fuel cell vehicle learning demonstration: spring 2007 ...1 fuel cell vehicle learning demonstration:...

1

Fuel Cell Vehicle Learning Demonstration:

Spring 2007 Results

Keith Wipke, Sam Sprik, Holly Thomas, Cory Welch1

Sigmund Gronich, John Garbak2

NHA Conference, San Antonio, TXMarch 20, 2007

1NREL, 2US Dept. of Energy

This presentation does not contain any proprietary or confidential information

NREL/PR-560-41389

2

Outline

3

Fuel Cell Vehicle Learning Demonstration Project Objectives and Targets

•

Objectives–

Validate H2

FC Vehicles and Infrastructure in Parallel–

Identify Current Status and Evolution of the Technology

•

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

4

Over Half of Project Vehicles Now Deployed, First-Generation Predominantly Uses 5000 psi

Tanks

On-Board Hydrogen Storage Methods

-

10

20

30

40

50

60

70

80

2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2006Q3 2006Q4

# of

Veh

icle

s (A

ll Te

ams)

Liquid H210,000 psi tanks5,000 psi tanks

Created Feb-28-2007

69

5

Infrastructure Hydrogen Production Methods

0

1

2

3

4

5

DeliveredCompressed H2

Natural Gas On-site Reforming

Electrolysis Delivered LiquidH2

Production Technology

# of

Sta

tions

Created 07-Mar-2007

~Half of the Project’s Infrastructure to Refuel Vehicles Has Been Installed –

4 Types

Hydrogen and gasoline stationWashington, DC

Mobile RefuelerSan Francisco, CA

DTE/BP Power Park, Southfield, MI

Autothermal

Reformer Chino, CA

Total: 10

6

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

Northern California

Southern California

Mid-Atlantic

Florida

Mar-15-2007Additional Planned Stations (3)

Additional Planned Stations (4)


SE Michigan


7

On-Road Data Received -- Running Totals

33562

113623

0

5000

10000

15000

20000

25000

30000

35000

Sep-04

Dec-04

Mar-05

Jun-0

5

Sep-05

Dec-05

Mar-06

Jun-0

6

Sep-06

Dec-06

Mar-07

MB

of D

ata

0

20000

40000

60000

80000

100000

120000

140000

# Tr

ips

MB of data# trips

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

Through March, 2007:>113,000 individual vehicle trips

33 GB of on-road data

8

PUBLISH

Analysis Calculations and Results are from NREL-Developed GUI –

Fleet Analysis Toolkit (FAT)

TripView

9

3rd

Set of Composite Data Products Published;

Updates/Additions Every Six Months

Dy no (1) Window- Sticke r (2) On-R oad ( 3)(4)0

10

20

30

40

50

60

70

80

Fuel

Eco

nom

y (m

iles/

kg H

2)

Fue l Economy

Crea te d: 1 6-Fe b -20 06

(3 ) Exclud e s tr ips < 1 mile . O ne da ta p o in t f or on -r oa d f lee t a ver ag e o f ea ch ma ke/ mo de l.

(1 ) One d ata p oint fo r e ac h make /mo de l. Co mbin ed City /Hwy f ue l ec on omy p e r DR AFT SAEJ2 57 2 .

(2 ) Adju ste d c omb ine d C ity/Hwy fue l e co no my (0 .78 x Hwy, 0 .9 x City ).

(4 ) Calc ulate d fr om o n- ro ad fue l c ell s tack cur re nt or mass flo w re ad ing s.

0

50

1 00

1 50

2 00

2 50

3 00

A ll OEMs

Veh

icle

Ran

ge (m

iles)

Vehicle R ange (1)

20 15 Targe t20 09 Targe t

Crea te d: 2 1-Fe b -20 06(1 ) Calc ulate d fr om co mbin ed Cit y/Hwy f ue l ec on omy ( dy no tes t) pe r D RAFT SAE J 25 72 a nd usa ble fu el on bo ar d.

Safety In ciden ts - Veh icle Op eration

0

1

2

3

4

5

6

7

8

9

10

'05

Q2

'05

Q3

'05

Q4

Num

ber

of In

cide

nts

Passen ger Compartmen t H2 alarm H2 releaseCrea ted 2 1-F eb- 200 6

Sa fety Inc idents - Infr as tr uc tur e2005 Q2 - Q4

C al ibrat ion/S ett ings

El ectrical

H 2 Leak/ Unpl anned Vent

N on-H2 Leak

M ischief, V andali sm

Environmental (Weather, P ower Disrupt ion, etc. )

U nconfirm ed/ False Alarm

0 1 2 3 4 5 6 7 8 9 10

Calib

ratio

n/Se

tting

sH2

Lea

k/Unp

lann

edVe

ntM

ischi

ef, V

anda

lism

Unc

onf

irmed

/Fals

eAl

arm

Gen

eral

Cat

egor

y

Num ber of Incident sC rea te d 2 1 -Fe b -2 00 6


-

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-F eb- 2006

0

1

2

3

4

5

6

7

8

9

A ll OEMs

Wei

ght P

erce

nt H

ydro

gen

(%)

Weight Percent Hy droge n

201 5 DOE M YPP Targe t1



Crea te d: 2 3-Fe b -20 061

S ome near-te rm targets have been achieved with compre ssed a nd liquid tanks. Emp ha sis is on advanced materials-ba se d technologies.

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

A ll OEMs

Mas

s H

2 pe

r Li

ter (

kg/L

)

Ma ss of H ydrogen Per Lite r




Crea te d: 2 3-F e b -20 061Emp has is is on ad van ce d ma ter ials- ba se d tec hno lo gie s.

0

2000

4000

6000

8000

10000

12000

All OE Ms

Num

ber o

f cyc

les

Hydrogen Tank Cycle Life

2015 DOE M YP P Target1



Created: 23-Feb-20061So me nea r-ter m targ ets have be en achieved with co mpre ssed and liq uid tanks. Empha sis is on advance d mate rials-ba sed techno lo gies.

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 S ampled from St ations(1)

Range of Report ed DataISO FDTS 14687- 2 Target

Created: 21-Feb-2006(1) Includes sampling from bo th e lec trolys is and re fo rming

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

NH 3

μmol/m ol (ppm)

0 5 10 15 20 25 30 35 40 45 50

Total S Compounds*

nmol/mol (ppb)Cre ate d: Ju n-01 -06 11 :0 2 AM *I nclude s SO2, COS, an d 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)

# o

f Ref

uelin

g E

vent

s

Histogram of Vehicle Ref ueling Rates

5 minute fill of5 kg at 350 bar


2006 Tech Val M ilestone2010 MYPP Adv Sto rage Materials Targ et

Created: 21-Feb-2006

-30

-20

-10

0

10

20

30

40

50

Deg

rees

Cel

sius

Ambient Temperature Du ring Operation

All OEM sCreated: 16-Feb-2006

Vehicle Hours: All OEM's Com binedthrough Q4 2005

02468

101214161820

0-50

50-100

100-150

150 -20

0

200-2

50

250-300

300 -35

0

350-400

400-45

0>4

50

T otal Vehicle Hou rs

Nu

mbe

r of V

ehic

les T otal Vehicle Hours = 7,831


Veh icle M iles: All OEM 's Combinedthro ugh Q4 2005

0

5

10

15

20

25

0-1500

1500-3000

3000-4500

4500-6 000

60 00-7500

75 00-9000

9000-10500

10500-12000

12000-13500

> 13500

T otal Ve hicle M ile s

Num

ber o

f Veh

icles

Tot al Ve hicle M ile s Traveled = 196,405


Cum ulative Veh icle Miles Traveled: All OEMs

-

50,000

100,000

150,000

200,000

250,000

Q205 Q305 Q405

Veh

icle

Mile

s T

rave

led

Creat ed: 16-Feb-2006

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

Re por ting Ca lendar Quarter

Mas

s o

f Hy

drog

en (k

g)

C reated 21-Feb-2006

0

10

20

30

40

50

60

70

All OEM s

Effic

ienc

y (%

)

Fuel Ce ll Syste m1 Efficiency2 at ~25% Net Power.

DOE Target

Crea ted : Au g-2 9-0 6 4 :09 PM

1 Gro ss sta ck p owe r m inus fu el ce ll sys tem a uxiliarie s, p er DRAFT SAEJ2 6 15 .

2 Ratio of DC out put en erg y to th e lo wer he ating valu e o f th e in pu t fu el ( hydr og en ).Exclud es po wer ele ctr on ics a nd ele ctric dr ive.

Dy no (1) Window-St ic ker (2 ) On- Road (3 )(4)0

10

20

30

40

50

60

70

80

Fuel

Eco

nom

y (m

iles/

kg H

2)

Fue l Economy

Crea te d: Au g-2 5 -0 6 10 :45 AM

( 3) Exclu de s tr ips < 1 m ile. One d ata po int f or o n-r oa d f lee t ave ra ge o f e ach make /mo d el.

( 1) On e d ata p oint fo r e ach make /mo d el. C omb in ed City /Hwy fu el e co no my pe r D RAFT SAEJ2 57 2.

( 2) Adju ste d c omb ined Cit y/Hwy f uel eco no my (0 .7 8 x Hwy, 0 .9 x City) .

( 4) Calc ulate d fr om o n-r oa d f ue l ce ll stac k cu rre nt or mass flo w re ad ings .

0 1 0 2 0 30 40 50 6 0 7 0 80 90 1 00

Vehicle Range Fa ctors

Pe rce nta ge of chassis dyno r ange 1.

All O

EMs

Win

dow

-Sti

cker

2

On-

Roa

d 3

Dyn

o 1

Crea ted : Au g-3 0-0 6 3 :0 9 PM

1. C alcu late d u sing the co mbine d city/h wy fu el e co no my fro m dyn o t est ing (no n- adju ste d) and u sab le f ue l on bo ar d

2. Ap p lying windo w-s ticke r c or rec tion fa cto rs for fu el e co no my: 0. 78 x Hwy a nd 0.9 x C ity

3. Us ing fue l-e co no my fro m on -ro ad d ata (e xclud ing trip s > 1 mile , co ns iste nt with oth er da ta p ro du cts )3. Us ing fue l-e co no my fro m on -ro ad d ata (e xclud ing trip s > 1 mile , co ns iste nt with oth er da ta p ro du cts )

0 10 20 30 40 50 60 70 80 90 1000

10

20

30

40

50

60

70

80

90

100R ange His togram : All OE Ms

Percentage of chassis dyno range1 b/w re fuelings

Per

cent

age

of r

efue

lings

P ercentageC umula tive Percentage

Crea ted: Aug -30 -06 3 :09 PM

T otal refuelin gs2 = 2048

1. Ran ge c alcu late d usin g t he co mbin ed city /hwy fue l e co no my fr om d yno te st ing (no t E PA ad jus ted ) and u sab le fue l o n b o ard .

2. Some re fu elin g eve nts ar e no t d ete ct ed /re p or ted d ue to d ata no ise o r inc omp let en es s.

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 I

ncid

ents

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/m in)

Nu

mb

er o

f Fu

elin

g E

ven

ts

Hi stogram of Vehicle Fuel ing Rates (Thru 2006Q2)

5 minute fill of5 kg at 35 0 bar

3 minute fill o f5 kg at 350 bar

200 6 Tech Va l Milestone201 0 MYPP Adv Storage Mat erials Ta rge t

Created : A ug-29 -0 6 4 :4 7 PM

Safety Incidents - Infrastructure2005 Q2 - 2006 Q2

Electrical

Non-H2 Le ak

Fai led/Broken Equipment

Mischief, Vand alism

Calib ration/ Settings/ Ma intenan ce

Environment (Weather, Pow er Disruptio n, etc.)

H2 Leak/Un plan ned Vent

Uncon firmed/F alse Alarm

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

Ele

ctri

cal

Faile

d/B

roke

nEq

uipm

ent

Cal

ibra

tion/

Sett

ing

s/M

aint

enan

ce

H2

Lea

k/U

npla

nned

Ven

t

Gen

eral

Cat

egor

y

Number of IncidentsCreated 30-A ug-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 P

urit

y (%

)

Hydrogen Purity Sampled from S tations(1)

Data RangeDataSAE J2719

Created : S ep -0 7-06 3:32 P M( 1) Includes sampling f rom both ele ctro lysis and ref orming

0 50 100 150

Adju stmentCheck On ly

OtherRepai r

Replacement

Maintenance: Average Labor Hours Per Station S ince Inception

S cheduledUn-Scheduled

0 2 4 6 8 10 12 14 16 18 20

Adju stmentCheck On ly

OtherRepai r

Replacement

M ainten ance: Average Number of Events P er Station Since Incep tion

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

# of Even tsHours

Co mparison of Scheduled/Un-Scheduled M ainten ance

Create d: A ug -30-06 3 :0 4 PM

-30

-20

-10

0

10

20

30

40

50

Deg

rees

Cel

sius

Ambient Temperature Dur ing Operation

All OEM sCreated : 16-Feb-2006

Vehicle Miles: All OEMs Com bined

02468

1012141618

0-1 500

1500-3000

3000-4 500

45 00-6000

6000-7 500

7500-9000

9000-10500

10500-12000

12000-13500>13500

Tot al Vehicle Miles

Num

ber o

f Veh

icle

s

Tota l M iles Trave led = 360,092

Through Q 2 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

Reporting Calendar Quarter

Mas

s of

Hyd

roge

n (k

g)

Created 24-Aug-2006

Cum ulative Vehicle Miles Trav eled : All OEMs

-

50,0 00

100,00 0

150,00 0

200,00 0

250,00 0

300,00 0

350,00 0

400,00 0

Q205 Q305 Q405 Q106 Q206

Vehi

cle

Mile

s Tr

avel

ed

Creat ed: 28-Aug-06

0 1 2 3 4 5 6 7 8 9 10

Particu lates

μg/L

H2 Impurities

Range of R eported D ata ISO FDTS 14687-2 Max R eported D etection 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)Cre ate d: Jun -01 -0 6 1 1:0 2 AM *In clu des SO2 , COS, and H2S.

99.98 4

99.98 6

99.98 8

99.99 0

99.99 2

99.99 4

99.99 6

99.99 8

100.00 0

Hyd

roge

n Pu

rity

(%)

H ydrogen P ur it y Sam pled from Sta tions(1)

R ange of Re por ted D ataISO FD TS 14 687- 2 Ta rget

Crea te d: 2 1-Fe b-2 0 06(1 ) In clud e s sa mp ling fr om b ot h e lect ro lysis a nd re fo rm ing

0

1

2

3

4

5

6

7

8

9

All OEM s

Wei

ght P

erce

nt H

ydro

gen

(%)

Weight Pe rce nt Hy drogen

2015 D OE MY PP Ta rget1



Crea te d: 2 3-Fe b-2 0 06

1Some near -term targets have been achieve d with compressed and liquid tanks. E mphasis is on advanced materials-based technologies.

0

0 .0 1

0 .0 2

0 .0 3

0 .0 4

0 .0 5

0 .0 6

0 .0 7

0 .0 8

0 .0 9

0.1

All OEM s

Mas

s H

2 pe

r Li

ter (

kg/L

)

Mas s of Hy drogen Pe r Lite r




Crea te d: 2 3-F e b-2 0 061Emph asis is o n a dva nce d ma ter ials- ba sed te ch no lo g ies.

0

2000

4000

6000

8000

10000

12000

All OE Ms

Num

ber o

f cyc

les

H ydrogen Tank C yc le Life

2015 DOE MYP P Target1



Crea ted: 23 -Feb -20061S ome nea r-term tar gets have been achieved with compr essed and liquid tanks. E mphasis is on advanced mater ials- based technologies.


-

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-A ug-2006

Number of Stations

0

1

2

3

45

6

7

89

10

200 5 Q2 20 05 Q3 2 005 Q4 2006 Q1 200 6 Q2

Repo rting Period

# of

Sta

tions

Created 28-Aug-06

H2 Production MethodsThrough Q2 2006

0

1

2

3

4

5

Deliv ered Compresse d H2 NG On-site Reforming Electro lysis Delive red L iquid H2

Production Technolgy

# of

Sta

tions

Cr eated 28-Aug-06

Veh icle Hou rs: All OEM's C ombin ed

0

5

10

15

20

25

0-100

100-200

200-300

300-4 00

400-500

500-600

600-700

700-800

800-900>900

To tal Vehicle Ho urs

Num

ber o

f Veh

icle

s

Throug h Q2 2006

Created: 25-Aug-06

T otal Veh icle Hou rs = 19,324

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

50

100

150

200

250

300

Veh

icle

Ran

ge (m

iles)

Vehicle Range1

2015 Target2009 Target

Create d: Oc t-03 -0 6 8:07 A M

(1) R ange is based on fuel economy and usable hydr ogen on-boar d the vehicle. On e dat a p oint for each make/model.(2) Fu el e co nomy from unadjusted combined C ity/Hwy per D RA FT SA EJ2572.(3) Fu el e co nomy from EPA Adjusted combine d City/H wy ( 0.78 x H wy, 0.9 x Cit y).(4) E xcludes trips < 1 mile. On e data p oint for on-r oad fleet average o f each m ake /m odel.(5) Fu el e co nomy calculat ed from on- road fuel cell stack cur rent or mass flow r eadings.

0200400600800

10001200140016001800200022002400

2006 Target

2009 Target

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

Max Hrs Ac cumulat ed (1)( 2) Av g Hrs Accumulated (1 )(3) Projec tion to 10% Degrada tion (4) (5)

Tim

e (H

ours

)

DOE Learning Dem onstration Fuel Cell Stack Durabil ity:Based on Data Through August 2006

Max ProjectionAvg Projection

Created : Oct -05-0 6 4 :3 2 PM

(1) Range bars cr eated using one data point for each OE M.(2) Range (hig hest and lowest) of the maximum operating hours accumulated to-date of any OE M's individual stack in "real-wo rld" operatio n.(3) Range (hig hest and lowest) of the aver age op erating hours accumulated to-date of all stacks in each OEM's flee t.(4) P rojection using on-r oad d ata -- degr adation calculated at high stack current. This criterion is used for assessing progre ss against DOE targets, may differ fr om OE M's end-of-life criterion, and does not address "catastrophic" failur e mo des, such as membr ane failure.(5) Using one nominal projection per OEM: "Max P roje ction" = highest nominal proje ction, "A vg P rojection" = average nominal projectio n. The shade d g reen bar represents an engineering judgment of the uncertainty due to data and methodo logy limitations. P rojections will change as additional data are accumulated.

0 1 2 3 4 5 6 7 8 9 10

Particulates

μg/L

H2 Impuri ti es

Data Range SAE J271 9 Meas ured Less Than or Equal To (Det ection L imite d)

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 /m ol (ppm)

0 10 20 30 40 50 60 70 80 90 100

Total S *

nmol /mol (ppb)Created : S ep -2 6-06 3:47 P M

*Calculated from SO2, COS , H2S , CS 2, and Methyl Mercaptan (CH3SH).

30 Composite Data Products Have Now Been

Published

0

200400600800

1000120014001600

1800200022002400

2006 Target

2009 TargetActual Operating Hour s Accumulated To-Date Projected Hours to 10% Degradation

Ma x Hrs Accumula ted (1) (2) Avg Hrs Ac cumulat ed ( 1)( 3) Project ion to 1 0% De gradat ion (4) (5)

Tim

e (H

our

s)

DOE Learning Demonstration Fuel Cel l S tack Durabili ty:Based on Data Through 2006 Q4


Created : F eb-28 -0 7 8:27 P M

(1) Range bars created using one data point for each OEM.(2) Range (highest and lowest) of the maximum operating hours accumulate d to- date o f any OEM's individual stack in "real-world" op eration.(3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OE M's fleet.(4) P rojection using on-road data -- degradation calculated at high stack current. This criter ion is use d for assessing progress against DOE targets, may differ f rom OE M's end-of -life criterion, and doe s not address "catastrophic" failure modes, such as membrane failure .(5) Using one nominal pr ojection per OEM: "Max P rojection" = highest nominal projection, " Avg Projection" = ave rag e nominal projection. The shaded green bar represents an engineering judgme nt of the uncertainty due to data and methodology limitations. Pr ojections will change as additional data are accumulated.

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

50

100

150

200

250

300

Veh

icle

Ran

ge (

mile

s)

Vehicle Range1

2015 Target2009 Target

Created : F eb-27 -0 7 4:49 P M

(1) Range is based on fuel economy and usable hydro gen on-board the vehicle. One data point for each make/model.(2) Fuel economy fr om unadjusted combined C it y/Hwy per D RAFT S AE J2572.(3) Fuel economy fr om EPA Adjusted combined C ity/Hwy (0.78 x Hwy, 0.9 x C ity).(4) Excludes trips < 1 mile. One data point for on-r oad fleet average of each make/model.(5) Fuel economy calculated from on -road fuel cell stack curr ent or mass flow readings.

Dyno (1) Window-S ticker (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 : F eb-27 -0 7 4:49 P M

(3) E xclude s tr ips < 1 m ile. One data point for on -road fleet average of each make/model.

(1) One data point for each make/model. C ombined City/H wy fuel economy per D RA FT SAE J2572.

(2) A djusted combined City /H wy fuel economy (0.78 x Hwy, 0.9 x C ity).

(4) C alculated f rom on-r oad f uel cell stack current or mass flow r eadings.

0

1 0

2 0

3 0

4 0

5 0

6 0

7 0

All OEM s

Effic

ienc

y (%

)

Fue l C ell Sy stem 1 Ef ficiency2 at ~2 5% N et Powe r.

DOE Ta rget

Crea te d: Au g-2 9 -06 4:0 9 P M

1 G ro ss sta ck p owe r m inu s f ue l ce ll syst em au xiliarie s, pe r D RAFT SAEJ2 61 5.

2 R atio of DC ou tpu t e ner gy to the lowe r hea ting valu e o f the inp ut f ue l (hy dr og en ).Ex clud es po we r e lec tro nics and e lec tric dr iv e.


0

5

10

15

20

25

30

35

40

45

50

2005

Q2

200 5 Q

3

200 5 Q

4

2 006 Q

1

2006

Q2

2006

Q3

2 006 Q

4

Nu

mbe

r of

Inci

den

ts

H2 Leak - D uring Fuel ingH2 Alarm - StackH2 Alarm - Fuel SystemH2 Alarm - Passenger Compartm ent

Created: 2/28/07 8:45A M

0

1

2

3

4

5

6

7

8

9

All OEM s

Wei

ght P

erce

nt H

ydro

gen

(%)

Weight Percent Hydrogen

2015 DOE MY PP Target1



Crea te d: 2 3-Fe b-2 0 061

Some near -term targets have been achieve d with compressed and liquid tanks. E mphasis 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 OEM s

Mas

s H

2 pe

r Lite

r (kg

/L)

Mass of Hydrogen Per Lite r




Crea te d: 2 3-Fe b-2 0 061Emph asis is o n a dva nce d ma ter ials- ba sed te ch no lo g ies.

0

2000

4000

6000

8000

10000

12000

All OEM s

Num

ber o

f cyc

les

Hydrogen Tank Cycle Lif e




Crea te d: 2 3-Fe b-2 0 061

Some near -term targets have been achieve d with compressed and liquid tanks. E mphasis is on advanced materials-based technologies.

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20

102030405060708090

100110120130140150160170180190200210220230240250260270

Avg Fuel Rate (kg/min)

Num

ber

of F

uelin

g Ev

ents

Hi stogram of Fuel ing RatesAl l Light Duty Through 2006Q4

5 minute fill o f5 k g at 350 bar

3 minute fill of5 kg at 3 50 ba r

2006 Te ch Val Miles tone2010 MYPP Adv Storage Mate rials Targe t

Created : F eb-28 -0 7 1 :4 2 PM

Total Infrastructure Safety Events by Severity and Event Type Through 2006 Q4

05

101520253035404550556065

Non-Event Near Miss Incident

Severity

Num

ber

of E

vent

s

H2 Re lease - Significant, NO IgnitionElectrica l IssueNon-H2 ReleaseAutomatic System ShutdownEquipment MalfunctionAlarms OnlyH2 Release - Minor , NO Ignition

C reated 07- Mar-2007

-30

-20

-10

0

10

20

30

40

50

60

Deg

rees

Cel

siu

s

Ambient Temperature During Operation

All OEMsCreate d: Ma r-0 7-07 3:35 PM

Vehicle Hours: All OEMs Combined

0

2

4

6

8

10

12

14

16

18

0-10

0

100-2

00

200 -30

0

300 -40

0

400-5

0 0

500-6

0 0

600-7

0 0

700-80

0

800-90

0>90

0

Tota l Ve hicle Hour s

Num

ber

of V

ehic

les

Through Q4 2006

Created: 28-Feb-07

Total Vehicle Hours = 28,545

Through Q4 2006Vehicle Hours: All OEMs Combined

0

2

4

6

8

10

12

14

16

18

0-10

0

100-2

00

200 -30

0

300 -40

0

400-5

0 0

500-6

0 0

600-7

0 0

700-80

0

800-90

0>90

0

Tota l Ve hicle Hour s

Num

ber

of V

ehic

les

Through Q4 2006

Created: 28-Feb-07


Through Q4 2006Vehicle Miles: All OEMs Combined

0

2

4

6

8

10

12

14

0-2000

2000-4000

4000-6 000

6000-8000

8000-10000

10000-1

2000

12000-1

4000

14000

-1 6000

16000-1

8000

>18000

Tota l Ve hicle Mile s

Num

ber o

f Veh

icle

s

Total M iles Traveled = 573,064

Through Q4 2006

Creat ed: 28-Feb-07

Cumulative Vehicle Miles Traveled: All OEMs

-

100,000

200,000

300,000

400,000

500,000

600,000

700,000

2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2006Q3 2006Q4

Vehi

cle

Mile

s Tr

avel

ed

Created: 28-Feb-07


-

10

20

30

40

50

60

70

80

2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2006Q3 2006Q4

# of

Veh

icle

s (A

ll Te

ams)

Liquid H210,000 psi tanks5,000 psi tanks

Created Feb-28-2007

Cumulative Hydrogen Produced or Dispensed

0123456789

10111213141516171819202122

Q2 2005 Q3 2005 Q4 2005 Q1 2006 Q2 2006 Q3 2006 Q4 2006

Calendar Quarter

Mas

s of

Hyd

roge

n (k

g) (t

hous

ands

)

Created 2 0-Feb-20 07

99.7399.7499.7599.7699.7799.7899.79

99.899.8199.8299.8399.8499.8599.8699.8799.8899.89

99.999.9199.9299.9399.9499.9599.9699.9799.9899.99

100

Hyd

rog

en F

uel Q

ualit

y In

dex

(%)

Hydrogen Fuel Qual ity Index Sam pled from Stations(1)

Data R ang eDataSA E J2719

Created : F eb-28 -0 7 12:0 6 PM(1) Includes sampling from both electrolysis and reform ing

99.98 4

99.98 6

99.98 8

99.99 0

99.99 2

99.99 4

99.99 6

99.99 8

100.00 0

Hyd

roge

n Pu

rity

(%)

H ydrogen P ur it y Sam pled from Sta tions(1)

R ange of Re por ted D ataISO FD TS 14 687- 2 Ta rget

Crea te d: 2 1-Fe b-2 0 06 (1 ) In clud e s sa mp ling fr om b ot h e lect ro lysis a nd re fo rm ing

0 1 2 3 4 5 6 7 8 9 10

Parti culates

μg/L

H2 Impuri ti es

Data Range SAE J271 9 Meas ured Less Than or Equal To (Det ection L imite d)

0 500 1000 1500 2000 2500 3000

(N2 + He + Ar)

0 5 10 15 20 25 30 35 40

H20 Total HC

O2 CO2

CO NH3

μmol /m ol (ppm)

0 10 20 30 40 50 60 70 80 90 100

Total S *

nmol /mol (ppb)Created : F eb-28 -0 7 12:0 6 PM *Calculated fr om SO2, C OS , H2S, CS 2, and Methyl Mercaptan (C H3SH ).

0 1 2 3 4 5 6 7 8 9 10

Particu lates

μg/L

H2 Impurities

Range of R eported D ata ISO FDTS 14687-2 Max R eported D etection 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)Cre ate d: Jun -01 -0 6 1 1:0 2 AM *In clu des SO2 , COS, and H2S.

0 20 40 60 80 100 120 140 160 180 200

Adjustm entCheck Only

OtherRepair

Replacem ent

M aintenance: Average Labor Hours Per Station Since Inception

ScheduledUn-Scheduled

0 5 10 15 20 25 30

Adjustm entCheck Only

OtherRepair

Replacem ent

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

Created : Feb-28 -0 7 7:16 PM

Online Stations

0

2

4

6

8

10

12

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2 2006 Q3 2006 Q4

Reporting Period

Num

ber o

f Sta

tions

Crea ted 20-Feb-2007

Infrastructure Hydrogen Production Methods

0

1

2

3

4

5

Deliv eredCompressed H2

Natural Gas On-site Reforming

Electrolysis Delivered LiquidH2

Production Technology

# of

Sta

tions

Cre ated 07 -Ma r-20 07

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 refuel ings

Perc

enta

ge o

f ref

uel

ings

PercentageCum ulative Percentage

Created : Feb-26 -0 7 12:5 3 PM

Total refuelings2 = 5480

1. Range calculated using the combined City/Hwy fuel economy from dyno testing ( not E PA adjusted) and usable fuel on board.

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

0 10 20 30 40 50 60 70 80 90 100

V ehicle Range Factors

P ercentage of chassis dyno range1.

All

OEM

s

Win

dow

-Sti

cker

2

On

-Ro

ad 3

Dyn

o 1

Created : Feb-26 -0 7 12:5 3 PM

1. Calculated using the combined C ity/Hwy fuel economy from dyno testing (non-adjusted) and usable f uel on board.

2. Applying w indow-sticker correction factors f or fuel economy: 0.78 x Hwy and 0.9 x C ity.

3. Using f ue l economy from on-road data (excluding trip s > 1 mile, consistent with other data pro ducts).3. Using f ue l economy from on-road data (excluding trip s > 1 mile, consistent with other data pro ducts).

Inf rastructure Safety Trend and Online Stations

11 10

20

31

104110

94

0

2

4

6

8

10

12

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2 2006 Q3 2006 Q4

Reporting Period

Num

ber

of S

tatio

ns

0

20

40

60

80

100

120

Num

ber o

f Ref

uelin

gs

Num ber of Onl ine Stations

Average Refuelings Between SafetyEvents

Cre ated 28 -Feb -20 0 7

Type of Infrastructure Safety Ev ent by Quarter Through 2006 Q4

0

2

4

6

8

10

12

14

16

18

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2 2006 Q3 2006 Q4

Rep orting Period

Num

ber o

f Eve

nts

IncidentNear M issNon-EventStations OnlineAverage # Events/Station

Created 07-Mar-2007

Primary Factors of Infrastructure Safety Events Through 2006 Q4

0 10 20 30 40 50 60 70

T otal Non-Events

Total Near Miss

Total Incidents

Seve

rity

Number Of Events

Calibration/Setting s/ Software Controls

En vironment (Weather, P ower Disruption, Other)

Inadequate/ Non-working Equipment

No t Yet Determined

Mischief, Vandalism, SabotageMaintenance Required

Design Flaw

Operator/P ersonnel Error

Created 07-Mar-2007

0 2 4 6 8 10 12 14 16 18 200

102030405060708090

100110120130140150160170180190200210220230240250

Tim e (m in)

Num

ber

of F

uelin

g Ev

ents

H istogram of Fuel ing Tim esAl l Light Duty Through 2006Q4


0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 50

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

Am ount Fueled (kg)

Num

ber

of F

uelin

g Ev

ents

Hi stogram of Fueling AmountsAl l Light Duty Through 2006Q4


10

New Web Site Now Provides Direct Access to Latest Composite Data Products

http://www.nrel.gov/hydrogen/cdp_topic.html

12

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 50

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

Amount Fueled (kg)

Num

ber o

f Fue

ling

Even

ts

Histogram of Fueling AmountsAll Light Duty Through 2006Q4

Created: Feb-28-07 1:43 PM

Actual Vehicle Refueling Amounts from >3700 Events: Measured by Stations or by Vehicles

Average amount: 2.15 kgMedian: 2.13 kg

13

0 2 4 6 8 10 12 14 16 18 200102030405060708090

100110120130140150160170180190200210220230240250

Time (min)

Num

ber o

f Fue

ling

Even

tsHistogram of Fueling Times

All Light Duty Through 2006Q4


>

Actual Vehicle Refueling Times from >3700 Events: Measured by Stations or by Vehicles

Average time: 4.19 minMedian: 2.83 min

78% of refueling events took <5 min

14

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20102030405060708090

100110120130140150160170180190200210220230240250260270

Avg Fuel Rate (kg/min)

Num

ber o

f Fue

ling

Even

tsHistogram of Fueling Rates

All Light Duty Through 2006Q4



2006 Tech Val Milestone2010 MYPP Adv Storage Materials Target


Actual Vehicle Refueling Rates from >3700 Events: Measured by Stations or by Vehicles

Average rate: 0.71 kg/minMedian: 0.75 kg/min

20% of refueling events exceeded 1kg/min

15

Updated Results for Hours Accumulated and Projected Hours to 10% Stack Voltage Degradation

0200

400600

8001000

120014001600

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 2006 Q4



(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.

Accumulation of FC stack operating hours continues to grow, but projections are still

necessary to compare to targets

Note: 10% voltage drop 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.

16

99.7399.7499.7599.7699.7799.7899.7999.8

99.8199.8299.8399.8499.8599.8699.8799.8899.8999.9

99.9199.9299.9399.9499.9599.9699.9799.9899.99

100

Hyd

roge

n Fu

el Q

ualit

y In

dex

(%)

Hydrogen Fuel Quality Index Sampled from Stations(1)

Data RangeDataSAE J2719

Created: Feb-28-07 12:06 PM(1) Includes sampling from both electrolysis and reforming

Hydrogen Quality Index Close to Target Except for Some High Inert Gas Measurements

17

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)

0 500 1000 1500 2000 2500 3000

(N2 + He + Ar)

0 5 10 15 20 25 30 35 40

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: Feb-28-07 12:06 PM *Calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

Hydrogen Impurities Sampled from All Stations to Date In General, Inert Gases and Sulfur Suffer from High Detection Limits

Sulfur measurements continue to be detection-limited

High inert gases due to detection limits, not measured values

18

H2 FCV Safety –

An Issue Has Been Identified Relative to H2 Sensor Alarms and is Currently Being Addressed


0

5

10

15

20

25

30

35

40

45

50

2005

Q2

2005

Q3

2005

Q4

2006

Q1

2006

Q2

2006

Q3

2006

Q4

Num

ber o

f Inc

iden

ts

H2 Leak - During FuelingH2 Alarm - StackH2 Alarm - Fuel SystemH2 Alarm - Passenger Compartment

Created: 2/28/07 8:45AM

19

Infrastructure Safety Trend and Online Stations

11 10

20

31

104110

94

0

2

4

6

8

10

12

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2 2006 Q3 2006 Q4

Reporting Period

Num

ber

of S

tatio

ns

0

20

40

60

80

100

120

Num

ber o

f Ref

uelin

gs

Number of Online Stations

Average Refuelings Between SafetyEvents

Created 28-Feb-2007

Average Refuelings

Between Infrastructure Safety Events Has Increased by ~10X Since Beginning of Project

>20,000 kg H2 Produced or Dispensed from this Project

20

Severity Decreased: Only Infrastructure Non- Events

Have Been Reported in Last 3 Quarters

Type of Infrastructure Safety Event by Quarter Through 2006 Q4

0

2

4

6

8

10

12

14

16

18

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2 2006 Q3 2006 Q4

Reporting Period

Num

ber

of E

vent

s

IncidentNear MissNon-EventStations OnlineAverage # Events/Station

Created 07-Mar-2007

21

Most of Infrastructure Safety Reports are Non-Events (and Most of Those, Alarms Only)

Total Infrastructure Safety Events by Severity and Event Type Through 2006 Q4

05

101520253035404550556065

Non-Event Near Miss IncidentSeverity

Num

ber o

f Eve

nts

H2 Release - Significant, NO IgnitionElectrical IssueNon-H2 ReleaseAutomatic System ShutdownEquipment MalfunctionAlarms OnlyH2 Release - Minor, NO Ignition

Created 07-Mar-2007

22

No Single Primary Factor Leading to Majority of Infrastructure Safety Events

Primary Factors of Infrastructure Safety Events Through 2006 Q4

0 10 20 30 40 50 60 70

Total Non-Events

Total Near Miss

Total Incidents

Seve

rity

Number Of Events

Calibration/Settings/ Software Controls

Environment (Weather, Power Disruption, Other)

Inadequate/ Non-working Equipment

Not Yet Determined

Mischief, Vandalism, Sabotage

Maintenance Required

Design Flaw

Operator/Personnel Error

Created 07-Mar-2007

23

Vehicle Operating Hours and Miles Traveled Distribution

The bulge of operating hours and miles traveled has now shifted to right.

New Gen 1 vehicles continue to be introduced, but 2nd

bulge will appear at left with Gen 2 vehicle introduction starting this fall.

Vehicle Miles: All OEMs Combined

0

2

4

6

8

10

12

14

0-200

0

2000

-4000

4000

-6000

6000

-8000

8000

-10000

1000

0-120

00

1200

0-140

00

1400

0-160

00

1600

0-180

00

>1800

0

Total Vehicle Miles

Num

ber o

f Veh

icle

s

Total Miles Traveled = 573,064

Through Q4 2006

Created: 28-Feb-07

Vehicle Hours: All OEMs Combined

0

2

4

6

8

10

12

14

16

18

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>90

0

Total Vehicle Hours

Num

ber o

f Veh

icle

s

Through Q4 2006

Created: 28-Feb-07


Through Q4 2006Vehicle Hours: All OEMs Combined

0

2

4

6

8

10

12

14

16

18

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>90

0

Total Vehicle Hours

Num

ber o

f Veh

icle

s

Through Q4 2006

Created: 28-Feb-07


Through Q4 2006

24

Summary

•

First half of project completed–

69 vehicles and 10 stations deployed–

570,000 miles traveled, 20,000 kg H2 produced or dispensed–

113,000 individual vehicle trips analyzed–

Project to continue through 2009•

More detailed examination of project safety now possible–

Updated data templates allowed more detailed reporting–

Infrastructure safety has seen dramatic improvement–

H2 sensor alarm issue being resolved on vehicles•

Compressed H2 refueling time, amount, and rates indicates this technology could meet customer’s refueling time expectations–

Key will be having adequate station coverage•

Total of 30 composite data products published to-date–

New web site allows direct web access to the most current CDPs

25

Questions and Discussion

Project 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

fuel cell vehicle learning demonstration: spring 2007 ...1 fuel cell vehicle learning demonstration:...

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