LongCell – Service Life Prediction and Service Life-Optimised Dynamic Operation of PEM Fuel Cells

How can fuel cell systems be operated more efficiently, with a longer service life, and more cost-effectively? The new LongCell research project is dedicated to addressing this question.

The goal of the LongCell project is to develop a digital twin for polymer electrolyte membrane fuel cells (PEM fuel cells) that realistically simulates aging and degradation processes. Based on this, innovative model-based control strategies will be developed to dynamically adapt fuel cell operation and specifically avoid harmful operating conditions. This is intended to extend the service life of the systems, increase efficiency, and reduce operating costs.

Digital Twin and Optimized Control Strategies

In this project, the ZBT is responsible for the development and experimental validation of the digital twin, as well as for investigating degradation mechanisms on a specially equipped fuel cell test bench. Building on this, the Institute for Control Engineering (IRT) at RWTH Aachen University is developing model-predictive control strategies that resolve the trade-off between high efficiency and minimal degradation, thereby enabling operation optimised for service life.

Grafische Darstellung des Ablaufschemas eines Forschungsprojekts

Further Develop Hydrogen Technologies, Strengthen Small and Medium-Sized Enterprises

The methods developed will be validated through a combination of simulation and experimentation and are intended, in particular, to provide small and medium-sized enterprises (SMEs) with new tools for the development, design, and operation of fuel cell systems. In this way, LongCell strengthens the competitiveness of small and medium-sized enterprises and contributes to the further development of hydrogen technologies.

The research project is being carried out as part of the Joint Industrial Research (IGF) program. The goal of the funding program is to enable small and medium-sized enterprises, in particular, to gain access to innovative technologies and scientific findings through precompetitive research.

Project information

Title: LongCell – Model-Based Service Life Prediction and Service Life-Optimised Dynamic Operation of PEM Fuel Cells

Term: 1 July 2026 – 31 December 2028

Funding: IGF—Industrial Collaborative Research Program of the Federal Ministry for Economic Affairs and Energy
Grant amount: 524,764.19 euros

Project partners:

ZBT – The Hydrogen and Fuel Cell Center
Institute for Control Engineering (RWTH Aachen)

Contact

Project manager

Matthias Bahr

+49 203 7598-3124

m.bahr@zbt.de

Control & Regulation – Our Services

In the Controls division at ZBT, we develop operational strategies for controlling and regulating electrochemical systems. This includes methods for improving efficiency and detecting degradation at the MEA, stack, and full-system levels—with a focus on dynamic load profiles and real-world operating conditions.

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