Ballard presents 120 kW fuel cell module for heavy-duty vehicles
The Canadian manufacturer is presenting the newest generation of its FCmove-XD fuel cell module at the Advanced Clean Transportation (ACT) Expo at the Las Vegas Convention Centre. The module, which was specially developed for heavy commercial vehicles, now has a volumetric power density of 0.36 kW per litre and a gravimetric power density of 0.48 kW per kilogram. This achieves “the highest volumetric power density in the industry for heavy-duty applications”, Ballard writes.
The performance of the fuel cell drive remains unchanged: up to three modules with 120 kW each can be combined to produce an output of up to 360 kW. The Canadians now state a service life of more than 30,000 operating hours – or more than one million miles in lorry operation with typical work cycles. Previously, a good 20,000 operating hours was regarded as a guide value.
According to the manufacturer, this is due to 33 per cent fewer parts, which should also significantly increase reliability and reduce costs. Furthermore, the improved module is said to have a wider operating temperature range (up to 95 degrees) and better conditions for quick maintenance. Thanks to simplified assembly, only half the time will be needed to manufacture FC modules in future.
Ballard states that the efficiency of the fuel cell modules for the system is more than 60 per cent. In other words, almost two thirds of the total electricity used also reaches the edges. The lower efficiency compared to battery-electric vehicles is often seen as the sticking point for the lack of economic efficiency in hydrogen applications.
“We are laser focused on strengthening the economic value proposition for heavy-duty Ballard FCmove XD mobility customers,” commented Mircea Gradu, Chief Engineering Officer at Ballard. With the launch of the ninth generation, his company continues to push the boundaries: “Our innovative FCmove®-XD delivers significant improvements in reliability, durability, efficiency, power density, scalability, serviceability, and total cost of ownership.”
Silvano Pozzi, Vice President for Product Line Management at Ballard, also emphasises the different requirements in the highly segmented truck market: “One of the compelling features of our new FCmove®-XD is scalability based on modularity. We can offer customers efficient integration of 120 kW, 240 kW, and 360 kW solutions dependent on truck class, use case, and duty cycle. For example, two engines, totalling 240 kW of power output, can be easily installed in the engine compartment of a typical Class 8 heavy-duty truck, enhancing standardization and redundancy.” Class 8 is the highest vehicle category in the heavy-duty truck sector in the USA.
Ballard plans to initially manufacture the improved FCmove-XD module at its plant in Oregon – as this will “enable compliance with Buy America regulations from 2025”, according to the manufacturer. The choice of location is therefore about subsidies. Future large-scale production is also expected to take place in the US at a later date at Ballard’s recently announced 3-gigawatt factory in Rockwall, Texas. Ballard’s portfolio generally comprises fuel cell modules with a power range of 45 to 120 kW.
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