-cell.eu Stationary power production and CHP
beneficial. The ability to convert ‘waste’ hydrogen into electricity and Project Information Partners achieving the status of ‘pull through’ technology for carbon capture and Project reference: fCH JU 123456 CenCorp (CNC) storage (CCS), would enable AFCs to Call for proposals: 2010 Finland play a crucial role in helping the EU Application area: 3 – Stationary Power meet its reduced CO2 emission targets Generation & Combined Heat and Teknologian Tutkimuskeskus – and improve Europe’s energy security. Power (CHP) Technical Research Centre of Finland Project type: rTD (VTT) Topic: SP1-JTI-FCH.2010.3.2: Next Finland Expected socio and generation cell and stack designs economic impact Contract type: collaborative project Air Products Start date: 1 December 2011 (AIRP) UDE’s substrate model has already End date: 30 Nov 2014 ongoing UK been used in AFC’s production Duration: 36 months process, leading to improvements Project cost: € 2,9 M Nanocyl (NCL) in fuel cell performance. Project funding: € 1,4 M Belgium
LASER-CELL results from first year have University of Duisburg – Essen (UDE) been used by a major UK university to Project Coordinator Germany examine the use of laser-drilled metal sheets as GDLs in PEM fuel cells. Dr Gene LEWIS AFC Energy PLC The partners expect the improvements UK in laser-processing technology to significantly reduce the cost of key Dr Martin THOMAS components in AFC’s fuel cells, as well [email protected] as providing benefits to other fuel cell types, and industries including aviation and emitter-wrap-through solar cells. © laser-cell
Sintering results using the Nd:YAG laser in combination with a cylindrical lens.
Programme Review 2012 - Final Report 113 LoLiPEM Long-life PEM-FCH &CHP systems at temperatures ≥100°C
Key Objectives Challenges addressed Technical approach and achievements
The key objective of the LoLiPEM project A PEMFCH operating in the temperature The key milestones and deliverables is to give a clear demonstration that long- range of 100-130°C is highly desirable and include life SPG&CHP systems based on PEMFCHs could be decisive for the development • The preparation of PFSA and SAPs operating at temperatures higher than of SPG&CHP systems based on membranes stable at a temperature 100°C can now be developed on the PEMFCHs. LoLiPEM aims to operate in higher than 100°C basis of knowledge on the degradation this temperature range exceeding the • Development of new long-life catalytic mechanisms of membranes disclosed by state-of-the-art (70-80°C). The lower electrodes and MEAs operating in the some LoLiPEM partners. Stable perfluoro temperature is the main drawback above temperature range sulfonic acid (PFSA) and new stable for PEMFCH development. Several • Accelerated ageing tests and long-term non-perfluorinated ionomers, such as advantages including easier warm water single cell tests sulfonated aromatic polymers (SAPs), are distribution in buildings, reduced anode • Development of a prototype of a the materials mostly used in this project poisoning due to carbon monoxide modular SPG&CHP system based on for the membranes development for the impurities in the fuel, improved fuel multi-PEMFCHs also utilizing the new MEAs preparation. These innovative MEAs oxidation kinetics, etc. would be long-life MEAs. are developed for operating above 100°C. gained by operating above 100°C. • Benchmarking the single-cell and the modular prototype performance at temperatures above 100°C against the best literature results New protocols for the evaluation of mass transport properties of membranes and MEA as well as for the testing of MEA in fuel cell have been elaborated and successfully applied.
114 Fuel Cells and Hydrogen Joint Undertaking www.LoLiPEM.eu Stationary power production and CHP
Expected socio and economic impact Project Information Partners
Novel PFSA and SAP membranes Project reference: FCH JU - Grant CNR-ITM able to withstand temperatures Agreement no.245339 Italy higher than 100°C are prepared Call for proposals: year 2008 and successfully tested. Innovative Application Area: SP1-JTI-FCH.3: The University of Rome “Tor Vergata”, electrodes are prepared with a new Stationary Power Generation & CHP Italy electrodeposition process which allows Project type: Research and all the electrocatalyst nanoparticles Technological Development The University of Provence to be in contact with both the Topic: SP1-JTI-FCH.3.3 Degradation France ionically conducting ionomer and the and lifetime fundamentals electronically conducting electrode Contract type: Collaborative project The University of Saarbrucken, materials. MEAs are prepared and tested Start date: 01-01-2010 Germany at operating temperatures above 100°C. End date: 31-12-2012 Duration: 36 months EDISON SpA Project total costs: € 2.927.174 Italy Project funding: € 1.360.277 Fumatech Germany Project Coordinator Matgas 2000 Dr. Giuseppe BARBIERI Spain The Institute on Membrane Technology - National Research Council ( ITM-CNR) Cracow University of Technology Poland Tel: +39 0984 492029 Fax: + 39 0984 402103 [email protected]; [email protected]
Programme Review 2012 - Final Report 115 LOTUS Low Temperature Solid Oxide Fuel Cells for micro- CHP Applications
Key Objectives Challenges addressed Technical approach and achievements
The main objective of the project State of the art SOFC technology runs at During the 1st year the system will be will be to develop a proof-of- temperatures around 800-900°C which defined and modelled and materials concept fuel cell system: imposes high thermal stress on the for the stack module improved. This • based on state of the art Solid materials used in the SOFC stack. Running will lead to the delivery of a full stack at Oxide fuel cell technology at lower temperatures (650-700°C) could the end of year 2. In the mean time the • operating on as low stack temperature improve the stability of the stack and other modules: desulfurization, external as possible, with a target of 650°C, to therefore increase the reliability. It has reformer, burner and heat exchangers will solve the known failure mechanisms been proven on a single cell and stack be developed. To reduce system costs, of HT SOFC systems level that at these lower temperatures mass-produced off-the-shelf components • Reducing down time by integrating a the performance of the SOFC materials will be used where possible. low cost, high efficient Gas Air Delivery is sufficient. In the LOTUS project a system based on mass produced micro-CHP system will be designed and In the end of year two all module and field proven components a prototype built based on the 650°C developments culminate in the • integrate all needed power operating stack which meets cost and prototyping of a system and testing it in electronics, components and efficiency targets. Next to the reduced the last 6 month of the project. connections for a direct temperature the biggest challenge replacement of conventional is the integration of components heating appliances to reduce parts and heat loss. • use a modular concept and design practices from the heating appliances industry to reduce maintenance and repair downtime and costs • an electrical system efficiency of minimal • a total system efficiency of minimal 80%.
116 Fuel Cells and Hydrogen Joint Undertaking www.lotus-project.eu Stationary power production and CHP
Expected socio and economic impact Project Information Partners
The use of distributed combined Project reference: FCH JU 256694 SOFCPower heat and power will greatly increase Call for proposals: 2009 Italy the energy efficiency compared Application Area: Stationary power with conventional power plants and generation and CHP Fraunhofer-institut für Keramische boilers. When the production and Project type: Research and technologien und Systeme transportation of the same amount Technological development Germany of electricity and heat to a home by Topic: SP1-JTI-FCH.2009.3.5: Proof-of- conventional means will take up to concept fuel cell systems Domel, d.d. about 170 units, producing those Contract type: Collaborative project Slovenia with a SOFC system at the point of Start date: 01 January 2010 use, only 100 units are needed. This End date: 31 December 2013 University of Perugia will reduce the energy consumption Duration: 36 months Italy between 35 to 40% with accompanied Project cost: € 2.954.984 similar CO2 emission reductions Project funding: €1.632.601 European Commision, Directorate- General Joint Research Centre Belgium Project Coordinator
Hygear Fuel Cell systems Netherlands
Contact: Mr. Ellart de Wit [email protected]
Programme Review 2012 - Final Report 117 MAESTRO MembrAnEs for STationary application with RObust mechanical properties
Key Objectives Challenges addressed Technical approach and achievements
MAESTRO aims to establish methods An issue clearly highlighted in the The MAESTRO project is developing to increase the mechanical stability of Multi-Annual Implementation Plan in solutions to the above bottlenecks state of the art low equivalent weight the stationary application area is the through a range of approaches to perfluorosulfonic acid membranes need to address lifetime requirements improve the mechanical stability of for stationary application of proton of 40,000 hours for cell and stack, state of the art perfluorosulfonic acid exchange membrane fuel cells (PEMFC) and the call for improved materials (PFSA) type PEM fuel cell membranes to increase their durability and cell leading to step change improvements via improved polymer chemistries and lifetime. The concept will be validated over existing technology in terms of manipulation of membrane architecture. by the integration of the robust, performance, endurance, robustness The final project target for the membrane mechanically stabilised membranes into and cost. In general, failure mechanisms is to have increased the tensile strength MEAs, which will be tested in realistic of PEMFC membranes are of two main (compared with the benchmark material conditions, including stability under types: chemical (e.g. from attack by at the project beginning) by 50%, with dynamic conditions, start/stop events peroxide radicals on susceptible polymer a milestone at the mid-term stage of and stand-by mode, in compliance end groups), and mechanical, which improvement by 20-25%. In terms of with performance targets of the originates from weak intermolecular the MEA integrating the mechanically Multi-Annual Implementation Plan. interactions between polymer chains. stabilised membranes, the target is for While methods of chemically stabilising 4000 hours of operation under conditions the polymer end groups have been relevant to stationary application, with developed, failure due to insufficient performance degradation less than 10% membrane mechanical properties limits compared to beginning of life. cell and stack lifetime. The problem Key technical items delivered in year is exacerbated by the trend in use of 1 of the project include: Protocols for membranes of thickness only 25-30 µm characterisation of membranes and (compared with the use of membranes MEAs including accelerated stress of ca. 175 µm some 10 years ago), and testing and long-term operation; the desire to employ lower equivalent Elaboration of benchmark MEAs and weight membranes that can enable their characterisation according to these higher temperature operation, but which protocols; Development of membranes are inherently mechanically weaker and having elastic modulus increased by negatively impact membrane strength. 78% compared with that of the project benchmark, while retaining conductivity of ca. 0.01 S cm-1 at 25 % relative humidity and 0.2 S cm-1 at 90 % relative humidity; State of the art report on approaches to membrane mechanical stabilisation.
118 Fuel Cells and Hydrogen Joint Undertaking www.maestro-fuelcells.eu Stationary power production and CHP
Expected socio and economic impact Project Information Partners
The long lifetime resulting from excellent Project reference: FCH JU 256647 Centre National de la Recherche chemical stability and enhanced Call for proposals: 2009 Scientifique (Montpellier) mechanical properties, associated with Application Area: Stationary France sufficiently high operation temperature Project type: Research and will contribute to reliability and costs Technological Development Solvay-Solexis reduction of stationary power generation Topic: SP1-JTI-FCH.2009.3.2: Materials Italy systems, and improve European development for cells, stacks and competitiveness in this market area. balance of plant Johnson-Matthey Fuel Cells The availability of mechanically Contract type: Collaborative project UK robust and performant membranes Start date: 01/01/2011 will also have positive impact on fuel End date: 31/12/2013 Università di Perugia cell application in other sectors such Duration: 36 months Italy as, for example, transportation. Project total costs: € 2264765 Project funding: € 1040049 Pretexo France Project Coordinator
Deborah Jones Centre National de la Recherche Scientifique Université Montpellier 2 Institut Charles Gerhardt Montpellier, France
Programme Review 2012 - Final Report 119 MCFC-CONTEX Molten Carbonate Fuel Cell catalyst and stack component degradation and lifetime: Fuel Gas CONTaminant effects and EXtraction strategies
Key Objectives Challenges addressed Technical approach and achievements
Reducing the carbon footprint of 1) (accelerated) experimental The first line of activity requires extensive our society is imperative. This can investigation in realistic conditions long-term testing of the MCFC. It is an be achieved both by capturing and of the effects of 2H S, HCl, HF, important step, involving harmonization confining anthropogenic CO2 emissions Siloxanes on the anode, and of test procedures and equipment within as by replacing fossil-based fuels with of SO2, NOx at the cathode the consortium. The gas analysis system renewable or waste-derived fuels. MCFCs 2) Numerical modelling of MCFC is developed as well as the LIBS part of are unique in being able to do both these performance and long-term behaviour the device is now complete and under things. However, the degradation caused under clean and poisoned conditions calibration. by the contaminants in these gases must 3) Development of an industrially be addressed. MCFC-CONTEX aims to suited, transportable device for The second line of investigation entails tackle the problem of degradation by high-resolution real-time gas characterization and development trace contaminants from two sides: analysis and trace detection of clean-up materials and processes, 1) investigation of poisoning through innovative laser techniques focusing on the most promising options mechanisms caused by alternative (LIBS – laser-induced breakdown to be selected at the start of the project. fuels and applications and precise spectroscopy – and Raman) Ultimately a pilot-scale gas cleaning unit determination of MCFC tolerance 4) Characterization of commercial optimized for the applications considered limits for long-term endurance; adsorbents and catalysts for will be developed and run. 2) optimization of fuel and gas cleaning optimized cleaning in terms of cost- to achieve tailored degrees of effectiveness, and development purification according to MCFC of a prototype cleaning system. operating conditions and tolerance.
120 Fuel Cells and Hydrogen Joint Undertaking http://mcfc-contex.enea.it/ Stationary power production and CHP
Expected socio and economic impact Project Information Partners
MCFC-CONTEX actively contributes Project reference: FCH JU 245171 Technical University Munich (TUM) towards the development of Call for proposals: 2008 Germany technologies that need to take over Application Area: S from conventional energy supply Project type: Research and Marmara Research Centre (MAM) systems in the near future, due to Technological Development Turkey EU policy measures as well as mere Topic: SP1-JTI-FCH.3.3: Degradation necessity of sustainability. In particular, and lifetime fundamentals University of Genoa (UNIGE) the results aimed at in gas analysis Contract type: Collaborative project Italy and biogas clean-up systems will be Start date: 01 January 2010 Royal Institute of Technology (KTH) widely applicable across the entire End date: ongoing (01 October 2013) Sweden field of renewable energy conversion. Duration: 36 months Optimizing the operating conditions of Project cost: € 4,429,336.10 OVM-ICCPET Institute (OVM) the MCFC allows to tap into the huge Project funding: € 1,841,929.27 Romania and expanding European market of small-medium-scale, anaerobic digestion Joint Research Centre (JRC) waste treatment. And separation of CO2 Project Coordinator Belgium from power plant exhaust fumes using the MCFC (producing power instead of Italian Agency for New Technologies, consuming it) has a potentially colossal Energy and sustainable economic global market. So far, promising results development (ENEA) have been obtained in the determination Via Anguillarese 301, 00123 – Rome, of poisoning mechanisms by H2S ITALY and SO2; in the selection of adequate cleaning materials and design of a Contact: Mr Angelo MORENO suitable gas clean-up system; in the [email protected] development of the high-resolution, real-time gas analysis device, and in the Mr Stephen McPHAIL set-up of the basic numerical model. [email protected]
Programme Review 2012 - Final Report 121 METPROCELL Innovative fabrication routes and materials for METal and anode supported PROton conducting fuel CELLs
Key Objectives Challenges addressed Specific objectives: - Development of novel electrolyte (e.g. BTi02, BCY10/BCY10) and METPROCELL aims to develop innovative PCFC is one of the most promising electrode materials (e.g. NiO-BIT02 Proton Conducting Fuel Cells (PCFCs) technologies to reach the requirements and NiO-BCY10/BCY10 anodes) by using new electrolytes and electrode related to cogeneration applications, with enhanced properties for materials dedicated to 500-600°C. The especially in the case of small power improved proton conducting fuel cell architecture will be optimised on systems (1-5 kWel). The investigation cells dedicated to 500-600°C. both metal and anode supports, with the in the concept of advanced thin-film - Development of alternative aim of improving the cell performance, ceramic fuel cell technology at operating manufacturing routes using durability and cost effectiveness. Further intermediate temperatures between cost effective thermal spray objectives are the development of cost- 400 and 700 °C aims to improve the technologies such detonation effective manufacturing routes and characteristics (thermal cycling, heat spraying (electrolytes and protective bringing the proof of concept of PCFCs transfer, current collection) as well as coatings on interconnects) and by the set-up and validation of short drastically lower the costs of the system. plasma spraying (anode). stacks in relevant industrial systems. - Development of innovative proton The aim of METPROCELL is to develop conducting fuel cell configurations innovative Proton Conducting Fuel Cells to be constructed on the basis (PCFCs) by using new electrolytes and of both metal supported and electrode materials and implementing anode supported cell designs. cost-effective fabrication routes based - To up-scale the manufacturing on both conventional wet chemical procedures based on both conventional routes and thermal spray technologies. wet chemical methods and thermal Following a complementary approach, spraying for the production of flat Stack the cell architecture will be optimised Cells with a footprint of 12 x 12 cm. on both metal and anode type - Bring the proof of concept of these supports, with the aim of improving novel PCFCs by the set-up and the performance, durability and validation of prototype like stacks cost effectiveness of the cells. in two relevant industrial systems, namely APU and gas/micro CHP.
122 Fuel Cells and Hydrogen Joint Undertaking www.metprocell.eu/about.html Stationary power production and CHP
Expected socio and economic impact Project Information Partners
The PCFC technology could significantly Project reference: FCH JU 277916 EUROPAICHES INSTITUT contribute to industrialise the fuel Call for proposals: 2010 ENERGIEFORSCHUNG cell technology by improving the Application Area: Stationary Power ELECTRICITE DE FRANCE/UNIVERSITAT cell characteristics and drastically Generation & CHP KARLSRUHE (TH) lowering the system costs. In this sense, Project type: Research and Germany METPROCELL´s results will contribute Technological Development to an increase the system efficiency, Topic: SP1-JTI-FCH.2010.3.1 Materials Centre National de la Recherche through a better utilization of the development for cells, stacks and Scientifique heat produced and a better BoP, a balance of plant (BoP) France lower operating temperature down Contract type: Collaborative project to 600 ºC, a reduction of the energy Start date: 01 December 2011 DANMARKS TEKNISKE UNIVERSITET consumption of at least 7-10% and the End date: ongoing Denmark elimination of the fuel dilution (since Duration: 36 months water is formed at the cathode). Project cost: € 3.4 million TOPSOE FUEL CELL A/S Project funding: € 1.8 million Denmark
Ceramic Powder Technology AS Project Coordinator Norway
TECNALIA RESEARCH & INNOVATION HÖGANÄS AB Spain Sweden
Contact: Dr.-Ing. Maria PARCO MARION TECHNOLOGIES S.A. [email protected] France
Programme Review 2012 - Final Report 123 METSAPP Metal Supported Sofc Technology for Stationary and Mobile Application
Key Objectives Technical approach Novel anode designs will be developed and achievements and fundamental studies will be conducted on La- and/or Nb-doped
Most SOFC demonstrations with ceramic Metal supported cells have been n-type SrTiO3 materials. To enhance cells in real system operation have scaled up to a 300 cm2 footprint. ASR anode performance, catalysis-promoting until now revealed problems regarding on 12x12 cm foot print of 0.27 ohm elements such as Mn and Ga will be reliability issues. Attention to reliability cm2 has been verified. Extensive failure introduced into the titanate perovskite and robustness has especially been paid mode modelling has been created as a lattice in order to enhance oxidation in connection with SOFC technology for development platform for further stack activity and improve mixed ionic/ mobile application. Modelling studies design optimisation within the project. electronic conductivity, respectively. as well as recent practical experience Robust seals and stack assembling has Materials featuring low Cr evaporation has proved how up-scaling of cells and been implemented based on novel laser and improved corrosion resistance will stacks to larger more industrially relevant welding techniques. Corrosion protection be provided by a thin film coating of sizes generally leads to lower reliability of metallic interconnects by combined Fe-22Cr strip steels with submicron Co in real system operation and intolerance Co-Ce coating, which is based on a and Co/Ce films. To ensure high cell and towards system abuse and operation continuous PVD technology has been stack component robustness, physical failures. The aim of the METSAPP project developed. models for the different governing failure is to develop novel cells and stacks modes and mathematical models for based on a robust and reliable up-scale- related random processes, accelerated able metal supported technology for Summary/overview test procedures will be validated. stationary as well as mobile applications The electro-chemical model of the with the following primary objectives: The project is dealing with key repeatable stack elements will be used for 1. Robust metal-supported cell design, parameters limiting the long term optimising the cell size and flow patterns ASRcell < 0.5 ohmcm2, 650ºC stability of current metal supported of the interconnected components. 2. Cell optimized and up-scaled cells. For the metal support layers and CFD & FEM modelling will be used for to > 300 cm2 footprint cermet layers the type and amount of minimising pressure drop across the 3. Improved durability for stationary metal and ceramic components will cells and contact resistance between
applications, degradation < 0.25%/kh be optimized. Compositions of Sc2O3 cells and interconnects. Small stacks
4. Modular, up-scaled stack design, and/or Y2O3 doped ZrO2 will form the with larger cells will be developed and stack ASRstack < 0.6 ohmcm2, 650ºC ionic conducting component in the tested with respect to electrochemical 5. Robustness of 1-3 kW stack verified backbone structure of the anode layer. performance and mechanical robustness. 6. Cost effectiveness, industrially Improved nano-structured electrodes relevance, up-scale-ability illustrated. adapted to the metal-supported cell concept will be developed and tailored for high performance aiming at a 40.00 hour lifetime operated on natural gas.
124 Fuel Cells and Hydrogen Joint Undertaking www.metsapp.eu Stationary power production and CHP
Expected socio and economic impact Project Information Partners
The societal impact is expected to be Project reference: FCH JU Grant Sandvik Materials Technology AB seen along the lines of a faster and agreement no: 278257 Sweden solid opening of the market related to Call for proposals: 2010 SOFC systems for many applications, Application Area: JTI-FCH Danmarks Tekniske Universitet such as micro-CHP in single houses, the Project type: Research and Denmark distributed generation of power and Technological Development heat in apartment houses, hospitals, Topic: SP1-JTI-FCH.2010.3.1 Materials AVL List GmbH banks and office buildings and APU development for cells stacks and Austria for the transport sector (trucks and balance of plant (BoP) ships). This will result in a much more Contract type: Collaborative project Chalmars Tekniske Hoegskole AB efficient and clean means of utilizing Start date: 25 October 2011 Sweden our fuel resources for the production End date: ongoing of electricity and heat, and will hence Duration: 36 months Karlsruhe Institute of Technology have a tremendous impact on the future. Project cost: € 7,886,782 Germany Successful integration of SOFCs into Project funding: € 3,396,470 million the market will thus bring the EU one University of St. Andrews step closer in achieving the targets for UK 2020 (20% cut in greenhouse gases, Project Coordinator 20% increase in energy efficiency and ICE Stromungsforschung GmbH 20% energy from renewable sources). Topsoe Fuel Cell A/S Austria The robust, reliable (and cheaper) SOFC Denmark systems of European players will create Joint Research Centre (JRC) important high-tech, clean-tech jobs Contact: Administration Technical European Commision in Europe while producing sales on the [email protected] Belgium global market. The potential market for [email protected] micro-CHP units is a significant part of the approx. 5 million boilers that are sold in the EU (Germany: 800 000) every year.
Programme Review 2012 - Final Report 125 MMLCR Working towards Mass Manufactured, Low Cost and Robust SOFC stacks
Key Objectives Technical approach Summary/overview and achievements Lightweight SOFC stacks are currently The project addresses a novel design The project has been slowed down by a being developed for stationary solution for lightweight SOFC stacks transfer process involving the movement applications such as residential CHP that decouple the thermal stresses of the project coordination from Juelich units, for automotive applications within the stack and at the same time, to the University of Birmingham. such as APUs and for portable devices. allow optimal sealing and contacting. They supply electrical efficiency of up In this way, the capability for thermal Nevertheless, the first successful supply of to 60%, a high fuel flexibility, being cycling is enhanced and degradation parts and production of single repeating able to operate on syn-gas from Diesel resultant of contact, reduced. units has commenced. Laser supported reforming as well as LPG, methane or glass welding has rendered promising hydrogen, and promising cost savings The design is highly suitable for industrial results, and the design of a manufacturing due to greatly reduced amounts manufacturing and automated assembly. unit has begun. of steel interconnect material. The industrial partners will build up the necessary appliances for low cost In mobile and portable applications, production and automated quality the requirements for thermal cycling control, stacking and assembly of stacks. are high. It is therefore essential that lightweight stacks have excellent thermal cycling and rapid start-up capabilities. The stack design pursued here supplies a compensation of thermo- mechanical stresses between cell and cell frame / repeating unit. Thin steel sheets with protective coating are used for the sake of cost reduction and extended stack lifetime, as well as for stationary applications. The project looks into various facets of improved components (sealing, interconnects, contacting, cells) from the point of view of mass manufacturing and automated assembly that will be cost-efficient.
126 Fuel Cells and Hydrogen Joint Undertaking Stationary power production and CHP
Expected socio and economic impact Project Information Partners
The design targets lower production Project reference: FCH JU 278525 Forschungszentrum Jülich GmbH cost, increased quality and especially Call for proposals: 2010 Germany shorter start-up times for SOFC Application Area: 3 stacks and thus systems. Project type: Research and Technical BORIT Development Belgium Topic: SP1-JTI-FCH.2010.3.2: Next generation cell and stack designs Rohwedder Micro Assembly GmbH Contract type: Collaborative project Germany Start date: 01 January 2012 End date: ongoing CSIC Duration: 30 months Spain Project cost: € 4.5 Mio. Project funding: € 2.07 Mio. Bekaert Belgium
Project Coordinator Turbocoating Italy University of Birmingham United Kingdom SOFCpower SpA Italy Dr Robert STEINBERGER-WILCKENS School of Chemical Engineering University of Birmingham Edgbaston Birmingham B15 2TT United Kingdom
Tel. : +44 121 415 8169 R.SteinbergerWilckens@ bham.ac.uk
Programme Review 2012 - Final Report 127 PREMIUM ACT PREdictive Modelling for Innovative Unit Management and https://www-premiumact.cea.fr ACcelerated Testing procedures of PEFC www.MRTfuelcell.polimi.it/premiumact.html
Key Objectives This degradation is double: decrease In parallel, multi-physics models are of the electrical power with time and developed to enable the description degradation of the components. As of the phenomena appearing during A general objective is to contribute to multiple factors induce degradation the ageing at the different scales of the improvement of stationary PEFC (materials used for the catalysts or for the cell and for different conditions, systems durability, one of the main the membrane, operating conditions considering as well the decrease of the hurdles to overcome before successful such as cell temperature, gases electrochemical performance as the market development, knowing that composition), it is also necessary to alteration of the MEA materials features the target required is 40000h. understand the link between the (catalysts, electrodes and membranes); Premium Act specific objectives are to different degradation mechanisms. models validation being conducted propose a reliable method to predict The challenges of Premium Act are related through specific single cell tests. lifetime, to benchmark components to the approach which is to combine The core technical part of the project will and to improve operating strategies specific experimental and modelling be to combine all the information coming of real systems, in order to reach tools to study the degradation at different from the experimental tests or analyses the following achievements: scales from fuel cell performance and from the modelling to propose and • Relative prediction of durability - the down to microstructure of materials. validate relevant accelerated tests able ranking of durability predicted between to couple various degradation factors different MEAs is in agreement with Additional issue is the consideration and to assess different MEAs’ lifetime ranking obtained in real conditions; of two strategic fuel cell technologies more rapidly than with normal tests. • Absolute prediction of durability - the for stationary markets: DMFC (Direct Final expected outcomes are operating method is successful in predicting the Methanol Fuel cell) power generators strategies able to improve the lifetime observed lifetime with reduced testing and PEMFC (Proton Exchange of the systems considered and a duration thanks to accelerated tests; Membrane Fuel cell) power CHP methodology to predict the life time of • Innovative unit management systems fed by reformate hydrogen. their MEAs. strategies - the strategies allow a measurable durability increase in the stacks and systems of the industrial Technical approach Expected socio and partners without negative impact and achievements economic impact on the customer needs’ fulfilment. The technical approach has been built The project contributes directly to the on technical tasks interconnected in the development of the European fuel Challenges addressed right way to complete the challenging cell activities at least related to the objectives described above. three industrial partners involved. Main issue is the durability of fuel First step is to identify and understand Premium Act aims at developing a cell system for micro Combined the causes of degradation, particularly methodology adaptable to the multiple Heat and Power applications. of Membrane Electrode Assemblies, PEFC technologies for the improvement It is necessary to first identify and in real conditions (with a focus on the of systems durability. In this sense, understand the causes of fuel cells accelerating features). These conditions the success of the project should degradation in real conditions. are thus reproduced on small devices to help to overcome one of the main Degradation is mainly related to the estimate MEAs’ lifetime. Then, analyses bottlenecks preventing fuel cells market degradation of the Membrane Electrodes are conducted on the components, to development for European providers Assemblies (MEAs), core of the fuel cells elucidate how their microstructure or of stationary fuel cell systems and where electrical power is produced. their properties are degraded during fuel will contribute to cross cutting issues cell operation. relevant for European R&D and fuel cell
128 Fuel Cells and Hydrogen Joint Undertaking https://www-premiumact.cea.fr www.MRTfuelcell.polimi.it/premiumact.html Stationary power production and CHP
industry development. Thus, reliable systems corresponding to the technical Project Information Partners specifications of the energy global market could be widespread, which will Project reference: Grant agreement IRD FUEL CELLS A/S change the end-user habits towards the n° 256776 Denmark stationary energy management and will Call for proposals: FCH JU 2009 - 1 help to reduce greenhouse gas emission. Application Area: Stationary FC POLITECNICO DI MILANO systems Italy The project also deals with education Project type: Research by involving post-doctoral researchers, Topic: SP1-JTI-FCH.2009.3.1: DLR PhD and MSc students in activities Fundamentals of fuel cell degradation Germany at CEA, DLR & POLIMI. To have the for stationary power applications best impact as possible on the PEFC Contract type: Collaborative Project ICI CALDAIE early market community, results and Start date: 01 March 2011 Italy data collected in the project will be End date: 28/02/2014 disseminated through scientific papers Duration: 36 months JRC IE & conferences. A major dissemination Project cost: € 5.4 million European Commission action has been the organization of the Project funding: € 2.5 million Public workshop on “Characterization SOPRANO and quantification of MEA degradation France processes” organized at CEA/Grenoble Project Coordinator the 26 & 27th September 2012. CEA - LITEN This project could otherwise France contribute to Safety, Regulations, Codes and Standards for future Contact: Mrs Sylvie ESCRIBANO standards definition thanks to [email protected] project outcomes on traditional and accelerated testing & on degradation models for both fuel cell technologies considered, PEMFC and DMFC.
Programme Review 2012 - Final Report 129 RAMSES Robust Advanced Materials for Metal Supported SOFC
Key Objectives Technical approach Manufacturing and integration of the new and achievements MSC technology into a short stack for a final proof-of-concept. For the proof-of- The RAMSES project aims at developing The technical objective of this project concept, the target is to produce full-scale an innovative high performance, robust, is the development of a SOFC cell with cells, with the best architecture, materials durable and cost-effective Solid Oxide an improved lifetime due to the low and processes and to integrate them into Fuel Cell based on the Metal Supported operating temperatures (600-700°C) a planar short stack (approx 100 W) and a Cell concept i.e. the deposition of thin while achieving high performances by tubular stack (approx 75 W). Performance ceramic electrodes and electrolyte applying advanced low-temperature will be evaluated at 600-700°C first with on a porous metallic substrate. electrodes and electrolyte materials. hydrogen and second with internal steam Both planar and tubular cells will be The Metal Supported Cell concept methane reforming (ISR). developed. By considering advanced (MSC) will in addition reduce statistically materials tailored for this application, based mechanical failures, since such cells will be able to operate at this type of cell is intrinsically more 600-700°C in hydrogen and methane mechanically robust, and decreasing steam reforming is also considered. manufacturing cost by decreasing the Degradation upon thermal and amount of expensive ceramic materials redox cycling is also studied. to minimum. Cost reduction of Balance- of-Plant components will also be achieved because of the lower operating Challenges addressed temperature (e.g. insulation, heat exchangers and recycle blowers). The achievement of such performance needs several key- Two technological objectives are developments to be addressed: targeted: • manufacturing of a durable The development of a performing, metallic substrate durable and cost-effective Metal- • deposition of the ceramic layers Supported Cell. Metal-supported Cell without affecting the substrate development will include both the microstructure, with a special emphasis metal-substrate development and the cell on the dense electrolyte deposition development itself. The major innovative • proof-of-concept via the integration of activities will be focused on the design the cells into a short stack, supported of the cell and the development of by inspection techniques to evaluate manufacturing processes, with a major the good quality of components focus on the deposition of the electrolyte, at each step of the process which is a key issue of this project. • testing activities to determine the performance and durability of cells and stacks, and to investigate specifically identified failure mechanisms.
130 Fuel Cells and Hydrogen Joint Undertaking www.ramses-project.org Stationary power production and CHP
Expected socio and economic impact Project Information SOFCpower S.r.l. (SP) Fuel cell applications can contribute Project reference: FCH JU 256768 Italy significantly to European public Call for proposals: 2009 policy objectives for energy security, Application Area: Centre National de la Recherche air quality, reduction of greenhouse Project type: Research and Scientifique gas emissions and industrial Technological Development (CNRS-BX) competitiveness. According to the Topic: SP1-JTI-FCH.2009.3.2: Material France European Hydrogen and Fuel Cell development for cells, stacks and Technology Platform and to the IPHE, balance of plant (BoP) Höganäs AB cost and durability/reliability are the two Contract type: Collaborative project (HÖGANÄS) major impediments to SOFC widespread Start date: 01 January 2011 Sweden development and commercialization. End date: ongoing Within the EU supportive policy Duration: 36 months Baikowski framework to stimulate research, Project cost: € 4.7 million (BAIKOWSKI) development and deployment, the 3 Project funding: € 2.1 million France year RAMSES project will produce a robust, highly performing and durable AEA S.r.l cell for stack manufacturers addressing Project Coordinator (AEA) the Combined Heat and Power (CHP) Italy application. The expected impact of the Julie MOUGIN project will be the availability of a stable Commissariat à l’Energie Atomique et Stiftelsen SINTEF competitive SOFC cell, with significantly aux Energies Alternatives (CEA) (SINTEF) improved mechanical reliability, as DRT/LITEN/DTBH/LTH, 17 rue des Norway well as combined redox-thermal Martyrs, F-38054 Grenoble Cedex 9, cycling, and lower manufacturing France Ikerlan S. Coop. costs, particularly regarding materials. (IKL) As a result it will contribute to make [email protected] Spain SOFCs more attractive and affordable, for a market entry in CHP applications Copreci S. Coop. at the horizon 2015 – 2020. Partners (COPRECI) Spain Commissariat à l’Energie Atomique et aux Energies Alternatives National Research Council Canada CEA (NRC) France Canada
Programme Review 2012 - Final Report 131 ReforCELL Advanced multi-fuel Reformer for CHP-fuel CELL systems
Key Objectives Summary/overview Aditonally, REforCELL hopes to increase the efficiency and lifetime of the Distributed power generation via Micro reformer, create novel stable catalysts ReforCELL aims at developing a high Combined Heat and Power systems and highly permeable and more stable efficiency PEM fuel cell micro Combined has been proven to overcome the membranes. Afterwards, suitable Heat and Power system (net energy disadvantages of a centralized plant reactor designs for increasing the mass efficiency > 42% and overall efficiency since it can provide savings in terms and heat transfer will be realized and > 90%) based on a novel, more efficient of Primary Energy consumption and tested at laboratory scale. The most and cheaper pure hydrogen production energy costs. However, wide exploitation suitable reactor design will be scaled unit (5 Nm3/h), together with an of these systems is still hindered by up at prototype level (5 Nm3/h of pure optimized design of the subcomponent high costs and low reliability due hydrogen) and tested in a CHP system. for the BoP. The target will be pursued to the complexity of the system. with the integration of a reforming and The connection of the novel reformer purification system in one single unit REforCELL aims at developing a highly within the CHP will be optimized using Catalytic Membrane Reactors. efficient heat and power cogeneration by designing heat exchangers and system based on: i) design, construction auxiliaries required in order to decrease and testing of an advanced reformer the energy losses in the system. The Technical approach for pure hydrogen production with project aims to increase the electric and achievements optimization of all of the components efficiency of the system above 42% of the reformer (catalyst, membranes, and the overall efficiency above 90%. The industrial requirements of the m-CHP heat management etc) and ii) the design system have been completed. The study and optimization of all the components A complete lifecycle analysis of the system identified the characteristics of state-of- for the connection of the membrane will be carried out and a cost analysis and the-art technology regarding reactor, reformer to the fuel cell stack. business plan for reformer manufacturing PEM, BoP, raw material specifications and and CHP systems will be supplied. integrated CHP systems. The goal was to The main idea of REforCELL is to develop define the industrial requirements for the a novel, more efficient and cheaper introduction of a CHP system in industry. multi-fuel membrane reformer for pure Related to the Catalytic Membrane hydrogen production in order to intensify Reactor, the first Ni based catalysts, both the process of hydrogen production commercial and new developments through the integration of reforming are been characterised. Besides, the and purification in one single unit. process depositions for developing the membranes have been set up and first Pd based selective layers have been deposited. Studies on interdiffusion layers and support quality are on-going. © reforcell
132 Fuel Cells and Hydrogen Joint Undertaking www.reforcell.eu Stationary power production and CHP
Expected socio and economic impact Project Information Partners
A target cost of 5000 €/kWel by 2020 Project R eference: FCH JU Grant Eindhoven University of Technology has been proposed to enlarge the use Agreement nº 278997 Netherlands of residential micro-CHP systems. The Call for proposals: FCH-JU-2010-1 cost of the reformer is an important Application Area: SP1-JTI-FCH.3: Commissariat à l’Energie Atomique et part of the overall cost, accounting Stationary Power Generation & CHP aux Energies Alternatives for around 25 % of overall costs in Project type: Research and France domestic micro-CHP. In this context, Technological Development REforCELL aims to develop an advanced Topic: SP1-JTI-FCH.2010.3.3 Politecnico di Milano reformer for CHP applications. The Component improvement for Italy project will directly impact the stationary power applications performance of individual components Contract type: Collaborative project STIFTELSEN SINTEF of fuel cell systems, the optimization of Start date: 01/02/2012 Norway interaction between BoP components End date: 31/01/2015 and mature stacks, the components Duration: 36 months ICI Caldaie S.P.A. which are viable for mass production, Project cost: € 5,590,762 Italy lifetime, cost and recyclability. Project funding: € 2,857,211 HyGear BV Netherlands Project Coordinator SOPRANO INDUSTRY FUNDACION TECNALIA RESEARCH France AND INNOVATION Spain Hybrid Catalysis BV Netherlands Contact: Mr. Alberto GARCIA-LUIS [email protected] Quantis Sàrl Switzerland
JRC –JOINT RESEARCH CENTRE- EUROPEAN COMMISSION Belgium
Programme Review 2012 - Final Report 133 ROBANODE Understanding and minimizing anode degradation in hydrogen and natural gas fuelled SOFCs
Key Objectives Challenges addressed Technical approach and achievements
One of the main obstacles for The project’s aim is to develop a The main objective of ROBANODE is to commercialization of Solid Oxide Fuel detailed study of the mechanism of the understand the interrelations between Cells (SOFCs) is insufficient durability, anode degradation processes, through the degradation factors so that targeted which is largely due to degradation of identification of similarities/differences in modifications in the structure and the anode electrode. Anode degradation the degradation behaviour of unmodified morphology of the Ni based anodes in hydrogen fuelled SOFCs corresponds and modified (via different methods can be made. To achieve this objective mainly to micro-structural changes due to and modifiers) state of the art Ni-based modelling in combination with thermal and/or electrochemical sintering cermet anodes, assisted by detailed experimental observations is used, aiming and oxidation/reduction of the anode, characterization of the anode materials at simulating the physicochemical and due to interruption of the fuel supply. (as-prepared and used). An important electrochemical process taking place at Anode degradation in SOFCs using point of the proposed strategy is the the electrochemical interface and on the natural gas or other hydrocarbon fuels is development of a theoretical model for catalytic surface of the anode. In this way additionally due to carbon deposition and the description of the performance and diagnostic tools will be developed by a sulphur poisoning, which result in severe degradation of the anode, with non- combination of short-term experimental decrease of both the electrocatalytic adjustable parameters, which will accept observations and modelling so that the activity of the anode and its catalytic as input values of parameters which long term prediction of the functional activity for internal reforming or direct will be experimentally determined. performance of the anode can be oxidation of the fuel. The key objective achieved. of ROBANODE is the development of an integrated strategy for understanding the mechanism of anode degradation in SOFCs. This is envisaged through a combination of theoretical modelling with experiments over an extended range of operating conditions, using a large number of modified state-of-the- art (SoA) Ni-based cermet anodes. obanode © r
134 Fuel Cells and Hydrogen Joint Undertaking http://robanode.iceht.forth.gr/ Stationary power production and CHP
Expected socio and economic impact Project Information Partners
The direct economic benefits that Project reference: FCH JU 245355 FORTH/ICE-HT (Coordinator) may result from ROBANODE can Call for proposals: 2008 Greece be summarized as follows: Application Area: SP1-JTI-FCH.3: • Reduction in the degradation rate Stationary Power Generation & CHP Technische Universität Clausthal (TUC) of state of the art SOFCs which Project type: Research and Germany
operate with H2 or natural gas Technological Development • Long-term durability and Topic: SP1-JTI-FCH.3.3: Degradation National Technical University of Athens reduction of the commercial cost and lifetime fundamentals (NTUA) of hydrocarbon fuelled SOFCs. Contract type: Collaborative project Greece Start date: 01/01/2010 Indirect socio-economic benefits End date: 31/12/2012 Ecole Polytechnique Federale de are additionally expected, since Duration: 36 months Lausanne (EPFL) commercialization and wide use Project total costs: € 3 394 888.00 Switzerland of SOFCs will result in a significant Project funding: € 1 568 530.00 reduction of air pollution. These general Agencia Estatal Consejo Superior de socio-economic benefits which are Investigaciones Cientificas (CSIC) expected to result from ROBANODE Project Coordinator Spain can be summarized as follows: • Exploitation of the existing Dr. Symeon Bebelis Centre National de la Recherche natural gas and liquid petroleum Associate Professor Scientifique (CNRS) gas (LPG) network and easier Foundation for Research and France introduction of SOFCs into Technology Hellas, Institute of households and public buildings. Chemical Engineering and High Ceramics and Refractories • Easier market penetration of Temperature Chemical Processes Technological Development Company fuel cell and renewable energy (FORTH/ICE-HT) (CERECO S.A.) technologies with a highly positive Greece Greece impact on the reduction of air pollution, health and environment. [email protected] Saint-Gobain Centre de Recherches et • Development of renewable d` Etudes Europeénes (Saint Gobain) energy sources for decentralised France energy supply. • Creation of highly specialized jobs in different regions of the European Union.
Programme Review 2012 - Final Report 135 SCOTAS SOFC Sulphur, Carbon, and re-Oxidation Tolerant Anodes and Anode Supports for Solid Oxide Fuel Cells
Key Objectives Challenges addressed Technical approach and achievements
Solid oxide fuel cells (SOFCs) have a The metal nickel is a major material Oxide ceramics based on strontium great advantage in their fuel flexibility in today’s SOFCs and commonly used titanates have been investigated in compared to other fuel cells (such as together with ceramic as a composite previous EU projects (Real-SOFC and PEMFC), and thus are particularly suited material for the fuel electrode and SOFC600) and developed up to button for stationary cogeneration of heat and support. Although it performs satisfactory cell sizes. The approach in this project is power based on natural gas or other and is stable at the reducing conditions to integrate three of the most promising hydrocarbon fuels. The aim of the project and operating temperatures of SOFCs, the compositions into a full cell and thus is to demonstrate a new more robust type choice of nickel makes the fuel electrode evaluate their performance under of solid oxide fuel cell for application in very sensitive to carbon deposition at low application relevant conditions. small scale, combined heat and power steam / oxygen contents, deactivation systems (micro CHP). Thus, the project by traces of sulphur present (e.g. as Key milestones have been the selection is a material based approach to increase odorants in pipeline natural gas) and of three candidate compositions and the micro CHP robustness, simplify operation mechanical failure of the electrode evaluation of test routines within the strategies and thus reduce system costs. during re-oxidation caused by loss first year of the project and the selection It addresses in particular critical issues of fuel during operation. These three of the best suited materials for anode in the StartUp/Shut Down phase and major failure mechanisms have to be and support structures at mid term. The during grid outage/system failures. addressed today at the system level. final assessment of the cell concept will The project will demonstrate a new take place at stack level according to test full ceramic SOFC cell with superior conditions specified by the industrial robustness as regards to sulphur partners. At the end of the project a 1 kW tolerance, carbon deposition (coking) and stack built on these new cells is scheduled re-oxidation (redox resistance). Having to be tested in a real micro CHP system, a more robust cell will thus enable the namely the Galileo system from Hexis AG. system to be simplified, something of particular importance for small systems, e.g. for combined heat and power (CHP). © scotas-sofc
136 Fuel Cells and Hydrogen Joint Undertaking www.scotas-sofc.eu Stationary power production and CHP
Expected socio and economic impact Project Information Partners
It is expected that the outcome of Project reference: FCH JU 256730 Forschungszentrum Juelich GmbH the project will be improved anode Call for proposals: 2009 Germany and anode support materials, which Application Area: Stationary Power improves the performance in regards Generation & Combined Heat and Hexis AG to the identified failure mechanisms Power (CHP) Switzerland for fuel tolerance (sulphur and carbon) Project type: Research and and re-oxidation resistance in SOFCs. Technological Development Topsoe Fuel Cell A/S Thus, the project can contribute Topic: SP2-JTI-FCH.3.2: Materials Denmark significantly to fulfilling the electrical development for cells, stacks and efficiency, lifetime and target costs balance of plant (BOP) University of St Andrews requirement for SOFCs used with the Contract type: Collaborative Project UK relevant types of fuels and applications. Start date: 01/10/2010 A further socio–economic factor is End date: 30/09/2013 (ongoing) the replacement of nickel (nickel Duration: 36 months oxide during fabrication) by a more Project total costs: € 4.4 million environmentally friendly ceramic Project funding: € 1.7 million as a major element in the fuel electrode and support structure. The project has so far proven Project Coordinator that sufficient performance levels can be reached and technically Dr. Peter Holtappels relevant cell sizes be fabricated. Danmarks Tekniske Universitet, At present optimisation of the Department of Energy Conversion and cell fabrication for systematic cell Storage, Frederiksborgvej 399, 4000 and stack testing is on focus. Roskilde, Denmark
Programme Review 2012 - Final Report 137 SOFC-Life Solid Oxide Fuel Cells – Integrating Degradation Effects into Lifetime Prediction Models
Key Objectives Challenges addressed Technical approach and achievements
The project addresses the quantification Long-term stable operation of Solid Oxide The project follows a systematic approach and understanding of the details of Fuel Cells (SOFC) is a basic requirement to analysis of some of the most important major Solid Oxide Fuel Cells’ (SOFC) for introducing this technology to the degradation mechanisms. It concentrates continuous degradation effects. The stationary power market. Electricity on the ‘continuous’ (baseline) degradation goal is to isolate effects occurring on generating equipment is usually phenomena determining stack behaviour the anode and cathode side of SOFC designed for lifetimes of 10 years and in the long term. By deconstructing and develop descriptions of the above, corresponding to between 40 the SOFC stack into isolated elements degradation mechanisms as functions 000 to over 100 000 hours of operation. and interfaces, these are exposed to of distinctive operating parameters The continuous degradation of fuel the physical conditions found in typical (mainly temperature, atmosphere cell voltage commonly observed SOFC system operation (and beyond). At and current density). These functional has to be reduced so that the loss regular intervals, specimen are taken form descriptions are meant to represent the of power remains within acceptable the experiments and thus a time series of physical and chemical changes of basic limits during the lifetime. The project the gradual development of degradation materials and layer properties over time. aims at a better understanding of effects are recorded. This time-lapse This information will be integrated the degradation phenomena as a photography type approach is designed into higher level models that are then tool for mitigating these effects and specifically to allow the modelling of capable of predicting single degradation as a first step towards developing physical change over time. phenomena and their combined effect accelerated testing methods. on SOFC cells and single repeating units. Key milestones, deliverables Anode sub-model Cathode sub-model Integrated model(s) for predicting cell and SRU level degradation Identification, Assessment and Simulation of Major Degradation Parameters - Concluding report (M36). © sofc-life
138 Fuel Cells and Hydrogen Joint Undertaking Stationary power production and CHP
Expected socio and economic impact Project Information Topsøe Fuel Cell A/S Denmark The project aims at improving the Project reference: FCH JU 526885 longevity of SOFC and as such Call for proposals: 2009 Commissariat à l´Energie Atomique contributes towards the market Application Area: 3 (Stationary) France introduction and economic development Project type: Basic Research of the stationary fuel cell sector. Topic: SP1-JTI-FCH.3.1: Degradation DTU-EC and lifetime fundamentals Denmark Achievements/Results to date Contract type: Collaborative Project First experiments have been conducted Start date: 01/01/2011 Eidgenössische Materialprüfungs- and the evaluation is under way. End date: 31/12/2013 und Forschungsanstalt Duration: 36 months Switzerland Project total costs: € 5.700.000 Project funding: € 2.400.000 Institute of High Temperature Electrochemistry Russia Project Coordinator Teknologian tutkimuskeskus VTT L.G.J. de Haart Finland IEK-9 FZ Jülich GmbH, 52425 Jülich Ecole Polytechnique Fédérale Lausanne Germany Switzerland
[email protected] Imperial College UK
Partners Electricité de France France Hexis AG Switzerland Zürcher Hochschue für Angewandte Wissenschaften HTceramix Switzerland Switzerland
Programme Review 2012 - Final Report 139 SOFCOM SOFC CCHP with poly-fuel: operation and management
Key Objectives Challenges addressed The plant will be in operation as CCHP plant, with heat recovery from the exhaust for the production of hot services The proposal is an applied research The general aim is the technological (e.g. hot water) and conditioning services project devoted to demonstrate the improvement of a virtual combination (through an adsorption chiller). Also, technical feasibility, the efficiency of fuel and technology: biogenous the plant will be completed with a CO2 and environmental advantages of fuels (biogas, bio-syngas) as renewable separation from the anode exhaust and
CCHP (a three product plant based fuels in high efficiency electrochemical with a section of CO2 management (and on cogeneration of cooling, heat CCHP generators (solid oxide fuel cells), disposal) integrated with the primary fuel and power) based on SOFC (solid able also to effectively separate and processing system. oxide fuel cell technology) fed by reuse the CO2 contained in its exhaust different typologies of biogenous streams. To achieve this, the project A second proof-of-concept SOFC system primary fuels (biogas and bio- foresees the design, installation and (Helsinki, Finland) will be demonstrated syngas, locally produced), also optimization of two demonstration considering a SOFC stack operating integrated by a process for the CO2 plants, with the aim of facing and solving with a syngas from biomass gasification. separation from the exhaust gases. all the technical problems correlated This second demonstration plant will be The activity will be devoted to the to the coupling of biogenous fuels and concentrated on the operation of a SOFC scientific improvement of SOFC fed by SOFC, with CO2 removal. In particular, stack with a lean gasification fuel; all the biofuels, but especially to the technical the following target will be faced: concerns related to a proper fuel gas and economical management of two (1) Fuel issues considering detailed cleaning for fuelling the fuel cell system. demonstration of complete energy poisoning mechanisms, advancing in systems based on SOFCs. Several issues cleaning and processing technologies; will be addressed: the impact of the (2) Define and operate new proof-of- Expected socio and fuel pollutants on the SOFC and fuel concept fuel cell systems fully integrated economic impact processing units, and consequently with biomass processing units and the necessity of gas cleaning; the carbon sequestration and handling The main impact of the project will be operation of the integrated plants in technologies; (3) Maintenance, safety, the ‘proof-of-concept’ demonstration CCHP configuration; the design and repair and de-commissioning of fuel of two SOFC units integrated with optimization of the carbon sequestration- cell systems on a demonstration scale. biogas or bio-syngas, respectively. management modules; the analysis Such fuels have a wide potential in and implementation of maintenance terms of availability and diffusion over and repair strategies of those plants. Technical approach the territory. The fuels considered are Finally, the lessons learned from the and achievements not only of interest because of their demonstration will be used for pre- carbon neutrality, but also for certain normative issues and scale-up analysis The research activity will be devoted to peculiarities. In the case of biogas coming of this typology of integrated plants. the scientific, technical and economical from the sewage plant, it represents a management of two demonstration by-product of a dedicated process of of complete energy systems based on waste-water treatment. Such plants have SOFCs. already a large diffusion over the territory (especially in urban areas where the A first proof-of-concept SOFC system continuously collected sewage has to be (Torino, Italy) will be able to operate with treated - only in Italy, more than 120 large biogas produced in an industrial waste plants in urban areas exist), with a mature water treatment unit (WWTU). technology already developed behind.
140 Fuel Cells and Hydrogen Joint Undertaking www.sofcom.eu Stationary power production and CHP
Therefore it already subsists a huge biogas potential ready to be exploited, Project Information Partners and therefore a large market potential for such SOFC integrated systems. Project reference: FCH JU “SP1- Politenico di Torno The bio-syngas option is another JTI-FCH.2010.3.4: Proof-of-concept (POLITO) interesting one, investigated within and validation of integrated fuel cell Italy the project, which will face different systems” BoP integration and cleaning issues. Call for proposals: year 2010 Teknologian Tutkimuskeskusvit Again the market potential of such Application Area: Area SP1-JTI-FCH.3: (VTT) integrated systems is high, especially Stationary Power Generation & CHP Finland for those areas where the biomass Project type: Demonstration feedstock is ready available. Topic: Proof-of-concept and validation TOPSOE FUELCELL A/S (TOFC) of integrated fuel cell systems Denmark Another relevant impact accomplished Contract type: Collaborative Project by the project will be represented by Start date: 01/11/2011 Societa Metropolitana Acque Torino the CCS capability of the integrated End date: 31/10/2014 (SMAT) SPA systems studied and tested during Duration: 36 months Italy the project. Plants with a negative Project total costs: € 6,219,613 carbon emission balance will be then Project funding: € 2,937,753 MATGAS 2000 A.I.E. (MATGAS) the focus and objective of our project, Spain with an interest of such architectures of plants also in terms of energy Project Coordinator Consiglio Nazionale delle Ricerche economy and energy policy. (CNR-ITAE) Massimo Santarelli Italy Finally a major impact will be represented Department of Energy, Politecnico di by the CCHP mode of the tested Torino (Italy) Institut Energtyki demonstration units. Such operational Corso Duca degli Abruzzi 24, 10129 (IEN) mode will permit to achieve not only high Torino Poland electrical efficiency (>45% with biogenous Italy fuel), but also global efficiencies Ecole Polytechnique Federale de exceeding values around 80-85%. [email protected] Lausanne (EPFL) Therefore, the project foresees the Switzerland design, installation and optimization of demonstration plants, with the aim Technische Universitaet Muenchen of facing and solving all the technical (TUM) problems correlated to the coupling of Germany biogenous fuels and SOFC (with CO2 removal), with an optimization of their Universita degli Studi di Torno technological structure to achieve a (UNITO) optimization of their economic revenues. Italy
Programme Review 2012 - Final Report 141 SOFT-PACT Solid Oxide Fuel Cell micro-CHP Field Trials
Key Objectives Expected socio and Expected socio and economic impact economic impact
SOFT-PACT has been established As of now, the project has been successful Key outputs from the project (an EU to undertake a large scale field in contributing towards mitigating the market study, data from two field trials, demonstration of a Solid Oxide effects of climate change through a more building of installation capability and Fuel Cell (SOFC) generator that efficient use of energy. Specifically, the the completion of the development can be utilised in residential BlueGen unit used in the pathfinder field of a optimised integrated FC system) applications. The objectives are to: trial displaces 4.5 Tonnes of CO2 p.a. (in address the major hurdles / barriers that the UK), using electricity made at 60% net are limiting a full scale system of fuel · Design, develop and deploy efficiency. These field trials will discover cell deployment, which are namely: the integrated fuel cell mCHP systems real world issues in their deployment. reduction in the total cost of the system, · Facilitate the training and re-skilling of compared to other microgeneration installation and maintenance engineers European leadership in fuel cells will devices; development of the supply · Provide remote control and play a key role in creating high-quality chain for key components (inverters, diagnostics of all the systems from employment opportunities, from strategic filters, etc) to enable cost reduction and a central point in real time R&D to production, craftsmen and statistical proof of the system’s reliability · Identify and quantify benefits installers; the number of employees will and maintenance requirements from to the homeowner be increase throughout the consortium gathering long-term field test data · Ensure long-term reliability and and supply chain due to this project. which will provide the manufacturer life data from the systems. with the confidence to offer long-term product warranties. However these alone will not place the product in homes Technical approach as these systems require qualified and and achievements specialized hybrid (electrical, mechanical and IT) installation and maintenance So far, an EU Market Study has been engineers. Aware of this gap, this project published, showcasing the most endeavours to begin the creation of this favourable EU member countries for capability, while also validating its ability the deployment of Fuel Cell technology, to safely control and operate a multitude based microCHP (Combined Heat and of systems at multiple locations in real Power). time and ensuring the ability to avoid the need for maintenance call outs.
142 Fuel Cells and Hydrogen Joint Undertaking www.soft-pact.eu Stationary power production and CHP
This project aims to prove that a series of fuel cell appliances can be installed Project Information Partners into occupied residential locations and show that at least 50% of its fuel Project reference: FCH JU 278804 CERAMIC FUEL CELLS GMBH can be turned into electrical energy – Call for proposals: 2010 Germany something which has been originally Application Area: Stationary power only demonstrated in a laboratory. It production and CHP IDEAL BOILERS LIMITED will then gather sufficient real time Project type: Demonstration UK data on system performance to show Topic: SP1-JTI-FCH.2010.3.5 the generating efficiency and the life of Contract Type: Collaborative Project HOMA SOFTWARE BV a system is within the manufacturer’s Start date: 07 July 2011 Netherlands targets: 40,000 hours on key components. End date: 07 July 2014 Duration: 36 months Designing the final version of an Project cost: € 10.4 million integrated system will take the findings Project funding: € 3.95 million from the pathfinder field trial into consideration in order to enhance reliability and serviceability while Project Coordinator miniaturising the current prototype in order to meet acceptable size E.ON NEW BUILD & TECHNOLOGY constraints for domestic installation. LIMITED UK Cost and performance analysis of the systems sub-components will be Contact: Mr Andrew Thomas performed and redesigned as necessary [email protected] to meet the JTI AIP commercial system cost target of €4-5k per kWe in mass production (post 2015).
Programme Review 2012 - Final Report 143 STAYERS STAtionary PEM fuel cells with lifetimes beyond five YEaRS
Key Objectives Challenges addressed Technical approach and achievements
Economical use of PEM fuel cell power The PEM fuel cell consists of several The project foresees the following steps: for stationary applications demands a alternatingly stacked components, such lifetime from the fuel cells of at least as membrane-electrode-assemblies 1. Duration experiments in a real-life a minimum of 5 years, or more than (MEAs) and bipolar plates, pressed stationary fuel cell plant from Nedstack 40,000 hours of continuous operation. together by housing. The MEA consists and at SINTEF and SolviCore at lab- This, in contrast to the large scale of subcomponents like gas diffusion scale with stacks composed of the application for automotive use, which layers, catalyst layers and a thin state-of-the art reference materials, has dedicated PEM research on low cost membrane, separating reactant gases. like the membrane provided by Solvay production techniques with practical The bipolar plate is a carbon composite, Specialty Polymers Italy. lifetimes of the fuel cells of 5,000 hours. electrically connecting neighbour The main objective of STAYERS is cells and distributing reactant gases 2. Model improvement and analysis of materials research leading to the throughout the MEA electro-active area. on-line and off-line measurements by production of a full size, 10 kW JRC. Post-mortem analysis on stacks prototype PEM fuel cell stack, capable of All these components face harsh returning from durability experiments operating continuously during 40,000 conditions imposing chemical and yields data on the degradation hours in a system for stationary power mechanical stress that during operation, processes. Based on these results generation in a chlor-alkali plant. change the structure and composition, improved MEA’s and stack components The lifetime of the 40,000 hours will be thereby lowering the power output of will be produced as well as a fine tuned proven by extrapolation over a long the fuel cell and limiting the lifetime. model. duration data. The initial phase of the operating conditions like temperature, project consists in establishing the gas humidification and gas feed 3. Subsequent series of duration dominant degradation mechanisms play a role in the fuel cell lifetime. experiments are started and SINTEF will of the state-of-the-art MEA and also perform accelerated lifetime tests. setting up the initial framework Within the project it will be attempted for the theoretical model. to determine the dominant degradation 4. The final period starts with the most mechanisms in a real life stationary promising stacks. From the model and PEM Power Plant. Subsequently these from data extrapolation the lifetime can components and operational parameters be predicted. will need optimising to reach the goal of 40,000 hours of continuous operation. © stayers
144 Fuel Cells and Hydrogen Joint Undertaking www.stayers.eu Stationary power production and CHP
Expected socio and economic impact Project Information Partners
One of the main aims of the FCH-JU is: Project reference: FCH JU 256721 SOLVICORE GMBH & CO KG “... placing Europe at the forefront of Call for proposals: 2009 Germany fuel cell and hydrogen technologies Application Area: Stationary power worldwide and enabling the market Project type: Research and SOLVAY SPECIALTY POLYMER S.P.A. breakthrough of fuel cell and hydrogen Technology Development Italy technologies …” To reach this goal, Topic: SP1-JTI-FCH.2009.3.2: Materials it is essential that the durability development for cells, stacks and SINTEF of the stack and its components balance of plant (BoP) Norway is significantly improved and at a SP1-JTI-FCH.2009.3.1: Fundamentals well mature and cost competitive of fuel cell degradation for stationary JRC-JOINT RESEARCH CENTRE- level. STAYERS will contribute to this power application EUROPEAN COMMISSION by developing a stationary PEMFC Contract type: Collaborative project Belgium stack with 40,000 hours lifetime. Start date: 01 January 2011 End date: 31 December 2013 The project will also strengthen Duration: 36 months the knowledge about degradation Project cost: € 4.1 million mechanisms in PEM fuel cells. At the Project funding: € 1.9 million same time STAYERS will create business opportunities, not only for its partners, but also for the whole of the fuel cell Project Coordinator community. Commercial prospects for PEM FC-generators are very promising NEDSTACK FUEL CELL TECHNOLOGY if a guaranteed stack lifetime of 5 years BV can be given. Society will benefit by less Netherlands
CO2-emission, pollution-free, low noise transport, and clean silent generators. Contact: Mr Jorg Coolegem [email protected]
Programme Review 2012 - Final Report 145 DURAMET Improved durability and cost-effective components for new generation solid polymer electrolyte direct methanol fuel cells
Key Objectives Challenges addressed Technical approach and achievements
Direct Methanol Fuel Cells (DMFCs) Specifications and protocols for assessing The market segments for DMFCs deal with have been postulated as suitable direct methanol fuel cells components portable generators, UPS, back-up power systems for power generation in the and devices such as membranes, catalysts, systems and portable micro-fuel cells. fields of portable power sources, MEAs and stacks have been delivered. The project results regarding enhanced remote and micro-distributed energy These are available to the public through performance and cost reduction materials generation and auxiliary power units the project website. Low temperature and devices will be of interest for an (APU). The main objective of the membranes with improved conductivity emerging European fuel cells industry DURAMET project is to develop cost- and reduced methanol cross-over in the short term. The materials are effective components for DMFCs with have been developed. Enhanced demonstrated in devices which are enhanced activity and stability in order anode and cathode electro-catalysts technically representative of power to reduce stack costs and improve as well as catalytic layers including ranges and application requirements for performance and durability. The project specific promoters have allowed for which DMFCs can be used in early-market deals with the development of DMFC the achievement of an increase in applications. Moreover, this technology components for application in auxiliary performance with respect to baseline provides the potential to reduce pollution, power units and portable systems. formulations. Proton conductivity values energy use, and greenhouse gases. as high as 180 mS/cm at 150 °C have been obtained with high temperature membranes. These results appear promising in relation to the development of high temperature DMFCs with enhanced reaction kinetics.
Monopolar plates and DMFC ministack operating under passive mode for portable
© duramet applications
146 Fuel Cells and Hydrogen Joint Undertaking www.duramet.eu Early Markets
Summary/overview Project Information Partners Direct Methanol Fuel Cells (DMFCs) working at low and intermediate Project reference: FCH JU 278054 Centre National de la Recherche temperatures (up to 130-150 °C) and Call for proposals: 2010 Scientifique (CNRS) employing solid protonic electrolytes have Application Area: Early market France been postulated as suitable systems for Project type: Research and power generation in the field of portable technological development FUMA-TECH Gesellschaft fuer power sources, remote and micro- Topic: SP1-JTI-FCH.2010.4.4: Funktionnelle Membranen und distributed energy generation as well as Components with advanced durability Anlagentechnologie MBH (FUMATECH) auxiliary power units (APU) in stationary for Direct Methanol Fuel Cells Germany and mobile applications. DMFCs utilize Contract type: Collaborative Project liquid fuel to deliver continuous power and Start date: 01/12/2011 Centro Ricerche FIAT SCPA (CRF) they have lower fuel storage and handling End date: ongoing Italy constraints than hydrogen fuelled fuel Duration: 36 months cells. In order to be competitive within the Project cost: € 2,956,874.00 Technische Universitaet Muenchen portable and distributed energy markets, Project funding: € 1,496,617.00 (TUM) the DMFCs must be reasonably cheap, Germany characterised by high durability and capable of delivering high power densities. Project Coordinator IRD Fuel Cells A/S (Industrial Research & Before these technologies can reach full Development A/S) (IRD) scale production, specific problems have to CONSIGLIO NAZIONALE DELLE Denmark be solved especially the high cost and the RICERCHE CNR-ITAE short term stability. The activities of this Istituto di Tecnologie Avanzate per Politecnico Di Torino (POLITO) project are focused on new cost-effective l’Energia “Nicola Giordano” Italy membranes with better resistance than Via Salita S. Lucia sopra Contesse, 5 Nafion to methanol cross-over as well as 98126 Messina PRETEXO (PXO ) the drag of Ru ions. Improved durability Italy France electro-catalysts are developed with the aim to reduce costs, degradation and JRC -Joint Research Centre – European noble metals content. To validate the Commission (JRC-IE) new membranes and electro-catalysts Belgium materials, the specific development of membrane-electrode assembly will be carried out with tailored hydrophobic- hydrophilic electrode characteristics. The new developed components will thus be validated in short stacks to assess their performance and durability under practical operation. Specific attention will be devoted to the exploitation, dissemination and training of young researchers.
Programme Review 2012 - Final Report 147 FCpoweredRBS Demonstration Project for Power Supply to Telecom Stations through FC technology
Key Objectives Summary/overview Technical approach and achievements
The objectives of this · The first prototype based on the · Deliverables D2.1 Energy profile project are as follows: Dantherm FC is fully operating in for Radio base Station released. the UNIROMA2 Lab where system · Deliverable D2.2 Target Specification - Demonstrate the advantages of optimization activities have been released which includes the hydrogen and fuel cells with the running details of the system solution supporting hydrogen re-fuelling · The test protocol definition is still under architecture and specifications infrastructure for delivering the development at research centres of the single components. expected power supply service, · All the TELCO Operators sites have been · Deliverable D5.2 - Installation and compared to the solutions used today chosen and related surveys have been permitting procedure released. executed. A wide shortlist of potential · Deliverable D10.1 - Project - Demonstrate a significant number sites has been selected to be prepared web-site up and running of sites which are based on to eventually change some trial sites sufficient maturity levels of fuel under the customer’s request. cell systems & hydrogen supply · The permit procedure contracts solutions. Benchmarking of different have been signed with Telecom Italia technical configurations for fuel cells (negotiation on going for WIND and integrated with renewable sources. H3G) · Training session preparation and dissemination activities are ongoing.
148 Fuel Cells and Hydrogen Joint Undertaking http://fcpoweredrbs.eu/ Early Markets
Expected socio and economic impact Project Information Partners
· The activities on solution definition Project reference: FCH JU 278921 Ericsson Telecomunicazioni were longer than expected to fulfil the Call for proposals: Italy customer’s requirements and improve 2010 (FCH-JU-2010-1) efficiency. Additional development Application Area: Early Market Dantherm Power A.S. was needed to best integrate the Project type: Demonstration Project Denmark different equipment in the system Topic: SP1-JTIFCH. 2010.4.2 · The project will manage to minimize “Demonstration of industrial Greenhydrogen DK APS impacts on the field activities in order application readiness of fuel cell Denmark to avoid affecting the final project dates generators for power supply to off- · An amendment will be requested grid stations, including the hydrogen Mes SA for a change in the DOW without supply solution” Switzerland including impacts on the overall Contract type: Collaborative project project budget (two additional sites Start date: 01 January 2012 Joint Research Centre (JRC) with Methanol to replace the two sites End date: ongoing European Commission Natural Gas that will be not delivered) Duration: 36 months Belgium Project cost: € 10,591,649 Project funding: € 4,221,270 Universita Degli Studi di Roma Tor Vergata Italy Project Coordinator
ERICSSON TELECOMUNICAZIONI Italy
Ms. Rossella Cardone [email protected]
Mr. Giancarlo Tomarchio [email protected]
Programme Review 2012 - Final Report 149 FITUP Fuel cell field test demonstration of economic and environmental viability for portable generators, backup and UPS power system applications
Key Objectives fuel cell suppliers according to a test Technical approach protocol developed within the project. and achievements Test protocol is used to conduct extensive The project aims at increase the tests in field trials in sites selected by final The achievements of the project visibility of fuel cells systems as a users in Italy, Switzerland and Turkey. The since its beginning are: potential alternative to conventional performance is logged and analysed to - 19 fuel cell systems produced and backup power sources (batteries draw conclusions regarding commercial installed across Europe: 13 systems in and diesel generators) and prove viability and degree to which they selected final user sites and 6 systems to potential customers in different meet customer requirements, as well as in R&D centres for benchmarking; industrial sectors their advantages. suggesting areas for improvement. A - Initialization of benchmarking and The technical objectives to meet lifecycle cost analysis using data from the field testing of the fuel cell systems with these systems are: project will be carried out to determine - Initialization of a proposal for - Reliability of greater than 95% economic value proposition over the LCA analysis of the systems - Durability of more than 1500 hours incumbent technologies such as batteries installed and tested (real-time or extrapolated) or diesel generators.The system producers - Initialization of the proposal for the - Response time of <5ms use the results to obtain valuable first unique certification procedure - More than 1000 cycles (real hand feedback from customers, optimise - Development of a definitive version of time or extrapolated). their systems as needed, and demonstrate website and different dissemination commercial viability. On the other hand, activities. final users from the telecommunications Summary/overview will experience first-hand the advantages of fuel cells for their applications under A total of 19 market-ready fuel cell real world conditions. The optimisation systems from 2 suppliers (ElectroPS, potential is expected from the production FutureE) have been installed as UPS/ process itself, from the installation of a backup power sources in selected sites significant amount of fuel cell systems across the EU. Real-world customers and from the testing. The project will also from the telecommunications are using develop a certification procedure valid in these fuel cell-based systems, with power the selected EU countries under the lead levels in the 1-10kW range, in their sites. of TÜV Süd. A level of technical performance (start- up time, reliability, durability, number of cycles) that qualifies them for market entry is under evaluation, with the aim of accelerating the commercialisation of this technology in Europe and elsewhere. The demonstration project involves the benchmarking of units from both
150 Fuel Cells and Hydrogen Joint Undertaking www.fitup-project.eu Early Markets
Expected socio and economic impact Project Information Partners
- Demonstrate the readiness of the Project reference: FCH JU 256766 Futuree fuel cell solutions gmbh FC UPS systems to compete in the Call for proposals: 2009 Germany marketplace with conventional Application Area: Early Markets - SP1- systems in the short term. JTI-FCH.4 Environment Park - To show the functional capability of Project type: Research and Italy the new technology and to motivate Technological Development European operators to handle it. Topic: SP1-JTI-FCH.2009.4.2: Fachhochschule zentralschweiz - - Support the development of cleaner Portable generators, backup and UPS hochschule luzern and more efficient technologies power systems Switzerland through the substitution of Contract type: Collaborative project batteries and diesel generators. Start date: 01 November 2010 United nations industrial development - Create an on-field testing bed End date: 31 October 2013 organization database that will provide Duration: 36 months Austria useful data in light of the Project cost: € 5.41 million commercialisation process. Project funding: € 2.47 million Joint Research Centre - Provide the means to jump over the Netherlands technical barriers that hinder the extensive penetration of hydrogen Project Coordinator TUV SUD INDUSTRIE SERVICE gmbh technologies: reliability, lifetime. Germany - Enhance sustainable development Electro Power Systems, SpA by the promotion of hydrogen Italy Swisscom (Schweiz) AG technologies which are closely Switzerland linked to the penetration of Ms. Ilaria ROSSO renewable energies. [email protected] Wind telecomunicazioni s.p.a. - Contribute to the development and Italy application of codes and standards related to hydrogen safety. Anton Nidwalden Switzerland
Site in Switzerland Polycom - EPS © fitup
Programme Review 2012 - Final Report 151 HyLIFT-DEMO European demonstration of hydrogen powered fuel cell material handling vehicles
Key Objectives Challenges addressed Technical approach and achievements
The overall purpose and ambition of The project is conducted by a consortium The fuel cell system is to be demonstrated HyLIFT-DEMO is to conduct a large of European companies that for several in material handling vehicles from three scale demonstration of hydrogen years have invested significantly in vehicle manufacturers, representing powered fuel cell material handling developing and testing hydrogen and various market segments and vehicles, which enables a following fuel cell technology for material handling system integration approaches. deployment and commercial market vehicles. The demonstration is expected to introduction starting no later than 2013. be handled in fleets of at least 3-4 The detailed HyLIFT-DEMO project The technology is now advanced to a 3rd vehicles; end-users envisaging larger objectives are the demonstration of generation level that allows for a large fleets will be preferred. Larger fleets at least 30 material handling vehicles scale demonstration before commencing would lead to a more viable business as well as the demonstration of the market deployment. Also extensive case for the supporting hydrogen corresponding hydrogen refuelling market analyses have encouraged the refuelling infrastructure, but also to infrastructure at end-user sites. partners to focus on the market segments an efficient service and maintenance of 2.5-3.5 tons forklifts and airport tow set up. As well as minimizing the final The project partnership will conduct tractors, as these segments provide the number of demonstration sites, the accelerated laboratory durability tests strongest value proposition for fuel cell project will endeavour to place these and validate the value proposition of vehicles in the material handling sector as close as possible to each other as the technology and the reaching of the within Europe. Thus the demonstration this lowers costs both for maintenance commercial and environmental targets. activities can lead directly to a following trips and for hydrogen distribution. Further objectives are to plan market deployment with a solid and and to secure the initiation of proven value proposition for the vehicle The supply of hydrogen for the sites will Research and Development (R&D) end-users. either be from local sources or through of the 4th product generation. commercial subcontracting tendering Finally, the project will contribute to from local gas suppliers. The refuelling the establishment of an appropriate infrastructure will either be owned and / Regulations, Codes and Standards or operated by project partners, the end- (RCS) framework which enables smooth user or other local partners or projects. commercialisation as well as to the motivation of European, national and regional stakeholders by performing adequate dissemination activities.
152 Fuel Cells and Hydrogen Joint Undertaking www.hylift.eu Early Markets
Expected socio and economic impact Project Information H2 Logic A/S Denmark HyLIFT-DEMO addresses a specific Project reference: FCH-JU-2009-1, and proven value proposition where Grant Agreement Number 256862 DanTruck A/S hydrogen and fuel cells replace use Call for proposals: AIP 2009 Denmark of diesel/LPG in 2.5-3.5 ton material Application Area: SP1-JTI-FCH.4: handling vehicles where batteries Early Markets Technical University of Denmark (DTU) cannot provide a satisfying solution. The Project type: Demonstration Denmark higher energy efficiency of the fuel cell Topic: SP1-JTI-FCH.4.1 Demonstration compared to the combustion engine of fuel cell-powered materials handling Linde AG enables the end-user to gain savings on vehicles and infrastructure Germany fuel costs that lead to a payback time Contract type: Collaborative Project of 3 years, at commercial price targets. Start date: 01/01/2011 European Commission, Directorate- End date: 31/12/2013 General Joint Research Centre (JRC), The ambition and driving force of the Duration: 36 months Institute for Energy HyLIFT-DEMO activities and partners Project total costs: € 7,077,942 Belgium are to enable a following deployment Project funding: € 2,881,245 and market introduction starting no Stiftelsen SINTEF later than 2013. Therefore the targets Norway to be reached within the project as Project Coordinator well as the demonstration model and Hydrogen Fuel Cells and Electro- relations to end-users are set-up with Hubert Landinger mobility in European Regions (HyER) & a future commercial value chain in Ludwig-Bölkow-Systemtechnik GmbH European Hydrogen Association (EHA) mind. One work package within the Daimlerstr. 15 project will be dedicated to planning 85521 Ottobrunn c/o The Italian Federation of Scientific the commercialisation and ensure Germany and Technical Associations initiation of market deployment. Italy [email protected] TÜV SÜD Industrie Service GmbH Germany Partners
Ludwig-Bölkow-Systemtechnik GmbH (LBST) Germany © hylift-demo
Programme Review 2012 - Final Report 153 IRAFC Development of an Internal Reforming Alcohol High Temperature PEM Fuel Cell Stack
Key Objectives Challenges addressed Technical approach and achievements
Polymer Electrolyte Membrane Fuel The complexity of the balance of plant The main objective of the proposal is the Cells (PEMFCs), which typically consume of a fuel cell-fuel processor unit development of an internal reforming o H2 and O2, operate at 80-100 C and challenges the design and development alcohol high temperature PEM fuel produce electricity without polluting of compact and user friendly fuel cell cell. To achieve this, the following the environment, seem to be the most power systems. The main concept in this goals should be accomplished: technically advanced energy conversion project is the incorporation of an alcohol system for stationary/mobile applications reforming catalyst into the anodic • Design and synthesis of robust polymer and have the highest potential for compartment of the fuel cell, so that electrolyte membranes for HT-PEMFCs, market penetration. However, the methanol reforming takes place inside which enable operation within the absence of a worldwide infrastructure the fuel cell stack. The development of temperature range of 190-220oC. for transport and distribution of pure an Internal Reforming Alcohol - High hydrogen, in addition to the presence Temperature PEM Fuel Cell (IRAFC) • Development of alcohol, (methanol or of well-established and developed fossil poses an ambitious technological and ethanol) reforming catalysts, for the fuel-based network, favors the short research challenge which requires production of low carbon monoxide term solution of on-site (stationary) the effective combination of various content hydrogen, in the temperature or on-board (mobile) hydrogen technological approaches regarding range of HT-PEMFCs, i.e. at 190-220oC. production from reforming of various materials development, chemical hydrocarbons (e.g. natural gas, gasoline) reaction engineering and stack design. • Integration of steam reforming or alcohols (e.g. methanol, ethanol). The proposed fuel cell comprises of catalyst and high temperature MEA in a compact Internal Reforming Therefore, the ultimate goal of the • A high temperature membrane Alcohol - High Temperature PEMFC. project is to provide High Temperature electrode assembly (HT-MEA), able to Integration may be achieved via PEM Fuel Cells, which operate up to operate at temperatures of 190-220oC. different configurations as related to 210 C°, and to combine them with a • A steam reforming catalyst, which can the position of the reforming catalyst. methanol reformer operating at the either be (i) present together with the same temperature range and deliver a Pt-based electrocatalyst in the anode, The proposed compact system differs compact internal alcohol reformer-high (ii) deposited on the gas diffusion layer from conventional fuel processors and temperature PEM fuel cell (IRAFC) device or (iii) deposited on the surface of allows for efficient heat management, that can be fed with liquid methanol. monolithic structures, which should be since the “waste” heat produced by functional at the operating temperature the fuel cell is in-situ utilized to drive of the fuel cell. the endothermic reforming reaction. The targeted power density of the system is 0.15 W/cm2 at 0.7 V.
154 Fuel Cells and Hydrogen Joint Undertaking http://irafc.iceht.forth.gr/index.php Early Markets
Expected socio and economic impact Project Information Partners
• Internal alcohol reforming - Fuel Project reference: FCH-JU-2008-1 Advent Technologies S.A. cell development will intensify the Call for proposals: 2008 Greece mass production of renewable fuels Application Area: SP1 Cooperation
(like methanol by the CO2 reduction) Topic: SP1-JTI-FCH-4.2: Fuel supply University of Maria Curie-Sklodowska with positive economic effects. technology for portable and micro FC Poland • The reduction on oil dependence Contract type: Joint Technology will increase economic security. Initiatives – Collaborative Projects Nedstack Fuel Cell Technology BV • Energy produced by a fuel cell (FCH) Netherlands will be characterized as high Start date: 01 January 2010 quality energy because of the high End date: ongoing Centre National de la Recherche conversion efficiency from chemical Duration: 36 months Scientifique to electrical energy (~50%) almost Project cost: € 2.5 million France twice as high compared to internal Project funding: € 1.4 million combustion engines, and because Foundation for Research and of the zero emissions of pollutants Technology HELLAS, Institute of and greenhouse gases (due to Project Coordinator Chemical Engineering and High
the recycling of CO2 to produce Temperature Processes renewable fuels) to the environment. Dr. Joannis Kallitsis Greece • The extensive use of fuel cells Advanced Energy Technologies will reduce air pollutants Greece Institut für Mikrotechnik Mainz GmbH in metropolitan areas. Germany [email protected]
Programme Review 2012 - Final Report 155 ISH2SUP
In situ H2 supply technology for micro fuel cells powering mobile electronics appliances
Key Objectives Challenges addressed Technical approach and achievements
The key objective of the project is to The targeted power range is 5 – 20 The technical approach adopted by develop a fuelling system for micro-fuel W. Within this range there are many the project is to develop the two cells. The concept is based on in-situ electronic appliances for mobile use, cartridge technologies in parallel and production of hydrogen. Two novel like phones, laptops, cameras, etc, which test them in two application devices solutions are proposed: one is based on suffer short operation time caused by during the last project year. The test using NaBH as the fuel and the other easily draining batteries. We like to devices chosen are a smart mobile one on utilizing catalyzed electrolysis develop fuel cartridges for the chargers phone and a laptop computer. Both of methanol. The primary application or use-extenders of those devices. these devices are standard commercial area is fuel cell based power sources Challenges are related in addition to appliances for which the project will of mobile and portable electronic safety issues, to technical design making build a specific hydrogen driven non- appliances. The ISH2 project concentrates the cartridges usable for common people grid charger or use-extender. The key on research and development of the and finally to environmental issues targets in the development phase are: hydrogen cartridge technology and making them recyclable or disposable. • Prototype of 20 Wh NaBH4- the electrical system. Development of Borohydrid (NaBH4)-technology to make cartridge for a mobile phone micro-fuel cells is excluded, validation hydrogen producing cartridges is already charger (CEA, myFC). of the fuelling system will be performed well known, but needs still studying and • Prototype of 120 Wh NaBH4 with commercially available small development to make it functioning well container for a fuel cells power fuel cells. The main practical targets in small scale and for a long use period. pack (CEA, Hydrocell). are to prove the feasibility of each Catalyst based electrolysis of methanol is • Electrolyser cartridge-fuel cell fuelling technology and to fulfill the a new method, which needs more basic system prototype for a non-grid RCS requirements of mobile/portable studies. In the project we have studied long term power source for 10 electronic appliances in consumer use of two catalysts, platinum and an W devices( Aalto, Hydrocell). markets, and to scheme a logistics system enzyme. At present state of the project • Electrolyser-PEM fuel cell for disposable or recyclable cartridges the platinum catalyst has been chosen system prototype with a better used for fuelling the proposed system. for further development because of methanol conversion (Wh/ problems to obtain high enough energy ml) than DMFCs (Aalto) efficiency in hydrogen production when • Control electronics for the the enzyme catalyst is used. both fuelling concepts
The project will produce reports as well three different cartridge prototypes as the deliverables.
156 Fuel Cells and Hydrogen Joint Undertaking http://autsys.tkk.fi/en/ISH2 Early Markets
Expected socio and economic impact Project Information Partners
The project is targeting to prototypes, Project reference: FCH JU Aalto University (former TKK) which will open up possibilities Call for proposals: 2008 Finland for further product development. Application Area: Early Markets Decisions to that direction will Project type: Research and CEA be made during 2013. Technological Development France Topic: Early Markets 4.2. Fuel Supply Both of the concepts of in-situ technology for portable and myFC production of hydrogen are not microfuel cells Sweden limited to the small power range. Contract type: Collaborative Project Preliminary investigation to enlarge Start date: 01/01/2010 Hydrocell the area to 100 W – 1kW will be done End date: 31/03/2013 Finland during the project. This will open Duration: 36 months applications e.g. to portable tools, Project total costs: € 1,7 million small backboard motors etc. Project funding: € 1 million
As a future perspective, electrolysis by the aid of enzyme opens up interesting Project Coordinator possibility to produce hydrogen from different kind of bio-decomposable Professor Aarne Halme wastes including alcohols or sugars. Aalto University
The energy level around 3 W/l H2 can School of Electrical Engineering be reached, which is considerably Department of Automation and lower than that of water electrolysis. Systems Technology Simultaneously the BOD value of visiting address: Otaniementie 17, the waste water could be decreased. FI-02150 Espoo, Finland This is one way to continue the study postal address: P.O. Box 15500, made in the project with biocatalyst. FI-00076 AALTO Finland
tel.+358 505553390 [email protected]
Programme Review 2012 - Final Report 157 MobyPost Mobility with hydrogen for postal delivery
Key Objectives Challenges addressed Technical approach and achievements
MobyPost aims to implement hydrogen MobyPost addresses the following 2011 Designing and fuel cell technology systems in challenges: • Vehicle Power train Mechanical material handling vehicles, according • Complete solar-to-wheel solution structure Ergonomics and style to an environmentally respectful developing an innovative concept • Infrastructure Dimensioning of strategy. The approach is generating for fuel cell electric vehicles and equipment & monitoring system significant data which will prove the incorporating hydrogen production Safety and regulation analysis viability of the technology and, initiate into existing postal buildings for its its commercialization in this specific utilization on the spot. 2012 Building niche market. MobyPost aims to develop • Fuel cell electric vehicle used every • Vehicle Power train final electric vehicles powered by fuel cells day on heavy duty cycle and under test Manufacturing of 10 using hydrogen locally produced by demanding climatic conditions FCEV Homologation renewable energy means: solar panels (including summer and winter time). • Infrastructure PV generator installed on the roofs of the buildings. • Autonomous energy production - Electrolyser On-site storage MobyPost will implement low pressure Hydrogen is produced on-site by Refueling station Certification storage solutions for hydrogen in two coupling an electrolyser to solar panels fleets of five vehicles on two different sites at the different MobyPost sites. 2013 Testing for postal mail delivery. Development • Implementing metal hydride tanks for • Vehicle Postmen training Deployment of the vehicles and the associated hydrogen storage - to guarantee safety, of the FCEV Performance monitoring refueling stations will be carried out, MobyPost will use low pressure storage • Infrastructure Performance monitoring in line with all certification processes which considerably improves on-board Dissemination and knowledge transfer required and, taking into account public safety. acceptance of this mobility system. The first year dedicated to the design of both infrastructure and vehicle has allowed for clearly defining the requirements for both sub-systems (hydrogen production and fuel cell electric vehicle). The consortium partners have already started to design their components in order to adapt them to the project needs (Fuel cell, tanks, electrolyzers), in parallel with the creation of the model and first level of simulation. The first models for vehicle framework and ergonomics have been issued. As defined, the final design should be achieved during 2012, in parallel with the modification of the buildings and sites for welcoming the MobyPost experiment.
158 Fuel Cells and Hydrogen Joint Undertaking www.mobypost-project.eu Early Markets
Expected socio and economic impact Project Information Partners
The MobyPost project will first Project reference: FCH JU 256834 Institut Pierre Vernier and foremost contribute to the Call for proposal: 2009 France achievement of 2020 EU’s objectives Application area: Early Markets in terms of sustainable development Project type: Demonstration Steinbeis Europa Zentrum by demonstrating the reality of a real- Topic: SP1-JTI-FCH.2009.4.1 Germany life existing decarbonized mobility Demonstration of fuel cell powered system whose development will materials handling vehicles and European Institute for Energy Research rapidly accelerate in the near future. infrastructure Germany Contract type: Collaborative project The expected outcomes are: Start date: 01-02-2011 MaHyTec sarl • Favor the transferability of developed End date: 31-01-2014 France technologies to other delivery services. Duration: 36 months • Accelerate and effectively support the Project total costs: € 8,209,872 Ducati Energia S.p.a emergence and consolidation of the Project funding: € 4,262,057 Italy Fuel Cell Electric Vehicle industry. • Disseminate the project outcomes La Poste at local and European levels in Project Coordinator France order to promote innovative and sustainable transportation means. Nathalie ORIOL MES Institut Pierre Vernier Switzerland The second main impact is the 24 rue Alain Savary, 2500 Besançon acceleration of social acceptance for France UTBM novel technologies. The MobyPost France concept will be tested directly by [email protected] professionals who are in daily contact H2Nitidor s.r.l with the public - The Postmen. Italy This will increase the project’s visibility and knowledge that people have on this technology.
Programme Review 2012 - Final Report 159 SHEL Sustainable Hydrogen Evaluation in Logistics
Key Objectives Related to the demonstrations, the The main objective of the project is the site assessments and preparation for delivery of 9 optimised FC FLTs for the demonstrations have been carried demonstration, using an existing FLT FC The overall purpose of the SHEL project is out following the AMFE methodology, prototype design developed by UNIDO- to demonstrate the market readiness of and main Codes & Standards have ICHET and their partner CUMITAS. Two the technology and to develop a template been reviewed in order to obtain the types of vehicles will be used to the for future commercialization of hydrogen certification procedure. demonstration: counterbalanced and powered fuel cell based materials reach type, will utilise an existing Fuel handling vehicles for demanding, Cell Module but will investigate the high intensity logistics operations. Technical approach development of next generation energy and achievements saving technologies which can greatly This project will demonstrate 10 Fuel Cell improve the fuel cell operation lifecycle. ForkLift Trucks (FC FLT) and associated This project will show 10 FC FLTs hydrogen refuelling infrastructure and associated hydrogen refuelling across at least 4 sites in Europe. Real infrastructure across 4 sites in Europe: Achievements/ time information will be gathered to Turkey, UK, Spain and Greece. The Results to date demonstrate the advantages of using Turkish site will be within the Petkim fuel cells to current technologies and Petrokyma (Turkey´s largest chemical • Both FC purchasing bids fast procedures will be developed to complex), where the demonstration have been launched. reduce the time required for product will use industrial off-gas hydrogen for • The site assessment study has certification and infrastructural build 1 year; the UK demonstration will be been carried out following a FMEA approval. Moreover, to ensure the widest at the Port of Felixstowe for 6 months, methodology. For the FMEA top level dissemination of the results, the project the Spanish demonstration will be at hazards/events related to equipment/ will build a comprehensive Stake Holder the CEGA Logistics site in Vitoria for components/processes have been Group of partners to pave the way for one year and the Greek demonstration identified, potential failure modes and wider acceptance of the technology. will be placed at the new central effects defined, and inherent safety logistic centre of AB Vassilopoulos and potential prevention and/or supermarket chain during at least 1 year. mitigation corrective actions designed. Challenges addressed The demonstration will therefore be used • Main codes and standards have to investigate commercial operation of been revised and checked with Up to now analysis of the current State the trucks in three likely early market local authorities in order to define of Art across various FC FLT international sectors under real conditions. the certification process. demonstration has been done. • Each site preparation works According to the FC system, the Key milestones have been commenced. consortium is now in the phase of purchasing the FC systems and The project, started on January 2011, has assembling the fleet. a well defined strategy to demonstrate 10 FC FLT and associated hydrogen Expected socio and supply mechanisms across a minimum economic impact of 4 countries. Each site will demonstrate a different type of infrastructure based The consortium brings together a upon future possible commercial strong cluster of partners from Europe’s hydrogen resources available in Europe. hydrogen and fuel cell sector with key industrial partners -a gas company (AP), a Fork Lift truck OEM (Cumitas) and a logistic company (CEGA)-.
160 Fuel Cells and Hydrogen Joint Undertaking www.shel.eu Early Markets
The project contributes to achieving the following impacts: Project Information Turkey Air Products (Europe) (AP) Impact 1: Demonstration of two types of Project reference: FCH JU UK FC-based vehicles (10 vehicles in total) Call for proposals: FCH-JU-2009-1 across four different sites in Europe. The Application Area: SP1-JTI-FCH.4: Early Centre for Renewable Energy Sources & demonstration will give the participant Markets 10.3 Saving (CRES) partners in-depth field experience to Project type: Demonstration Greece accelerate medium term commercialization Topic: SP1-JTI-FCH-2009.4.1 of FC vehicle across the EU member states. Demonstration of fuel cell-powered Commission of the European materials handling vehicles and Communities - Directorate General Impact 2: Prove durability of infrastructure Joint Research Centre (JRC) fuel cell concept, functionality of Contract type: Collaborative Project Netherlands hydrogen refuelling infrastructure Start date: 01/01/2011 and demonstrate end user End date: 30/06/2014 Instituto Tecnológico del Juguete (AIJU) acceptance of the project. Duration: 42 months Spain This demonstration of pre-commercial Project total costs: € 4,645,500.00 products will confirm system specifications, Project funding: € 2,443,095.00 Instituto Nacional de Técnica lifecycle costs and training needs Aerospacial (INTA) for product installation and use, and Spain demonstrate public acceptance. Project Coordinator Impact 3: Development of Fundación para el Desarrollo de las certification procedures Dr. Oscar Miguel Nuevas Tecnologías del Hidrogeno en It will identify and improve the speed (Energy Department Manager) Aragón (FHA) of certification from the relevant IK4-CIDETEC Spain European Agencies, promoting Parque Tecnológico de San Sebastián international standards and developing Paseo Miramón, 196. 20009 Donostia - University of Hertfordshire (UH) procedures for certification within San Sebastián UK the European member states. [email protected] Federazione delle Associazioni Scientifiche e Techniche (FAST/EHA) Italy Partners Hygear BV (HYGEAR) IK4-CIDETEC Netherlands Spain CEGA Logistics (CEGA) International Centre for Hydrogen Spain Energy Technologies (UNIDO-ICHET) Cukurova Makina Imalat ve Ticaret (CUMITAS)
© shel Turkey
Programme Review 2012 - Final Report 161 SUAV Microtubular Solid Oxide Fuel Cell Power System development and integration into a Mini-UAV
Key Objectives Challenges addressed Technical approach and achievements
The objectives of the project is to design, Firstly, the top level requirements (TLR) This project aims to produce fuel cell optimise and build a fuel cell power for the packaged system were defined, components of longer cycling lifetimes generator for small Unmanned Aerial resulting in the demand of weight and at a reasonable price, thereby allowing Vehicles (mini-UAV). The stack to be volume limitations. The restrictions for SOFCs to be used in portable and other developed will be integrated together the fuel cell generator, including all applications. Widespread adoption with the required fuel processor and balance of plant components are 3.88 of SOFC technologies will give the mechanical as well as electrical balance kg with respect to weight and 3.32 environmental benefits of reduced fossil of plant components. The fuel cell litres with respect to the volume. These fuel usage (via increased efficiency) generator will be packaged and placed specifications include the fuel that is to be and reduced emissions. Because into a mini-UAV. The advanced mini-UAV carried throughout the flight. of the improved efficiency of SOFC will be tested in a flight mission with the Based on the Top Level Requirements, microgeneration, the consumption of goal to achieve a flight endurance that the development of the mSOFC stack fuel will decrease. This represents a large is three-times longer than batteries. was performed. The stack will consist saving of fuel cost, which in the future of several microtubular cells connected will result in a savings of imported fuel. to each other in parallel to achieve the Two other economic benefits follow required stack power of 250 W (end of from this: first, there is an export market life power). This will ensure long flight in Europe and overseas, which will missions with a total runtime of 600 h. The reward the first successful introduction present status of the cells is a power of of this technology; and second, the 0.23 W/cm2 at 60% fuel utilization feeding reduction in pollution will likely lead pure hydrogen (cell temperature 750 °C to significant health improvements and hydrogen volume flow of 60 ml/min). and a drop in medical costs.
The stack development is accompanied by system modelling with respect to the desired power output of 250 W (end of life). The system modelling considers all parts of the power generator as a SOFC stack, heat exchangers and fuel processing. Results of system modelling and stack development are exchanged between the two work packages to improve both development tasks – stack development targeting to the required end of life power of 250 W (or 600 h runtime) and system models validated with real data from stack development.
162 Fuel Cells and Hydrogen Joint Undertaking www.suav-project.eu Early Markets
Summary/overview Project Information Partners
SUAV aims to design, optimise and build a Project reference: FCH JU 278629 ADELAN Ltd. 100-200W mSOFC stack, and to integrate Call for proposals: 2010 UK it into a hybrid power system, comprising Application Area: of a stack and a battery. Additional RTD on new portable and micro Fuel CATATOR AB components are, a fuel processor to Cell solutions Sweden generate reformate gas from propane Project type: Research and and other equipment for the electrical, Technological Development Consiglio Nazionale delle Ricerche ITAE mechanical and control balance of the Topic: SP1-JTI-FCH.2010.4.5 Italy plant. All these components will be Contract type: Collaborative Project integrated into a mini Unmanned Aerial Start date: 01/12/2011 EADS Deutschland GmbH Vehicle .The project intends to optimise End date: 30/11/2014 Germany the mission duration, making efficiency Duration: 36 months less of a concern at the time. All these Project total costs: € 4,187,100 EADS UK Ltd. components will be constituents of an Project funding: € 2,109,518 UK entire fuel cell power generator, which will first be tested in the lab and, after further efceco Erich Erdle optimisation and miniaturisation, in a mini Project Coordinator Germany UAV platform. The achievement of these objectives will result in an improvement HyGear Fuel Cell Systems B.V. University of Birmingham in mini-UAV endurance by a factor of Westervoortsedijk 73, P.O.Box 5280 UK 3 over conventional battery power. 6802 EG Arnhem Netherlands West Pomeranian University of A single microtubular cell with a power Technology, Szcecin of 0.23 W/cm2 was achieved, with a fuel Dr. Ellart de Wit Poland utilization of 60% (pure hydrogen). The [email protected] next step is to perform tests with synthetic SurveyCopter reformate gas comprised of components France as they form in an effluent of a CPOX reactor (hydrogen, carbon monoxide, oxygen and unconverted propane). From the fuel processor development, the real composition of the CPOX effluent is to be transferred to the stack development (WP3) and system modelling (WP5).
Programme Review 2012 - Final Report 163 FC-EuroGrid Evaluating the Performance of Fuel Cells in European Energy Supply Grids
Key Objectives Challenges addressed Technical approach and achievements
The main objective of the project is Stationary fuel cells operate under a The project will establish pertinent to establish technical and economic variety of constraints which are defined application categories (among them: targets and benchmarks that allow the by the energy supply grid they are µCHP, CHP, decentralised electricity assessment of fuel cells in stationary integrated into and the application production, etc.), establish benchmarks power generation. The fuel savings they serve. Generally, stationary fuel from the performance of competing power and CO2 emission reductions will cells offer the advantages of high generating technology (in the different be a function of the electricity grid efficiency operation with low emissions, EU countries), identify the technical and structure and the fuels employed. low noise and modular design. economic targets for the key applications, Using these results it will be possible Nevertheless, it must be acknowledged and review the potential of the different to determine, whether a fuel cell that the GHG savings from a fuel cell fuel cell technologies to fulfil them. The installation effectively improves operated on the German grid will very goal is to collect all data necessary in fuel use and improves the CO2 much differ from those of a fuel cell evaluating the performance of stationary footprint, amongst other criteria. producing electricity in France –due fuel cells in the European energy markets This leads up to a more focused allocation to the difference in carbon footprint of (predominately heat and electricity) and of research funding, identification of the French electricity supply system. paving the way to objective criteria of best R&D gaps and objective comparison of Different fuel cell types (PEFC, HT-PEFC, practice and minimum standards, as well fuel cell with competing technologies. MCFC, SOFC) display different efficiencies as an appraisal of the type of applications The project will discuss the methodology in electricity production from natural gas. that actually lead to reductions in gross adopted with EU and worldwide energy consumption, emissions and stakeholders in order to established As a result of this complex situation depletion of fossil energy resources. a recognised assessment and there is no simple means of predicting benchmarking frame of reference. the advantages a stationary fuel cell Key milestones, deliverables system will offer in any given energy The main milestones refer to the finalisation supply environment. The task of setting of project work and the onset of discussion minimum benchmark targets for projects with the FCH JU and stakeholders from to be awarded funding under the FCH JU approx. month 16 onwards. scheme was therefore abandoned since there was no sensible way of setting Key deliverables include data collections general conditions that would apply (‘atlas’) of European electricity grids, independently of technology and system handbook of methodology and integration across the whole of Europe. benchmarking, and the status and gap analysis for stationary fuel cell systems.
164 Fuel Cells and Hydrogen Joint Undertaking Cross-cutting activities
Expected socio and economic impact Project Information Partners
The project will supply Project reference: FCH JU 256810 European Institute for Energy Research • a quantifiable technical understanding Call for proposals: 2009 Germany of the interaction of stationary fuel cell Application Area: 3 (Stationary) technology with various European Project type: Support Action E.ON Ruhrgas electricity supply grids with respect to Topic: SP1-JTI-FCH.2009.3.8: Germany greenhouse gas abatement and Applications specific targets for improved economy of fuel, stationary power generation and Teknologiantutkimus- keskus VTT • associated benchmarks and indicators related technology benchmark Finland suitable to describe the superiority (or Contract type: Coordination and inferiority) of specific fuel cell concepts Support Action ENEA vis à vis competing technologies with Start date: 01/10/2010 Italy respect to efficiency, emissions, End date: 30/09/2012 economic and operational data etc., Duration: 24 months Grontmij AB • targets for fuel cell development and Project total costs: € 849.684 Sweden criteria for the selection of best Project funding: € 588.982 performing project proposals, and Institute of Power Engineering • status reports on the development Poland status of stationary fuel cells and the Project Coordinator technology gaps that remain to be EBZ GmbH shut, along with indications for the Dr. Robert Steinberger-Wilckens Germany focus of future development work. University of Birmingham, Department of Chemical Engineering, Edgbaston, University of Birmingham Achievements/Results to date Birmingham B15 2TT UK The cataloguing and benchmarking UK data have been compiled and the development of the methodology of [email protected] technology comparison is under way.
Programme Review 2012 - Final Report 165 FC-HyGuide Guidance document for performing LCAs on Hydrogen and Fuel Cell Technologies
FC-HyGuide includes two autonomous Key Objectives Technical approach projects and consortia: HyGuide and FC- and achievements Guide. The overall goal of the project is to The guidance documents were developed While FC-Guide focuses on fuel cell develop a specific guidance document(s) in a multi stage stakeholder approach. technologies, HyGuide addresses for application to hydrogen and fuel In the first stage a draft version of the hydrogen production systems. cell technologies, and related training guidance documents were developed by material with courses for practitioners the project consortia and introduced to The two consortia, led by PE in industry and research. These the technical expert group of the project. INTERNATIONAL resp. ENEA agreed documents (one on hydrogen supply Feedback gained during the expert group during the project negotiation phase to technologies, one on fuel cells) are based workshop was integrated and advanced collaborate closely over the course of on and in line with the International versions of the guidance documents the project. The collaboration included a Reference Life Cycle Data System were prepared. In the following stage common work programme, interlinked (ILCD) Handbook, coordinated by the they passed a second consultation round. work packages, and mutual choices on European Commission’s JRC-IES. This consultation was public. Before the key overall LCA methodological topics. The main objective of the FC-HyGuide documents were finally released, an The advisory board / review panel and the project is the development of guidance independent external third party review technical expert group were also shared documents and accompanying LCA report process was performed to ensure the by both consortia. The reason for the templates to evaluate the environmental quality of the documents. Dissemination collaboration between the two consortia benefits of new technologies in the field and communication were core elements was to produce more value for the FCH of fuel cell and hydrogen applications. which were performed during the JU funding and to avoid contradictory It is foreseen that the guidance entire project period. Two training results. For that reason, the only public documents developed within FC- courses on the developed guidance domain used, is FC-HyGuide. HyGuide will be applied in all on-going documents completed the project. A and future FCH JU projects calling graphical overview of the concept of for Life Cycle Assessment (LCA). stakeholder involvement within FC- HyGuide is given in the following graph. Challenges addressed
The challenge of FC-HyGuide is to provide consistent, widely accepted and applicable rules (following the ISO 14025 approach: product category rules) for performing LCA of hydrogen and fuel cell systems. The guidance documents (HyGuide and FC-Guide) can serve as these rules, which define “how” LCA must be conducted within projects funded by the FCH JU.
166 Fuel Cells and Hydrogen Joint Undertaking www.fc-hyguide.eu Cross-cutting activities
Expected socio and economic impact Project Information Partners
The FC-HyGuide project is finalized. The Project reference: FCH JU Grant Universitaet Stuttgart (USTUTT) outcome of the project can be used in all Agreement No.: 256328 Germany hydrogen and fuel cell application areas Call for proposals: 2009 (horizontal approach) asking for LCA. Application Area: Cross-Cutting Issues Karlsruher Institute of Technology (KIT) FC-HyGuide facilitates a more effective Project type: Support Action Germany policy evaluation and decision making Topic: SP1-JTI-FCH.2009.5.5 by providing guidance for evaluating LIFE CYCLE ASSESSMENT (LCA) European Hydrogen Association (EHA), the environmental performance of Contract type: Coordination and Belgium, represented by The Italian fuel cell and hydrogen systems. Support Action Federation of Scientific and Technical Start date: 01/10/2010 Association (FAST) End date: 30/09/2011 Italy Duration: 12 months Project total costs: € 366.318 European Commission represented by Project funding: € 366.318 Joint Research Centre (JRC-IE) Netherlands Project Coordinator
Dr. Oliver Schuller PE INTERNATIONAL AG Hauptstr. 111-113 70771 Leinfelden-Echterdingen Germany
Phone +49 (0) 3 41 – 4 65 33 89 Fax +49 (0) 3 41 - 1 49 91 92 GSM +49 (0) 1 51 – 24 155 887
Programme Review 2012 - Final Report 167 HyCOMP Enhanced Design Requirements and Testing Procedures for Composite Cylinders intended for the Safe Storage of Hydrogen
Key Objectives Challenges addressed The final objective of HyCOMP is to improve the full set of requirements while ensuring the structural integrity of the Currently, the most mature technology for Current regulations do not allow cylinders. For that, the following technical storing hydrogen is in compressed form exploiting the full potential of carbon approach is performed. in high-pressure cylinders. To improve fibre materials. New and revised standards Damage mechanisms and failure modes volumetric and gravimetric performances, are in process, but the work is done of composite vessels are first identified at carbon fibre composite cylinders are based on a traditional and conservative a material scale on plate specimens and currently being developed. However, way of determine the performance of a then at a structural scale on cylinders, current standards do not allow cylinder cylinder. Furthermore, the requirements under cyclic, static and hybrid loads, design to be optimized. In particular, in these standards are often not based representative of service conditions for the safety factor relative to the burst on degradation processes in composite three different applications: stationary, pressure ratio appears to be conservative, materials, but have been adapted from transportable and automotive uses. The which results in the cylinders being standards covering metallic cylinders. most relevant parameters characterizing overdesigned and thus costly. service life in terms of gas pressure-related Therefore a potential clearly exists to loads and temperature are identified in In this context, this project aims at: enhance the standards for achieving order to check that the critical operational • To develop a better understanding further improved levels of safety while loads have been properly characterized in of the damage accumulation avoiding overly conservative construction the test program. processes in composite cylinders requirements, in particular through a and the degradation rate as a better understanding of the degradation Knowing that carbon fibre reinforced function of the type of load and mechanism actually occurring in carbon plastic (CFRP) materials mainly damage environmental conditions, fibre composite materials. The objective by fibre breakage, a non-destructive • To enhance design requirements for of HyCOMP is to bring this potential to test based on acoustic emission has composite cylinders for storage or fruition for producing improved type been preferred to quantify the level of transport of compressed hydrogen, approval and batch testing protocols. damage produced in the composite • To improve the full set of wrapping. Nevertheless, a destructive requirements defined for ensuring the The main outcome of the project will be burst test is finally performed to estimate structural integrity of the cylinders a documentation of the real performance the influence of damage on the cylinder throughout their service life, of composite cylinders to support residual strength. Furthermore, a • To improve procedures for type Authorities and Industry in making particular attention is paid on material and approval and batch testing. enhanced RCS. manufacturing parameters that should be subjected to a quality assurance plan because they strongly impact cylinder Technical approach performances (initial strength as well as and achievements long-term properties of cylinders). Numerical models are then developed HyCOMP is based on an experimental and in agreement with experimental results numerical approach that will provide a and observations in order to predict comprehensive scientific basis of damage damage accumulation in the composite accumulation mechanisms that occur in wrapping and then cylinder failure. The the composite wrapping under typical estimation of the probability of failure for a loads in service. required lifetime will be used to define the acceptable safety factor.
168 Fuel Cells and Hydrogen Joint Undertaking www.hycomp.eu Cross-cutting activities
Based on the findings from the experimental work, appropriate testing Project Information Partners protocols will be defined to demonstrate the cylinder fitness for service and Project reference: FCH JU 256671 Air Liquide resistance to its anticipated service life. Call for proposals: 2009 France Finally, findings and recommendations Application Area: will be summarized and disseminated so Hydrogen production and storage Armines that they can be used by the international Project type: Research and France hydrogen and fuel cell community, in Technological Development particular for Regulation, Codes and Topic: SP2-JTI-FCH.1.5 – Pre-normative Bundesanstalt für Materialforschung Standards initiatives. Research on Composite Storage und Prüfung (BAM) Contract type: Collaborative Project Germany Start date: 01/01/2011 Expected socio and End date: 31/12/2013 The CCS Global Group LTD economic impact Duration: 36 months UK Project total costs: € 3 802 542 The outcome of the project will have Project funding: € 1 380 728 (36 %) Commissariat à l’énergie Atomique a direct economic and social impact (CEA) on high pressure composite cylinders France intended for the storage of hydrogen. Project Coordinator First, the project will provide all the data EADS Composites Aquitaine necessary to argue in favour of a decrease Clémence Devilliers France of the cylinder safety factor. A direct Air Liquide consequence is then a decrease of the Centre de Recherche Claude Delorme Faber Industrie composite thickness, so a decrease of the 1, chemin de la Porte des Loges Italy quantity of carbon fibre. Knowing that Les Loges en Josas carbon fibre represents the largest part B.P. 126 Raufoss Fuel System in the final cost of a cylinder, a decrease 78354 Jouy-en-Josas Cedex Norway of the cylinder cost is thus expected. France Wroclaw University of Technology (WUT) Furthermore, the structural integrity [email protected] Poland of high pressure composite cylinders Tel.: +33 1 39 07 60 66 will be demonstrated during the Joint Research Centre of the EC, project by determining appropriate Institute for Energy and Transport testing protocols and defining pass/ (JRC-IET) fail criteria to ensure the cylinder Netherlands fitness for service and resistance to its service life. These results will Alma Consulting Group contribute to a better social acceptance France of hydrogen as an energy vector.
Programme Review 2012 - Final Report 169 HyFacts Identification, Preparation and Dissemination of Hydrogen Safety Facts to Regulators and Public Safety Officials
Key Objectives Challenges addressed Expected socio and economic impact
The HyFacts project aims to develop Main goal of the HyFacts project is Fuel Cell and Hydrogen Technologies and disseminate fully up-to-date the gathering, analysis, synthesis and shall be implemented in Europe in contemporary material for customized dissemination of the technical content order to gain specific knowledge training packages for regulators identified in the first stage of the project in applying these technologies and and public safety experts providing by providing an adequate format which bringing them to a breakthrough accurate information on the safe and can easily be absorbed by the target by reaching the necessary “critical environmentally friendly use of hydrogen group. Depending on the different target mass”. Only if the number of fuel cell as an energy carrier for stationary groups, the material will be delivering a cars, refuelling stations, small and and transport applications under real different depth of information, reflecting large centralised and decentralised conditions. The training material will focus on the needs of the respective persons hydrogen systems in operation, the on the fundamental aspects of hydrogen representing different levels of one necessary impact on public acceptance safety and on the safety approaches regulating institution. and involvement can be achieved. and criteria developed in standards For reaching this aim, the regulators, and according to which hydrogen In order to achieve a good learning which sometimes hold up approval of systems are engineered for the safe use result, short courses have proven to be systems prior to their implementation, of hydrogen under all circumstances. one of the adequate means of spreading need to be trained in understanding excellence to specific target groups along and safe use of hydrogen and with distance learning. its related technologies much better and should even be brought to a supportive attitude.
170 Fuel Cells and Hydrogen Joint Undertaking www.hyfacts.eu Cross-cutting activities
Up to date several deliverables could be finalized. Project Information Partners
The general structure of the training Project reference: FCH JU TÜV SÜD Akademie GmbH material has been defined and most Call for proposals: year 2010 (TUV) of the content has been finalized. Application Area: Cross cutting Germany Questionnaires have been sent out to Project type: Coordination and the target audience in Germany, UK Support Action Air Liquide Hydrogen Energy and France. The answers have been Topic: Fuel cells and Hydrogen (AL) analysed and the scope of the training Contract type: Coordination and France material as well as the training structure support action has been adopted to their specific Start date: 01/02/2011 The CCS Global Group Ltd. requirements. A poster as well as hand End date: 01/07/2013 (CCS) out brochures have been produced and Duration: 36 months UK the project website is online with a lot of Project total costs: € 1 million information on the project. The first short Project funding: € 1 million Federazione delle Associazioni course will be conducted soon and the Scientifiche e Tecniche first draft training material will be tested. (FAST/EHA) Project Coordinator Italy
Christian Machens Health and Safety Laboratory Project Manager HyFacts Project (HSL) TÜV SÜD Akademie GmbH UK Wiesenring 2 D - 04159 Leipzig University of Ulster Germany (UU) UK Phone: +49 (0) 3 41 – 4 65 33 89 Fax: +49 (0) 3 41 - 1 49 91 92 GSM: +49 (0) 1 51 – 24 155 887
Programme Review 2012 - Final Report 171 Hyindoor Pre Normative Research on the in-door use of fuel cells and hydrogen systems
Key Objectives The generated knowledge will be Technical approach translated into safety guidelines, and achievements including specific engineering tools The aim of Hyindoor is to develop the supporting their implementation. • Development of the knowledge capability to specify practical means and Recommendations for normative / base required in order to be able strategies that will prevent or mitigate the regulatory requirements are expected to to predict H2 behavior indoor and potential consequences of a hydrogen lead to the adoption of the results by the consequences in the case of early release indoors. This will be implemented wider stakeholder community and their or late ignition (results expected with a risk-based approach: i.e. the higher introduction into RCS. Envisaged unique January 2013 – June 2014) the expected frequency of the release, the results can give Europe a leading position • Definition of improved criteria more stringent the acceptance criteria. in the sector. The benefits of optimised for allowing hydrogen and FC design and RCS upgrade are expected systems indoors (recommendations to significantly improve the prospects of for RCS – September 2014) Summary/overview hydrogen as an energy carrier. • Issuing of safety guidelines (to be published on Hyindoor Hyindoor addresses knowledge website by August 2014) gaps regarding indoor hydrogen – Sizing of enclosure openings or accumulations, vented deflagrations, and forced ventilation in the function under-ventilated jet fires. This includes of H2 release parameters improved criteria for indoor HFC systems – Sizing of the vent area for to avoid hazards; sizing of openings for deflagration mitigation in relation natural ventilation and specification of to the accumulated inventory and forced ventilation systems; and sizing of obstruction in the enclosure the vent area for deflagration mitigation. • Dissemination of the project
outputs through H2 safety Analytical, numerical and experimental community and industrials studies in Hyindoor will be guided by the (Advanced Research Workshop expectable, foreseeable or conceivable envisaged in Brussels for September release conditions for fuels cells (FC) 2013 and Stakeholders dissemination systems in early markets’ power range and workshop in December 2014). building or FC cabinet characteristics.
Example of HFC indoor application – Forklift © hyindoor
172 Fuel Cells and Hydrogen Joint Undertaking www.hyindoor.eu Cross-cutting activities
Expected socio and economic impact Project Information CCS Global Group Ltd (CCS) Hydrogen Fuels Cells (HFC) technology Project reference: FCH JU 278534 UK is expected to constitute a major Call for proposals: 2010 contribution for environmental Application Area: Early markets Commissariat à l’Energie Atomique et protection and rational use of Project type: Research and aux Energies Alternatives energy. However, hydrogen as an Technological Development (CEA) energy carrier requires a sound Topic: Priority 4.6 of the call FCH- France safety framework of harmonized JU-2010-1 Regulations and Codes and Standards Contract type: Collaborative project National Centre for Scientific Research (RCS) to reach commercialisation. Start date: 1 January 2012 Demokritos End date: 31 December 2014 (NCSRD) The generated knowledge of Hyindoor Duration: 36 months Greece will feed into safety guidelines. The Project cost: € 3,657,760 experimental work will significantly Project funding: € 1,528,974 Karlsruhe Institute of Technology enhance the understanding of (KIT) hydrogen dispersion and combustion; Germany the increased predictive ability of Computational Fluid Dynamics (CFD) Project Coordinator Health and Safety Laboratory modelling will enable its applicability (HSL) to particular settings and simple L’AIR LIQUIDE S.A. UK models will be proposed for industrial CRCD use to size mitigation means. (Centre de Recherche Claude Dehorme) Hygear Fuel Cell Systems Chemin de la Porte des Loges B.P. 126 (HFCS) Les-Loges-en-Josas Netherlands 78354 Jouy-en-Josas, France University of Ulster Contact: Ms. Sidonie RUBAN (UU) [email protected] UK
Joint Research Centre Partners (JRC) Netherlands Air Liquide (AL) LGI Consulting France (LGI) France
Programme Review 2012 - Final Report 173 HYPROFESSIONALS Development of educational programmes and training initiatives related to hydrogen technologies and fuel cells in Europe
Key Objectives Challenges addressed Technical approach and achievements
Today’s technicians and students The main challenge is to find the right Mapping of existing training programs are the next generation of potential guidelines in order to establish hydrogen • What has been done so far in H2FCs? fuel cell users and designers and technologies at current vocational • How is innovation in vocational education is now a critical step training. In order to do that, existing training funded? towards the widespread acceptance training programs related to hydrogen • How does vocational training evolve? and implementation of hydrogen fuel and fuel cells in the EU were identified cell technology in the near future. to provide a good base for educational Proposals for initiatives Development of training initiatives activities and also the gap between • Who are the “offer and the demand”? for technical professionals aiming to educational trainings and industry • What will be the mismatch of “the secure the required mid- and long-term needs. After that, specific initiatives, offer and demand”? availability of human resources for proposals, guidelines and projects • What could be done? At what time? hydrogen technologies will be started. were developed to get consolidated The work will be carried out for educational programs for technical Testing and implementation vocational education, including training at different levels, implementing of initiatives industry, SMEs, educational institutions the results of the project and involving • Pilot actions within the project and Authorities. Coordination and different stakeholders (industry, SMEs, • Seed for new steps (broader initiatives cooperation are key factors to fulfil educational entities, authorities...). outside the scope of the project) the objective of developing a well- Furthermore, the dissemination of the trained work-force which will support results at different target audiences Dissemination plan technological development. for the purpose of facilitating the • Workshops with Target Groups. acceptance and implementation Bringing together industry education, of these technologies by means authorities... of education has been achieved (2 • Website, media... workshops developed) as well as several pilot actions involving different European countries have been done. ©hyprofessionals
174 Fuel Cells and Hydrogen Joint Undertaking www.hyprofessionals.eu Cross-cutting activities
Expected socio and economic impact Project Information Partners
The socio and economic impact of Project reference: Foundation for Hydrogen in Aragon the project is anchored in setting Grant Agreement nº: 256758 Spain up the road map for conventional Call for proposals: FCH-JU-2009-1 educational systems in order to add Application Area: AA5 – FAST, Federation of Scientific and the new hydrogen technologies to Cross-cutting issues Technical Association educational programs. This way, industry Project type: Support Action Italy and SMEs will have a well-trained Topic: SP1-JTI-FCH.2009.5.1: work-force in the medium term. Development of educational San Valero Foundation In the short-term, a library with programmes Spain educational resources about hydrogen Contract type: Coordination and and fuel cells is available on the project Support Action UNIDO ICHET website. This way, some pilot actions Start date: 01/01/2011 Austria took place for teaching different target End date: 31/12/2012 groups like vocational training students, Duration: 24 months European Commission, graduates, technicians and teachers. Project total costs: € 432.116,00 Directorate-General Joint Spread among several fields such as Project funding: € 373.537,00 Research Centre, automotive, maintenance or renewable Institute for Energy energies, the information sessions give Belgium a clear picture of the diverse aspects of Project Coordinator hydrogen technologies, what they do WBZU and why they are useful and important. Luis Correas Usón Germany Foundation for the Development of New Hydrogen Technologies in Aragon Association PHYRENEES Parque Tecnológico Walqa. Ctra. France Zaragoza N330A, km 566. 22197 Cuarte (Huesca) Environment Park Spain Italy
[email protected] CPI, Centre for Process Innovation UK Contact for communication Marieke Reijalt [email protected]
Programme Review 2012 - Final Report 175 HyQ Hydrogen fuel Quality requirements for transportation and other energy applications
Key Objectives Challenges addressed Technical approach and achievements
HyQ consists of pre-normative studies to One of the challenges addresses in HyQ The approach developed in HyQ can be provide a strong support to Regulation is to evaluate the impact of pollutant on divided in two parts. The first one deals Codes and Standards organizations the PEMFC performance in the condition with the determination of the highest in order to normalize an acceptable as representative as possible of the real acceptable amount of impurities in fuel quality for PEMFC for automotive application conditions. To the best of H2 which does not impact the fuel cell application. Depending on the way to our knowledge, the results discussed for performance. To do that, 4 institutes produce and purify hydrogen, it can the determination of the standard had are performing tests, in both identical contain different kind of pollutants been obtained in conditions that are not conditions(reproducibility) and then in which impact the performances representative of the real automotive different conditions to obtain maximum and the durability of PEMFC. application. Indeed, the impact of of results. The impact of impurities (CO,
To facilitate the emergence of the pollutant can be dramatically different H2S, HCHO) is checked under single potential mass market represent by depending on the conditions in which the cell and stack configuration, with and the automotive application, a standard test has been performed. without recirculation. In another part, hydrogen quality is becoming a partners specialized in gas analysis necessity. One of the objectives of HyQ Another issues addressed in HyQ is are improving analytical method to is to increase knowledge on the impact to be able to propose standards that quantify the amount of impurities in H2. of pollutants commonly find in the could be used to certify the purity level The problem with the actual standard hydrogen produced by economically of hydrogen by assurance quality. By is that it’s difficult to certify that2 H sustainable industrial processes. Thus, example, if no method exists (or are very reaches the quality requested and/or are relevant scientific results from HyQ will expansive) to prove that the amount costly. At the end of the project, after give strong arguments in the discussion of an impurity in the hydrogen fuel is inter-laboratories comparison, report on the fuel quality for PEMFC. Another low enough to follow the standard, it is on the best measurement method and objective of the project is to improve problem to certify the quality of the gaz. gas sampling will give input for the the analytical methods used to guaranty Formaldehyde and sulphur compound establishment of unified protocols. the quality specified in the standard. are in this case and their impact are addressed in HyQ to see if a so low level (respectively 0.01 ppm and 4 ppb) recommended in the actual standard are justified or not.
176 Fuel Cells and Hydrogen Joint Undertaking
Cross-cutting activities
Expected socio and economic impact Project Information Partners
To sum up, HyQ results will give strong Project type: Support action European Commision, inputs to the Regulation, Code and Project reference: FCH JU 256773 Joint Research Centre (JRC) Standard organisation. Accepted Call for proposals: 2009-1 Belgium standards based on consensus between Application Area: pre-normative the actors of the hydrogen economy research on hydrogen quality Zentrum fur Sonnenenrgie und for automotive application will give Project type: Support Action Wasserstoff-Forschung (ZSW) strength to the development of a mass Topic: SP1-JTI-FCH.1: Transportation Germany market. Of course, a special emphasis and Refuelling Infrastructure; SP1-JTI- is put on the automotive application. FCH.2009.1.6: Pre-normative research Air Liquide (AL) Indeed, even if the potential widespread on fuel quality France distribution of fuel cell vehicles could Contract type: Collaborative project, not reach the actual fleet of more than small or medium scale focused Total Raffinage Marketing (Total) 1 billon cars all over the world. The research project France money and matter flow that could Start date: 01 March 2011 be generated by this sector will be End date: on-going Element Energy (EE) huge and an approved international Duration: 36 months UK standard will facilitate the negotiation Project cost: € 3,718,853.00 processes between the actors of the Project funding: € 1,385,219.00 Axane (Axane) hydrogen economy and will help also France in unifying the links of the chain from gas producer to end-users. In the same Project Coordinator National Physical Laboratory (NPL) way, results obtained here will be very UK helpful for the stationary application. Commisseriat à l’Energie Atomique et aux Energies Alternatives (CEA) VSL Dutch Metrology Institute (VSL) France Netherlands (French Atomic Energy Commission) CCS Global group Ltd (CCS) Pierre-André JACQUES UK 17 rue des Martyrs 38054 Grenoble Cedex 9 Shell Downstream Services France International (Shell) Netherlands +33(0)4 38 78 06 99 [email protected] Linde (Linde) Germany
VTT Technical Research Centre of Finland (VTT) Finland
Programme Review 2012 - Final Report 177 TEMONAS TEchnology MONitoring and ASsessment
Key Objectives 2. The first-of-its-kind, TEMONAS Technical approach complements technology assessments and achievements (internal viewpoint) with an equally TEMONAS will enable the FCH-JU strong technology monitoring (external There has been a preceding phase to obtain an accurate assessment of viewpoint) system and the possibility of intensive ascertainment of all the progress, both towards its objectives to combine these two aspects of necessary features in detail, based of and in terms of its position within the technology management into one the extensive experience of the partners global field of energy technologies. integrated application while producing working in international R&D projects. The a single integrated summary result. results have already been implemented TEMONAS is an advanced TEchnology and the software is in the testing phase. MONitoring and ASsessment tool for 3. TEMONAS focuses on monitoring Practical work with real data is currently the R&D area. It enables decision makers analyses, the performance or structural taking place in order to learn about and project managers to continuously changes in their time dependency and possibly necessary improvements. The monitor the progress of their projects in both technical and social domains. final version of the software package against their own targets and against will be produced in due time. developments in the market. It also 4. Advanced methodologies are applied allows for benchmarking with worldwide to each of the modules’ functions, innovations. TEMONAS is designed for such as Multi-Criteria Decision Aid hydrogen and fuel cells as first application tools which allow the treatment of but can also be used for several other complex, multi-dimensional, nonlinear kinds of complex innovation. evaluations necessary for TMA.
5. TEMONAS features a largely automated Challenges addressed Report Generator for various outputs such as MS Power Point presentations The main innovative aspect of TEMONAS and written reports to be processed in is the supply of a smart Technology word processing packages. Monitoring and Assessment (TMA) tool, beyond what is commercially available and based in transparent, yet well- designed and implemented IT, therefore allowing for accessible methodology, specifically designed for project and programme evaluation purposes.
1. TEMONAS is an integrated IT based tool for a well-documented, highly automated, objectified technological data set and also a tool for benchmark management, technology assessment as well as a wide rage of technology monitoring with selection mechanisms
based on a variety of commercialisation © temonas parameters.
178 Fuel Cells and Hydrogen Joint Undertaking www.temonas.eu Cross-cutting activities
Expected socio and economic impact Project Information Partners
The main expected impact of the Project reference: FCH JU 278862 Planungsgruppe Energie und Technik TEMONAS project is the provision of Call for proposals: 2010 GbR (PLA) an advanced management tool for the Application Area: Fuel Cells and Germany FCH-JTI. If all functionalities required Hydrogen by the call specifications can be fully Project type: Cross Cutting EUROPEAN FUEL CELL FORUM AG implemented in an integrated tool, then Topic: Technology Monitoring and (EFCF) we expect that it will enhance the JTI’s Assessment Switzerland capacity to make decisions on the basis Contract type: Coordination and of repeatable and objective information. Support Action Commissariat à l’Energie Atomique et Start date: 01 September 2011 aux Energies Alternatives (CEA) The FCH-JU will profit from this End date: 28 February 2013 France enhanced information base in terms of: Duration: 18 months - Performance-monitoring of individual Project cost: € 1,8 million JANINA AGNIESZKA SWIECH-SKIBA projects vis-a-vis benchmarks and Project funding: € 1,3 million (CSMS) overall program objectives Poland - Overall assessment of program performance in comparison to Project Coordinator Bana Consulting (Bana) international benchmarks Portugal - Provision of rationale for CLIMT GmbH discussions about program/ Austria synergesis consult.ing Herbert Wancura call structure and enabling the (SYN-HW) strategic steering of decisions. Contact: Mr Peter Claassen Austria [email protected]
Programme Review 2012 - Final Report 179 TrainHy Building Training Programmes for Young Professionals in the Hydrogen and Fuel Cell Field
Key Objectives The course content and the choice of The key deliverables include a data course elements by the student can collection (‘atlas’) of European Training interact with the necessities of her/his Measures for Young Professionals The project aims at: main profession. in the field, presentation material, • deriving specifications for a Fuel Cell handouts, experimental material and Hydrogen education and training The course programme offers ECTS for trainers (experimentation curriculum for post-graduates (young points to those who desire to obtain materials and textbooks) and professionals, master of sciences and them, especially university students. It two summer school courses. doctoral students) from the review of will also offer ‘Continuous Programme of existing training programmes specific Development’ (CPD) credits. to FCH in Europe (with respect to scope, Expected socio and effectiveness, structure and cost), The project intends to introduce a economic impact • designing a curriculum and coherent coordination between different organisational structure to supply suppliers of training courses. In order • The project directly addresses high-level professional training to achieve the highest quality of these the problem of building suitable to the above mentioned group of measures, the cooperation will be human resources for the students in the areas of Fuel Cell performed on the basis of stringent unrestricted development of and Hydrogen technologies, quality control and compatibility with the European Fuel Cell and Hydrogen • building a financing scheme and educational goals and general acceptance businesses. It contributes to business model oriented at a long- of the course(s) in the academic world. enforcing the competitiveness of term sustainable performance the European economic area. of such a curriculum, • It develops a concept for an • initiating such a structure Technical approach educational system across a number and performing first test and achievements of post-graduate educational levels. elements of these courses, • It establishes selected course elements • evaluating the suitability and success The approach of the project is to develop and assesses their potential to increase of the initiated activities, suggesting a curriculum for the field of Fuel Cell hiring rates of course participants. further action and presenting an and Hydrogen technologies aimed at • It will lead to the establishment action plan with organisational post-graduate students and young of the developed curriculum and financial information. professionals. Elements of this curriculum, concept within the European namely summer school events, will be post-graduate educational system held in 2011 and 2012. They will be used and the programmes of life- Challenges addressed to verify and evaluate the applicability long learning in the framework of the curriculum concepts and develop of vocational Continuous Post-graduates are offered the a course and e-learning structure within Development Programmes. opportunity to improve and complete which the educational programme can the skills most relevant to their current be organised. Universities will be invited The 1st Joint European School on occupation without interrupting their to adopt the curriculum and the courses Fuel Cell and Hydrogen Technology professional life – therefore making the offered within their training programme, took place in Viterbo, Italy, from curriculum and education & training including grant of ECTS points. The 22.8-02.9.2011. It consisted structure valuable for businesses and developed programme and organisational of four separate courses: academic institutions alike since it does structures are intended to be further not remove the trainees from their sustained after termination of the project. • A Primer on Hydrogen and ongoing assignments. Fuel Cell Technology, 21 August - 27 August 2011
180 Fuel Cells and Hydrogen Joint Undertaking www.hysafe.org/TrainHyProf Cross-cutting activities
• An Introduction to Solid Oxide Fuel Cell Technology, 21 Project Information Partners August - 27 August 2011 • An Introduction to Low Temperature Project reference: FCH JU 256703 Forschungszentrum Jülich GmbH Fuel Cell Technology, 28 August Call for proposals: 2009 Germany - 02 September 2011 Application Area: 5 (Cross Cutting) • Solid Oxide Fuel Cell Design Project type: Support Action Risø-DTU and Modelling, 28 August Topic: SP1-JTI-FCH.20095.1: Denmark - 02 September 2011. Development of educational programmes University of Ulster The 2nd Joint European School on Contract type: UK Fuel Cell and Hydrogen Technology Coordination and Support Action took place in Iraklio, Crete, from 16.- Start date: 01/10/2010 Heliocentris 29.09.2012. It consisted of a total of End date: 30/09/2012 Germany nine ‘modules’, each lasting one week: Duration: 24 months • Low Temperature Fuel Cells Project total costs: € 345.722 University of Birmingham • SOFC Project funding: € 269.105 UK • Fuel Cell Modelling • Safety of Hydrogen Technologies • Electrochemistry for fuel Project Coordinator cells and electrolysers / Characterisation methods Prof. Robert Steinberger-Wilckens • Hydrogen technology University of Birmingham, Department • SOFC Systems & Balance of Chemical Engineering, Edgbaston, of Plant Components Birmingham B15 2TT • Electrolysis UK • System modelling. [email protected]
Programme Review 2012 - Final Report 181
European Commission
Fuel Cells and Hydrogen Joint Undertaking — Programme Review 2012 — Final Report
Luxembourg: Publications Office of the European Union
2013 — 182 pp. — 21 x 29.7 cm
ISBN 978-92-79-29158-6 doi 10.2777/79943
How to obtain EU publications Free publications: • via EU Bookshop (http://bookshop.europa.eu); • at the European Commission’s representations or delegations. You can obtain their contact details on the Internet (http://ec.europa.eu) or by sending a fax to +352 2929-42758. Priced publications: • via EU Bookshop (http://bookshop.europa.eu); Priced subscriptions (e.g. annual series of the Official Journal of the European Union and reports of cases before the Court of the Justice of the European Union): • via one of the sales agents of the Publications Office of the European Union (http://publications.europa.eu/others/agents/index_en.htm). KI-32-13-168-EN-C