by Lewitz | Jan 17, 2025 | Germany, Market, News
The German fuel cell manufacturer Proton Motor has announced the provisional end of its production activities at the end of 2024 if no new investor is found. Despite diligent efforts to save the Bavarian company, it announced in mid-September that the employees of the Puchheim branch would have their employment contracts terminated at the end of the planned period in order to ensure an orderly winding down of business activities.
Proton Motor is part of the British company Proton Motor Power Systems PLC, whose Board of Directors came to the conclusion in November 2024 that “the orderly shutting down of the company” was the “most appropriate course of action.” Although alternative sources of funding were still being sought to keep the company in operation in 2025, no viable solution had been identified by the end of November. Proton Motor Power Systems shares have lost around 85 percent of their value in the space of a year.
At the end of August 2024, the main investor announced that it would be withdrawing from the financing by the end of 2024. Although outstanding customer orders would be fulfilled as far as possible, new contracts could only be concluded once financing and the future direction of the company had been clarified.
In the summer of 2024, Manfred Limbrunner, the Director of Communications, who has since been made redundant, announced that his company was planning to move to Fürstenfeldbruck by mid-2025, where a factory was to be built in which up to 5,000 fuel cell systems and 30,000 stacks could be produced automatically every year.
by Monika Roessiger | Dec 13, 2024 | Development, Germany, hydrogen development, Market, News
Patented process as a cost-effective alternative to electrolysis
The course to success of Siqens began with special methanol fuel cells. Then came the electrochemical hydrogen separation (EHS) in addition, based on the self-developed HT-PEM-FC stacks. With their help, hydrogen can be separated from natural gas or waste gases from industry and waste incineration with a high degree of purity. The manufacturer also sees EHS in combination with its own fuel cells as a solution to the last mile problem.
Whether in the South American jungle or at an altitude of 3,000 meters in the Swiss mountains, in a research station in the Antarctic or at a border post in northern Scandinavia – in all these places HT-PEM fuel cells from Siquens are in use, which supply electricity for radio and measuring stations or cameras, as Thomas Klaue, managing director of the company founded as a startup in Munich in 2012, states.
The special methanol fuel cells are also, however, in less exotic places: For example, they serve in the lighting of German highway construction sites or aviation obstruction lighting of wind parks. The “Ecoport” FC systems consist of fuel cell stacks with a high-temperature polymer electrolyte membrane (HT-PEM) and a reformer. “In the reformer, pure hydrogen is obtained from methanol,” according to engineer and doctor of business administration Klaue. “This hydrogen then passes through the HT-PEM fuel cell. Our system works with industrial methanol, however, at a fraction of the cost compared to high-purity methanol.”
These systems therefore differ significantly from direct methanol fuel cells (DMFCs), in which a liquid methanol-water mixture is passed through the FC. For that, the methanol has to be as pure as for medical purposes, which is correspondingly expensive, explains Klaue, who has been CEO of Siqens since the end of 2019. The efficiency and power range of DMFCs are comparatively low, and they do not tolerate low temperatures well. Other indirect methanol fuel cells with PEM and reformer are available in both the low and high temperature range, but these would require manufacturer-specific methanol-water mixtures with lower energy density, according to Klaue. With a consumption of 0.6 liters per kilowatt-hour of electricity, Siqens is the market leader in efficiency. The Ecoports, according to Klaue “our bread and butter business,” have a peak electrical output of 800 or 1,500 watts (continuous operation: 500 or 1,000 watts).
FC as a replacement for diesel generators
Methanol, which has long been used in industry, like other liquid fuels, can be transported and stored cost-effectively. Because of this, (methanol) fuel cells are particularly suitable for areas without a connection to an electricity grid and where an uninterruptible power supply must be guaranteed, for example in the emergency power supply for critical infrastructure. Up to now, this function has mostly been performed by diesel generators, but these will little by little be replaced by fuel cells in the future – and not only because of their significantly lower CO2 emissions: They also work more quietly and are free of particulate matter and nitrogen oxides.
Ecoport 800
Demand for the patented systems, with which the southern German company has been on the market since 2019, is rising. For example, agencies, companies and operators of telecommunications systems are interested in the methanol fuel cells from Siqens, which according to Klaue are robust and reliable and can also be used far away from civilization. This applies to all climate zones, from minus 20 to plus 50 degrees Celsius. What’s more, the operating costs are around 75 percent lower than those of diesel generators. This year, the Munich-based company, which employs around 30 people, expects to sell several hundred of its HT-PEM fuel cell systems.
That the need to use hydrogen and fuel cell technologies for reasons of climate protection is increasing is beyond question today. The Siqens CEO stressed however: “We are convinced that the hydrogen economy will only be a success with price-competitive solutions, especially when it comes to last-mile distribution.”
FC as a replacement for diesel generators
In addition to fuel cells, the company has been offering a very special technical solution for producing pure hydrogen since 2022: electrochemical hydrogen separation (EHS). In this patented process, the feed gas flows through an HT-PEM stack, which is also used in the Ecoport, states Klaue. “The stack with the MEAs is comparable to a sieve that, under tension, is only permeable to the hydrogen molecules that have been reduced to protons on the anode side. On the cathode side, the protons get the electrons back. The product is highly pure hydrogen.” With this method, hydrogen can be separated, purified and processed from very different media. This can be natural gas or exhaust gas that is produced in industrial processes or from waste incineration. The hydrogen can also be obtained from natural reservoirs such as natural gas deposits.
And because methanol is a good hydrogen carrier, the EHS system can also avoid the last mile problem: From the methanol transported via the natural gas network, hydrogen is produced directly on site at the consumer’s premises CO2-free. “In 10 liters of methanol, approximately one kilogram of hydrogen is chemically bound,” calculates Thomas Klaue. This is more than in a standard 70-kilogram compressed gas cylinder that contains 50 liters of hydrogen compressed to 200 bar. The yield with that is only 0.8 kilograms. Instead of transporting hydrogen in bundles of heavy steel bottles or in pressure tanks by trailer, as was previously the case, a lot of money can be saved through the employment of methanol fuel cells.
Transport and storage costs currently make up the largest percentage of the hydrogen price. “This is even more true if the deployment location can only be reached by helicopter,” added Klaue. “The ratio of transport weight to useful H2 weight is for methanol ten to one versus one hundred to one for compressed gas cylinders.”
1 kg hydrogen for less than two euros
During EHS, likewise to water electrolysis, electricity is used. However, the energy requirement is significantly lower: Per kilogram of hydrogen, only three to five kilowatt hours of electricity would be needed; so around ten percent of the electricity required for electrolysis. “This produces hydrogen in fuel cell quality at a price of less than two euros per kilogram,” states Klaue. The technology is flexible, scalable and can be adapted to a wide range of gases. Such a system, which only takes up an area of one to two square meters depending on its capacity, can be connected directly to the gas network.
The EHS process could produce a good 100 kilograms of hydrogen per day with three stacks, which is enough for an H2 refueling station, according to Thomas Klaue. The modular design also allows several tonnes per day to meet the needs of an industrial company. “Electrochemical hydrogen separation is definitely an attractive alternative to other H2 technologies, as it consumes comparatively little energy and has a high selectivity for hydrogen,” according to the CEO.
Following an initial pilot project in Australia, there is now a second one in Germany: In the Unterfranken city of Haßfurt, hydrogen is being obtained from the natural gas grid using EHS. The municipal utilities of the city are known as pioneers, because they have been relying on renewable energies since the 1990s: photovoltaics, wind power and biogas from farmers in the region. Since 2016, they have had an electrolyzer to generate hydrogen from surplus wind power.
Now, with the help of EHS technology from Siqens, they are tapping into the municipal gas grid as a source of hydrogen. This is done in cooperation with the Helmholtz-Institut Erlangen-Nürnberg and the Institut für Energietechnik of the university Ostbayerische Technische Hochschule Amberg-Weiden. The hydrogen separated from the natural gas is compressed and stored and, as needed, converted into electricity via a fuel cell.
As many gas network operators want to add green hydrogen to their natural gas in the future, such solutions for separating and processing climate-neutral gas could soon become more significant. “By separating the gases using EHS at the point of consumption, the end customer can be supplied directly with high-purity ‘green’ hydrogen,” says Thomas Klaue. In other words, hydrogen of the quality required for industrial processes or fuel cell vehicles. For this reason, Klaue also argues vehemently in favor of maintaining the gas grids.
In February of this year, he publicly appealed to the German economy ministry to reconsider the dismantling plans; for cost reasons alone. “In addition, the planned H2 core grid will not be able to supply the entire country with green energy for a long time without great effort,” he says. However, because the nationwide gas network is largely suitable for hydrogen, the infrastructure should be used for the future transportation of green hydrogen, to supply industry and communities with climate-friendly energy.
by Christian Machens | Dec 3, 2024 | Development, Germany, News
HAZOP analysis with AI support
In the year 1999, Christian Machens developed the world’s first fuel cell boat, the Hydra, and thereby laid the foundation for innovations that will extend far into the future. Now, 25 years later, he is once again setting standards in the technology landscape – this time with a world first that has the potential to fundamentally change the safety analysis of systems.
In modern technology, carrying out a HAZOP (hazard and operability) analysis is essential for systems with high risk potential. This analysis is carried out by a team of experienced engineers under the leadership of a “HAZOP chair” to identify possible dangers in systems such as fuel cell or electrolysis systems and to develop suitable countermeasures. In Germany this is also referred to as PAAG, which precisely describes the process of recognizing dangers, assessing their effects and determining countermeasures.
Traditionally, the role of the HAZOP chair requires not only technical know-how, but also strong social skills. The trick is to use imagination and experience to extract all critical scenarios from the discussions and document them in a structured form. In this, not only is the dangerousness of the scenarios assessed, but also their probability of occurrence, in order to ultimately create a ranking of the risks and requirements for the reliability of the countermeasures.
But how safe is it to leave security-relevant decisions to an AI (artificial intelligence)? “It’s not about handing over safety responsibility to a machine, but rather about simplifying repetitive tasks,” stresses Machens.
“I would like to pass on the expertise in the field of explosion protection and hydrogen that I have accumulated over the last decades to an artificial intelligence. AI is already used in many areas today, but it has not yet been used to support HAZOP analyses.”
Christian Machens
Procedure
In a typical HAZOP meeting, up to eight engineers discuss various aspects of a system over several days, from gas and cooling water loops to the reliability of the power supply and specific dangers for people in the vicinity of the system. These meetings are not only time-consuming and costly, but also stressful for those involved. In addition, the experience of the participants significantly influences the result.
Typically, a HAZOP is performed when the P&ID (piping and instrumentation diagram) of a facility is completed. This is where the new, intelligent software comes into play. It analyzes the existing information, detects weak points in the system and automatically suggests measures to eliminate them.
The real world first is that the AI recognizes and analyzes the P&ID, which is usually available as a DXF or DWG file, and then automatically fills in the associated HAZOP table. This process saves those involved many hours of work and makes the work much easier.
“It is important to understand that AI is not replacing humans. The responsibility for the safety of the system always remains with people. But the system can significantly simplify the paperwork, speed up the process and save costs,” according to Machens. In addition, the AI system has knowledge of essential legal principles, such as EN and ISO standards as well as DGUV and TRGS regulations. This makes it possible to offer “just in time” compliant solution suggestions during the HAZOP.
For implementation of this groundbreaking idea, Machens received financing from the bank Sächsische Aufbaubank (SAB), which underlines the economic potential of this development. The development of the AI system is being carried out in collaboration with MOVE Technology GmbH, an experienced company in the field of AI development.
“I am currently training several AI models so that they can correctly recognize the individual components in the P&ID and understand their interaction. The next step is the performance of a full HAZOP analysis,” states Machens.
Presented at the 18th Explosion Protection Days
The results of this development were presented on September 24, 2024 as part of the 18th Explosionsschutztage (Explosion Protection Days) at the Haus der Technik in Essen. The AI system “HAZOP-KI” will next be further tested and optimized in a large engineering firm that plans exhaust gas treatment and hydrogen systems. The system will soon be available to other interested users with a monthly license.
“Of course, the question of data security also arises,” stresses Machens. “The AI is installed and operated directly on the servers of the respective users. This way, sensitive data always remains in the hands of the user.”
In summary, this development is a valuable tool for engineering offices, certification bodies, insurance companies and operators of safety-critical systems. An AI cannot replace humans. However, it offers excellent support when carrying out HAZOP analyzes and can also be of important help to less experienced engineers.
by Klaus Vollrath | Dec 2, 2024 | Development, Europe, Germany, Market, News
Insights into a rapidly developing technology
Extremely high demands are placed on tools for punching, stamping and forming sheet metals. In some cases, accuracies of between 1 µm and 2 µm are required during manufacturing. The level of challenge increases drastically the larger the tool and the thinner the sheet. The stamping plates for the sheet-metal parts in fuel cell bipolar plates are a prime example. Bipolar plates are thin structures made from welded sheet-metal half shells that enclose the filigree flow fields. They are built up one after another in many layers, with the membrane electrode assemblies sandwiched in between, to produce the final stack.
Bipolar plates for fuel cells that will be used in automotive applications commonly consist of stamped, punched sheet-metal half shells that are welded together to produce hollow pieces. The manufacture of suitable stamping and punching tools is a constraining factor given the current technology available. Thinner sheets would indeed reduce the weight of fuel cells. However, as the material becomes thinner, the die clearance becomes narrower and the geometry must be more accurate. The accuracies asked of stamping and punching tools and presses are therefore extremely demanding.
Interest is focused on the development of a suitable process chain for manufacturing stamping and punching tools for the production of sheet-metal parts. Key points are the demands on the steel for the tools, the computer aided design/manufacturing software (CAD/CAM software), the necessary micro-milling tools, the properties of the machine tool, the lubrication and cooling of the milling cutters as well as the metrological testing and documentation of quality.
Companies working in this area include, for example, Hufschmied, MHT, Röders, Open Mind, Voestalpine and Zeiss. Together they outlined the current state of development as part of a seminar with more than 50 attendees. The results presented at the event are not only relevant for those involved with bipolar plates, but also for other sectors such as micro-production, precision engineering, medical technology or aerospace.
Ultra-hard steel: Böhler K888 Matrix
The stamping tool must have an extremely high dimensional accuracy, excellent wear resistance and low adhesion tendency in order to economically produce the extremely fine structures present in bipolar plates. Another prerequisite is excellent machinability. This presumes a low proportion of primary carbides in a hard matrix structure (matrix steel). Furthermore, the carbides should only be very small and distributed evenly across the whole cross section since coarse examples can break up during cutting and may cause surface imperfections. This is why steel produced from powder metal is used.
The Böhler K888 Matrix was chosen which is a material with a maximum carbide proportion of less than 2 percent. This is supplied in an annealed condition with a Brinell hardness of under 280 HB and achieves a Rockwell hardness of 63 +1 HRC after hardening at temperatures between 1,070 °C and 1,120 °C. This material thus demonstrates excellent wear resistance even in comparison with high-carbide materials.
Machining trials by Hufschmied have shown that the material is still extremely workable and can achieve extremely high surface qualities. It also responds well to coating which in turn leads to an increased service life.
CAD/CAM software
A suitable numerical control (NC) program is essential for optimal component quality. To create these NC programs, Open Mind offers a CAD/CAM system called hyperMILL which meets all requirements. The software calculates the tool paths with utmost accuracy and thus provides NC data with the appropriate exactness. Nevertheless, several factors need to be borne in mind: To fully take into account the topology of the component in order to calculate the tool paths, geometric features such as sharp edges, recesses and the condition of the surface transitions must be analyzed and identified. This information is then fed into the calculations and roughly controls the point distribution in the tool path.
In addition, further optimization can be carried out, for instance the adaptation of the feed. This allows the milling tool to machine the component at a constant feed rate. The “soft overlap” option prevents visible transitions by using various milling tools or strategies and reduces the time spent on manual finishing to virtually zero.
It is also important to link geometrically identical structures within a component that are either automatically or manually identified or defined. The appropriate tool paths that were initially created for an individual area can then be transposed to the previously identified or manually defined positions and connected fully automatically using the transformation function. This removes the need for unnecessary movements. This process allows calculation times in the CAM system to be significantly reduced.
Milling machine requirements
The machining of dies for bipolar plates is characterized by high material hardness, small tools with diameters of well under 1 millimeter as well as stringent demands on surface quality and accuracies down to the 1-µm range. What is more, the small contours require long running times which presuppose a very high long-term thermal stability of the machine tool.
Röders machine tools set themselves apart thanks, among other things, to their frictionless direct drives, highly rigid roller guideways, frictionless weight compensation of the Z-axis, high-speed precision spindles and highly accurate tool measurement. A particular feature is the 32-kHz sampling frequency in all control loops which enables the rapid correction of even the smallest deviations. Another key element is the sophisticated temperature management system which keeps the medium that circulates through all the main machine components at a stable temperature to within ± 0.1 K. This allows tolerances to be reliably maintained in the lower micrometer range.
The Hufschmied tools from the Bumble-Bi series used to machine various sections of the demonstrator (50 mm x 40 mm) on the Röders system along with relevant machining times, Source: Röders/Hufschmied
Bumble-Bi micro-tools from Hufschmied
The task of machining stamping tools for bipolar plates presents milling tools with a particular challenge. This is due to the hardness of the material being cut and the long program running time which in some cases lasts well over 100 hours. What is more, the required accuracies allow only minimal wear. To meet this challenge, Hufschmied developed the specially designed Bumble-Bi series of micro-tools. These include high-feed milling cutters for roughing as well as torus cutters, ball cutters and flat ball cutters. The latter are a hybridized version of a torus cutter and a ball cutter. All tools receive a physical vapor deposition or PVD coating, creating extremely smooth surfaces which enable temperature to be well managed. The milling tools used to make the demonstrator are summarized in a table alongside their operating parameters.
The entire sleeve of the MHT medium distributor encloses the tool holder without touching it or rotating with it. Air and lubricant are fed underneath the spindle via the docking station.
Optimal lubrication with the MHT medium distributor
When it comes to cutting processes, the right combination of cooling, lubrication and chip removal from the working area is crucial. The MHT medium distributor enables efficiency while also saving on energy and cost. The key element is a conical sleeve, which is attached to the tool holder and is exchanged with it during a tool change, yet does not rotate with the milling cutter. The sleeve is docked underneath the spindle and from there supplies it with compressed air and lubricant.
Most of the cooling and cleaning work is performed by the compressed air that is sprayed out of the nozzles arranged in a ring on the lower edge of the sleeve. The powerful air jet immediately removes chips and their heat content from the milling cutter and the workpiece. The lubricant, made from carefully selected hydrocarbons, is fed through in extremely low quantities (2 to 10 milliliters an hour). This is sufficient to ensure optimal lubrication for cutting operations. Heat build-up when hard cutting is reduced by around 50 percent. Significant advantages are much longer lifespans for tools, increased cutting performance of the machine and improved workpiece surfaces.
Measuring equipment and quality control
The manufacturing of bipolar plate stamping tools involves the use of milling cutters with diameters as small as 0.2 mm. For quality control purposes, it is necessary to measure extremely small and narrow contour areas, for example on the sides of the flow channels and on the cut edges. As this means measurements as low as single micrometers, the measurement uncertainty of the measuring system used should be 10 times better than the manufacturing tolerances being examined. This is something that few coordinate-measuring machines are able to achieve.
So that these measuring points can be expertly captured and without excessive effort, the task was given to a Zeiss DotScan optical sensor with a measuring rate of up to 1,000 measuring points per second which was moved with an articulated unit in three different angular positions during scanning.
Measurement of the demonstrator using a Zeiss DotScan optical sensor with a mean percentage error of 1.8 µm + L/350. To facilitate better measurement of the sides, the sensor was moved with an RDS articulated unit and on a Zeiss Contura coordinate-measuring machine during scanning. Image: Zeiss
Results
The presented results (spread ±3 µm) prove the efficiency of the process chain outlined in this article. By selecting the correct components and choosing the right methods, it is possible to achieve a high degree of reliability even when machining high-strength or very hard tool steels. It also allows high quality standards to be met, though this requires all aspects to be considered in detail.
Author: Klaus Vollrath
by Hydrogeit | Oct 16, 2024 | Development, Europe, Germany, hydrogen development, News
FES unveils H2 truck in Zwickau
Where East Germany’s famous Trabant cars were once made, H2 trucks will now exit cleanly from the production hall. This technological shift from two-stroke engines to fuel cell trucks won’t just benefit automotive service provider FES. Michael Kretschmer, minister president of the German state of Sachsen who witnessed the milestone on July 22, 2024, hopes the region as a whole will reap the rewards.
Minister President Kretschmer said at the presentation: “The unveiling of the FES fuel cell truck is an excellent example of the innovative capability and technical know-how present in Sachsen. Such projects are essential to position Sachsen as a leading center in advanced vehicle development while also contributing significantly to the protection of the environment.”
Former Trabant production site
FES can trace its origins back to 1904 when August Horch Motorwagenwerke was founded. This later gave rise to the Sachsenring Automobilwerke Zwickau in 1957 which became known for the development and production of East Germany’s iconic car – the Trabant – also affectionately known as the “Trabi.”
Following German reunification, in 1992 the company emerged as FES. A member of the Volke Group, FES has since established itself as a development service provider for national and international automotive manufacturers, various suppliers as well as the railroad and aerospace industries. It now employs approximately 850 members of staff.
FES’ ambition is to develop and manufacture vehicles that facilitate “sustainable and environmentally friendly mobility.” That includes both battery and fuel cell power systems. FES has been working in the electric transportation sector for 15 years; seven years ago it was decided to also integrate fuel cells, such as the FEScell system. According to company information, this is the “world’s smallest fuel cell system for autonomous internal logistics vehicles.” In series production since 2021, the systems have been used in industrial trucks at the BMW factory in Leipzig, for instance.
Fig. 2: Cars through the ages – from Trabi to Audi
Christian Schwamberger, CEO of FES (see fig. 1), explained: “In our view, hydrogen is […] a genuine alternative to the internal combustion engine even for goods transportation.” All those involved are particularly proud that “this innovative project” could be carried out “entirely using internal funds and without state support.”
“You have shown through quality and performance that you have what it takes.”
Sachsen’s Minister President Michael Kretschmer
Latest technology from Sachsen
The H2 truck is a production-ready vehicle weighing 18 metric tons which can be variously configured in terms of overall weight (up to 26 metric tons) and layout according to customer specifications. The fuel cell that is used – just like the tank system – is provided by technology partner Toyota; the powertrain is supplied by Framo, which is based in Löbichau.
The electric dual engine has a continuous output of 280 kilowatts, 120 kW of which is delivered by the fuel cell (170 kW from 2025). The LiFePO4 battery enables a maximum output of 308 kW for 30 seconds (the battery can be recharged via a Combined Charging System). According to FES, this type of battery is slightly heavier, but the associated fire risk is lower than in comparable systems.
The carbon-composite hydrogen tanks are located behind the cab and hold 33 kilograms at 700 bar, sufficient energy for the 350- to 500-kilometers (215- to 310-mile) range. FES’ head of development Hartmut Schimmel (see image on page 4) commented: “We built the truck to meet 700 bar, but it can be filled at any 350-bar station.” What’s more, additional H2 tanks can be installed if required.
The base vehicle is a third-generation MAN TGM and can be repaired – if necessary – at a regular workshop. The electric rear axle is designed for 1 million kilometers (620,000 miles), reported Schimmel with pride. He added that this is “no junior research project”; rather the FC truck is “entirely suitable for long distance.”
In addition, Schimmel led H2-international to understand that the FC truck will be available to preorder shortly and ready for delivery from 2025 onward. This assumes that potentially interested parties are now actually prepared to place orders.
Fig. 3: Alongside company owner Martin Volke (left), the former German transportation minister Andreas Scheuer was among the guests of honor – here in conversation with Rainer Albrecht, the founding shareholder of FES in 1992 (right)
