Fuel Cell Equipment Design

Understanding Fuel Cell Technology and Its Growing Importance

Fuel cell technology represents one of the most promising pathways toward a sustainable energy future, offering clean, efficient power generation across numerous applications. As Atlantic Canada positions itself as a leader in the emerging hydrogen economy, the demand for expertly designed fuel cell equipment has never been greater. From stationary power systems to transportation applications, fuel cells are transforming how industries approach energy challenges while significantly reducing carbon emissions.

Fuel cells operate through an electrochemical process that converts hydrogen and oxygen into electricity, with water and heat as the only byproducts. Unlike conventional combustion-based power generation, this process achieves efficiencies ranging from 40% to 60%, with combined heat and power configurations reaching up to 85% overall efficiency. For Maritime industries seeking to meet increasingly stringent environmental regulations while maintaining operational competitiveness, fuel cell equipment design offers a compelling solution.

The engineering challenges associated with fuel cell equipment design are substantial, requiring expertise in electrochemistry, thermal management, materials science, and systems integration. Professional engineering firms must navigate complex design parameters while ensuring systems meet rigorous Canadian safety standards and perform reliably in the challenging environmental conditions characteristic of Nova Scotia and the broader Atlantic region.

Key Components of Fuel Cell System Design

Designing fuel cell equipment requires a comprehensive understanding of the numerous subsystems that must work in harmony to deliver reliable power. Each component presents unique engineering challenges that demand careful analysis and precision design work.

Fuel Cell Stack Design

The fuel cell stack serves as the heart of any fuel cell system, where the actual electrochemical conversion occurs. Stack design involves careful consideration of:

• Membrane electrode assembly (MEA) configuration – selecting appropriate catalyst loadings, typically ranging from 0.1 to 0.4 mg/cm² of platinum for proton exchange membrane (PEM) systems

• Flow field plate design – optimising channel geometry for uniform reactant distribution while minimising pressure drops

• Active area sizing – determining cell dimensions based on power requirements, with individual cells typically producing 0.6 to 0.7 volts under load

• Stack architecture – configuring the number of cells in series to achieve desired voltage output, commonly 200-400 cells for larger systems

• Compression system design – maintaining consistent contact pressure across the stack, typically 1-2 MPa for optimal performance

Balance of Plant Systems

The balance of plant (BoP) encompasses all supporting equipment that enables the fuel cell stack to operate effectively. These systems often account for 50-60% of the total system cost and significantly impact overall efficiency. Critical BoP components include air handling systems with compressors or blowers capable of delivering air at 2-3 bar absolute pressure, humidification systems maintaining membrane hydration at 80-100% relative humidity, and cooling systems designed to reject heat loads of 1-2 kW per kW of electrical output.

Hydrogen Supply and Management

Fuel cell equipment design must address hydrogen storage, delivery, and management with particular attention to safety. Design considerations include storage system selection (compressed gas at 350-700 bar, liquid hydrogen at -253°C, or metal hydride storage), pressure regulation from storage pressure down to stack operating pressure of 1-3 bar, and flow control systems capable of responding to load changes within milliseconds. For installations in Nova Scotia's variable climate, hydrogen systems must also account for temperature fluctuations ranging from -30°C to +35°C throughout the year.

Engineering Challenges in Maritime Applications

The Atlantic Canadian context presents unique engineering challenges that must be addressed in fuel cell equipment design. The maritime environment, with its salt air, high humidity, and temperature extremes, demands robust design solutions that ensure long-term reliability and performance.

Corrosion Resistance and Material Selection

Marine and coastal environments accelerate corrosion processes significantly, requiring careful material selection throughout fuel cell systems. Enclosures must utilise marine-grade stainless steel (316L or higher), aluminium with appropriate anodising or coating, or engineered polymers. Electrical connections require enhanced protection through conformal coatings and hermetic sealing. Experience with projects throughout Nova Scotia has demonstrated that standard industrial specifications often prove inadequate for coastal installations, necessitating materials testing and qualification specific to maritime conditions.

Thermal Management in Variable Climates

Nova Scotia's climate presents thermal management challenges at both extremes. Winter operations require systems capable of cold start procedures at temperatures as low as -25°C, while summer conditions demand cooling system capacity for ambient temperatures exceeding 30°C. Effective thermal management design incorporates variable-speed coolant pumps, thermostatically controlled cooling circuits, and freeze protection measures including coolant glycol concentrations of 40-50% for PEM systems.

Integration with Maritime Industries

Atlantic Canada's traditional industries—fishing, shipping, offshore energy, and port operations—represent significant opportunities for fuel cell adoption. Fishing vessels can benefit from fuel cell auxiliary power units providing hotel loads of 10-50 kW while reducing noise and emissions. Port facilities are increasingly considering fuel cell systems for cargo handling equipment, with typical power requirements of 30-100 kW per unit. The engineering challenge lies in designing systems that integrate seamlessly with existing operations while meeting Transport Canada and classification society requirements.

Design Standards and Regulatory Compliance

Fuel cell equipment design in Canada must comply with an evolving framework of standards and regulations that ensure safety and performance. Professional engineers bear responsibility for ensuring designs meet all applicable requirements while anticipating future regulatory developments.

Canadian Standards Association Requirements

CSA standards provide the foundation for fuel cell equipment design in Canada. Key standards include:

• CSA/ANSI FC 1 – Stationary fuel cell power systems, establishing requirements for installation, operation, and maintenance

• CSA HGV 4.2 – Compressed hydrogen fuel dispensing systems

• CSA B51 – Boiler, pressure vessel, and pressure piping code, applicable to hydrogen storage systems

• CAN/CSA-C22.2 No. 62282-3-100 – Safety requirements for stationary fuel cell power systems

Compliance with these standards requires thorough design documentation, component certification, and often third-party testing and verification.

Provincial and Municipal Requirements

Nova Scotia's Technical Safety Division oversees the installation and operation of fuel cell equipment, with requirements including registration of hydrogen storage vessels, electrical permit requirements for grid-connected systems, and site-specific safety assessments for installations exceeding certain hydrogen inventory thresholds. Municipal building codes and zoning bylaws may impose additional requirements, particularly for installations in urban areas such as Halifax, Dartmouth, or Truro.

Classification Society Requirements for Marine Applications

Fuel cell systems intended for marine vessels must comply with classification society rules from organisations such as Lloyd's Register, DNV, or Bureau Veritas. These requirements address explosion protection, ventilation design, and system redundancy to ensure vessel safety under all operating conditions.

Emerging Applications and Market Opportunities

The fuel cell equipment market is expanding rapidly, with several application areas showing particular promise for Atlantic Canada. Understanding these opportunities enables engineering firms to develop targeted expertise and deliver solutions that address regional needs.

Hydrogen Production and Export Infrastructure

Nova Scotia's abundant wind and tidal resources position the province as a potential hydrogen production and export hub. Projects currently under development could produce hundreds of thousands of tonnes of green hydrogen annually, requiring extensive fuel cell and electrolyser infrastructure. Equipment design for these applications involves scale considerations ranging from multi-megawatt electrolyser systems to fuel cell power plants providing grid stabilisation services.

Transportation and Fleet Applications

Commercial vehicle fleets represent a growing market for fuel cell technology, with particular relevance for Atlantic Canada's logistics sector. Fuel cell electric trucks offer zero-emission operation with refuelling times of 10-15 minutes and ranges exceeding 500 kilometres—advantages over battery electric alternatives for regional transport applications. Equipment design for transportation applications demands attention to weight minimisation, vibration resistance, and rapid dynamic response to load changes.

Remote and Off-Grid Power

Atlantic Canada's numerous remote communities and industrial sites present opportunities for fuel cell systems as alternatives to diesel generation. Fuel cell systems operating on hydrogen produced from local renewable resources can reduce fuel transport costs while eliminating emissions. System designs for these applications emphasise reliability, with target availabilities exceeding 95% and maintenance intervals extending to 8,000 operating hours or more.

Design Process and Engineering Methodology

Successful fuel cell equipment design follows a structured engineering methodology that addresses technical requirements while managing project risks and costs. This process ensures that final designs meet performance specifications and can be manufactured, installed, and maintained effectively.

Requirements Definition and System Specification

The design process begins with thorough requirements definition, establishing power output (kW), operating voltage, efficiency targets, and environmental operating conditions. For Atlantic Canadian applications, specifications must address temperature ranges from -30°C to +40°C, relative humidity from 20% to 100%, and exposure to salt-laden air for coastal installations. Load profiles—whether steady-state, load-following, or intermittent—significantly influence system architecture and component selection.

Conceptual Design and Trade Studies

Conceptual design explores alternative system configurations, with trade studies comparing options based on performance, cost, reliability, and maintainability. Key decisions at this stage include fuel cell technology selection (PEM, solid oxide, alkaline, or other types), hydrogen storage approach, and integration architecture. Engineering analysis tools including computational fluid dynamics, electrochemical modelling, and thermal simulation support quantitative comparison of alternatives.

Detailed Design and Analysis

Detailed design develops selected concepts into complete, manufacturable designs. This phase produces mechanical drawings, electrical schematics, control system specifications, and bill of materials. Finite element analysis verifies structural integrity under operating loads and environmental conditions. Failure modes and effects analysis (FMEA) identifies potential failure mechanisms and ensures appropriate mitigation measures are incorporated into the design.

Prototyping, Testing, and Validation

Physical testing validates design assumptions and verifies performance against specifications. Testing protocols address steady-state performance, transient response, thermal cycling, and durability. For safety-critical applications, accelerated life testing and abuse testing demonstrate system behaviour under fault conditions. Test results feed back into design refinement, closing the loop between analysis and physical validation.

Partner with Sangster Engineering Ltd. for Your Fuel Cell Projects

The transition to hydrogen and fuel cell technologies represents both a significant engineering challenge and a tremendous opportunity for Atlantic Canadian industries. Successfully navigating this transition requires engineering expertise that spans electrochemistry, mechanical systems, electrical design, and regulatory compliance—all applied with an understanding of the unique conditions and requirements of Maritime applications.

Sangster Engineering Ltd. brings decades of professional engineering experience to fuel cell equipment design projects throughout Nova Scotia and Atlantic Canada. Our team combines technical depth with practical project delivery experience, helping clients move from concept to operational systems efficiently and effectively. Whether you are exploring fuel cell technology for a new application, developing hydrogen infrastructure, or seeking to optimise existing fuel cell equipment, we provide the engineering expertise your project demands.

Contact Sangster Engineering Ltd. today to discuss how our fuel cell equipment design capabilities can support your clean energy objectives. Our Amherst office serves clients throughout the Maritimes, delivering professional engineering services that meet the highest standards of technical excellence and regulatory compliance. Let us help you harness the potential of fuel cell technology for your operations.

Partner with Sangster Engineering

At Sangster Engineering Ltd. in Amherst, Nova Scotia, we bring decades of engineering experience to every project. Serving clients across Atlantic Canada and beyond.

Contact us today to discuss your engineering needs.