1. Fuel Cells AND Batteries - Key Enablers for Zero Emission Vehicles -
Dr. Andreas Truckenbrodt
AFCC Automotive Fuel Cell Cooperation Corp.
Burnaby, Canada
HFC 2009
June 1, 2009
AFCC: The Centre for Fuel Cell Stack Development for Daimler AG and Ford Motor Company

3. Well-to-wheel CO2 potential

4. A diverse powertrain portfolio is required to cover all applications
Mobility Scenarios
long distance
cross country
city
Combustion Engine
Hybridization
Plug-In/Range Extender
Battery Electric
Fuel Cell Electric
A diverse powertrain portfolio is required to cover all applications
Klick

5. Both require infrastructure
Buildup of charging infrastructure
Buildup H2-Infrastructure
Investment [€]
Investment [€]
Public parking
Commercial parking sites
Private parking place (50%)
Workplace
Start invest
for a minimal- infrastructure
Number of vehicles
Number of vehicles
Investment for the charging infrastructure depends on vehicles sales
H2-infrastructure requires start-up investments
Overall costs for infrastructure are similar, though shape is a little different

6. Both are approaching near-term commercialization
F-Cell
smart ed

7. Batteries – Promise and Challenges
High worldwide sentiment for EV/PHEV’s
Batteries are making good progress technically and cost-wise
But EV/PHEV’s are not farther ahead than fuel cells
Many challenges remain
May 27 announcement Chrysler/DOE: $448 million dollars to develop EV/PHEV – includes $365 million for a 365 vehicle test fleet
Very few vehicles on the road in customer hands to prove market potential – many are just starting a test fleet phase

8. Fuel cell roadmap - The path to commercialization
Passenger Cars
Lead application
Generation 1
Technology Demonstration
Generation 1
Technology Demonstration
F-Cell
Generation 1
Technology Demonstration
Bus
Sprinter
Generation 2
Customer Acceptance
2004
Generation 2
Customer Acceptance
B-Class F-Cell
Generation 2
Customer Acceptance
2010
Generation 3
Cost Reduction I
Future Generations
2013
Generation 4
Market Introduction
Cost Reduction II
Future Generations
201x
Generation 5
High Volume Series Production
202y
Fuel cell passenger cars will drive the volume

9. Gen 1: Technology demonstration From Necar 1 (1994) to F-Cell and Fuel Cell Buses (2004-2008)
JHFC Program
Japan
Sinergy EDB Project Singapore
California
Fuel Cell Partnership
DoE Program USA
Bus Project Beijing
China
Clean Energy Partnership Germany
European Bus Project
HyFLEET:CUTE
Bus Project STEP
Perth, Australia
National Innovation Program H2 and Fuel
Cell Germany
European Zero Regio Project
MBUSA
MB NL Berlin
DSEA
MBJ
Other end of timeline and technology: hydrogen and fuel cells
Convinced that hydrogen and fuel cells are the ultimate solution but it will take a while until we see them replace the combustion engine propulsion
It is extremely important to gain experience with real-life driving of fuel cell vehicles
Proud to have the biggest fleet of fuel cell vehicles out there in real-life, customer testing programs
60 F-Cell Vehicles
in customer operation
36 Buses (Citaro) in
Europe, Australia, China
3 Sprinter
Europe, USA
∼ km
∼ h
∼ km
∼ h
∼ km
∼ h
100 vehicles since 2004

10. Generation 2: Full customer acceptance
Fuel cells have also made huge progress
Generation 1: Technology demonstration
Generation 2: Full customer acceptance
A-Class F-Cell
B-Class F-Cell
Looking at the B-Class F-Cell, which we will lease to customers starting next year, and comparing it to the current fuel cell vehicle generation of the A-Class F-Cell, you can see we have made huge progress in terms of size, power, fuel consumption and range.
We are well along the way to meeting the requirements we have set for the serial production of fuel cell vehicles.
In the B-Class we will have a stack lifetime of more than 2000 hours.
The power of the electric motor will be 100 kW which gives us a maximum speed of 180km/h
The reliability of the vehicle has been improved
The range will be extended to 400 km, because of increased hydrogen storage capacity
We will be able to start the vehicle from a temperature lower than 0° Celsius
And we will use a lithium-ion battery instead a nickel-metal-hydrid battery to improve the overall efficiency of the car.
2004 – 2009
Worldwide 90 cars, 39 buses
from 2009
Small series production
Size
- 40%
Power
+30%
Consumption
-30%
Range
+150%
B-Class F-Cell:
Higher stack lifetime
Increased power (65kW 100kW)
Higher reliability
Longer range (160km 400km)
Freeze start ability below 0°C
Li-Ion battery
[l/100km]
[km]
[l]
[kW]

11. Status of fuel cell technology
Performance
Safety
Comfort
Freeze start
Range
Reliability
Longevity
Package/weight
Cost

12. Fuel cell achievements and challenges
Gen 3: Full scale running prototypes
Gen 2: On road 2009

13. For fuel cells we know how to get the cost down
Goal: Competitive to the incumbent technologies
Volume increase, economies of scale” (4-5x)
Technology improvements (3x)
Supplier development
New, cooperative business models
Magnitude of the task: factor 15

14. Cost driven development goals
Stack
reduce Pt loading from 1 mg/cm2 to mg/cm2
develop improved cathode catalyst material and application technology without negative impact on lifetime
reduce active stack area
increase catalyst activity at full and part load (fuel economy !) while reducing Pt loading
reduce bipolar plate cost through high volume manufacturing technologies (metal plates or carbon plates)
improve membrane performance under dry and hot conditions to accommodate reduced/eliminated humidifier system concept
improve unit cell/ flow field concept to accommodate reduced/eliminated hydrogen recirculation system concept
System
reduce/eliminate humidifier
reduce/eliminate hydrogen recirculation loop
reduce component cost (compressor, sensors, valves, tank, power electronics etc.)
cost
per-formance
life- time

15. Solve joint problems jointly
Our industry does not need proprietary solutions to every problem
As the cost of these solutions gets higher and higher, no one company can afford to develop all of them
Nor will our customers pay the price tag for a custom solution…….to a generic problem
The path to success in the last century probably is not going to be the path to success in this one.
This drives us toward collaboration with other automakers and suppliers on the development of the cornerstone technologies of our collective future.

16. … and we'll always manage brand differentiation …

17. All stakeholders are in charge !
Automotive Industry
Fuels/Energy Industry
clean and efficient
reliable
affordable
improved conv. fuels
alternative fuels
infrastructure
If everybody plays a long, we can move a lot.
It‘s not the automotive industry alone, but it‘s us together – hand in hand – with other partners.
Nonetheless, we have to focus on what we can do ourselves.
And I want to show you, that we CAN do quite a lot –
our achievements so far serve as a proof
Customer
Public Institutions
choice of vehicle
driving behaviour
"feel comfortable"
relevant framework
incentives
research

18. Key Messages
It is “fuel cells AND batteries”
Fuel cells work fine - #1 focus is now on cost reduction, and we know how to get there
The strong commitment from the car manufacturers needs to be joined by the other stakeholders