Ecological fossil fuel alternatives

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List of deliverables

Deliverable Title

Summary

Complete deliverable

D1.2: Project shared workspace implemented and operational

To fulfil two fundamental internal project communication requirements: i) efficient exchange between partners of information about VOLUMETRIQ project ii) decentralised and secured archiving of the documents generated, one independent and secured web-based communication tool: Project Shared Workplace – PSW has been implemented with a restricted access for project partners only.Among all the functionalities installed on this PSW, for now partners have a total access to the following tools:
  • Document sharing and archiving
  • Meeting organization
  • General project communication
  • Online working document
  • Individual project management
The PSW maintenance is therefore an on-going activity that will go along with the project lifetime.
D1.2 
D2.1: Stack requirements provided for further component analysisThis deliverable concerns a set of fuel cell stack requirements which have been derived from vehicle specifications defined by the OEMs. The project target is to build a fuel cell stack of 90 kW continuous power at specific operating conditions as described in this report. The requirement specifications will be used to further breakdown the necessary component properties in order to fulfil the general system requirements D2.1
D2.2: Stack component requirements derived and agreed amongst component and stack development partnersThis document contains the key stack component requirements for the VolumetriQ project and covers, bipolar plate, gasket, sealed coated catalyst membrane and gas diffusion layer. The component requirements were derived from the stack performance and test requirements provided by OEM’s. D2.2
D2.3: Stack component test scope and procedures

This deliverable concerns test scope and test procedures corresponding to the general requirement specifications as described in D2.1. The goal is to ensure repeatability of test results and to define representative operating conditions and test protocols. This will close the loop from stack specification to test verification. The test results can then be compared to the initial set of requirements and prove the compliance of the product. Test conditions will be delivered for the following operating conditions:

1.    Test conditions for polarisation curves
2.    Leak test procedure
3.    Freeze start sequence
4.    Start –up and shut-down sequence
5.    Drive cycle as reference conditions for durability tests

Other, safety related test requirements, will be treated elsewhere as for example described in ISO-Standards or OEM test standards.

D2.3

D3.3: Supply of components for membrane after second material improvement in line with target characteristics defined

Reinforced membranes comprising ePTFE reinforcement are a standard for automotive fuel cell application given the low thickness and the better mechanical properties compared to competitive technologies, despite a series of unsolved issues defining some limits to this technology.
The introduction of an innovative material (PBI) and an innovative reinforcement geometry (open web) is key for further improve performance of automotive fuel cell membranes. The ionomer used for impregnation must be designed around this innovative structure, must be highly stable and conductive in the typical conditions of automotive fuel cell; the solvent formulation must be selected to be compatible with the support and ionomer in order to keep the open web structure as such during solvent evaporation. Additionally, specific chemical scavenger, must be used to improve the chemical stability of the ionomer membrane. Specific ionomer must be also developed for the cathode side electrode to prevent oxygen diffusion limitation when low Pt loading is used.
The aim of WP3 is the development of innovative material which will be then integrated in reinforced membranes and MEAs.
A second set of materials is presented in this deliverable after 28 months of activities
Confidential
D4.1: Baseline CCM supplied for testingThe project Baseline MEA, developed in the former FCH JU project MAESTRO, based on a reinforced membrane comprising electrospun PBI reinforcement and Solvay Aquivion ionomer has been provided and tested successfully using ex-situ characterisation techniques and in-situ beginning of life single cell performance measurements. The Baseline MEA performance was extremely promising, especially under hot, dry operating conditions, but mechanical strength of the membrane still needs to be improved in order to meet the project durability targets.Confidential
D4.2: CCMs meet 2.0 A/cm2 at 0.6 V in relevant single cell protocolThis report summarises the Membrane Electrode Assembly development work carried out by Johnson Matthey Fuel Cells and ElringKlinger (EK) to meet the mid-term performance target of 2.0 A/cm2 at 0.6 V in an EK NM5 type single cell.  The development successfully focussed on catalyst coated membrane (CCM) components compatible with high volume processes and the optimisation of said processes to maximise screener single cell performance. Initially the developed CCM performance did not translate well into the NM5 single cell and did require optimisation of its in-cell compression as well as the introduction of an alternative gas diffusion layer (GDL), first introduced in FCH 2 JU project INSPIRE (700127), in order to maximise its performance and achieve the mid-term performance target.Confidential
D5.1: Optimum bipolar plate design for performance and manufactureThis report describes the bipolar plate (BPP) optimisation work carried out by ElringKlinger (EK) to meet the high performance targets of 2.5 A/cm² @ 0.6 V in an automotive fuel cell stack of the next generation. BPP design in particular flow field patterns were optimised based on EK’s current available NM5 stack technology showing the potential of meeting high performance targets.
Beside performance aspects, the development work focussed on design issues ensuring a plate layout compatible with high volume processes. Quality control methods for series production of BPPs were optimised and evaluated to finally implement these techniques at EK’s BPP production line.
Confidential
D5.2: Production process and quality control methodology for plate manufactureHigh-precision bipolar plates with low tolerance variations are key components for automotive stacks with their demand for very high power densities and reliability. With the confirmation that a specific technological approach has been identified to meet these targets in a prototype manufacturing environment, it is still challenging to transfer such concepts to high volume production lines. This report describes EK’s experience with high speed production tools and its established manufacturing technology to produce automotive bipolar plates in a series production including related quality control methods.
Furthermore an introduction is given to the improvements on the manufacturing processes and the in line quality measurements developed within VOLUMETRIQ.
D5.2
D6.1: Optimised CCM supply and stack assembly processCCM supply is an important process of the stack assembly due to high costs of the material itself. Therefore it is necessary to utilise as much of the catalyst coated membrane as possible. CCMs are mainly produced directly on rolls so that the further processing has to adapt to this design, ensuring a maximum output of the used material. Furthermore the feeding, processing and process linking has to be analysed and adapted where appropriate to meet the high utilisation rates demanded to minimise costs. Within VOLUMETRIQ, punching and cutting processes for CCM supply were analysed in detail and the most promising technique was identified as rotary die cutting. Satisfying results regarding form tolerance as well as fringes and form defects especially in the edge regions of CCM sheets were achieved at high web speeds. Future work should consider methods to achieve process capability for the identified parameters of the performed tests. For CCM handling, a cycle time improvement of 61 % compared to the current CCM handling process in EK´s automated cell assembly was tested. Assuming the CCM is more critical than the GDL with respect to handling processes, results and identified parameters can be transferred for handling the GDL using a parallel robot and similar vacuum gripper. The knowledge gained in handling MEAs will be transferred to other handling processes in the stack assembly line, in particular to the stacking process. Initial tests of the automated stack assembly line confirmed chosen handling, transfer and assembling processes embedded in EK’s automated stack assembly line. A roll feed automated CCM supply unit was successfully integrated and tested. Concepts for a high volume production have been worked out, having the potential to reduce the cycle time of the whole MEA assembly process of approximately 72 %. Furthermore concepts for very high volume productions, in particular for the MEA assembling process, have to be developed and if possible tested and evaluated.Confidential
D6.2: Key Component Parameters For Stack ComponentsIn order to establish a robust and consistent volume manufacturing process, it is necessary to build and deliver stacks with little standard deviation concerning performance and lifetime. Therefore, it is crucial to identify the most significant key component characteristics and to define them in a way that process capability targets of the stack are met.
Potentially significant parameters were identified. They were then evaluated using sensitivity analysis and design iteration to identify critical quality control parameters for each component including tolerances and mean values. The impact of component misalignment on cell-to-cell balance was also evaluated.
Confidential
D7.1 Project WebsiteThe VOLUMETRIQ project website is designed to fulfil project communication and dissemination needs in the direction of the whole scientific community and the public through relevant information including:
  • project overall objectives, partners & structure information
  • project activities: news, meetings, publications …
  • project resources: links, related events …
  • project contact information

All the partners will collectively participate in the dissemination objective of the website by providing up-to-date information

D7.1 
D7.2: Dissemination and knowledge management protocol To protect the intellectual property rights, confidentiality and the legitimate interests of the partners, a Dissemination Protocol is necessary so, information to be communicated or disseminated will be managed and receive the agreement of the Project Steering Committee before the information is deemed publishable.D7.2

D7.3: Dissemination and communication bundle

During the first 24M of the VOLUMETRIQ project, various dissemination and communication measures have been undertaken by the consortium. Target groups include industry, academia, government bodies and the public.D7.3
 

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