Ballard launches 9th generation high-performance fuel cell engine for heavy-duty vehicles at ACT Expo 2024

Ballard Power Systems has unveiled its ninth generation, high-performance fuel cell engine, the FCmove^®-XD, at the Advanced Clean Transportation (ACT) Expo at the Las Vegas Convention Center. Ballard is exhibiting at Booth 1821 from May 21-23, 2024.

The FCmove®-XD delivers the highest volumetric power density in the industry for heavy-duty applications, featuring an engine volumetric power density of 0.36kW/L and gravimetric power density of 0.48kW/kg. The scalable 120kW fuel cell engine integrates DC/DC regulated output, enabling up to three modules to operate as one system with a single interface, capable of delivering a combined 360kW of zero-emission power output.

With a design life of 30,000+ hours of operation - or over one million miles in truck operation at typical duty cycles - the FCmove®-XD engine is developed to deliver class-leading durability and low total cost of ownership.

Enabled by an innovative “open architecture” design and other new design advances, the powerful and compact FCmove^®-XD enables several important performance improvements, including:

• 120kW power output from our latest high-performance single stack
• 33% reduction in total parts count, significantly improving reliability and reducing costs
• Ultra-high peak system efficiency at >60%, enabling improved fuel consumption (lower total cost of ownership) and efficient heat rejection
• Wide operating temperature range, up to 95°C
• Integrated power controller incorporates DC/DC converter, air compressor inverter, and a power distribution unit, along with proprietary software controls, enables improved engine operation and efficiency
• Rapid up and down transient times, with an innovative hot stand-by mode enabling rapid power increase
• Improved manufacturability with >50% assembly time reduction
• Easier access to parts for faster and lower-cost field maintenance
• Compliance with applicable safety codes and standards

In addition to its in-house FCmove^®-XD innovations and design improvements over the past three years, Ballard has enjoyed strong collaboration with a maturing supply chain on new balance of plant component designs and related non-recurring engineering.

Collectively, these integrated and parallel work streams have resulted in a category leader, boasting higher performance on all key metrics with significantly lower capital cost and operating costs for customers and end users.  

Ballard plans to initially manufacture the FCmove^®-XD at its Oregon facility, enabling “Buy America” compliance starting in 2025, with future high-volume manufacturing expected at Ballard Rockwall Giga 1, Ballard’s recently announced 3GW Gigafactory planned to be built in Rockwall, Texas.