The 21 st Century Truck Partnership Fuel Cell Technologies for Auxiliary Power Jud Virden Pacific Northwest National Laboratory Ken Howden U.S Department of Energy Alternatives to Truck Engine Idling Workshop, Des Moines, Iowa, June 22, 2004
21 st Century Truck: A Government-Industry Research Partnership DOE / EE FreedomCAR and Vehicle Technologies DOT / RSPA Intelligent Vehicle and Highway Safety R&D UNITED STATES ENVIRONMENTAL PROTECTION AGENCY EPA / OTAC Vehicle Emissions Regulations DOD / Army TACOM NAC Military Vehicle R&D 2
21CTP Technology goals focus on key areas for medium & heavy duty vehicles Engine Systems Heavy-Duty Hybrids Parasitic Losses Idle Reduction Safety Develop new engine combustion regimes in conjunction with new advanced fuels. Advance the state of heavy-duty hybrid R&D, a subject of interest for both military (Department of Defense) and commercial applications. Minimize parasitic energy losses to improve vehicle efficiency. Advance idle reduction technologies (in collaboration with the Environmental Protection Agency). Strengthen the safety and security of heavyduty vehicles carrying the nation s goods (in collaboration with the Department of Transportation). Support Research, Development and Demonstration 3
Reduce Parasitic Losses in Class 8 Trucks 21 st Century Truck Partnership Goals Demonstrate 20% reduction in heavy vehicle drag coefficient by 2012 Demonstrate 50% reduction in essential auxiliary power loads on heavy vehicle by 2012 Validate 15-20% weight reduction in Class 8 tractor-trailer through materials optimization 4
Auxiliary Power Requirements 21 st Century Truck Technology Roadmap TABEL I Potential Electrical Loads Power Required Small Truck HVAC, coolant pump, water pump, starter, oil pump, 1-5kW compartment fans, catalyst heater, valve control, direct injection, electric suspension, computer, communications, electric power steering, heated windshield, lights, etc. Power site equipment (compressor, lights, etc.) 5kW Medium Truck HVAC, lights, coolant pump, starter, oil pump, water 1-5 kw pump, compartment fans, computer, communications, lights, heated windshield, etc Transit Bus HVAC, lights, communications, lights, coolant pumps, 30-40 kw air compressor, hydraulic pump/power steering, doors, multiplex system, fuel pumps starters, oil pump, water pump, compartment fans, computer, communications Vocational Base electrical loads, lights, HVAC, battery charging, 1-5 kw communication, computer, Power for task at Idle (I.e., mixer, pumps, lifts, etc.)? Tractor Trailer Base electrical loads, lights, battery charging, 1-3 kw communication, computer, Hotel loads: (engine& fuel heating lighting, HVAC, 3-5KW computer, appliances) Full truck electrification; all of the above plus, water and 5-15 kw oil pumps, starter, cooling fans, transmission and hydraulic system, brake compressors, fuel and air handling systems Trailer refrigeration, other external power up to 30 kw 5
Heavy Truck Power Requirements Average Load Max. Load Accessory Type (kw) (kw) Electrical Accessories 0.7 1.0 Air Compressor 2.3 6.0 AC Compressor 2.2 4.5 Engine Cooling Fan 1.1 22.0 Power Steering 0.8 7.5 TOTAL 7.1 41.0 SAE J1343 Revised Aug 2000 6
Annual U.S. Emissions Saved Using APUs in Class 8 Trucks (vs. Idling) (Source: ANL/ESD-43, 2001) Diesel fuel saved: - 419 million gallons/yr CO 2 reduced: - 4.64 million tons/yr Assumes: - 2.1 million Class 8 trucks - 311,000 have overnight routes (APU candidates) 7
Modular HVAC Variable speed compressor more efficient and serviceable 3X more reliable compressor no belts, no valves, no hoses leakproof refrigerant lines instant electric heat Truck Electrification Starter Generator Motor Beltless engine product differentiation improve systems design flexibility more efficient & reliable accessories Shore Power or Inverter Supplies DC Bus Voltage from 120/240 Vac 50/60 Hz Input Supplies 120 Vac outlets from battery or generator power Auxiliary Power Unit Supplies DC Bus Voltage when engine is not running fulfills hotel loads without idling main engine overnight Down Converter Supplies 12 V Battery from DC Bus Compressed Air Module Supplies compressed air for brakes and ride control Electric Oil Pump Higher reliability variable speed Packaging flexibility Electric Water Pump Higher reliability variable speed faster warm-up less white smoke lower cold weather emissions 8
21 st Century Truck Partnership Goals Develop and demonstrate 5-30 kw fuel cell APUs that use multiple fuels and operate at > 35% efficiency for under $400/kW by 2012 Develop new codes and standards for electrification of trucks and truck stops Applications include: Idle Reduction Truck Electrification Refrigeration Units Solid Oxide Fuel Cell Identified as best longer-term option 9
Heavy Vehicle Fuel Cell APU Specifications Long-Haul Heavy Vehicle APU APU power, 3-30kW Weight: 110 lbs, 5kW Size: 50 liters(13 gallons), 5kW Operates on diesel fuel tolerates 15 ppm sulfur in fuel 20,000 hr life 2000 cold starts <$400/kW ($2000 for 5kw) When will there be a Fuel cell that can meet these Initial targets? Now? 2005? 2010? 2015?? 10
Fuel Cells Fuel cells convert fuel energy into electrical energy electrochemically High efficiency 40%-60% Little or no pollution Only byproduct is water and heat Utilize multiple fuels Quite 11
Fuel Cells Solid Oxide Fuel Cells SOFC Operate at 700-1000 o C Utilize H 2 and CO as fuel High efficiency with reformed fuel Planar design has potential to reach $400/kW New technology Slow start up times Transportation reliability & durability unproven >$10,000/kW prototype Proton Exchange Membrane PEM Operates at approx. 90 o C Requires relatively pure H 2 High efficiency with pure H 2 Fast start-up times Cold weather issues 10 years in development Fuel cells integrated into vehicles and being tested on the road $3000 kw current cost 12
Solid Oxide Fuel Cell Basics 13
Simple Fuel Cell System Fuel Air Hydrogen Fuel Reformation Storage hydrogen CO 2,CO Fuel Cell Electric Power Utilizes air/hydrogen Produces only water Promise of high conversion efficiency Spent Fuel Combustor and Heat Exchanger Exhaust 14
Fuel Cell Vehicle World Survey 2003 Breakthrough Technology Institute, February 2004 Last 10 years fuel cells have progressed from research novelties to prototype and demonstration models. 300 light duty fuel cell vehicles built and operated world-wide(also investigating APU) 11 major industry/government partnerships worldwide. Estimates > $1B have been invested world-wide 20 major companies developing light duty vehicles and components Commercialization to ramp up by 2010. High volume by 2015-2020. 15
Fuel Cell Buses 65 Fuel Cell buses being operated world-wide Nearly all are PEM powered(90kw>200kw) Most powered by compressed hydrogen stored in high pressure tanks on roof of bus Prototype buses have run tens of thousands of miles. Evaluating performance in revenue service, maintenance costs, reliability and durability Cost are high, reliability and durability improvements required Government support for public buses 16
Solid Oxide Fuel Cell Efforts World Wide USA Siemens Westinghouse Delphi / BMI General Electric Cummins / SOFCo Fuel Cell Energy Acumentrics Franklin Fuel Cells TMI Ztek Europe: Haldor Topsoe (Denmark) Sulzer (Switzerland) Rolls-Royce (UK) Cere Power (UK) Australia: CFCL Japan Mitsubishi Heavy Industries Mitsubishi Materials Tokyo Gas TOTO 17
DOE Solid State Energy Conversion Alliance 2005 $800/kilowatt Prototypes: 3-10 kilowatts Six industrial teams: Delphi Cummins/McDermott Honeywell Siemens Westinghouse Power Corp. Acumentrics FuelCell Energy 2010 $400/kilowatt Commercial applications 2015 FutureGen Plants 70-80% efficient Generate electricity and hydrogen Sequester greenhouse gases Operable on gasified coal Transportation <$200/kW 18
Fuel Cell for Heavy Vehicle Applications Cummins Power Generation International Truck & Engine SOFC Holding LLC Delphi Volvo Truck North America PACCAR Ida Tech,LLC(PEM) Donaldson Company Toro Company University California, Davis Accumentrics NAC, SwRI Cummins Peterbilt Freightliner(PEM) University of California, Davis PEM, hydrogen 19
Freightliner, UC Davis SAE 2000-01-3488, C.J. Brodrick, S.W. Gause III, et. al. (PEM) fuel cell stacks in series to generate up to 30 volts DC. An 1800 watt inverter is available to convert this to 1.4 kw at 110/120 volts AC. The hydrogen is stored in a 52 gallon tank at 2500 psi. The prototype truck is capable of outputting 1.4 kw for 24 hours on a single 52 gallon tank of hydrogen. The current system weighs approximately 100 lbs. 20
Accumentrics 5kW APU National Automotive Center, Sunline,Cummins, Dynatec Industries,General Dynamics,Michelin, Peterbilt 21
Delphi Automotive Systems Note: New GEN 3 design is 132 gram/repeat unit compared to Gen2 s 375 grams 22
ReforWER Hot-Zone Module (HZM) Flat plate reformer Interlayered with anode tail gas combustors (Waste Energy Recovery) Integrated Stack Module Two 30-cell stacks in series Fuel/Air Prep & Start Burner 0.7V/cell x 60 =42 Volts Cathode Air Preheat Heat Exchangers Integrated Component Manifold Stack is started up by heating with cathode air 23
Cummins Power Generation, SOFCo 24
PEM Fuel Cell APU PEM are most advanced fuel cells for prime mover transportation applications To be successful for Class 8 heavy vehicle APU applications, PEM must operate on diesel fuel Requires breakthrough on diesel reforming and carbon monoxide clean-up Size, cost, reliability and durability 25
SOFC Fuel Cell APU SOFC are still in the laboratory & prototype stage Tremendous progress has been made in last 5 years Future efforts will focus on: increased power density reduced fabrication & manufacturing cost long-term operation on diesel fuel reformate transportation reliability & durability Must get volume up across multiple markets to get cost down 26