The GRASSHOPPER project aims to create a next-generation MW-size Fuel Cell Power Plant unit (FCPP), which is more cost-effective and flexible in power output, accomplishing an estimated CAPEX below 1500 EUR/kWe at a yearly production rate of 25 MWe. Large MW size PEM FCPP have been demonstrated, such as in the DEMCOPEM-2MW project, however at too high Capex level and without dynamic operation features for grid support. Grasshopper tackles these issues enabling a controlled, renewables-based energy infrastructure. The power plant will be demonstrated in the field as 100 kW sub-module pilot plant, implementing newly developed stacks, MEA’s and BoP system components, combining benefits of coherent design integration. Cost and technical optimisation will be achieved with improvements targeting MEAs (increasing current density, active area, reducing material costs incl. Pt loading), stack design (increasing stack size, power density and operating pressures, while streamlining manufacturability) and overall system balance of plant (modular design, simplified header and manifolds for gas distribution, high efficiency PV inverters, using off-the-shelf equipment where possible). This unit will be operated continuously for 8 months in industrially-relevant environment for engaging grid support modulation as part of an established on-site Demand Side Management (DSM) programme. This consortium unites component suppliers (JMFC, NFCT), research institutions (ZBT, Polimi) and integrators (AI, INEA) who will partner with existing energy market stakeholders (DSO, TSO) and EU smart grid projects committed to participate as advisory board members. This collaboration maximises the business case value proposition, by ensuring the delivered technology will respond to grid services’ requirements for flexible dynamic power operation. Innovative DSM programmes will be completed to establish the best path forward for commercialization of the technology for a fast response FCPP.

The Design 2 service project aims at simplifying both residential and commercial fuel cell systems for easy, fast and save system service and maintenance. In order to make best use of lessons learned and available resources, this project jointly works on two distinguished technologies (PEMFC and SOFC) in two different markets (residential & extended UPS). Both SME manufacturers are committed to establish lean after-sales structures, a significant step towards mass manufacturing and deployment. Maintenance is one significant part of Total Cost of Ownership of FC systems. Pooling the operational experience of field test programs, such as ene.field and Callux, critical analysis will lead to a priority list of required technical changes. For cold Balance of Plant Components, joint efforts will focus on the desulphuriser and the water treatment system. Actions are taken for both simplified maintenance and extended durability for prolonged service intervals. Logistics for replacement component supply will be considered. For the hot component parts, the manufacturers work on their individual hot topics to adapt and simplify the design of the current units, e.g. to allow replacement of individual components instead of sub-units. A large decrease of costs impact is expected once individual stacks can be changed in a simple maintenance operation instead of complete sub-units. It is important that such operations can be performed by a significant pool of qualified installers. This is addressed by the elaboration of simple technical manuals that will be exposed to real-life practical technicians in training programs. These actions aim at decreasing the technical barrier to service systems. Finally, the improved BoP units will be validated by testing single and multiple units. Beyond the classical features of high efficiency and silent operation, this will also add values like flexibility and modularity of FC technologies with respect to individual customer requests.

HYDRAITE project aims to solve the issue of hydrogen quality for transportation applications with the effort of partners from leading European research institutes and independent European automotive stack manufacturer, together with close contact and cooperation with the European FCH industry. In this project, the effects of contaminants, originating from the hydrogen supply chain, on the fuel cell systems in automotive applications are studied. As an outcome, recommendations for the current ISO 14687 standards will be formulated based on the technical data of the impurity concentrations at the HRS, FC contaminant studies under relevant automotive operation conditions, and inter-compared gas analysis. The methodology for determining the effect of contaminants in automotive PEMFC system operation will be developed by six leading European research institutes in co-operation with JRC and international partners. In addition, a methodology for in-line monitoring of hydrogen quality at the HRS, as well as sampling strategy and methodology for new impurities, gas, particles and liquids, will be evolved. Three European laboratories will be established, capable of measuring all of the contaminants according to ISO 14687 standards, and provide a strong evidence on the quality and reliability on their result. Beyond the project, the three laboratories will offer their services to the European FCH community. In addition, a network of expert laboratories will be set, able to provide qualitative analysis and the first analytical evidence on the presence or absence of these new compounds with potential negative effect to the FCEV. The efficient dissemination and communication improves the resulting data and input for the recommendations for ISO standards of hydrogen fuel. The project and its results will be public, to boost the impact of the project outcomes and to enhance the competitiveness of the European FC industry.