NUVERA CONFIDENTIAL Alternative Energy Efficient Simple Clean Today Alternative Energy Efficient Simple Clean Today FORZA TM Rail Power Module 2 nd INTERNATIONAL HYDROGEN TRAIN AND HYDRAIL CONFERENCE Herning, Denmark – June 7 th 2006
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NUVERA CONFIDENTIAL
AlternativeEnergy
EfficientSimpleClean
Today
AlternativeEnergy
EfficientSimpleClean
Today
FORZATM Rail Power Module
2nd INTERNATIONAL HYDROGEN TRAIN AND HYDRAIL CONFERENCE
Herning, Denmark – June 7th 2006
NUVERA CONFIDENTIAL
Nuvera Company OverviewNuvera is focused on the commercialization of hydrogen-based energy systems containing advanced fuel processors and/or PEM fuel cells.
Diverse set of shareholders
Product development focus
Company differentiators:Metallic stack architecture
Design for industrial applications
AndromedaPowerFlow Forza
NUVERA CONFIDENTIAL
Product Development Portfolio
PowerTap
PowerFlow
PowerFlowTM (5 kWe H2PMs for industrial trucks)
PowerTapTM (NG-based H2 generator: 50 kg/day )
ForzaTM (120 kWe H2PMs for Chloralkali plants)
AvantiTM (NG, 4.6 kWe, η>30% net HHV, CHP plant)
STARTM (on-board gasoline FP subsystem)
AndromedaTM (automotive FC stack ass’y)
Andromeda
STAR
Avanti
Forza
NUVERA CONFIDENTIAL
Metallic hardware
Standard approach– Graphite material based (10-30 $/kg)– Flow fields curved on the plate
Nuvera approach– Flat SS plate (5.5 $/kg)– SS porous structure
OEM (GM, Honda, Toyota, DC) are studying ways to operate the transitionto metal plates for achieve DOE targets
NUVERA CONFIDENTIAL
Cathode Water InjectionFuel cell temperature can be managed using sensible or latent heat.
Conventional Cooling & HumidificationConventional Cooling & Humidification
CWI Technology
Stack size reduction
Reduced BOP
Reduced air blower &
HX fan parasitics
Flowfield enhancement
Patented technology
FuelCellHX
HX
Sep
WaterReservoir/Saturator
CoolantReservoir
P
Air
Cathode Water InjectionCathode Water Injection
FuelCell
HX
Sep
WaterReservoir
PAir
CWI is used exclusively for thermal regulation of the XDS-900 stack.
NUVERA CONFIDENTIAL
FCS in several vehicle architecturesYear 2000
INVERTER
ELECTRICMOTOR
ENERGY
INVERTER
ELECTRICMOTOR
BATTERYPACK
FCS
H2
AIR
APU-Range Extender
DCDC
DCDC
INVERTER
ELECTRICMOTOR
DCDC
ENERGY
INVERTER
ELECTRICMOTOR
DCDC
BATTERYPACK
FCS
H2
AIR
FIAT SEICENTO HYDROGEN
INVERTER
ELECTRICMOTOR
FCS
INVERTER
ELECTRICMOTOR
H2
AIR
Panda HYDROGEN
Year 2004
Effi
cien
cyE
ffici
ency
impr
ovem
ent
impr
ovem
ent e
volu
tion
evol
utio
n
Bottle H2
Stack
DC/DCConverter
InverterRadiatorElectric
motor
Battery pack
Air compressor
Water separator
3-PHASE ELECTRIC MOTOR
BATTERY PACK
FUEL CELL SYSTEM
NUVERA CONFIDENTIAL
Andromeda II stack performance
0
0,2
0,4
0,6
0,8
1
1,2
0,00 0,20 0,40 0,60 0,80 1,00 1,20 1,40 1,60Current Density (A/cm2)
Ave
rage
cel
l vol
tage
(V
)-20,0
0,0
20,0
40,0
60,0
80,0
100,0
120,0
140,0
Pow
er (
kW)
Max Power @ Max Pressure;High Performance
Max power @ Low pressure;High system efficiency
1,3 kW/l
1,6 kW/l
Peak power range
Nominal power operating range
78 liters volumeMax height = 210mm140kg weightVoltage range = 230-384VOperating Power < 80 kW Two connections per fluidBOB integratedT range = 40-72°C (dry)
40-80°C (humid)T storage = -20°CT start up > -20°C
Andromeda II specs. sheet
NUVERA CONFIDENTIAL
FORZATM – Initial target are electrochemical plants
UP TO 20% OF ENERGY SAVINGS – 100% POLLUTION FREEUP TO 20% OF ENERGY SAVINGS UP TO 20% OF ENERGY SAVINGS –– 100% POLLUTION FREE100% POLLUTION FREE
NaClWater
Electricity
E E E E E E
600V
FORZA Modular Systems
Courtesy of UhdenoraCourtesy of Uhdenora
ININNaOHCl2
OUTOUT
Heat + Water +
DC CurrentBy Product Hydrogen
Installation on C/A plants is covered by a Nuvera patent: “Method for the integration of fuel cells into electrochemical plants”, Pat.No 6,423,203 B1 Dated Jul 23,2002
NUVERA CONFIDENTIAL
System testing (Nuvera – UHDENORA)
FORZA Core Module + BOP8 x 116 cell stacks (>650 V)
Net power ~120 kWe
Fuel Cell Qualification LabOsio, ITALY
NUVERA CONFIDENTIAL
Single cell (full active area) durability
0,4
0,45
0,5
0,55
0,6
0,65
0,7
0,75
0,8
0 2000 4000 6000 8000 10000 12000
Time (hours)
Cel
l Pot
entia
l (V)
Nuvera Fuel Cells Durability Testing on PRIMEA 5621 MEA
(H2-N2 fuel mix, low pressure, direct cathode water injection)
A single cell test on full active area (500 cm2) MEA and all other full scale stackmaterials and design considerations (metalliccomponents, flowfielddesign, reactant feeds, etc.)
8% decay (-6 µV/ hr)
NUVERA CONFIDENTIAL
Results: 100 MWh MilestoneThe FORZA Core Module passed its first major operational milestone: production of 100 MWh of electric power with > 90% Availability.
0102030405060708090
100110120
0 5 10 15 20 25 30 35 40Elapsed Time (Days)
Ener
gy (M
Wh)
75%
80%
85%
90%
95%
100%
Ava
ilabi
lity
(%)
Forza Energy (MWh)
Phase Availability (%)
2 31
SystemShakedown
BOPStabilizaton
TestCampaign
NUVERA CONFIDENTIAL
System testing in a chlorate plant
Chlorate cell room (Italy) Skid installation (120 kW)
Power electronics Control Box
NUVERA CONFIDENTIAL
An Evolution from…
BC Rail
NUVERA CONFIDENTIAL
….To The Ultimate in Clean Transport
BC Rail
NUVERA CONFIDENTIAL
Fuel Cell Advantages for Locomotives
Over Diesel Engine– Torque– Efficiency– Noise – Emissions
Over Batteries– Energy Capacity– Recharge Time
fuel cells have particular advantage in non-attainment areas with < 20% higher lifecycle cost than diesel engines
NUVERA CONFIDENTIAL
Fuel Cell Advantages over Electric Trains
Fuel cell powered locomotives can roam – the system can grow without major commitments to new lines– unlike electrification, needs no critical traffic density to justify – Avoids either a totally new track or much interference with
existing traffic while electrifying– Can begin with a few prototypes
Power demand can avoid peak periodsIn 1998, Caltrain costed electrification of an existing 124-km commuter line at $376 MPro-rated, the 32 km from Charlotte to Mooresville is $100 M
– Should easily buy enough fuel-cell locomotives
NUVERA CONFIDENTIAL
To Summarize..
Fuel Cell locomotives potentially offer the best of two worlds
– Flexibility, efficiency, and low infrastructure cost of the diesel-electric locomotive
– Zero vehicle emissions, low noise, and oil-independence of the catenary electric locomotive
– Have particular advantage in non-attainment areas with < 20% higher lifecycle cost than diesel engines
NUVERA CONFIDENTIAL
Forza Rail Power Module (RPM)Power
– 125 kW (net), 150 kW (gross)
Voltage– 900V ±10% @ 0A to 600V ±10%
@ 250A ±10% Unregulated
Compact– 1.6m x 1.2m x 1.5m– 1500 kg, ~ 3 m3, 500 kg/m3
Rugged– Railway duty– High Stacks Durability– Three axis shock loading
Field Serviceable– Serviceable Fuel Cell Stacks– Automatic Valves, Controls– Pumps, Tanks, Filters
NUVERA CONFIDENTIAL
RPM Design and Safety
Design Features– Solid, Low-Risk Design– Rugged, Compact, High-G Package– Proven XDS-900 Stacks– Proven PowerFlow High-Efficiency Recycle System– Totally Self-Contained
Two types of safety system trigger shutdown procedures
E-Stop – Emergency shutdown that is immediate and results in all components returning to their non-powered/normal positions.
Soft E-Stop – Controlled system shutdown which executes the automated shutdown procedure.
NUVERA CONFIDENTIAL
Locomotive & Off-Road Experience – 17 kW
3.6 ton mining locomotive
Nuvera’s 17 kW PEM fuel cell
Successful operation in harsh conditions
Project is managed by Vehicle Projects, LLC
Our experience with locomotive applications is second to none
NUVERA CONFIDENTIAL
Locomotive & Off-Road Experience – 90 kW
23 ton mine loader
Nuvera’s 90 kW PEM fuel cell
Testing to commence soon
Project is managed by Vehicle Projects, LLC
Caterpillar-Elphinstone diesel base vehicle
Our experience with locomotive applications is second to none
NUVERA CONFIDENTIAL
Locomotive & Off-Road Experience – 150 kW
One FORZA RPM delivered to Asia-Pacific in Jan 06
Nuvera’s 150 kW PEM fuel cell
FORZA exceeded contractual specs in power
NUVERA CONFIDENTIAL
Locomotive & Off-Road Experience – 1.2 MW
109 metric-ton-road-switcher
8 Nuvera’s FORZA RPM PEM fuel cell
Project commence in 2007
NUVERA CONFIDENTIAL
F U E L C E L L S
EXPERIENCE
The Future of Energy®
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