U.S. Zero Emission Bus Evaluation Results & Status. Leslie Eudy National Renewable Energy Laboratory May 16, 2016

Transcription

1 U.S. Zero Emission Bus Evaluation Results & Status Leslie Eudy National Renewable Energy Laboratory May 16, 2016

2 ZEB Evaluation Objectives Validate zero-emission bus 1 (ZEB) performance and cost compared to DOE/FTA targets and conventional technologies Document progress and lessons learned on implementing fuel cell systems in transit operations to address barriers to market acceptance Current FCEB Targets 2 Units 2016 Target Ultimate Target Bus lifetime Years / miles 12/500,000 12/500,000 Powerplant lifetime Hours 18,000 25,000 Bus availability % Roadcall frequency (Bus/fuel cell system) Operation time Miles between road call Hours per day/ days per week 3,500/15,000 4,000/20,000 20/7 20/7 Maintenance cost $/mile Fuel economy Miles per diesel gallon equivalent ZEB technologies include fuel cell electric buses (FCEB) and battery electric buses (BEB) 2 Fuel Cell Technologies Program Record # 12012, Sep 2012, 2

3 FCEB Data Summary for Specifications for TRL 7 FCEBs included in data summary FCEB Identifier ACT ZEBA SL AFCB Transit Agency AC Transit SunLine Number of Buses 13 4 Bus OEM Van Hool ElDorado National Bus length/height 40 ft / 136 in 40 ft / 140 in Fuel Cell OEM US Hybrid Ballard Model PureMotion 120 FCvelocity, HD6 Power (kw) Hybrid System Siemens ELFA, integrated by Van Hool BAE Systems HybriDrive Design strategy FC dominant FC dominant Energy Storage - OEM EnerDel A123 Type Li-ion Nanophosphate Li-ion Capacity 17.4 kwh 11 kwh # cylinders 8 8 Capacity (kg) / Pressure (Bar) 40 / / 350 OEM = original equipment manufacturer ACT ZEBA = AC Transit Zero Emission Bay Area SL AFCB = SunLine American Fuel Cell Bus FC = fuel cell ACT ZEBA SL AFCB

4 Top Fuel Cell Powerplant Exceeds 22,000 Hours Total Hours Top fuel cell powerplant (FCPP) >22,000 hours, surpassing DOE/DOT 2016 target; 71% of FCPPs (12) over 10,000 hours 30,000 25,000 DOE/DOT Ultimate Target: 25,000 20,000 15,000 10,000 DOE/DOT 2016 Target: 18,000 Average: 11,495 5, In-Service FCPPs ACT ZEBA SL AFCB Total hours accumulated on each FCPP as of 2/29/16 4

5 5 Average Bus Availability by Month Target: 85% Ultimate Target: 90% Availability (%) Summary (from 3/2011) Average availability: 73% FCPP Availability: 91% ZEBA AFCB Average FC system only Availability = planned operation days compared to actual operation days

6 Availability Summary: 2015 Data 6 Hybrid Propulsion 2% FC System 13% Traction Batteries 2% Bus Maintenance 6% PM 2% Two ZEBA buses were down most of 2015 for FC system issues that were difficult to diagnose; removal of those two buses from data brings availability to 84% Available 75% Hybrid Propulsion 2% FC System 3% Traction Batteries 2% FCEB Fleet Number % Available 4, FC system Hybrid propulsion Traction batteries Bus maintenance PM 89 2 Total days 4, Unavailability categorized based on current reported diagnosis and could change as new information is received. Bus Maintenance 7% PM 2% Available 84%

7 Fuel Economy (mpdge) Monthly Fuel Economy compared to Baseline Target: 8 mpdge Average FCEB: 6.85 Diesel: 4.28 CNG: ACT ZEBA ACT Diesel (Gillig) SL AFCB SL CNG Highly variable depending on duty cycle: average speed, terrain, auxiliary loads 7

8 Miles between roadcall Reliability: Miles Between Roadcall (MBRC) 8 25,000 20,000 Ultimate FC System MBRC Target 15, FC System MBRC Target 10,000 5,000 Ultimate Bus MBRC Target Bus MBRC Target Bus MBRC FC System MBRC FCEB reliability continues to increase and has surpassed ultimate targets Maintenance staff becoming more familiar with system, applying new tools to anticipate and fix issues before they fail in service

9 9 Current Status of FCEBs Fleet Minimum Fleet Maximum Fleet Average Bus lifetime (years) Bus lifetime (miles) 8, ,203 91,381 Power plant lifetime (hours) 2,013 22,203 11,462 Bus availability (%) Fuel fills (number per day) Roadcall frequency bus (MBRC) 4,374 4,513 4,492 Roadcall frequency fuel cell system (MBRC) 19,085 23,261 22,532 Operation time (average hours per day) Scheduled and unscheduled maintenance cost ($/mile) Range (miles) Fuel economy (miles per DGE) Data Summary from 2 fleets 16 total buses. 1 Buses from one fleet are still under warranty, although most of the maintenance is handled by transit staff

10 Foothill Transit BEBs 10 Specifications Foothill BEBs FCEB Identifier BEB Transit Agency Foothill Transit Number of Buses 12 Bus OEM Proterra Bus length/height 35 ft / 126 in Charging strategy Motor Rated Power (kw) Energy Storage - OEM Type Capacity Fast-charge, onroute Permanent magnet, UQM, PP (peak) Altairnano Lithium-titanate 368 volts, 88 kwh

11 Fuel Economy (mpdge) Average High Temperature (F) 11 Monthly Fuel Economy compared to Baseline BEB (35-ft) CNG (Orion, 40-ft) CNG (NABI, 42-ft) Avg High Temp (F) BEB average: 2.15 kwh/mi, mi/dge CNG baselines: Orion 40-ft: 4.4 mi/dge NABI 42-ft: 4.51 mi/dge

12 Availability Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15 Number of days 12 Average Bus Availability by Month 100% 90% 80% Reasons for Unavailability ESS 70% 60% Charging issues Electric drive 50% 50 PM 40% 40 Bus 30% 30 BEB 20% 20 CNG 10% 10 Target 0% 0 w/o 2013 Average availability: 90% w/o outlier: 93%

13 Availability Summary Unavailable Available 10% 90% Bus 7% PM 0% Charging issues 0% Electric drive 2% ESS 1% Foothill Number % Energy Storage System (ESS) Electric drive Charging issues Bus maintenance Preventive maintenance Total unavailable days Total available days 4,

14 Miles Between Roadcall 14 Reliability: Miles Between Roadcall (MBRC) 250, ,000 BEB Bus MBRC BEB Propulsion MBRC BEB Battery MBRC CNG Bus MBRC 150,000 CNG Propulsion MBRC Bus MBRC Target ESS MBRC Target 100,000 50,000 0 Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15 Early results show the BEB performance meets the ultimate targets.

15 15 Current Status of BEBs Fleet Minimum Fleet Maximum Fleet Average Bus lifetime (years) Bus lifetime (miles) 17,243 40,532 33,437 Bus availability (%) Charges (number per day) Roadcall frequency bus (MBRC) 5,748 31,944 9,331 Roadcall frequency propulsion system (MBRC) 1,724 32,743 25,078 Roadcall frequency energy storage system (MBRC) 133,748 Operation time (average hours per day) Scheduled and unscheduled maintenance cost ($/mile) Fuel economy (miles per DGE) Data from only 1 fleets 12 total buses 1 Buses are currently under warranty all advanced technology maintenance is handled by OEM

16 Remaining Challenges and Barriers for ZEBs Common to all ZEBs Develop robust supply chain for components and parts Increase learning curve for maintenance staff training and tools Reduce cost, both capital and operating Specific to FCEBs Increase durability and reliability of components Continue transition of build process to OEM Addition of fueling infrastructure Specific to BEBs Plan/build of opportunity charging stations & garage chargers Select appropriate routes for technology Address challenge of electric rates and demand charges 16

17 For more information NREL Hydrogen Technology Validation web page: Contact Info: Leslie Eudy Phone: