Smarter Solutions for a Clean Energy Future

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1 April 8, 2013 FUEL CELL ENGINEERING SERVICES Smarter Solutions for a Clean Energy Future TJ Lawy Platform Manager, Engineering Services 2013 BALLARD POWER SYSTEMS, INC. ALL RIGHTS RESERVED.

2 Who We Are Ballard Power Systems, Inc. is a recognized global leader in clean energy PEM fuel cells Design, manufacturing, distribution, support Commercial market focus 355 employees Operations: Canada, U.S.A. (University of Maryland; Bend, OR), Mexico, Denmark Ballard headquarters facility Burnaby, BC, Canada April 23,

3 Ballard Unrivalled PEM Intellectual Property Portfolio Over 200 patents/applications owned and license rights to >1,000 patents/applications owned by Daimler, Ford & IdaTech MEA designs Plate designs Catalyst Coated Membranes Gas Diffusion Layer materials Fuel cell systems Manufacturing processes Fundamental knowledge in key areas of stack operation, system integration and fuel processing April 23,

4 Automotive Fuel Cell Development Extensive experience in automotive fuel cell technology Vehicular Fuel Cell Alliance with DaimerChrysler & Ford Hundreds of units supplied to Alliance partners & other OEMs Meet Tier 1 supplier requirements Technology development program enabled: Reduced cost, enhanced reliability, increased lifetime, improved manufacturability, freeze start capability, higher power density Features have been transferred to today s commercial products Products manufactured to automotive quality standards: ISO certified APQP Six Sigma tools and methodologies Process and designs verified and validated April 23,

5 Automotive Customers By 2011, Ballard had supplied >500 fuel cell products to 9 of the top automotive companies April 23,

6 Fuel Cell Product Portfolio Ballard s product portfolio includes industry leading PEM fuel cell stacks, fuel cell modules and complete fuel cell system solutions April 23,

7 World Class Product Development & Manufacturing Capability Fully equipped R&D engineering and test center 58,000 square foot hydrogen safe test lab accumulates roughly 400,000+ hours of in house testing each year with integrated data collection and reporting Test stands are capable of simulating duty cycle conditions for a range of product applications Test station capacity <100 W to 333 kw High volume PEM fuel cell manufacturing facility Automated manufacturing techniques replace discrete, labor intensive processes in 110,000 square foot facility Sufficient capacity through 2013, with capability to scale up production kw scale fuel cell system production Flexible, low cost manufacturing in facilities located in Hobro, Denmark and Tijuana, Mexico Annual capacity for >5,000 ElectraGen units April 23,

8 Engineering Services April 23,

9 Engineering Services Apply Ballard know how, infrastructure, unique diagnostic tools and design capabilities to accelerate development Testing Services Design/Analysis Services Stack/Component Prototyping Services Engineering Service Offering Product Development Applications Engineering Reference Systems Fuel Cell Testing Services Manufacturing and Prototyping Failure Analysis and Failure Diagnostics Predictive Simulation and Modeling Test Stations and Infrastructure Improvement Sample Customers 9 April 23,

10 Product Development Ballard offers custom services in all aspects of product design & research ranging from components through to prototype fuel cell stacks and complete systems System modeling & design Balance of plant components Hardware Bi polar plates Membrane electrode assembly (MEA) Catalyst coated membrane (CCM) Gas diffusion layer (GDL) Reformers and fuel processors (UMD) Prototype light weight, low power air cooled fuel cell stack concept CCM roll Bi polar plate designs April 23,

11 Case Study: Fuel Cell Home Generator for African Market Program with AngloAmerican Platinum to develop reformate home generator system Plan to support electrification of rural South Africa > 4 million households with no grid connection Strong return for fuel cells vs. alternative off grid solutions Flexible fueling options LPG& methanol Ballard and AngloAmerican have partnered Ballard developing a fuel cell stack for this specific application April 23,

12 Applications Engineering We have assisted our customers with development 50+ fuel cell systems ~2000 installed telecom systems >3,000 of fork lift trucks operating +50 fuel cell buses operating +300 fuel cell cars operating Ballard is experienced in developing technology to customer requirements, success mainly driven by development approach learned from Ford and Daimler April 23,

13 Reference Systems Stack Controls Humidification Hydrogen Recirculation Coolant Flow and Temperature Control Air Supply April 23,

14 Reference Systems Integration and use Manual System P&ID Detailed BOM with supplier information Test Report Control Strategy April 23,

15 Reference Systems 1020 ACS Air Cooled Stack Reference System 2.8kW Net 9SSL Liquid Cooled Stack Reference System 15kW Net April 23,

16 Fuel Cell Testing Services Specialized testing protocols for characterizing fuel cell stack technologies Benchmark Ballard and OEM components, stacks or hardware Push operational boundaries run application specific operating conditions Ballard s accelerated testing protocols minimize total test time, accelerating stresses by up to 150x Comprehensive suite of test stands capable of simulating duty cycles and environmental conditions for a range of product applications 60+ test stations can perform tests such as dynamic, durability, freeze start, ambient start and system representative testing Sizes range from components, single cells, and small stack testing, to large bus fuel cell module testing Accelerated test methodologies Flexible fueling options Ballard test facilities in Burnaby, BC April 23,

17 Failure Analysis and Failure Diagnostics Ballard applies structured processes (FRACAS, 8D) to identify and resolve material and product failure issues Wide array of analysis tools available to understand how components change with use, and over time, and how those changes may lead to failure In depth knowledge of fuel cell failure modes and contamination Services available range from raw data files to a full analysis of the results Areas of expertise include: SEM and optical microscope investigation Catalyst degradation & content analysis Leak testing and leak location Chemical analysis and contaminant identification Characterization of material degradation Validating test protocols & field data April 23,

18 Predictive Simulation & Modeling Ballard has developed sophisticated in house modeling capability that can be leveraged to reduce design time Fuel cell performance models accurate to ±2% of cell voltage Membrane durability and performance degradation models to predict time to failure under different load cycles, or in different operating conditions Flow and thermal analysis in the system, stack, or unit cell Water management modeling in flow fields and MEAs Structural analysis for compression of MEAs, seals, plates and stack hardware Services available range from model results, analysis reports or executable models April 23,

19 Infrastructure Improvement Capitalize on know how gained in development of Ballard s world class R&D, test and production facilities Test station design and build Standard or custom designs depending on customer requirements Simple load bank to high power dynamic test station with environmental chamber Consultation services for: Hydrogen infrastructure, use and safety within facility Lab and facility layout and design Fuel cell manufacturing pilot plant and layout Clean room design April 23,

20 Engineering Services Ballard s Engineering Services team can work with you to help define your requirements, and explore options for an Engineering Services solution. Evaluate Requirements Develop Solution Execute Plan April 23,

21 Summary Ballard s engineering services provide a high value way to accelerate your fuel cell development efforts towards commercialization Our fuel cell science, engineering and manufacturing skill sets are not to be found elsewhere in the marketplace Leverage Ballard s unique knowledge of PEM fuel cells and downstream system integration activities to create industry leading clean energy power solutions April 23,

22 Engineering Services Portfolio TJ Lawy Platform Manager, Engineering Services +1 (604) Come to our booth Hall 27 Booth D67 April 23,

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