Upload
others
View
0
Download
0
Embed Size (px)
Citation preview
Technology Validation: Fuel Cell Bus Evaluations
Leslie Eudy National Renewable Energy Laboratory June 19, 2014
Project ID# TV008
This presentation does not contain any proprietary, confidential, or otherwise restricted information.
2
Overview
• Project start date: FY03 • Project end date: 10/2014*
• A. Lack of current fuel cell vehicle (bus) performance and durability data
• C. Lack of current H2 fueling infrastructure performance and availability data
FY13 DOE funding: $300K Planned FY14 DOE funding: $300K Total DOE project value (pre-FY2013): $2.577 M (11 yr) Additional funding: DOT/Federal Transit Admin. and CARB
Timeline
Budget
Barriers
• Transit Fleets: Operational data, fleet experience
• Manufacturers: Vehicle specs, data, and review
• Fuel providers: Fueling data and review
Partners
*Project continuation and direction determined annually by DOE.
3
Relevance • Validate fuel cell electric bus (FCEB) performance and cost compared to
DOE/DOT targets and conventional technologies • Document progress and “lessons learned” on implementing fuel cell systems in
transit operations to address barriers to market acceptance
Current Targets* Units 2016 Target Ultimate Target
Bus lifetime Years / miles 12/500,000 12/500,000
Powerplant lifetime Hours 18,000 25,000
Bus availability % 85 90
Roadcall frequency (Bus/fuel cell system)
Miles between road call 3,500/15,000 4,000/20,000
Operation time Hours per day/ days per week 20/7 20/7
Maintenance cost $/mile 0.75 0.40
Fuel economy Miles per diesel gallon equivalent 8 8
* Fuel Cell Technologies Program Record # 12012, Sep 2012, www.hydrogen.energy.gov/pdfs/12012_fuel_cell_bus_targets.pdf
4
Approach Data Collection/Analysis • NREL 3rd Party
analysis uses standard protocol for collecting existing data from transit partners
• Includes comparisons to conventional technology buses in similar service (diesel, CNG, diesel hybrid)
Individual Site Reports • Documents
performance results and experience for each transit agency
• Builds database of results
• Reports published and posted on NREL web site
Annual FCEB status report • Crosscutting analysis
comparing results from all sites
• Assesses progress and needs for continued success
• Provides input on annual status for DOE/DOT Targets
5
Accomplishments: Progress Toward Targets NREL Assesses Technology Readiness Levels
Bus OEM Length
(ft) Fuel Cell System Hybrid System Design Strategy Energy Storage TRL Level
Van Hool 40 ClearEdge
Power Siemens ELFA integrated
by Van Hool Fuel cell dominant Lithium-based batteries 7
New Flyer 40 Ballard Siemens ELFA integrated
by Bluways Fuel cell dominant Lithium-based batteries 7
ElDorado 40 Ballard BAE Systems Fuel cell dominant Lithium-based batteries 7
Proterra 35 Hydrogenics Proterra integration Battery dominant Lithium-based batteries 6
Manufacturer teams for FCEBs currently operating in the United States
Data included in Presentation
6
Accomplishments: Progress Toward Targets Data Summary for 2014
FCEB Identifier ACT ZEBA BCT AT SL AT SL AFCB Transit Agency AC Transit BC Transit SunLine SunLine Number of Buses 12 20 1 1 Bus OEM Van Hool New Flyer New Flyer ElDorado National Bus length/height 40 ft / 136 in 40 ft / 137 in 40 ft / 137 in 40 ft / 140 in Fuel Cell OEM ClearEdge Power Ballard Ballard Ballard Model PureMotion 120 FCvelocity, HD6 FCvelocity, HD6 FCvelocity, HD6 Power (kW) 120 150 150 150
Hybrid System Siemens ELFA,
integrated by Van Hool
Siemens ELFA, integrated by
Bluways
Siemens ELFA, integrated by
Bluways
BAE Systems HybriDrive
Design strategy FC dominant FC dominant FC dominant FC dominant Energy Storage - OEM EnerDel Valence Valence A123
Type Li-ion Li-ion Li-ion Nanophosphate Li-ion
Capacity 17.4 kWh 47 kWh 47 kWh 11 kWh # cylinders 8 8 6 8 Capacity (kg) / Pressure (Bar) 40 / 350 56 / 350 43 / 350 50 / 350
ACT ZEBA BCT SL AT SL AFCB
Specifications for FCEBs included in data summary New fleet
7
Accomplishments: Progress Toward Targets Data Summary for 2014
FCEB Identifier ACT ZEBA BCT AT SL AT SL AFCB Transit Agency AC Transit BC Transit SunLine SunLine Number of Buses 12 20 1 1 Bus OEM Van Hool New Flyer New Flyer ElDorado National Bus length/height 40 ft / 136 in 40 ft / 137 in 40 ft / 137 in 40 ft / 140 in Fuel Cell OEM ClearEdge Power Ballard Ballard Ballard Model PureMotion 120 FCvelocity, HD6 FCvelocity, HD6 FCvelocity, HD6 Power (kW) 120 150 150 150
Hybrid System Siemens ELFA,
integrated by Van Hool
Siemens ELFA, integrated by
Bluways
Siemens ELFA, integrated by
Bluways
BAE Systems HybriDrive
Design strategy FC dominant FC Dominant FC dominant FC dominant Energy Storage - OEM EnerDel Valence Valence A123
Type Li-ion Li-ion Li-ion Nanophosphate Li-ion
Capacity 17.4 kWh 47 kWh 47 kWh 11 kWh # cylinders 8 8 6 8 Capacity (kg) / Pressure (Bar) 40 / 350 56 / 350 43 / 350 50 / 350
ACT ZEBA BCT SL AT SL AFCB
Specifications for FCEBs included in data summary New fleet
Hybrid system optimization and integration is the primary difference between designs
8
Accomplishments: Progress Toward Targets Hybrid System Comparison ACT ZEBA
BCT
SL AT
SL AFCB
Hybrid System Comparison of Design and Integration Challenges
Siemens ELFA, integrated by Van Hool
ZEBA – 2010 deployment, first time integration by bus OEM using proven components, needed significant optimizations early in demo, multiple software changes to system and battery controls, experienced early issues with diagnosing intermittent faults
Siemens ELFA, integrated by Bluways
(originally ISE)
BCT – 2010 deployment, optimized for reliability as opposed to fuel efficiency, original integrator went bankrupt forcing other partners to step up support, non-moveable deadline for deployment (2010 Olympics) resulted in less time to fully optimize and test, made several modifications after deployment – primary changes were increased hydrogen storage to improve range and added heating for winter
Siemens ELFA, integrated by Bluways
(originally ISE)
AT – 2009 deployment, pilot bus to BCT fleet, early tests of pilot bus in BC showed improvements were needed to meet BCT requirements, bus was later updated to almost match BCT specs – primary difference is hydrogen storage, bus was sold to SunLine and put into service in California
BAE Systems HybriDrive
AFCB – late 2012 deployment, design based on a proven diesel hybrid propulsion design (more than 3,000 are operating around the world), modified to FC system power , integrator worked closely with OEM, plan to move toward full integration by bus OEM for future builds, at least 6 more buses being produced for several agencies
9
Accomplishments : Progress Toward Targets Top Fuel Cell Powerplant exceeds 16,000 Hours
Total hours accumulated on each FC powerplant (FCPP) as of 2/28/14
0
50
100
150
200
250
300
Hou
rs o
f Ope
ratio
n (1
,000
)
Hours of Fuel Cell Operation by Bus Fleet
Jun-10
Aug-10
Oct-10
Dec-10
Feb-11
Apr-11
Jun-11
Aug-11
Oct-11
Dec-11
Feb-12
Apr-12
Jun-12
Aug-12
Oct-12
Dec-12
Feb-13
Apr-13
Jun-13
Aug-13
Oct-13
Dec-13
Feb-14
SunLineBC TransitCTT NutmegACT ZEBA
Created: Apr-03-14 8:05 AM
Total Hours = 294,074Top 3 FCPP hours: • 16,419 • 11,908 • 9,903
60% of FCPPs over 7,000 hours
10
Accomplishments : Progress Toward Targets Average Bus Availability improves by 20%
0
10
20
30
40
50
60
70
80
90
100S
ep-1
1
Oct
-11
Nov
-11
Dec
-11
Jan-
12
Feb-
12
Mar
-12
Apr
-12
May
-12
Jun-
12
Jul-1
2
Aug
-12
Sep
-12
Oct
-12
Nov
-12
Dec
-12
Jan-
13
Feb-
13
Mar
-13
Apr
-13
May
-13
Jun-
13
Jul-1
3
Aug
-13
Sep
-13
Oct
-13
Nov
-13
Dec
-13
Avai
labi
lity
(%)
SL AT BCT ZEBA AFCB Average
Target: 90%
Monthly bus availability
Availability = planned operation days compared to actual operation days
Bus issues (radiator leak, camera) and battery issues lowered availability for SunLine buses
Average availability 2013: 57% 2014: 69%
11
FC System, 4,804, 15%
Hybrid Propulsion,
15,301, 47%
PM, 4,328, 13%
General Maintenance, 7,954, 25%
BCT ATLabor hours
Fuel Cell System, 81,
17%
Hybrid Propulsion,
36, 7%
Traction Batteries, 239,
49%
General Maintenance,
130, 27%
SL AT
Fuel Cell System, 4, 2%
Hybrid Propulsion, 9,
5% Traction Batteries, 14,
7%
General Maintenance,
164, 82%
PM, 8, 4%
SL AFCB
Fuel Cell System, 173,
11% Hybrid Propulsion,
129, 8%
Traction Batteries, 226,
14%General Maintenance,
1,027, 66%
Event Prep, 13, 1%
ZEBA
Accomplishments : Progress Toward Targets Reasons for Unavailability by Site
1,586 total days
199 total days 486 total days
32,388 hours
12
Highly variable depending on duty cycle: average speed, terrain, auxiliary loads
Accomplishments : Progress Toward Targets Monthly Fuel Economy compared to Baseline
0
1
2
3
4
5
6
7
8
9
10A
pr-1
1M
ay-1
1Ju
n-11
Jul-1
1A
ug-1
1S
ep-1
1O
ct-1
1N
ov-1
1D
ec-1
1Ja
n-12
Feb-
12M
ar-1
2A
pr-1
2M
ay-1
2Ju
n-12
Jul-1
2A
ug-1
2S
ep-1
2O
ct-1
2N
ov-1
2D
ec-1
2Ja
n-13
Feb-
13M
ar-1
3A
pr-1
3M
ay-1
3Ju
n-13
Jul-1
3A
ug-1
3S
ep-1
3O
ct-1
3N
ov-1
3D
ec-1
3
Fuel
Eco
nom
y (m
pDG
E)
ZEBA ACT Diesel SL AT SL AFCB
SL CNG BCT AT BCT Diesel
Target: 8 mpg
13
Accomplishments : Progress Toward Targets Comparison to Previous Generation FCEBs
FCEB Identifier VH1 (Van Hool 1st Gen) VTA
Transit Agency AC Transit, CTTRANSIT, SunLine
Santa Clara Valley Transportation Authority (VTA)
Number of Buses 5 3 Bus OEM Van Hool Gillig Bus length/height 40 ft / 139 in 40 ft / 144 in Fuel Cell OEM UTC Power Ballard Model PureMotion 120 P5-2 Power (kW) 120 300
Hybrid System Siemens ELFA, integrated by ISE Corp Not a hybrid system
Design strategy FC dominant N/A Energy Storage - OEM MES-DEA N/A
Type sodium/Nickel Chloride N/A
Capacity 53 kWh N/A # cylinders 8 11 Capacity (kg) / Pressure (Bar) 50 / 350 55 / 350
Specifications for 1st Generation FCEBs
VTA
VH1
14
Accomplishments : Progress Toward Targets Monthly Miles 2 Times higher than 1st Gen
Transit agencies are increasing service; approaching target, but still lower than conventional buses
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
VH1 VTA ACTZEBA
BCT AT SL AT SL AFCB
Aver
age
Mon
thly
Mile
s
FCB Diesel CNG
Second generationFirst generation
Avg: 2,418
Avg: 1,191
Target 3,000
15
0
1
2
3
4
5
6
7
8
9
VH1(low)
VH1(high)
VTA ACTZEBA
BCT AT SL AT SLAFCB
Fuel
eco
nom
y (m
pDG
E)FCB Diesel CNG
Second generationFirst generation
Accomplishments : Progress Toward Targets Fuel Economy up to 2 Times Better than Baseline
Lowest fuel economy was for 1st gen system that was not a hybrid (VTA) Highly variable depending on duty cycle, but generally higher than baseline buses
Non-hybrid system had lower fuel economy than diesel baseline
Large heating system impacted fuel economy
16
Accomplishments : Progress Toward Targets Availability Increased to 69%
Recent issues with FCEBs at SunLine lowered availability for 2nd gen SL AFCB - Difficulty of diagnosing source of leak resulted in extended downtime Availability was 84% prior to issue.
0
10
20
30
40
50
60
70
80
90
100
VH1 VTA ACTZEBA
BCT AT SL AT SL AFCB
Perc
ent A
vaila
bilit
yTarget: 90%
Second generationFirst generation
Avg: 66 Avg: 69
17
Accomplishments : Progress Toward Targets Reliability: Bus MBRC 48% higher than 1st Gen
*MBRC = miles between roadcall
Total MBRC Propulsion MBRC FC System MBRC 1st Gen average 1,263 1,555 7,710 2nd Gen average 1,863 2,523 9,554 Percent improvement 48% 62% 24%
0
5,000
10,000
15,000
20,000
25,000
VH1 VTA ACT ZEBA BCT AT SL AT SL AFCB
Mile
s B
etw
een
Roa
dcal
l
Total MBRC
Propulsion MBRC
FC System MBRC
Second generationFirst generation
2016 FC System Target
Propulsion System Target
Total Bus Target
18
Accomplishments and Progress: Responses to Previous Year Reviewers’ Comments
• Consider looking at past data to show progress. Compare data from previous generation buses. o Comparisons to first generation FCEBs included in this presentation
(Slides 14-17)
• Provide more detail in the differences in generations of buses to better inform the direction in the performance of the products. o Selected specifications of the early and current generation buses are
included in the presentation. (Slide 6)
• If possible, NREL should identify the cause of the large increase in fuel economy and availability of the AFCB over the AT buses at SunLine. o Descriptions of the difference in these systems are included in the
presentation (slides 6-8)
19
Collaborations • Transit agencies provide data on buses, fleet experience, and training,
and review reports o California: AC Transit, BurbankBus, Golden Gate Transit, Santa Clara VTA,
SamTrans, SunLine, San Francisco MTA o Connecticut: CTTRANSIT o Alabama: Birmingham-Jefferson County o Texas: Capital Metro, Austin o Illinois: Chicago Transit Authority
• Manufacturers provide some data on buses and review reports o Bus OEMs: Proterra, Van Hool, New Flyer, ElDorado National o FC OEMs: Ballard, Hydrogenics, ClearEdge Power, Nuvera o Hybrid system OEMs: BAE Systems, GE, Van Hool, US Hybrid
• Other organizations share information and data o National: CARB, NAVC, CTE, CALSTART o International: Various organizations from Germany, Iceland, Brazil, Canada,
China, Japan, England, Norway, Italy, Sweden
20
Remaining Challenges and Barriers For technology validation and data collection project: • Establish good relationships with additional transit agencies to
allow data collection for new FCEB designs • Continue data collection to track progress as buses age, and to
understand operational costs after buses are out of warranty For industry to meet technical targets and commercialize FCEBs: • Increase durability and reliability of the fuel cell, battery system,
and other components • Improve integration/optimization of systems and components • Transition build process with OEM taking the primary role for bus
production • Transition all maintenance to transit staff (no onsite OEM support) • Reduce cost, both capital and operating
21
2013 2014 20151 2 3 4 1 2 3 4 1 2 1 2
Advanced T echnology F C E B C A T housand P alms 1 S unLineB C T rans it F C E B B C Whistler 20 Whis tler Trans it, C anada
Oakland AC Trans itS an R afael GGT
VTA, S amTransC A T housand P alms 1 S unLineIL C hicago 1 C TA
NY Inthaca 1 TC TAOH C leveland 1 GC R TA
AF C B (T IG G E R ) C A T housand P alms 2 S unLineC T AF C B C T Hartford 1 C TTR ANS ITB urbank F C E B C A B urbank 1 B urbankB usC ompound B us 2010 * C A S an F rancisco 1 S FMTAB irmingham F C E B * AL B irmingham 1 B J C TAMassachusetts AF C B * MA B oston 1 MB TA
T X Austin C ap MetroDC Washington DC DOT
Next-gen C ompound B us * C A S an F rancisco 1 S FMTAB attery Dominant AF C B * C A T housand P alms 1 S unLine* National F uel C ell B us P rogram project
C olor coded by F uel cell dominant hybrid electricDes ign S trategy:
B attery dominant hybrid electric
Diesel hybrid with fuel cell primarily for for accessories
Advanced C omposite F C E B * 1
13
American F uel C ell B us (AF C B ) *
Fuel C ell E lec tric B us E valuations for DOE , FT A, and C AR B
ZE B A Demonstration * C A
Demons tration S tate#
B us esC ity
Proposed Future Work
Jun 2014
22
Proposed Future Work
• Remainder of FY 2014 o Complete following data analyses/reports:
– AC Transit, ZEBA Demo Report, Apr 2014 – SunLine AFCB Report, Jun 2014 – BC Transit Final Report, Aug 2014 (demo ended Mar 2014) – 2013 Annual Status Report, Sep 2014
o Begin data collection on FCEBs in Birmingham and Austin
• FY 2015 o Kick off new FCEB evaluations as buses go into service o Complete Individual Site reports as scheduled o Complete annual crosscutting analysis across sites
23
Summary Documented progress toward targets:
Units Current Status 2016 Target Ultimate Target
Bus lifetime Years / miles 5/100,000 12/500,000 12/500,000
Powerplant lifetime1 Hours 1,000 – 16,000 18,000 25,000
Bus availability % 55 – 72 85 90
Roadcall frequency2
(Bus/fuel cell system) Miles between
road call 1,500 – 4,000 / 6,000 – 19,000 3,500/15,000 4,000/20,000
Operation time Hours per day/ days per week 19/7 20/7 20/7
Maintenance cost $/mile 0.39 – 1.60 0.75 0.40
Fuel economy Miles per diesel gallon equivalent 4.5 – 7.3 8 8
Range miles 220 – 310 300 300
1 Fuel cell hours accumulated to date from newest FCPP to oldest FCPP. Does not indicate end of life. 2 MBRC: range from lowest to highest for current designs