Materials for Proton Exchange Membranes and Membrane Electrode Assemblies for PEM Fuel Cells

Report Summary

The global market value of components for PEM fuel cell membrane electrode assembly (MEA) as defined by the membrane, the bipolar plates, the gaseous diffusion layers, and the catalyst ink and electrodes, is an estimated $383 million in 2010. This market is expected to grow at a 20.6% compound annual growth rate (CAGR) over the 5-year forecast period to reach $977 million in 2015.

Of the PEMFC MEA components, membranes have the greatest value, estimated at $200 million in 2010. By 2015, this sector will be worth $424 million, a compound annual growth rate (CAGR) of 16.2%.

Inks and catalysts have the second largest share but will experience the highest growth rate of the aforementioned components. This sector is valued at $103 million in 2010 and is forecast to increase at a 28% compound annual growth rate (CAGR) to reach $354 million in 2015.

INTRODUCTION

STUDY GOALS AND OBJECTIVES

This analysis focuses on the three main components of the membrane electrode assembly (MEA) for proton exchange membrane fuel cell (PEMFC). These include:

• Membranes
• Gaseous diffusion layers and bipolar plates
• Catalysts and inks

Polymer membranes that are the electrolyte and therefore the heart of the fuel cell, and they receive extra attention. The report also examines the history and advancing technology of these components, the companies involved in these developments, the current and projected incentives, and the projected markets for such technologies.

Identified as a practical solution to many of the technological and environmental problems facing the world today, the proton exchange membrane (PEM) fuel cell is appropriate as a power source for transportation, stationary distributive power, and small-scale applications such as portable electronic products. Applications for all types of fuel cells are still evolving. In the process of this evolution, the different proton exchange membrane materials and MEAs will evolve and be adapted to more specific uses.

Identifying how researchers are solving the search for better membranes that have greater tolerances to poisoning, greater durability, and lower costs is a major objective of the report. The U.S. Japanese, Chinese, and European Union governments are pouring billions of dollars of loans, subsidies, and outright grants into fuel cell research and development — and at the same time there has been a series of brutal confrontations between Congress and the President’s administration over continued fuel cell vehicle funding. Meanwhile, European and Far Eastern government subsidies increase.

Commercialization of the fuel cell is not solely influenced by engineers and scientists working on stacks and reformers. (This is also brought about by subsidies by the government, lobbying efforts, venture capitalists, and most of all by some consumers actually finding a need or desire for the product.) A major cost issue addressed is the critical issue of the catalyst component.

REASONS FOR DOING THE STUDY

Fuel cells are viewed as potential candidates for auxiliary power, mobile power, stationary distributed or central power, and portable product power. Advances in the technology are made, but sometimes these advances reveal even more challenges to be met. Slowly there is the realization that total dependency on hydrocarbon fuels is not a viable economic option. Proton exchange membrane fuel cells have a part in securing energy security for the country, improving the environment, greatly reducing urban pollution, and creating jobs in manufacturing as the technology advances. They can also provide a cost-effective and performance-driven rival for advanced batteries.

This study analyzes components of the PEM fuel cell, a technology offering the promise of greatly reduced environmental impact and excellent performance, price, and efficiency advantages. Recent historic developments and approaches are described along with recent commercial developments and the state of the art. Hydrogen feed fuel cells are based on the electrochemical reaction between hydrogen and oxygen. This electrochemical process does not pollute the environment with hydrocarbons, particulates or any sulfur or nitrogen oxides. The study identifies the opportunities and technological requirements of the proton exchange membrane fuel cell and the MEA and the bipolar plates for the PEM fuel cell. When several units of the membrane electrode assembly are capped off with a bipolar plate and properly assembled, the arrangement is referred to as a stack.

Questions to be answered include determining a timetable for PEM fuel cell commercialization, as well as what types of membranes and membrane assemblies are needed to make this possible.

INTENDED AUDIENCE

This report is intended to provide a unique analysis of the broadly defined global proton exchange membrane market and will be of interest to a variety of current and potential fuel cell users as well as fuel cell makers and component and membrane makers. This report also can provide valuable information in terms of assessing investment in particular technologies and, therefore, should benefit investors directly or indirectly. The vital importance of platinum as a catalyst for PEM fuel cells is addressed. Anyone interested in the precious metals market, in nanomaterials, or in alternative catalysts will find the evaluations of the technology of interest. BCC Research wishes to thank those companies, government agencies, and university researchers that contributed information for this report.

This analysis is designed to be as comprehensive as possible. This document is intended to be value to a broad audience of business, technical, investment, and regulatory professionals. It is an information source for an emerging industry as well as a reference on a developing technology. It presents analysis and forward-thinking evaluations that will be of advantage to manufacturers; material suppliers; and to local, state, and federal government entities. Corporate planners will benefit from the report’s evaluation of the demands for proton exchange membranes, membrane electrode assemblies, and platinum catalyst and the companies involved in their development and manufacture. Others may find the broad discussions of energy policy, environmental impact, platinum supply, and chemical synthesis of membranes to be of considerable value in understanding the opportunities and problems facing the fuel cell industry in the near- to mid-term.

SCOPE OF REPORT

The fuel cell industry in various forms has been developing for decades. There are notable examples of fuel cell successes. The proton exchange membrane fuel cell is emerging as a winner in many of the primary categories that fuel cells can satisfy. Existing membranes and assemblies still have room for improvement. Proton exchange membrane fuel cell development and commercialization is an ever-changing process. This BCC Research analysis examines the market and technology for the materials and technology of proton exchange membranes and electrode assemblies and for bipolar plates for PEMFCs, including direct methanol fuel cells (DMFCs). This includes the gas diffusion layer (GDL), the catalyst ink/electrode, the membrane itself, and the bipolar plate. Ancillary stack assembly materials such as bolts, gaskets, tie-outs, and final assembly and packaging costs are excluded.

This report details the actuals for 2006, 2009, and 2010 and compound annual growth rate (CAGR) projections for 2015 for the North American, European, Far Eastern, and rest-of-world markets. Selected 2006 actuals will help as a basis for today’s markets and tomorrow’s projections. When appropriate, consensus, optimistic, and pessimistic scenarios are presented. A patent analysis and discussion for power sources and vehicle components describes where research is performed and emphasizes intellectual property issues.

METHODOLOGY

An in-depth analysis of technical and business literature and published dissertations, a review of the history of the technologies involved, interviews with industry experts, company representatives, federal government researchers, and university scientists provide an assessment of the outlook for the next generation of PEMFCs and membrane electrode assemblies. Other information sources include product literature from suppliers, scientific references, conferences, patent searches.

Both primary and secondary research methodologies were used in preparing this report, which is based on interviews with commercial and government sources, literature reviews, and patent examinations. Throughout the report, past market data is expressed in current dollars, and estimates and projections are in constant 2010 dollars. Historic markets (2006 and 2009) and the projected market for 2015 are provided. Most market summaries are based on a consensus scenario that assumes no unanticipated technical advances and no unexpected legislation. When appropriate, pessimistic, consensus, and optimistic market scenarios characterize several developmental markets. Totals are rounded to the nearest million dollars. When appropriate, information from previously published sources is identified to allow a more detailed examination by clients.

Table of Contents

CHAPTER ONE: INTRODUCTION
STUDY GOALS AND OBJECTIVES
REASONS FOR DOING THE STUDY
INTENDED AUDIENCE
SCOPE OF REPORT
METHODOLOGY
INFORMATION SOURCES
ANALYST CREDENTIALS
RELATED BCC REPORTS
BCC ONLINE SERVICES
DISCLAIMER

CHAPTER TWO: SUMMARY

SUMMARY
SUMMARY TABLE GLOBAL PEMFC MEA MARKET, THROUGH 2015 ($ MILLIONS)
SUMMARY FIGURE GLOBAL PEMFC MEA MARKET, THROUGH 2015 ($ MILLIONS)

CHAPTER THREE: PROTON EXCHANGE MEMBRANE FUEL CELL OVERVIEW
FUEL CELL TECHNOLOGY
PROTON EXCHANGE MEMBRANE FUEL CELL FUNDAMENTALS

FIGURE 1 GENERIC PEMFC DIAGRAM SHOWING COMPONENTS

FUEL AND FUEL REFORMING FUNDAMENTALS
Improved Hydrogen Separation
Filtering Hydrogen and Oxygen
Georgia Tech Analysis of Fuel Cell Failure Modes
THE DIRECT METHANOL FUEL CELL VARIATION

FIGURE 2 SCHEMATIC DMFC CHEMISTRY

PROTON EXCHANGE MEMBRANE FUEL CELL COMPANIES

TABLE 1 PEMFC AND DMFC MAKERS

PROTON EXCHANGE MEMBRANE FUEL CELL MARKET DRIVERS
MARKET SEGMENTATION AND INDUSTRY CONCENTRATION
Portable Market Sector Market Drivers and Market Factors

TABLE 2 TYPES OF PORTABLE PRODUCTS

TABLE 3 IMPORTANT PORTABLE PRODUCT CONCEPTS

TABLE 4 PORTABLE FUEL CELL MARKET DRIVERS

TABLE 5 PORTABLE FUEL CELL MARKET FACTORS

Stationary Market Sector Market Drivers and Market
Factors
Uninterruptible Power Supplies
Combined Heat and Power
Utility Load Leveling
Stationary Market Drivers

TABLE 6 STATIONARY FUEL CELL MARKET DRIVERS

TABLE 7 STATIONARY FUEL CELL MARKET FACTORS

Transportation Market Sector Market Drivers and Market Factors

TABLE 8 TRANSPORTATION FUEL CELL MARKET DRIVERS

TABLE 9 TRANSPORTATION FUEL CELL MARKET FACTORS

“Other” Market Sector Market Drivers and Market Factors
Portable Military Products

TABLE 10 SELECTED PORTABLE BATTERY-POWERED MILITARY PRODUCT ROLES

Recreational Vehicles
Anti-Idling Power
“Other” Market Drivers

TABLE 11 “OTHER” FUEL CELL MARKET DRIVERS

TABLE 12 “OTHER” FUEL CELL MARKET FACTORS

GLOBAL PEMFC MARKET FORECASTS

TABLE 13 GLOBAL PEMFC MARKET BY APPLICATION, THROUGH 2015 ($ MILLIONS)

FIGURE 3 GLOBAL PEMFC MARKET BY APPLICATION, 2010 ($ MILLIONS)

TABLE 14 GLOBAL PEMFC MARKET BY REGION, THROUGH 2015 ($ MILLIONS)

FIGURE 4 GLOBAL PEMFC MARKET BY REGION, 2010 ($ MILLIONS)

Optimistic and Pessimistic Scenarios

TABLE 15 GLOBAL PEMFC MARKET BY APPLICATION, THROUGH 2015 ($ MILLIONS)

CHAPTER FOUR: MEMBRANE ELECTRODE ASSEMBLIES
MEMBRANE ELECTRODE ASSEMBLY BACKGROUND

FIGURE 5 SCHEMATIC SIMPLE MEA

PERFORMANCE GOALS FOR MEAS

TABLE 16 FUEL CELL MEA PERFORMANCE GOALS

MEA FABRICATION AND ASSEMBLY

FIGURE 6 SCHEMATIC FOR CONCEPTUAL MEA CREATION

MEMBRANE ELECTRODE ASSEMBLY FUNCTIONAL STACK DESIGNS
ELECTROCHEMISTRY
WATER MANAGEMENT
ANCILLARY FACTORS
MEMBRANE ELECTRODE ASSEMBLY DEVELOPMENT APPROACHES
3M Innovative Properties Co. Approach
DuPont Approach
GM Approach
Hoku Scientific Approach
PEMEAS/E-Tek Approach
Palcan Power Systems Approach
ReliOn/Avista Approach
Gore Approach
Other Approaches
CARBON CORROSION AND GRAPHITES
Asbury Graphite Mills Approach
Crystal Graphite Approach
Timcal Synthetic Graphite Approach
DIRECT METHANOL FUEL CELL MEA APPROACHES
Gillette Co.
Sony Corp.
Los Alamos National Laboratory
California Institute of Technology
University Of Connecticut
Direct Methanol Fuel Cell Corp.
Gore DMFC
Maxdem Technologies
Russian Academy of Sciences
Ube Industries, Ltd.
Sumitomo Metal Approach
Oorja Approach
Panasonic Approach

TABLE 17 PANASONIC DMFC SPECIFICATIONS

University of Dayton Approach
Arizona State University
Rice University Approach
Drexel University Approach
GLOBAL MEA COMPONENT FOR PEMFCS STRUCTURE AND FORECAST
MEMBRANE ELECTRODE ASSEMBLY INDUSTRY STRUCTURE

TABLE 18 ESTIMATED MEA COMPANY MARKET SHARES, 2010 (%)

BIPOLAR PLATE MARKET STRUCTURE
GAS DIFFUSION LAYERS AND CARBON STRUCTURE
INK AND CATALYST STRUCTURE
PUTTING IT ALL TOGETHER: MEA MARKET FORECAST

TABLE 19 GLOBAL MEA COMPONENT MARKET, THROUGH 2015 ($ MILLIONS)

FIGURE 7 GLOBAL MEA MARKET SHARES, 2010 (%)

TABLE 20 GLOBAL MEA COMPONENT MARKET BY REGION, THROUGH 2015 ($ MILLIONS)

PROTON EXCHANGE MEMBRANES FOR FUEL CELLS
MEMBRANE BACKGROUND
Types of Membranes
Membrane Processes
Proton Exchange Membrane Fuel Cell Membranes
WHAT MAKES A GOOD PEM FUEL CELL MEMBRANE?
PROTON EXCHANGE MEMBRANE FUNCTIONAL FACTORS

TABLE 21 MEMBRANE PARAMETER VARIABLES

PROTON EXCHANGE MEMBRANE ELECTROLYTE COMPATIBILITY FACTORS

TABLE 22 PEM ELECTROLYTE ISSUES

MEMBRANE TEMPERATURE TOLERANCE FACTORS
High-Temperature Tolerance

TABLE 23 ADVANTAGES OF A HIGHER TEMPERATURE MEMBRANE FOR A PEM FUEL CELL

Freezing Temperature Tolerance
MEMBRANE WATER TOLERANCE FACTORS

FIGURE 8 WATER TRANSPORT IN A PEM FUEL CELL

Protonated Water Clusters
FUEL TOLERANCE FACTORS
FUEL CELL MEMBRANE STRUCTURE
MEMBRANE FABRICATION AND SYNTHESIS

TABLE 24 APPROACHES TO FUEL CELL IONOMER SYNTHESIS

TABLE 25 MEMBRANE FABRICATION TECHNIQUE

PHASE SEPARATION
CASTING SOLVENT
Ethylene Glycol as Solvent
IMPACT OF MEMBRANE THICKNESS
MEMBRANE FUNCTIONALIZATION
Membrane Pretreatment
MEMBRANE MATERIAL COMPOSITIONS
PERFLUORINATED POLYMER MEMBRANES
Perfluorocarbonsulfonic Acid Ionomers
Nafion PFSA Membranes

TABLE 26 FUNDAMENTAL PROPERTIES OF NAFION PFSA MEMBRANES

Gore Select

TABLE 27 CONDUCTANCE COMPARISONS

Aciplex
Flemion
Polytetrafluoroethylene Durability Enhancement
BERKELEY LAB’S MATERIALS SCIENCES DIVISION AND UC BERKELEY’S DEPARTMENT OF CHEMICAL ENGINEERING POLYMER MEMBRANE
UNIVERSITY OF ROCHESTER THIN FILTER
POLYFUEL HYDROCARBON MEMBRANE
MIT AND THE UNIVERSITY OF PENNSYLVANIA
NANOCOMPOSITE MEMBRANE BARRIERS
TORAY INDUSTRIES HYDROCARBON MEMBRANE
AKRON POLYMER SYSTEMS APPROACH
DAYCHEM LABORATORIES APPROACH
JSR MULTILAYERED STRUCTURE
BALLARD POWER SYSTEMS BAM MEMBRANES
MODIFIED POLYSTYRENE SULFONATED MEMBRANES
VICTREX POLYETHER ETHER KETONE (PEEK)
HOKU SCIENTIFICS SEK MEMBRANE
UNIVERSITY OF CALGARY
TOSOH’S POLY(ARYLENE ETHER SULFONE)
SULFONATED POLY(ARYLENE ETHER) SULFONES
Sulfonated Poly(Arylene Ether) Sulfones (Continued)

TABLE 28 VIRGINIA TECH BPS MEMBRANE PROPERTIES COMPARED WITH NAFION

Functionalization and Direct Synthesis of Sulfonated Membranes
Reduced Electro-Osmotic Drag
Conductivity
ARGONNE NATIONAL LAB DENDRITIC SULFONATED POLYARYL ETHER
DAIS ANALYTIC SULFONATION OF STYRENE CONTAINING BLOCK COPOLYMERS
Ethylene Styrene Interpolymers
Polystyrene Sulfonic Acid/Polyvinyl Alcohol Blend
Gas Technology Institute Membrane
Sulfonated Perfluorocyclobutane
HETEROCYCLIC AND POLYBENIMIDIZOLE MEMBRANES
PEMEAS and Celtec
University of Texas Variations of PBI Membrane
Plug Power and DOE and PBI
Renssalaer’s Chain-Transfer (RAFT) Polymerization
Samsung Polyimide Derivative
Other Modifications of PBI
SULFONATED POLYIMIDES
Tailored Imides
POLY(BISBENZOXAZOLE) [PBO]
UNIVERSITY OF MASSACHUSETTS CO-POLYMERS
COMPOSITE MEMBRANES
Aciplex and Titanias
Inorganic-Organic Composite
Modified Siloxane (ORMOSIL)
Organic/Heteropolyacids and Nafion
Aniline and Perfluorosulfonic Acid Polymer
Random Fibers and Perfluorinated Membranes
Ionic Gel Fill
Zirconium Phosphonate Fill
Oxidation Resistant Carbon Supports
NOVEL AND EXPERIMENTAL PEM MATERIALS
BASF Polyurethane Elastomer
Georgia Tech Triazole Booster
Dow XUS 13204.1
Altergy Freedom Power
3M Acid Functional Fluoropolymers Membrane
Glass Membranes
Microcell Microfiber
Oak Ridge National Lab Metallized Bio-Cellulosics
University of Florida Intermediate-Temperature Proton-Conducting Membranes
MEMBRANE COMPANIES

TABLE 29 COMPANIES PRODUCING ION SELECTIVE MEMBRANES FOR PEM FUEL CELLS

TABLE 30 ESTIMATED PEMFC FLUOROPOLYMER MEMBRANE COMPANY MARKET SHARES, 2010 (%)

ASAHI GLASS CO., LTD.
ASAHI KASEI CHEMICALS CORP.
BALLARD POWER SYSTEMS
U.S. Headquarters
DAIS ANALYTIC CORP.
DUPONT FUEL CELLS
GINER ELECTROCHEMICAL SYSTEMS, LLC
GOLDEN ENERGY FUEL CELL CO., LTD.
GORE FUEL CELL TECHNOLOGIES
HOKU SCIENTIFIC, INC.
HYDROGENICS CORP.
IDATECH, LLC
JSR CORP.
MAXDEM, INC. (COMBRIDGE DISPLAY)
PLUG POWER
POLYFUEL
RELION
TORAY INDUSTRIES, INC.
UNITED TECHNOLOGY CORP. FUEL CELLS
OTHERS
GLOBAL PEMFC MEMBRANE MARKET STRUCTURE AND FORECAST
PEM MEMBRANE MATERIALS MARKET SHARE

TABLE 31 PROTON EXCHANGE MEMBRANE MATERIAL BY TYPE, 2010 VERSUS 2015 (%)

PEM MEMBRANE MATERIALS VALUE

TABLE 32 GLOBAL PROTON EXCHANGE MEMBRANES FOR PEMFCS MARKET BY APPLICATION, THROUGH 2015 ($ MILLIONS)

TABLE 33 GLOBAL PROTON EXCHANGE MEMBRANES FOR PEMFCS MARKET BY REGION, THROUGH 2015 ($ MILLIONS)

CHAPTER FIVE: MEA, GASEOUS DIFFUSION LAYERS, AND BIPOLAR PLATES
GASEOUS DIFFUSION LAYERS
GASEOUS DIFFUSION LAYER BACKGROUND
ATTRIBUTES OF GAS DIFFUSION LAYERS

TABLE 34 ATTRIBUTES NEEDED FOR GAS DIFFUSION LAYER MATERIALS

GAS DIFFUSION LAYER MANUFACTURING

TABLE 35 PROS AND CONS OF GDL MANUFACTURING TECHNIQUES

Developments at GrafTech International
Developments at Umicore AG
Developments at Ballard Material Products
Developments at Johnson Matthey
Developments at Lydall, Inc.
Developments at Mitsubishi Rayon
Developments at SGL Carbon Group

TABLE 36 TYPICAL PROPERTIES OF SIGRACET GAS DIFFUSION LAYER

Developments at Toray/Mitsui
Developments at Rensselaer Polytechnic Institute
Developments at Zoltek
Developments at Cabot and IRD Fuel cell
Other Developments
BIPOLAR PLATES
BIPOLAR PLATE BACKGROUND
BIPOLAR PLATE DESIGNS

TABLE 37 DESIGN CONSIDERATIONS FOR BIPOLAR PLATES

TABLE 38 MATERIAL TYPES FOR BIPOLAR PLATES

Corrosion Protection of Metallic Plates
Ballard Powers’ Bipolar Metal Plate
Surface Modification
Tech-Etch Metal Plates
ECPower/Sorapec Approach
Entegris Approach
Generics Porous Plates Approach
T8 Series
IdaTech Layered Bipolar Plate Assembly
Use of Thermoplastic
Intelligent Energy’s Proprietary Design
Nisshinbo Approach
PEM Plates Approach
Illinois Urbana-Champaign Fuel Cell Separator Plate Having Controlled Fiber Orientation
Plug Power Assembly
Porvair Approach
SGL Technologies Approach

TABLE 39 SGL BIPOLAR PLATE TYPICAL PROPERTIES

Bac2 ElectroPhen
Improved Gasket Approach
ACAL Platinum-free Cathode
Federal-Mogul’s Liquid Elastomer Molding
AEG Carbon Fiber-Elastomer Composite Bipolar Plates
myFC Polymer Electrolyte Membrane Fuel Cell FuelCellSticker
DMFC ANODE APPROACHES
Toshiba Approach
DuPont GEN IV Approach
Medis Conductive Polymer Approach
Generics CMR Approach
Energy Ventures Research Approach
PolyFuel Approach
Smart Fuel Cell Approach
MEA, GDL, AND BIPOLAR PLATE COMPANIES
10X MICROSTRUCTURES
3M
ASBURY GRAPHITE
BALLARD POWER SYSTEMS
DIXON TICONDEROGA CO.
DAIMLER
Mitsubishi Fuso
Orion Bus Industries (Daimler Buses North America)
Smart GmbH
DUPONT FUEL CELL
ELECTROCHEM, INC.
ENTEGRIS, INC.
GENERAL ELECTRIC
GENERAL MOTORS, CORP.
GORE FUEL CELL TECHNOLOGIES
GRAFTECH INTERNATIONAL, LTD.
HOKU SCIENTIFIC, INC.
HYDROGENICS CORP.
HONDA
Honda U.S. Headquarters
HORIZON FUEL CELLS AND RIVERSIMPLE
Horizon Fuel Cells and Riversimple (Continued)
ICM PLASTICS
JOHNSON MATTHEY FUEL CELLS RESEARCH
Johnson Matthey Fuel Cells (USA)
LYNNTECH
MANHATTAN SCIENTIFICS, INC.
Research Headquarters
MATERIALS AND ELECTROCHEMICAL RESEARCH CORP.
MITSUBISHI RAYON CO., LTD.
MORGAN CRUCIBLE CO.
MORPHIC TECHNOLOGIES
NEDSTACK FUEL CELL TECHNOLOGY
NISSHINBO INDUSTRIES, INC.
NUVERA FUEL CELLS
Nuvera Fuel Cells Europe
PALCAN FUEL CELLS, LTD.
PLUG POWER
PORVAIR FUEL CELL TECHNOLOGY
PROTONEX TECHNOLOGY CORP.
RELION/AVISTA LABS
SGL CARBON
SGL Technik
SHARP CORP.
SMART FUEL CELL AG (SFC)
SPECTRACORP
SUMITOMO METALS
SUPERIOR GRAPHITE CO.
TIAX
TICONA
TIMCAL GRAPHITE & CARBON
TORAY INDUSTRIES, INC.
UNIDYM (ARROWHEAD RESEARCH CORP.)
UTC POWER
ZOLTEK MATERIALS GROUP
GLOBAL BIPOLAR PLATES AND GDLS FOR PEMFCS STRUCTURE FORECAST

TABLE 40 GLOBAL PEMFC BIPOLAR PLATE AND CARBON MARKET BY APPLICATION, THROUGH 2015 ($ MILLIONS)

FIGURE 9 GLOBAL PEMFC BIPOLAR PLATE AND CARBON MARKET BY APPLICATION, 2006-2015 ($ MILLIONS)
FIGURE 10 GLOBAL MARKET SHARES OF PEMFC BIPOLAR PLATE AND CARBON BY TYPE, 2010 (%)

TABLE 41 GLOBAL PEMFC BIPOLAR PLATE AND CARBON MARKET BY REGION, THROUGH 2015 ($ MILLIONS)

CHAPTER SIX: CATALYSTS AND INKS
BACKGROUND
CATALYST DURABILITY
CATALYST PARTICLE SIZE
CATALYST COATED MEMBRANES
DuPont Approach
PolyFuel Approach
Aerogel Composite Approach

FIGURE 11 PREPARATION OF CARBON AEROGEL SUPPORTED PLATINUM

GS Carbon Approach
Ramot University Approach
LOW CATALYST LOADING APPROACHES
Ballard Approach
COMBINATORIAL CATALYST TECHNIQUES
INNOVATIVE MATERIALS AND NANOMATERIALS
Platinum Alloys
Anode Durability
Nanoparticles
Kyoto University
Hong Kong University of Science and Technology
Los Alamos National Laboratory and Brookhaven National Laboratory
Brown University
Brookhaven National Laboratory
University of Central Florida
Cornell University
Georgia Tech and Xiamen University
MIT Researchers Take First Atomic-Scale Compositional Images of Fuel Cell Nanoparticles
Nanofibers
Nanolevel Platinum/Carbon Electrocatalyst for Cathode
University of Wisconsin-Madison Nanoparticle Catalyst
University of Houston Lattice-Strained Core-Shell Nanoparticle Catalyst
Acta Base Metal Cathode Catalyst
Lawrence Berkeley and Argonne National Laboratories Alloy
Nanowires
University of Rochester Sizing Nanowires
Jet Propulsion Laboratory Nanophase Nickel-Zirconium Alloy Approach
University of Texas at Austin Palladium-Based Alloy Catalysts
TIAX, LLC Nanostructured Thin Film Catalysts

FIGURE 12 PROJECTED COST AT HIGH VOLUME MANUFACTURING (%)

TABLE 42 PERFORMANCE AND COST SUMMARY

SDK High-Efficiency Catalysts Platinum Substitute for PEFCs
Washington University in St. Louis Bimetallic Fuel Cell Catalyst
Simple Tech Heterogeneous Catalysis Technology
Brown University Platinum Nanocubes
Johnson Matthey Fuel Cells, Ltd. and the NECLASS Project
University of Rochester “Black Metal” Approach
Transition Metal Nanosized Catalysts
Texas Tech University Platinum Nanodots
CATALYST INK COMPOSITIONS
APPLIED RESEARCH & DEVELOPMENT ISRAEL FORMULATION
OTHER CATALYST INK FORMULATIONS
SW Research and Gore Approach
UTC Fuel Cells Approach
Jet Propulsion Laboratory Approach
Angstron Materials Graphene
Northwestern University and the McCormick School of Engineering and Applied Science Graphene Films
Samsung Electronics Approach
CARBON COMPOSITE ELECTROCATALYST POWDERS
CABOT APPROACH
ASYMTEK JET DISPENSING APPROACH
CATALYST AND INK COMPANIES
ACTA SPA
ALFA AESAR-JOHNSON MATTHEY CO.
Johnson Matthey Co.
ANGLO PLATINUM
AQUARIUS PLATINUM PTY, LTD.
BASF CORP.
IMPALA PLATINUM HOLDING, LTD. (IMPLATS)
Impala Platinum Holding (U.K.)
LONMIN PLATINUM, PLC
Lonmin South Africa
NORILSK NICKEL
Stillwater Mining
OM GROUP, INC.
QUANTUMSPHERE, INC.
STILLWATER
TANAKA PRECIOUS METALS
GLOBAL PEMFCS CATALYST AND INK STRUCTURE AND FORECAST
PLATINUM MARKETS AND CONSUMPTION

TABLE 43 WORLD MINE PRODUCTION AND RESERVES: MINE PRODUCTION PGMS (KG)

TABLE 44 WORLD PLATINUM DEMAND (THOUSAND OZS)

PALLADIUM MARKETS AND CONSUMPTION
CATALYST AND INK VALUE

TABLE 45 GLOBAL PEMFC CATALYST AND INK MARKET, THROUGH 2015 ($ MILLIONS)

FIGURE 13 GLOBAL PEMFC CATALYST AND INK MARKET, THROUGH 2015 ($ MILLIONS)

TABLE 46 GLOBAL PEMFC CATALYST AND INK MARKET BY REGION, THROUGH 2015 ($ MILLIONS)

CHAPTER SEVEN: INDUSTRY STRUCTURE AND COMPETITIVE ASPECTS
INDUSTRY ENVIRONMENT AND TRADE PRACTICES
ENVIRONMENTAL ISSUES
PEMFC REGULATORY ISSUES AND GOVERNMENT INVOLVEMENT
U.S. DOE Direct PEM Fuel Cell Funding
Topic 1 Alternative Electrode Deposition Processes ..... 297
Topic 2 Novel MEA Manufacturing
Topic 3 Rapid MEA Conditioning
Topic 4 Process Modeling for Fuel Cell Stacks
Topic 5 Process and Device for Cost Effective Testing of Cell Stacks
Topic 6 Manufacturing Technologies for Reducing the Cost of High-Pressure Composite Conformable Tanks
U.S. Federal Fuel Cell Vehicle Funding
Overall U.S. Federal Fuel Cell Funding

TABLE 47 2010 BUDGET HYDROGEN AND FUEL CELL TECHNOLOGIES FUNDING PROFILE BY SUBPROGRAM ($ THOUSANDS)

U.S. Fuel Cell Council Analysis of Funding Priorities
Office of Science
National Hydrogen Association
National Science Foundation
Department of Defense
Army Research Laboratory
USAF Research Laboratory
Naval Research Laboratory
National Aeronautics and Space Administration (NASA)
Jet Propulsion Laboratory
Global Incentives and Research Efforts
ACADEMIC INSTITUTIONS’ INVOLVEMENT IN FUEL CELL DEVELOPMENT

TABLE 48 MAJOR INSTITUTIONAL RESEARCH INTO PEM FUEL CELLS

MEA DISTRIBUTION CHANNELS
INDUSTRY PURCHASING INFLUENCES AND PRICES

TABLE 49 HISTORIC PLATINUM PRICES (DOLLARS PER TR OZ)

TABLE 50 HISTORIC PALLADIUM PRICES (DOLLARS PER TR OZ)

LIFE-CYCLE COSTS

LIST OF TABLES

SUMMARY TABLE GLOBAL PEMFC MEA MARKET, THROUGH 2015 ($ MILLIONS)
SUMMARY FIGURE GLOBAL PEMFC MEA MARKET, THROUGH 2015 ($ MILLIONS)
TABLE 1 PEMFC AND DMFC MAKERS
TABLE 2 TYPES OF PORTABLE PRODUCTS
TABLE 3 IMPORTANT PORTABLE PRODUCT CONCEPTS
TABLE 4 PORTABLE FUEL CELL MARKET DRIVERS
TABLE 5 PORTABLE FUEL CELL MARKET FACTORS
TABLE 6 STATIONARY FUEL CELL MARKET DRIVERS
TABLE 7 STATIONARY FUEL CELL MARKET FACTORS
TABLE 8 TRANSPORTATION FUEL CELL MARKET DRIVERS
TABLE 9 TRANSPORTATION FUEL CELL MARKET FACTORS
TABLE 10 SELECTED PORTABLE BATTERY-POWERED MILITARY PRODUCT ROLES
TABLE 11 “OTHER” FUEL CELL MARKET DRIVERS
TABLE 12 “OTHER” FUEL CELL MARKET FACTORS
TABLE 13 GLOBAL PEMFC MARKET BY APPLICATION, THROUGH 2015 ($ MILLIONS)
TABLE 14 GLOBAL PEMFC MARKET BY REGION, THROUGH 2015 ($ MILLIONS)
TABLE 15 GLOBAL PEMFC MARKET BY APPLICATION, THROUGH 2015 ($ MILLIONS)
TABLE 16 FUEL CELL MEA PERFORMANCE GOALS
TABLE 17 PANASONIC DMFC SPECIFICATIONS
TABLE 18 ESTIMATED MEA COMPANY MARKET SHARES, 2010 (%)
TABLE 19 GLOBAL MEA COMPONENT MARKET, THROUGH 2015 ($ MILLIONS)
TABLE 20 GLOBAL MEA COMPONENT MARKET BY REGION, THROUGH 2015 ($ MILLIONS)
TABLE 21 MEMBRANE PARAMETER VARIABLES
TABLE 22 PEM ELECTROLYTE ISSUES
TABLE 23 ADVANTAGES OF A HIGHER TEMPERATURE MEMBRANE FOR A PEM FUEL CELL
TABLE 24 APPROACHES TO FUEL CELL IONOMER SYNTHESIS
TABLE 25 MEMBRANE FABRICATION TECHNIQUE
TABLE 26 FUNDAMENTAL PROPERTIES OF NAFION PFSA MEMBRANES
TABLE 27 CONDUCTANCE COMPARISONS
TABLE 28 VIRGINIA TECH BPS MEMBRANE PROPERTIES COMPARED WITH NAFION 117
TABLE 29 COMPANIES PRODUCING ION SELECTIVE MEMBRANES FOR PEM FUEL CELLS
TABLE 30 ESTIMATED PEMFC FLUOROPOLYMER MEMBRANE COMPANY MARKET SHARES, 2010 (%)
TABLE 31 PROTON EXCHANGE MEMBRANE MATERIAL BY TYPE, 2010 VERSUS 2015 (%)
TABLE 32 GLOBAL PROTON EXCHANGE MEMBRANES FOR PEMFCS MARKET BY APPLICATION, THROUGH 2015 ($ MILLIONS)
TABLE 33 GLOBAL PROTON EXCHANGE MEMBRANES FOR PEMFCS MARKET BY REGION, THROUGH 2015 ($ MILLIONS)
TABLE 34 ATTRIBUTES NEEDED FOR GAS DIFFUSION LAYER MATERIALS
TABLE 35 PROS AND CONS OF GDL MANUFACTURING TECHNIQUES ..... 163
TABLE 36 TYPICAL PROPERTIES OF SIGRACET GAS DIFFUSION LAYER
TABLE 37 DESIGN CONSIDERATIONS FOR BIPOLAR PLATES
TABLE 38 MATERIAL TYPES FOR BIPOLAR PLATES
TABLE 39 SGL BIPOLAR PLATE TYPICAL PROPERTIES
TABLE 40 GLOBAL PEMFC BIPOLAR PLATE AND CARBON MARKET BY APPLICATION, THROUGH 2015 ($ MILLIONS)
TABLE 41 GLOBAL PEMFC BIPOLAR PLATE AND CARBON MARKET BY REGION, THROUGH 2015 ($ MILLIONS)
TABLE 42 PERFORMANCE AND COST SUMMARY
TABLE 43 WORLD MINE PRODUCTION AND RESERVES: MINE PRODUCTION PGMS (KG)
TABLE 44 WORLD PLATINUM DEMAND (THOUSAND OZS)
TABLE 45 GLOBAL PEMFC CATALYST AND INK MARKET, THROUGH 2015 ($ MILLIONS)
TABLE 46 GLOBAL PEMFC CATALYST AND INK MARKET BY REGION, THROUGH 2015 ($ MILLIONS)
TABLE 47 2010 BUDGET HYDROGEN AND FUEL CELL TECHNOLOGIES FUNDING PROFILE BY SUBPROGRAM ($ THOUSANDS)
TABLE 48 MAJOR INSTITUTIONAL RESEARCH INTO PEM FUEL CELLS
TABLE 49 HISTORIC PLATINUM PRICES (DOLLARS PER TR OZ)
TABLE 50 HISTORIC PALLADIUM PRICES (DOLLARS PER TR OZ)

LIST OF FIGURES

SUMMARY FIGURE GLOBAL PEMFC MEA MARKET, THROUGH 2015 ($ MILLIONS
FIGURE 1 GENERIC PEMFC DIAGRAM SHOWING COMPONENTS
FIGURE 2 SCHEMATIC DMFC CHEMISTRY
FIGURE 3 GLOBAL PEMFC MARKET BY APPLICATION, 2010 ($ MILLIONS)
FIGURE 4 GLOBAL PEMFC MARKET BY REGION, 2010 ($ MILLIONS)
FIGURE 5 SCHEMATIC SIMPLE MEA
FIGURE 6 SCHEMATIC FOR CONCEPTUAL MEA CREATION
FIGURE 7 GLOBAL MEA MARKET SHARES, 2010 (%)
FIGURE 8 WATER TRANSPORT IN A PEM FUEL CELL
FIGURE 9 GLOBAL PEMFC BIPOLAR PLATE AND CARBON MARKET BY APPLICATION, 2006-2015 ($ MILLIONS)
FIGURE 10 GLOBAL MARKET SHARES OF PEMFC BIPOLAR PLATE AND CARBON BY TYPE, 2010 (%)
FIGURE 11 PREPARATION OF CARBON AEROGEL SUPPORTED PLATINUM
FIGURE 12 PROJECTED COST AT HIGH VOLUME MANUFACTURING (%)
FIGURE 13 GLOBAL PEMFC CATALYST AND INK MARKET, THROUGH 2015 ($ MILLIONS)