11
EKPO: INDUSTRIALIZATION OFFUEL CELL STACK PRODUCTION
Phi l ipp St iefelEKPO Fue l Ce l l Te chno log ie s G m bH
6. Marktplatz Zulieferer Wasserstoff-und Brennstoffzellenindustrie17. August 2021
Content
2021/08/17 3
E K P O : F U E L C E L L S TA C K P R O D U C T I O N
/ EKPO at a glance
/ Experience and Competences
/ Market Demand
/ Value Chain Stack Production
/ Current Stage Industrialization
/ Next Stage Industrialization
EKPO Fuel Cell Technologies GmbH
The mobility turnaround
4
E K P O F U E L C E L L T EC H N O LO G I E S
More than 1 5 0 E M P LOY E E S
Addressing G LO B A L F U E L C E L L business
Headquartered in D E T T I N G E N / E R M Sclose to Stuttgart (Germany)
Initial production capacity of up to 1 0 , 0 0 0 U N I T S per year
More than 1 5 0 PAT E N T S
2021/08/17 EKPO Fuel Cell Technologies GmbH
Roadmap and Technology
5
E X P E R I E N C E A N D C O M P E T E N C E S
2021/08/17 EKPO Fuel Cell Technologies GmbH
Joint Venturebetween ElringKlingerand Airbus
Customized development of metallic bipolar plate
Co
mp
on
ent
| P
rod
uct
Cu
sto
mer
| F
ield
First field application of EK FC-Stacks
(Forklift)
Start of fuel cell stack development(graphitic bipolar plate)
Start of stack development NM5 (> 50 kW)(metallic BPP)
Start of stack development NM12 (> 120 kW)(metallic BPP)
SOP NM5evo(76 kW)
NM5evo System integration in HD Truck
SOP NM12 single(123 kW)
SOP NM12 twin(205 kW)
Customized development of Media Supply ASM
2000 2010 2012 2014 2016 2018 2020 2022 2024 2030
Highly integrated fuel cell stack module
High-volume series order for NM5evo stack module
Joint Venturebetween ElringKlinger and Plastic Omnium
AEROSTACK
Market Demand / 30% reduced CO² fleet emissions in HD
transport sector in Europe by 2030 * official target EU
/ No new HD Trucks with fossil ICE Technologyin Europe from 2040 * ACEA Policy Paper: 12/2020
/ Potential: 60.000 – 100.000 FCEV Trucks p.a.in Europe by 2030 * FCHJU & Roland Berger 12/2020
/ Estimation up to 10.000 stacks p.a. @EKPO by 2025
Target to reach: Cost down
˃ Design to Cost(modular and scalable design, high manufacturability)
˃ Economies of Scale through volume increase
˃ Industrialized stack production(minimized cycle time and scrap rate, robust processes)
6
E K P O : F U E L C E L L S TA C K P R O D U C T I O N
FCHJU & Roland Berger Study „Fuel Cells Hydrogen Trucks“ 12/2020
2021/08/17 EKPO Fuel Cell Technologies GmbH
Value Chain
7
Pre-Assembly
Stack Assembly
Stack Compression
EoLPEM StackShipment
Coated coil
CCM
GDL
Pre-Process
Manufacturing Bipolar plate
Injection molding plastic components
Pre-Assemblyend plates
Assembly of MEA
Completion of stack module
Plastic granules
Automated stacking
End of Line Testing
Final Assembly
Completion ofmedia supply ASM
Automatedcompression
Manufacturing SoGDL
2021/08/17 EKPO Fuel Cell Technologies GmbH
E K P O : F U E L C E L L S TA C K P R O D U C T I O N
Current Stage Industrialization
8
/ High added value along the wholemanufacturing process chain
/ Industrialized design of stackmodule and components
/ Automotive quality standardsfor series production
/ High technical cleanliness
/ Modular and highly flexibleseries production processes
˃ Scalable in cell size
˃ Scalable in cell count
˃ Scalable in volume up to
10k Stacks := 3M Cells := 680* or 1.000** MW p.a.
Production capacity sufficient until Mid of 2020‘s, flexibility for new product launches and design changes
2021/08/17 EKPO Fuel Cell Technologies GmbH
* Base NM5evo, 76 kW** Base NM12, 123 kW
E K P O : F U E L C E L L S TA C K P R O D U C T I O N
Stack Assembly Line
9
/ Fully automated stacking andcompression process
/ Cycle time up to 5s per cell
/ Inline roll feeding and cutting of CCM
/ High positioning accuracy
/ High precision compression process
/ Reproducable quality through 100% inline QCand 100% traceability
/ Highly flexible process and machine layout
˃ Scalable in cell size
˃ Scalable in cell count
˃ Scalable in volume
2021/08/17 EKPO Fuel Cell Technologies GmbH
E K P O : F U E L C E L L S TA C K P R O D U C T I O N
Next Stage Industrialization
10
/ Design to Cost for stack module and all components
/ Adapted design for highest manufacturability
/ New process technologies containing continuous processes
/ Sufficient technical cleanliness
/ Use of Artificial Intelligence (AI) for maximized productivity
/ High volume stack production with robust processes
˃ Cycle time up to 2 Hz per cell
˃ Cycle time up to 3 min per stack module
˃ Scalable in volume up to
100k Stacks := 30M Cells := 6,8* or 10** GW p.a.
Capacity necessary by end of 2020‘s, high volume, lower level of flexibility
2021/08/17 EKPO Fuel Cell Technologies GmbH
E K P O : F U E L C E L L S TA C K P R O D U C T I O N
Activities focused and supported withinpublic funding projects and work streams
˃ Hydrogen IPCEIProject: NextGen HD Stack
˃ HyFaB
˃ VDMAArbeitsgemeinschaft Brennstoffzellen
* Base NM5evo, 76 kW** Base NM12, 123 kW
THANK YOU.
