Status of U.S. Hydrogen Infrastructure and Fuel Cell Vehicle Technology Learning Demonstration. Steven Chalk

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1 Status of U.S. Hydrogen Infrastructure and Fuel Cell Vehicle Technology Learning Demonstration Steven Chalk DOE Hydrogen Program Manager March 6, 2006 JHFC Conference, Tokyo Big Sight 1

2 Outline Controlled Fleet & Infrastructure Project Overview Data Collection and Processing First Public Results Now Available: Composite Data Products 2

3 Project Objectives and Targets Objectives Validate H 2 FC Vehicles and Infrastructure in Parallel Identify Current Status of Technology and its Evolution Re-Focus H2 Research and Development Support Industry Commercialization Decision by 2015 Key Targets Performance Measure 2009* 2015** Fuel Cell Stack Durability 2000 hours 5000 hours Vehicle Range 250+ miles 300+ miles Hydrogen Cost at Station $3/gge $2-3/gge Hydrogen and gasoline station, WA DC Photo: Shell Hydrogen * To verify progress toward 2015 targets ** Subsequent projects to validate 2015 targets 3

4 Status: 4 Teams Have Signed Cooperative Agreements with DOE, 1 Under Negotiation (1) (1) (1) Fuel cells supplied by Ballard 4

5 Refueling Stations from All Four Teams Begin to Create 5 Regional Networks Northern California SE Michigan Additional Planned Stations DaimlerChrysler & BP (up to 2) General Motors & Shell (1) ChevronTexaco (up to 2) Mid-Atlantic Additional Planned Stations General Motors & Shell (2) Additional Planned Stations Ford & BP (up to 4) DaimlerChrysler & BP (up to 3) General Motors & Shell (1) ChevronTexaco & Hyundai (up to 2) Southern California Online Stations Ford & BP ChevronTexaco DaimlerChrysler & BP General Motors & Shell Other Companies Florida Additional Planned Stations DaimlerChrysler & BP (2) General Motors & Shell (1) ChevronTexaco (2) Additional Planned Stations Ford & BP (1) 5

6 Teams are Fielding Four Main* Types of Vehicles *DaimlerChrysler will also have FCV Sprinter vans *Kia Sportage FCVs will also be used 6

7 Sample Hydrogen Refueling Infrastructure Photos: DTE DTE/BP Power Park, Southfield, MI LAX refueling station Hydrogen and gasoline station, WA DC Photo:Shell Hydrogen Chino, CA Photo: H2CarsBiz 7

8 Data Collection: Overview Key Vehicle Data Stack Durability Fuel Economy (Dyno & On-Road) and Vehicle Range Fuel Cell System Efficiency Maintenance, Safety Events Top Speed, Accel., Grade Max Pwr & Time at 40C Freeze Start Ability (Time, Energy) Continuous Voltage and Current (or Power) from Fuel Cell Stack, Motor/Generator, Battery & Key Auxiliaries: (Dyno & On-Road) Key Infrastructure Data Conversion Method Production Emissions Maintenance, Safety Events Hydrogen Purity/Impurities Refueling Events, Rates H 2 Production Cost Conversion, Compression, Storage and Dispensing Efficiency 8

9 Overview of Options for International H2 Vehicle Fleet Data Sharing Publicly Shared Result How US Project is Gathering Data Alternative Methods for Providing Same Public Result # Composite Data Product Current Measurements to Provide Detailed Data Possible Alternatives for Composite Data Reporting 1 Fuel Cell Durability (hours) Fuel Cell Voltage & Current to Examine Degradation Report Hours Until 10% Degradation or Stack Changeout 2 Vehicle Driving Range (km) On-Road and Chassis Dynamometer Distance & Tank Temp/Press Data Calculated from Fuel Economies in #6 below 3 H2 Production Cost ($/kg) Detailed Breakdown of Cost Using H2A Tool Report H2 Production Cost Using H2A Tool 4 FC & Powertrain Reliability (MTBF) Detailed Maintenance Data from Vehicles Report MTBF for FC and Powertrain 5 Vehicle Cold & Ambient Start Time (min) Cold-Start Test Data at both cold and ambient conditions Third-Party Witnessed Cold-Start Time In Qualified Test Fac. 6 Fuel Economy: On-Road and Dyno (L/100km) Fuel Cell Current or H2 mass flow and Vehicle Speed On-Road and Dyno Fuel Economy Compared to Conv. Veh. 7 Normalized Simulation Fuel Economy (L/100km) Detailed On-Road Data Sufficient to Create ADVISOR model Not Necessary 8 Fuel Cell System Efficiency (%) On-Road and Dyno Voltage, Current, Net Power, H2 Purge Rate Not Necessary 9 Frequency/Type of Vehicle Safety Incidents (#/quarter) Detailed list of Vehicle Safety Incidents and Descriptions Same 10 Demonstrated H2 Storage Mass Density (kg H2/kg total) H2 Weight % Reported from Each Tank Manufacturer Same 11 Volumetric H2 Storage Density (kg H2/L system) H2 kg/l Reported from Each Tank Manufacturer Same 12 Vehicle H2 Tank Cycle Life (cycles) Reported Tank Cycle Life Same 13 H2 Production Efficiency by Technology (%) Detailed Energy Usage at Each Stage of Production Not Necessary 14 Co-Production Combined Heat & Power Efficiency (%) Detailed Efficiency for FC Electric Production & Waste Heat Usage Not Necessary 15 H2 Production Cost by Technology ($/kg) Detailed Cost Breakdown Usuing H2A Tool for Each Station Not Necessary 16 H2 Purity By Production Method (%) Detailed H2 PurityTest Results Quarterly from Each H2 Station Same 17 Level of H2 Impurities (ppm) Detailed Impurity Breakdown by Station Same 18 Refueling Rate Histogram (kg/min) Refueling time and H2 amount data for each refueling event Same 19 Infrastructure Maintenance by Month (hours/month) Detailed Infrastructure Maintenance Data for Each Station Same 20 Infrastructure Safety Incidents (events/quarter) Detailed List and Description of Infrastructure Safety Events Same 21 Range of Ambient Temperatures Vehicles Experienced (deg) Ambient Temperature During Each Vehicle Trip Same 22 Histogram of Vehicle Operating Hours Achieved (# veh) Detailed Vehicle Operating Hours by Trip for Each Vehicle Same 23 Histogram of Vehicle Operation vs. Mileage (# veh.) Detailed Mileage Accumulation for Each Vehicle by Trip Same 24 Total Vehicle Miles Traveled by Quarter (# miles) Detailed Vehicle Mileage Accumulation Log Same 25 Number of Vehicles Using Low or High Pressure Tanks (# veh) Data on Max Tank Pressure for Each Vehicle Same 26 Cumulative Hydrogen Production (kg) H2 Production by Month for Each Station Same 9

10 Details of Possible International H2 Vehicle Fleet Data Sharing Publicly Shared Result How US Project is Gathering Data Alternative Methods for Providing Same Public Result # Composite Data Product Current Measurements to Provide Detailed Data Possible Alternatives for Composite Data Reporting 1 Fuel Cell Durability (hours) Fuel Cell Voltage & Current to Examine Degradation Report Hours Until 10% Degradation or Stack Changeout 2 Vehicle Driving Range (km) On-Road and Chassis Dynamometer Distance & Tank Temp/Press Data Calculated from Fuel Economies in #6 below H2 Production Cost ($/kg) Detailed Breakdown of Cost Using H2A Tool Report H2 Production Cost Using H2A Tool 3 10

11 Details of Possible International H2 Vehicle Fleet Data Sharing Publicly Shared Result How US Project is Gathering Data Alternative Methods for Providing Same Public Result FC & Powertrain Reliability (MTBF) Vehicle Cold & Ambient Start Time (min) Fuel Economy: On-Road and Dyno (L/100km) Normalized Simulation Fuel Economy (L/100km) Fuel Cell System Efficiency (%) Frequency/Type of Vehicle Safety Incidents (#/quarter) Demonstrated H2 Storage Mass Density (kg H2/kg total) Volumetric H2 Storage Density (kg H2/L system) Vehicle H2 Tank Cycle Life (cycles) Detailed Maintenance Data from Vehicles Cold-Start Test Data at both cold and ambient conditions Fuel Cell Current or H2 mass flow and Vehicle Speed Detailed On-Road Data Sufficient to Create ADVISOR model On-Road and Dyno Voltage, Current, Net Power, H2 Purge Rate Detailed list of Vehicle Safety Incidents and Descriptions H2 Weight % Reported from Each Tank Manufacturer H2 kg/l Reported from Each Tank Manufacturer Reported Tank Cycle Life Report MTBF for FC and Powertrain Third-Party Witnessed Cold-Start Time In Qualified Test Fac. On-Road and Dyno Fuel Economy Compared to Conv. Veh. Not Necessary Not Necessary Same Same Same Same 11

12 Details of Possible International H2 Vehicle Fleet Data Sharing Publicly Shared Result How US Project is Gathering Data Alternative Methods for Providing Same Public Result H2 Production Efficiency by Technology (%) Co-Production Combined Heat & Power Efficiency (%) H2 Production Cost by Technology ($/kg) H2 Purity By Production Method (%) Level of H2 Impurities (ppm) Refueling Rate Histogram (kg/min) Infrastructure Maintenance by Month (hours/month) Infrastructure Safety Incidents (events/quarter) Detailed Energy Usage at Each Stage of Production Detailed Efficiency for FC Electric Production & Waste Heat Usage Detailed Cost Breakdown Usuing H2A Tool for Each Station Detailed H2 PurityTest Results Quarterly from Each H2 Station Detailed Impurity Breakdown by Station Refueling time and H2 amount data for each refueling event Detailed Infrastructure Maintenance Data for Each Station Detailed List and Description of Infrastructure Safety Events Not Necessary Not Necessary Not Necessary Same Same Same Same Same 12

13 Details of Possible International H2 Vehicle Fleet Data Sharing Publicly Shared Result How US Project is Gathering Data Alternative Methods for Providing Same Public Result Range of Ambient Temperatures Vehicles Experienced (deg) Histogram of Vehicle Operating Hours Achieved (# veh) Histogram of Vehicle Operation vs. Mileage (# veh.) Total Vehicle Miles Traveled by Quarter (# miles) Number of Vehicles Using Low or High Pressure Tanks (# veh) Cumulative Hydrogen Production (kg) Ambient Temperature During Each Vehicle Trip Detailed Vehicle Operating Hours by Trip for Each Vehicle Detailed Mileage Accumulation for Each Vehicle by Trip Detailed Vehicle Mileage Accumulation Log Data on Max Tank Pressure for Each Vehicle H2 Production by Month for Each Station Same Same Same Same Same Same 13

14 Project Now Well Underway Current Status of Data Reporting to the Hydrogen Secure Data Center at NREL On-Road Data Received -- Running Totals # files Data Size (MB) # Files Data Size (MB) Sep-04 Oct-04 Nov-04 Dec-04 Jan-05 Feb-05 Mar-05 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Jan-06

15 Vehicle Data Analysis: Automated Process from CD/DVD Delivery to Results miles/(kg H2) On-Road Fuel Economy: All Vehicles Weighted Average Fuel Economy = 47.6 miles/kg H2 All trip lengths included in calculations 0 V1 V2 V3 V4 V5 V6 V7 V8 V9 4 V10 Vehicle Identifier Number of Refuelings Range Histogram: Vehicle 1 Maximum range b/w refuelings = 175 miles Voltage (V) Predicted Voltage (V) 400 Vpred = *log(current) *current 10.0 hours of data per curve fit data points per curve fit Time(oper hrs) = Current (A) Operating Time (hrs) Actual CurveFit 95%CI:Observation = = = = = 250A Distance b/w Refueling (miles) 15

16 Analysis Controlled by New NREL-Developed GUI: Fleet Analysis Toolkit (FAT) 16

17 FAT GUI Includes TripView to Dive Deeper and Investigate Individual Trips and Refuelings 17

18 On-Road Voltage Degradation Analysis: Polarization Curve Fitting, Piecewise in Time 18

19 Voltage Degradation Analysis: Individual-Stack Methodology 240 Voltage vs. Operating Hours at 300A: Vehicle17-Stack1 Predicted Voltage at 300A Nominal zero hrs = 207V 16 mv/hr Threshold for 10% drop = 186V 99.7 % 1067 hrs 1314 hrs 1734 hrs Probability of Exceeding Oper. Hours STACK Operating Hours 19

20 Voltage Degradation Analysis: Multiple-Stack-Average Methodology Predicted Voltage at 300A Voltage vs. Operating Hours at 300A: All Stacks Nominal zero hrs = 206V 11 mv/hr Threshold for 10% drop = 185V % 1504 hrs 1803 hrs Vehicle15-Stack1 Vehicle16-Stack2 Vehicle17-Stack hrs Probability of Exceeding Oper. Hours STACK Operating Hours 20

21 Accomplishment: Baseline Vehicle Chassis Dynamometer Testing Completed by All 4 Teams One vehicle per team per geographic region 11 vehicles tested using SAE J2572 Some teams may elect to use test results for EPA certification DaimlerChrysler/BP Ford/BP Chevron/Hyundai-KIA GM/Shell 21

22 Composite Data Products are Main Output to Public and Hydrogen Community Highlighted CDPs Have Been Completed and Will Be Presented 22

23 Dynamometer and On-Road Fuel Economy 80 Fuel Economy Fuel Economy (miles/kg H 2 ) Dyno (1) Window-Sticker (2) On-Road (3)(4) Created: 16-Feb-2006 (1) One data point for each make/model. Combined City/Hwy fuel economy per DRAFT SAEJ2572. (2) Adjusted combined City/Hwy fuel economy (0.78 x Hwy, 0.9 x City). (3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model. (4) Calculated from on-road fuel cell stack current or mass flow readings. 23

24 Vehicle Range Based on Dyno Results and Usable H2 Fuel Stored On-Board 300 Vehicle Range (1) 2015 Target 2009 Target 250 Vehicle Range (miles) Data indicate improved H2 storage technologies that can be packaged in a vehicle are necessary to meet range targets 0 All OEMs Created: 21-Feb-2006 (1) Calculated from combined City/Hwy fuel economy (dyno test) per DRAFT SAE J2572 and usable fuel on board. 24

25 Safety Incidents Vehicles Safety Incidents - Vehicle Operation Number of Incidents Strong vehicle safety record indicates very few start-up issues, and no fundamental safety problems with the vehicles '05 Q2 '05 Q3 '05 Q4 Created 21-Feb-2006 Passenger Compartment H2 alarm H2 release 25

26 Vehicle H2 Storage Technologies Include 350 bar, 700 bar, and Liquid H2 On-Board Hydrogen Storage Methods 70 # of Vehicles (All Teams) Data indicate first generation vehicle fleet still being deployed; Fleet is now largest H2 FC vehicle fleet in the world 10 - Q205 Q305 Q405 5,000 psi tanks 10,000 psi tanks Liquid H2 Created 16-Feb

27 Status of On-Board H2 Storage Technologies Being Validated Number of cycles Hydrogen Tank Cycle Life 2015 DOE MYPP Target DOE MYPP Target DOE MYPP Target 1 Weight Percent Hydrogen (%) Weight Percent Hydrogen 2015 DOE MYPP Target DOE MYPP Target DOE MYPP Target 1 Created: 23-Feb All OEMs All OEMs 1 1 Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based technologies. Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based technologies. Created: 23-Feb-2006 Mass H2 per Liter (kg/l) Mass of Hydrogen Per Liter 2015 DOE MYPP Target DOE MYPP Target DOE MYPP Target 1 Compressed and liquid H2 tanks meet durability and short term weight %, but don t meet long-term weight % or volumetric capacity targets for vehicles Created: 23-Feb Emphasis is on advanced materials-based technologies. All OEMs 27

28 Hydrogen Purity Sampled from Stations Meets Target Majority of the Time Hydrogen Purity Sampled from Stations (1) Range of Reported Data ISO FDTS Target Hydrogen Purity (%) Created: 21-Feb-2006 (1) Includes sampling from both electrolysis and reforming 28

29 Hydrogen Impurities Sampled from All Stations Includes On-Site Reformation, Electrolysis, and Delivered H2 H 2 Impurities Range of Reported Data ISO FDTS Max Reported Detection Limit Particulates µg/l (N2 + He + Ar) NH3 Total S Compounds* CO CO2 O2 Total HC H2O Created: 23-Feb µmole/mole *Includes SO2, COS, and H2S. Improved sampling technologies are necessary to improve low-concentration sensitivities 29

30 Actual Vehicle Refueling Rates: Measured by Stations or by Vehicles Histogram of Vehicle Refueling Rates 2006 Tech Val Milestone 2010 MYPP Adv Storage Materials Target 30 # of Refueling Events minute fill of 5 kg at 350 bar 3 minute fill of 5 kg at 350 bar 10 5 Future analyses could compare impact of communication and non-communication fills on fill rates and completeness of fill Created: 21-Feb Refueling Rate (kg H2/minute) 30

31 Safety Incidents Infrastructure General Category Unconfirmed/False Alarm H2 Leak/Unplanned Vent Mischief, Vandalism Calibration/Settings Created 21-Feb-2006 Non-H2 Leak H2 Leak/Unplanned Vent Electrical Calibration/Settings Safety Incidents - Infrastructure 2005 Q2 - Q4 Environmental (Weather, Power Disruption, etc.) Mischief, Vandalism Unconfirmed/False Alarm Number of Incidents Data indicate a strong infrastructure safety record; Station robustness to external forces and false alarms could be improved 31

32 Range of Ambient Temperature During Vehicle Operation 50 Ambient Temperature During Operation 40 Degrees Celsius Fuel cell vehicles are currently able to operate in extreme conditions. Future tests will determine capability of starting in cold temperatures All OEMs Created: 16-Feb

33 Vehicle Operating Hours Number of Vehicles Vehicle Hours: All OEM's Combined through Q Total Vehicle Hours = 7,831 Data reflect youthful nature of current fleet >450 Created: 16-Feb-2006 Total Vehicle Hours 33

34 Vehicles vs. Miles Traveled Vehicle Miles: All OEM's Combined through Q Total Vehicle Miles Traveled = 196, >13500 Total Vehicle Miles Number of Vehicles Created: 16-Feb-2006 Data reflect youthful nature of current fleet

35 Cumulative Vehicle Miles Traveled Cumulative Vehicle Miles Traveled: All OEMs 250,000 Vehicle Miles Traveled 200, , ,000 50,000 Rate of mileage accumulation increasing as initial fleets become fully deployed - Q205 Q305 Q405 Created: 16-Feb

36 CDP#26: Cumulative H2 Produced or Dispensed 7,000 Cumulative Hydrogen Produced or Dispensed All Teams Combined Mass of Hydrogen (kg) 6,000 5,000 4,000 3,000 2,000 1,000 Current deployment of new H2 refueling stations for this project is about 20% complete 0 Created 21-Feb-2006 Q Q Q Reporting Calendar Quarter 36

37 Find... The latest news, reports & announcements Status information about program solicitations Fuel cell and hydrogen "basics" information 2006 Annual DOE Hydrogen Program Merit Review and Peer Evaluation Meeting May 16-19, Arlington, VA 37