Yong Yang. PEM Fuel Cell System Manufacturing Cost Analysis for Automotive Applications. President. October, 2013

Transcription

1 PEM Fuel Cell System Manufacturing Cost Analysis for Automotive Applications Yong Yang President October, 2013 Austin Power Engineering LLC 2310 W 9 th ST UNIT 1 Austin, TX USA yang.yong@austinpowereng.com 2013 Austin Power Engineering LLC

2 Introduction Overview Have been working on fuel cell manufacturing cost modeling for US DOE, UK Carbon Trust, and commercial clients since SOFC PEMFC DMFC Electrolyzer H2 Storage Battery Commercial Clients PEMFC Carbon Trust SOFC PEMFC H2 Storage Battery US DOE US DOE Fuel Cell Manufacturing Cost Modeling TIAX Austin Power Chief Manufacturing cost model developer Chief Manufacturing cost model developer 1

3 Approach Manufacturing Cost Modeling Methodology This approach has been used successfully for estimating the cost of various technologies for commercial clients and the DOE. Technology Assessment Manufacturing Cost Model Scenario Analyses Verification & Validation Literature research Definition of system and component diagrams Size components Develop bill-of- materials (BOM) Define system value chain Quote off-shelve parts and materials Select materials Develop processes Assembly bottom-up cost model Develop baseline costs Technology scenarios Sensitivity analysis Economies of Scale Supply chain & manufacturing system optimization Life cycle cost analysis Cost model internal verification reviews Discussion with technical developers Presentations to project and industrial partners Audition by independent reviewers 100% 100% 100% 100% 100% 100% Pt Nafion Ionomer Pt 99.9% 98.5% Anode Ink 99% 98.5% Cathode Ink 99.9% 98.5% 100% 100% Purchased GDL Anode Side Catalyst Layer 99% 98.5% Membrane Processes 99% 98.5% Cathode Side Catalyst Layer 100% 98.5% Hot Press Lamination Total Cost of Owership ($) 80,000 70,000 60,000 50,000 40,000 30,000 20,000 10,000 PEMFC Plug Hybrid Vehicle Full Battery Electric Vehicle 6.3% Balance of Stack 2.4% Seal 8.4% Bipolar Plate 26.1% Stack Assembly Stack Conditioning 2.7% Membrane 8.0% Electrode 41.0% Purchased GDL 100% 100% 0 3-Year TCO 5-Year TCO 10-Year TCO 15-Year TCO GDL 5.1% 2

4 Air (POX only) Nat. Gas Water NG line in To Vehicle Fuel Reformer H2 High Pressure Cascade Storage System CNG High Pressure Cascade Storage System Electrolyzer or SMR, High-Pressure Compressor Heat Catalytic Burner H 2 -rich gas Dispenser Security Fence H 2 -poor gas PSA 99.99% pure H 2 Underground Piping with shared conduit Fire Detector Covered Fueling Island Property of: TIAX LLC 1061 De Anza Blvd. Cupertino, CA Low Pressure Storage Flow cntrlr Fuel Station Perimeter Gaseous Fuel Dispensing Islands Task 5 CNG/Hydrogen Fueling 10 ft Vent Compressor with intercoolers Medium Pressure Storage Flow cntrlr Building Hydrogen and CNG fueling station High Pressure Storage Flow cntrlr SIZE DWG BY DWG NO REV A Stefan Unnasch B S SCALE 1" = 8 ft 5 Jan 2004 SHEET 1 OF 1 Cooling Tower Cold Water Anode Powder Prep Tape Cast Slip Cast Electrolyte Small Powder Prep Vacuum Plasma Spray Screen Print Slurry Spray Blanking / Slicing Sinter in Air 1400C Forming of Interconnect QC Leak Check Shear Interconnect Cathode Small Powder Prep Screen Print Vacuum Plasma Spray Slurry Spray Paint Braze onto Interconnect Sinter in Air Braze Finish Edges Approach Manufacturing Cost Modeling Methodology Combining performance and cost model will easily generate cost results, even when varying the design inputs. Conceptual Design Process Simulation Process Cost Calcs $10 $9 $8 Material Process $7 CO 2 H 2 O Wafer Cost ($) $6 $5 $4 $3 $2 $1 $0 apping CMP idation Coating g SiO2 ring Ni ering E Coating tepper ring Ag ripping Coating tepper g SiO2 RIE Si g SiO2 hing NI System layout and equipment requirements Energy requirements Equipment size/ specs Process cost Material cost Site Plans Capital Cost Estimates Product Costs Interconnect 80,000 70,000 PEMFC Plug Hybrid Vehicle Full Battery Electric Vehicle Anode Electrolyte Fabrication Cathode Total Cost of Owership ($) 60,000 50,000 40,000 30,000 20,000 Site Plan - Fueling Station Note: Alternative production processes appear in gray to the bottom of actual production processes assumed Stack Assembly 10, Year TCO 5-Year TCO 10-Year TCO 15-Year TCO Safety equipment, site prep, land costs High and low volume equipment costs Product cost (capital, O&M, etc.) 3

5 Approach Example Manufacturing Flow Chart The bottom-up cost approach will be used to capture accurately the manufacturing costs for each fabrication step. 100% 100% 100% 100% Viton Gasket 99% 95% Purchased GDL 99.9% 98.5% 100% 100% Sheet Metal Bipolar Plate 99% 95% 100% 100% Pt Anode Ink Anode Side Catalyst Layer 100% 100% Viton 99% 98.5% 100% 98.5% 100% 98.5% 99% 95% 99.9% 100% 99.5% 100% 100% 100% Nafion Ionomer 99% 98.5% Membrane Hot Press Die Cut Processes Lamination MEA Frame Seal Molding Stack Assembly Testing 99% 98.5% 100% 100% Pt Cathode Ink 99.9% 98.5% Cathode Side Catalyst Layer Purchased GDL 100% 100% Purchased Hardware BUY 100% 100% MAKE Process Yield Material Utilization MEA Continuous Fabrication Process Stack Fabrication Process True-value-mapping analysis virtualizes costs in each fabrication step, which breaks down costs into materials, labor, capex, utility, maintenance, etc. 4

6 Approach Manufacturing Cost Structure Austin Power Engineering s manufacturing cost models can be used to determine a fully loaded selling price to consumers at high or low volumes. Corporate Expenses Research and Development Sales and Marketing General & Administration Warranty Taxes Profit Sales Expense General Expense Fixed Costs Equipment and Plant Depreciation Factory Expense Consumer Selling Price Tooling Amortization Equipment Maintenance Utilities Building Indirect Labor Cost of capital Overhead Labor Direct Labor Manufacturing Cost Variable Costs Manufactured Materials Purchased Materials Fabrication Labor Assembly Labor Indirect Materials Direct Materials We assume 100% financing with an annual discount rate of 10%, a 10-year equipment life, a 25-year building life, and three months working capital YY 5

7 Approach Scope Our cost assessment includes a fuel cell system, an on-board H2 storage, and a hybrid battery pack which is for a middle size passenger vehicle. PEMFC System On-board H2 Storage Hybrid Battery 80 kw net Stack Membrane Electrode GDL/MPL Bipolar Plate Seal & Gasket Balance of Stack BOP Fuel Management Thermal Management Air Management Water Management Balance of System Control Board Valves & Sensors Fittings & Piping Wire Harness Others Assembly, QC, and Conditioning Type IV Composite Tank Fill Port High Pressure Regulator Valves & Sensors Fittings & Piping Assembly & Inspection Compressed Hydrogen Storage Li-Ion hybrid battery (40kW, 1.2kWh) PEM Fuel Cell System Li-Ion Battery Pack Fuel Cell Hybrid Electric Vehicle Power System 6

8 PEMFC System 80 kw net PEM Fuel Cell System Preliminary System Design The 80 kw net direct hydrogen PEM fuel cell system configuration was referenced in previous and current studies conducted by Argon National Laboratory (ANL). Key Parameters Stack 3M NSTFC MEA 25 µm supported membrane mg/cm 2 Pt Power density: 984 mw/cm 2 Metal bipolar plates Non-woven carbon fiber GDL Air Management Honeywell type compressor /expender Air-cooled motor / Air-foil bearing 80 kw net Fuel Cell System Schematic 1 25 W DMFC system configuration 1, 2 1. DOE Fuel Cell Technologies Program Record, Fuel Cell System Cost R. K. Ahluwalia, X. Wang, and R. Kumar, Fuel cells systems analysis, 2012 DOE Hydrogen Program Review, Washington DC, May 14-18, Water Management Cathode planar membrane humidifier with pre-cooler No anode humidifier Thermal Management Micro-channel HX Fuel Management Parallel ejector / pump hybrid 7

9 System Assumptions 80 kw net PEM Fuel Cell System Preliminary Design Based on ANL s stack performance analysis, we made the following system and material assumptions for the cost estimation. Stack Components Unit Current System Comments Production volume systems/year 500,000 High volume Stacks net power kw 80 DOE 2012 Stacks gross power kw 88 DOE 2012 Cell power density mw/cm DOE 2012 Peak stack temp. Degree C 87 DOE 2012 Peak stack pressure Bar 2.5 DOE 2012 System Voltage (rated power) Volt 300 DOE 2012 Platinum price $/tr.oz. $1,100 DOE 2012 Pt loading mg/cm DOE 2012 Membrane type Reinforced 3M PFSA Membrane thickness micro meter 25 GDL layer None-woven carbon paper GDL thickness micro meter kpa pressure MPL layer thickness micro meter 40 Bipolar plate type 76Fe-20Cr-4V with nitridation surface treatment Bipolar plate base material Thickness micro meter 100 Seal material Viton Pt price was $1,100/tr.oz. for the baseline, which was consistent with other DOE cost studies. 8

10 80 kw net PEMFC System Stack Membrane Configuration & Process We assumed a double-side dispersion coating process (US 2008/ ) to an eptfe-supported membrane process. eptfe 3M PFSA Supported Membrane Thickness (µm) Porosity (%) 95% - Bulk Density (g/cm 3 ) Material Cost $5/m 2 3M Ionomor:$80/lbs* * DOE FCTT feedback Unwind eptfe Film Unwind PP Film Splicer Splicer Guide Top eptfe Film Coating Guide Cartridge Coater Gauge Microwave Annealing / Dryer Cooling Gauge Quality Control Laminating Winding With Roll Changer Packaging Bottom eptfe Film Coating 9

11 80 kw net PEMFC System Stack Membrane Cost The reinforced 25 µm 3M PFSA membrane is estimated to cost ~$19/m 2 on an active area basis, with materials representing ~85% of the cost. Component Membrane Manufactured Cost 1 Material ($/m 2 ) ($/kg) Process ($/m 2 ) ($/kg) Film Handling $6.33 $ $0.34 $5.78 Coating $10.07 $ $0.44 $7.42 Drying & Cooling $0.00 $0.00 $1.98 $33.64 Quality Control $0.00 $0.00 $0.04 $0.60 Membrane Manufactured Cost ($19/m 2 ) Equipment & Tooling 4.7% Labor Cost 0.9% Capital Costs 7.0% Others 2.4% Laminating $0.00 $0.00 $0.05 $0.93 Packaging $0.03 $0.43 $0.03 $0.46 Subtotal $16.42 $ $2.87 $48.83 Total ($/m 2 ) ($/kg) 1 Manufactured cost on an active area basis or per kg of finished membrane basis (accounts for scrap and yield) 2 3M PFSA ionomer cost assumed to be $80/lb based on FCTT feedback. 3 eptfe cost assumed to be $5/m 2 Material Cost 85.0% 10

12 80 kw net PEMFC System Stack Electrodes Configuration & Process Organic whisker support was fabricated by physical vapor deposition (PVD) with vacuum annealing process. Catalysts were coated to this layer via vacuum sputtering process. Aluminum Coated Film Substrate Growing Whisker Layer Perylene Red PR-149 Pre-soak Phase I Pre-soak Phase II PVD Annealing Sputtering Sputtering Sputtering Sputtering Sputtering Pt Pt Pt Co Mn Using three Pt targets Pt Whisker Distribution 1 Nanostructured Thin Film Catalyst before transfer to a PEM 2 1 M. K. Debe, Advanced Cathode Catalysts and Supports for PEM Fuel Cells, DOE Merit Review, May M. K. Debe, Durability Aspects of Nanostructured Thin Film Catalysts for PEM Fuel Cells, ECS Transactions, 1(8) (2006) 11

13 80 kw net PEMFC System Stack Electrodes Cost The 2012 electrode cost estimate of $86/m 2 which was dominated by Platinum price. We have assumed Pt price to be $1,100/tr.oz. or $35.4/g. Manufactured Cost Anode 1 ($/m 2 ) Cathode 1 ($/m 2 ) Total 1 ($/m 2 ) Material $25.97 $50.33 $76.30 Capital Cost $1.79 $2.94 $4.73 Labor $0.16 $0.19 $0.35 Tooling $1.18 $1.75 $2.93 Other 2 $0.53 $0.76 $1.29 Total $29.63 $55.97 $85.60 Electrode Manufactured Cost ($86/m 2 ) Captial Cost 5.5% Labor Cost 0.4% Tooling & Equip. 3.4% Others 1.5% 1 m 2 of active area 2 Other costs include utilities, maintenance, and building Material Cost 89.1% 12

14 80 kw net PEMFC System Stack GDL + MPL Configuration & Process We cost a non-woven carbon paper GDL with MPL based on discussions with formerly Ballard Material Products on their AvCarb GDS3250 for automotive applications. Material Pressure (kpa) Bare GDL GDL with PTFE Treatment GDL with PTFE Treatment + MPL Thickness (µm) Porosity (%) % 88% 80% Areal Weight (g/m 2 ) Materials Carbon Fiber loading: 15 /m 2 10 wt% PTFE; PTFE loading: 15 g/m 2 Ink/Resin loading: 25 g/m 2 4 g/m 2 Carbon black loading: 16 g/m 2 Mixing Carbon Fiber Solution Carbon Paper Making Ink/Resin Impregnation In Line Inspection Oxidation Carbonization Inspection MPL Metering Coating (2 wet layers) Hydrophobic Treatment In Line Inspection Graphitization Mixing MPL Solution Mixing PTFE Solution 13

15 80 kw net PEMFC System Stack GDL + MPL Costs The non-woven carbon paper GDL (for both anode and cathode) cost about $12/m 2, on an active area basis. Manufactured Cost 1 GDL ($/m 2 ) GDL (Anode + Cathode) ($/m 2 ) Material $0.88 $1.76 Capital Cost $1.86 $3.71 GDL Manufactured Cost ($12/m 2 ) Others 16.0% Material Cost 15.0% Labor $0.31 $0.63 Tooling $1.88 $3.76 Other 2 $0.94 $1.88 Total $5.87 $11.73 Equipment & Tooling 32.0% Capital Costs 31.7% 1 Manufactured cost on an active area basis 2 Other costs include utilities, maintenance, and building Labor Cost 5.4% 14

16 80 kw net PEMFC System Stack MEA Assembly Process The anode and cathode organic whisker layers were hot pressed to the membrane with Teflon backing sheets. GDL layers were laminated to the coated membrane and were formed an MEA in roll good form. The MEA was cut into sheets and molded with a frame seal. Anode Side Teflon Sheet Anode Side Anode Side GDL Catalyst Layer Membrane Hot Press Peel PTFE Hot Press Die Cut Mold Lamination Sheets Lamination MEA Frame Seal Cathode Side Teflon Sheet Cathode Side Cathode Side GDL Catalyst Layer Batch Process Continuous Process 15

17 80 kw net PEMFC System Stack MEA + Frame Seal Costs The MEA with frame seal together were estimated to cost about $128/m 2. Manufactured Cost 1 Material - Membrane - Electrode - GDL MEA ($/m 2 ) Frame Seal ($/m 2 ) $6.07 MEA & Seal Manufactured Cost ($128/m 2 ) Tooling & Equip. 7.1% Labor 1.9% Others 3.4% Capital Cost $9.80 $1.71 Labor $1.15 $1.24 Captial Cost 9.0% Tooling & Equipment $7.60 $1.46 Other 2 $3.63 $0.70 Subtotal $ $11.17 Total Manufactured cost on a per m 2 of active area basis 2 Other costs include utilities, maintenance, and building 3 Active area to Total area ratio reduced from 85% to 75%, based on feedback from OEMs and FCTT Material 78.7% 16

18 80 kw net PEMFC System Stack Thermal Nitrided Metal Bipolar Plate The metal bipolar plate cost was based on discussions with ORNL on their thermal nitriding process 1 for specific alloys, e.g. Fe-20Cr-4V. Anode Side 0.65 mm Parameter Specifications Base Material Thickness (mm) 0.1 Coolant Channel Cathode Side 1.00 mm 0.35 mm 0.35 mm 0.9 mm Base Material Base Material Surface Treatment 76Fe-20Cr-4V Pre-oxidation + Thermal Nitridation # of Tiles in a Pair of Bipolar Plate 2 Cooling Channel Yes Joint Method Spot + Edge Laser Welding Fe 20 Gr 4 V Foil 100 micro meter Assume $5/lbs Stamping Half Plate Laser Welding Whole Plate Thermal Nitridation 4 Seven-Stage Progressive Die 2,3 1. Nitrided metallic bipolar plates, M.P. Brady, et al., ORNL, DOE Merit Review presentation, May US (Hitachi) 3. Discussion with Minster Press Inc., April Preferential thermal nitridation to form pin-hole free Cr-nitrides to protect proton exchange membrane fuel cell metallic bipolar plates, M.P. Brady, et al., Scripta Materialia 50 (2004)

19 80 kw net PEMFC System Stack Thermal Nitrided Metal Bipolar Plate Cost The cost of the nitrided Fe-20Cr-4V metal bipolar plates was estimated to be ~$57/m 2 or ~$6/kW. Component Bipolar Plate Manufactured Cost 1 ($/m 2 ) Material Process Bipolar Plate Manufactured Cost 2 ($/kw) Material Process Stamping $25.02 $11.06 $2.78 $1.23 Laser Welding $0.00 $8.73 $0.00 $0.97 Nitridation $0.00 $ $1.39 Subtotal $25.02 $32.26 $2.78 $3.58 Total $57.28 $6.36 Equipment & Tooling 16.3% Bipolar Plate Manufactured Cost ($57/m 2 ) Labor Cost 11.7% Others 10.5% Material Cost 43.7% Capital Costs 17.8% 1 Manufactured cost on an active area basis 2 Manufactured cost on a kw net basis As a based material, Fe-20Cr-4V is a specialty metal and could have higher price than the conventional base materials, such as SS316, etc. 18

20 80 kw net PEMFC System Stack Gasket Cost The cost of the gasket was estimated to be ~$7/m 2. Manufactured Cost 1 Gasket ($/m 2 ) Material $0.62 Capital Cost $1.93 Gasket Manufactured Cost ($7/m 2 ) Others 17.2% Material Cost 9.0% Labor $1.26 Tooling $1.86 Other 2 $1.18 Total $6.85 Equipment & Tooling 27.1% Capital Costs 28.2% 1 Manufactured cost on an active area basis 2 Other costs include utilities, maintenance, and building Labor Cost 18.5% Transfer molding was used to fabricate the seals between the MEA and bipolar/cooling plate. The seal material is Viton which costs ~$20/lb. 19

21 80 kw net PEMFC System Stack Cost The 80 kw net PEM fuel cell stack cost $24/kW. Electrodes, bipolar plates, and membranes were the top three cost drivers. Stack Components Stack Manufacturin g Cost ($/kw) Comments Membrane $2.14 PFSA ionomer ($80/lb) Electrode $9.51 3M NSTFC GDL Bipolar Plate $1.30 $6.36 No-Woven carbon paper Nitrided metallic plates Seal $2.00 Viton BOS $0.55 Manifold, end plates, current collectors, insulators, tie bolts, etc. Final Assembly $1.40 Robotic assembly Stack 2 Hours Conditioning 0.60 Total stack kw net PEM Fuel Cell Stack Cost ($23.9/kW kw net ) Stack Conditioning Stack Assembly 2.5% Membrane 5.8% Balance of Stack 9.0% 2.3% Seal 8.4% Bipolar Plate 26.7% GDL 5.5% Electrode 39.9% 1. Stack assembly cost category included MEA assembly and stack QC; QC included visual inspection, and leak tests for fuel, air, and coolant loops. 2. Results may not appear to calculate due to rounding of the component cost results. 20

22 80 kw net PEMFC System BOP Water Management System Cost The water management system OEM cost 1,2 was projected to be $128. Component Cathode Planar Membrane Humidifier Factory OEM Cost 1 Cost R. K. Ahluwalia and X. Wang, Automotive Fuel Cell System with NSTFC Membrane Electrode Assemblies and Low Pt Loading, July 21, High-volume manufactured cost based on a 80 kw net power PEMFC system. Does not represent how costs would scale with power (kw). 3 Assumes 15% markup to the automotive OEM for BOP components The cathode planar membrane humidifier cost was estimated using bottom-up costing tools. 21

23 80 kw net PEMFC System BOP Thermal Management System Cost The thermal management system OEM cost 1,2 was projected to be $404. Component Factory Cost 1 OEM Cost 1,2 HT Radiator LT Radiator Air Precooler - 20 HT/LT Radiator Fan - Motor - Fan HT Coolant Pump - Motor - Pump LT/Air Precooler Coolant Pump Other - 5 Total High-volume manufactured cost based on a 80 kw net power PEMFC system. Does not represent how costs would scale with power (kw). 2 Assumes 15% markup to the automotive OEM for BOP components Radiator Structure US Patent 7,032,656 The air precooler, radiator fan, coolant pumps, and their motors were assumed to be purchased components; hence their price included a markup. 22

24 80 kw net PEMFC System BOP Fuel Management System Cost The fuel management system OEM cost 1,2 was projected to be $382. Component Factory Cost 1 OEM Cost 1,2 H 2 Blower H 2 Ejectors - 20 H 2 Demister - 61 Solenoid Valves - 23 Purge Valve Check valve 9 10 Total Parker Hannifin Brochure for Model 55 Univane Compressor 1 High-volume manufactured cost based on a 80 kw net power PEMFC system. Does not represent how costs would scale with power (kw). 2 Assumes 15% markup to the automotive OEM for BOP components The H 2 ejectors, H 2 demister, and solenoid valves were assumed to be purchased components; hence their price included a markup. 23

25 80 kw net PEMFC System BOP Air Management System Cost The air management system OEM cost 1,2 was projected to be $936. Component Factory Cost 1 OEM Cost 1,2 CEM (Compressor, Expander, Motor, Motor Controller Air demister Air/H 2 mixer - 27 Flow orifice - 5 Air filter - 4 Total High-volume manufactured cost based on a 80 kw net power PEMFC system. Does not represent how costs would scale with power (kw). 2 Assumes 15% markup to the automotive OEM for BOP components CEM: Honeywell, DOE Program Review, Progress Report & Annual Report, 2005 The air demister, air/h 2 mixer, flow orifice, and air filter were assumed to be purchased components; hence their price included a markup. 24

26 80 kw net PEMFC System System Cost The 80 kw net PEM fuel cell system cost $53/kW at the mass production volume. Stack, air management, and thermal management were the top three cost drivers. System Components System Manufacturing Cost ($/kw) Comments Stack $23.87 Water management Cathode side humidifier, $1.6 etc. Thermal management $5.0 HX, coolant pump, etc. Air management $10.1 CEM, etc. Fuel management $4.8 H2 pump, etc. Sensors, controls, wire Balance of system $3.9 harness, piping, etc. System assembly $3.9 Total system 1, 2 $ kw net PEM Fuel Cell System Cost ($4,256/system) Balance of System 7.3% Fuel Management 9.0% Air Management 19.0% System Assembly 7.4% Thermal Management 9.5% Water Management 3.0% Stack 44.8% 1. Assumed 15% markup to the automotive OEM for BOP components 2. Results may not appear to calculate due to rounding of the component cost results. The 80 kw net direct hydrogen PEM fuel cell system cost $4,256 at the mass production volume. 25

27 Compressed H2 Storage System Configuration The 5,000 PSI type IV compressed hydrogen tank design was referenced in studies TIAX conducted on hydrogen storage 1, 2. Filling Station Interface Refueling Interface Check Valve in Fill Port Fill System Control Module Temperature Transducer Pressure Transducer Pressure Relief Device Ball Valve Solenoid Valve (Normally Closed) Pressure Relief Valve Primary Pressure Regulator Check Valve *Schematic based on both the requirements defined in the draft European regulation for Hydrogen Vehicles: On-board Storage Systems and US Patent 6,041,762. Compressed Hydrogen Storage System Schematic 1, 2 Compressed Gaseous Hydrogen Tank Hydrogen Line Data & Comm. Line In-Tank Regulator Hydrogen Line to Fuel Control Module** Data & Comm. Line to Fuel Cell Stack **Secondary Pressure Regulator located in Fuel Control Module. Key Parameters System Pressure: 5,000 PSI Single Tank Design Usable H2: 5.6 kg Safety Factor: 2.25 Tank Carbon Fiber: Toray T700S Carbon Fiber Cost: $12/lbs Carbon Fiber / Resin Ratio: 0.68 : 0.32 (weight) Translational Strength Factor: 81.5% Fiber Process: Filament Winding Liner: HDPE Pressure Regulator In-tank 1. E. Carlson and Y. Yang, Compressed hydrogen and PEM fuel cell system, Fuel cell tech team freedomcar, Detroit, MI, October 20, S. Lasher and Y. Yang, Cost analysis of hydrogen storage systems - Compressed Hydrogen On-Board Assessment Previous Results and Updates for FreedomCAR Tech Team, January, 2007 The single tank design had a usable hydrogen storage capacity of 5.6 kg. 26

28 Compressed H2 Storage System Specification Assumptions for the hydrogen storage tank design were based on the literature review and third-party discussions. Stack Components Unit Current System Comments Production volume systems/year 500,000 High Volume Usable hydrogen Kg 5.6 Recoverable H2 in the tank IV With HDPE liner Tank type IV With HDPE liner Tank pressure PSI 5,000 # of tanks Per System 1 Safety factor 2.25 Tank length/diameter ratio 3:1 Carbon fiber type Toray T700S Carbon fiber cost $/lbs 12 Carbon fiber vs. resin ratio 0.68:0.32 Weight Carbon fiber translational 81.5% Strength factor Damage resistant outer layer material S-Glass S-Glass cost $/lbs 7 Impact resistant end dome material Rigid Foam Rigid foam cost $/kg 3 Liner material HDPE Liner thickness Inch 1/4 In tank regulator cost $/unit 150 Could be replaced by cheaper E-glass 27

29 Compressed H2 Storage System Manufacturing Process A vertically integrated manufacturing process was assumed for the tank and BOP components. Major Tank Components Aluminum End Boss HDPE liner Carbon fiber composite layer Glass fiber composite layer End domes (rigid foam) Major BOP Components In-tank primary pressure regulator Valves & sensors Filling interface Pressure release devices Piping & fitting HDPE Gel Carbon Fiber Al Stock Boss Machining Liner Molding Pressure liner Liner Surface Gel Coat CF PrePreg Filament Winding Cure / Cool down Ultrasonic Inspection Final Inspection BOP Assembly Dimension Weight Inspection Pressure Test End Domes Assembly Cure / Cool down Glass Fiber Out Layer Winding BOP Rigid Glass Components Foam Fiber 28

30 Compressed H2 Storage System Cost In the 5,000 PSI baseline system, the carbon fiber composite layer was the dominant cost driver. System Components 2012 System Manufacturing Cost ($/kwh) Comments Hydrogen kg H2 Pressure Tank Liner - Carbon fiber layer - Glass fiber layer Pre-preg carbon fiber cost $36/kg - Foam Primary pressure regulator 0.80 In-tank design Valves & sensors valves, 1 temperature sensor, 1 pressure sensor Fill port 0.43 Fittings, piping, safety device, Pressure relive valve, burst 0.64 etc. valve, etc. Assembly & inspection 0.88 Including pressure test Total system CH2 Storage System Cost ($3,028/system) Valves & Sensors 5% Fill Port 3% Regulator 5% Glass Fiber Composite 4% Pipe & Fitting 4% Others 8% Carbon Fiber Composite 71% The 5,000 PSI compressed hydrogen storage tank system cost $3,058 at the mass production volume. 29

31 PEMFC Hybrid Energy Storage Lithium-ion Battery Pack A lithium-ion battery pack will provide hybridization of a fuel cell vehicle which will improves fuel economy as well as having the function as a startup battery. Battery Management Systems (BMS) Low Voltage Monitorin g High Voltage System Lithium-ion Battery Pack Battery Modules Thermal Management System BOP Key Parameters System Power: 40 kw Energy capacity: 1.2 kwh usable Power to energy ratio: 33:1 Percent SOC: 80% Fade: 20% Cell Cell format: Pouch cell Cathode active Material: manganese spinel Anode active material: graphite Battery Cells 2 1. US patent US patent

32 PEMFC Hybrid Energy Storage Battery Pack Manufacturing Strategy A vertically integrated manufacturing process was assumed for the four-level battery pack fabrication: electrode, cell, module, and pack. Electrodes Cells Modules Packs 31

33 PEMFC Hybrid Energy Storage Battery Pack Cost The lithium-ion battery system cost $862 /kwh. Battery management system and packaging have higher cost contributions. Cost Category Cell Cost ($/cell) Pack Cost ($/pack) Material $7.88 $775 Labor $1.51 $ Equipment & tooling $1.38 $48.03 Utility $0.79 $26.76 Labor 11% Battery System Cost ($862 /kwh) Utility 3% Capex 5% Maintenance 2% Capital 4% building 0% Maintenance $0.67 $23.79 Capital cost $1.18 $37.85 Building $0.15 $5.72 Total $13.56 $1, Materials & Purchased Components 75% Total ($/kwh)* $ $ * Based on usable energy (1.88 kwh x 0.8 x0.8 = 1.2 /kwh ) The 1.2 kwh lithium-ion battery system cost $1,034 per pack at the mass production volume. 32

34 Conclusion The overall PEM fuel cell system, onboard hydrogen storage, and hybrid battery costs are approximately $8,318 per vehicle. $3,028/System Compressed Hydrogen Storage $4,256/system PEM Fuel Cell System Li-ion Battery Pack 13% $1,034/system Li-Ion Battery Pack Compressed Hydrogen Storage System 36% PEM Fuel Cell System 51% The mass production manufacturing cost of the 80 kw net PEMFC stack was estimated to be $23.8/kW. The mass production OEM cost of the 80 kw net PEMFC system was estimated to be $53.2/kW The 5.6kg compressed on-board hydrogen storage system was estimated to be $16.4/kWh at the mass production. The hybrid lithium-ion battery (40kW, 1.2kWh) costs $1,034 per pack. 33

35 Thank You! Contact: Yong Yang Austin Power Engineering LLC 2310 W 9 th ST #1, Austin TX yang.yong@austinpowereng.com 34