hydrogen and fuel cells for electromobility : the...
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Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
HYDROGEN AND FUEL CELLS FOR ELECTROMOBILITY : THE HY WAYDEMONSTRATION PROGRAM AND PROGRESS IN FC STACK DEVE LOPMENT
| 2HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
SUMMARY
• Context • Hydrogen mobility in world • Hydrogen mobility in France
• HYWAY : program overview • Introduction • Working Method• FLEET data analysis• Beyond HYWAY
• Development of next generation Fuel cell System
• Perspectives
| 3HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
• Fuel cell vehicles • Electric vehicle including battery a least for the system
start-up• clean vehicle (only water produced)• low level of noise• High efficiency compared to conventional engines
• Use of fuel • Refuelling duration =3 min-5min (for optimised 700
bars refuelling station) • Range : approximatively 600 km and independent of
climatic conditions (Temperature) • Easy to monitor the energy level stored in tank
• Availability of hydrogen (need of hydrogen refuelling station)
• Cost of fuel cell system
ADVANTAGES AND DRAWBACKS OF FCEV
| 4
OVERVIEW OF ACTUAL AND FUTURE PEMFC MARKETS
Overview of projected sales of individual fuel cell vehicles during 2015-2025
• Increase of number of system shipped during last year
• Increase of power installed• Mainly used for stationary
applications
• Increase of number of Fuel cell vehicles is planned during next years.
| 5
Main worldwide automotive suppliers program
2015
2016
2015
2013
2020
1000 véhicules en2015
700 véhicules en2015
2000 véhicules en2016
3000 véhicules en2017
30 000 véhicules en2020
2015
200 véhicules en2015
1000 véhicules en2016
2020
2015 2020
2015 2017
700 véhicules en2016
2020
2014 2017
| 6
TOYOTA MIRAI EXAMPLE
https://youtu.be/oOUjqxec4bA
CaractéristiquesDimensions L x l x h 4,890 / 1,815 / 1,535 m
Empattement 2,780 mVolume du coffre 361 l
Poids à vide 1.850 kgMoteur
SystèmePile à combustible + moteur électrique +
batterie Ni-Mh de 1.6 kWhPuissance 154 ch immédiatement
Couple 335 Nm immédiatement0 à 100 km/h 9,6 sVitesse maxi 178 km/Autonomie 500 km (données constructeur)
Temps de recharge 3-5 minutes
Tarifs 66.000 euros HT
Available in Asia, in North America and in Europe when hydrogen refuelling station already exists (Deutschland, Denmark, United Kingdom and Belgium) ; Not in FRANCE
| 7| PAGE 7
HYDROGEN MOBILITY - FRANCE (OCTOBRE 2014)
Captive float to start infrastructure deployment before a g lobal coverage of
Clusters will be the base of future national infrastructure
Source : www.afhypac.org/images/documents/h2_mobilit_france_fr_final.pdf
Le Projet HYWAY
� Déploiement de 50 utilitaires
Kangoo ZE hybrides
batteries/hydrogène
� 2 stations de distribution
d’hydrogène à Lyon et
Grenoble
� Premiers véhicules en
circulation en 2015
Déploiement Manche
� Déploiement de 40 utilitaires
et bus
� 1 station de distribution
d’hydrogène à Saint-Lô
� 10 véhicules en circulation en
2015
2015: premiers déploiements
PRESENTATION OF HYWAY PROJECT
| 9HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
CONTEXT : OUR PARTNERS
| 10HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
CONTEXTPROJECT OBJECTIVES
• Deployment of a FCHEV captive fleet (50 vehicles) simultaneously with the installation of 2 Hydrogen Refueling Station (port of Lyon, Grenoble GEG)
• Multi users• Multi customers (La Poste, CETUP, DHL, etc…)• Analysis of Hydrogen Refueling Station /Vehicles usages• Validation of the economic deployment model HRS/Vehicles
ENJEU
HRS – Grenoble GEG
FCHEV Fleet (Kangoo ZE-H2)
| 11HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
CONTEXTTHE VEHICLE
• Renault Kangoo ZE MAXI + FC kit from Symbio• Type: serial hybrid• Battery pack: 22 kW.h• FC Stack: 5 kW• H2 Tank: 350 bar, 1,5 kg H2
ENJEU
Kangoo at HRS – Grenoble GEG
Kangoo ZE-H2
| 12HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
CONTEXTCEA OBJECTIVES
CONTEXTE ET POSITIONNEMENT PAR RAPPORT À LA STRATÉGIE INTERNE
� 1st large scale feedback on FC stack based on bipolar plate developed at CEA,
CEA activities in HYWAY:• Analysis of the fleet’s data (vehicle data, FC system data)• Optical and electrochemical analysis of the degradation MEA,• Replacing original MEA by MEA made in CEA,
Beyond HYWAY:• Specific test and characterization to capitalize data and feedback on
FC system in real usage
• CEA is involved in the preparation of Grenoble site for local H2 production (HYWAY 2)
| 13HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
WORKING METHOD
Understand
Measure
Analyze
ModelSimulate
Experiment
Apply
CharacterizeQuantify
Validate
Optimize
Deploy
IndustrialPartners
| 14HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
FLEET DATA ANALYSISDATA RECOVERY AND PROCESSING
Automatic data recovery
Processing line
| 15HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
FLEET DATA ANALYSISDIFFERENT LEVEL OF ANALYSIS
second, minute, hour day, month, year
Level 1:Temporal data analysis
Level 2:Periodic data analysis
Level 3:Global fleet data analysis
Inter-vehiclecomparison
Usage, performance group, etc.
| 16HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
FLEET DATA ANALYSISEXAMPLE OF RESULTS
Full hybrid
batterypredominant
Hydrogenpredominant
Low usage
Data acquisition still in progress
| 17HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
FLEET DATA ANALYSISEXAMPLE OF RESULTS
Data acquisition still in progress
| 18HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
BEYOND HYWAYSPECIFIC INSTRUMENTATION
• Use of FCMS (Fuel Cell Monitoring System) developed in CEA• Current • Voltage• Qair• …
� Knowledge of the real temporal operating point� Hydrogen balance, system efficiency, hybridization rate
On boardData logger
Current, Voltage sensorFCMS
| 19HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
BEYOND HYWAYSPECIFIC INSTRUMENTATION
� Following up of the operating point evolution� Statistical analyze of the data� Identification of degradations signature
In progress
| 20HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
BEYOND HYWAYSPECIFIC TESTS
• Periodic test on stack• Measurement of the performance evolution
Using polarisation curves Using Cyclic voltammetry
| 21HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
BEYOND HYWAYSPECIFIC TESTS
• Periodic samples water (from cathodic exhaust)
• Analysis of samples• Ion chromatography:
• F- Concentration
• ICP-MS• Catalyst: Pt, Co• Bipolar plate component: Fe, Cr, Ni, etc.
• Checking with data recorded on a single cell on test bench
Kangoo during water sampling
| 22HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
BEYOND HYWAYSPECIFIC TESTS
• Postmortem analysis• Identification of degradation occurring in the different components of
MEA and in bipolar plate
| 23HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
BEYOND HYWAYLINK WITH OTHER ACTIVITIES
Tech-Eco Studies on Hydrogen components
H2 Vehicles Monitoring
Specification
• Product definition• Manufacturing
process definition
Cost Database
• From suppliers’ quotations and literature
• Covers Rawmaterials, consumables, Production equipment and tools, Labour, Misc.
Cost Model
• Activity BasedCosting Method
Multiscale & multiphysics Modeling
H2 Station Monitoring
| 24HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
• CEA is following one of the biggest fleet of hydrogen vehicles in Europe• After 12 months of experiment:
• More than 190 000 km traveled• More than 1200 H2 refueling
• 1/3 of the vehicle in operation are intensively used• 1/3 of the fleet is moderately used• 1/3 of the fleet is poorly used• The global usage of the vehicle is increasing (user adaptation period to
this new technologies)• A lot of data are recorded at different scale to capitalize over the use of
PEMFC stack in real conditions.• These data will be used to optimise fuel cell system operation and to prepare
the next generation of fuel cell system
HYWAY PERSPECTIVES
IMPROVEMENT OF FUEL CELL SYSTEM FOR AUTOMOTIVE APPLICATIONS
HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
| 26HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
• Fuel cell system needs to be improved before a mass ive deployment
IMPROVEMENT OF FUEL CELL SYSTEM FOR AUTOMOTIVE APPLICATIONS
1. Decrease of system cost 2. Increase the overall system efficiency 3. Increase the durability of fuel cell system and fuel cell stack
Sources : D.O.E. & EU FCH-JU road map
| 27HYWAY | Séminaire Dautreppe | O. GUILLERMIN / S. ROSINI | décembre 2016
DECREASE OF COST FUEL CELL SYSTEM
~50%
50 % of stack cost is due to catalyst � Need to reduce catalyst loading and/or to
replace platinum by less expensive materials
� Increase of stack power density = decrease of number of components and as a consequence the cost of stack
50 % of system cost is due to stack
| 28
COST : DECREASE OF PLATINUM LOADING
Mat
urity
leve
l
Optimisation of platinum utilisation: Structuration of platinum supported electrode by physical deposition and electrode formulation
Example: MEA with 0.2 mgPt/cm²total loading (vs 0,5 mg/cm² ref, loading)
� no significant degradation after more than 2500 hours of operation in representative transportation conditions
Non platinum catalyst • Nitrogen doped catalyst,
A. Morozan, et al., Energy Environ. 2011 ; A. Morozan et al., ChemSusChem 2012.
• Bio-inspired Ni catalyst,….
Nanos-structured platinum catalyst• Core-shell structure,Galbiati et al., Electrochemica Acta 2014, 125, 107-116.
• Platinum nanotubesLepesant M. thesis 2014
• Mettalic alloy (PtNi; PtNiAu,…)
| 29
DECREASE OF COST :IMPROVEMENT OF STACK POWER
• Improvement of stack power is another key point to reduce the fuel cell stack cost and to facilitate s ystem integration. • Optimise water management at MEA scale• Optimise mass transport limitation through bipolar plates
optimisation and through electrode manufacturing
| 30
STRUCTURATION OF MEAS FOR WATER MANAGEMENT OPTIMISATION
L. Jabbour et al., Feasibility of in-plane GDL structuration: Impact on current density distribution in large-area Proton Exchange Membrane Fuel Cells, Journal of Power Sources, 299, 380-390, (2015)
Classical MEA: Homogeneous hydrophilic properties within the surface
Low current densities due to membrane dryingDecrease of catalytic utilisation
Homogenisation of current within the surface
Optimisation of hydrophilic properties over the surface by adding a gradient
Increase of hydrophobic properties
Air in
H2 out
H2 in
H2 out
| 31
STACK & BIPOLAR PLATE CONCEPTION
ACTIVE AREA DESIGN
QUALIFICATIONFLUIDIC MODELING
HOMOGENEITY OF FLOW DISTRIBUTION WITHIN THE
CHANNELSCHANNEL/RIB DESIGN MODELLING
BIPOLAR PLATE CAD
Material selection, gasket geometry, fluids inlet/outlet,
coating technology…
OUTPUTSPpile
Rendement pileUpile min/max
CourantSurface active
Pertes de charges
INPUTSPsystème
Rendement systUpile min/max
Densité de puissanceConditions opératoires
PRELIMINARY SIZING VS. SPECIFICATIONS
| 32
EXAMPLE OF MODELLING COMBINED WITH EXPERIMENTAL VALIDATION
Electrochemical and Thermal modelling of PEMFC stack including all components and with simplified water transport model
Measurement of water distribution within stack in real operating conditions @ NIST
SIM
ULAT
ION
EX
PE
RIE
NC
E
• Good correlation between experimental and simulation results
• Water distribution mainly linked to temperature distribution within the MEA surface.
F. Nandjou et al., IJHE, 41 (2016) 15573-15584
| 33
STACK DEVELOPMENTS
• Optimisation of MEA performances • Optimisation of bipolar plates performances • Decrease of the mass and volume of bipolar plates
ANR H2PAC GENEPAC
Industrial THERMOPAC
Program
Industrial NEIGE Program
Improvement of stack power density
> DOE & EU targets
| 34
DURABILITY ISSUES
Improvement of stack durability:
� Understanding of degradation phenomena occurring in real operation (Hyway
feedback)
� Mitigate degradation by
� materials designing
� and by optimisation of system control
Improvement of stack durability:
� Understanding of degradation phenomena occurring in real operation (Hyway
feedback)
� Mitigate degradation by
� materials designing
� and by optimisation of system control
Sources : D.O.E. & EU FCH-JUroad map
| 35
EVIDENCE OF HETEROGENEOUS DEGRADATION OF MEAAGED UNDER AUTOMOTIVE CONDITIONS
Laure Guétaz, Sylvie Escribano, Olivier Sicardy, Journal of Power Sources 212 (2012) 169-178
Aged MEAFresh MEA
XRD : 6 nmXRD : 3 nm
At air outlet (& H 2 inlet): high H 2O content induces classical Electrochemical Ostwald ripening
Aged MEAFresh MEA
XRD : 13 nmXRD : 3 nm
At air inlet (& H 2 outlet): fuel starvation induces reverse current mechanism
| 36
Commercial
FGLs+MWCNTs
IMPROVEMENT OF MATERIALS DURABILITY : DECREASE OF CARBON CORROSION
• Carbon corrosion occurs in fuel cell due to • Oxidant atmosphere• Start/stop
• Carbon corrosion induces • Loss of platinum (decrease of platinum surface)• Loss of porosity
• More resistant carbon for fuel cell electrode manufacturing• Carbon nanotubes • Graphene layer
FGL
MWCNT
Increase of electrode stability
| 37
EMS: OPTIMAL PREDICTIVE ENERGY MANAGEMENT FUNCTION OF FUEL CELL STATE OF HEALTH (SOH)
R. da Fonseca et al., Fundamental and Developments of Fuel Cell Conference (FDFC), Karlsruhe, 2013.
Modeling of degradation phenomena based on experimental studies:
Catalyst surface losses
10 5,02 % 11.9
5 4,95 % 12.1
1 4,3 % 13.3
( )% 0tSoH∆ kmHg2
As fuel cell is used in a hybrid configuration, we have one degree of liberty to manage the power between the fuel cell and batteryand maintain the fuel cell in targeted conditions
High potential: Ostwald ripening
High current: Starvation Hot point
Optimum durability
Pt d
egra
datio
nra
te (
m²/
s)
Stack power output (/W)
� Decrease of degradation using an optimised control command strategy
| 38
CONCLUSION
PEMFC is mature technology for automotive applicati ons.- Beginning of commercialization by OEM
Main achievements after ten years of R&D : - Decrease of platinum content without performance losses (/3)- Lifetime (at least 2500 hours) - Pmax about 1W/cm2 at stack level (x2)- Stack power density :3,5 kW/L (x2.5)
� Technology ready for early deployment
� Further R&D needed to fulfill manufacturers targets - Cost decrease (low platinum /platinum free catalyst,…)- Life Cycle Analysis (LCA)- Improved durability (by X2 to X3) - Feedback from field testing to orientate accurately R&D
Commissariat à l’énergie atomique et aux énergies alternatives17 rue des Martyrs | 38054 Grenoble Cedexwww-liten.cea.fr
Établissement public à caractère industriel et commercial | RCS Paris B 775 685 019
Thanks to CEA team involved in PEMFCdevelopment Thank you for your attention
Contact: olivier.guillermin@cea.frsébastien.rosini@cea.fr
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