Ballard launches 9th generation high-performance fuel cell engine for heavy-duty vehicles at ACT Expo 2024
Ballard Power Systems (NASDAQ: BLDP) has introduced its 9th generation fuel cell engine, the FCmove®-XD, at the ACT Expo 2024 in Las Vegas. The new engine boasts the highest volumetric power density in the industry, with significant improvements in reliability, efficiency, and cost-effectiveness. The scalable 120 kW engine can deliver up to 360 kW of power with a design life exceeding 30,000 hours, making it ideal for heavy-duty applications. Key features include a 33% reduction in parts count, over 60% system efficiency, a wide operating temperature range, and compliance with safety standards. Initial manufacturing will take place in Oregon, with high-volume production planned for Texas.
- Introduction of the 9th generation fuel cell engine, FCmove®-XD, with high-performance features.
- Highest volumetric power density in the industry for heavy-duty applications at 0.36 kW/L.
- Scalable power output, with a single engine delivering 120 kW and up to 360 kW with three modules.
- Design life of over 30,000 hours, equating to over one million miles in truck operation.
- 33% reduction in total parts count, improving reliability and reducing costs.
- Ultra-high peak system efficiency exceeding 60%, enhancing fuel consumption and heat rejection.
- Wide operating temperature range up to 95°C.
- Integrated DC/DC converter, air compressor inverter, and power distribution unit for better efficiency.
- Over 50% reduction in assembly time, improving manufacturability.
- Initial manufacturing in Oregon with future high-volume production in Texas, compliant with 'Buy America' standards.
- No immediate details on the cost of the new FCmove®-XD engine, which could impact its market adoption.
- Potential challenges in scaling up production to meet anticipated demand.
- High dependency on successful collaboration with supply chain partners for new component designs.
- Future high-volume manufacturing reliant on the successful construction and operation of the new Texas Gigafactory.
Insights
The launch of Ballard Power Systems' 9th generation fuel cell engine, FCmove®-XD, represents a significant leap forward in fuel cell technology for heavy-duty vehicles. The engine features impressive metrics such as an engine volumetric power density of 0.36 kW/L and a gravimetric power density of 0.48 kW/kg. These are the highest in the industry for heavy-duty applications.
The modular design of the engine is noteworthy, enabling up to three modules to operate as one system, which can deliver a combined 360 kW of zero-emission power. This scalability is beneficial for various truck classes and duty cycles, enhancing integration flexibility and redundancy. The reduction in parts count by
It's important to emphasize the peak system efficiency at >60%, which not only lowers the total cost of ownership but also optimizes fuel consumption. Rapid transient times and hot stand-by mode indicate advanced performance metrics, particularly in dynamic operational conditions. Overall, this launch aligns with the industry's push towards sustainable and cost-effective driving solutions.
From a market perspective, Ballard's new fuel cell engine is poised to make a considerable impact. The heavy-duty vehicle market is particularly demanding, with high utilization rates and stringent payload requirements. The FCmove®-XD's advancements in power output, efficiency and scalability directly address these demands. The improved manufacturability and reduced assembly time by
Moreover, the positive initial customer engagement suggests that there is a strong market interest, which could translate into significant sales and market penetration. This product launch can potentially position Ballard Power Systems as a leader in the heavy-duty fuel cell market, likely increasing its market share. The strategic collaborations with the supply chain further strengthen Ballard's competitive edge by integrating new design innovations and reducing production costs.
"We are laser focused on strengthening the economic value proposition for heavy-duty mobility customers," said Mircea Gradu, Ballard's Chief Engineering Officer. "With the unveiling of our 9th generation of fuel cell engine – the FCmove®-XD – we continue to push the boundaries and are once again raising the bar and re-setting the industry standard for PEM fuel cell engine performance. Our innovative FCmove®-XD delivers significant improvements in reliability, durability, efficiency, power density, scalability, serviceability, and total cost of ownership."
The FCmove®-XD delivers the highest volumetric power density in the industry for heavy-duty applications, featuring an engine volumetric power density of 0.36 kW/L and gravimetric power density of 0.48 kW/kg. The scalable 120 kW fuel cell engine integrates DC/DC regulated output, enabling up to three modules to operate as one system with a single interface, capable of delivering a combined 360 kW of zero-emission power output.
With a design life of 30,000+ hours of operation – or over one million miles in truck operation at typical duty cycles – the FCmove®-XD engine is developed to deliver class-leading durability and low total cost of ownership.
Enabled by an innovative "open architecture" design and other new design advances, the powerful and compact FCmove®-XD enables several important performance improvements (as compared to our prior-generation engine), including:
- 120 kW power output from our latest high-performance single stack;
33% reduction in total parts count, significantly improving reliability and reducing costs;- Ultra-high peak system efficiency at >
60% , enabling improved fuel consumption (lower total cost of ownership) and efficient heat rejection; - Wide operating temperature range, up to 95°C;
- Integrated power controller incorporates DC/DC converter, air compressor inverter, and a power distribution unit, along with proprietary software controls, enables improved engine operation and efficiency;
- Rapid up and down transient times, with an innovative hot stand-by mode enabling rapid power increase;
- Improved manufacturability with >
50% assembly time reduction; - Easier access to parts for faster and lower-cost field maintenance;
- Compliance with applicable safety codes and standards;
"The power and performance requirements of the highly-segmented truck market are particularly demanding due to various use cases, including high vehicle utilization rates and payload requirements," said Silvano Pozzi, Vice President, Product Line Management. "One of the compelling features of our new FCmove®-XD is scalability based on modularity. We can offer customers efficient integration of 120 kW, 240 kW, and 360 kW solutions dependent on truck class, use case, and duty cycle. For example, two engines, totalling 240 kW of power output, can be easily installed in the engine compartment of a typical Class 8 heavy-duty truck, enhancing standardization and redundancy."
Mr. Gradu concluded, "In addition to our in-house FCmove®-XD innovations and design improvements over the past 3 years, we have enjoyed strong collaboration with our maturing supply chain on new balance of plant component designs and related non-recurring engineering, and we also made important investments in certain production tooling. Collectively, these integrated and parallel work streams have resulted in a category leader, boasting higher performance on all key metrics with significantly lower capital cost and operating costs for customers and end users. Initial pre-launch customer engagement has been very exciting."
Ballard plans to initially manufacture the FCmove®-XD at its
Ballard Power Systems' (NASDAQ: BLDP; TSX: BLDP) vision is to deliver fuel cell power for a sustainable planet. Ballard zero-emission PEM fuel cells are enabling electrification of mobility, including buses, commercial trucks, trains, marine vessels, and stationary power. To learn more about Ballard, please visit www.ballard.com.
This release contains forward-looking statements concerning the specifications and performance of the FCmove®-XD fuel cell engine, its uses, planned volume manufacturing and scale of market adoption . These forward-looking statements reflect Ballard's current expectations as contemplated under section 27A of the Securities Act of 1933, as amended, and Section 21E of the Securities Exchange Act of 1934, as amended. Any such forward-looking statements are based on Ballard's assumptions relating to its financial forecasts and expectations regarding its product development efforts, manufacturing capacity, and market demand.
These statements involve risks and uncertainties that may cause Ballard's actual results to be materially different, including general economic and regulatory changes, detrimental reliance on third parties, successfully achieving our business plans and achieving and sustaining profitability. For a detailed discussion of these and other risk factors that could affect Ballard's future performance, please refer to Ballard's most recent Annual Information Form. Readers should not place undue reliance on Ballard's forward-looking statements and Ballard assumes no obligation to update or release any revisions to these forward-looking statements, other than as required under applicable legislation.
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SOURCE Ballard Power Systems Inc.
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