Fuel Cells R&D Overview - DOE Hydrogen Program: About …

1 Dr. Dimitrios Papageorgopoulos fuel Cell Technologies Office2019 Annual Merit Review and Peer Evaluation MeetingFuel Cell R&D OverviewApril 29, DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEFuel Cells : Pillar of H2& fuel Cell Technologies R&DGOAL: Advance fuel cell technologies for transportation, stationary and cross-cutting applicationsMaking fuel Cells our Future, TodayFuel CellsH2& fuel Cells Program: Early-Stage R&D AreasHydrogen Early-stage applied R&D and innovation in Hydrogen andfuel cell technologies leading to:Focus Energy security Resiliency Affordability Strong domestic DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEO bjectivesFuel Cells MYRD&D to enable fuel cell power systems competitive with incumbent and alternative technologiesLight-duty vehiclesPrimary and back-up powerExpanded focus includes medium-and heavy-duty applications and energy DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICETa rge t sFuel Cell Cost DurabilityEfficiency$40/kW$30/kW*5,000 hrs8,000 hrs*65%80,000 hrs50% 90% $1,000/kW**$1,500/kW**2025 Targets by Application * Ultimate (Beyond 2030)

2 ** For Natural Gas** For Biogas Electrical targets allow fuel Cells to compete with incumbent and advanced alternative DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEC hallenges and StrategyDurability andcost are the primary challenges to fuel cell commercialization and must be met concurrentlyEarly-stage materials and components R&D to achieve low-cost, high-performance fuel cell in multiple components are required to meet targetsR&D portfolio focused on PEMFCs, but also includes longer-term technologies ( AEMFCs) & higher temp fuel Cells ( MCFCs) for stationary DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEL ight-Duty Vehicle Cost DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICES trategic Analysis Guides fuel Cell R&D Priorities2018 PEMFC Stack Cost Breakdown* PGM elimination mitigates US dependence on precious metal imports42%25%39%Catalyst costis projected to be the largest single component of the PEMFC stack cost at high volumeCatalyst cost fractionStrategy Reduce or eliminate PGM levels in catalysts * Improve MEA DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEI mprovements* SA Inc.

3 , bottom-up analysis of model system manufacturing cost,high volume manufacturing with next-gen lab technology SA Inc., bottom-up analysis of model system based on commercially available FCEVsFuel Cell Cost Status $50/kW* for 100,000 units/year $45/kW* for 500,000 units/year $181/kW* for 1,000 units/year $210/kW for currently commercialized on-road technology at 1,000 units/year67% cost reduction since 2006 Light-Duty fuel Cell Cost Improvements1401188476635755545352534445 4030+25+20+20+20+19+15+12+11+10+7+7+5+50 20406080100120140160180FC System Cost (2016$/kWnet)100,000 sys/yr500,000 sys/yrTargetCost analysis is not adjusted to account for DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICET owards a Combined Durability-System Cost Metric* SA Inc., bottom-up analysis of model system manufacturing cost,high volume manufacturing with next-gen lab technology Coming soon.

4 Combined durability-system cost metric for state of the art light-duty vehicles$0$20$40$60$80$100$120$140$160$1 802006200820102012201420162018 fuel Cell System Cost at 100k systems per year (2016$/kWnet)DOE 2025 Cost Target1 DOE Ultimate Cost Target11 DOE Cost Targets based on 500,000 systems per year01,0002,0003,0004,0005,0006,0007,000 8,0009,00010,000$0$20$40$60$80$100$120$1 40$160$1802006200820102012201420162018 Demonstrated Durability (hrs) fuel Cell System Cost at 100k systems per year (2016$/kWnet)DOE 2025 Cost Target1 DOE Ultimate Cost Target1 DOE Ultimate Durability TargetDOE 2025 Durability Target1 DOE Cost Targets based on 500,000 systems per year01,0002,0003,0004,0005,0006,0007,000 8,0009,00010,000$0$20$40$60$80$100$120$1 40$160$1802006200820102012201420162018 Demonstrated Durability (hrs) fuel Cell System Cost at 100k systems per year (2016$/kWnet)DOE 2025 Cost Target1 DOE Ultimate Cost Target1 DOE Ultimate Durability TargetDOE 2025 Durability TargetOn-Road FCS Cost21 DOE Cost Targets based on 500,000 systems per year2 Estimated value for costPreliminary Durability-Adjusted Cost:$75 DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEM edium-and Heavy-Duty Vehicle Cost DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEM edium-and Heavy-Duty Vehicles (MDVs/HDVs) Analysis of 12 truck vocations suggests 3 system sizes fit majority Needs met with multiple 80 kW fuel cell stacks Domestic MD/HD Truck market is large and growing ( ~ 400,000 sold in 2016) Main stack limitations: durability, cost Coming soon: Truck targetsSA Inc.

5 2017 cost DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEMDV Cost Analysis Highlights R&D Needs Based on 2018 cost estimate for 160 kWnetsystem suitable for buses and medium-duty trucks High-volume manufacturing cost: $92/kWnet(100,000 systems/year)Bipolar Plates20%Catalyst and Application53%Membrane9%Balance of Stack5%MEA Frame/Gaskets8%GDLs5%PEMFC stack cost breakdown*Manufacturing volume: 100,000 systems/yearComing in 2019: Heavy-duty fuel cell truck cost DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEFuel Cell Systems for HDVs: Catalyst Loading and DurabilityHigh durability demand of HDVs requires increased PGM loadingR&D is needed to develop low-cost, efficient MEAs (at low-PGM loading) with durability extending far beyond what is required for light-duty applications Power Output (kW)Pt content (mgPt/cm2)System Cost ($/kWnet)

6 100k * * analysis*2019 Preliminary resultsAhluwalia, et DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEFuel Cells Program BudgetFunding$0$5,000,000$10,000,000$15, 000,000$20,000,000$25,000,000$30,000,000 $35,000,000FY18FY19 FOA 2019 Testing and TechnicalAssessmentFuel Cell Performance andDurabilityMEAs, Cells , and Other StackComponentsElectrolytes/ MembranesCatalysts and ElectrodesFY 2018 Appropriation = $ MFY 2019 Appropriation = $ MFunding distribution reflects target oriented emphasis on early-stage applied R& DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEE lectroCat(ElectrocatalysisConsortium) DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEA ccomplishments and Next StepsElectroCat (Electrocatalysis Consortium)GoalAccelerate the deployment of fuel cell systems by replacing platinum-based catalysts with platinum group metal-free (PGM-free) catalystsCore Lab TeamHigh-throughput (H-T) materials discovery, characterization, and testingDesign and synthesis of PGM-free catalysts and electrodes, modeling Continued significant progress in catalyst and electrode development Coupled H-T with machine learning to expedite optimization Partnered with 5 newly awarded FOA projects, 1 newly awarded lab call and disseminating PGM-free catalyst test protocols and best DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEE lectroCat.

7 Enhancing PGM-Free Mass ActivityDemonstrated MEA performance of 27 mA/cm2 at VIR -freewith H2/O2, a nearly70% improvement over 2016 baselineElectroCatincreasing focus on PGM-free catalyst durability and achieving light-duty vehicle-relevant DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEE lectroCat: Advancing PGM-free Catalysts Through Partnerships Atomically dispersed Fe-N-C catalyst (U. Buffalo) H2/air performance: 113 mA/cm2at V, nearly the 2018 project baseline Ta rge t for automotive application: 300 mA/cm2at V Nearly 85% increase in peak power density over baselineEarly 2018 NowFC171 Litster, et al. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICELow-PGM Catalyst R& DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEO rdered PtCoAlloys Improve Low-PGM Catalyst Durability Both projects cite several examples PGM utilization >8 kW/gPGM Have not yet met all targets concurrentlyCharacteristicUnitsGM (ordered-PtCo/HSC-f)LANL (L10 PtCo/Vu)2025Ta rgetPGM loading (cathode) (anode: ) ( ) (total.)

8 Mg/cm2)Mass activity ViR - activity loss%4540<40%Performance at >300 Degradationat A/cm2mV2526<30 Power at ratedpower (150 kPaabs) > at rated power (250 kPaabs) utilization (150 kPaabs) > DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICENew intermetallic catalysts meet durability targetsUnitsMeasuredTa rg etMass Activity Loss [1]%4040 Degradation at A/cm2[1]mV2630 Current Density at at V, 150 at V, 250 Loading [2] [1] 30K square wave cycles, V[2] CathodeNovel L10-PtCo@Pt/Vulcan catalyst meets or approaches DOE catalyst and MEA targetsBOLEOLO rdered PtCoalloy nanoparticles have improved Co retention and retain ordered structure during fuel cell testing, enabling high durabilityBaseline PtCoOrdered PtCoBOL Co%48%27%EOL Co%12%17%FC161 J. Spendelowet al., DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEFC-PAD: Consortium to Advance fuel Cell Performance and DurabilityMissionEnhance the performance and durability of polymer electrolyte membrane fuel Cells while simultaneously reducing their costConsortium fosters sustained capabilities and collaborationsPart ofNew in FY2019 CoreConsortium TeamPrime PartnersFC-PAD.

9 fuel Cell Performance and focus on heavy-duty applications, especially increasing MEA durability towards ultimate target (preliminary 25,000 h)New FOA partners expected in DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICEE xpediting Membrane R&D In collaboration with ARPA-E IONICS program Serves to coordinate and accelerate the research community investigating polymer electrolyte membranes for energy conversion (and storage) devices. Initial focus AEMFCsWorkshop May 30following Spring ECS in DallasMembranes Working DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICER eversible fuel Cell R& DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICELong-Term Grid Energy Storage via Reversible fuel Cells (RFCs)RFCs offer a broad range of versatile energy services, including energy storage, which improve the grid s reliability and resiliencyConcept: Store grid electricity as H2for later conversion back to DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICETa rge t-Driven RFC R&DViability and cost-competitiveness of RFCs require innovative R&D to: improve roundtrip efficiency and durability; decrease levelized cost of electricity/storage to <10 /kWh/cycle*.

10 Meet long-term system capital cost targets by power and energy of less than $1250/kW and $150/kWh** (Chapter 3, Table )*Detailed RFC technical targets drafted; will be requesting input from DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICERFC R&D Innovation Targets Low- and High-T TechnologiesLow-T PEM Example:Proton pre-project dataBallard pre-project dataWUSTL supports:Ru doped TiO2(RTO)Nbdoped TiO2(NTO)Sb doped SnO2(ATO)WUSTLS upported Bifunctional ORR/OER catalystWUSTLA dvanced MembranesReinforced PFSA based membraneBallard + Proton50cm2performance and durability validation LBNL + PajaritoPowdersMEA Integration and Optimization25cm2 URFC Performance and DurabilityPtPtPtIrIrIrIrMaterials/compon ent R&D to advance both fuel cell and electrolyzerperformanceFC313N. Danilovicet al., DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICENew fuel Cell Applications Explored in 2019 WorkshopsBringing together leading industry representative and stakeholders to discuss current R&D needs and technology gapsFCHEA / Department of Energy fuel Cells R&D WorkshopMay 15, DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE Applied Early-Stage R&D addresses cost reduction, performance and durability enhancement of materials and stack components, including catalysts and membranes ElectroCat coordinates with newly awarded FOA projects to expedite the development of PGM-free catalysts and electrodes FC-PA D, including industry/university partners.