FuelCellsWorks

For years many companies, governments and researchers have predicted that our energy future must lie with the universe’s simplest element. The mooted hydrogen economy would use the gas to store and transport renewable or low-carbon energy, and power fuel cells in the transport sector or in portable electronics.

But creating the necessary society-wide infrastructure has proved difficult and expensive to get off the ground. And now a rival idea, first suggested in 2006 by Nobel chemistry laureate George Olah at the University of Southern California, has received a boost.

The methanol economy, say its supporters, could be with us much sooner than the hydrogen one.

Hydrogen dangers

Olah’s rationale is that modifying our existing oil and petrol-focused infrastructure to run on methanol will be much easier than refitting the world’s liquid-fuel-based economy to deal with an explosive gas.

Methanol has already been used to power portable gadgets and could potentially power vehicles and other devices. Now US chemists have worked out the conditions needed to make the feedstock for methanol production using renewable energy.

The research is significant because just as the lack of an efficient way to generate and store hydrogen is a major barrier to the idea of running civilisation on it, sourcing methanol on a vast scale is a similarly major hurdle.

Clean solution

The best way to make methanol is from syngas, a mixture of hydrogen and carbon monoxide, using the Fischer-Tropsch process. This uses catalysts to convert the syngas into liquid hydrocarbons. The process is used today to make diesel and other liquid fuels from coal, and kept South African cars going during the country’s international isolation in the 1980s and 90s.

However, the whole point of the methanol economy would be to create a greener society, so any syngas must come from an environmentally friendly source, not fossil fuels.

Now chemist Scott Barnett at Northwestern University in Evanston, Illinois, and colleagues have shown that a solid oxide electrolysis cell, more normally used to split water into hydrogen and oxygen, could be that source.

Viable brew

Using a mix of one part CO₂, one part hydrogen and two parts water in the device generates syngas at a rate which compares favourably with the processes used to make it from natural gas, says Barnett. At peak conditions of 800 °C and 1.3 volts, the system can produce 7 standard cubic centimetres of syngas per minute for every square centimetre of the electrolysis cell’s surface.

The next stage, turning the syngas into methanol, is a standard industrial reaction that is well understood.

Barnett’s method requires a steady stream of water vapour and CO₂, but both gases are released when the methanol is used in fuel cells, and could be captured and re-used, he says.

That would add to the costs involved, but a hydrogen economy would require similar gas-capture technology, says Barnett, because hydrogen production requires a plentiful source of fresh water, which is heavy to cart about.

Olah thinks Barnett’s study is a useful one. “This [methanol economy] approach is now starting to be implemented around the world,” he says. “New methanol plants are being built in China, South Korea, Japan and Iceland.”

Limited scope

But others remain sceptical that methanol will ever occupy more than a small niche. There are several well-known problems with the use of methanol. Like hydrogen, and unlike petrol, methanol is not a source of energy, but simply an energy store, points out Ulf Bossel at the European Fuel Cell Forum in Oberrohrdorf, Switzerland. “The energy carried by methanol is less than was needed to make it,” he adds.

Barnett agrees that methanol is a poor substitute for using the power from a renewable generator like a wind turbine directly. But he says that in cases where direct use is not possible, liquid methanol beats the efficiency of hydrogen for storage and transportation.

Methanol could be used to store energy from renewable sources that often produce more electricity than is needed at a particular time, he says, and could also be useful at off-grid sites.

In these situations, Bossel agrees a modest methanol economy makes sense. “The hydrogen idea is gradually fading,” he says. “Methanol could be a better solution because it is easier to handle.”

New drop-in ‘AEROPAK’ fuel cell system makes stealthy electric UAS fly longer & farther

SINGAPORE, June 3, 2009 /PRNewswire via COMTEX/ — AEROPAK, a next-generation fuel cell power system recently developed by Horizon Fuel Cell Technologies will increase the flight endurance of small and stealthy electric unmanned aerial systems (UAS) by as much as 300 percent. The fuel cell technological advancements will bring significant enhancements to UAS, making them more effective in persistent intelligence, surveillance and reconnaissance (ISR) missions, a main focus area for leading defense and security organizations around the world.

Starting evaluation shipments this summer, Horizon’s new AEROPAK brings an immediate performance improvement over today’s best available battery systems. Designed for high-impact and able to operate at up to 22,000 feet (6500m), the complete system integrates Horizon’s record-setting fuel cell technology with new refillable dry-fuel cartridges. Storing 900Wh of usable electrical energy and weighing just 4.4 lbs (2kg), the AEROPAK provides up to four times the endurance capability of advanced lithium batteries currently in use. The miniaturized power system makes it very easy to use as drop-in replacement for battery packs currently in service, eliminating costly airframe modifications.

According to G2 solutions, a Seattle-based market research firm specializing in Aerospace/Defense, “The use of pervasive UAS is increasing because the persistent ISR capabilities they bring are unmatched.”

Electric-powered UAS bring important capabilities – reduced acoustic signature, smaller size – and offer real advantages – lower acquisition cost, fuel savings – to ISR operations. Where battery performance limits the effective use of these promising systems, the AEROPAK next-generation fuel cell power systems will improve versatility and open new mission possibilities for smaller electric UAS.

In addition to increasing flight endurance, the new fuel cell system also makes it possible for small tactical UAS to integrate more power-hungry electronic devices such as electro-optical sensors, infrared cameras and laser designators. The new fuel cell systems can also be used to power remote ground systems and recharging stations, or even serve as an auxiliary electric power supply for larger systems.

Horizon’s AEROPAK is the first of a series of commercially available fuel cell systems that can be customized to fit a variety of platforms and scaled up to provide as much as several kilowatts of power, making it suitable for all sizes and configurations of electric powered UAS.

Over the next 10 years, industry analysts expect the acquisition market for UAS to exceed $44 billion in the U.S. alone. According to Ron Stearns of G2 solutions, “Fuel cells have the potential to improve the Size, Weight and Power (SWaP) configuration for tactical UAS propulsion, leading to increased UAS endurance or expanded sensor and/or communications-relay capabilities.”

Horizon Fuel Cell Technologies has been demonstrating its unique capabilities with a series of pioneering flights, which included “Hyfish,” a 1kW fuel cell powered jet-wing UAS integrated by the German Air & Space Agency (DLR) and the “Pterosoar,” which set a new FAI world record for distance in 2007 with the support of NASA. The new AEROPAK will be displayed at the 2009 Paris Air Show (booth B075) alongside several UAS airframes powered by Horizon’s fuel cell power systems.

About Horizon Fuel Cell Technologies Pte. Ltd.

Headquartered in Singapore, Horizon Fuel Cell Technologies develops and manufactures high performance lightweight and compact fuel cell systems used in aerospace, as well as a global marketer and developer of several award-winning consumer and industrial fuel cell products now commercial in a number of early markets. For more information on AEROPAK or to set up an appointment at the upcoming Paris Air Show, please contact aeropak@horizonfuelcell.com or visit www.horizonfuelcell.com

VANCOUVER, B.C. — While Ballard Power Systems (TSX:BLD) pushes fuel cells for forklifts and backup power, some investors are still stuck on the decision to give up the dream of someday supplying fuel-cell powered automobiles.

With more consumers turning to environmentally friendly vehicles and the restructuring of the automotive industry, a few long-term Ballard shareholders wondered at the company’s annual meeting Tuesday if automobiles powered by fuel cells should still be on the wish list.

Ballard president and chief executive John Sheridan predicted commercial production of automotive fuel cells won’t likely happen until about 2015, at the earliest.

Sheridan said there are “major obstacles” in both the production and cost of getting the technology to market.

“I would love to see the technology … but in terms of the commercial reality, we just don’t see it,” Sheridan said at the meeting.

In an interview afterwards, Sheridan said he isn’t surprised some investors can’t seem to let go of the auto side of the business.

“There is a romanticism about cars, and a lot of people are very concerned about the car world right now and the car sector,” Sheridan said.

In early 2008, Ballard closed a deal to sell its automotive fuel cell development business to Daimler AG and Ford Motor Co. (NYSE:F)

Daimler and Ford manage and fund automotive fuel cell technology development programs through a new private company located at Ballard’s facilities in Burnaby, B.C.

Ballard has kept a 20 per cent stake in the venture, but doesn’t provide any ongoing funding.

“As a public company – a company that has to make a return for shareholders – we made the right decision,” Sheridan said in the interview.

“In terms of the longer-term technology challenge for automotive, I really hope it’s successful, but it is long term.”

He said Ballard could get back into the business when it does become a reality, but not with the same goals as it had in the past.

“Would we switch gears and become a major fuel cell automotive player? No,” he said.

“As a component supplier? Sure, we would take a look at that.”

Sheridan said the business is now focused on materials handling, which includes fuel cell for forklifts in warehouses, as well as backup power.

The company signed a deal in October to supply fuel cells for telecom backup power in India, which it sees as a growing market for the technology. The deal with ACME Group and IdaTech LLC is for 1,000 units in 2009 and 9,000 units in 2010.

Ballard also recently stepped out of the fuel-cell cogeneration business, another hopeful market from its more recent past.

Last month it dissolved a cogeneration joint venture with Ebara Corp. of Japan for producing electricity and hot water in Japanese homes, saying it would take too long to develop the technology.

Ballard said the decision won’t change its guidance, or its projection to sell about 4,000 fuel-cell units in 2009.

Ballard is projecting annual revenues of about $68 million this year, which is at the lower end of its guidance.

The company is also counting on its technology for use in transit buses. It has a deal to supply a handful of fuel-cell powered transit buses to the Vancouver 2010 Olympics.

Vancouver-based Ballard recently reported a first-quarter loss of US$18.6 million, citing weak shipments and falling revenues along with restructuring costs from recent staff cuts.

The company, which reports in U.S. dollars, said the loss amounted to 22 cents per share for the quarter ended March 31.

The most recent results included $1.1 million worth of severance costs when the company laid off 32 employees, or seven per cent of its workforce, earlier this month.

The loss was compared to a profit of $81 million or 87 cents per share for the same period last year, buoyed by a $97-million gain from the sale of its automotive fuel cell development business to Daimler and Ford.

Quarterly revenue fell to $8.1 million during the quarter, down nearly 50 per cent from year-earlier levels of $16 million, as weakness in the auto sector crimped demand for the company’s products.

Ceres Power announces the successful design, build and testing of 1kW grid‐connected Combined Heat
and Power (”CHP”) products meeting all of the deliverables under the Alpha phase of the CHP
programme in conjunction with British Gas. This important milestone has been achieved within the
timescale set out in the roadmap presented at Ceres Power’s CHP update with British Gas on 24th June
2008.
The grid‐connected 1kW CHP products were tested on mains natural gas under representative
residential operating conditions, meeting most of a typical home’s electricity requirements as well as
exporting and importing power to and from the grid as required. The Ceres CHP product integrates the
Company’s 1kW Fuel Cell Module with all of the ancillary boiler components into a single unit meeting
all of the home’s hot water and central heating requirements, thereby avoiding the need for a separate
boiler. The wall‐mountable CHP product uses the same natural gas, water and electricity connections as
existing boilers and has been designed for ease of installation, service and maintenance.
During the trialling conducted in the Alpha phase, key tests were witnessed and data verified by British
Gas and an independent third party gas appliance testing company appointed by British Gas. All of the
Alpha CHP product requirements including performance, size, weight and regulatory compliance were
successfully achieved. British Gas has issued an acceptance certificate that triggers the £2m Alpha
milestone payment to be paid to Ceres.
The Company has already commenced the design and procurement activities of the Beta phase of the
CHP programme to produce Beta CHP units for in‐field trials, incorporating refinements arising from the
Alpha phase testing. The fit‐out of the new volume manufacturing plant in Horsham is well underway
with initial operations scheduled to begin in H2 2009. The Company is on track to achieve market launch
of the residential CHP product with British Gas in H2 2011.
The Company will provide the market with a technical update including progress of the CHP programme
at the announcement of its full year preliminary results in September 2009.
Gearoid Lane, Managing Director of British Gas New Energy, said:
“We are delighted that the Alpha phase CHP product testing has been successfully completed and all of
the agreed deliverables have been completed on schedule. This significant achievement underpins the
potential mass market opportunity of the Ceres CHP product for the UK residential market.”

Peter Bance, CEO of Ceres Power, commented:
“The successful completion of the Alpha phase is a very significant achievement and we are now
investing in the Company’s operational capabilities to deliver the residential CHP product in volume.
Ceres Power’s fuel cell CHP product has the potential to make a material contribution to the
development of a low carbon economy and help the UK meet its climate change targets.”

– Cutting-edge technology used at Beijing Olympics will make its California debut –

Volkswagen Group of America will showcase its Passat Lingyu fuel cell vehicles at the State Capitol on Wednesday, June 3, 2009. The Passat Lingyu is a zero-emission vehicle powered by a hydrogen fuel cell that can go up to 90 mph and up to 140 miles before a refueling. In light of new federal greenhouse gas regulations, California’s new Low Carbon Fuels Standard and regulations due to AB 32, these vehicles are one example of a potential zero-emission car of the future. The Passat Lingyu debuted during the Olympic Games in Beijing, China and traveled more than 50,000 miles with zero emissions.

Members of the media are invited to a presentation on Volkswagen Group’s advanced technologies and a test drive of the vehicles. To schedule a test drive time slot, please contact Amy Thoma at athoma@wilsonmillercom.com or by calling 916-551-1383.

      WHO:    Volkswagen Group of America
      WHAT:   Debut Passat Lingyu Hydrogen Fuel Cell vehicle in California
      WHEN:   Wednesday, June 3, 2009
              Breakfast and Presentation 8:30-10:00 AM
              Ride and Drive 10:00AM - 2:00PM
      WHERE:  Breakfast and Presentation: 6th floor cafeteria
              East Wing, Capitol Building
              Ride and Drive: L Street between 11th and 12th

  About Volkswagen Group of America, Inc.

Volkswagen Group of America, Inc. is a wholly-owned subsidiary of Volkswagen AG, the world’s third largest automaker and the largest carmaker in Europe. It houses the U.S. operations of a worldwide family of distinguished and exciting brands including Audi, Bentley, Bugatti, Lamborghini and Volkswagen, as well as VW Credit, Inc. Founded in 1955, the company’s headquarters are in Herndon, Va.

Volkswagen Group of America brings to the U.S. vehicles that marry the science of engineering and the art of styling, with the goal of offering attractive, safe, and environmentally sound automobiles that are competitive and set world standards in their respective classes.

The company has approximately 2,500 employees in the United States and sells its vehicles through an 800-strong dealer network. With increasing popularity for its brands in the U.S., the company has set the goal of reaching one million car sales in the country by 2018.

East Tennessee will be the location of demonstration fuel cell technology developed by Silicon Valley-based Bloom Energy.

Bloom Energy’s demonstration site will be able to generate 100 kilowatts of electricity that could be a precursor to the potential siting of a manufacturing facility in Tennessee.

The system will be at the Electric Power Board headquarters in Chattanooga and will be close to a final version that Bloom Energy plans to introduce in the broader market later this year, according to CEO KR Sridhar, who announced the planned installation Wednesday at the Tennessee Valley Corridor Summit. Chattanooga also is home to a 5 kilowatt installation made by Bloom Energy near the University of Tennessee. That system has been in place for two years.

Bloom Energy, which has kept development of the “solid oxide fuel system” close to the vest, has spent several years and $250 million developing the fuel cell technology, according to industry reports. The units are “fuel agnostic,” Sridhar said, meaning they can be powered by a variety of inputs, including biomass and natural gas.

The project is receiving funding through a federal appropriation as well as support from the Electric Power Board’s research and development organization, according to Joe Ferguson, head of special projects for the Enterprise Center, a Chattanooga-based economic development organization. Ferguson said the Electric Power Board expects delivery of the equipment “before the end of June.”

He said Bloom Energy’s earlier test site at UT-Chattanooga’s SIM Center, a computation research facility, had shown the technology to be very reliable.

Soarus LLC has commercialized Nichigo G-Polymer, a water solution polymer with potential uses in fuel cell systems.
Soarus, based in Arlington Heights, Ill., introduced the material earlier this year, commercial development manager Jim Swager said in a recent phone interview. The material is made at two Japanese plants operated by Soarus’ parent firm, Nippon Gohsei Co. Ltd. of Osaka, Japan. Current annual capacity for G-Polymer is about 5 million pounds.

Production can be added if needed at a Nippon Gohsei plant making EVOH (ethylene vinyl alcohol) resins in La Porte, Texas, but Swager said that Soarus has no definite timetable on when that move will be made.

G-Polymer is described as a high amorphous content vinyl alcohol resin where crystallinity can be tailored down to the point of being totally amorphous. The material, available in pellet or powder form, has excellent gas barrier properties and can be used in household power fuel cell systems and in fuel cell powered cars. G-Polymer can be used in all extrusion processes as well as in injection molding and also is biocompostable, officials said.

Swager said G-Polymer bridges the gap between EVOH and PVOH (polyvinyl alcohol) resins. Officials also said the material provides high strength, flexibility and antistatic properties when used in nonwoven fabrics, polymer alloys, multilayer film and similar applications.

Soarus represents Nippon Gohsei’s North American technical and marketing efforts for Soarnol-brand EVOH and other related products.