Progress in Hydrogen Fuel Cell Powered Vehicles in Action

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1 Progress in Hydrogen Fuel Cell Powered Vehicles in Action Melbourne, March 30 th, 2006 Manfred Schuckert EvoBus GmbH, Germany Coordinator CUTE/STEP/Beijing FC Bus Trials

2 Structure 1. Introduction 2. Technology development and set-up of large FC demonstration projects 3. Experiences with Fleet Operations all over the world 4. The next generation of FC vehicles 5. Technology Improvement Requirements and Outlook

3 Greenhouse Gas Emissions from 1990 to 2003: Is there a necessity for alternative propulsion systems because of Climate Change? -0,4-1,4-1,9-1,9-2,3-6,0-8,2-13,0-16,1-18,2-24,2-28,3-31,9-34,4-38,5-44,4-46,1-46,2-50,0-50,8-58,5-66,2 25,8 25,6 24,2 23,3 22,5 21,5 16,5 13,3 12,8 11,5 9,3 6,8 5,3 1,5 1,3 41,7 37,8 36,7 + - Tschechische Rep. EU Slowenia France Schweden Kroatia Iceland Luxembourg UK Germany Slowakiai Ungarn Poland Russia White Russia Rumania Ukraine Bulgary Estland Lethenia Litauen Schwitzerland Monaco Japan Norwegian Liechtenstein Belgium Spain Portugal Greece Irland Canada Australia Newsealand Finnland Austria USA Italy Danemark Netherlands What about China and India? All in Percentage GWP

4 Crude Oil Prices since 1861: Is today s price extraordinary? US-$ ( ) 06

5 Proven Reserves of Crude Oil (in Billion Barrel) Should someone be concerned? North America/Mexico Europe /Eurasia TOTAL: TOTAL: In Total: 1050 Bill. Barrel Worldwide Central-/South America Africa Near East Asia / Australia 06 TOTAL: TOTAL: TOTAL: TOTAL: Source: Focus 02/06

6 Energy Needs: Two Scenarios for the next 50 years: The increasing importance of renewables is essential for both scenarios. Demographics Urbanization Resource constraints Technology Social and personal priorities Incomes & demand Liberalization Competition and innovation Evolutionary developments Social benefits Revolutionary developments Customer benefits Source: Exploring the Future: Energy Needs, Choices and Possibilities - Scenarios to 2050, Shell, 2001 Dynamics as Usual maturing new technologies intense competition gradual shift from high to low carbon fuels increasing importance of renewables new infrastructure logic consumer pull disruptive new technology The Spirit of the Coming Age The need for alternative fuels is inevitable within the next decades. Whether we have 20 or 50 years - both are short periods of time to build up a new energy world - we have to start now.

7 Technology: The transition process from an established world to a new one can be dramatically accelerated by new disruptive technologies, which offer attractive perspectives for new businesses, products, and markets with additional customer benefits. business value new technology business value new technology established technology driving technology microprocessor established technology driving technology fuel cell time time The transition process in the IT, communication, and controls business was driven by the microprocessor. A similar process is expected in the t energy, fuel, transportation business by the upcoming fuel cell technology

8 Why Fuel Cell Vehicles? Fuel cell technology can pave the way into a new era of mobility: Zero-emissions vehicles Efficiency twice as high as IC engine Driving pleasure high dynamic characteristic provided by electric drive Comfort of pure electrical driving Oil independence Power supply on board for Hybrid internal/external electrical Hybrid loads, as well as integration of extra passenger comfort Diesel features Greenhousegas Emissions / g CO 2 /km Internal Combustion Engine Gasoline Fuel Cell Hybrid (Hydrogen from onsite natural gas steam reforming) Source: EUCAR Study for Europe in Fuel Cell Hybrid (Hydrogen from central Electrolysis powered by renewable energy sources) Energy Consumption MJ/100km

9 Fuel cell vehicles of DaimlerChrysler Future Hydrogen Passenger Cars Phase 1 Phase 2 Necar 2 Necar 4 Necar 4 Advanced Chrysler Natrium F-Cell Methanol Passenger Cars Necar 3 Jeep Command Necar 5 Hydrogen Light-Duty Vehicles Necar 1 Feasibility Studies and Market Preparation Sprinter»Fit For Daily Use«Hydrogen Heavy-Duty Vehicles NeBus Citaro

10 Preparing the market - Worldwide fleet operations Iceland Hydrogen Economy ECTOS Clean Energy Partnership Germany European Bus Project CUTE Bus Project Beijing China JHFC Program Japan California Fuel Cell Partnership DoE Program USA Largest fuel cell fleet worldwide More than 100 DaimlerChrysler fuel cell vehicles in daily operation. Sinergy EDB Project Singapore Bus Project STEP Perth, Australia

11 Big demonstration projects are a huge challenge and a huge risk! Needs for the Fuel Cell technology Lack of field experience with fuel cell systems and electric engines in mobile applications Operability of on-site hydrogen production facilities and referring high pressure filling stations Country specific certification of fuel cell systems and high pressure hydrogen storage systems Acceptance test of the new technology and of hydrogen as a fuel First FC fleet trial 10 European metropolitan areas in 8 European countries will demonstrate the possibilities of 30 fuel cell driven buses Fuel cell powered buses running for 2 years in regular service Leading European infrastructure companies (oil and gas producers) are setting up a hydrogen infrastructure 10 different hydrogen supply infrastructures Approximately 40 European companies and universities are included Motivation for the NEFLEET Project

12 Mercedes-Benz Citaro Fuel Cell Bus - Technical Design Main Target: Generate Reliability by using as many Series Components as possible Dynetek Composite Hydrogen Tanks (350 bar, 40 kg H 2, Al-Liner, Carbon Fibre) Reuland Electric Motor Ballard Fuel Cell Supply Unit 2 Ballard Fuel Cell Modules (each 150 kw GP ) Modine Convection Cooler Unit Webasto Air Condition Unit ZF Automatic Transmission DaimlerChrysler distribution gearcase Auxiliary Components Saminco Power Inverter, etc.

13 Large scale demonstration projects require pre-series production technologies, while the vehicles still be handled very cautious by governments and authorities Up to 15 Fuel Cell Busses in the production Line at one time Realisation in 2003

14 CUTE / ECTOS / STEP: Performance of the FC buses Performance of the Fuel Cell Buses In total the 33 Fuel Cell Buses accumulated about km (varies from km to km per site) The operating hours account so far to about hrs (varies from 1200h to 3000h per bus) On a day with an average availability of bus and infrastructure the buses carry up to passengers TOTAL HOURS ~ hrs TOTAL KILOMETERS ~ km London Perth Madrid London Perth Madrid Porto Stockholm Amsterdam Luxembourg Hamburg Barcelona Reykjavik Stuttgart Porto Stockholm Amsterdam Luxembourg Hamburg Barcelona Reykjavik Stuttgart

15 CUTE / ECTOS / STEP: Performance of the FC buses Performance of the Fuel Cell Buses (km performed) Significant differences between the sites due to various influences mainly fuel supply. Successful confirmation of original project design. Lifetime and maturity of the FC-stacks were much better than anticipated.

16 Milestones F-Cell 2002 F-Cell 2002 Technical data Vehicle type Fuel cell system Drive train Fuel Range Max. speed Battery Mercedes-Benz A-Class PEM, 72 kw Electric asynchronous motor Power (Permanent / Peak): 45 kw / 65 kw Max. torque: 210 Nm Hydrogen (350 bar) km (NEDC) 140 km/h NiMH, air cooled Power (Permanent / Peak): 15 / 20 kw Nominal capacity: 6.5 Ah, 1.4 kwh

17 The next Generation: Compact Sports Tourer Concept B-Class F-Cell at a glance kw 0 High torque electric motor provides additional 35kW of power km A-Class F-Cell B-Cell B-Class A-Class F-Cell F-Cell F-Cell F-Cell 0 Increased operating range due to enhanced fuel storage capacity. 400 B-Cell B-Class F-Cell Cold start ability below 0 C Higher lifetime & reliability are closing the gap to market maturity. Higher stack lifetime of 2000h Li-ion HV battery

18 One look into the Future: F600 HYGENIUS Research car with fuel-cell drive (Tokyo Motor Show 2005)

19 F600 HYGENIUS Research car with fuel-cell drive (Tokyo Motor Show 2005) 40 percent smaller stack* Over 30 percent more power and up to 66 percent more torque* Consumes around 24 percent less energy* Consumes the equivalent of 2.9 litres of fuel per 100 kilometres Can be started at temperatures as low as -25 C First time to store the electrical energy in high-power lithium-ion battery *Compared to A-Class F-Cell Fuel Cell System (max.) Drive Power (permanent/max.) Maximal torque Fuel Range V max Battery Peak Power (perm./max.) Capacity PEM, 80 kw (90kW) Electric Motor 60 kw / 85 kw 350 Nm comp. Hydrogen, 700 bar > 400 km 174 km/h Li-Ion 30 kw / 55 kw 1,5 kwh

20 The HyFLEET:CUTE-Project The NEXT Generation: Fuel Cell Bus Prototype in HyFLEET:CUTE Main focus: Further weight reduction and avoidance of a complex roof bracing Tank system 350 Bar: Reduction of 1-2 tank cylinder(s) due to higher efficiency -> Weight reduction of 100 kg per cylinder 700 Bar: Usage of existing CUTE/ECTOS-fuelling stations problematic Energy accumulator for Booster operation and regenerative braking Hybridbattery Supercaps Cooling system Reduction of size due to higher efficiency lower power output integrated heat management for conditioning Auxiliary drive demand controlled FC-System Utilization of next generation passenger car systems Redundant emergency operation installation on the roof installation in the rear part (horizontal engine) Drive train central engine as before 2 engines with summation gear wheel hub motor

21 The Fuel Cell System: Still a way to go until automotive fully competitive Further Fuel Cell System Development need to address: Further improvements in power and weight/power Freezing Compatibility (< - 20 C) Increased Lifetime > 5000h Reduction of the complexity Cost Reduction Mass production aspects kg/kw 21 kg/kw power to weight ratio Mark 5 Improvements of Stack Weight/power Ratio in the last decade: kg/kw Mark 7 5 kg/kw 4 kg/kw Mark 8 Diesel 1-2 kg/kw Mark Near future 0,78 kg/kw *) 0,65 kg/kw *) Honda 2003/04

22 Achievements and challenges future Achievements Challenges high efficiency zero/ultra low emissions low noise high driving comfort performance, package & weight use of alternative fuels new innovative vehicle concept basic demonstration of customer benefits further technical development: cost weight reliability and lifetime hydrogen storage freeze start Policy framework & financial planning Infrastructure Improvements commercial fuel cell vehicles Significant improvements in 10 years Next steps: Large scale demonstrations Manage the transition from demonstration projects to commercial fuel cell vehicle applications