AGENDA

1. INTRODUCTION ORGANISATION

2. FUEL CELL TECHNOLOGY (FCT) INTRODUCTION

3. OVERVIEW - ADVANTAGES & CHALLENGES

4. TECHNOLOGICAL ADVANCEMENTS

5. CURRENT STATUS & ECONOMICS OF FCEV

6. FUTURE PERSPECTIVES
 Introduction to FCT

Futuristics “Next Generation Power Source & Mobility Solutions

(“Energy - Efficiency - Economy”) - Fuel Cell Technology

1. What is Fuel cell Technology (FCT)?

2. Major Difference Battery and FCT?
3. Disadvantages of Current Battery Electric Vehicle (BEV)?
4. Why BEV and FCEV are not in popular in current market ?
Fuel cell – Basics, Working, Types & Applications
What is a Fuel Cell?

A fuel cell is an electrochemical device which converts the chemical energy of a fuel and an
oxidant (pure oxygen or air) directly into electricity without the intermediate step of classical,
chemical combustion used in the conventional process of heat extraction from a fuel.

Conventional method with intermediate steps Fuel Cell Technology

4
Timeline History of Fuel Cell Development
THE HISTORY & THE JOURNEY TO FCEVS
History of H2 Mobility

World Growth of H2
Powered Vehicles

Main Challenges

https://doi.org/10.3390/su151511501
Fuel Cell Types (1/2)
Common Operating System Electrical
Fuel Cell Type Applications Advantages Dis-advantages
Electrolyte Temperature Output Efficiency
• Requires expensive
• Solid electrolyte catalysts.
reduces corrosion
& electrolyte • High sensitivity to
• Backup power fuel impurities.
Solid organic management
Polymer Electrolyte 60 % (direct) • Portable power
problems. • Low temperature
polymer poly- <1 kW – 250 • Small
Membrane Fuel Cell 50 - 100 °C • Low temperature. waste heat.
perfluoro sulfonic kW 25-40 % distributed
(PEMFC) • Quick start-up.
acid. (reformed) generation
• Waste heat
• Transportation
temperature not
suitable for
Combined Heat and
Power (CHP).

Solid organic • High energy

Direct Methanol • Consumer • Low power output.
polymer poly- storage.
Fuel Cell goods
perfluoro 50 – 100 °C Up to 1.5 kW 20 – 25 % • No reforming • Methanol is toxic and
• Laptops
needed. flammable.
(DMFC) • Mobile phones
sulfonic acid. • Easy storage and
transport

An aqueous solution • Expensive removal of

• Cathode reaction CO2 from fuel and air
Alkaline Fuel Cell of potassium 10 kW – 100 • Military
90 – 100 °C 60 % faster in alkaline streams required
(AFC) hydroxide soaked in kW • Space
electrolyte, higher (CO2 degrades the
a matrix. electrolyte).
performance.
 (2/2)
Common Operating System Electrical
Fuel Cell Type Applications Advantages Dis-advantages
Electrolyte Temperature Output Efficiency
50 kW – 1 MW • Higher overall • Requires expensive
Liquid phosphoric efficiency with CHP. platinum catalysts.
Phosphoric Acid Fuel (250 kW • Distributed
acid soaked in a 150 – 200 °C 32-38 % • Increased tolerance • Low current and
Cell (PAFC) generation
matrix. module to impurities in power.
typical) hydrogen. • Large size/weight.
• High temperature
A liquid solution of <1 kW – 1 MW • Electric • High efficiency. speeds corrosion and
lithium, sodium, utility • Fuel flexibility. breakdown of cell
Molten Carbonate (250kW
and/or potassium 600 – 700 °C 45-47 % • Large • Can use a variety of components.
Fuel Cell (MCFC) module distributed catalysts. • Complex electrolyte
carbonates soaked
in a matrix. typical) generation • Suitable for CHP. management.
• Slow start-up.

• High efficiency.
• High temperature
• Auxiliary • Fuel flexibility.
enhances corrosion
Solid zirconium power • Can use a variety of
and breakdown of
• Electric catalysts Solid
Solid Oxide Fuel Cell oxide to which a cell components.
650 - 1000°C 5 kW – 3 MW 35-43 % utility electrolyte reduces
(SOFC) small amount of • Slow start-up.
• Large electrolyte
yttria is added. • Brittleness of
distributed management
ceramic electrolyte
generation problems
with thermal cycling.
• Suitable for CHP.
Components of Fuel Cell
Sl. No. Component Materials Used
1 Fasteners Stainless steel
2 End plates Aluminum
3 Current collector plates Gold plated copper
4 Flow field plates Graphite
5 Sealing gaskets Silicon
6 Gas diffusion layer Carbon paper
7 Catalyst layer Platinum on carbon
8 Membrane Nafion
Proton Exchange Membrane Fuel Cell (PEMFC)
1. A fuel cell is an electrochemical device which
directly converts the chemical energy of a
fuel into electricity, emitting water as their
only waste product
2. Two to three times more efficient that an
internal combustion engine
3. Fuel cell stack is quiet, has no moving parts,
produces zero tailpipe emissions
4. Single cell produce 1.0 volts DC. These single
fuel cells connected in series are called
stacks.

Anode Reaction: 𝟐𝑯𝟐 → 𝟒𝑯+ + 𝟒𝒆−

+
Cathode Reaction: 𝑶𝟐 + 𝟒𝑯 + 𝟒𝒆− → 𝟐𝑯𝟐

Overall, Cell Reaction: 𝟐𝑯𝟐 + 𝑶𝟐 → 𝟐𝑯𝟐 𝐎

Various Fuel Cell Types
Thermodynamics of Fuel Cell Process
• A fuel cell converts chemical energy into electrical
energy
• Potential difference between the cathode and
anode are achieved under thermodynamically
reversible conditions with some energy will
inevitably be lost as heat.

Electrical work (W) = EIΔt {E: Cell Vtg, I: Current, t= Time}

Amt of Electricity IΔt = nF {n= No.of Electron, F= Faradays Con.}
W = -nFEcell
The Gibbs free energy is the maximum amount of work done on
the system: W = ΔG In thermodynamics, work done by the system on the surroundings is considered negative
because it results in a loss of energy from the system. Conversely, work done on the
ΔG = −nFEcell
system by the surroundings is positive, indicating a gain of energy by the system.

Max. cell potential,

If all the potential chemical energy for a reaction went into electrical work and there was
no heat transfer, there would be no entropy change; dG = dH.
Fuel Cell (PEMFC)
The voltage of a cell is related to the difference in the standard electrode potentials of the anode and cathode
materials.
The theoretical voltage for PEMFC: 1.23 V based on the standard Gibbs free energy change for the
electrochemical reaction H2 & O2 to form H20
Electrochemical Reaction: H2+ ½ O2 → H2​O
1. Gibbs Free Energy Change (ΔG∘): The standard Gibbs free energy change (25°C and 1 atm) is ~-237.13
kJ/mol.

2. Relationship Between Gibbs Free Energy and Voltage: ΔG∘ = −nFE∘

Where:
1. ΔG∘ is the Gibbs free energy change
2. n is the number of moles of electrons transferred (2 moles for this reaction)
3. F is the Faraday constant (96,485 C/mol96,485C/mol)
4. E∘ is the standard cell potential (theoretical voltage)

Calculating the Theoretical Voltage: E∘=−ΔG∘​/nF

E∘ = − (−237,130 J/mol) / (2×96,485 C/mol)

E∘ ≈ 1.23 V
PERFORMANCE EVALUATION OF PEMFC HOW 1.23 to 0.65v????
❖ The maximum electrical work obtainable in a fuel cell operating at
constant temperature and pressure is given by the change in the
Gibbs free energy of the electrochemical reaction,
W = ∆G = –nFE
❖ If we consider the case of reactants and products being in the
standard state, then
∆G0 = –nFE0
❖ The overall reactions givencan be used to produce both electrical
energy and heat
∆G = ∆H – T∆S
The maximum amount of electrical energy available is ∆G as
mentioned above, and the total thermal energy available is ∆H. The ❖ A fuel cell can be operated at different current densities; the
amount of heat that is produced by a fuel cell operating reversibly is corresponding cell voltage then determines the fuel cell efficiency.
T∆S.
❖ Decreasing the current density increases the cell voltage, thereby
Fuel Cell Efficiency increasing the fuel cell efficiency.

❖ In fact, as the current density is decreased, the active cell area must be
increased to obtain the desired amount of power
The ideal efficiency of a fuel cell operating irreversibly may be stated as
 Fuel cell – Catalyst Development

Restricted circulation under NDA 16

 Current Status of Fuel Cell Technology
Cost Split-ups of FC Stack Bipolar Plate in FC Stack

In order to achieve fuel cell technology, to become economically competitive with other power sources,
❖ Innovating Low-Cost High-Energy Density Catalyst and Coating Technique
❖ Bipolar Plate Material and Design
❖ Fabrication Methods

Restricted circulation under NDA 17

Evolution of FC Catalyst Developments

Catalyst
Development
Criteria:
❖ Innovative Material Selection/Preparation
Non-Noble Metal
Catalyst ▪ Eco Friendly Noble Metal
Catalyst
▪ Mass Production
Under Research
▪ Cost Effective (Contains lesser utilisation of Noble metals)
❖ Higher Performance and Durability for Long Run
Pure Pt Catalyst

Pt/C Carbonaceous Support

on Pt
Current Research

Pt-Pd/C Graphene Support on

Bi- Metallic Catalyst Pt

Pt-NiTiO3/C
Metal Oxide Catalyst

Restricted circulation under NDA 18

 TEL _CATALYST - MATERIAL DEVELOPMENT
X-Ray Diffraction (XRD)

High Resolution Transmission Electron

Microscope (HRTEM)
HR TEM FTIR SEM

Scanning Electron Microscope (SEM/EDAX)

Atomic Absorption Spectrometry(AAS)

Equipment for Material
characterisation
Inductively Coupled Plasma (ICP) AFM THERMAL EVAPORATOR PVD

Thermogravimetric Analyzer (TGA) AAS

X-Ray Photoelectron Spectroscopy (XPS)

Physical/ Chemical Vapour Deposition XRD

(PVD/CVD)

Cyclic Voltammetry Multichannel

Electrochemical
Electro Chemical Testing
Test system
Chrono Amperometry
CV&CA
Restricted circulation under NDA 19
* All of these equipment are available at our Partner facilities
 Fuel cell – Stack Development

Restricted circulation under NDA 20

PEMFC Stacks

A small stack of about 10 cells

PEMFC EXPOLED VIEW
Membrane Electrode Assembly
Hydrogen FCEV system
FCEV Markets
FC Manufacturers
The Top OEM Fuel Cell Fuel Cell Vehicle
Manufacturers: Manufacturers:
1.Hyundai Fuel Cell 1. Toyota Mirai
2.Doosan Fuel Cell 2. Hyundai Nexo
3.Horizon Fuel Cell 3. Honda Clarity
4. Gaussian Trucks
4.Ballard Fuel Cell
5. General Motors
5.Nuvera Fuel Cell
6.Air Liquide Fuel Cell
7.Hydrogenics Fuel Cell
8.Intelligent Energy Fuel Cell
9.PowerCell Fuel Cell
10.Nedstack Fuel Cell
11.Proton Fuel Cell
12.Plug Fuel Cell
Fuel Cell Electric Vehicle – Status & Techno
Commercials

1. H2 production & Challenges

2. Challenges
3. Indian Foray into Hydrogen Mobility
4. Analysis & Anticipated Timeline
5. Future of H2 Business
 H2 Production By type

• Grey H2 high
FCEV % of Total Vehicle % of used FCEV@ 2021 • Japan is the pioneer in
H2 production + FCEV
• Toyota - Mirai

https://doi.org/10.3390/su151511501
THE HISTORY & THE JOURNEY TO FCEVS
History of H2 Mobility

World Growth of H2
Powered Vehicles

Main Challenges

https://doi.org/10.3390/su151511501
 WHERE THE WORLD STANDS ON HYDROGEN MOBILITY
Japan FCEV Sales growth

GERMANY INVESTS IN ITS HYDROGEN SECTOR

• US $3.75 billion - to boost the green hydrogen sector

• Germany is expected to invest in a 100 MW green hydrogen facility
• Japan set sales targets for FCEVs, aiming for in Morocco
200,000 units - 2025 and 800,000 units - 2030 • Germans announced a blueprint for the world’s largest hydrogen
grid, covering about 5,900 km, and the first phase of 1,200 km will
be ready by 2030
Key initiatives
• Supporting energy R&D : NEDO – 500
Programs – Industry – university collaboration
• Establishing hydrogen supply: chains –
overseas project – Middle east, Australia etc
• Developing infrastructure for FCEVs: - 320 fuel
stations
INDIA’S FORAY INTO HYDROGEN MOBILITY

1. SUSTAINABILITY TARGETS SHIFTED INDIA’S FOCUS TO GREEN HYDROGEN - Set a goal to make its e-
mobility industry energy-independent by 2047

2. MISSION OUTCOMES:
- Green hydrogen production capacity of at least 5 million metric tons (MMT) per annum
- investment in the National Green Hydrogen Mission of Rs 19,744 crore
- 50 MMT per annum of greenhouse gas (GHG) emissions are expected to be averted by 2030
3. INVESTMENTS BY THE INDIAN GOVERNMENT
- The government has designated Rs 17,490 crore (88.6%) of the mission’s total budget for incentives
to generate green hydrogen and manufacture electrolyzers, - Green Hydrogen Transition (SIGHT)
Programme.
-The National Green Hydrogen Mission is expected to attract a total investment of Rs 800,000 crore by
2030 and create around 600,000 jobs.
4. IMPACT ON INDUSTRY
- Heavy-duty trucks are expected to be significant in the hydrogen mobility space - By 2030, it is estimated
that 12,000 FCEV heavy-duty trucks will be running on Indian roads
- Tata Motors, Cummins, KPIT etc - developing low- and zero-emission propulsion technology solutions for
commercial vehicles in India.
 COMPARING FCEVS & BEVS

1. Driving Range
2. Refuelling Time
- BEVs typically need 30 minutes to attain an 80% charge
- fast charging typically comes at a higher cost per kWh and has a negative
impact on battery life.
- the economic and commercial viability of these innovations in BEVs is unknown.

Global availability of hydrogen

fueling stations for road vehicles
by country, 2022

• The average range of an FCEV is 483 km, compared to the

322 km range offered by a BEV.
• The Toyota Mirai FCEV provides a range of 650 km, while
only a few high-end BEVs can deliver around 565 km.
 COMPARING ENERGY EFFICIENCY OF FCEVS AND BEVS

The key
challenges
FCEVs and BEVs
must overcome
as they grow
their
infrastructure:
- High initial
setup costs.
- Safety
concerns
- Real estate
requirements
ANTICIPATED TIMELINE