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Fuel Cell Systems

As part of research projects and industrial collaborations, we develop simulation-based fuel cell systems together with our partners.

We combine our expertise in system modelling with the operational management of component test benches to simulate real system environments for test tasks.

Another focus is on the qualification of system components and materials. The topics of service life optimisation and cost reduction for fuel cell systems and components are addressed through the development of qualification methods with the support of flexible test bench setups.

Fuel cell system modelling

The analysis of interactions within a fuel cell system is crucial – both for system development and for the optimisation of individual components. At ZBT, precise system simulations are carried out using a multi-validated fuel cell model that can be flexibly integrated into various development environments.


The simulation includes the implementation of control strategies and controllers as well as the in-situ and ex-situ characterisation of the system components. These approaches enable a well-founded analysis and optimisation of the overall system.

 

Fields of work and services:

  • Characterisation and qualification of system components
  • Integration of components into simulation environments
  • Development and parameterisation of system simulations and fuel cell models
  • Implementation of control strategies and controllers
  • Simulation-based analysis and optimisation of fuel cell systems
zwei Personen in einem Labor bedienen einen Teststand

In-situ characterisation of materials

ZBT offers high-precision in-situ test methods for the characterisation and qualification of materials used in various areas of a fuel cell system. With our in-house developed test procedures, we quickly and reliably test both proven and new materials for PEM fuel cell systems.


Fields of activity and services

Our newly developed test chamber enables the qualification of a wide variety of materials – from solids (e.g. plastics) to liquid substances (e.g. assembly aids) and powdered functional additives (e.g. additives).


We also have a comprehensive portfolio of analysis methods at our disposal:

  • Hydrogen permeation measurement
  • Investigation of hydrogen embrittlement
  • Mechanical tests
  • Resistance measurement
  • REM-EDX analyses (scanning electron microscopy with energy dispersive X-ray spectroscopy)
  • Corrosion current measurement
  • Thermal conductivity measurement
  • Dynamic differential calorimeter (DSC)
  • Thermogravimetric analysis (TGA)

Characterisation of FC system components

ZBT offers state-of-the-art test benches for systems and components, which can be combined with environmental simulation measurements if required. With a test setup consisting of three identical system test stations, stack and system components can be specifically tested for degradation and performance stability in continuous operation. Thanks to our many years of experience and the in-house development of all test benches, we can respond flexibly to individual customer requirements and implement tailor-made solutions.


Fields of activity and services

  • System test benches: For comprehensive testing of stacks and components
  • Flexible single-cell test benches: For precise single-cell analyses
  • Long-term investigations: 2 x 3 test stations for system-oriented endurance tests
  • In-situ characterisation: i-V characteristics, EIS (electrochemical impedance spectroscopy), CV, LSV and boundary current densities
  • Spatially resolved measurements: For detailed analysis of local effects
  • CAD-supported test bench development: Tailor-made solutions for specific requirements

Investigations into the influence of pollutants and H2 quality

The ZBT analyses the influence of external pollutants on PEM fuel cells and system components such as humidifiers. One focus is on investigating air pollutants and their effects on MEAs and humidifier membranes under realistic conditions. Pollutant concentrations and operating parameters are simulated to analyse the influence under different load cycles. The limit values obtained provide filter manufacturers with valuable data for optimal component design.


Another focus is the investigation of H2 quality and its influence on the service life of PEM fuel cells. Pollutants such as CO, H2S or NH3 can accumulate in the recirculation circuit of a system and accelerate the degradation of the stack. High-precision analysis in the ppb range and system-oriented short stack tests enable a targeted evaluation of these effects.


Tests and measurement methods

  • Hydrogen permeation measurement
  • Hydrogen embrittlement
  • Mechanical tests
  • In-situ characterisation: i-V, EIS, CV, LSV, boundary current density
  • REM-EDX analyses
  • µ-GC (micro gas chromatography)
  • IMR-MS (Ion Molecule Reaction Mass Spectrometry)

Contact

Head of Department Fuel Cell Systems

Dr.-Ing. Ulrich Misz
+49-203-7598-3313
Get in touch

Contact

Head of Department New Materials and Technologies

Dr. Susanne Palecki
+49 203 7598-2352

Our latest projects

MUSCL: ZBT develops degradation model for optimising the operating strategy of fuel cell trucks

Fuel cell systems can be a sustainable alternative to diesel drives in long-distance lorry transport. In a new research project, ZBT is developing a degradation model to simultaneously maximise the energy efficiency and service life of fuel cells through efficient operating strategies.

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Project launch: Development of a multi-port cathode valve for fuel cell systems

Multi-port valves could reduce the number of valves in the cathode path of fuel cell systems, with advantages for mobile applications in particular. ZBT and Rheinmetall-Pierburg want to develop such a valve in order to reduce the use of materials and resources as well as costs in fuel cell production. ZBT is focussing on simulation, material tests and functional and endurance tests.

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Membrane Electrode Assemblies

We analyse electrochemical processes in fuel cells and electrolysis systems and characterise their components, such as catalysts, polymers, membranes and gas diffusion layers (GDS), using physical and chemical methods.

Bipolar Plates and Seals

We support our customers and partners in the development and production of high-performance bipolar plate and sealing solutions for PEM fuel cell stacks – from material development and design to component qualification and the production of bipolar plates and sealing solutions, as well as the development of innovative manufacturing processes.

Stack Technologies

As part of research projects and industrial collaborations, we work with our partners to develop high-performance fuel cell stacks for mobile, stationary and portable applications.