FROZEN – Strategies for the safe use of fuel cells at very low temperatures

Fuel cells are supposed to be a reliable alternative drive system for transportation and mobility, even in very cold regions. But what effect do sub-zero temperatures have on PEM fuel cells? And what are the operating strategies that prevent frost-related damage? The FROZEN consortium is getting to the bottom of these questions.

To ensure that fuel cells can also be used reliably and permanently for mobile applications in cold regions, we need to understand frost-induced degradation mechanisms even better and develop strategies to prevent frost damage. The ZBT, the Chair of Thermodynamics of Mobile Energy Conversion Systems (TME) at RWTH Aachen University and EKPO Fuel Cell Technologies are currently working together on this in the FROZEN research project.

A frozen soap bubble backlit – photo by Aaron Burden on Unsplash

At the latest project meeting at the TME, current test results on freeze-thaw cycles and freeze starts were discussed. The focus was on the investigation of material changes under frost stress, the simulation of freeze-thaw cycles and freeze starts as well as the development of models to predict damage mechanisms. The next steps for operating single cells and short stacks at sub-zero temperatures in the laboratory were also planned.

The productive exchange shows how closely industry and research work together in FROZEN to enable the safe and long-lasting operation of fuel cells even at low temperatures.

Group photo of nine people in front of a white wall

Project information

Project title: FROZEN – Frost damage to PEM fuel cells for mobile applications and strategies for safe use at low temperatures

Project partners:

EKPO Fuel Cell Technologies
Chair of Thermodynamics of Mobile Energy Conversion Systems (TME) at RWTH Aachen University
ZBT – The Hydrogen and Fuel Cell Center

Project management organisation: Project Management Jülich (PtJ)

The project is being funded as part of the “Hydrogen Republic of Germany” ideas competition organised by the Federal Ministry of Research, Technology and Space (BMFTR) as part of the German government’s 7th Energy Research Programme.

Ice crystals – Photo by Erin McKenna on Unsplash

Contact

Group Manager Materials Analysis and Quality Assurance
New Materials and Technologies Department

Verena Lukassek

v.lukassek@zbt.de

Other current projects

7. April, 2026

PEMELYonROLL: Scalable roll-to-roll production for PEM electrolysis MEAs

The PEMELYonROLL project is developing scalable manufacturing processes for high-performance CCM and MEA for PEM water electrolysis. The aim is to develop material-efficient, quality-assured and industry-oriented manufacturing processes.

30. March, 2026

NEREUS – Next-Generation Scalable AEM Electrolysers as Sustainable Hydrogen Production System

NEREUS develops next-generation anion exchange membrane electrolysers (AEM electrolysers) for high-performance, long-lasting and cost-efficient hydrogen production.

30. March, 2026

FeNCy-PEM – Production and use of precious metal-free Fe-N-C catalysts

FeNCy-PEM develops scalable, precious metal-free Fe-N-C catalysts and integrates them into the production and application of PEM fuel cells.

17. March, 2026

HyQualityLab4NRW – Laboratory for AI-supported quality control and assurance in H2 research

With the “HyQualityLab4NRW”, a high-performance AI-supported material analysis laboratory is being set up at the ZBT to enable research institutions and industry to carry out comprehensive quality control of their products.

12. March, 2026

PARZELL: Qualitative and quantitative PFAS analysis in realistic PEM electrolysis and fuel cell operation

The PARZELL research project systematically investigates the release of PFAS from PEM electrolysers and PEM fuel cells and develops methods to realistically measure, evaluate and reduce emissions in the long term.

12. March, 2026

HiHyPe: New AEM technology for electrochemical hydrogen compressors

The HiHyPe project is developing a low- to non-precious metal AEM technology for electrochemical hydrogen compressors, thereby strengthening the future of the hydrogen economy.

4. March, 2026

HY-Infra – Cross-border Project to analyse Hydrogen Infrastructure in the Meuse-Rhine Region

Hy-Infra strengthens the cross-border hydrogen infrastructure in the Rhine-Meuse region. The interregional project creates transparency about future hydrogen requirements and derives the necessary infrastructure by 2030/2035.

4. March, 2026

NH3Avi – Inline production of metal-supported SOFC MEAs for aviation

Climate-neutral flying requires new energy sources – and new production technologies. NH3Avi is developing metal-supported SOFC membrane electrode assemblies (MEA) for use with ammonia in aviation.