Fuel Cell Engineering Services

®
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Smarter Solutions for a Clean Energy Future
Fuel Cell Engineering Services
Smarter Solutions for a Clean Energy Future
Corporate Background
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• Ballard Power Systems, Inc. is a recognized global leader in clean energy PEM fuel cells
• Design, manufacturing, distribution & support
• Multi‐market focus – backup power, material handling equipment, distributed generation & buses
• 2012 revenue of $59.2M
• 355 employees
• Headquarters in Burnaby, BC, Canada
• Operations: Canada, Denmark, U.S.A. (University of Maryland & Bend, OR [formerly IdaTech])
Burnaby HQ facility
Maryland
Bend, OR
Hobro
USA
USA
Denmark
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Ballard – Unrivalled PEM Intellectual Property Portfolio
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Over 200 patents/applications owned and license rights to >1,000 patents/applications owned by Daimler, Ford & IdaTech
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MEA designs
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Plate designs
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Catalyst Coated Membranes
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Gas Diffusion Layer materials
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Fuel cell systems
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Manufacturing processes
Fundamental knowledge in key areas of stack operation, system integration and fuel processing
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Fuel Cells in the Field
~2,000 installed telecom systems
>3,000 forklift trucks operating NASDAQ:BLDP ~45 fuel cell buses operating 
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+300 fuel cell cars operating • Ballard is experienced in developing technology to customer requirements, success mainly driven by development approach learned from Ford and Daimler April 4, 2013  4
Automotive Fuel Cell Development
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• Extensive experience in automotive fuel cell technology
• Vehicular Fuel Cell Alliance with DaimerChrysler & Ford
• Hundreds of units supplied to Alliance partners & other OEMs
• Meet Tier 1 supplier requirements
• Technology development program enabled:
• Reduced cost, enhanced reliability, increased lifetime, improved manufacturability, freeze start capability, higher power density
• Features have been transferred to today’s commercial products
• Products manufactured to automotive quality standards:
• ISO certified
• APQP
• Six Sigma tools and methodologies
• Process and designs verified and validated
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Automotive Customers
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• By 2011, Ballard had supplied >500 fuel cell products to 9 of the top automotive companies April 4, 2013  6
Fuel Cell Product Portfolio
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Fuel Cell Stacks
• 500W‐2kW
• >4k hrs
Fuel Cell Modules
Complete Fuel Cell Systems
• 2kW‐8kW
• Up to 30k hrs
• 4kW‐20kW
• Up to 12k hrs
• 100kW
• >5k hrs
• 75kW‐150kW
• Up to 12k hours
• 2kW & 5kW • Direct hydrogen
• Rack‐
mountable & outdoor
• 2.5kW & 5kW • Methanol fuelled
• Outdoor
• Multi‐MW power
Ballard product portfolio includes industry‐leading fuel cell stacks, fuel cell modules and complete fuel cell system solutions ... average product cost reduction of 60% in 2009‐12 timeframe
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World Class Product Development & Manufacturing Capability
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• Fully equipped R&D engineering and test center
• 58,000‐square foot hydrogen‐safe test lab accumulates roughly 400,000+ hours of in‐house testing each year with integrated data collection and reporting
• Test stands are capable of simulating duty cycle conditions for a range of product applications
• Test station capacity <100 W to 333 kW
• High‐volume PEM fuel cell manufacturing facility
• Automated manufacturing techniques replace discrete, labor intensive processes in 110,000‐square foot facility • Sufficient capacity through 2013, with capability to scale‐up production
• kW‐scale fuel cell system production
• Flexible, low‐cost manufacturing in facilities located in Hobro, Denmark and Tijuana, Mexico
• Annual capacity for >5,000 ElectraGen™ units April 4, 2013  8
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Engineering Services
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Fuel Cell Engineering Services
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• Ballard’s engineering services provide a high‐value way to accelerate your fuel cell development efforts
• Our team provides tools and technologies for development, optimization, integration and validation of fuel cell components, stacks and systems • Leverage a high level of competency in a range of specialized activities, including:
• Applications engineering
• Reference systems • Product development
• Fuel cell testing services
• Simulation and modeling
• Failure analysis
• Infrastructure improvement
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Applications Engineering
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• Ballard’s unique knowledge of PEM fuel cells supports fuel cell stack customers in their system design and integration activities
1.
Provides guidance in determining appropriate Ballard fuel cell stack for customer’s application
2.
Supports customer’s system design efforts, through expertise in:
• Evaluating tradeoffs at stack/system level
• Stack/system interfaces and interactions
• Troubleshooting during design process
• Material selection & compatibility
• Component selection & sourcing
• Codes & standards, certification
FCvelocity™‐HD6 power module integrated into bus system
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Automotive Industry Requirements
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• Ballard has experience providing fuel cells for the automotive and transportation industries. • Design for shock & vibration, experience with modeling and testing for shock & vibration
• Stacks capable of being subjected to, and starting in freezing conditions. Dynamic test stations that can test fuel cells and systems under these conditions
• Design and conformity testing for ISO and SAE standards for fuel cells in transportation applications
• EMC/EMI testing at the component and vehicle level
• System design and experience with in‐service fleets, keeping contaminants out, and making system components robust to harsh environments
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Reference Systems
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• Ballard’s reference systems can dramatically reduce development time for a wide variety of stationary and motive power applications
• Leverage existing reference system design to begin customization to meet specific application requirements
• Provides baseline for technology evaluation
• Acts as a test platform for ongoing component development
• Prototype reference systems include major balance of plant components:
• Air compressor
• Coolant pump
• Hydrogen pressure control
• Hydrogen recirculation pump
• Controller and control software
Prototype liquid‐cooled reference system, incorporating FCvelocity™‐9SSL fuel cell stack
• Documentation and specifications for system and major components
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Product Development
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• Ballard offers custom services in all aspects of product design & research ranging from components through to prototype fuel cell stacks and complete systems
• System modeling & design
• Balance of plant components
• Hardware
• Bi‐polar plates
Prototype light‐weight, low‐power air‐cooled fuel cell stack concept • Membrane electrode assembly (MEA)
• Catalyst coated membrane (CCM)
• Gas diffusion layer (GDL)
• Utilize automotive robust engineering design practices
• Apply rigor of a Tier 1 automotive supplier
• Focuses on early concept risk assessments, parameter‐
diagrams, failure modes and effects analysis (FMEA) and design verification against the DFMEA
Bi‐polar plate designs
• Evaluation of tails of design and operation
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Fuel Cell Testing Services
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• Specialized testing protocols for characterizing fuel cell stack technologies
• Benchmark Ballard and OEM components, stacks or hardware
• Push operational boundaries – run application‐specific operating conditions
• Ballard’s accelerated testing protocols minimize total test time, accelerating stresses by up to 150x
• Comprehensive suite of test stands capable of simulating duty cycles and environmental conditions for a range of product applications
• 60+ test stations can perform tests such as dynamic, durability, freeze start, ambient start and system representative testing
• Sizes range from components, single cells, and small stack testing, to large bus fuel cell module testing • Accelerated test methodologies
• Flexible fueling options
Ballard test facilities in Burnaby, BC
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Failure Analysis
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• Ballard applies structured processes (FRACAS, 8D) to identify and resolve material and product failure issues
• Wide array of analysis tools available to understand how components change with use, and over time, and how those changes may lead to failure
• In‐depth knowledge of fuel cell failure modes and contamination
• Services available range from raw data files to a full analysis of the results
• Areas of expertise include:
• SEM and optical microscope investigation
• Catalyst degradation & content analysis
• Leak testing and leak location
• Chemical analysis and contaminant identification
• Characterization of material degradation
• Validating test protocols & field data
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Simulation & Modeling
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• Ballard has developed sophisticated in‐house modeling capability that can be leveraged to reduce design time
• Fuel cell performance models accurate to ±2% of cell voltage
• Membrane durability and performance degradation models to predict time to failure under different load cycles, or in different operating conditions
• Flow and thermal analysis – in the system, stack, or unit cell
• Water management modeling in flow fields and MEAs
• Structural analysis for compression of MEAs, seals, plates and stack hardware
• Services available range from model results, analysis reports or executable models
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Infrastructure Improvement
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• Capitalize on know‐how gained in development of Ballard’s world‐class R&D, test and production facilities
• Test station design and build
• From a simple load bank to run a reference system, to high‐power dynamic test stations, Ballard can design
and deliver custom test solutions for your facility
• Consultation services for:
• Hydrogen infrastructure, use and safety within facility
• Class 1, Div 2 lab environment
• Lab and facility layout and design
• Fuel cell manufacturing pilot plant and layout
• Clean room design
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Engineering Services for Fuel Cell Developers
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• Ballard has extensive knowledge, research capability and specialized equipment that is extremely valuable to fuel cell and fuel cell component developers
• Material Analysis and Testing
• Structural properties of fuel cell materials
• Tensile strength testing (Instron), DMA, environment chamber testing, thermogravimetric analysis
• Hydrogen aging testing capability
• Prototyping Services
• Stack prototyping for small scale testing, including: GDL, catalyst layer, MEA, CCM
• Catalyst Research
• Ballard’s in‐depth electrochemical knowledge provides the background to benchmark customer catalysts. Based on customer catalyst design, Ballard can provide information and design details for specific areas of improvement
• Degradation Studies
• Ballard has significant information on degradation of all major components
• Where information is missing, gaps can be filled with accelerated testing
• Membrane, catalyst, MEA, plates, seals, stack, contamination
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Engineering Services Portfolio
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Summary
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• Ballard’s engineering services provide a high‐value way to accelerate your fuel cell development efforts towards commercialization
• Our fuel‐cell science, engineering and manufacturing skill sets are not to be found elsewhere in the marketplace
• Leverage Ballard’s unique knowledge of PEM fuel cells and downstream system integration activities to create industry‐leading clean energy power solutions
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