Fuel Cells: An Effective Rooftop Backup Power Solution Ballard Power Systems Inc. 9000 Glenlyon Parkway Burnaby, BC V5J 5J8 Canada Telephone: 604.454.0900 Fax: 604.412.4700 www.ballard.com (NASDAQ: BLDP) (TSX: BLD)
Telecom Back Up Power Rooftop Application With the rapid expansion of wireless communication systems worldwide, and the increasing socioeconomic benefits of mobile phone technology, the need for dependable and economical backup power is critical. Electric grid loss throughout the year, whether from severe weather, natural disasters, or limited grid capacity, is an ongoing challenge for network operators. In densely populated areas such as urban centers around the world, many of the telecom base station sites are located on rooftops. These sites present unique challenges when it comes to providing adequate duration backup power which adheres to the relevant codes and regulations for safe operation, fuel storage, fire safety and logistics as well as environmental, noise and vibration considerations. Challenges with Incumbent Solutions in Rooftop Locations Ballard ElectraGen - ME system installed at a rooftop location in Manila, Philippines. Batteries Batteries are a typical solution for telecom sites requiring short duration backup power. However, there are a number of challenges faced when siting them at a rooftop location including: Heavy weight: a large battery bank could require roof structural reinforcement; Limited runtime: typically 4-6 hours; Temperature sensitivity: need to be protected in a climate controlled environment; Fire safety issues: batteries can produce flammable gasses during recharging, and improper charging can cause battery explosion and/or fire; Disposal issues: many batteries contain hazardous materials. Diesel Generators A common solution to provide longer duration backup power is to install a diesel generator at telecom sites, but operators will face significant challenges at rooftop sites, including: High noise levels: operating noise levels are unacceptable in a dense urban environments; Vibration: incompatible with most building regulations and occupants; Harmful emissions: emissions include high levels of particulate matter (PM), sulfur oxides (SOx),nitrous oxides (NOx), carbon monoxide (CO), carbon dioxide (CO 2 ); Significant size (including fuel storage tank): most of rooftop sites have limited space and it may require site operator to rent additional space; Heavy weight: could require roof structural reinforcement; Stringent regulations: installation of a diesel generator on a rooftop requires permitting which could lead to project delays and be very difficult to obtain in most cases; Community issues: operators often encounter difficulty gaining acceptance by local community / building owners; Fuel safety: diesel fuel is highly flammable and environmentally hazardous. Fuel Cells: An Effective Rooftop Backup Power Solution Page 2
Fuel Cell Benefits A fuel cell is a DC power generator which combines hydrogen fuel and oxygen from air to produce electrical energy efficiently, quietly and reliably. Fuel cells produce electricity without combustion, which means that, unlike internal combustion engines, they generate little (if any) noise, vibration, air pollution, or greenhouse gases and operate at high efficiencies over a wide range of loads. Unlike batteries, fuel cells will continue to operate for as long as fuel is available - there is no need for replacement or periodic lengthy recharging. Additionally, since fuel cells store their fuel in external storage tanks, the maximum operating range of a fuel cell-powered device is limited only by the amount of fuel that can be carried. Fuel cell backup power systems use either hydrogen gas or liquid fuel like methanol/water mix as fuel. See table below for a comparison of current backup power technologies. Backup power solution for Telecom sites Telecom Backup Power - Technology Comparison Direct Hydrogen Fuel Cell System Liquid Methanol Fuel Cell System Diesel Generator VRLA Batteries Power Generation Technology Electrochemical conversion Electrochemical conversion Electro-mechanical (combustion engine) Electrochemical conversion Power Output DC DC AC (ATS and rectifier) DC Autonomy Several hours (limited by gas Several days but not limited if refueling re-fueling Several days but not limited if storage) Several hours Fuel Type Compressed hydrogen gas (99.95%) Methanol/water (62%/38%) Diesel Chemicals (PbO2, Li ) Fuel Consumption ~0.8 Nm 3 /kwh 1 L/kWh ~0.5 L/kWh AC power for floating/recharging Power Density: kwh in a 50L storage volume 10 kwh 50 kwh 100 kwh <8kWh Efficiency 40% 25-30% 10-20% (@2-5kW) NA Fuel Physical State Gas Liquid Liquid Liquid/solid Fuel Transport Container Stainless steel tank @150-200 bars Plastic container or drum Plastic container or drum Plastic container Emission Level CO2 0 g/kwh 783 g/kwh 1,500 g/kwh 0 g/kwh CO 0 g/kwh 0.17 g/kwh 8.0 g/kwh 0 g/kwh NOx 0 g/kwh 0.0 g/kwh (NO2 only) 7.5 g/kwh 0 g/kwh SOx 0 g/kwh 0 g/kwh 12.0 g/kwh 0 g/kwh Particulate matter 0 g/kwh 0 g/kwh 0.8 g/kwh 0 g/kwh Maintenance Very low (clean air filter once a Very low (clean air filter once a year) year) High (filter, oil change...) Very low Fuel Toxicity None Low Medium (diesel spills) High Theft Potential Very low Very low High High Weight (for several days autonomy) Fuel cell system = 75kg + 60kg per gas cylinder (4 hrs of autonomy per cylinder) Fuel cell system = 280kg (fuel = 200kg) > 1,000kg with fuel Several tons (for large battery banks) Suitability for Rooftop Installation Difficult Yes No Weight is a concern for large batteries Vibration No No Yes No Noise Level < 47 db @ 7m < 47 db @ 7m 68 db @ 7m 0 db Unit Footprint (W x D x H) 0.5 x 0.57 x 0.62 m (excl. hydrogen storage) 1.4 x 1.1 x 1.7 m (incl. fuel tank) 2 x 1 x 1.4 m (excl. fuel tank) Varies depending on backup time required Fuel Cells: An Effective Rooftop Backup Power Solution Page 3
ElectraGen - ME System Ballard s methanol-fueled ElectraGen - ME system is the ideal solution to provide telecom operators with reliable backup power at rooftop sites. With few moving parts 1 and no degradation during standby periods, fuel cell technology provides an attractive solution compared to existing backup power systems. Available in 2.5 kw and 5 kw configurations, ElectraGen - ME fuel cell systems are designed for high reliability, long autonomy and minimal maintenance. This fuel cell system addresses many of the challenges commonly found with rooftop locations and has already been successfully deployed on rooftops in Southeast Asia, Japan (including Tokyo), South Africa and the Americas. Autonomy: The ElectraGen - ME fuel cell system was developed for telecom backup power applications that require run times of days instead of hours between refueling. The integrated fuel tank will provide the following autonomy at the site: Size/Weight: the ElectraGen - ME is a relatively lightweight option in comparison to alternatives. The unit weighs 280kg when empty and measures 1.4 x 1.1 x 1.7 m including the built in fuel tank. Emissions: 1 The fuel cell itself contains no moving parts. Ancillary equipment/balance of plant parts may incorporate some moving parts. Fuel Cells: An Effective Rooftop Backup Power Solution Page 4
Noise: with an operating noise level of < 47 db at 7m, the ElectraGen - ME will meet most noise level requirements. Fuel Storage: With an integrated fuel tank of 220L (59gal); Ballard s ElectraGen - ME system meets US regulations. Secondary fuel containment is available if required by local regulations. Fuel will not freeze in low temperature, and will not deteriorate over the ten year system design life. Re-fueling: The ElectraGen - ME system is easily refueled using common equipment familiar to the industry. Pails, drums, and larger tanks are used to transport fuel to the sites. At the site, fuel may be poured into the onboard fuel tank, or manual and DC-powered transfer pumps may be utilized. HydroPlus Fuel Compared to an electrolyzer or a compressed hydrogen fuel cell system, the ElectraGen - ME system simplifies approvals and installation, including at rooftop sites, since on-site storage of hydrogen is eliminated. The system generates its own hydrogen on-demand through its innovative fuel reformer technology. This patented technology enables the ElectraGen - ME systems to operate on HydroPlus liquid fuel (methanol-water), which has five times more energy for the same volume than compressed hydrogen while occupying a significantly smaller footprint. HydroPlus fuel is a mixture of methanol and de-ionized water (62% methanol by weight), and is used to power Ballard s ElectraGen - ME fuel cell systems. HydroPlus fuel is rich in hydrogen, essential for fuel cell applications, and offers advantages over other common industrial fuels. HydroPlus liquid fuel powered systems are particularly beneficial when onsite storage or handling of bottled hydrogen is not feasible, when overall system footprint is a priority, or where long runtime is required. HydroPlus fuel is readily available worldwide and comes in a variety of containers to fit customer needs, including IBC tote, 55 gallon drums and 5 gallon (19 liter) containers. In comparison to the short lifetime of diesel or gasoline fuel, HydroPlus fuel is stable and has a lifetime of years if properly stored. As part of Ballard s complete backup power offering, we work with select partners to provide certified HydroPlus fuel for our ElectraGen - ME systems. We select and certify HydroPlus fuel suppliers worldwide to ensure availability of high quality fuel for our customers. Certification & Approvals: Ballard s ElectraGen - ME fuel cell system meets CE requirements, is TÜV CUE approved, and meets the requirements of CAN/CSA C22.2 No. 61010-1, UL 61010-1, EN 61010-1, IEC 62282-3-1, ANSI/CSA America FC-1, and JIS C 8822. The system has been approved for installation and operation by local jurisdictions, including the New York City Fire Department and Kanto region (Tokyo, Japan) fire authorities and is manufactured in a TÜV certified factory. Fuel Cells: An Effective Rooftop Backup Power Solution Page 5
Typical Rooftop Application Case Study Scenario Assumptions: Rooftop site in a city center DC load: 4kW (83A @ 48VDC) Standby power requirement for 24 hours Fuel required Space required (not including setbacks) Weight Direct Hydrogen Fuel Cell System 2400 ft 3 (69m 3 of H2) 8 x B50 cylinder 17 ft 2 (1.6 m 2 ) 1945 lbs (885kg) Methanol Fuel Cell System 28 gallons (106 liters) 17 ft 2 (1.6 m 2 ) 860 lbs (390kg) Battery Bank electric grid 12 ft 2 (1.2m 2 ) 6000 lbs (3 metric ton) Diesel Generator 15 gallons (55 liters) 16 ft 2 (1.5m 2 ) > 1000 lbs (460kg) excluding starting batteries, transfer switch, electrical interface, etc. Ballard Rooftop Deployment Experience More than 100 Ballard ElectraGen - ME systems have been successfully installed on rooftops in major cities across the world. It was often the only alternative to provide more than 8 hours of backup power to critical telecom sites. Ballard and its partners have secured approval from local authorities and building owners in 100% of these rooftop sites. Permits were secured and operation allowed, in spite of the very different and variable country-specific regulations and requirements. Ballard ElectraGen - ME system installed at a rooftop location in Jakarta, Indonesia. Ballard ElectraGen - ME system installed at a rooftop location in Tokyo, Japan. Fuel Cells: An Effective Rooftop Backup Power Solution Page 6
Key learnings from our rooftop installations: Permitting: it is important to check local regulations (often with the Fire Department) prior to installation. The Ballard team will assist in addressing local regulations. An inspection of a test site is sometimes required by local authorities. Acceptance by local resident & building owner: a short presentation of fuel cell technology and its advantage is often the best way to secure approval by building owner and residents. Ballard has marketing material available to assist you. Noise level: The ElectraGen - ME system has passed the most stringent noise level tests (city of Tokyo). System installation: A crane or manual hauling (if building height is only a couple of levels) is often required to install the unit on site. Crane rental should be included in site costing. Re-fueling: Most of sites are manually refilled using small easy to carry, UN-approved plastic fuel containers. Some building regulations prevent HydroPlus fuel to be transported via the elevator, requiring that the fuel must be carried via the staircase. Fuel which can be handcarried is an important advantage during long power outages when elevators are not functioning. Ballard ElectraGen - ME fuel cell backup power system installed at a rooftop telecom site. Fuel Cells: An Effective Rooftop Backup Power Solution Page 7