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NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
Fuel Cell Technology Status Voltage Degradation
2013 DOE Annual Merit Review
Jennifer Kurtz, Huyen Dinh, Sam Sprik, Genevieve Saur, Chris Ainscough, Mike Peters
May 14, 2013 This presentation does not contain any proprietary, confidential, or otherwise restricted information.
Project ID# FC081
2
Overview
Timeline Project start date: July 2009 Project end date: October 2013* Percent complete: On-going
Barriers Durability of state-of-the-art fuel cell stacks and systems
Budget Total project funding
DOE share: $450k Contractor share: $0
Funding received in FY13: $150k Funding received FY09–12: $300k
Partners 68 fuel cell developers contacted 15 fuel cell developers shared data
*Project continuation and direction determined annually by DOE
3
Relevance: Objectives Benchmark state-of-the-art fuel cell durability
o Develop snapshot of state-of-the-art fuel cell durability o Uniformly apply analysis method to data accumulated in lab o Obtain independent assessment and status of state-of-the-
art fuel cell technology
Leverage analysis experience o Utilize analysis methods, experience, and data from fuel cell
field demonstrations (e.g., DOE’s FCV Learning Demonstration and Early Market demonstrations)
o Compare lab and field data
Collaborate with key fuel cell developers o Provide feedback to fuel cell developers o Investigate factors affecting fuel cell durability o Study differences between lab and field durability o System price benchmarking
All data is supplied voluntarily and published results are updated annually.
4
CDPs
DDPs
Public
Composite Data Products (CDPs) • Aggregated data across multiple systems,
sites, and teams • Publish analysis results once a year without
revealing proprietary data2
Detailed Data Products (DDPs) • Individual data analyses
• Identify individual contribution to CDPs • Shared once a year only with the partner
who supplied the data1
1) Data exchange may happen more frequently based on data, analysis, and collaboration 2) Results published via NREL technology validation website, conferences, and reports (http://www.nrel.gov/hydrogen/proj_learning_demo.html)
Approach: Analysis and Reporting of Real-World Operation Data
Results
Bundled data (operation & maintenance/safety) delivered
to NREL annually Internal analysis
completed annually in HSDC
5
CDP and DDP Schedule
Op Hr Proj Hr Op Hr Proj Hr Op Hr Proj Hr Op Hr Proj Hr0
5000
10000
15000
20000
25000
30000
35000
40000
45000
49% of data setsare short stacks2
Backup
47% of data setsare short stacks2
Automotive
20% of data setsare short stacks2
Forklift
45% of data setsare short stacks2
Prime
Hou
rs
25th-75th PercentileMax Op HrAvg Op HrMax Proj Hr3
Avg Proj Hr3
DOE Target4
NREL cdp_lab_01
Created: Mar-30-12 4:20 PM
(1) At least 9 fuel cell developers supplied data. Analysis will be updated periodically.(2) PEM & SOFC data from lab tested, full active area short stacks and systems with full stacks. Data generated from constant load, transientload, and accelerated testing between 2004 and early 2011.(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.(4) DOE targets are for real-world applications; refer to Hydrogen, Fuel Cells, & Infrastructure Technologies Program Plan.
Op Hr Proj Hr
Automotive
Example DDPs
Sample Data Set 1 Sample Data Set 2
0 200 400 600 800 1000 1200 1400 1600 1800 2000220
230
240
250
260
270
280
290
300
Op Hours
Volta
ge
Voltage vs. Operation Hours at 300A: Vehicle19-Stack1
871
900
847
288
259
0
0.2
0.4
0.6
0.8
1Stack Weight Factors
Wei
ght V
alue
Overal
l
DatQty
DatGap
DR1ci
DR2ci
Created: Oct-09-08 3:01 PM
warm-up time=10 min
pwr rate filt=1000 kW/s
amp rate filt=1000 A/s
pts per fit=2500
1 data pt every 1seconds
0 200 400 600 800 1000 1200 1400 1600 1800 2000220
230
240
250
260
270
280
290
300
Op Hours
Volta
ge
Voltage vs. Operation Hours at 300A: Vehicle19-Stack1
871
900
847
288
259
0
0.2
0.4
0.6
0.8
1Stack Weight Factors
Wei
ght V
alue
Overal
l
DatQty
DatGap
DR1ci
DR2ci
Created: Oct-09-08 3:01 PM
warm-up time=10 min
pwr rate filt=1000 kW/s
amp rate filt=1000 A/s
pts per fit=2500
1 data pt every 1seconds
Example Data Results (if needed) Draft CDPs
Initial Review
(~1 weeks)
Final Draft CDPs
(< 1 week)
Final Review
(< 1 week)
Finalized CDPs
(< 1 week)
Data Process
& Analysis
(~4 weeks excluding data processing and analysis)
6
• Record operation hour for segment
Approach: Raw FC Data Processing Example Data
• Record voltages from polarization fit at set currents
• Segment fuel cell voltage and current data
• Apply polarization fit 1
2
3
4
1
2
3
4
0 200 400 600 800 1000 1200 1400 1600 1800 2000220
230
240
250
260
270
280
290
300
Op Hours
Volta
ge
Voltage vs. Operation Hours at 300A: Vehicle19-Stack1
871
900
847
288
259
0
0.2
0.4
0.6
0.8
1Stack Weight Factors
Wei
ght V
alue
Overal
l
DatQty
DatGap
DR1ci
DR2ci
Created: Oct-09-08 3:01 PM
warm-up time=10 min
pwr rate filt=1000 kW/s
amp rate filt=1000 A/s
pts per fit=2500
1 data pt every 1seconds
5 6
7
8
9
5
6
7
8
9
Plot polarization fit voltage at a specific current Apply robust segmented linear fit (if trend suggests non-linear degradation trend) Record fit y-intercept (nominal voltage drop)
Record operation hour when fit crosses 10% nominal voltage drop Investigate fit quality
7
Accomplishment: Annual Update Completed FY09 FY10 FY11 FY12 FY13
Op Hr Proj Hr Op Hr Proj Hr Op Hr Proj Hr Op Hr Proj Hr0
5000
10000
15000
20000
25000
30000
35000
40000
45000
49% of data setsare short stacks2
Backup
47% of data setsare short stacks2
Automotive
20% of data setsare short stacks2
Forklift
45% of data setsare short stacks2
Prime
Hou
rs
Operation Hours and Projected Hours to 10% Voltage Drop1
25th-75th PercentileMax Op HrAvg Op HrMax Proj Hr3
Avg Proj Hr3
DOE Target4
NREL cdp_lab_01
Created: Mar-30-12 4:20 PM
(1) At least 9 fuel cell developers supplied data. Analysis will be updated periodically.(2) PEM & SOFC data from lab tested, full active area short stacks and systems with full stacks. Data generated from constant load, transientload, and accelerated testing between 2004 and early 2011.(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.(4) DOE targets are for real-world applications; refer to Hydrogen, Fuel Cells, & Infrastructure Technologies Program Plan.
10% 15% 20% 25%0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
22000
Voltage Degradation Levels2,6
Proj
ecte
d H
ours
3,4,
5
Durability Lab Data Sets1 - Average projected Hour Sensitivity to Voltage Degradation Levels
Average -ForkliftAverage -PrimeAverage -AutomotiveAverage -Backup
NREL cdp_lab_02
Created: Mar-30-12 2:00 PM
(1) PEM & SOFC data from lab tested, full active area short stacks and systems with full stacks. Data generated from constant load, transient load, and accelerated testing between 2004 and 2011.(2) 10% Voltage degradation is a DOE metric for assessing fuel cell performance.(3) Curves generated using the average of each application at various voltage degradation levels.(4) The projection curves display the sensitivity to percentage of voltage degradation, but the projections do not imply that all stacks will (or do) operate at these voltage degradation levels.(5) Projections may be limited by demonstrated operation hours to minimize extrapolations.(6) The voltage degradation levels are not an indication of an OEM's end-of-life criteria and do not address catastrophic stack failures such as membrane failure.
Gen1 Auto (1) Gen2 Auto (1) Lab Auto (2)0
2000
4000
6000
8000
10000
12000
14000
2006 Target
2009 Target
2015 Target
Proj
ecte
d H
ours
to 1
0% V
olta
ge D
rop
Comparison of Fuel Cell Vehicle Field and Lab Durability Projections
Average Projection3
Max Projection3
NREL cdp_lab_03
Created: Mar-21-12 4:50 PM
(1) Gen1 and Gen2 Data from DOE's Learning Demonstration (2005 - 2010)(2) Lab data providers may not be the same as participants in DOE's Learning Demonstration. 49% of data are full active area short stacks.(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.
2008 2009 2010 2011 20120
50
100
150
200
250
Ope
ratio
n H
ours
[1,0
00]
0
20
40
60
80
100
Dat
a Se
t Cou
nt
Cumulative Lab Data Operation Hours and Dates
05/2
009
CD
Ps1
12/2
009
CD
Ps1
06/2
010
CD
Ps1
07/2
011
CD
Ps1
03/2
012
CD
Ps1
Prime Op HrsForklift Op HrsAuto Op HrsBackup Op HrsInactive Data SetsActive Data Sets
NREL cdp_lab_04
Created: Mar-30-12 4:02 PM 1) Data set count at publication of a CDP set - where a data set represents a short stack, full stack, or system test data.
MHE Field (1) Lab MHE (2)0
5000
10000
15000
20000
25000
Proj
ecte
d H
ours
to 1
0% V
olta
ge D
rop
Comparison of Fuel Cell Material Handling Equipment Field and Lab Durability Projections
Average Projection3
Max Projection3
NREL cdp_lab_05
Created: Mar-21-12 5:39 PM
(1) MHE Data from DOE's Early Market Demonstration (2009 - )(2) Lab data providers may not be the same as participants in DOE's Field Demonstration. 20% of data are full active area short stacks.(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 500
10
20
30
40
50
60
70
80
90
100
Dat
a Se
t1 [%]
Power Capability2 [kW]
Power Capability of Test Data Sets
BackupAutomotiveForkliftPrime
NREL cdp_lab_06
Created: Mar-30-12 2:30 PM
>50
1) A data set represents a short stack, full stack, or system test data.2) Power capability represents the maximum power for a data set but not necessarily the load profile or time at a power level.
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 100000
5
10
15
20
25
Operation Hours
Dat
a Se
ts1 [%
]
Operation Hours and Data Sets Operated Beyond 10% Voltage Degradation
Data Sets < 10% VdegData Sets2 > 10% Vdeg
NREL cdp_lab_07
Created: Mar-30-12 4:02 PM
>10000
1) A data set represents a short stack, full stack, or system test data.2) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and does not address catastrophic failure modes. Some data sets have operated beyond 10% voltage degradation because they are able to satisfy the operating requirements at a higher percentage of voltage degradation or the test is designed to operate until a failure.
All Short Stack Full Stack System Steady Duty Cycle Accelerated0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
22000Projected Hours to 10% Voltage Degradation by Configuration and Test Condition
Proj
ecte
d H
ours
to 1
0% V
olta
ge D
egra
datio
n1,2
Average -BackupAverage -AutomotiveAverage -ForkliftAverage -Prime
NREL cdp_lab_08
Created: Mar-30-12 3:02 PM
Configurations, All Test Conditions Test Conditions3, All Configurations1) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and does not address catastrophic failure modes.2) Not all applications have data sets in each configuration or test condition group.3) Steady - little or no change to load profile Duty Cycle - load profile mimics real-world operating conditions Accelerated - test profile is more aggressive than real-world operating conditions
Op Hr Proj Hr Op Hr Proj Hr Op Hr Proj Hr Op Hr Proj Hr0
5000
10000
15000
20000
25000
30000
35000
40000
45000
53% of data setsare short stacks2
Backup
50% of data setsare short stacks2
Automotive
0% of data setsare short stacks2
Forklift
45% of data setsare short stacks2
Stationary
Hou
rs
Operation Hours and Projected Hours to 10% Voltage Drop - Lab Data Sets1
25th-75th PercentileMax Op HrAvg Op HrMax Proj Hr3
Avg Proj Hr3
DOE Target4
NREL cdp_lab_01
Created: Aug-02-11 6:21 PM
(1) At least 9 fuel cell developers supplied data. Analysis will be updated periodically.(2) PEM & SOFC data from lab tested, full active area short stacks and systems with full stacks. Data generated from constant load, transientload, and accelerated testing between 2004 and early 2011.(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.(4) DOE targets are for real-world applications; refer to Hydrogen, Fuel Cells, & Infrastructure Technologies Program Plan.
10% 15% 20% 25%0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
Voltage Degradation Levels2,6
Proj
ecte
d H
ours
3,4,
5
Durability Lab Data Sets1 - Average Projected Hour Sensitivity to Voltage Degradation Levels
Automotive Average ProjectionBackup Average ProjectionForklift Average ProjectionStationary Average Projection
NREL cdp_lab_02
Created: Aug-02-11 6:22 PM
(1) PEM & SOFC data from lab tested, full active area short stacks and systems with full stacks. Data generated from constant load, transient load, and accelerated testing between 2004 and early 2011.(2) 10% Voltage degradation is a DOE metric for assessing fuel cell performance.(3) Curves generated using the average of each application at various voltage degradation levels.(4) The projection curves display the sensitivity to percentage of voltage degradation, but the projections do not imply that all stacks will (or do) operate at these voltage degradation levels.(5) Projections may be limited by demonstrated operation hours to minimize extrapolations.(6) The voltage degradation levels are not an indication of an OEM's end-of-life criteria and do not address catastrophic stack failures such as membrane failure.
Gen1 Auto (1) Gen2 Auto (1) Lab Auto (2)0
2000
4000
6000
8000
10000
12000
14000
2006 Target
2009 Target
2015 Target
Proj
ecte
d H
ours
to 1
0% V
olta
ge D
rop
Comparison of Fuel Cell Vehicle Field and Lab Durability Projections
Average Projection3
Max Projection3
NREL cdp_lab_03
Created: Aug-02-11 6:21 PM
(1) Gen1 and Gen2 Data from DOE's Learning Demonstration (2005 - 2010)(2) Lab data providers may not be the same as participants in DOE's Learning Demonstration. 53% of data are full active area short stacks.(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.
2008 2009 2010 20110
50
100
150
200
250
Ope
ratio
n H
ours
[1,0
00]
0
20
40
60
80
100
Dat
a Se
t Cou
nt
Cumulative Lab Data Operation Hours and Dates
05/2
009
CD
Ps1
12/2
009
CD
Ps1
06/2
010
CD
Ps1
07/2
011
CD
Ps1
Prime Op HrsForklift Op HrsAuto Op HrsBackup Op HrsInactive Data SetsActive Data Sets
NREL cdp_lab_04
Created: Aug-02-11 6:44 PM 1) Data set count at publication of a CDP set
MHE Field (1) Lab MHE (2)0
5000
10000
15000
20000
25000
Proj
ecte
d H
ours
to 1
0% V
olta
ge D
rop
Comparison of Fuel Cell Material Handling Equipment Field and Lab Durability Projections
Average Projection3
Max Projection3
NREL cdp_lab_05
Created: Aug-02-11 6:21 PM
(1) MHE Data from DOE's Early Market Demonstration (2009 - )(2) Lab data providers may not be the same as participants in DOE's Field Demonstration. 0% of data are full active area short stacks.(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.
Op Hr Proj Hr Op Hr Proj Hr Op Hr Proj Hr Op Hr Proj Hr0
5000
10000
15000
20000
25000
30000
35000
40000
45000
56% Short Stack Data Sets2
Automotive
33% Data Sets Still Operating
93% Short Stack Data Sets2
Backup
59% Data Sets Still Operating
0% Short Stack Data Sets2
Forklift
50% Data Sets Still Operating
71% Short Stack Data Sets2
Stationary
29% Data Sets Still Operating
Hou
rs
Durability Lab Data Sets1 - Hours
25th-75th PercentileMax Op HrAvg Op HrMax Proj Hr3
Avg Proj Hr3
DOE Target4
NREL cdplab01
Created: Jun-01-10 4:00 PM
(1) At least 8 fuel cell developers supplied data. Analysis will be updated periodically.(2) PEM & SOFC data from lab tested, full active area short stacks and systems with full stacks. Data generated from constant load, transientload, and accelerated testing between 2004 and early 2010.(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.(4) DOE targets are for real-world applications; refer to Hydrogen, Fuel Cells, & Infrastructure Technologies Program Plan.
10% 15% 20% 25%0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
22000
Voltage Degradation Levels2,6
Proj
ecte
d H
ours
3,4,
5
Durability Lab Data Sets1 - Average Projected Hour Sensitivity to Voltage Degradation Levels
Automotive Average ProjectionBackup Average ProjectionForklift Average ProjectionStationary Average Projection
NREL cdplab02
Created: Jun-01-10 4:01 PM
(1) PEM & SOFC data from lab tested, full active area short stacks and systems with full stacks. Data generated from constant load, transient load, and accelerated testing between 2004 and early 2010.(2) 10% Voltage degradation is a DOE metric for assessing fuel cell performance.(3) Curves generated using the average of each application at various voltage degradation levels.(4) The projection curves display the sensitivity to percentage of voltage degradation, but the projections do not imply that all stacks will (or do) operate at these voltage degradation levels.(5) Projections may be limited by demonstrated operation hours to minimize extrapolations.(6) The voltage degradation levels are not an indication of an OEM's end-of-life criteria and do not address catastrophic stack failures such as membrane failure.
Gen1 Auto (1) Gen2 Auto (1) Lab Auto (2)0
2000
4000
6000
8000
10000
12000
14000
2006 Target
2009 Target
2015 Target
Proj
ecte
d H
ours
to 1
0% V
olta
ge D
rop
Comparison of Fuel Cell Vehicle Field and Lab Durability Projections
Average Projection3
Max Projection3
NREL cdplab03
Created: Jun-01-10 4:00 PM
(1) Gen1 and Gen2 Data from DOE's Learning Demonstration (2005 - 2010)(2) Lab data providers may not be the same as participants in DOE's Learning Demonstration. 56% of data are full active area short stacks.(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.
Automotive Forklift StationaryApplication Category
Tim
e [H
ours
](5)
0
5000
10000
15000
20000
25000
30000
35000
40000
45000Automotive Target6
Stationary Target6
Created: Dec-01-09 4:29 PM
(1) The DOE 10% voltage degradation metric isa general metric for assessing voltagedegradation, which may not be the same as anOEM's end-of-life criteria and does not address"catastrophic" failure modes such as membranefailure. (2) Collected data consists of lab test data fromshort stacks and systems in multiple applications. (3) Collected data was generated with varioustest bench operation such as constant currentand accelerated degradation tests. (4) Operating period for collected data spansfrom 2004 to early 2009. (5) The upper limit of the bar represents themaximum operating time to 10% voltagedegradation. (6) The DOE Automotive and Stationary targetsare applied to real-world applications; refer toHydrogen, Fuel Cells, & InfrastructureTechnologies Program Plan.
PEM Fuel Cell Stack 10% Voltage Degradation Projections1 -Laboratory Durability Test Data2-4
Op Hr Proj Hr Op Hr Proj Hr Op Hr Proj Hr Op Hr Proj Hr Op Hr Proj Hr Op Hr Proj Hr0
5000
10000
15000
20000
25000
30000
35000
40000
45000
Backup Automotive Bus Forklift Portable
N
ot E
noug
h D
ata
for C
DP
Prime
Hou
rs
Operation Hours and Projected Hours to 10% Voltage Drop1
25th-75th PercentileMax Op HrAvg Op HrMax Proj Hr3
Avg Proj Hr3
DOE Target4
NREL cdp_lab_01
Created: Mar-21-13 8:54 PM
(1) At least 15 U.S. and international fuel cell developers supplied data. Analysis is updated periodically.(2) PEMFC, DMFC & SOFC data from lab tested, full active area short stacks and systems with full stacks. Data generated from constant load,transient load, and accelerated testing between 2004 and early 2012.(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.(4) DOE targets are for real-world applications; refer to Hydrogen, Fuel Cells, & Infrastructure Technologies Program Plan.
10% 15% 20% 25%0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
22000
Voltage Degradation Levels2,6
Proj
ecte
d H
ours
3,4,
5
Durability Lab Data Sets1 - Average projected Hour Sensitivity to Voltage Degradation Levels
Average -ForkliftAverage -PrimeAverage -BusAverage -AutomotiveAverage -Backup
NREL cdp_lab_02
Created: Mar-25-13 1:02 PM
(1) PEM & SOFC data from lab tested, full active area short stacks and systems with full stacks. Data generated from constant load, transient load, and accelerated testing between 2004 and 2012.(2) 10% Voltage degradation is a DOE metric for assessing fuel cell performance.(3) Curves generated using the average of each application at various voltage degradation levels.(4) The projection curves display the sensitivity to percentage of voltage degradation, but the projections do not imply that all stacks will (or do) operate at these voltage degradation levels.(5) Projections may be limited by demonstrated operation hours to minimize extrapolations.(6) The voltage degradation levels are not an indication of an OEM's end-of-life criteria and do not address catastrophic stack failures such as membrane failure.
Gen1 Auto (1) Gen2 Auto (1) Lab Auto (2)0
2000
4000
6000
8000
10000
12000
14000
2006 Target
2009 Target
2015 Target
Proj
ecte
d H
ours
to 1
0% V
olta
ge D
rop
Comparison of Fuel Cell Vehicle Field and Lab Durability Projections
Max Projection3
Average Projection3
NREL cdp_lab_03
Created: Mar-21-13 8:57 PM
(1) Gen1 and Gen2 Data from DOE's Learning Demonstration (2005 - 2010)(2) Lab data providers may not be the same as participants in DOE's Learning Demonstration. 50% of data are full active area short stacks.(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.
2008 2009 2010 2011 2012 20130
50
100
150
200
250
300
Ope
ratio
n H
ours
[1,0
00]
0
20
40
60
80
100
Dat
a Se
t Cou
nt
Cumulative Lab Data Operation Hours and Dates
05/2
009
CD
Ps1
12/2
009
CD
Ps1
06/2
010
CD
Ps1
07/2
011
CD
Ps1
03/2
012
CD
Ps1
03/2
013
CD
Ps1
Backup Op HrsAuto Op HrsBus Op HrsForklift Op HrsPrime Op HrsActive Data SetsInactive Data Sets
NREL cdp_lab_04
Created: Mar-21-13 8:58 PM 1) Data set count at publication of a CDP set - where a data set represents a short stack, full stack, or system test data.
MHE Field (1) Lab MHE (2)0
5000
10000
15000
20000
25000
Proj
ecte
d H
ours
to 1
0% V
olta
ge D
rop
Comparison of Fuel Cell Material Handling Equipment Field and Lab Durability Projections
Max Projection3
Average Projection3
NREL cdp_lab_05
Created: Mar-21-13 9:14 PM
(1) MHE Data from DOE's Early Market Demonstration (2009 - )(2) Lab data providers may not be the same as participants in DOE's Field Demonstration. 67% of data are full active area short stacks.(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 500
10
20
30
40
50
60
70
80
90
100
Dat
a Se
t1 [%]
Power Capability2 [kW]
Power Capability of Test Data Sets
BackupAutomotiveBusForkliftPrime
NREL cdp_lab_06
Created: Mar-21-13 8:58 PM
>50
1) A data set represents a short stack, full stack, or system test data.2) Power capability represents the maximum power for a data set but not necessarily the load profile or time at a power level.
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 100000
5
10
15
20
25
Operation Hours
Dat
a Se
ts1 [%
]
Operation Hours and Data Sets Operated Beyond 10% Voltage Degradation
Data Sets2 > 10% VdegData Sets < 10% Vdeg
NREL cdp_lab_07
Created: Mar-21-13 8:59 PM
>10000
1) A data set represents a short stack, full stack, or system test data.2) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and does not address catastrophic failure modes. Some data sets have operated beyond 10% voltage degradation because they are able to satisfy the operating requirements at a higher percentage of voltage degradation or the test is designed to operate until a failure.
All Short Stack Full Stack System Steady Duty Cycle Accelerated0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
22000Projected Hours to 10% Voltage Degradation by Configuration and Test Condition
Proj
ecte
d H
ours
to 1
0% V
olta
ge D
egra
datio
n1,2
Average -PrimeAverage -ForkliftAverage -AutomotiveAverage -Backup
NREL cdp_lab_08
Created: Apr-01-13 1:42 PM
Configurations, All Test Conditions Test Conditions3, All Configurations1) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and does not address catastrophic failure modes.2) Not all applications have data sets in each configuration or test condition group.3) Steady - little or no change to load profile Duty Cycle - load profile mimics real-world operating conditions Accelerated - test profile is more aggressive than real-world operating conditions
0 10 20 30 40 50 60 70 80 90 100
Data Sets [%]
Configurations by Data Set
Backup
Automotive
Bus
Forklift
Prime
Full Stack Full System Short Stack Single Cell
NREL cdp_lab_09
Created: Mar-26-13 11:30 AM
2010 2011 2012 20132
4
6
8
10
12
14
16
18Average Projected Hours to 10% Voltage Drop1,2
Year
Proj
ecte
d H
ours
[1,0
00]
BackupAutomotiveForkliftPrimeBus
NREL cdp_lab_10
Created: Apr-01-13 2:32 PM
(1) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.(2) At least 13 fuel cell developers supplied data, including international. Analysis is updated periodically.
2010 2011 2012 20130
2
4
6
8Backup
Proj
ecte
d H
ours
[1,0
00]
2010 2011 2012 20130
5
10
15Automotive
Proj
ecte
d H
ours
[1,0
00]
2010 2011 2012 20130
5
10
15
20
25Forklift
Proj
ecte
d H
ours
[1,0
00]
2010 2011 2012 20130
10
20
30
40
50
Proj
ecte
d H
ours
[1,0
00]
Prime
Avg Proj HrMax Proj Hr25th-75th Percentile
NREL cdp_lab_11
Created: Apr-01-13 2:32 PM
Projected Hours to 10% Voltage Drop1,2
(1) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.(2) At least 13 fuel cell developers supplied data, including international. Analysis is updated periodically.
0 10 20 30 40 50 60 70 80 90 100
Data Sets [%]
Fuel by Data Set
Backup
Automotive
Bus
Forklift
Prime
Hydrogen Reformate
NREL cdp_lab_12
Created: Apr-01-13 3:06 PM
0 10 20 30 40 50 60 70 80 90 100
Data Sets [%]
Test Conditions by Data Set
Backup
Automotive
Bus
Forklift
Prime
Accelerated Duty Cycle Steady
NREL cdp_lab_13
Created: Mar-25-13 1:51 PM
0 10 20 30 40 50 60 70 80 90 100
Backup
Automotive
Forklift
Prime
Data Sets [%]
Current Density Point by Data Set1
<=0.2 [A/cm2] <=0.4 [A/cm2] <=0.6 [A/cm2] <=0.8 [A/cm2] <=1.0 [A/cm2] <=1.2 [A/cm2]
NREL cdp_lab_14
Created: Apr-01-13 10:20 AM 1) Current density referenced are the points at which the voltage degradation is analyzed in CDP Lab 01
The current analysis set is the 5th annual update. The number of data sets, participants, and results have increased each year.
8
2008 2009 2010 2011 2012 20130
50
100
150
200
250
300
Ope
ratio
n H
ours
[1,0
00]
0
20
40
60
80
100
Dat
a Se
t Cou
nt
Cumulative Lab Data Operation Hours and Dates
05/2
009
CD
Ps1
12/2
009
CD
Ps1
06/2
010
CD
Ps1
07/2
011
CD
Ps1
03/2
012
CD
Ps1
03/2
013
CD
Ps1
Backup Op HrsAuto Op HrsBus Op HrsForklift Op HrsPrime Op HrsActive Data SetsInactive Data Sets
NREL cdp_lab_04
Created: Mar-21-13 8:58 PM 1) Data set count at publication of a CDP set - where a data set represents a short stack, full stack, or system test data.
Accomplishments: Data Set Count and Operation Hours 04/2013 CDPs include 98 data sets analyzed, 78% retired 16 new data sets since 05/2012 14 CDPs (6 new since 05/2012)
9
* DOE Targets Under Review
* *
Accomplishments: Voltage Degradation Results by Application The average projected times to 10% voltage drop are 2,500, 3,600, 6,200, 14,600, and 9,300 for backup power, automotive, bus, forklift, and stationary applications, respectively.
PEMFC & SOFC data from lab tested, full active area short stacks and systems with full stacks. Data generated from constant load, transient load, and accelerated testing and includes 15 U.S. and international fuel cell developers.
10
Accomplishments: Voltage Degradation by Configuration and Test Condition
All Short Stack Full Stack System Steady Duty Cycle Accelerated0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
22000j g g y g
Proj
ecte
d H
ours
to 1
0% V
olta
ge D
egra
datio
n1,2
Average -PrimeAverage -ForkliftAverage -AutomotiveAverage -Backup
NREL cdp_lab_08
Created: Apr-01-13 1:42 PM
Configurations, All Test Conditions Test Conditions3, All Configurations1) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and does not address catastrophic failure modes.2) Not all applications have data sets in each configuration or test condition group.3) Steady - little or no change to load profile Duty Cycle - load profile mimics real-world operating conditions Accelerated - test profile is more aggressive than real-world operating conditions
Not all applications have data sets in each configuration or test condition group. Steady – little of no change to load profile Duty Cycle – load profile mimics real-world operating conditions Accelerated – test profile is more aggressive than real-world operating conditions
Updated since 05/2012
Grouping by configuration and test condition is important because of influences on degradation projects. Conclusions are still difficult to identify because of limited data and many variations in these groups. Further study and additional data are needed.
11
Accomplishments: Breakdown of Data Set Configuration Used for Voltage Degradation Results
0 10 20 30 40 50 60 70 80 90 100
Data Sets [%]
Backup
Automotive
Bus
Forklift
Prime
Full Stack Full System Short Stack Single Cell
NREL cdp_lab_09
Created: Mar-26-13 11:30 AM
Configuration is connected to test objective, technology generation, setup, and design. Configuration can have a significant impact on the voltage degradation projects and is an area for continued study and data gathering.
12
Accomplishments: Breakdown of Data Set Test Conditions Used for Voltage Degradation Results
0 10 20 30 40 50 60 70 80 90 100
Data Sets [%]
Backup
Automotive
Bus
Forklift
Prime
Accelerated Duty Cycle Steady
NREL cdp_lab_13
Created: Mar-25-13 1:51 PM
Steady operation is a common protocol for all studied applications. Test condition has a significant impact on the voltage degradation and is an area for continued study and data gathering.
13
Accomplishments: Breakdown of Current Densities Used for Voltage Degradation Results
0 10 20 30 40 50 60 70 80 90 100
Backup
Automotive
Forklift
Prime
Data Sets [%]
y y
<=0.2 [A/cm2] <=0.4 [A/cm2] <=0.6 [A/cm2] <=0.8 [A/cm2] <=1.0 [A/cm2] <=1.2 [A/cm2]
NREL cdp_lab_14
C t d A 01 13 10 20 AM
Current density point at which the projected time to 10% voltage degradation is analyzed varied based on available data, test purpose, and application. Future analysis will look to publish voltage degradation at common current density points.
New since 05/2012
14
Accomplishments: Average Projected Hours to 10% Voltage Degradation by Year
2010 2011 2012 20132
4
6
8
10
12
14
16
18Average Projected Hours to 10% Voltage Drop1,2
Year
Proj
ecte
d H
ours
[1,0
00]
BackupAutomotiveForkliftPrimeBus
NREL cdp_lab_10
Created: Apr-01-13 2:32 PM
(1) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.(2) At least 13 fuel cell developers supplied data, including international. Analysis is updated periodically.
Most applications have seen an increase in average time to 10% voltage degradation over the last three years. Averages may decrease from year to year based on new data sets added and varied test conditions and configurations.
15
Accomplishments: Project Information Package
System price data for price benchmarking
Pamphlet with participation details and benefits
Website with published results and presentations Example CDP results
for price data
New since 05/2012
Metadata for voltage degradation analysis
16
Collaborations • Working with multiple fuel cell developers
o 15 of 68 fuel cell developers contacted have supplied at least one dataset o Reasons for developers not providing data include concerns over voluntary
proprietary data sharing, availability of data sets with high operation time that are a good fit to include in the analysis, and readily accessible data in the requested format.
o Data contributors are not identified yet because of limited data sets by application category.
• Gathering PEMFC, DMFC, and SOFC datasets • Data sharing is completely voluntary • Participation in DOE durability working group and presentation of status
to fuel cell tech team • Ongoing effort with fuel cell developers to:
o Include new data sets (particularly in the stationary category) o Update datasets already included if applicable o Include new fuel cell developers
17
Future Work
• Publish report on durability analysis method • Add price information to the project collaboration pamphlet • Continue cultivating existing collaborations and developing new
collaborations with fuel cell developers. • Next planned update is 03/2014 • Possibilities that may be included in the next update are:
o Expand results aimed at improving data comparability and statistical confidence
o Voltage degradation at common and multiple current density points and power points
o Price benchmarking o Results by testing protocol o PEM, SOFC, & DMFC o Single cell o Investigate other aging parameters for fuel cell durability (e.g.
start/stops, soak time)
18
Future Work: Price Data
Objective: Report on status and establish expectation of current price data at low volumes.
1) DOE cost targets for 1 – 10 kW residential (http://www1.eere.energy.gov/hydrogenandfuelcells/mypp/pdfs/fuel_cells.pdf) 2) Data estimate source is from ARRA installations in 2012 dollars. 3) Data estimate source is from public information in 2012 dollars for US and international companies and multiple fuel cell types (≤5kW).
2 2 3
19
Summary Relevance: Independent assessment of state-of-the-art fuel cell technology provides one location for fuel cell durability status from leading fuel cell developers with a uniform analysis and reporting method on a variety of proprietary data.
Approach: Leverage capabilities established under other technology validation activities (NRELFAT) and industry collaborations.
Accomplishments: Fifth annual results were updated for 5 applications plus started portable and include new details based on metadata and durability trends over time and international developers. The data are fully integrated into NRELFAT and an online interface provides information on the project, connection for interested collaborators, and all publications. Improved project information material for details and benefits of participation.
Collaborations and Future Work: Continue expanding analyzed data sets, included fuel cell developers, and results and have price benchmarking.
20
Technical Backup
21
Relevance - Benefits of Lab Fuel Cell Durability Analysis
External • One source of durability status
for DOE from the leading fuel cell developers
• Independent technology assessment with uniform analysis on proprietary data
• Highlights technology successes
• Helps adoption of fuel cell technology
• Identifies areas for continued development
• Possible to study differences between field and lab performance
• Benchmarking against CDPs • Analysis method may provide
a new way to study fuel cell durability
• Collaboration with NREL’s technology validation team; dedicated analysis team with experience in multiple fuel cell applications
• Provide information that is very useful for external partners (e.g. DOE) without revealing proprietary information
• Possible to study differences between field and lab performance
Internal
22
Accomplishments: Voltage Degradation by Year
2010 2011 2012 20130
2
4
6
8Backup
Proj
ecte
d H
ours
[1,0
00]
2010 2011 2012 20130
5
10
15Automotive
Proj
ecte
d H
ours
[1,0
00]
2010 2011 2012 20130
5
10
15
20
25Forklift
Proj
ecte
d H
ours
[1,0
00]
2010 2011 2012 20130
10
20
30
40
50
Proj
ecte
d H
ours
[1,0
00]
Prime
Avg Proj HrMax Proj Hr25th-75th Percentile
NREL cdp_lab_11
Created: Apr-01-13 2:32 PM
Projected Hours to 10% Voltage Drop1,2
(1) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and doesnot address catastrophic failure modes.(2) At least 13 fuel cell developers supplied data, including international. Analysis is updated periodically.
23
Accomplishments: Data Set Power Capability
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 500
10
20
30
40
50
60
70
80
90
100
Dat
a Se
t1 [%]
Power Capability2 [kW]
Power Capability of Test Data Sets
BackupAutomotiveBusForkliftPrime
NREL cdp_lab_06
Created: Mar-21-13 8:58 PM
>50
1) A data set represents a short stack, full stack, or system test data.2) Power capability represents the maximum power for a data set but not necessarily the load profile or time at a power level.
The power capability illustrates the range of fuel cell power for the data sets by application and that many of the data sets are low power either because of short stacks or because high power is not required.
1) A data set represents a short stack, full stack, or system test data. 2) The power capability represents the maximum power for a data set, not the load profile
or time at a power level.
24
Accomplishments: Data Set Operation Hours and the Percentage of Data Sets That Have Passed 10% Voltage Degradation
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 100000
5
10
15
20
25
Operation Hours
Dat
a Se
ts1 [%
]
Operation Hours and Data Sets Operated Beyond 10% Voltage Degradation
Data Sets2 > 10% VdegData Sets < 10% Vdeg
NREL cdp_lab_07
Created: Mar-21-13 8:59 PM
>10000
1) A data set represents a short stack, full stack, or system test data.2) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as end-of-life criteria and does not address catastrophic failure modes. Some data sets have operated beyond 10% voltage degradation because they are able to satisfy the operating requirements at a higher percentage of voltage degradation or the test is designed to operate until a failure.
Many data sets have not (or did not) pass the metric of 10% voltage degradation. Data sets operated beyond 10% voltage degradation because end-of-life criteria may be greater than 10% voltage degradation or the test is designed to operate until a failure.
1) A data set represents a short stack, full stack, or system test data. 2) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it
may not be the same as end-of-life criteria and does not address catastrophic failures.
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