Over the past four years, approximately 20 project partners have collaborated intensively on the groundbreaking StasHH project. Their shared goal? To standardize fuel cell modules for heavy-duty applications, paving the way for a more sustainable future.
In this combined interview, we aim to provide readers with a deeper understanding of how such a large-scale collaborative initiative works and the impact it strives to have. Previously, project coordinator Federico Zenith (SINTEF) shared his perspectives in an engaging video interview, shedding light on the StasHH project.
Now, we turn to a diverse group of experts involved in StasHH to reflect on the project's challenges, accomplishments, and the path forward. Their insights offer a unique window into the dynamics of partnership and the drive of standardization in an evolving field.
Our interviewees are:
- Ruud Bouwman (New Technologies), VDL
- Giampaolo Sibilia (EU Operations Director), Nuvera
- Thomas Wannemacher (Team Leader Certification & Documentation) & Jan Bochinger (Head of Sales), Proton Motor
- Edward Sciberras (Research Engineer), Damen
- Markus Kogler-Lichtenegger (Senior Software & Controls Engineer Fuel Cell), AVL
- Chakib Diab (Project Manager), FEV
What is your company’s role in the project?
- Ruud Bouwman (VDL): VDL was leader of work package (WP) 3; specifically on the standardization of size and interfaces of FCMs. We are also a user of StasHH fuel cell modules in trucks and gensets: a hydrogen powered generator set.
- Giampaolo Sibilia (Nuvera): The StasHH project is intended to define a standard applicable to a suite of fuel cell modules. Multiple stakeholders are involved in the project, including fuel cells manufacturers, OEMs, users, and testing and verification bodies. Nuvera’s role as fuel cell manufacturer has been to participate in the standard definition process, and to build two fuel cells modules conforming to the standard’s specifications. These two prototypes were tested by CEA in France.
- Thomas Wannemacher & Jan Bochinger (Proton Motor): As a fuel cell manufacturer, we were one of the first members during the proposal phase of the project. So, we were fully committed to supply modules and to work together to define the StasHH Standard. We were the first to deliver a developed system to FEV for testing and we are proud of that.
- Edward Sciberras (Damen): Damen participated in this project as a shipbuilder, thus representing the maritime use case. We brought requirements and experience from ship power system integration.
- Markus Kogler-Lichtenegger (AVL): AVL was involved in the definition of the digital interface for fuel cell modules, together with SINTEF.
- Chakib Diab (FEV): During StasHH project FEV took the lead of work package 4 ‘Fuel Cell Modules’ in which the fuel cell module suppliers had to build their prototypes in-house under the neutral leadership of a neutral partner. In addition to this, FEV also supported other work packages and mainly WP 5, in which we developed the first StasHH ‘mobile test rig’ that was used to operate the test on the prototypes modules. FEV also performed in-house tests on these modules.
If you were involved in defining the specifications of the standard or the building of a standardized fuel cell module: How did your company go about it?
- Ruud Bouwman (VDL): The first proposal for a standard was proposed by VDL and discussed and optimized with all partners. We looked into all the sizes of different applications. Based on that and the input of the ideas of Bosch - who was part of the advisory committee of the project - we made a proposal for size and interfaces. At the time, the pandemic was in full swing, which made it harder to fully discuss the proposal. However, we managed to arrange the necessary online meetings before the deadline and delivered the specifications by the end of January 2021.
- Giampaolo Sibilia (Nuvera): There has been very good interaction among the partners to arrive to a standard that is representative of market needs. Throughout fuel cell construction and subsequent testing and verification in partners’ facilities there has been both good learning and productive cooperation.
- Thomas Wannemacher & Jan Bochinger (Proton Motor): We are used to specific requirements of customer applications. However, it was difficult to make a product accustomed to the StasHH Standard, because of the limitations and construction space available. We also had a lot of trouble finding the right components at the time. We use grafitic plates for the fuel cell modules, known for having a long lifetime and being bigger. So, with the small construction space, it was hard to include all the other relevant components. In the end, the good cooperation between all our departments, made that we succeeded.
- Edward Sciberras (Damen): We looked at the applicable rules and regulations and investigated how a system built with StasHH modules could be built. We considered a specific ship design to see how the modular fuel cell power system could be integrated in the rest of the existing power system.
- Chakib Diab (FEV): FEV was involved in the communication standard definition. Also, we defined the ‘site acceptance test’ (SAT) and (‘factory acceptance test’ (FAT).
How did your company tackle the testing of the standardized fuel cell module?
- Chakib Diab (FEV): The developed Mobile Test Rig by FEV were used to successfully operate 2 Module at our own facility in Aachen, further 2 Module were assembled but testing could not be performed (Module software had to be reworked to fulfil StasHH standard)
How does the standardized fuel cell module compare to other fuel cell systems available on the market?
- Ruud Bouwman (VDL): This fuel cell module is very efficient for not mass produced systems like gensets, ships, off-road equipment like excavators, etc. These systems are generally not produced 100.000 times per year, but only a couple of times. In that case it is handy if it is a standard size. If a fuel cell is always needed in the same environment for huge quantities per year, you should develop a fuel cell module special for only that purpose.
- Giampaolo Sibilia (Nuvera): The standardized fuel cell module offers vehicle integrators and OEMs the ability to develop powertrains with the confidence that they will have the ability to incorporate fuel cells from multiple providers without significant redesign. This will help reduce overall development and manufacturing costs, create fuel cell application know-how that can be used across platforms, and accelerate the introduction of both new and next-generation deployments. Standardized fuel cell modules will also drive the standardization of interface componentry, further reducing the cost of fuel cell application development and adoption.
- Thomas Wannemacher & Jan Bochinger (Proton Motor): At Proton Motor we mainly sell standard products for the stationary applications. The StasHH standardized module is still seen as a customer specific product for now and not in our catalogue yet. If Proton Motor continues*, we will probably focus on the stationary market. We haven’t had any requests yet from the market for this module. The more requests will follow, the more the product will ripen to a real, standardized module and the quality level will rise.
- Edward Sciberras (Damen): We see a high level of integration of components in the StasHH module, and the fact that it is standardized, helps us include defined standard fuel cell modules for our projects.
- Markus Kogler-Lichtenegger (AVL): The fuel cell modules which are available on the market have already a quite high maturity. Introducing the STASHH standard will enhance their capabilities for usage in different domains and in stacked applications.
- Chakib Diab (FEV): The modules are generally comparable. Our Standard defines the size of the fuel cell module and the protocols that are exchanged between the module and the vehicle or vessel etc., which simplifies the integration.
(* At the time of the interview, the future of Proton Motor was unsure and a new investof had to be found.)
Can you discuss the scalability of the standardized module? How easily can it be adapted to different sizes and types of heavy-duty vehicles?
- Ruud Bouwman (VDL): As VDL we used the PlasticOmnium and the Toyota fuel cell modules in the same vehicle. This showed the flexibility already. As a matter of fact, it was easy, because it was standardized. And, in the H2Haul project we build 2 heavy-duty trucks with a fuel cell module, based on the StasHH Standard. Furthermore, we build a genset with a Freudenberg fuel cel module as well.
- Giampaolo Sibilia (Nuvera): The StasHH standard comprises a total of seven different sizes intended to fit multiple configurations among heavy-duty vehicles, stationary, rail, maritime and other applications. A StasHH-compliant module will conform to one of those specifications, and vehicle integrators will be able to choose the model most suitable for their use. The standardization of connections and interfaces make integration of fuel cell modules into the overall powertrain more straightforward.
- Thomas Wannemacher & Jan Bochinger (Proton Motor): It is very easy to put several modules together and connect them. In addition, the way we designed it according to the StasHH Standard, there are certain balance of plant components, which are not integrated into the module. Thanks to this wise approach, you don’t need each component for each module. For example, this way you reduce the amount of water separators.
- Edward Sciberras (Damen): For maritime power systems, the power requirements will almost certainly always require multiple StasHH modules. The standardized design of the modules means that our development effort is reduced in scaling of the system across projects and suppliers, as well as benefiting from the experiences in other industries and applications.
- Markus Kogler-Lichtenegger (AVL): The AVL contribution to the project, the digital interface, is designed to be easily adoptable to variable sizes of fuel cell modules and is independent of the application (marine, heavy-duty, stationary, …).
- Chakib Diab (FEV): In very simple words: depending on the power output needed, several modules can be stacked and connected to each other.
Which challenges have you faced in the project?
- Ruud Bouwman (VDL): The project is divided into three parts. The size, the connection area and the communication. The connection area and the type of connection are still a challenge. It would have been too difficult on a technical level to make this equal for all the fuel cells and standardizing it wouldn’t have been accepted (yet) by the industry probably. But, the area for the interfaces and communication are set, which will save time with regards to the connections and it also means that they will at least speak the same language. Since all software related matters are difficult to standardize, we are pleased that the dimensions and communication are the same. In the end, mechanical adjustments, like relocating tubes, are easily made.
- Thomas Wannemacher & Jan Bochinger (Proton Motor): In the beginning of the project we missed the information of the original equipment manufacturer on the space available for example. Later on, the biggest challenge was finding the right components to match the power and safety requirements. If a component used during the design phase, is not available anymore during the procurement or production phase, it will affect so many things on the whole.
- Edward Sciberras (Damen): As with other development projects, identifying and gaining experience with the applicable rules and regulations for integrating fuel cell modules and their ancillary systems provided valuable learning experiences.
- Markus Kogler-Lichtenegger (AVL): The biggest challenge was to consider all inputs from the different applications of the project partners. We faced various communication protocols, fuel cell module architectures and electrical topologies, which found a common basis in the proposed standard.
- Chakib Diab (FEV): During the planning and development of the mobile test rigs, assumptions had to be made to ensure that all the fuel cell modules that would be developed by the suppliers, could be operated with the rig. Additionally, some fuel cell modules specifications were not standardized, such as the integration for the DC/DC converter which was challenging for the testing.
What do you hope to gain from this project?
- Ruud Bouwman (VDL): VDL is already very, very happy with the standardization of the communication and the size of the standard modules. This reduced the development time exponentially (especially the communication), which is the main gain.
- Giampaolo Sibilia (Nuvera): Our hope is that standardized modules and componentry will streamline vehicle integration, removing significant barriers to adoption. We expect the market for fuel cell applications to expand, allowing Nuvera to sell our products in higher volumes.
- Thomas Wannemacher & Jan Bochinger (Proton Motor): On a technical level we already gained a lot of knowhow on components that we can adopt to other products. The technical specifications that we received at the beginning of the project, were the best we ever had. This very clear requirement sheet was helpful in designing a product that is well documented. Of course, we hope that others in the branch will follow. To be able to exchange one system by another, would be the aim in the future.
- Edward Sciberras (Damen): We hope to be able to collaborate with other users of the StasHH fuel cell modules and learn from their experiences. And in the end, contribute to the definition of a standard fuel cell module which can facilitate the integration of fuel cells into maritime applications.
- Markus Kogler-Lichtenegger (AVL): This project was a big step forward to harmonize the development of fuel cell modules which supports the market acceptance and should encourage the original equipment manufacturers (OEMs) for this technology.
- Chakib Diab (FEV): I hope that after the project completion, a community will follow the topic and develop this standard further, which will bring all fuel cell module suppliers to commit and produce StasHH compliant modules.
All FCMs who joined the StasHH project at the closing event during the European Hydrogen Week 2024. (All except Proton Motor, which was unable to join, but who did provide a quote.)
Thomas Wannemacher from Proton Motor: "The concept behind this project, where all competitors collaborate hand in hand, is truly remarkable. In our view, it's quite exceptional how well we managed to work together towards the common goal of a standardized fuel cell module."
Watch the StasHH video interview as well:
