The document discusses advances in fuel cell technology for hybrid transit buses. It provides information about Ballard Power Systems, a leader in PEM fuel cells, including their intellectual property portfolio, products, engineering services, and experience deploying over 45 fuel cell buses worldwide. Key points include reductions in emissions from fuel cell buses compared to diesel, advantages of fuel cells for buses, and Ballard's work to increase power density, lifetime, and reduce costs of their fuel cell modules and stacks for commercial bus applications.

1. Nov 18, 2013
Advances in Fuel Cell
Hybrid Transit Buses
© 2012 BALLARD POWER SYSTEMS, INC. ALL RIGHTS RESERVED.

2. Who We Are
 Ballard Power Systems, Inc. is a
recognized global leader in clean
energy PEM fuel cells
 Design, manufacturing, distribution,
support
 Multi-market focus
 ~355 employees worldwide
 Headquarters in Burnaby, BC, Canada
 Operations: Canada, Denmark, U.S.A.
(University of Maryland; Bend, OR), Mexico
Burnaby HQ facility
Maryland
Bend, OR
Tijuana
Hobro
USA
USA
Mexico
Denmark
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3. Unrivalled Intellectual Property Portfolio
 Over 200 patents/applications
owned, and license rights to >700
patents/applications owned by
Daimler & Ford

MEA designs

Plate designs

Catalyst Coated Membranes

Gas Diffusion Layer materials

Manufacturing processes
 Intellectual property (“IP”) portfolio
also includes know-how and trade
secrets, developed with over 25
years of research and product
development

Fundamental knowledge in key
areas of stack operation, system
integration and fuel processing
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4. Ballard Fuel Cells in the Field
~2,000 installed
telecom systems
>3,000 forklift trucks
operating
~45 fuel cell buses
operating
+300 fuel cell cars
operating
Ballard is experienced in developing technology to customer requirements, success mainly driven by
development approach learned from Ford and Daimler
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5. Fuel Cell Product Portfolio
Fuel Cell
Stacks
• 500W-2kW
• Up to 8k hrs
• 2kW-8kW
• Up to 30k hrs
Fuel Cell
Modules
Complete
Fuel Cell
Systems
• 4kW-20kW
• Up to 12k hrs
• 100kW
• >5k hrs
• 75kW-150kW
• Up to 20k hours
• 2kW & 5kW
• Direct
hydrogen
• Indoor (rackmountable) &
outdoor use
• 2.5kW & 5kW
• Methanol fuelled
• Outdoor use
• Multi-MW power
Ballard product portfolio includes industry-leading fuel cell stacks, fuel cell modules and
complete fuel cell system solutions
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6. Fuel Cell Engineering Services
 Ballard’s engineering services provide a high-value means to
accelerate customers’ fuel cell development efforts
 Ballard’s team provides tools and technologies for development,
optimization, integration and validation of fuel cell components,
stacks and systems
 Facilitates development of new business opportunities through
access to new applications
 Leverages a high level of competency across a range of specialized
activities, including –






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Applications engineering
Reference systems
Product development
Fuel cell testing services
Simulation and modeling
Failure analysis
Infrastructure improvement
Ballard test facilities in Burnaby, BC

7. Fuel Cell Bus Emission Reductions
SORT 1 & 2 Drive Cycle Data
 Eliminates tailpipe
900
emissions
800
 Nitrogen Oxides (NOx)
700
12 years
 Sulphur Dioxides (SOx)
600
 Particulate Matter (PM)
500
 Greenhouse Gas Emission
12 years
400
reductions
300
 Calculated on a well to wheel
basis
200
100
 Improved fuel efficiency
One year
0
 1.5-2.5x improvement over
conventional diesel buses on an
energy equivalent basis
One year
CO2 Displaced (T)
Energy saved (MJ 000)
Source: Testing witnessed by TUV for 13 metre Van Hool fuel
cell electric bus on SORT 1 & 2 drive cycles, dated June 24,
2013
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8. Fuel Cell Bus Advantages
 Reduced noise and
comfortable ride
 Flexibility of operation
• Freedom from overhead or
underground charging system
• No range limitations
 Proven track record
• More than 15 years of operation
in revenue service
• Credible 3rd party operational data
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9. Bus Program Evolution
PHASE 1 - Proof of Concept
1991-1992
Vancouver, Canada
PHASE 2 - Commercial Prototype
1993-1995
Vancouver, Canada
PHASE 3 - Fleet Demonstration Alpha Sites
1996-1999
3 Vancouver, Canada & 3 Chicago, USA
PHASE 4 - Fuel Cell Engines Beta Sites
1999-2002
Palm Desert, USA
PHASE 5 - Serial Production
2002-2009
5 Continents, CUTE (30), Perth (3),
California (3), Beijing (3)
PHASE 6 – Hybridization of Fuel Cells
2009 - Current
40+ CanadaEuropeUSABrazil
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10. FCvelocity®-HD6
 Unique features…
 Power density: 400 kgs, delivering 150 kW gross
power
 Leveraging state of the art automotive stack
technology (economies of scale)
 Module lifetime 10+ years
 Offered with a 12,000 hr or 5 year fuel cell stack
warranty
 Available in 150 or 75 kW configurations to
appropriately match bus type and application
 Air compressor supplied separately
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11. Fuel Cell Bus Integration
Steered second axle
Electric drive motor group
Air compressor for bus
Ballard HD6 fuel cell
Air Filter for fuel cell
Process air compressor
Invertor group
Brake resistors
24 V Inverter
Air conditioning unit
Compressor for airco unit
Hydrogen storage group
Energy storage–battery pack
Cooling unit for battery pack
Cooling unit for fuel cell
Smarter Solutions for a Clean Energy Future
February 24, 2011
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12. Whistler, B.C. - Largest FC Hybrid Fleet in the World
 Logged more than
3.5 million kilometers
in public transit
revenue service
 150,000 hours in
revenue service
 Consumed more than
350,000 kilograms H2
dispensed
 More than 16,000 safe
refueling events
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13. Current Fuel Cell Bus Deployments
48 Ballard powered buses operating worldwide
Europe: 23
Canada: 20
United States: 3
India: 1
27 additional Ballard powered buses
planned for 2014/2015
Brazil: 1

14. TFL Fleet
• TFL Bus fleet of 8 buses
• 5 buses In service since
2010
• Over 300,000 km in
revenue service
• Ballard providing services
to maintain the buses
• Currently high availability
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15. Oslo Fleet
• Van Hool 13 meter 3 axle
buses
• 5 buses In service since
2012
• Over 100,000 kms of
operation
• High availability
• Operator Unibuss
maintaining buses with
telephonic support from
Van Hool and Ballard
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16. San Remo, Italy
• Van Hool 13 meter 3 axle
buses
• 5 buses delivered in Sep
2013
•Driver training and site set
up in progress
• Revenue operation
expected to start in Dec
2013
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17. Future EU Fleet (Ballard Powered)
• Van Hool 13 meter 3 axle
buses
• 10 buses to Aberdeen in
Feb 2014
• 5 buses in Flanders in
Mar 2014
• 2 buses in Cologne in
Mar 2014
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18. FCvelocity-HD7 Module
• Latest generation fuel cell stacks
• Reduced parts count
• Higher FC stack durability
• Lower price
• Air compressor and coolant
pump included in scope of supply
• Lower Parasitic loads
• Scalable from 50 to 200 kW
• Available by Q2 / 2014
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19. Fuel Cell Stack Lifetime
>18,000 hrs
15,000 hrs
12,000 hrs
>10,000 hrs
4,000 hrs
Demonstrated
in service
demonstrated
in service in
Whistler,
London
Current offering;
validated via
accelerated
lifetime testing
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20. Product Cost Reductions
30%
 Leveraging
automotive volumes
 Production
Environment
 Direct Material
reductions
Smarter Solutions for a Clean Energy Future
15 - 20%
 Enhanced Membrane
Electrode Assembly
(MEA) reducing
warranty accrual costs
35 - 40%
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21. Fuel Cell Bus Commercialization
Putting fuel cells to work
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