Ballard Power Systems

Ballard Power Systems

Fuel Cells – Current Status and Prospects for the Future

David Musil, P. Eng.Project Engineer, Advanced Automotive Development

March 30, 2006

2 March 30, 2006

Outline

1. Background on Ballard Power Systemsa. Brief Historyb. Technical Progress to Date

2. Current Status and Benefitsa. Benefits of Fleet Programs to Fuel Cell Developmentb. Remaining Challenges

3. Future Developmenta. Ballard’s Next Generation Fuel Cell Stackb. Future Development of Fuel Cellsc. Path to Commercialization

4. Conclusions

3 March 30, 2006

Outline

1. Background on Ballard Power Systemsa. Brief Historyb. Technical Progress to Date

2. Current Status and Benefitsa. Benefits of Fleet Programs to Fuel Cell Developmentb. Remaining Challenges

3. Future Developmenta. Ballard’s Next Generation Fuel Cell Stackb. Future Development of Fuel Cellsc. Path to Commercialization

4. Conclusions

4 March 30, 2006

History of Ballard Power Systems

Founded in 1979 under the name Ballard Research Inc. to conduct research and development in high-energy lithium batteries.

In 1983, Ballard began developing proton exchange membrane (PEM) fuel cells.

Proof-of-concept fuel cells followed beginning in 1989.

From 1992 to 1994, sub-scale and full-scale prototype systems were developed to demonstrate the technology.

To date, Ballard has supplied fuel cells for over 130 fuel cell vehicles in 24 cities worldwide, including the CUTE, STEP, China, and California fleet bus programs, and Daimler Chrysler, Ford, and Honda automotive fleets.

Ballard also builds fuel cells for non-automotive and stationary applications.

5 March 30, 2006

Ballard’s Fuel Cell Progress

Power Density [W/L] of Ballard's Fuel Cell Products

1133.31109.01096.5

360.3

771.7

0.0

200.0

400.0

600.0

800.0

1000.0

1200.0

1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002

Time [Years]

Pow

er D

ensi

ty [W

/L]

Mk 901 Mk 902Mk 8

Mk 7

Mk 5

6 March 30, 2006

Mk902 LD and HD Stacks

Based on Light Duty (LD) automotive stack architecture

Cell active area and terminal voltage sized for automotive application.

Modular design designed for ease of repair.

MK902 Light Duty (LD)

Mk 902 LD Mk 902 HD

4 cell row 6 cell row

440 Cell 960 Cell

85kW/300A 150kW/240A

MK902 Heavy Duty (HD)

7 March 30, 2006

Outline

1. Background on Ballard Power Systemsa. Brief Historyb. Technical Progress to Date

2. Current Status and Benefitsa. Benefits of Fleet Programs to Fuel Cell Developmentb. Remaining Challenges

3. Future Developmenta. Ballard’s Next Generation Fuel Cell Stackb. Future Development of Fuel Cellsc. Path to Commercialization

4. Conclusions

8 March 30, 2006

Fuel Cell Vehicle Design Cycle

Fuel Cell Vehicle

Design Iteration

Specifications Development

Concept Development <CR Phase>

Implementation Readiness

<IR Phase>

Design Verification

<DV Phase>

Job 1

Research and Development

3 years

2 -3 years

1-2 years1 year

1 year

9 March 30, 2006

Bus Cell Row Lifetime Status (Data to end of 2005)

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000+

Cell Row Operating Hours (Hrs)

Nu

mbe

r of

CR

's

CR Operational

CR Failed

Early Life Failures

(0 – 1000 Hours)

Mid-Life Failures

(1000 – 2000 Hours)

Long Life Failures

(2000+ Hours)

10 March 30, 2006

Number of Bus Failure Modes (Mk 902 – Data to end of Dec 2005)

Bus Stack Module Failure Mode Resolution Progress

-15

-10

-5

0

5

10

Sep-02

Dec-02

Mar-03

Jun-0

3

Sep-03

Dec-03

Mar-04

Jun-0

4

Sep-04

Dec-04

Mar-05

Jun-0

5

Sep-05

Dec-05

Time

Num

ber o

f Act

ive

Failu

re M

odes

Require Further Investigation

Resolution Planned

Failure Mode Resolved

Supplier Defects, Manufacturing Issues, Stack/System Interface Issues, and Random Failures of Relatively High Frequency

Random Failures of Relatively Low Frequency, Wearout, Robustness, and Materials Development/Durability

11 March 30, 2006

Mk902 – Failure Modes

Principle failure mechanisms of the Mk902

LeaksChemical attack of membraneContaminants in platesFatigue

Performance LossCorrosionCatalyst damage

Low CellsRandom failure modes leading to localized damage (usually

repairable)

12 March 30, 2006

Benefits of Fleet Programs to Fuel Cell Development

Generation of “real-world” data not available from labs.

Large data set helps identify and eliminate short, medium, and long-life failure modes.

World-wide exposure of fleets enables fuel cells to operate in numerous driving and environmental conditions. This leads to improved fuel cell designs and more realistic driving simulations in the laboratories.

Development of support industry and training of maintenance and support workers.

13 March 30, 2006

Benefits of Fleet Programs to Fuel Cell Development

Fleet programs provide validation of environmental regulation implementation schedules.

Data gathered from fleet vehicles allows for advances and changes in codes and standards for safety and certification (ex. Hydrogen emission standards - SAE J2578).

Operating conditions, specifications, and test methods can be applied to other automotive and non-automotive fuel cell applications.

14 March 30, 2006

Mk902 – Remaining Challenges

Desirable features lacking in Mk902

High temperature operationHigh temperature enables smaller fuel cells, lower cost, smallerradiator

Low catalyst loading and high power densityPrinciple material cost drivers

Low relative humidityComplicated reactant gas humidification system drives cost and volume

FreezableMk902 series is not freezable. Requires additional support equipment to permit outside storage.

15 March 30, 2006

Outline

1. Background on Ballard Power Systemsa. Brief Historyb. Technical Progress to Date

2. Current Status and Benefitsa. Benefits of Fleet Programs to Fuel Cell Developmentb. Remaining Challenges

3. Future Developmenta. Ballard’s Next Generation Fuel Cell Stackb. Future Development of Fuel Cellsc. Path to Commercialization

4. Conclusions

16 March 30, 2006

Next Generation Improvements

1. Power Density ImprovementsImproved catalystsLower cell pitchHigher cell performance

2. Improved DurabilityMembrane improvementsCatalyst improvementsSeal material improvements

3. Freeze start capability

4. Higher temperature operation

5. Lower relative humidity operation

6. Lower costHigher cell performance requires less materialLower cost materials

17 March 30, 2006

Technology Roadmap

…in one fuel cell design

REDUCING COST

INCREASING DURABILITY

INCREASING POWER DENSITY

IMPROVING FREEZE START

Ballard will demonstrate commercially

viable automotive

technology by 2010

Based on U.S. Department of Energy (DOE) Requirements.

Ballard publishes the technology updates yearly.

Forms the basis of “must meet” requirements internally.

Roadmap requirements are cascaded to component and stack roadmaps, and the technology routemap.

18 March 30, 2006

Stack Power Density

19 March 30, 2006

Durability

20 March 30, 2006

Freeze Start

21 March 30, 2006

Cost

22 March 30, 2006

Fuel Cell Vehicle Adoption

Today - 2007 2008 - 2012 2012 - 2014

CARB target: 25,000 fuel cell vehicles

Initial limited production

More fueling stations

CARB target: 2,500 fuel cell vehicles

Controlled central fleet demonstrations

100s of vehicles

Customer demonstration programs

50% plus powered by Ballard

DEVELOPING TECHNOLOGY FOR LIMITED COMMERCIAL INTRODUCTION

PROVING THE TECHNOLOGYON THE ROAD

MANUFACTURING FOR COMMERCIAL INTRODUCTION

23 March 30, 2006

FCV Commercialization Scenarios

Note: Based on Hybrid experienceSource: Office for the Study of Automotive Transportation (UMTRI), JD Power, Monitor Analysis

0

250

500

750

1,000

1,250

1,500

2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023

OptimisticBaselinePessimistic

Units

(000s)

Potential FCV Market Adoption Curves (Based on Hybrid Experience)

Pre-Commercial Activities

Variable 2: FCV Adoption RatesOptimistic: 250k in 6yrs; 500k in 6yrsBaseline: 250k in 6yrs; 500k in 7yrs

Pessimistic: 250k in 6yrs; 500k in 9yrs

Variable 2: FCV Adoption RatesOptimistic: 250k in 6yrs; 500k in 6yrsBaseline: 250k in 6yrs; 500k in 7yrs

Pessimistic: 250k in 6yrs; 500k in 9yrs

Variable 1: Commercial Launch DateOptimistic: 2012Baseline: 2013

Pessimistic: 2015

Variable 1: Commercial Launch DateOptimistic: 2012Baseline: 2013

Pessimistic: 2015

24 March 30, 2006

Outline

1. Background on Ballard Power Systemsa. Brief Historyb. Technical Progress to Date

2. Current Status and Benefitsa. Benefits of Fleet Programs to Fuel Cell Developmentb. Remaining Challenges

3. Future Developmenta. Ballard’s Next Generation Fuel Cell Stackb. Future Development of Fuel Cellsc. Path to Commercialization

4. Conclusions

25 March 30, 2006

Concluding Remarks

1. Background on Ballard Power SystemsBallard has been developing PEM fuel cells since 1983.Ballard fuel cells have made huge gains in power density since 1993.

2. Current Status and Benefits

Fleet programs generate data that enables learning which can be applied to future fuel cell designs. The current design shows many advances, but is not optimal.

3. Future Development

Ballard's next generation fuel cell has progressive technology improvements aligned with long term targets established by governments and industry.Achieving the long term targets will demonstrate a commercially viable automotive fuel cell design in 2010.

26 March 30, 2006

Concluding Remarks

1. Background on Ballard Power SystemsBallard has been developing PEM fuel cells since 1983.Ballard fuel cells have made huge gains in power density since 1993.

2. Current Status and Benefits

Fleet programs generate data that enables learning which can be applied to future fuel cell designs. The current design shows many advances, but is not optimal.

3. Future Development

Ballard's next generation fuel cell has progressive technology improvements aligned with long term targets established by governments and industry.Achieving the long term targets will demonstrate a commercially viable automotive fuel cell design in 2010.

27 March 30, 2006

Concluding Remarks

1. Background on Ballard Power SystemsBallard has been developing PEM fuel cells since 1983.Ballard fuel cells have made huge gains in power density since 1993.

2. Current Status and Benefits

Fleet programs generate data that enables learning which can be applied to future fuel cell designs. The current design shows many advances, but is not optimal.

3. Future Development

Ballard's next generation fuel cell has progressive technology improvements aligned with long term targets established by governments and industry.Achieving the long term targets will demonstrate a commercially viable automotive fuel cell design in 2010.