ACstyria Hotspot FCHBuilding Synergies for Mobility –

The European Perspective

Graz, October 22 and 23, 2015

Fuel Cells in Heavy DutyVehicles and Stationary

ApplicationsPeter Prenninger | AVL

TOGETHER WE MOVE

FUEL CELLS IN HEAVY DUTY VEHICLES AND STATIONARY APPLICATIONS

AC STYRIA HOTSPOT FCH /H2

Peter Prenninger, Juergen Rechberger

AVL List GmbH

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 3

KEY FIGURES

5 powertrain

elements

EXPERIENCE

65 years!

GLOBAL FOOTPRINT

30 engineering locations

>220 test beds Global customer support

network

ONEPARTNER

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 4

RESEARCH 10% of

turnover in-house R&D

STAFF

7.470 employees

65% engineers &

scientistsINNOVATION 1500granted patents

GROWTH

SALES 1991:

0.1 billion €

2014:

1.15 billion €

prev. 2015

1.3 billion €

FIVE ELEMENTS OF THE POWERTRAIN

BATTERY & FUEL CELL

IC ENGINE

TRANSMISSION

CONTROL STRATEGYELECTRIC MOTOR

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 5

SOLUTIONS FOR ALL CUSTOMER SEGMENTS

Powertrain Engineering

Simulation & Testing

Development PlatformConstruction

Passenger Cars

Racing2-Wheelers

Commercial Vehicle

Agriculture

MarineLocomotive

Power Plants Aviation

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AVL POWERTRAIN DEVELOPMENT NETWORK OF TECHNICAL CENTERS

Ann Arbor, USAPlymouth, USA

Basildon, UK

Shanghai, CHN

Paris, FRA Lake Forest, USA

Remscheid, GERMunich, GER Stuttgart, GERRegensburg, GERNeuenstadt, GER Ingolstadt, GER

Sao Paulo, BRA Sydney, AUS

Coventry, UK

Tianjin, CHN

Steyr, AUT

Haninge, SWE

Södertälje,SWE

HQ Graz, AUT

Gotenborg, SWE

+ another

9 Engineering

Offices

Delhi-Gurgaon, IND

Tokyo, JAP

Seoul, KOR

Budapest, HUN Gebze, TUR

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 7

CONTENT

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 8

AVL Fuel Cell Systems

AVL SOFC Products

3kW mobile APU

10kW stationary power generator

Summary

CONTENT

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 9

AVL Fuel Cell Systems

AVL SOFC Products

3kW mobile APU

10kW stationary power generator

Summary

AVL FUEL CELL SYSTEMS

SOFC APU3kW Diesel fuelled

portable power

generator for truck,

marine and defence

applications

SOFC CHPDevelopment of a

SOFC CHP unit for

decentralized power

generation (>60%

electrical efficiency)

AVL R&D since 2002 with expert team and fuel celllaboratory (currently 10 fuel cell test benches -single cell to 30kW(1) stack/system testing)

Focus AVL Fuel Cell Technology:

Development-, optimization-, test- and integrationof fuel cell systems (PEM & SOFC)

Diagnoses and monitoring systems

PEMFC and SOFC CFD simulation

Component development (e.g. media supply, reformers,…)

Reliability and durability development & validation

Simulation/design/packaging/system integration

Species mole fractions (-):

O2

x

H2 H2O N2

y

z

CFD SimulationPEM & SOFC CFD

simulation with multi

physics codeAVL

FIRETM

AVL THDATM

Industry leading

PEM stack

monitoring (in use

by 6 auto OEMs)

PEM SystemsCustomer specific

system development

and integration

(1)… upgrade to 150kW already initiated

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 10

AVL FUEL CELL ACTIVITIES

Testing &

Benchmarking

Component

developmentPrototype development

System

Validation

Vehicle Application

Simulation (thermal, mechanical, electrochemical)

Control system

development

Stack Diagnoses and

on-board monitoring

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 11

MAIN APPLICATION AREAS

Heavy Duty Trucks

Anti idling regulations

Fuel cost savings

CO2 credits

Low noise

5min idling ban

Marine

Power supply of hotel loads

of small to medium yards

Low noise operation

Same fuel as main engine

No harmful emissions

Silent watch

Mission duration

Fuel cost reduction

Logistic fuel

Special Vehicles

Range Extender(Long term)

Conventional fuel

High efficiency

Low noise operation

No harmful emissions

Long range & fast refill

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 12

AVL SOFC APU (AUXILIARY POWER UNIT)

Mobile power Diesel fuelledwithout noise and emissions! Other markets:

Remote Power Supply

Marine

Special Vehicles

Design Targets:

3kW electrical power

10kW thermal power

el. efficiency ~35%

Fuel: road diesel (< 15 ppm S)

80L, 75kg

~ 55dB(A) noise

8000h lifetime

300/3000 cold/warm cycles

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AVL SOFC APU GENERATION I

APU Stack Module

Anode blower

Air blower

Gas processing unit

Incl. reformer, start-burner,

off-gas cleaning,heat

exchange,manifoldingValves

Fuel pumps

STAND ALONE SOLID OXIDE FUEL CELL AUXILIARY POWER UNIT

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AVL APU GENERATIONS

Gen. 1.0 Gen. 1.1 Gen. 2.0

nominated for

Austrian

Innovation

Award 2013

Gen. 3

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 15

AVL SOFC APU Gen. 2

• 3kW electrical power

• 10kW thermal power

• el. efficiency ~35%

• Fuel: european road diesel (< 10 ppm S)

• 75L, 60kg

• < 55dB(A) noise

AVL SOFC APU Gen. 1

• 1,5kW electrical power

• 10kW thermal power

• el. efficiency ~28%

• Fuel: sulfor free diesel (< 1 ppm S)

• 90 L, 100 kg

• < 75dB(A) noise

STAND ALONE APU TESTING

Stack eff. ~ 35%

Cycle eff. ~25%

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Gen II APU on test rig

Prototype power electronics

APU DEMONSTRATION PROJECTS

Significant advantages

due to low noise and

compatability with vehicle

fuel

Demo project in

cooperation with:

AVL program is focused at the

moment on a first commercial

small-series for special

applications. Market release in

2017 intended.

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DEVELOPMENT OF MSC SOFC TECHNOLOGY

New cell concept enabling

various applications due to:

Rapid start up capability

Robust cell due to elimination of

most ceramics

Lower temperature operation

High power density

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 18

This new cell concept enables applications such as passenger

car range extenders based on conventional fuels!

Electrical efficiency (DC) of 55 % at 6 kWel demonstrated

Stable operation at different loads from 30% to 110% of rated

power

No observable degradation after 1.500 h of dedicated testing

Hot gas anode recirculation concept confirmed

Start-up time about 10 h

Total system testing > 3.000 h

Component test results available for >15.000 h

Acceptable noise of system without acoustic measures in

operation

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 19

RESULTS ACHIEVED (1ST GEN)

CONTENT

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 20

AVL Fuel Cell Systems

AVL SOFC Products

3kW mobile APU

10kW stationary power generator

Summary

DEVELOPMENT OF A SOFC CHP PLATFORM

Development Targets:

Complete stand-alone ~5-10 kWel modular system platform as a

basis for commercial SOFC CCHP products in the power range of

5-500 kW

Electrical efficiency > 55 %, Total efficiency > 90 %

Water neutral operation

Lifetime: 80.000 h (design target)

Cost target <2000 €/kW (for series product with appropriate

Partners: Stack

System

Stack module

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SOFC CHP – HOW DOES IT WORK?

HEX

HEX

Reformer

Brenner

StackModul

Verdichter

Verdichter

NG

Luft

Anode

Kathode

Desulf.

Heating Cooling Electricity

>60% Electric Efficiency

~90% Total Efficiency

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 22

COMPONENT DEVELOPMENT

Start-up burner(for combustion with

preheated air)

Desulphurizer

Air

NG

Exhaust

4

2

0

6

8

10

Reformer B

Reformer C

Reformer D

18

16

14

12

350 400 450 500

Reformer Temperatur [°C]

550 600

CH

4 -

Mo

lverh

ält

nis

[%]

Reformer A

Reformer(Natural gas steam reforming)

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STACK MODULE DEVELOPMENT

integration of single stacks to achieve desired output power

Key challenges: thermal integration & gas distribution

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 24

SYSTEM DESIGN AND PACKAGING

Front

19

30

900

Rear

Hotbox

BoP

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OPERATION: 500 h TEST @ 3.3 & 6.0 kWEL

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SOFC CHP: RESULTS & CONCLUSIONS

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SOFC as most efficient technology to convert natural gas into electricity, especially on small- to medium scale for distributed generation.

10kW SOFC CHP platform developed with international partnersfrom industry and academia

Platform as building block for larger systems from 20kW to 500kW.

Potential of SOFC CHP to completely replace gas engines in stationary power generation and CHP applications.

CONTENT

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 28

AVL Fuel Cell Systems

AVL SOFC Products

3kW mobile APU

10kW stationary power generator

Summary

SUMMARY

Fuel Cells in Heavy Duty Vehicles and Stationary Applications | Peter Prenninger | 2015-10-22 | 29

AVL APU featuring the highest power density SOFC system in the world reaching 3kWel, 30% efficiency, below 55dB(A) noise operated on conventional diesel fuel (ULSD)

Costs, durability and sulfur tolerance as remaining challenges.

Multi-fuel capablility: only modifications for NG, CNG, LNG, propane, butane, LPG, methanol, ethanol,…

Cost level of Diesel engine gen-sets to be reached in the timeframe of 2020-25

First series product (e.g. for special vehicles) possible in 2017

MSC SOFC technology as significant improvement of SOFC APU comparedto state-of-the-art ASC technology.

AVL as provider of prototypes for demonstration projects and small scaleseries products up to licence agreements for local manufacturing & salespartnerships

www.avl.com

THANK YOU

ACStyria Autocluster

Parkring 1

8074 Raaba-Grambach

AUSTRIA

www.acstyria.com

+43 316 40 96 96 - 0

TOGETHER WE MOVE