Nedstack, a Dutch developer and manufacturer of fuel cell power solutions for maritime and industrial applications, is collaborating with several partners as it seeks to advance the technology for manufacturing and integration of its proton electric membrane fuel cell stacks and power systems — while also developing higher-power systems and planning for increased mass production in the future. Recent projects include collaborations with thyssenkrupp Automation Engineering, ComAp, AE Driven Solutions GmbH, RWTH Aachen University, Groenevelt Marine Construction and ZBT Center for Fuel Cell Technology.
Perhaps the most significant project came to fruition in November when Nedstack and the ZBT Center for Fuel Cell Technology in Duisburg, Germany unveiled a third-generation PEM fuel cell platform that the partners have been working on for about five years. Serving as the cornerstone of Nedstack’s future product portfolio, it represents a significant leap forward in power output, mass-production capability, and cost-effectiveness for the hydrogen industry, say the partners, capable of driving widespread adoption of hydrogen-based solutions across various sectors. Key factors cited are:
- Enhanced Power Output: The third-generation PEM fuel cell concept boasts a remarkable increase in power output with breakthrough technology that paves the way for the development of more powerful, power dense and efficient hydrogen-based applications across stationary and maritime industries.
- Mass-Production Ready: Designed with mass production in mind, the platform is tailored to meet the rigorous demands of large-scale manufacturing with streamlined production processes and cost-efficient design.
- Meeting Industry Cost-Targets: Aligning with industry cost-targets, making hydrogen technology more economically viable. Affordability factor is essential in enabling widespread adoption of hydrogen-based solutions across multiple sectors.
In October, Nedstack and thyssenkrupp Automation Engineering formalized their collaboration at Electromobile Production Days in Aachen, an event organized by the PEM institute of RWTH Aachen University. They joined forces through a memorandum of understanding to supply a semi-automated PEM fuel cell production system. Development of the system has been in the making since 2020 through a series of simultaneous engineering projects. The collaboration aims to reinvent fuel cell manufacturing by integrating advanced automation technologies with Nedstack’s 25 years of fuel cell production experience, aiming to reduce production costs, improve quality control and enhance efficiency.
A key aspect of the collaboration is the installation of the state-of-the-art systems in Nedstack’s Giga Factory in Arnhem, where the company is headquartered, that is part of the flagship IPCEI-Hy2Tech project. The Giga Factory, with its extensive production capabilities, is planned to become a hub for the production of fuel cell technology.
“We are thrilled to take our longstanding relationship with thyssenkrupp Automation Engineering to the next level,” said Jos Lenssen, Chief Research Officer at Nedstack. “The cooperation with thyssenkrupp enables us to bring best practices in advanced manufacturing from the automotive and battery space into the hydrogen economy. During the last three years of in-depth cooperation we have not only designed the production system but have also been able to re-design our products to allow for advanced manufacturing and automated assembly.”
Thomas Kuschel, Deputy Head of Hydrogen Solutions at thyssenkrupp Automation Engineering, commented, “This partnership is an exciting development for both companies and it demonstrates the potential for synergistic collaboration between leaders in their respective fields. We are enthusiastic about the opportunities ahead and on the enabling impact of advanced manufacturing to further accelerate the roll-out of the hydrogen economy.”
Only a few weeks earlier, Nedstack announced it had formed a strategic partnership with ComAp of Czech Republic to develop advanced control solutions for fuel cell power generation. By integrating fuel cell technology seamlessly into independent power generation systems, they aim to redefine together the power generation landscape by developing advanced control solutions that seamlessly integrate and harmonize fuel cell system control strategies, ensuring that fuel cell power generation meets the rigorous demands of the power generation industry while meeting relevant grid codes requirements and adhering to the industry’s best practices.
“We believe that Nedstack’s expertise in fuel cell solutions and ComAp’s leadership in power generation control systems will create a strong partnership that will enable further optimization of power generation resources, and support much needed transition towards environmental sustainability,” says Lukas Novak, Bi-fuel and Hydrogen Segment Manager at ComAp. Based in Prague with 23 offices and 13 subsidiaries globally, ComAp designs control systems for power generation and energy management.
German Nieto, Sr. System Architect at Nedstack, commented: “We are excited to work alongside ComAp in this strategic partnership. Together, we aim to provide the power generation industry with a powerful synergy of fuel cell technology and advanced control solutions, propelling us toward a greener and more sustainable future.”
Successful integration requires a holistic perspective, the companies note. By synchronizing control strategies, they aim to ensure that fuel cell systems operate in harmony with power generation processes and renewable assets on the grid or in micro-grids, also facilitating grid stability by providing fast response capabilities to match fluctuating power demands while complying to the relevant grid codes.
Preparing for Gen3 Platform
In another recent move, Nedstack has entered into a partnership with testing and engineering firm AVL, based in Remscheid, Germany. AVL will provide co-development, sampling and verification services to support the industrialization of Nedstack’s third generation stack platform. The Gen3 platform has been under development since 2017 and is on track for start of production in the first quarter of 2025. By joining forces, the companies aim to bring the new cell to mass production, leveraging AVL’s advanced facilities and capabilities in stack development and integration.
“We are thrilled to cooperate further with AVL under this formal framework. It will help us package half a decade of advanced cell development in a stack platform which facilitates integration in various systems using all the best practice in which AVL is so proficient,” said Mark Rankenberg, CTO of Nedstack. “By combining our expertise, resources, and ongoing collaboration, we are taking a giant step towards the mass production of third generation PEM fuel cell technology, which holds immense potential for a wide range of applications.”
The aim is to enhance its manufacturability, scalability, and overall performance, ultimately enabling the seamless integration of PEM fuel cell technology into various industrial applications such as zero-emission ships, stationary power, and off-grid power systems.
“Our partnership with Nedstack is the next step to industrialize fuel cell technology for a mass market, make it affordable and hence accelerate technology deployment,” said Juergen Rechberger, VP of Hydrogen & Fuel Cell of AVL. “By combining Nedstack’s cutting-edge cell technology with AVL’s extensive stack engineering and test capabilities, we are poised to unlock the full potential of third generation PEM fuel cell technology, revolutionizing the future of clean and sustainable power solutions.”
In another move, Nedstack, AE Driven Solutions GmbH, and the Chair of Production Engineering of E-Mobility Components of RWTH Aachen University announced in May a strategic partnership to accelerate the industrialization of PEM fuel cell technology in Europe, and to contribute to the European Union’s ambitious target of net-zero greenhouse gas emissions by 2050.
The partnership brings together the complementary strengths of the three participants, with Nedstack upscaling its fuel cell production organization, and AE Driven Solutions acting as an industrialization partner on behalf of RWTH Aachen University. The goal is to enable cutting-edge research in the field of fuel cell production system development, advanced manufacturing, and cost planning. The collaboration aims to nurture European domestic fuel cell manufacturing – a strategic net-zero industry under the European Net-Zero Industries Act – and to support the growth of green jobs in Europe. Through this partnership, Nedstack will source services and support from AE Driven Solutions which serves as a collaborative academic institution for the university.
“We are excited to partner with AE Driven Solutions and PEM of RWTH Aachen University to employ the principles of advanced manufacturing theory on our Fuel Cell Giga Factory project which constitutes one of Europe’s largest fuel cell production environments,” said Bas Strijker, COO of Nedstack. ”This partnership will enable us and our supply chain to leverage the collective strengths of our organizations to deliver on Europe’s hydrogen economy targets and to contribute to a more sustainable future.”
”This collaboration is a significant step forward in driving the development of advanced manufacturing of PEM fuel cells in Europe,” said Strijker. ”By fostering domestic production, we can ensure a sustainable supply chain for these critical components and contribute to the growth of net-zero industries in Europe. This will create green jobs and climate protection measures while contributing to energy security in Europe.”
”The partnership with Nedstack and PEM of RWTH Aachen University is an exciting opportunity for AE Driven Solutions to contribute to Europe’s net-zero greenhouse gas emissions target by employing our widely recognized expertise on advanced manufacturing of fuel cell technology to one of Europe’s promising case studies,” said Tobias Reil, CEO of AE Driven Solutions GmbH. ”We are looking forward to working together and contributing to gigawatt scale manufacturing of fuel cells while harvesting significant cost reductions in the process.”
”We are pleased to collaborate with Nedstack and AE Driven Solutions to drive the development of advanced manufacturing of PEM fuel cells,” said Mario Kehrer, Chief Engineer at PEM of RWTH Aachen University. ”This partnership will enable us to apply our leading position in fuel cell production engineering to a state-of-the-art case study and to participate in building the fuel cell factory of the future.”
Prospects grow for maritime implementations
Meanwhile, Nedstack continues to drive integration of its fuel cells onboard vessels with new placements and platforms. One such placement is powering Dutch shipping company Future Proof Shipping’s renamed H2 Barge 1, launched in May with a retrofit fuel cell system. Since then the first hydrogen-powered zero emissions inland shipping container vessel, formerly named FPS Maas, has been operating regularly between the Port of Rotterdam and a terminal in Meerhout, Belgium. Seen as a major boost for maritime sustainability, H2 Barge 1 is expected to reduce greenhouse gas emissions by about 2,000 tons of CO2 equivalent per year.
The hydrogen and fuel cell system is rated at 825 kW capacity for propulsion and auxiliary power. Supported by a 5 kWh lithium-ion battery pack, the vessel’s cutting-edge technology includes a 750V DC bus bar and advanced e-motor for propulsion. Future Proof, based in Rotterdam, is already engaged in converting a second vessel to hydrogen power, this one to use a Ballard fuel cell system, and aims to have ten of them in operation in the next five years.
In one of its most recent maritime applications, in January Nedstack signed a contract for the delivery of a portable fuel cell system, supplying power to a sustainable workboat for the Province of Overijssel. The collaborative project features Nedstack’s MPU 20-400-AC, a versatile mobile PEM fuel cell system applicable for both maritime and mobile uses.
The system will serve as an emission-free range extender on board the workboat, recharging the onboard battery when shore power is unavailable during longer working days. Additionally, it can be easily detached from the ship for various on-shore mobile duties. It can operate as a standalone unit, capable of autonomous start-ups, forming a 400 Volt 50 Hz microgrid that can replace diesel generators and other traditional off-grid technologies. For more info, see www.nedstack.com.
