Results from the Vehicle/Infr

Learning Demonstration 

Keith Wipke, Senior Engineer 

Cory Welch, Holly Thomas, Sam 

National Renewable Energy Labo

2006 DOE Hydrogen Progra

Merit Review and Peer Evaluation 

May 18, 2006

NREL/PR-560-39936Presented at the 2006 DOE Hydrogen, Fuel Cells & Infrastructure Technologies Program Annual Merit Review in Washington, D.C., May 16-19, 2006.
Disclaimer and Government Lic

This work has been authored by Midwest Research Institute (MRDE-AC36-99GO10337 with the U.S. Department of Energy (the “States Government (the “Government”) retains and the publisherfor publication, acknowledges that the Government retains a non-irrevocable, worldwide license to publish or reproduce the publishallow others to do so, for Government purposes.Neither MRI, the DOE, the Government, nor any other agency theemployees, makes any warranty, express or implied, or assumes responsibility for the accuracy, completeness, or usefulness of anapparatus, product, or process disclosed, or represents that its usany privately owned rights. Reference herein to any specific comprocess, or service by trade name, trademark, manufacturer, or oconstitute or imply its endorsement, recommendation, or favoring any agency thereof. The views and opinions of the authors and/oherein do not necessarily state or reflect those of MRI, the DOE, tagency thereof. 
Project Objectives and Ta

Objectives

ÎValidate H

2 FC Vehicles and Infrastructure i

ÎIdentify Current Status of Technology and it

ÎRe-Focus H

2 Research and Development

ÎSupport Technology Readiness Milestone b

Hydrogen refueling station, Chino, CA Photo: NREL

* To verify progress toward ** Subsequent projects to vHydrogen Cost at Station Vehicle Range Fuel Cell Stack Durability Performance Measure * To verify progress toward ** Subsequent projects to vHydrogen Cost at Station Vehicle Range Fuel Cell Stack Durability Performance Measure 

Key Targets
Teams are Fielding 

Four Main Types of Veh

Validation also includes FCV Sprinter vans
Representative Hydrogen R

Infrastructure Supporting V

Chino, CA

LAX refueling station

Photo: H2CarsBiz

Photos: DTE

DTE/BP Power Park, Southfield, MI

Hydrogen and gasoline station, WA DC Photo:Shell Hydrogen
Refueling Stations from All Four T

Vehicle/Infrastructure Performance in V

Northern California

Southern California

Ap-07-06

Additional Planned Stations (3)

Additional Planned Stations (4) A

Additional Planned Stations (2)

SE Michigan
Project Produces Results for Bo

and the Industry Project T

Raw Data, 

Reports

Hydrogen Secure Data 

Center (HSDC)

• Located at NREL: Strictly Controlled Access• Detailed Analyses, Data Products, Internal Reports

Co

• agre

D

• 

co

• 

in
On-Road Data Received -- Running T

0

5000

1000015000200002500030000

Sep-04

Oct-04

Nov-04

Dec-04

Jan-05

Feb-05

Mar-05

Apr-05

May-05

Jun-05

Jul-05

Aug-05

Sep-05

Oct-05

Nov-05

Dec-0

# Files

# D

Project Now Well Underway: 1st Year o

Current Status of Data Reporting to the Hydrogen Secur

2005 Review

Through March, 2006:

24,000 individual vehicle trips

15.6 GB of on-road data
New Fleet Analysis Toolkit (F

Automate the Analys
First 16 of 26 Composite Data 

Published Earlier This Y

Highlighted 

Co

Composite 

Main Outp

Hydrog
Dynamometer Testing Complete

Fuel Economy Under Controlled 

One vehicle per team per geograph11 vehicles tested using SAE J2572

Chevron/Hyundai-KIA DaimlerChrysler/

GM/Shell 
Dynamometer and On-Road Fu

Dyno (1) Window-Sticker (2) O

0

1020304050607080

Fuel Economy (miles/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/mo(1) One data point for each make/model. Combined City/Hwy fuel economy per DRA(2) Adjusted combined City/Hwy fuel economy (0.78 x Hwy, 0.9 x City).(4) Calculated from on-road fuel cell stack current or mass flow readings.
Vehicle Range Based on Dyno 

Usable H

2 Fuel Stored On

0

50

100150200250300

All OEMs

Vehicle Range (miles)

Vehicle Range(1)

Created: 21-Feb-2006 (1) Calculated from combined City/Hwy fuel economy (dyno test) per DRAFT SAE J2

Data 

storage 

being p

necess
Vehicle H2 Storage Technolog

350 bar, 700 bar, and Liq

On-Board Hydrogen Storage Methods

-

10203040506070

Q205 Q305 

# of Vehicles (All Teams)

5,000 psi tanks 10,000 psi tanks Liqu

Created 16-Feb-2006

First generation vehicle 

fleet still being deployed. 

Fleet is now largest H2 FC 

vehicle fleet in the world.
Technical Status of On-Board 

Technologies Being Vali

0123456789

Weight Percent Hydrogen (%)

W

Created: 23-Feb-2006

1Some near-term targets have been achieved with 

0

0.010.020.030.040.050.060.070.080.09

0.1

All OEMs

Mass H2 per Liter (kg/L)

Mass of Hydrogen Per Liter

2015 DOE MYPP Target12010 DOE MYPP Target12007 DOE MYPP Target1

Created: 23-Feb-2006

1Emphasis is on advanced materials-based technologies.

0

2000400060008000

1000012000

All OEMs

Number of cycles

Hydrogen Tank Cycle Life

2015 DOE MYPP Target12010 DOE MYPP Target12007 DOE MYPP Target1

Created: 23-Feb-2006

1Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based technologies.

Compress

tanks me

short term 

don’t m

weight % 

capacity ta
Hydrogen Purity Sampled fro

Meets Target Majority of th

99.98499.98699.98899.99099.99299.99499.99699.998

100.000

Hydrogen Purity (%)

Hydrogen Purity Sampled from Stations(1

RangISO F

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

W

im

a
Actual Vehicle Refueling 

Measured by Stations or by 

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 

05

10152025303540

Refueling Rate (kg H2/minute)

# of Refueling Events

Histogram of Vehicle Refueling Rates

5 minute fill of5 kg at 350 bar

2006 Tech Val Mil2010 MYPP Adv S

Created: 21-Feb-2006

Future analyses could compare impact of 

communication and non-communication 

fills on fill rates and completeness of fill
Range of Ambient Tempe

During Vehicle Operat

-30-20-10

0

1020304050

Degrees Celsius

Ambient Temperature During Operation

All OEMs

Created: 16-Feb-2006

Fue

ab

t

Futur

to s
Vehicle Operating Ho

and Miles Traveled Distri

Vehicle Hours: All OEM's Combined

through Q4 2005

02468

101214161820

0-50

50-100

100-150

150-200

200-250

250-300

300-350

350-400

400-450

>450

Total Vehicle Hours

Number of VehiclesTotal Vehicle Hours = 7,831

Created: 16-Feb-2006

Fleet is young, b

usage is increasing 

fleets are approa

Gen 1 vehicle de

Cumulative Hydrog

All T

0

1,0002,0003,0004,0005,0006,0007,000

Q2 2005 

Re

Mass of Hydrogen (kg)

Created 21-Feb-2006

Large amount of 

hydrogen used includes 

both vehicle refueling 

and on-site electricity 

production
Summary

First year of the 5-year project comple

Î59 vehicles now in fleet operationÎSeveral new refueling stations openedÎNo major safety problems encountered

Project has identified current technicato program targets

ÎWill track improvements from 2nd generatio

introduced mid-way through project

Future public results will include:

ÎFC durability, reliability, efficiency, and staÎH2 production cost, efficiency, and mainten
Questions and Discuss

Contact: Keith Wipke, National Renewa

303.275.4451, keith_wipke@nhttp://www.nrel.gov/hydrogen/proj_t