Hydrogen Learning Demonstration Project: Fuel Cell ...1. Calculated using the combined city/hwy fuel economy from dyno testing (non-adjusted) and usable fuel on board 2. Applying window-sticker

11

Hydrogen Learning Demonstration Project:

Fuel Cell Efficiency and Initial DurabilityKeith Wipke, Cory Welch, Holly Thomas, Sam Sprik1

Sigmund Gronich, John Garbak2

Fuel Cell Seminar, 2006

Session: #1C : Transportation IINovember 15, 2006Honolulu, Hawaii

1NREL, 2US Dept. of Energy

This presentation does not contain any proprietary or confidential informationNREL/PR-560-40766

2

Disclaimer and Government License

This work has been authored by Midwest Research Institute (MRI) under Contract No. DE-AC36-99GO10337 with the U.S. Department of Energy (the “DOE”). The United States Government (the “Government”) retains and the publisher, by accepting the work for publication, acknowledges that the Government retains a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for Government purposes.

Neither MRI, the DOE, the Government, nor any other agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its

use would not infringe any privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not constitute or imply its endorsement, recommendation, or favoring

by the Government or any agency thereof. The views and opinions of the authors and/or presenters expressed herein do not necessarily state or reflect those of MRI, the DOE, the Government, or any agency thereof.

3

Outline

•

Project Objectives and Overview•

Industry Partners; H2 vehicles and stations

•

Process and Methodology for Making Results Public•

Key Fall 2006 Results–

Vehicles•

Net fuel cell system efficiency•

Fuel economy and range•

Fuel cell durability–

H2 Refueling Infrastructure•

Total H2 produced or dispensed •

Safety Events•

Refueling Rates•

H2 station fuel purity and impurities

•

Summary and Future Results

4

Project Objectives and Targets•

Objectives–

Validate H2

FC Vehicles and Infrastructure in Parallel–

Identify Current Status of Technology and its Evolution

–

Assess Progress Toward Technology Readiness –

Provide Feedback to H2

Research and Development

Performance Measure 2009* 2015**

Fuel Cell Stack Durability 2000 hours 5000 hours

Vehicle Range 250+ miles 300+ miles

Hydrogen Cost at Station $3/gge $2-3/gge

* To verify progress toward 2015 targets** Subsequent projects to validate 2015 targets

Key Targets

Photo: NRELHydrogen refueling station, Chino, CA

5

Teams are Fielding Four Main Types of Vehicles

Validation also includes FCV Sprinter vans

Majority of 63 vehicles deployed to-date use 5,000 psi compressed H2 tanks

63

6

Representative Hydrogen Refueling Infrastructure Supporting Vehicles

LAX refueling station

Hydrogen and gasoline station, WA DCChino, CA

DTE/BP Power Park, Southfield, MI

7

Number of Stations

0

1

2

3

4

5

6

7

8

9

10

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2

Reporting Period

# of

Sta

tions

Created 28-Aug-06

Number and Type of Learning Demo Hydrogen Refueling Stations Online

H2 Production MethodsThrough Q2 2006

0

1

2

3

4

5

Delivered Compressed H2 NG On-site Reforming Electrolysis Delivered Liquid H2

Production Technolgy

# of

Sta

tions

Created 28-Aug-06

~1/2 of stations are producing H2 on-site

~1/2 of 20 planned refueling stations are online

4

9

8

Refueling Stations from All Four Teams Test Vehicle/Infrastructure Performance in Various Climates

Northern California

Southern California Florida

09-22-06Additional Planned Stations (3)

Additional Planned Stations (4)

SE Michigan Mid-Atlantic



9

Providing Data Analysis and Results for Both the Public and for the Industry Project Teams

Raw Data, Reports

Hydrogen Secure Data Center (HSDC)

•

Located at NREL:

Strictly Controlled Access

•

Detailed Analyses, Data Products, Internal Reports

Composite Data Products

•

Pre-agreed upon

aggregate data results for public

Detailed Data Products

•

Only shared with

company which originated the data

•

No confidential

information

Data is delivered to NREL’s Hydrogen

Secure Data Center (HSDC) on CD/DVDs

Data protected in HSDC for 5 years after data is developed under

EPACT 2005, Sec. 810

http://www.barrysclipart.com/barrysclipart.com/showphoto.php?photo=24290&papass=&sort=1&thecat=174

10

Five Quarters of Data Analyzed To-Date Current Status of Data Reporting to the Hydrogen Secure Data Center at NREL

On-Road Data Received -- Running Totals

0

5000

10000

15000

20000

25000

30000

Sep-0

4Oc

t-04

Nov-0

4De

c-04

Jan-0

5Fe

b-05

Mar-0

5Ap

r-05

May-0

5Ju

n-05

Jul-0

5Au

g-05

Sep-0

5Oc

t-05

Nov-0

5De

c-05

Jan-0

6Fe

b-06

Mar-0

6Ap

r-06

May-0

6Ju

n-06

Jul-0

6Au

g-06

Sep-0

6

MB

of D

ata

0

10000

20000

30000

40000

50000

60000

70000

80000

90000

100000

# Tr

ips

MB of data# trips

Through September, 2006:76,000 individual vehicle trips

27 GB of on-road data

11

PUBLISH

Analysis Calculations and Results are from NREL-Developed GUI –

Fleet Analysis Toolkit (FAT)

TripView

12

Quantity of Project Results Continues to Increase; Public Updates Every Six Months

Dyno (1) Window-Sticker (2) On-Road (3)(4)0

10

20

30

40

50

60

70

80

Fuel

Eco

nom

y (m

iles/

kg H

2)

Fuel Economy

Created: 16-Feb-2006

(3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.

(1) One data point for each make/model. Combined City/Hwy fuel economy per DRAFT SAEJ2572.

(2) Adjusted combined City/Hwy fuel economy (0.78 x Hwy, 0.9 x City).

(4) Calculated from on-road fuel cell stack current o r mass flow readings.

0

50

100

150

200

250

300

All OEMs

Vehi

cle

Ran

ge (m

iles)

Vehicle Range(1)

2015 Target2009 Target

Created: 21-Feb-2006 (1) Calculated from combined City/Hwy fuel economy (dyno test) per DRAFT SAE J2572 and usable fuel on board.

Safety Incidents - Vehicle Operation

0

1

2

3

4

5

6

7

8

9

10

'05

Q2

'05

Q3

'05

Q4

Num

ber o

f Inc

iden

ts

Passenger Compartment H2 alarm H2 releaseCreated 21-Feb-2006

Safety Incidents - Infrastructure2005 Q2 - Q4

Calibration/Settings

Electrical

H2 Leak/Unplanned Vent

Non-H2 Leak

Mischief, Vandalism

Environmental (Weather, Power Disruption, etc.)

Unconfirmed/False Alarm

0 1 2 3 4 5 6 7 8 9 10Cal

ibra

tion/

Setti

ngs

H2

Leak

/Unp

lann

edVe

ntM

isch

ief,

Vand

alis

mU

ncon

firm

ed/F

alse

Ala

rm

Gen

eral

Cat

egor

y

Num ber of IncidentsCreated 21-Feb -200 6

On-Board Hydrogen Storage Methods

-

10

20

30

40

50

60

70

Q205 Q305 Q405

# of

Veh

icle

s (A

ll Te

ams)

5,000 psi tanks 10,000 psi tanks Liquid H2Created 16-Feb-2006

0

1

2

3

4

5

6

7

8

9

All OEMs

Wei

ght P

erce

nt H

ydro

gen

(%)

Weight Percent Hydrogen

2015 DOE MYPP Target1



Created: 23-Feb-20061Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based technologies.

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

All OEMs

Mas

s H

2 pe

r Lite

r (kg

/L)

M ass of Hydrogen Per Liter




Created: 23-Feb-20061Emphasis is on advanced materials-based technologies.

0

2000

4000

6000

8000

10000

12000

All OEMs

Num

ber o

f cyc

les

Hydrogen Tank Cycle Life





99.984

99.986

99.988

99.990

99.992

99.994

99.996

99.998

100.000

Hyd

roge

n Pu

rity

(%)

Hydrogen Purity Sampled from Stations(1)

Range of Reported DataISO FDTS 14687-2 Target

Created: 21-Feb-2006(1) Includes sampling from both electrolysis and reforming

0 1 2 3 4 5 6 7 8 9 10

Particulates

μg/L

H2 Impurities

Range of Reported Data ISO FDTS 14687-2 Max Reported Detection Limit

0 20 40 60 80 100 120 140 160 180 200

(N2 + He + Ar)

0 1 2 3 4 5 6 7 8 9 10

H2O Total HC

O2 CO2 CO

NH3

μmol/mol (ppm)

0 5 10 15 20 25 30 35 40 45 50

Total S Compounds*

nmol/mol (ppb)Created: Jun-01-06 11:02 AM *Includes SO2, COS, and H2S.

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.80

5

10

15

20

25

30

35

40

Refueling Rate (kg H2/minute)

# of

Ref

uelin

g Ev

ents

Histogram of Vehicle Refueling Rates

5 minute fill of5 kg at 350 bar


2006 Tech Val Milestone2010 MYPP Adv Storage Materials Target


-30

-20

-10

0

10

20

30

40

50

Deg

rees

Cel

sius

Ambient Temperature During Operation

All OEMsCreated: 16-Feb-2006

Vehicle Hours: All OEM's Combinedthrough Q4 2005

02468

101214161820

0-50

50-10

0

100-1

50

150-2

00

200-2

50

250-3

00

300-3

50

350-4

00

400-4

50>4

50

Total Vehicle Hours

Num

ber o

f Veh

icle

s Total Vehicle Hours = 7,831


Vehicle M iles: All OEM 's Combinedthrough Q4 2005

0

5

10

15

20

25

0-150

0

1500

-3000

3000

-4500

4500

-6000

6000

-7500

7500

-9000

9000

-1050

0

1050

0-120

00

1200

0-135

00

>135

00

Total Vehicle Miles

Num

ber o

f Veh

icle

s

Total Vehicle M iles Trave led = 196,405


Cumulative Vehicle Miles Traveled: All OEMs

-

50,000

100,000

150,000

200,000

250,000

Q205 Q305 Q405

Veh

icle

Mile

s Tr

avel

ed


Cumulative Hydrogen Produced or DispensedAll Teams Combined

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

Q2 2005 Q3 2005 Q4 2005

Reporting Calendar Quarter

Mas

s of

Hyd

roge

n (k

g)

Created 21-Feb-2006

0

10

20

30

40

50

60

70

All OEMs

Effic

ienc

y (%

)

Fuel Cell System1 Efficiency2 at ~25% Net Power.

DOE Target

Created: Aug-29-06 4:09 PM

1 Gross s tack power minus fuel cell sys tem auxiliaries , per DRAFT SAEJ2615.

2 Ratio of DC output energy to the lower heating value of the input fuel (hydrogen).Exc ludes power electronics and electric drive .


10

20

30

40

50

60

70

80

Fuel

Eco

nom

y (m

iles/

kg H

2)

Fuel Economy

Created: Aug-25-06 10:45 AM

(3) Excludes trips < 1 mile. One data point for on-road fleet average o f each make/model.



(4) Calculated from on-road fuel cell stack current or mass flow readings.

0 10 20 30 40 50 60 70 80 90 100

Vehicle Range Factors

Percentage of chassis dyno range1.

All

OEM

s

Win

dow

-Stic

ker

2

On-

Roa

d 3

Dyn

o 1


1. Calculated using the combined city/hwy fuel economy from dyno testing (non-adjusted) and usable fuel on board

2. Applying window-sticker correction factors for fuel economy: 0.78 x Hwy and 0.9 x City

3. Us ing fuel-economy from on-road data (excluding trips > 1 mile, consis tent with other data products)3. Us ing fuel-economy from on-road data (excluding trips > 1 mile, consis tent with other data products)

0 10 20 30 40 50 60 70 80 90 1000

10

20

30

40

50

60

70

80

90

100Range Histogram: All OEMs

Percentage of chassis dyno range1 b/w refuelings

Perc

enta

ge o

f ref

uelin

gs

PercentageCumulative Percentage


Total refuelings2 = 2048

1. Range calculated using the combined city/hwy fuel economy from dyno testing (not EPA adjusted) and usable fuel on board.

2. Some refueling events are not detected/reported due to data noise or incompleteness.

Safety Incidents - Vehicle Operation

0

1

2

3

4

5

6

7

8

9

10

'05

Q2

'05

Q3

'05

Q4

'06

Q1

'06

Q2

Num

ber

of In

cide

nts

H2 Leak - StackH2 Leak - Fuel SystemH2 Leak While FuelingPassenger Compartment H2 alarm

Created: 8/28/2006

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20

50

100

150

Avg Fuel Rate (kg/min)

Num

ber o

f Fue

ling

Even

ts

Histogram of Vehicle Fueling Rates (Thru 2006Q2)





Safety Incidents - Infrastructure2005 Q2 - 2006 Q2

Electrical

Non-H2 Leak

Failed/Broken Equipment

Mischief, Vandalism

Calibration/ Settings/ Maintenance

Environment (Weather, Power Disruption, etc.)



0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Elec

trica

lFa

iled/

Brok

enEq

uipm

ent

Calib

ratio

n/Se

ttin

gs/

Mai

nten

ance

H2

Leak

/Unp

lann

edVe

nt

Gen

eral

Cat

egor

y

Number of IncidentsCreated 30-Aug-06

99.95299.95499.95699.95899.96099.96299.96499.96699.96899.97099.97299.97499.97699.97899.98099.98299.98499.98699.98899.99099.99299.99499.99699.998

100.000

Hyd

roge

n Pu

rity

(%)


Data RangeDataSAE J2719

Created: Sep-07-06 3:32 PM(1) Includes sampling from both electrolysis and reforming

0 50 100 150

AdjustmentCheck Only

OtherRepair

Replacement

Maintenance: Average Labor Hours Per Station Since Inception

ScheduledUn-Scheduled

0 2 4 6 8 10 12 14 16 18 20

AdjustmentCheck Only

OtherRepair

Replacement

Maintenance: Average Number of Events Per Station Since Inception

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

# of EventsHours

Comparison of Scheduled/Un-Scheduled Maintenance


-30

-20

-10

0

10

20

30

40

50

Deg

rees

Cel

sius

Ambient Temperature During Operation

All OEMsCreated: 16-Feb-2006

Vehicle Miles: All OEMs Combined

02468

1012141618

0-1500

1500-3

000

3000-4

500

4500-6

000

6000-7

500

7500-9

000

9000-1

0500

10500

-1200

0

12000

-1350

0>13

500

Total Vehicle Miles

Num

ber o

f Veh

icle

s

Total M ile s Trave led = 360,092

Through Q2 2006

Created: 25-Aug-06

Cumulative Hydrogen Produced or DispensedAll Teams

01,0002,0003,0004,0005,0006,0007,0008,0009,000

10,00011,00012,00013,00014,000

Q2 2005 Q3 2005 Q4 2005 Q1 2006 Q2 2006


Mas

s of

Hyd

roge

n (k

g)

Created 24-Aug-2006

Cumulative Vehicle Miles Traveled: All OEMs

-

50,000

100,000

150,000

200,000

250,000

300,000

350,000

400,000

Q205 Q305 Q405 Q106 Q206

Vehi

cle

Mile

s Tr

avel

ed

Created: 28-Aug-06

25 Composite Data Products Have Now Been Published, Including Updating 10 of the

16 Published in Spring 2006

0 1 2 3 4 5 6 7 8 9 10

Particulates

μg/L

H2 Impurities

Range of Reported Data ISO FDTS 14687-2 Max Reported Detection Limit

0 20 40 60 80 100 120 140 160 180 200

(N2 + He + Ar)

0 1 2 3 4 5 6 7 8 9 10

H2O Total HC

O2 CO2 CO

NH3

μmol/mol (ppm)

0 5 10 15 20 25 30 35 40 45 50

Total S Compounds*

nmol/mol (ppb)Created: Jun-01-06 11:02 AM *Includes SO2, COS, and H2S.

99.984

99.986

99.988

99.990

99.992

99.994

99.996

99.998

100.000

Hyd

roge

n Pu

rity

(%)


Range of Reported DataISO FDTS 14687-2 Target

Created: 21-Feb-2006(1) Includes sampling from both electrolys is and reforming

0

1

2

3

4

5

6

7

8

9

All OEMs

Wei

ght P

erce

nt H

ydro

gen

(%)

Weight Percent Hydrogen





0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

All OEMs

Mas

s H

2 pe

r Lite

r (kg

/L)

M ass of Hydrogen Per Liter




Created: 23-Feb-20061Emphasis is on advanced materials-based technologies.

0

2000

4000

6000

8000

10000

12000

All OEMs

Num

ber o

f cyc

les

Hydrogen Tank Cycle Life





On-Board Hydrogen Storage Methods

-

10

20

30

40

50

60

70

Q205 Q305 Q405 Q106 Q206

# of

Veh

icle

s (A

ll Te

ams)

5,000 psi tanks 10,000 psi tanks Liquid H2Created 25-Aug-2006

Number of Stations

0

1

2

3

4

5

6

7

8

9

10

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2

Reporting Period

# of

Sta

tions

Created 28-Aug-06

H2 Production MethodsThrough Q2 2006

0

1

2

3

4

5

Delivered Compressed H2 NG On-site Reforming Electrolysis Delivered Liquid H2

Production Technolgy

# of

Sta

tions

Created 28-Aug-06

Vehicle Hours: All OEM's Combined

0

5

10

15

20

25

0-100

100-2

00

200-3

00

300-4

00

400-5

00

500-6

00

600-7

00

700-8

00

800-9

00 >900

Total Vehicle Hours

Num

ber o

f Veh

icle

s

Through Q2 2006

Created: 25-A ug-06

Total Vehicle Hours = 19,324

National Hydrogen Association Conference

March 13, 2006

EVS-22 ConferenceOctober 26, 2006

Fuel Cell SeminarNovember 15, 2006

Dyno Range (2) Window-Sticker Range (3) On-Road Range (4)(5)0

50

100

150

200

250

300

Vehi

cle

Ran

ge (m

iles)

Vehicle Range1


Created: Oct-03-06 8:07 AM

(1) Range is based on fuel economy and usable hydrogen on-board the vehicle. One data point for each make/model.(2) Fuel economy from unadjusted combined City/Hwy per DRAFT SAEJ2572.(3) Fuel economy from EPA Adjusted combined City/Hwy (0.78 x Hwy, 0.9 x City).(4) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(5) Fuel economy calculated from on-road fuel cell stack current or mass flow readings.

0

200

400600

80010001200

14001600

18002000

22002400

2006 Target

2009 Target

Actual Operating Hours Accumulated To-Date Projected Hours to 10% Degradation

Max Hrs Accumulated (1)(2) Avg Hrs Accumulated (1)(3) Projection to 10% Degradation (4)(5)

Tim

e (H

ours

)

DOE Learning Demonstration Fuel Cell Stack Durability:Based on Data Through August 2006

Max ProjectionAvg Projection

Created: Oct-05-06 4:32 PM

(1) Range bars created using one data point for each OEM.(2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individual stack in "real-world" operation.(3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OEM's fleet.(4) Projection using on-road data -- degradation calculated at high stack current. This criterion is used for assessing progress against DOE targets, may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membrane failure.(5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = average nominal projection. The shaded green bar represents an engineering judgment of the uncertainty due to data and methodology limitations. Projections will change as additional data are accumulated.

0 1 2 3 4 5 6 7 8 9 10

Particulates

μg/L

H2 Impurities

Data Range SAE J2719 Measured Less Than or Equal To (Detection Limited)

0 50 100 150 200 250 300 350 400 450 500

(N2 + He + Ar)

0 1 2 3 4 5 6 7 8 9 10

H20 Total HC

O2 CO2

CO NH3

μmol/mol (ppm)

0 10 20 30 40 50 60 70 80 90 100

Total S*

nmol/mol (ppb)Created: Sep-26-06 3:47 PM *Calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

14

Controlled System Tests Verify High Fuel Cell System Conversion Efficiency

0

10

20

30

40

50

60

70

All OEMs

Effic

ienc

y (%

)

Fuel Cell System1 Efficiency2 at ~25% Net Power.

DOE Target


1 Gross stack power minus fuel cell system auxiliaries, per DRAFT SAEJ2615.

2 Ratio of DC output energy to the lower heating value of the input fuel (hydrogen).Excludes power electronics and electric drive.

In-Vehicle Fuel Cell System Efficiencies Ranged Between

52.5% and 58.1%, very close to DOE target of 60%Results obtained from

steady-state vehicle chassis dynamometer tests at

roughly ¼

power

15

Dynamometer and On-Road Fuel Economy from Learning Demonstration Vehicles


10

20

30

40

50

60

70

80

Fuel

Eco

nom

y (m

iles/

kg H

2)

Fuel Economy

Created: Aug-25-06 10:45 AM

(3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.



(4) Calculated from on-road fuel cell stack current or mass flow readings.

High Fuel Conversion Efficiency Translates into Relatively High Fuel Economy…

16

Dyno Range (2) Window-Sticker Range (3) On-Road Range (4)(5)0

50

100

150

200

250

300

Vehi

cle

Ran

ge (m

iles)

Vehicle Range1


Created: Oct-03-06 8:07 AM

(1) Range is based on fuel economy and usable hydrogen on-board the vehicle. One data point for each make/model.(2) Fuel economy from unadjusted combined City/Hwy per DRAFT SAEJ2572.(3) Fuel economy from EPA Adjusted combined City/Hwy (0.78 x Hwy, 0.9 x City).(4) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(5) Fuel economy calculated from on-road fuel cell stack current or mass flow readings.

Vehicle Range Based on Fuel Economy and Usable H2

Fuel Stored On-Board

…But Range Still Limited Due to Amount of H2 Packaged On-Board

17

Max Hrs Accumulated (1)(2) Avg Hrs Accumulated (1)(3)0

200

400

600

800

Tim

e (H

ours

)

DOE Learning Demonstration:Fuel Cell Stack Hours Accumulated Through August 2006


(1) Range bars created using one data point for each OEM.(2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individual stack in "real-world" operation.(3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OEM's fleet.

Learning Demo Fuel Cell Stack Hours Accumulated Through August 2006

Accumulation of FC stack operating hours takes significant calendar time, due to real-world nature of data accumulation

Example: How many weeks in 1000 hours?(25 weeks)*(40 hours/week) or(100 weeks)*(10 hours/week).

18

0 500 1000 1500 2000 2500100

120

140

160

180

200

220

240

STACK Operating Hours

Pred

icte

d Vo

ltage

at 3

00A

Voltage vs. Operating Hours at 300A: Vehicle16-Stack2

938

hrs

1560

hrs

Threshold for 10% drop = 186V

Nominal V @ zero hrs = 207V

95.1

%

13 mV/hr

0 500 1000 1500 2000 25000

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

Prob

abili

ty o

f Exc

eedi

ng O

per.

Hou

rs


Limited Data Necessitated Projecting the Time to 10% Fuel Cell Stack Voltage Degradation

0 50 100 150 200 250 300 350

200

250

300

350

Time (stack oper hrs) = 164

Current (A)

Volta

ge (V

)

Stack Degradation Analysis: Vehicle16-Stack2

2400 data points per curve fit

0 100 200 300 400 500 600100

150

200

STACK Operating Time (hrs)

Pred

icte

d Vo

ltage

(V)

Predicted (Curve Fit) Voltage vs. time for Vehicle16-Stack2

Technique Makes Performance Projection Based on All Available

FC Data; Includes Reporting Confidence in Results 0 500 1000 1500 2000 2500100

120

140

160

180

200

220

240

STACK Operating Hours

Pre

dict

ed V

olta

ge a

t 300

A

Voltage vs. Operating Hours at 300A: All Stacks

1504

hrs

1803

hrs

2270

hrs

Threshold for 10% drop = 185V

Nominal V @ zero hrs = 206V

100.

0 %

11 mV/hr

Vehicle15-Stack1Vehicle16-Stack2Vehicle17-Stack1

0 500 1000 1500 2000 25000

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

Prob

abilit

y of

Exc

eedi

ng O

per.

Hou

rs

Note: 10% is an R&D metric for FC stack degradation. It does not necessarily

indicate an end-of-life condition. OEMs may use other values or indicators.

19

Hours Accumulated To-Date and Projected Hours to 10% Stack Voltage Degradation

0200

400600800

10001200

14001600

1800200022002400

2006 Target

2009 Target

Actual Operating Hours Accumulated To-Date Projected Hours to 10% Degradation

Max Hrs Accumulated (1)(2) Avg Hrs Accumulated (1)(3) Projection to 10% Degradation (4)(5)

Tim

e (H

ours

)

DOE Learning Demonstration Fuel Cell Stack Durability:Based on Data Through August 2006

Max ProjectionAvg Projection


(1) Range bars created using one data point for each OEM.(2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individual stack in "real-world" operation.(3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OEM's fleet.(4) Projection using on-road data -- degradation calculated at high stack current. This criterion is used for assessing progress against DOE targets, may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membrane failure.(5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = average nominal projection. The shaded green bar represents an engineering judgment of the uncertainty due to data and methodology limitations. Projections will change as additional data are accumulated.

20

Cumulative Hydrogen Produced or DispensedAll Teams

01,0002,0003,0004,0005,0006,0007,0008,0009,000

10,00011,00012,00013,00014,000

Q2 2005 Q3 2005 Q4 2005 Q1 2006 Q2 2006


Mas

s of

Hyd

roge

n (k

g)

Created 24-Aug-2006

Cumulative Mass of H2 Produced or Dispensed

Current deployment of new H2

refueling stations for this project is about 50% complete.

Many mobile refuelers will be replaced with on-site generation

21

Safety Incidents - Infrastructure2005 Q2 - 2006 Q2

Electrical

Non-H2 Leak

Failed/Broken Equipment

Mischief, Vandalism

Calibration/ Settings/ Maintenance

Environment (Weather, Power Disruption, etc.)



0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Elec

tric

alFa

iled/

Bro

ken

Equi

pmen

t

Cal

ibra

tion/

Sett

ings

/M

aint

enan

ce

H2

Leak

/Unp

lann

edVe

nt

Gen

eral

Cat

egor

y

Number of IncidentsCreated 30-Aug-06

Safety Incidents –

Infrastructure

Station robustness to external forces and false

alarms could be improved.

H2 releases have been minor and related to

startup issues

22

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20

50

100

150

Avg Fuel Rate (kg/min)

Num

ber o

f Fue

ling

Even

ts

Histogram of Vehicle Fueling Rates (Thru 2006Q2)





Actual Vehicle Refueling Rates from >2000 Events: Measured by Stations or by Vehicles

Future analyses could compare impact of communication and non-communication fills on fill rates and completeness of fill

Average rate: 0.69 kg/minMedian: 0.72 kg/min

18% of refueling events exceeded 1kg/min

23

99.95299.95499.95699.95899.96099.96299.96499.96699.96899.97099.97299.97499.97699.97899.98099.98299.98499.98699.98899.99099.99299.99499.99699.998

100.000

Hyd

roge

n Pu

rity

(%)


Data RangeDataSAE J2719

Created: Sep-07-06 3:32 PM(1) Includes sampling from both electrolysis and reforming

Hydrogen Purity Sampled from Stations Close to Target Majority of the Time

Relatively high impurity detection limits affect

calculated purity results

24

0 1 2 3 4 5 6 7 8 9 10

Particulates

μg/L

H2 Impurities

Data Range SAE J2719 Measured Less Than or Equal To (Detection Limited)

0 50 100 150 200 250 300 350 400 450 500

(N2 + He + Ar)

0 1 2 3 4 5 6 7 8 9 10

H20 Total HC

O2 CO2 CO

NH3

μmol/mol (ppm)

0 10 20 30 40 50 60 70 80 90 100

Total S*

nmol/mol (ppb)Created: Sep-26-06 3:47 PM *Calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

Hydrogen Impurities Sampled from All Stations –

Includes On-Site Reformation, Electrolysis, and Delivered H2

High detection limits introduce larger uncertainty about meeting SAE targets

25

Summary

•

First 5-quarters of project completed–

63 vehicles now in fleet operation–

9 stations in operation to support project vehicles–

No major safety problems encountered–

Total of 25 composite data products published to-date•

Project has identified current technical status relative to program targets–

Will track improvements from 2nd

generation stacks/vehicles introduced mid-way through project

•

Future public results will include:–

6-month updates to existing composite data products–

Fuel cell cold start-up times–

H2

production cost and efficiency–

Other composite data products created based on insights learned

26

Questions and Discussion

Contact: Keith Wipke, National Renewable Energy Lab303.275.4451 [email protected]

All public Learning Demo papers and presentations are available online at http://www.nrel.gov/hydrogen/proj_tech_validation.html

OutlineProject Objectives and TargetsTeams are Fielding �Four Main Types of VehiclesRepresentative Hydrogen Refueling Infrastructure Supporting VehiclesNumber and Type of Learning Demo�Hydrogen Refueling Stations OnlineRefueling Stations from All Four Teams Test Vehicle/Infrastructure Performance in Various ClimatesProviding Data Analysis and Results for Both the Public and for the Industry Project TeamsFive Quarters of Data Analyzed To-Date�Current Status of Data Reporting to the Hydrogen Secure Data Center at NRELAnalysis Calculations and Results are from�NREL-Developed GUI – Fleet Analysis Toolkit (FAT)Quantity of Project Results Continues to Increase; Public Updates Every Six MonthsRESULTSControlled System Tests Verify High �Fuel Cell System Conversion EfficiencyDynamometer and On-Road Fuel Economy from Learning Demonstration VehiclesVehicle Range Based on Fuel Economy and Usable H2 Fuel Stored On-BoardLearning Demo Fuel Cell Stack Hours Accumulated Through August 2006Limited Data Necessitated Projecting the Time to 10% Fuel Cell Stack Voltage DegradationHours Accumulated To-Date and �Projected Hours to 10% Stack Voltage DegradationCumulative Mass of H2 �Produced or DispensedSafety Incidents – InfrastructureActual Vehicle Refueling Rates from >2000 Events: �Measured by Stations or by VehiclesHydrogen Purity Sampled from Stations Close to Target Majority of the TimeHydrogen Impurities Sampled from All Stations – Includes On-Site Reformation, Electrolysis, and Delivered H2

Summary

Documents

Hydrogen Learning Demonstration Project: Fuel Cell ...1. Calculated using the combined city/hwy fuel economy from dyno testing (non-adjusted) and usable fuel on board 2. Applying window-sticker