At the Gasgoo Awards 2022, SHANGHAI HYDROGEN PROPULSION TECHNOLOGY CO., LTD.’s high power density fuel cell stack platform technology for both passenger and commercial vehicles won. (“SHPT”) has applied to be a top 100 player in his chain of new auto supplies in China.

Photo credit: SHPT

explanation:

Based on the commercialization of both passenger and commercial vehicles, Shanghai Hydrogen Propulsion Technology Co. Ltd has developed a completely new fuel cell stack platform, PROME M4, ready for mass production. The power density of this stack platform reaches 5.1kW/L, and the peak power output of a single stack can be increased to 200kW. PROME M4 meets all the stringent technical requirements of commercial and passenger vehicles. This includes higher output, faster power response, longer durability, and stronger environmental versatility. In addition, the applications of this M4 stack are expanding to fields other than automobiles.

Photo credit: SHPT

Unique Advantages:

1. Low Pt loading, high performance, long life MEA design and mass production technology

By bridging the physico-chemical relationships between raw material properties, catalyst ink manufacturing process, catalyst layer structure, and MEA performance, the team developed a comprehensive framework for analyzing performance and predicting MEA durability. developed a simulation model. The team also built testing, evaluation and failure analysis capabilities for all critical raw materials, catalyst inks, catalyst structures and membrane electrode assembly components. By adopting an ultra-thin PFSA membrane and improving the water retention method, the MEA has a self-water balance function, covers extremely high temperature and low humidity usage range, and ensures durability under harsh conditions. The new generation MEA has a power density of 1.3W/cm2, a pt load of 0.27gPt/kW and an endurance of 15000 hours (compared to 1W/cm2, 0.3gPt/kW of the previous generation).

2. High performance, durable bipolar plate design

The team adopts an ultra-narrow wiggle flow field design (repeat distance ≤1.35mm) with a locally optimized structure. For durability, the team developed a coating design methodology, accelerated test conditions. Based on the test results, an operating voltage window for bipolar plates is established. Combining stack operating conditions and control strategy optimization, the coating durability exceeds 15000 hours.

3. High power density, high reliability stack integration technology

1) Performance Design Methodology: We have developed multiple numerical tools dedicated to fuel cell product design, including 1+1 dimensional simulation tools, 3D full-scale multiphase models, fluid dynamics models, and solid mechanics models. With all the tools available, the team performed several scientific and engineering tasks, including the precise definition of product specifications, the simulation of “gas-water-heat-electricity” multi-physical coupling processes, and the calculation and detection of chimney assembly forces. can solve technical problems. As a result, the PROME M4 stack exhibits obvious characteristics such as high performance without cathode humidification, low voltage fluctuation and long life. The M4 stack has 34% higher volumetric power density and 50% longer lifetime compared to the previous generation.

2) Structural Design Methodology: Invented a highly integrated stack enclosure structure with both positioning and limiting functions. Developed a composite structure of current collector, insulator, and end plate. Developed stack compression force correction technology. With these innovative designs, the M4 stack meets all customer requirements such as SAE J2380, IP67, GB/T2423.17, GB38031, GB/T33978.

application:

Fuel cell stack technology platforms for commercial and passenger vehicles can solve technical problems from both sources by simultaneously improving volumetric power density and durability.

1. For automotive applications: Based on technology developed from the platform, the power density of the stack has been increased to 5.1kW/L. With a peak power of 90kW, the M4L stack-based FCS can meet passenger car application requirements. On the other hand, the 200kW M4H stack developed from the platform typically meets the specifications of commercial vehicles that require 150kW of system power and 200kW of stack power. Stack and system field durability tests have reached 15,000 hours, which meets the requirements of commercial vehicles of all tonnage levels.

2. For non-vehicle applications: There are several fuel cell exhibition programs for freight, distributed generation, emergency power systems, and more. Technologies from the platform cover all the above application scenarios, fuel cell products have great potential. There are areas of application.

Expected:

As a form of clean energy, hydrogen plays a key role in achieving the goals of “carbon peaking and carbon neutrality”. Fuel cell vehicles are becoming a complement to pure electric vehicles due to their superior performance, and are an important pathway for the development of new energy vehicles. As an efficient energy conversion device, fuel cells are at the core of the development of fuel cell vehicles and the hydrogen industry. The technology developed by SHPT can be benchmarked for global leadership and enables mass production to automotive standards. Based on a 5-year lifecycle and a sales volume of 1,000 pieces per year, you can create a supply he chain worth over 10 billion. The hydrogen industry shows good development momentum and has a very wide range of future applications.