Hydrogen Fuel Cells for Heavy Duty, Road and Rail Applications Future Powertrain Conference 2019 Guy Bates, Consultant - Low Carbon Transport guy.bates@e4tech.com 27 February 2019 Strategy Energy Sustainability
E4tech perspective: Strategy Energy Sustainability International consulting firm, offices in UK and Switzerland Focus on sustainable energy, including electrified vehicles 21 years old this year, always independent Deep expertise in technology, business and strategy, market assessment, techno-economic modelling, policy support A spectrum of clients from start-ups to global corporations E4tech s annual Fuel Cell Industry Review www.fuelcellindustryreview.com 2
Drivers for hydrogen National policy and decisions by local authorities Paris Low Emission Zones Remove diesels by 2025 Discount on car sharing; free bike sharing and public transportation Financial support to replace petrol or diesel commercial vehicles London Low Emissions Zone (LEZ); not met EU Air Quality targets hence Central London Ultra LEZ in 2019 Pollution charge: pre- Euro 4 vehicles Single deck buses to be ZE (FC or BEV) by 2020 Double deck ZEV by 2025 Birmingham Clean Air Zone (CAZ) expected in 2020 FC bus fleet and refuelling station EV and LPG taxi initiatives Birmingham Cycle Revolution: 5% of trips 2023 Creation of Green Travel Districts Strong measures to decarbonise transport drives a mix of technologies, including hydrogen Focus is on passenger cars and heavy duty; non-road mobile machinery may not be exempt 3
Fuel cells offer EV benefits Favour heavy duty applications Fuel must be decarbonised: hydrogen or electricity Fuel cell power decouples from hydrogen energy unlike batteries Hydrogen has a higher energy density Benefit from EV acceleration and regeneration Neither very hot nor cold conditions strongly affect performance Hydrogen fuelling is fast; the model is familiar to oil companies and service station providers Source: Hydrogen Council 1 (2017) Battery-hydrogen hybrid to ensure sufficient power 2 Split in A- and B-segment LDVs (small cars) and C+-segment LDVs (medium to large cars) based on a 30% market share of A/B-segment cars and a 50% less energy demand 4
Heavy duty truck example An equivalent powertrain comparison Diesel Hydrogen truck 2 (FCET) Battery Electric Truck 3 (BET) Tank size 80 Gallons 60 kg H2 320kWh Additional powertrain cost - <$100,000 4 >$100,000 3 Additional powertrain weight - <2000 4 kg >2,500 4 kg Range per fuelling ~900 1 km ~480 2 km ~190 1,3 km Refuelling interval <1 /day 1-2/day Multiple times a day Refuelling time 5 minutes ~20 minutes [40 minutes] ~1 hour minimum (depends on charger) [5 hours] Batteries can t do it all A typical haulage daily run, 800km, a FCET will refuel in 40 minutes, most similar to diesel (1) Based on figures from Analysis of long haul battery electric trucks in EU - 2018 (2) Based on Toyota s Beta prototype. Refuelling @ 2.63 kg H2/min and 60 kg tank (DOE, 2015). (3) Based on the Nikola ONE & https://www.arb.ca.gov/msprog/actruck/docs/hdbevefficiency.pdf (4) Based on figures from H2FC Supergen conference 2019 5
Heavy duty truck example Current and future hydrogen refuelling price Initially, fuel costs will be relatively high Hydrogen costs can approach fossil fuel parity with high utilisation electrolysers and cheap renewable electricity, (other options exist) Hydrogen fuel cell truck Diesel Tank: 40 kg H2 Range: 380 1 km Current price: 10/kg H2 Industrial SMR scale price: 2/kg H2 Fills per duty cycle: 2.1 840 per duty cycle w/current prices 168 per duty cycle w/future industrial prices Tank: 80 gallons Range: 900 km Price: diesel in UK 2019 ~ 1.30/Litre. Fills per duty cycle: 0.9 350 per duty cycle (1) Based on Toyota s project portal - Alpha prototype. 6
Fuel cells are scalable and modular Offer initial design flexibility PEM fuel cells are preferred for transport applications, and use hydrogen A fuel cell - Multiple repeated layers sandwiched together to provide the right power Stacks are optimised for a particular operation e.g. Toyota Mirai stack (370 cells, 114kW) Reasonable sales are required for economical production e.g. Toyota expecting 30,000 units by 2020 Several stacks can be integrated in series for higher power PEM fuel cell assembly Toyota Mirai fuel cell stack Information and images from Toyota Global Newsroom - https://newsroom.toyota.co.jp/en/corporate/23722307.html 7
Case study Project Portal Alpha & Beta Bespoke fuel cell design would have been costly Two Mirai fuel cell stacks power the truck 12kWh battery, 500kW and 1,796Nm torque 10 more Beta prototype semi-trucks for drayage in California Gross weight capacity is more than 36.2 tonnes and Beta s estimated driving range is >480km per fill Consistent operating routes allow for straightforward refuelling In excess of 10,000 miles of operation achieved already Information and images from Toyota Global Newsroom - https://newsroom.toyota.co.jp/en/corporate/23722307.html 8
Further examples Buses, trains, ships and more trucks Buses Availability is improving Costs are reducing Europe is leading, Asia is set to overtake ICE commonality - 10-15 min refuelling, 300-450km range Marine Continues the trend for fuel cells in heavy duty applications Ferries for short distance Power for hotel loads Different fuels for different technologies Trains Passenger trains are now in operation in Germany; more are on order UK and other nations are showing interest An alternative to overhead electric lines or diesel power, they have a 1000km range More trucks! 800 Nikola Tre orders by Anheuser Busch 1000 Hyundai orders for Swiss supermarkets (for tax benefit) Stack power of 30kW in China is designed around the subsidy sweet-spot; increase to 60kW Information and images from the 2018 Fuel Cell Industry Review - http://www.fuelcellindustryreview.com/ 9
In summary An energy system transition is coming Heavy duty and off-highway is a major contributor to emissions and air quality problems Batteries can t do it all. Fuel cells offer EV benefits and a comparable operation of duty cycle Hydrogen fuel costs are able to reach parity with fossil fuels Technology costs are dropping, and the modular and scalable nature of fuel cells gives flexibility Heavy-duty hydrogen fuel cell examples across the sector A realistic, zero emission solution 10
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