This project will develop an open standard for heavy-duty fuel-cell modules in terms of size, interfaces, control and test protocols, with the objective of kickstarting the use of fuel cells and hydrogen in the heavy-duty mobility sector, where electrification with batteries is impractical. Multiple modules may be integrated in a system, similar to AA batteries; this will allow using the same modules for multiple sizes. Combined with the standardisation across several sectors (road, offroad, rail, maritime, etc.) represented by participating OEMs, the same modules will address a large pooled market. The size of the market, and the availability of multiple module suppliers (8 in this project alone) will create a fair competition environment where OEMs may choose and change vendors, driving down prices and activating a virtuous cycle through economies of scale and achieving one of the main goals of the FCH JU's Work Programme in the heavy-duty mobility sector. This project will also produce prototypes form 8 leading FC vendors, which will then be thoroughly tested by two independent institutes for compliance with the open standards produced by the project itself. The project will feature significant dissemination and outreach activities, especially towards external OEMs that may become customers of the module suppliers.

One of the most promising routes for decarbonising the transport sector is the use of electrochemical power and storage technologies (e.g. fuel cells, supercapacitors and batteries). However, challenges persist in terms of performance, durability, cost, integration together within vehicles (hybridisation) and interfacing with the electricity grid. This project will deliver a technology innovation chain that adopts a material-to-system approach. We will identify, optimise and scale-up new materials into devices, develop novel diagnostic techniques in the lab and for on-board monitoring and control, and validate the technologies in a hybrid vehicle. The objectives will be met by five interconnected work packages (WPs): Hierarchical Structured Electrodes (WP1) will combine the nano-micro scale structuring of lithium ion battery (LIB) materials with meso-scale electrode structuring to create novel hierarchical structured electrodes. The target will be to produce a range of new high power and high energy density combinations, achieved through a rational design approach based on arrangements of porosities and materials. Critical to this work will be close interaction with WP2 where meso-structure will be characterized by X-ray tomography. These 3D data will show to what extent manufacturing designs are realized (WP3), help to rationalize electrochemical performance, and guide subsequent iterations of design-make-test in a way not previously possible. Diagnostics and Correlative Metrology (WP2) will develop new methods of analysis to provide an unparalleled level of information about the internal working of batteries, fuel cells and supercapacitors and provide a mechanism for improving device design and materials formulation through a tightly integrated programme with WP1 on materials and WP3 on devices. System Level Integration and Evaluation (WP3), sits in a central position between materials and analysis in WP1 and 2 and grid and vehicle interfacing in WP4 and 5. This WP will integrate new materials into functioning devices and develop understanding of their performance and degradation characteristics. To examine on-board performance, real-time, system-level diagnostics and prognostics (to include, system models, state estimators and data management) will be developed to ensure safety, enable fault detection and extend system life. In WP4, Optimised Design of High-Rate Grid Interface, the interface of vehicle with the grid will be considered, with a particular focus on high-rate charging of electric vehicles (EV), whilst also minimising the grid impact of such high power chargers. This is envisaged via use of local off-vehicle energy storage at the charging station, to permit rapid recharge of EVs to the new high capacity on-vehicle energy stores (e.g. from WP1). This WP will study the optimal off-vehicle energy storage technology (e.g. supercapacitors, batteries, flow cells), characterise and diagnose the energy store performance at high rates and perform laboratory scale testing of a rapid charger. Finally, in WP5, In-Vehicle Aspects, Validation Platform and Impact, the newly-evolved electrochemical energy storage packages developed in earlier WPs will be validated in a hybrid vehicle. The data generated and derived equivalent circuits will be fed back into the design and innovation cycle, leading to better materials and devices. Findings will be delivered to project partners, and ultimately back to UK industry. The cross-disciplinary nature of the work and collaborative approach is ingrained in the work-plan, where, as well as having individual responsibility for a specific aspect of the work, each partner will contribute to at least two work-packages. We have strong industry support and will form an Industrial Advisory Committee to provide industry perspective and help us navigate the most relevant and impactful course through the project.

In this proposal we are bringing together a number of individuals and institutions with a varied and complimentary skill set appropriate for the proposed work. All members of the team have an extensive and world-class background in fuel cell research and development, and the institutions which they work are well provisioned to undertake this work. Furthermore we are supported by a number of Institutions and companies. The project is based around four research work packages and one coordinating work package. * Operation of fuel cells on "dirty" fuels Fuel cells typically require high quality hydrogen to prevent the poisoning of catalysts and membranes. This not only increases the cost of fuels, but limits the possible sources that can be used unless extensive clean-up methods are used. We intend to study the poisoning mechanism and poison content of fuels/air; develop catalysts with improved poison resistance. The goal is improvement in operation of fuel cells on typically available fuels in the near term, and use of "dirtier fuels" (biogenic sources) in the longer term. * Reduction of the cost of fuel cells Catalyst costs are one of the major components of fuel cell system cost (~25-30% of total). We intend to look at reduced platinum loading systems and how these systems interact with poor quality fuel/air. In the short term the desire is to reduce the cost and catalyst requirements. Over the longer term there is the desire to transition to new catalysts. Hence, we will also look at the development of new non-precious metal (or reduced precious metal) catalysts and the integration of these catalysts with new catalyst supports. * Improvement in fuel cell longevity Fuel cell longevity is a function of catalyst degradation and extreme conditions occurring during start-up/shut down and other extraneous events. Within this work package we will examine diagnostics to interrogate and understand the degradation processes and the development of improved catalyst supports and catalysts to resist degradation. * Improving fuel cell systems efficiency Improving fuel cell efficiency is associated with diagnosing the bottlenecks and those areas where the majority of losses are occurring. We will facilitate this process by developing and applying a range of in-cell and in-stack approaches to understand where those efficiency losses are occurring. At the same time we will examine the development of fuel cell balance of plant components to improve system efficiency. These approaches will be coupled with system modeling to assess the best areas to achieve performance gains.

Despite major technological development and the start of commercial deployments of the fuel cells and hydrogen technology, the public awareness of FCH technologies has lagged behind this technical progress so far, restricting the appetite of potential customers and risking a lack of support from policymakers. To address this challenge, a consortium of leading experts has come together, combining communication experts, PR of established manufacturers and technology suppliers and world-class experts on the societal benefits of low carbon technologies. Together, the they will deliver HY4ALL, an ambitious programme to drive a step-change in awareness and excitement around fuel cells and hydrogen and deliver clear and consistent messages that resonate with all audiences, from policymakers to the general public. The project will be active in minimum 11 member states, and will be closely linked to the large numbers of existing hydrogen initiatives and demonstrations, maximising its impact and allowing the communication strategy to influence dissemination work beyond the project for lasting effects. The project aims will be delivered through the following activities: • Development of an overarching communication strategy, that will form the basis for all subsequent project activities and will allow the FCH community to speak with ‘one voice’ • Creation of an interactive web portal for FCH technologies, providing a ‘one stop shop’ for visitors seeking information and acting as a single brand and hub for all other dissemination activities • A cross-European "hydrogen for society" roadshow with fuel cell vehicles travelling between cities across the EU. The roadshow will form the focal point for a variety of innovative dissemination activities, public debates, co-hosting of national vehicle and infrastructure launches • A robust assessment of of the macro-economic and societal benefits of FCH technologies, providing fact-based analysis used to convey clear messages

Fuel cell technologies suffer from key cost, efficiency and degradation issues that must be resolved before they can reach their full commercial potential. Unfortunately many of the limitations of current polymer electrolyte membrane fuel cell (PEMFC) technologies are introduced, or exacerbated, by the current design of their membrane electrode assemblies (MEAs). Homogeneously constructed MEAs (i.e. the industrially standard) suffer from heterogeneity in the distribution of current, pressure, reactant concentration, water distribution and temperature, leading to numerous unintended gradients across the fuel cell which act to heterogeneously utilise, and therefore degrade, catalysts, their supports and ion conducting membranes. In HETEROMEA, we will characterise and understand the impact of intrinsic heterogeneity on MEA performance and durability. This understanding will be used to inform the design and implementation of material heterogeneously within next-generation MEAs, to 'smooth out' inefficient gradients and produce a homogeneous distribution of current, water, reactant partial pressure in operational PEMFCs; i.e. we will produce MEAs where the constituents (including e.g. Pt, ionomer, porosity, membrane) are intelligently distributed inhomogeneously, mitigating performance and durability losses. This will be enabled via the utilisation of robotic ultrasonic spray printing, a tool that allows flexible but precise control over material loading and distribution. HETEROMEA will therefore deliver a significant improvement in catalyst utilisation, mass transport resistance, charge transfer resistance and flooding, while using a standard range of industry-relevant fuel cell materials (e.g. commercial catalysts).