Peak Performance. Zero Emissions.
#1 Product Transformation
Heavy-duty vehicles are among the biggest producers of CO2 emissions in road transport. In this segment, alternative drive concepts must meet particularly stringent requirements, because not only are commercial vehicles large and heavy, they also must transport huge volumes of goods cost-effectively, cover long distances, and allow fast refueling. EKPO’s NM20 fuel cell stack module was developed exactly for thispurpose.
In the heavy-duty segment and other areas of application EKPO Fuel Cell Technologies is focusing its efforts on hydrogen. With the new NM20, the company has launched its most powerful fuel cell stack module to date. EKPO has extensive expertise in the development, industrialization, and manufacture of fuel cell stack modules and components. These products are based on PEM technology, i.e., the focus is on proton exchange membrane fuel cells (PEMFC). Already, EKPO can draw on expertise across the entire process chain and operates a highly automated, cost-efficient manufacturing facility to automotive standards with a capacity of around 10,000 stacks per year.
EKPO
EKPO Fuel Cell Technologies GmbH (EKPO), which is headquartered in Dettingen/Erms, Germany, is a joint venture between ElringKlinger AG and French automotive supplier OPmobility SE that was established in March 2021. The EKPO product range includes custom developments and standard solutions for use in the mobility segment as well as in stationary systems and electrolyzers. The four fuel cell stack platforms NM5-evo, NM12-single, NM12-twin, and NM20 cover a power range that spans from 15 kW to more than 400 kW. All models offer a compact design, high power density, durability, and high efficiency. Moreover, EPKO’s metal bipolar plates are key components that offer significant advantages in respect of cost efficiency, power density, and cold start capability. The company, which employs around 240 people, holds more than 330 patents.
How does a fuel cell drive work and what are its benefits?
Just like battery-electric vehicles (BEVs), FCEVs (fuel cell electric vehicles) are powered by an electric motor. The crucial difference is that the power does not come from built-in batteries charged by means of an external power source. Instead, FCEVs generate the necessary electricity themselves with their own efficient power generation unit on board: the fuel cell. The fuel cell functions as an energy converter and produces electrical energy by means of a chemical reaction between the hydrogen in the fuel tank and oxygen from the ambient air. Water (vapor), as a by-product of the reaction, then exits through the exhaust – without any emissions whatsoever. The necessary hydrogen can be produced, for example, through the process of electrolysis, in which electrical energy breaks water down into its separate hydrogen and oxygen components. If the electricity used comes from regenerative sources, the fuel cell drive system is completely carbon neutral. In addition, generation and consumption can be “decoupled” and take place at different times and in distinct locations. Other major advantages of FCEVs are the short refueling time – the hydrogen tank takes just a few minutes to fill – and the possibility of adding hydrogen pumps to existing filling station networks. Moreover, FCEVs offer a large range. For example, trucks powered by fuel cells can cover more than 1,000 km on just one tank.
400 kW
At more than 400 kW, the NM20 stack module is EKPO’s most powerful model to date and was designed specifically for heavy-duty transport applications.
Key features of the NM20 stack module
At more than 400 kW, the NM20 is the most powerful stack module developed by EKPO to date and was designed especially for use in heavy-duty transport. Other potential applications are in off-highway vehicles, the rail sector, the marine industry, and stationary applications. The key features of the NM20 include high efficiency, lower hydrogen consumption, capability for higher operating temperatures, recyclability, and a long service life. These are all based on the high power density that is one of EKPO’s hallmarks, which was increased by more than 50% compared with previous generations of the product. Another advantage is that the media module, which is part of the scope of supply, is designed as a customer-friendly, highly functional system interface. It integrates essential functions for operation; in addition to a heat exchanger to preheat the hydrogen from the tank, the media module contains water separators, pressure control, purge and drain valves, and pressure and temperature sensors.
Also included is an ultra-modern monitoring system, which measures cell voltages, detects limit values, combines information, and shares it with the system using a CAN communication interface. But the NM20 represents much more than just a fuel cell stack: the new, modern stack platform performs key functions in the system and as a result offers genuine benefits for system integrators.
In his 1875 novel “The Mysterious Island,” Jules Verne wrote with great vision: “The energy of the future is water, which has been broken down by electricity.” Increasingly, this vision is becoming a reality, because thanks to its versatility, hydrogen is making inroads into the transport, industry ,and energy segments as an efficient source of energy. The transformation process is in full swing. EKPO is playing an active role and is making an important contribution to a sustainable future with its innovative fuel cell technology and components for electrolysis.
“Driving hydrogen solutions for a sustainable future”: this is the commitment made by the three managers at the helm of EKPO Fuel Cell Technologies GmbH. As CCO, Dr. Stefan Dwenger (left) is responsible for Sales and Marketing as well as Programs & Application Engineering. CEO Dr. Gernot Stellberger (center) leads the company and oversees Strategy, Finance, Purchasing, Human Resources, and Advanced Development. In his role as COO, Mark Passolt (right) is responsible for Production, Product Engineering, IT, Quality, and Sustainability Management.
Overview of EKPO stack family
The smallest platform, NM5-evo, operates at max. 370 A with a power output of 76 kW and is mainly used in light commercial vehicles and passenger cars. At up to 570 A, the NM12 platform comes in two versions – the NM12-single (up to 123 kW) and NM12-twin (up to 205 kW) – and is also used in applications with higher power requirements such as buses. The newest platform NM20, designed for the heavy-duty segment, achieves an output of more than 400 kW at a maximum current of 900 A and enables optimum integration into upcoming 800 V vehicle platforms. Apart from a larger active surface area, this is made possible by the huge increase in power density.
» Our latest stack module, the NM20, which is already in the prototyping phase, once again demonstrates our exceptional capabilities in the areas of innovation and industrialization. «
Dr. Gernot Stellberger, CEO of EKPO Fuel Cell Technologies GmbH
Performance and efficiency of the NM20
In addition to a high electrical output, the running costs of the vehicle are also crucial in the heavy-duty transport sector. And this is where the NM20 stack platform has so much to offer: at a stack load point of 200 kW, for example, an absolute efficiency increase of 11% compared with the previous NM12 benchmark can be achieved. This ensures more effective use of the hydrogen on board and reduces the operating costs of the system.
> 25000 h
The extremely long service life of the NM20 is of crucial importance in the heavy-duty segment in particular.
50 %
The power density of the NM20 has been increased by more than 50% compared to the previous generations.
105 °C
With a maximum operating temperature of up to 105°C, the NM20 stack module can be easily integrated into the respective application and is equipped to handle the most challenging requirements.
57 %
The significant increase in efficiency from 48% to 57% at the rated power point results in a further reduction in operating costs.
600 °C
There are more than 600 cells in the stack. The electrical output is in excess of 400 kW.
Hy2Tech
Good to know: the development and commercialization of the NM20 is being supported by the German Federal Ministry for Digital and Transport and the Ministry of the Environment, Climate and Energy Sector of the state of Baden-Württemberg in the context of the IPCEI “Hy2Tech” hydrogen program. IPCEI is the acronym for “Important Projects of Common European Interest,” a tool developed by the European Commission to promote innovative and strategically important key technologies. EPKO will receive funding of up to EUR 177 million until the end of 2027.
