State-of-the-art humidifier test bench by MANN+HUMMEL for higher fuel cell efficiency
As the world moves toward cleaner energy sources, fuel cell technology is a key solution for sustainable mobility. MANN+HUMMEL is leading this change by enhancing innovative filtration and improving fuel cell efficiency to meet the demands of a cleaner mobility.
Fuel cell adoption: Trends and insights
We are witnessing strong growth in fuel cell technology in modern mobility, driven by increasingly strict low- and zero-emission regulations worldwide. This shift toward cleaner mobility solutions is reshaping the automotive landscape, with hydrogen fuel cells becoming a promising alternative to traditional fossil fuel-powered vehicles. However, the fuel cell market faces significant uncertainties, mainly due to political and geopolitical factors. The absence of a single reliable source for market forecasting leads to a wide range of projections, with conservative and optimistic estimates often differing greatly. Despite these challenges, the hydrogen market is developing, with projects being implemented across various sectors.
Statistics on the growing use of fuel cells in transportation
The market potential for fuel cell technology is significant. Recent statistics show that fuel cell adoption in transportation is increasing. By the end of 2024, around 90,000 fuel cell vehicles are expected on the road globally, with 15,500 new vehicles added in 2023 alone. The bus and truck segments are likely to experience the most growth in new registrations, as larger vehicles can better benefit from fuel cell technology. However, forecasts for annual sales by 2030 vary widely, ranging from 2 to 87 billion US dollars. This variation highlights both the technology's potential and the uncertainties about its adoption rate.
The role of hydrogen as a clean energy source
Hydrogen is essential for the clean energy transition. Competing with various alternatives, it has significant potential for decarbonization in transportation, industry, and power generation. At MANN+HUMMEL, we are dedicated to improving hydrogen fuel cell efficiency and durability through innovative solutions, including advanced humidifier technologies. These advancements are critical to unlock the full potential of hydrogen fuel cells and speed up their adoption in transportation and beyond.
Humidity control: Factors affecting fuel cell performance
Function test of humidifiers
Humidity plays a crucial role in the conductivity and durability of fuel cell membranes. Proper humidification ensures efficient proton transfer between electrodes, which is vital for fuel cell operation. However, a careful balance is necessary: Low humidity can dehydrate the membrane, increasing internal resistance and lowering efficiency, while too much humidity can cause flooding, blocking reactant flow and reducing power output. To address this challenge, advanced water management strategies, including humidifiers, are needed.
The role of air filtration in enhancing fuel cell performance
Effective air filtration systems remove contaminants from the air supply, protecting delicate membranes from damage. Advanced solutions, such as mixed activated carbon media, offer efficient adsorption and particle filtration, protecting against harmful gases including SO₂, NOₓ, and NH₃, which can severely affect fuel cell operation. By ensuring a clean air supply, filtration systems are paramount for maintaining the efficiency of hydrogen drives and vehicles. They help prevent catalyst poisoning and channel blocking – two common issues that can greatly impact performance. This results in a stable and efficient fuel cell system that operates at peak performance for extended periods.
MANN+HUMMEL's humidifier for optimal intake air humidity
MANN+HUMMEL's innovative humidifier technology represents a major step forward in fuel cell humidity management. This system protects fuel cell membranes from the negative effects of both too low and too high moisture levels, as well as long-term degradation. The humidifier is designed to transfer moisture from exhaust air to intake air, ensuring consistent and optimal humidity within the fuel cell.
Sensors for recording humidity, temperature and pressure
Another important advantage of our humidifier is its low pressure loss. This improves overall fuel cell performance by minimizing energy waste and maximizing efficiency. With these advanced solutions in humidity control, water separation and air filtration, MANN+HUMMEL is at the forefront of enhancing the efficiency and lifespan of fuel cells, making significant contributions to the advancement of flexible power consumption, hydrogen-powered transportation and clean energy technologies.
Innovative humidifier test bench from MANN+HUMMEL
The innovative test bench developed by MANN+HUMMEL is an impressive tool for examining balance-of-plant components essential to fuel cell operation. This cutting-edge testing facility, representing a seven-digit investment, was established in its headquarters in Ludwigsburg, highlighting MANN+HUMMEL's commitment to advancing fuel cell technology.
Its main purpose is to measure and optimize the efficiency and lifespan of fuel cell components, especially humidifiers. The test stand maintains the required humidity under various conditions and optimizes important parameters such as mass flow, pressure, temperature and input humidity. With these results, it supports adaptation and optimization measures to improve humidifier designs in terms of optimal moisture transfer, efficient use of space and minimal pressure loss - with adjustable parameters that meet specific customer needs.
Humidifier test bench in Ludwigsburg - interior view
- Precise control: State-of-the-art hardware and software for exceptional accuracy
- Comprehensive testing: All-in-one assessment of performance and durability
- Versatile evaluation: Compares multiple designs in diverse conditions
- Advanced simulation: Replicates a wide range of real-world scenarios
- Unique capabilities: Combination of a wide range of parameters
- Efficient customization: Quick adjustment to meet customer-specific requirements
Functionality and purpose of our humidifier test bench
Our test bench features high-pressure blowers that can generate airflow up to 1,500 kg/h – comparable to filling a hot air balloon in just one hour. This outstanding capacity allows the simulation of fuel cell operations up to 350 kW, accomodating a wide range of applications. Key functions include air humidification and conditioning. The test stand humidifies air by adding steam under controlled conditions and manages air mass flow with set pressure and temperature, accurately replicating real-world operating scenarios.
The system can simultaneously test up to two test specimens in a temperature chamber that allows temperatures from -40 to 120 degrees Celsius. This is crucial for evaluating cold start capabilities and performance across different temperatures, ensuring that components can withstand various environmental conditions.
Special features of the test bench for fuel cells components
Humidifier test bench in Ludwigsburg - exterior view
A key feature of MANN+HUMMEL's test bench is its ability to automate and adapt test procedures. It measures moisture transfer, pressure loss, and conducts leak tests in a connected and flexible manner. The test bench excels in dynamic testing, using varying temperature, humidity, and pressure cycles for thorough durability assessments. This enables comprehensive product validation without having to switch test specimens between different test benches, which significantly streamlines the entire process.
Data analysis of the results
All results are stored in a database, which facilitates the creation of customer-specific reports and advanced data analytics. The collected data is invaluable for training and calibrating simulation models, improving understanding of humidifier efficiency, and speeding up the development of optimized solutions for future applications. Operational since early 2024 at MANN+HUMMEL's technology center in Ludwigsburg, the test bench has already demonstrated its value in fundamental investigations, validation of customer projects, and comparisons with existing results.
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Future innovations in fuel cell technology lead by MANN+HUMMEL
MANN+HUMMEL is dedicated to innovation in fuel cell technology, backed by significant investments in research and development. Our data-driven approach allows us to develop cutting-edge technologies that enhance fuel cell systems. We focus on improving the efficiency and lifespan of fuel cells, as these are crucial for the widespread adoption of clean energy.
Our expected breakthroughs in manufacturing processes and materials science aim to lower costs and increase scalability, making fuel cell technology more accessible and economically viable for various applications. Our ongoing work to optimize fuel cell components supports global efforts to reduce emissions and meet ambitious climate goals.
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