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Protonex powers test flights of Boeing Insitu ScanEagle UAV
NEWS / EDITORIAL The rollout of new fuel cell bus fleets at this unprecedented scale will be made possible by multiple cities and regions collaborating in joint procurement processes, allowing large orders to be placed with single bus suppliers. The procurement activities are organised into three geographic clusters, making it possible to provide common specifications for the buses and unlock the economies of scale. Element Energy, Cambridge, UK. Tel: +44 1223 852499, www.element-energy.co.uk Hydrogen Europe: www.hydrogeneurope.eu Fuel Cells and Hydrogen Joint Undertaking: www.fch.europa.eu
Ballard, Broad-Ocean wrap deal for fuel cell engine manufacture and sales in China
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allard Power Systems in Canada has closed the transaction announced in February relating to technology transfer, licensing and supply arrangements with strategic partner Zhongshan Broad-Ocean Motor Co Ltd, for the assembly and sale of FCveloCity® 30 kW and 85 kW fuel cell engines in China. Under the deal, Broad-Ocean will manufacture Ballard’s PEM fuel cell modules in three strategic regions in China, including Shanghai [FCB, March 2017, p9]. The deal has an estimated value of approximately US$25 million in revenue to Ballard over the initial fiveyear term, including $12 million in Technology Solutions revenue. Ballard has received initial payments totaling $3.6 million. In each of the three assembly operation locations, Broad-Ocean plans to engage with local governments as well as with bus and commercial vehicle OEMs for deployment of fuel cell buses and commercial vehicles incorporating Ballard-designed modules manufactured by Broad-Ocean. Broad-Ocean will make further payments to Ballard based on certain commissioning milestones, initial supply agreements, and recurring royalties. Ballard will also have the exclusive right to purchase fuel cell engines from any of the Broad-Ocean manufacturing operations for sale outside China. The fuel cell engines assembled by BroadOcean will utilise FCveloCity-9SSL stacks, initially manufactured by Ballard in Vancouver. Stack supply will be transferred to Guangdong Synergy Ballard Hydrogen Power Co Ltd, the joint venture owned by Guangdong Nation
May 2017
Synergy Hydrogen Power Technology Co Ltd and Ballard in the City of Yunfu, Guangdong Province, once the JV becomes fully operational, expected in late 2017 [November 2016, p8]. Thereafter Ballard will supply membraneelectrode assemblies (MEAs) on an exclusive basis for stacks manufactured by the JV. Ballard has also entered into a definitive equipment supply agreement with BroadOcean for the supply and delivery of 200 FCveloCity fuel cell engines to be used in demonstrations of clean energy buses and commercial vehicles in key Chinese cities. The engines will be manufactured and supplied by Ballard from its Vancouver site. ‘Broad-Ocean plans to seize early market demand for fuel cell buses and commercial vehicles in strategic demonstration projects in key Chinese cities,’ says Ballard president and CEO Randy MacEwen. ‘As a result, we will supply Broad-Ocean with 200 fuel cell modules in 2017 to support these initial projects. This $11 million order will be incremental to the expected $25 million value of the technology transfer deal.’ Broad-Ocean is a leading manufacturer of motors that power small and specialised electric machinery for electric vehicles, and for heating, ventilation and air-conditioning. Last summer it became Ballard’s largest shareholder, following a $28.3 million investment [August 2016, p9]. Ballard has also just signed a follow-on Technology Solutions contract with an unnamed leading global automotive OEM [see page 10]. Ballard Power Systems, Burnaby, BC, Canada. Tel: +1 604 454 0900, www.ballard.com Broad-Ocean: www.broad-ocean.com/en/index.html
MOBILE APPLICATIONS
Protonex powers test flights of Boeing Insitu ScanEagle UAV
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anadian-based Ballard Power Systems reports that its US subsidiary Protonex has successfully powered test flights of the Boeing Insitu ScanEagle small unmanned aerial vehicle (UAV) with the company’s PEM fuel cell propulsion system. Protonex delivered prototype modules to Insitu a year ago, for use in the ScanEagle [FCB, May 2016, p3]. The successful ScanEagle UAV platform has logged more than 800 000 flight hours in military and civilian applications. ‘These test flights have successfully demonstrated the integration and operation of our fuel cell propulsion system, as well as
EDITORIAL
C
alifornia is certainly keen to maintain its leading position in the deployment of fuel cell powered vehicles of all sizes and uses, with several recent developments at the heavier end of the scale. We reported last month on Toyota’s ‘Project Portal’ heavy-duty truck for use at the Port of Los Angeles in southern California, featuring two PEM fuel cell stacks adapted from its Mirai car [April 2017, p1]. It turns out that the neighbouring Ports of Long Beach and Los Angeles are becoming a busy location for heavy-duty vehicle demonstrations, with the imminent deployment of hydrogen fuel cell powered Class 8 heavy trucks from two more consortia. US Hybrid has unveiled a Navistar International port drayage truck featuring its 80 kW FCe™ 80 PEM fuel cell engine, while Kenworth Truck Company is developing a prototype Class 8 tractor unit powered by an 85 kW FCveloCity®-HD PEM fuel cell engine supplied by Ballard Power Systems [see page 1]. It’s not just about trucks – for many years, fuel cell buses have been demonstrated in commercial service by a number of transit agencies in California, including AC Transit in the San Francisco Bay Area and the Orange County Transportation Authority in Greater Los Angeles [March 2017, p3]. SunLine Transit Agency in the Coachella Valley, east of Los Angeles, has also been a long-time user of fuel cell buses, and it is maintaining its enthusiasm for zero-emissions public transportation with an order for five additional fuel cell buses, and the development of what will be the largest renewable hydrogen refueling station in the US [see page 12]. Under the new project, Hydrogenics will supply five 60 kW CelerityPlus™ PEM fuel cell modules for integration into New Flyer XHE40 Xcelsior® fuel cell buses. It will also upgrade SunLine’s heavy-duty refueling station with a new 1.5 MW HyLyzer™ unit that can produce up to 400 kg/day of hydrogen onsite, enough to refill 15 buses. The News Feature this month reports on work at the ZSW Centre for Solar Energy and Hydrogen Research in Baden-Württemberg, Germany, where researchers have developed a mobile certification system to ensure that gaseous hydrogen refueling equipment complies with international standards [see pages 14–15]. The unit allows them to check for compliance with the pressure and temperature limits, the infrared communication link between the vehicle and the refueling station, and the amount of hydrogen dispensed. The mobile inspection system takes hydrogen samples during and after refueling, to conduct quality assessments back in the ZSW lab.
Steve Barrett
Fuel Cells Bulletin
3
NEWS the high-pressure hydrogen fuel tank,’ says Paul Osenar, president of Protonex. ‘The tests also documented acoustic footprint reduction that will enable mission routes that take the ScanEagle closer to its targets.’ ‘In addition, test flights confirm that our fuel cell propulsion system offers power during flight that can be used to support greater payload diversity,’ continues Osenar. ‘When combined with improved reliability and other advantages over internal combustion systems, fuel cells are proving to be a tremendous fit for UAVs.’ The Protonex PEM fuel cell propulsion modules offer a significant (up to 5×) improvement in the expected MTBF (mean time between failures) over internal combustion engines, silent operation, 100% throttle flexibility (including mid-air start-stop capability), and the use of existing JP8 fuel in ground refueling systems. ‘Now in developmental testing, the Protonex fuel cell system has exceeded our power requirements, and has integrated very well with the initial target aircraft systems and with general unmanned aerial system (UAS) operations,’ says Peter Kunz, CTO at Insitu, a subsidiary of Boeing. ‘Additional performance tests and customer demonstrations are planned throughout the remainder of this year.’ In 2012 Insitu announced the first hydrogen fuel cell powered ScanEagle flight, in a collaboration with the US Naval Research Laboratory and Connecticut-based UTC Power, which supplied a 1.5 kW PEM fuel cell, integrated with NRL’s hydrogen fueling solution [May 2012, p5]. Ballard has also just finalised its deal with Zhongshan Broad-Ocean Motor for the assembly and sale of FCveloCity® fuel cell engines in China [see page 3], and signed a follow-on Technology Solutions contract with a global automotive OEM [see page 10]. Protonex Technology, Southborough, Massachusetts, USA. Tel: +1 508 490 9960, www.protonex.com Ballard Power Systems: www.ballard.com Insitu: www.insitu.com Insitu ScanEagle: http://tinyurl.com/insitu-scaneagle
SMALL STATIONARY
SOLIDpower wins big BlueGEN contract in Belgium with Elugie OLIDpower has won a E10 million (US$10.9 million) contract to supply at least 550 BlueGEN solid oxide fuel cell systems to its Belgian partner Elugie.
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Fuel Cells Bulletin
The contract highlights the increasing interest in this highly efficient SOFC technology for combined heat and power (CHP). The contract gives Elugie an option to extend the order to a total of 1200 BlueGEN units, which corresponds to overall sales of more than E20 million ($21.7 million) for SOLIDpower. ‘More and more owners of larger singlefamily homes and businesses are looking for a solution for generating electricity locally in an inexpensive and environmentally friendly way,’ says Bjorn van Haver, founder and MD of energy technology company Elugie, based near Antwerp. ‘And BlueGEN is an alternative to the critically discussed use of nuclear energy in Belgium.’ Belgium’s planned withdrawal from nuclear energy has led to the expansion of power generation using CHP plants using natural gas, which now has a 20% share of the national power mix – and where Elugie sees considerable potential for growth with the BlueGEN. ‘As a micro CHP appliance powered by natural gas, our BlueGEN can be combined with virtually any heating system on the market,’ says Andreas Ballhausen, MD of SOLIDpower in Germany. ‘This way, the generated heat is efficiently used by being fed into a hot water tank – enough to provide around 200 litres of hot water per day.’ SOLIDpower – with facilities in Italy, Germany and Switzerland – is a leading developer, manufacturer and distributor of SOFC-based products and technologies. Its BlueGEN commercial product – brought in through the acquisition of Ceramic Fuel Cells GmbH [FCB, August 2015, p10] – has demonstrated high efficiency and reliability in hundreds of installations worldwide [August 2016, p3]. In addition, its own EnGen-2500 – designed to optimise costs and introduce a uniform stack platform [May 2015, p3] – has been tested in the ene.field residential fuel cell demonstration programme in Europe [March 2016, p5]. The company is also partnering with Daesung [September 2016, p6] and Korea Electric Power [January 2017, p5] in South Korea to develop next-generation SOFC products and build a greater share in the country’s rollout of fuel cell technology. SOLIDpower SpA, Mezzolombardo, Trentino, Italy. Tel: +39 0461 1755 068, www.solidpower.com Elugie: www.elugie.com [in Flemish/Dutch]
PowerCell shows PS-5 system in Hannover
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owerCell Sweden unveiled its new PowerCell PS-5 fuel cell system
at the recent Hannover Messe trade fair in Germany, highlighting the company’s continuing industrialisation of products based on its PEM fuel cell technology. The PowerCell PS-5 system has a wide range of applications; it can be used as a spare power generator for small and medium-sized enterprises, or as part of a system for storing energy from intermittent renewable sources such as wind and solar. A prototype system has been tested in an energy-efficient property near Gothenburg since 2015. ‘I installed the PowerCell PS-5 prototype in my own property,’ says homeowner Hans-Olof Nilsson. ‘Solar panels power an electrolyser that generates hydrogen, and thus store the energy from the solar cells. When needed, I run the fuel cell system on the stored hydrogen, and get all the electricity and heat I need. I manage completely without other energy sources and I’m off the grid.’ The PowerCell PS-5 fuel cell system is based on the robust PowerCell S2 stack, and facilitates the increased use of renewable energy, as it is possible to integrate with solar photovoltaic (PV) panels. The system is designed to meet the need for eco-friendly, silent and reliable electricity generation and backup power systems for buildings, households, telecoms and traffic systems, and is delivered with a fully automated control system. The system is adapted to customer needs, and delivered with a power output of 1.6, 3.3 or 5.0 kW and voltage levels of 24 or 48 Vdc, and with liquid- or air-based cooling systems. PowerCell Sweden – a spinout from the Volvo Group – is developing and manufacturing PEM fuel cell systems for stationary and mobile applications [e.g. FCB, June 2016, p11 and January 2017, p3]. Its modular fuel cell platforms can operate on renewably produced hydrogen, but can also handle hydrogen reformed from biogas, natural gas, biodiesel or standard diesel. The company is targeting several international markets, including the Chinese automotive sector [April 2017, p12], for which it has boosted its S2 stack maximum output power to 35 kW. It has also combined its fuel cell and reformer technology to offer the PowerPac system, which runs on standard diesel with hydrogen [January 2017, p11]. PowerCell is also part of a new joint venture with NEL ASA and Hexagon Composites in Norway to create a one-stop-shop for customers wanting to utilise hydrogen technologies across the value chain [see page 11].
May 2017
Ballard, Broad-Ocean wrap deal for fuel cell engine manufacture and sales in China
B
allard Power Systems in Canada has closed the transaction announced in February relating to technology transfer, licensing and supply arrangements with strategic partner Zhongshan Broad-Ocean Motor Co Ltd, for the assembly and sale of FCveloCity® 30 kW and 85 kW fuel cell engines in China. Under the deal, Broad-Ocean will manufacture Ballard’s PEM fuel cell modules in three strategic regions in China, including Shanghai [FCB, March 2017, p9]. The deal has an estimated value of approximately US$25 million in revenue to Ballard over the initial fiveyear term, including $12 million in Technology Solutions revenue. Ballard has received initial payments totaling $3.6 million. In each of the three assembly operation locations, Broad-Ocean plans to engage with local governments as well as with bus and commercial vehicle OEMs for deployment of fuel cell buses and commercial vehicles incorporating Ballard-designed modules manufactured by Broad-Ocean. Broad-Ocean will make further payments to Ballard based on certain commissioning milestones, initial supply agreements, and recurring royalties. Ballard will also have the exclusive right to purchase fuel cell engines from any of the Broad-Ocean manufacturing operations for sale outside China. The fuel cell engines assembled by BroadOcean will utilise FCveloCity-9SSL stacks, initially manufactured by Ballard in Vancouver. Stack supply will be transferred to Guangdong Synergy Ballard Hydrogen Power Co Ltd, the joint venture owned by Guangdong Nation
May 2017
Synergy Hydrogen Power Technology Co Ltd and Ballard in the City of Yunfu, Guangdong Province, once the JV becomes fully operational, expected in late 2017 [November 2016, p8]. Thereafter Ballard will supply membraneelectrode assemblies (MEAs) on an exclusive basis for stacks manufactured by the JV. Ballard has also entered into a definitive equipment supply agreement with BroadOcean for the supply and delivery of 200 FCveloCity fuel cell engines to be used in demonstrations of clean energy buses and commercial vehicles in key Chinese cities. The engines will be manufactured and supplied by Ballard from its Vancouver site. ‘Broad-Ocean plans to seize early market demand for fuel cell buses and commercial vehicles in strategic demonstration projects in key Chinese cities,’ says Ballard president and CEO Randy MacEwen. ‘As a result, we will supply Broad-Ocean with 200 fuel cell modules in 2017 to support these initial projects. This $11 million order will be incremental to the expected $25 million value of the technology transfer deal.’ Broad-Ocean is a leading manufacturer of motors that power small and specialised electric machinery for electric vehicles, and for heating, ventilation and air-conditioning. Last summer it became Ballard’s largest shareholder, following a $28.3 million investment [August 2016, p9]. Ballard has also just signed a follow-on Technology Solutions contract with an unnamed leading global automotive OEM [see page 10]. Ballard Power Systems, Burnaby, BC, Canada. Tel: +1 604 454 0900, www.ballard.com Broad-Ocean: www.broad-ocean.com/en/index.html
MOBILE APPLICATIONS
Protonex powers test flights of Boeing Insitu ScanEagle UAV
C
anadian-based Ballard Power Systems reports that its US subsidiary Protonex has successfully powered test flights of the Boeing Insitu ScanEagle small unmanned aerial vehicle (UAV) with the company’s PEM fuel cell propulsion system. Protonex delivered prototype modules to Insitu a year ago, for use in the ScanEagle [FCB, May 2016, p3]. The successful ScanEagle UAV platform has logged more than 800 000 flight hours in military and civilian applications. ‘These test flights have successfully demonstrated the integration and operation of our fuel cell propulsion system, as well as
EDITORIAL
C
alifornia is certainly keen to maintain its leading position in the deployment of fuel cell powered vehicles of all sizes and uses, with several recent developments at the heavier end of the scale. We reported last month on Toyota’s ‘Project Portal’ heavy-duty truck for use at the Port of Los Angeles in southern California, featuring two PEM fuel cell stacks adapted from its Mirai car [April 2017, p1]. It turns out that the neighbouring Ports of Long Beach and Los Angeles are becoming a busy location for heavy-duty vehicle demonstrations, with the imminent deployment of hydrogen fuel cell powered Class 8 heavy trucks from two more consortia. US Hybrid has unveiled a Navistar International port drayage truck featuring its 80 kW FCe™ 80 PEM fuel cell engine, while Kenworth Truck Company is developing a prototype Class 8 tractor unit powered by an 85 kW FCveloCity®-HD PEM fuel cell engine supplied by Ballard Power Systems [see page 1]. It’s not just about trucks – for many years, fuel cell buses have been demonstrated in commercial service by a number of transit agencies in California, including AC Transit in the San Francisco Bay Area and the Orange County Transportation Authority in Greater Los Angeles [March 2017, p3]. SunLine Transit Agency in the Coachella Valley, east of Los Angeles, has also been a long-time user of fuel cell buses, and it is maintaining its enthusiasm for zero-emissions public transportation with an order for five additional fuel cell buses, and the development of what will be the largest renewable hydrogen refueling station in the US [see page 12]. Under the new project, Hydrogenics will supply five 60 kW CelerityPlus™ PEM fuel cell modules for integration into New Flyer XHE40 Xcelsior® fuel cell buses. It will also upgrade SunLine’s heavy-duty refueling station with a new 1.5 MW HyLyzer™ unit that can produce up to 400 kg/day of hydrogen onsite, enough to refill 15 buses. The News Feature this month reports on work at the ZSW Centre for Solar Energy and Hydrogen Research in Baden-Württemberg, Germany, where researchers have developed a mobile certification system to ensure that gaseous hydrogen refueling equipment complies with international standards [see pages 14–15]. The unit allows them to check for compliance with the pressure and temperature limits, the infrared communication link between the vehicle and the refueling station, and the amount of hydrogen dispensed. The mobile inspection system takes hydrogen samples during and after refueling, to conduct quality assessments back in the ZSW lab.
Steve Barrett
Fuel Cells Bulletin
3
NEWS the high-pressure hydrogen fuel tank,’ says Paul Osenar, president of Protonex. ‘The tests also documented acoustic footprint reduction that will enable mission routes that take the ScanEagle closer to its targets.’ ‘In addition, test flights confirm that our fuel cell propulsion system offers power during flight that can be used to support greater payload diversity,’ continues Osenar. ‘When combined with improved reliability and other advantages over internal combustion systems, fuel cells are proving to be a tremendous fit for UAVs.’ The Protonex PEM fuel cell propulsion modules offer a significant (up to 5×) improvement in the expected MTBF (mean time between failures) over internal combustion engines, silent operation, 100% throttle flexibility (including mid-air start-stop capability), and the use of existing JP8 fuel in ground refueling systems. ‘Now in developmental testing, the Protonex fuel cell system has exceeded our power requirements, and has integrated very well with the initial target aircraft systems and with general unmanned aerial system (UAS) operations,’ says Peter Kunz, CTO at Insitu, a subsidiary of Boeing. ‘Additional performance tests and customer demonstrations are planned throughout the remainder of this year.’ In 2012 Insitu announced the first hydrogen fuel cell powered ScanEagle flight, in a collaboration with the US Naval Research Laboratory and Connecticut-based UTC Power, which supplied a 1.5 kW PEM fuel cell, integrated with NRL’s hydrogen fueling solution [May 2012, p5]. Ballard has also just finalised its deal with Zhongshan Broad-Ocean Motor for the assembly and sale of FCveloCity® fuel cell engines in China [see page 3], and signed a follow-on Technology Solutions contract with a global automotive OEM [see page 10]. Protonex Technology, Southborough, Massachusetts, USA. Tel: +1 508 490 9960, www.protonex.com Ballard Power Systems: www.ballard.com Insitu: www.insitu.com Insitu ScanEagle: http://tinyurl.com/insitu-scaneagle
SMALL STATIONARY
SOLIDpower wins big BlueGEN contract in Belgium with Elugie OLIDpower has won a E10 million (US$10.9 million) contract to supply at least 550 BlueGEN solid oxide fuel cell systems to its Belgian partner Elugie.
S 4
Fuel Cells Bulletin
The contract highlights the increasing interest in this highly efficient SOFC technology for combined heat and power (CHP). The contract gives Elugie an option to extend the order to a total of 1200 BlueGEN units, which corresponds to overall sales of more than E20 million ($21.7 million) for SOLIDpower. ‘More and more owners of larger singlefamily homes and businesses are looking for a solution for generating electricity locally in an inexpensive and environmentally friendly way,’ says Bjorn van Haver, founder and MD of energy technology company Elugie, based near Antwerp. ‘And BlueGEN is an alternative to the critically discussed use of nuclear energy in Belgium.’ Belgium’s planned withdrawal from nuclear energy has led to the expansion of power generation using CHP plants using natural gas, which now has a 20% share of the national power mix – and where Elugie sees considerable potential for growth with the BlueGEN. ‘As a micro CHP appliance powered by natural gas, our BlueGEN can be combined with virtually any heating system on the market,’ says Andreas Ballhausen, MD of SOLIDpower in Germany. ‘This way, the generated heat is efficiently used by being fed into a hot water tank – enough to provide around 200 litres of hot water per day.’ SOLIDpower – with facilities in Italy, Germany and Switzerland – is a leading developer, manufacturer and distributor of SOFC-based products and technologies. Its BlueGEN commercial product – brought in through the acquisition of Ceramic Fuel Cells GmbH [FCB, August 2015, p10] – has demonstrated high efficiency and reliability in hundreds of installations worldwide [August 2016, p3]. In addition, its own EnGen-2500 – designed to optimise costs and introduce a uniform stack platform [May 2015, p3] – has been tested in the ene.field residential fuel cell demonstration programme in Europe [March 2016, p5]. The company is also partnering with Daesung [September 2016, p6] and Korea Electric Power [January 2017, p5] in South Korea to develop next-generation SOFC products and build a greater share in the country’s rollout of fuel cell technology. SOLIDpower SpA, Mezzolombardo, Trentino, Italy. Tel: +39 0461 1755 068, www.solidpower.com Elugie: www.elugie.com [in Flemish/Dutch]
PowerCell shows PS-5 system in Hannover
P
owerCell Sweden unveiled its new PowerCell PS-5 fuel cell system
at the recent Hannover Messe trade fair in Germany, highlighting the company’s continuing industrialisation of products based on its PEM fuel cell technology. The PowerCell PS-5 system has a wide range of applications; it can be used as a spare power generator for small and medium-sized enterprises, or as part of a system for storing energy from intermittent renewable sources such as wind and solar. A prototype system has been tested in an energy-efficient property near Gothenburg since 2015. ‘I installed the PowerCell PS-5 prototype in my own property,’ says homeowner Hans-Olof Nilsson. ‘Solar panels power an electrolyser that generates hydrogen, and thus store the energy from the solar cells. When needed, I run the fuel cell system on the stored hydrogen, and get all the electricity and heat I need. I manage completely without other energy sources and I’m off the grid.’ The PowerCell PS-5 fuel cell system is based on the robust PowerCell S2 stack, and facilitates the increased use of renewable energy, as it is possible to integrate with solar photovoltaic (PV) panels. The system is designed to meet the need for eco-friendly, silent and reliable electricity generation and backup power systems for buildings, households, telecoms and traffic systems, and is delivered with a fully automated control system. The system is adapted to customer needs, and delivered with a power output of 1.6, 3.3 or 5.0 kW and voltage levels of 24 or 48 Vdc, and with liquid- or air-based cooling systems. PowerCell Sweden – a spinout from the Volvo Group – is developing and manufacturing PEM fuel cell systems for stationary and mobile applications [e.g. FCB, June 2016, p11 and January 2017, p3]. Its modular fuel cell platforms can operate on renewably produced hydrogen, but can also handle hydrogen reformed from biogas, natural gas, biodiesel or standard diesel. The company is targeting several international markets, including the Chinese automotive sector [April 2017, p12], for which it has boosted its S2 stack maximum output power to 35 kW. It has also combined its fuel cell and reformer technology to offer the PowerPac system, which runs on standard diesel with hydrogen [January 2017, p11]. PowerCell is also part of a new joint venture with NEL ASA and Hexagon Composites in Norway to create a one-stop-shop for customers wanting to utilise hydrogen technologies across the value chain [see page 11].
May 2017