u.s. zero emission bus evaluation results. fceb and beb data reports nre… · 1 m 2 zeba sl afcb...
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U.S. Zero Emission Bus Evaluation Results
Leslie EudyNational Renewable Energy LaboratoryCaFCP Bus TeamMeetingCaFCP Bus Team MeetingDec 16, 2015
Presentation Overview
Summary of results from two recent reports:
2
Report complete and posted on NREL site Report in review by CARB
ZEB Evaluation Objectives• Validate zero‐emission bus (ZEB) performance and cost compared to DOE/DOT
targets and conventional technologies
• Document progress and “lessons learned” on implementing fuel cell systems in p ptransit operations to address barriers to market acceptance
CurrentFCEBTargets* 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 90y %
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 20/7p days per week
Maintenance cost $/mile 0.75 0.40
Fuel economy Miles per diesel 8 8
3
Fuel economy gallon equivalent 8 8
* Fuel Cell Technologies Program Record # 12012, Sep 2012, www.hydrogen.energy.gov/pdfs/12012_fuel_cell_bus_targets.pdf
Technology Readiness Levels
Manufacturer teams for ZEBs currently operating in the United States
Bus OEM Length (ft)
Fuel Cell System Hybrid System Design Strategy Energy Storage TRL Level
Van Hool 40 US HybridSiemens ELFA integrated by
Van HoolFuel cell dominant Lithium-based batteries 7
ElDorado 40 Ballard BAE Systems Fuel cell dominant Lithium based batteries 7ElDorado 40 Ballard BAE Systems Fuel cell dominant Lithium-based batteries 7
Proterra 35 Hydrogenics Proterra Battery dominant
FCEBLithium-titanate batteries 6
EVAmerica 32 Ballard Embedded Power Battery dominant FCEB Lithium-titanate batteries 6
P t 35 N/A P t B tt l t i Lithi tit t b tt i 7
4
Proterra 35 N/A Proterra Battery electric Lithium-titanate batteries 7
BYD 40 N/A BYD Battery Electric Iron-phosphate 6 - 7
Data included in Presentation
FCEB Data Summary for 2015
FCEB Identifier ACT ZEBA SL AFCBTransit Agency AC Transit SunLine
ACT ZEBA
Specifications for TRL 7 FCEBs included in data summary
Transit Agency AC Transit SunLineNumber of Buses 12 4Bus OEM Van Hool ElDorado NationalBus length/height 40 ft / 136 in 40 ft / 140 inFuel Cell OEM US Hybrid BallardModel PureMotion 120 FCvelocity, HD6Power (kW) 120 150
Hybrid SystemSiemens ELFA,
integrated by Van Hool
BAE Systems HybriDrive
SL AFCBHoolDesign strategy FC dominant FC dominantEnergy Storage ‐ OEM EnerDel A123
Type Li‐ionNanophosphate
Li‐ion
SL AFCB
Capacity 17.4 kWh 11 kWh# cylinders 8 8Capacity (kg) / Pressure (Bar) 40 / 350 50 / 350
5
Top Fuel Cell Powerplant exceeds 20,000 Hours
30,000
/ l
Total hours accumulated on each FC powerplant (FCPP) as of 9/30/15
71% of FCPPs
20,000
25,000DOE/FTA Ultimate Target
DOE/FTA 2016 Target
over 10,000 hours
15,000
,
otal
Hou
rs
DOE/FTA 2016 Target
5,000
10,000
T Average: 10,341
0
5,000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
6
AC Transit SunLineNREL cdp_busCreated Oct‐26‐15
Average Bus Availability
M thl b il bilit
90
100
DOE/DOT Target
Monthly bus availability
60
70
80 Transit Target
40
50
60
Perc
ent
10
20
30
Average availability: 73%FCPP A il bilit 91%
0
10 FCPP Availability: 91%
7
Average ACT ZEBA SL AFCB FC System onlyNREL cdp_busCreated Sep‐3‐15
Availability = planned operation days compared to actual operation days
Reasons for Unavailability by Siteb
Fuel Cell System
41%Bus-related
PM4%
ACT ZEBA Number %FC System 448 41Hybrid propulsion 88 8Traction batteries 88 8
41%
Hybrid Propulsion
8%Batteries
8%
39% Bus maintenance 427 39Preventive maint. 46 4Total unavailable days 1097 100Total planned days 4380
PM3%
ACT ZEBA SL AFCB Number %FC System 54 21Hybrid propulsion 95 37
Fuel Cell System
21%Bus-related29%
3% Hybrid propulsion 95 37Traction batteries 28 11Bus maintenance 75 29Preventive maint. 7 3Total unavailable days 259 100
Hybrid Propulsion
36%
Batteries11%
Total unavailable days 259 100Total planned days 920
Unavailability categorized based on current reported diagnosis and could
8
SL AFCBNREL cdp_bus
Created Sep‐3‐15
current reported diagnosis and could change as new information is received.
Monthly Fuel Economy compared to Baseline9
7
8
9.
5
6
l gal
lon
equi
v.
3
4
iles
per d
iese
l
1
2Mi
ZEBA SL AFCB ACT VH Diesel ACT Gillig Diesel SunLine CNG
0Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15
NREL cdp_busCreated Sep‐3‐15
9
FCEBs: AC Transit: 6.74 Baselines: Van Hool diesel: 4.4 SunLine: 6.43 Gillig diesel: 3.9
CNG: 4.51
Reliability: Miles Between Roadcall (MBRC)
20 000
25,000
FC System MBRC Ultimate Target
15,000
20,000
n R
oadc
all
Bus MBRC
y g
FC System MBRC 2016 Target
10,000
Mile
s B
etw
een Bus MBRC
FC System MBRC
0
5,000
M
Bus MBRC Ultimate Target
Bus MBRC 2016 Target
NREL cdp_busCreated Sep‐3‐15
10
Overall bus and FC System MBRC shows an upward trend, surpassing the 2016 and ultimate targets.
Summary of TRL 7 FCEB Results
Documented progress toward targets:
Fleet Min Fleet Max Fleet Avg. 2016 Target Ultimate TargetTarget
Bus lifetime (years) 0.25 4.9 3.6 12 12
Bus lifetime (miles) 7,978 117,217 81,108 500,000 500,000
P l tPowerplantlifetime1(hr) 667 20,024 10,102 18,000 25,000
Bus availability (%) 40 92 73 85 90
Roadcall frequency-Roadcall frequency-bus 1,809 6,849 4,280 3,500 4,000
Roadcall frequency-fuel cell system 9,045 104,886 20,531 15,000 20,000
M i t tMaintenance cost ($/mi)2 0.54 1.28 1.13 0.75 0.40
Fuel economy (mpDGE) 5.56 7.71 7.02 8 8
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1 Fuel cell hours accumulated to date. Does not indicate end of life.2 Maintenance cost data from most recent reports for each project.
Foothill Transit BEBs
FCEB Identifier BEBTransit Agency Foothill TransitN b f B 12
Specifications Foothill BEBs
Number of Buses 12Bus OEM ProterraBus length/height 35 ft / 126 in
Charging strategyFast‐charge, on‐
C a g g st ategyroute
MotorPermanent
magnet, UQM, PP220
R t d P (kW) 220 ( k)Rated Power (kW) 220 (peak)Energy Storage ‐ OEM AltairnanoType Lithium‐titanateCapacity 368 volts, 88 kWh
12
BEB Energy Use and Charges4 00080 000
3 000
3,500
4,000
60 000
70,000
80,000
2,500
3,000
50,000
60,000
Cha
rges
ed (k
Wh)
1,500
2,000
30,000
40,000
Num
ber o
f
Ener
gy u
s e
500
1,000
10,000
20,000
00
Energy use kWh Number of charges
13
Energy use kWh Number of charges
Average kWh per month: 61,174 Average # charges per month: 3,131
Monthly Fuel Economy compared to Baseline
80
90
100
16
18
20
F)
60
70
10
12
14
Tem
pera
ture
(F
omy
(mpD
GE)
30
40
50
4
6
8
Aver
age
Hig
h
Fuel
Eco
n o
10
20
0
2
4
BEB (35-ft) CNG (Orion, 40-ft) CNG (NABI, 42-ft) Avg High Temp (F)
BEB average: 2.15 kWh/mi, 17.48 mi/DGE
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average: . 5 kWh/mi, 7.48 mi/ GCNG baselines: Orion 40‐ft: 4.4 mi/DGE
NABI 42‐ft: 4.51 mi/DGE
Average Bus Availability
80
90
100
80%
90%
100%
ESS
Reasons for Unavailability
60
70
80
60%
70%
80%
days
ity
ESS
ChargingissuesElectric drive
40
50
40%
50%
Num
ber o
f d
Avai
labi
li
PM
Bus
10
20
30
10%
20%
30% BEB
CNG
Target
0
10
0%
10%
Apr-1
4
May
-14
un-1
4
Jul-1
4
Aug-
14
Sep-
14
Oct
-14
Nov
-14
Dec
-14
an-1
5
Feb-
15
Mar
-15
Apr-1
5
May
-15
un-1
5
Jul-1
5
Target
w/o 2013
15
A M J J A S O N D J F M A M J JAverage availability: 90%w/o outlier: 93%
Reasons for Unavailability
Electric drive
Charging issues
1%
ESS9%
drive22%
BusPM
Bus66%
2%
Foothill Number %ESS 40 9ESS 40 9Electric drive 101 22Charging issues 6 1Bus maintenance 301 66
16
Preventive maintenance 8 2Total unavailable days 456 100Total planned days 4,600
Reliability: Miles Between Roadcall (MBRC)
200,000
250,000BEB Bus MBRC
BEB Propulsion MBRC
BEB Battery MBRC
150,000
een
Roa
dcal
l CNG Bus MBRC
CNG Propulsion MBRC
Bus MBRC Target
100,000
Mile
s B
etw
e ESS MBRC Target
0
50,000
Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15
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Early results show the BEB performance meets the ultimate targets.
Remaining Challenges and Barriers for ZEBsS ifi FCEBSpecific to FCEBs
• Increase durability and reliability of components
• Continue transition of build process to OEM• Continue transition of build process to OEM
• Addition of fueling infrastructure
Specific to BEBsp
• Plan/build of opportunity charging stations & garage chargers
• Select appropriate routes for technology
• Address challenge of electric rates and demand charges
Common to all ZEBs
• Develop robust supply chain for components and parts
• Increase learning curve for maintenance staff—training and tools
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tools
• Reduce cost, both capital and operating
For more information
NREL Hydrogen Technology Validation web page:www.nrel.gov/hydrogen/proj_tech_validation.html
C t t I f L li E dContact Info: Leslie Eudy
Phone: 303‐275‐4412
Email: leslie eudy@nrel govEmail: leslie.eudy@nrel.gov
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