Innovative humidifier test bench from MANN+HUMMEL for advanced fuel cell technology
In our journey toward sustainable mobility, fuel cells are a promising solution for reducing emissions and meeting climate goals. In 2023, the transport sector accounted for about 25 percent of global greenhouse gas emissions, highlighting the urgent need to move away from fossil fuels. The automotive industry is increasingly adopting electric drives, especially fuel cells, which offer a zero-emission alternative. When powered by green hydrogen, fuel cell vehicles emit only water as exhaust, significantly lowering CO2, NOx and particulate matter emissions. By embracing fuel cell technology, the automotive sector contributes to global efforts to combat climate change and paves the way for cleaner mobility.
Fuel cells: Driving toward a zero-emission mobility
Understanding fuel cell types and technology
Humidifier testing
Among the various types of fuel cells, Polymer Electrolyte Membrane (PEM) fuel cells are the leading choice for mobility applications. Operating at around 80 degrees Celsius, PEM fuel cells provide high power density, making them ideal for compact vehicle designs. Their load flexibility allows quick adaptation to the acceleration and deceleration needs typical in automotive use.
At their core, fuel cells are electrochemical aggregates that convert the chemical energy of a fuel, usually hydrogen, into electricity, heat, and water. In a PEM fuel cell, hydrogen enters from the anode side, while ambient air flows in from the cathode side.
At the anode, hydrogen molecules (H₂) split into protons (H⁺) and electrons. The protons pass through the electrolyte membrane, which only allows these ions to move, while the electrons flow through an external circuit, generating electricity to power the motor. At the cathode, oxygen combines with the protons and electrons to produce water (H₂O), completing the reaction and ensuring zero-emission operation.
Advantages of fuel cell vehicles
Fuel cell vehicles offer a range of benefits, making them an excellent option for the future of transportation. Their most significant advantage is zero tailpipe emissions, releasing only water vapor and warm air, which greatly reduces urban air pollution. Additionally, fuel cells provide high energy efficiency compared to internal combustion engines, optimizing energy use.
Hydrogen’s high energy density allows for impressive driving ranges, which is especially beneficial for heavy goods transport, including trucks, buses, ships, airplanes, and rail. In these sectors, long range and rapid refueling are critical. Thus, fuel cell technology emerges as a compelling solution for decarbonizing not only personal transportation but also logistics and public transit.
Another key advantage is the fast refueling time, similar to that of conventional vehicles, which addresses a major concern for many drivers. Additionally, the quiet operation of fuel cells helps reduce noise pollution, contributing to more livable cities.
Overcoming obstacles: Challenges in fuel cell adoption
Despite the benefits of fuel cell technology, several challenges must be addressed for widespread adoption. These challenges include infrastructure issues, cost considerations, technical hurdles, and the critical need for humidification of the electrolyte membrane.
High production and material costs, especially for components like platinum catalysts, make fuel cell vehicles less competitive. Reducing these costs is crucial for fuel cells to effectively compete with conventional automotive technologies.
Key technical challenges include improving the durability of components, enhancing cold start capabilities, optimizing water management, and reducing the size and weight of fuel cell systems. Maintaining proper humidity levels is also essential to prevent the membrane from drying out or flooding, both of which can affect performance.
Humidity control systems are vital for ensuring optimal proton conductivity in the fuel cell membrane, directly affecting the performance and longevity of fuel cell systems. Proper humidification prevents degradation, while too much moisture can cause flooding, reducing efficiency. Therefore, achieving the right humidity level is crucial for reliable fuel cell operation.
Addressing all these challenges requires ongoing research, development, and investment in solutions enhancing fuel cell technology.
Innovative humidifier solutions from MANN+HUMMEL
Driving development: The importance of continuous technological advancements
Humidifier test bench in Ludwigsburg - outside view
With extensive experience in filtration technology since 1941, MANN+HUMMEL leads the way in solving these challenges. Our commitment to cleaner mobility is reflected in significant investments in research and development, especially in smart humidifier technologies and innovative testing solutions. Our latest investment in a state-of-the-art humidifier test bench highlights our dedication to enhancing fuel cell technology, improving the efficiency, performance and lifespan of fuel cells.
Innovations in humidity control: MANN+HUMMEL's powerful humidifier
We have introduced an innovative humidifier design using flat-sheet membranes, significantly improving fuel cell technology. This humidifier effectively transfers moisture from exhaust to intake air, maintaining optimal humidity levels within the fuel cell system. By preventing dehydration of the Polymer Electrolyte Membrane (PEM) and excessive humidity, it ensures reliable performance.
Compared to traditional hollow fiber membranes, the flat-sheet design offers lower pressure loss and more efficient water transfer. Its compact size allows flexible integration into various fuel cell systems, enhancing adaptability across different vehicle configurations.
This humidifier maintains optimal humidity without the need for external water sources, significantly improving overall system efficiency and extending the fuel cell stack's lifespan. By ensuring consistent proton conductivity, it prevents membrane degradation and helps sustain stable voltage output over time.
Innovations in testing solutions: MANN+HUMMEL's humidifier test bench
Analysis
MANN+HUMMEL has invested a substantial seven-figure sum in a state-of-the-art humidifier test bench at its headquarters in Ludwigsburg. This facility allows comprehensive testing of fuel cell components under real-world conditions, operating within a temperature range of -40 to +120 degrees Celsius, and enabling simultaneous testing of two examinees.
The unique combination of hardware and software enables precise control of test parameters and comprehensive data acquisition of measured values. This data is used for AI-supported training and the calibration of simulation models.
Humidifier test bench in Ludwigsburg - inside view
Our test stand excels in performance and durability testing, evaluating humidifier efficiency under various conditions and conducting extended durability tests beyond 1,000 hours. Its advanced design supports rapid optimization of humidifier technologies and helps better understand long-term degradation mechanisms. This innovative testing solution accelerates the development of efficient, durable fuel cell components. MANN+HUMMEL’s investment in testing infrastructure not only boosts R&D efficiency but also fosters collaboration with automotive partners, allowing quick adaptation to market demands and regulatory changes.
Through these innovations, MANN+HUMMEL is driving progress in fuel cell technology, committed to developing solutions that significantly enhance performance, efficiency, and longevity of fuel cells.
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MANN+HUMMEL's crucial role and vision in cleaner mobility
As a global filtration company, we are leading the clean mobility revolution. With over 80 years of expertise, we drive innovation in fuel cell technology through strategic R&D investments and our ambitious Carbon Zero Strategy, aiming for CO2-neutral production by 2035. Our efforts are setting new standards in clean transportation and advancing the goal of zero-emission vehicles across all sectors.
We are pioneers in fuel cell technology, taking a comprehensive approach to clean mobility that includes filtration and air quality. Our adaptability to changing mobility trends sets new efficiency standards, helping automakers meet stringent emissions regulations. This vision aligns with global efforts to combat climate change and positions us at the forefront of the sustainable mobility movement.
Our expertise and commitment will continue to shape the future of transportation.
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