Ballard Power Systems unveiled its 9th generation fuel cell engine

Ballard Power Systems unveiled its 9th generation fuel cell engine, the FCmove®-XD, at the Advanced Clean Transportation (ACT) Expo held at the Las Vegas Convention Center. This new engine represents a significant advancement in fuel cell technology for heavy-duty applications, delivering the highest volumetric power density in the industry with a volumetric power density of 0.36 kW/L and a gravimetric power density of 0.48 kW/kg. The FCmove®-XD is designed to be highly scalable, capable of integrating up to three modules to operate as a single system with a combined output of 360 kW of zero-emission power.

The FCmove®-XD is built for durability and efficiency, boasting a design life of over 30,000 hours of operation, equivalent to more than one million miles in typical truck operation. This new generation engine features numerous improvements over previous models, including a 33% reduction in total parts count, which enhances reliability and reduces costs. It also offers ultra-high peak system efficiency at over 60%, leading to better fuel consumption and lower total cost of ownership. The engine can operate in a wide temperature range up to 95°C and incorporates an integrated power controller with a DC/DC converter, air compressor inverter, and power distribution unit, along with proprietary software controls to enhance operation and efficiency.

Significant design enhancements make the FCmove®-XD more manufacturable, with a more than 50% reduction in assembly time, and easier to maintain in the field due to improved access to parts. Its rapid up and down transient times and an innovative hot stand-by mode enable quick power increases, making it highly responsive to varying operational demands. The engine also complies with all applicable safety codes and standards, ensuring safe and reliable performance.

Ballard’s FCmove®-XD is tailored to meet the demanding requirements of the heavy-duty truck market, which includes high vehicle utilization rates and significant payload needs. According to Silvano Pozzi, Vice President of Product Line Management, one of the most compelling features of the new FCmove®-XD is its modularity and scalability. This allows for efficient integration of 120 kW, 240 kW, and 360 kW solutions depending on the truck class and duty cycle. For example, two engines totaling 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.

Mircea Gradu, Ballard’s Chief Engineering Officer, highlighted the extensive collaboration with the supply chain and significant investments in production tooling that have contributed to the development of the FCmove®-XD. These efforts have resulted in an engine that leads the category in performance metrics while significantly lowering capital and operating costs for customers. Initial feedback from pre-launch customer engagements has been very positive.

Ballard plans to begin manufacturing the FCmove®-XD at its Oregon facility in 2025 to ensure compliance with “Buy America” regulations. Future high-volume manufacturing is planned for Ballard Rockwall Giga 1, a newly announced 3 gigawatt Gigafactory in Rockwall, Texas. The FCmove®-XD is set to redefine performance standards in the fuel cell industry, offering substantial improvements in cost efficiency and operational effectiveness.