Status of U.S. FCEV and Infrastruc

Learnin

g Demonstration Project

Keith WiJennifer Ramsde

g j

Ramsde

AinscouSaur 

M h 1 Marc

h

1

JHFC CoTokyo, JNREL/PR-56

This presentation does not contain any proprietary, confidential, or otherwise restricte

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the 
Outline

• Project Goals• V hi l d H Vehicle and H St ti D l t St t 2 Station Deployment Status

• Critical Performance Compared to Targets

• Highlights of Latest Vehicle and Infrastructu

Highlights of Latest Vehicle and Infrastructu

Analysis Results and Progress

• Learning Demo Next Steps

• Other Relevant U.S. Activities • Cross-Application Fuel Cell Analysis Resul• Summary

National Renewable Energy Laboratory 2 
Fuel Cell Electric Vehicle Learning 

Projj , , 

ect Objectives

, Relevance

, and 

• Objectives

– Validate H

2 FC Vehicles and Infrastructure in P

– Identify Current Status and Evolution of the Te

• Relevance

– Objectively Assess Progress Toward Technolo– Provide Feedback to H

2 Research and Develo

Performance Measure 2009 2015F l C ll St k D bilit 2000 hours 5000 hours

Key Targets

Fuel C

ell Stac

k

Durabilit

y 2000 hours 5000 hours

Vehicle Range 250+ miles 300+ milesHydrogen Cost at Station $3/gge $2-3/gge

National Renewable Energy Laboratory 3 

Burbank, CA station

Note: Project extended 2 years through 2011
Two Teams Concluded Their Projec

Three are Continuin

g g throu

gh 2011

Ford/BP and Chevron/Hyundai-Kia Conclude

Gen 1 Gen 2 Gen 

Daimler, GM, and Air Products Continue to De

Vehicles/Stations within Project throu

gh 

G 1

Gen 1

j g

Gen 

1

Gen 2

Gen 2

National Renewable Energy Laboratory 4 

(
Vehicle Status: All 350 bar Vehicles 

Onl

y g 700 bar Vehicles Continuin

g

160 

ed1

Vehicle Deployment by On-Board Hydrogen Stora

700 b

d

22 veh

13

120 140 

oyed/Retire700

bar on-roa

d

350 bar on-roadLiquid H2 on-road700 bar retired350 bar retired

6080 

100 

icles DeploLiquid H2 retired

20 40 60

ulative Veh

- Cum 

National Renewable Energy Laboratory 5 

(1) Retired vehicles have left DOE fleet and are no longer providing data to NREL(2) Two project teams concluded in Fall/Winter 2009 Created Sep-07-2010 8:43 AM

NREL CDP25 
Fueling Station Status: Stations that Con

Operate are Mostly Delivered Compresse

10

Learning Demonstration Hydrogen Station

7894567

tationsOperating Ou

Operating WitHistorical 200

1234

# of StHistorical 200

01

Delivered Compressed 

H2

Natural Gas On-Site 

Reforming

On-Site Electrolysis 

St ti T

National Renewable Energy Laboratory 6 

St

ation 

Type

NREL CDP32

Created Aug-24-10 4:05pm *Some project teams concluded Fall/Winter 2009. Markersshow the cumulative stations operated du
Out of 24 Project Stations, 15 Are Still O

(2/3 are operating outside of DOE projec

SF Bay Area 

10

2025

ons

Cumulative Stations

Continuing Outside of ProjectRetired StationsCurrent Project Stations 10

5

9

05

1015

Number of Statio

95

3

Reporting Period NREL CDP31 Created Aug-24-10 4:05pm

56

Los Angeles Area

D

Legend C tP j t

National Renewable Energy Laboratory 7 

Feb-3-2011

15

Current ProjectContinuing OutsideOther
Project Achieved Both Technical G

Outside Anal

ysis Used for Cost Eva

Vehicle Performance Metrics Gen 1 Vehicle Gen 2 Vehicle Fuel Cell Stack Durability 

Max Team Projected Hours to 

10% Voltage Degradation 1807 hours 2521 hours

Average Fuel Cell Durability Projection 821 hours 1062 hours

Max Hours of O

peration 2375 h 1261

h by a Single FC Stack to Date 2375

hours 1261

hours

Driving Range 103-190 miles 196-254 miles 

Fuel Economy (Window Sticker) 42 – 57 mi/kg 43 – 58 mi/kg 

Fuel Cell Efficiency at 1⁄4 Power 51 - 58% 53 - 59

% 

Fuel Cell Efficiency at Full Power 30 - 54% 42 - 53

% 

Infrastructure Performance Metrics H2 Cost at Station (early market)

On-site natural gas 

reformation

$7.70 - $10.30

On-site 

Electrolysis 

$10.00 - $12.90

Average H Fueling Rate 0 77 kg/min 

National Renewable Energy Laboratory 8 

Average

H

2 Fueling Rate

0.77 kg/min 

Outside of this project, DOE independent panels concluded at 500 replicate station

Distributed natural gas reformation at 1500 kg/day: $2.75-$3.50/kg (2006)

Distributed electrolysis at 1500kg/day: $4.90-$5.70 (2009)
What are the Most Recent Project R

Differences Between S

p g rin

g & Fall 2

80 Spring 2010 Results

• Most comprehensive set we ever 

bli h d

16 Fall 2010 

• Covers data from 2 

publi

s

h

e

d OEM CHIP j 

• Covers data from all 4 Learning 

Demo teams + CHIP project over 5 year period

OEMs + CHIP proje

• Emphasized change

months through use colors (new)

National Renewable Energy Laboratory 9 

5 year period colors (new)
Quantified Gen 2 Fuel Cell System 

Im

provement from Gen 1

26002800 Actual Operating Hours Accumulated To-Date Projected Hours to 1

DOE Learning Demonstration Fuel Cell Stack Durability:

Based on Data Through 2009 Q2

*

16001800200022002400

2009 Target

ours)

One Gen 1 stack 

accumulated almost 

2400 hours without 

maintenance

600800

100012001400

Time (H 2006 Targeto

Gen1 Gen2 Gen1 Gen2 Gen1 

0

200400600

Max Hrs Accumulated1,2 Avg Hrs Accumulated1,3 Projection to 10% V

(1) Range bars created using one data point for each OEM. Some stacks have accumulated hours beyond 10% volta(2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individual stack in (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 pr may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membrane (5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = average  The shaded projection bars represents an engineering judgment of the uncertainty on the "Avg Projection" due to d

National Renewable Energy Laboratory 10 

NREL CDP01

Created: Mar-23-10 10:39 AM

 The shaded projection bars represents an engineering judgment of the uncertainty on the Avg Projection due to d Projections will change as additional data are accumulated.(6) Projection method was modified beginning with 2009 Q2 data, includes an upper projection limit based on demons

Durability is defined by DOE as projected hours to 10% voltage degra

*
Fuel Cell Durability Comparison be

Field and Lab Data Shows Potentia

14000

Comparison of Fuel Cell Vehicle Field and Lab Durability Projectio

Average Projection

3

Max Projection

3 Improvements in durability 

1000012000

oltage Drop

Max Projection demonstrated

60008000

ours to 10% Vo

20004000

2009 Target2015 Target

Projected H

Gen1 Auto (1) Gen2 Auto (1) Lab 

0

2006 Target

National Renewable Energy Laboratory 11 

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 act(3) The DOE 10% voltage degradation metric is used for assessing voltage degradation; it may not be the same as ennot address catastrophic failure modes.
Completed Final Analysis of Gen 1 

S

ystem Power De

gradation

110120130

Max Fuel Cell Power Loss vs Op Hours: Gen1

Gen1 Data Range 25th & 75th Percentiles

Group MedianOutlier

y g

Need ~1000 hours 

to have higher

60708090

100

% Power(1) Note that 

de

gradation 

to have higher

confidence in 

slope of 

degradation

304050

 0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000

Stack Op Hour Segments(2)

1) Normalized by fleet median value at 200 hours.2) Each segment point is median FC power (+-50 hrs) Max Fuel Cell Power Loss v

g

flattens out after 

~200 hours A

p

2) Each segment point is median FC power (+-50 hrs).

 Box not drawn if fewer than 3 points in segment. NREL CDP69 Created: Mar-23-10 10:39 AM

90

100110120130

r(1)

Gen2 

4050607080

% Power From limited Gen 2 data 

received so far, trend of 

flattening after 200 

hours appears similar

Gen 2 re

of uncer

2

National Renewable Energy Laboratory 12 

30 0 100 200 300 400 500 600 700 800 900 100011

Stack Op Hour Seg

1) Normalized by fleet median va2) Each segment point is median  Box not drawn if fewer than 3 

NREL CDP70 Created: Mar-23-10 10:39 AM
Changes in Refueling Rate Trends: Ave

Refueling Rate Decreased 14%

1800

Histogram of Fueling Rates

Vehicle and Infrastructure

 2006 MYP 2012 MYP

Th h 2

120014001600

ts5 kg in

Through 2

 After 2009

Result of avera

800

10001200

of Fueling Event

5 kg in

5 minutes 

25464 Events

Average = 0.77 kg/min

23% >1 kg/min

Result of avera

fill increasing 

average fuel

also increas

25,464 fills

400600800

Number o 5 kg in 3 minutes

1730 Events

Average = 0.66 kg/min

3% >1 kg/min

1,730 fills

0 0 2 0 4 0 6 0 8 1 1 2 1 4 1 6 

0

200400 g

National Renewable Energy Laboratory 13 

0

0.2

0.4

0.6

0.8 1 1.2 1.4 1.6 

NREL cdp_fcev_18 Avg Fuel Rate (kg/min)

Created: Sep-15-10 9:34 AM
Real-World Driving Range Between Fue

Continues to Improve as Demonstration 

Distance Driven Between Refuelings: All OEMs

 Gen1

10

elings

 Refuelings 

1 = 18941

 Median distance between refuelings = 56 Miles Gen2 Refuelings1 = 6870 Median distance between refuelings = 81 Miles +45% 

entage of Refue Refuelings after 2009Q41 = 3185 Median distance between refue

+63% 

5

Perce

0 50 100 150 200 

0

Distance between refuelings [Miles]

2

National Renewable Energy Laboratory 14 

NREL cdp_fcev_80

1. Some refueling events are not detected/reported due to data noise or incompleteness.2. Distance driven between refuelings is indicative of driver behavior and does not represent the full range of the ve

Created: Sep-07-10 9:16 AM
Rate of Mileage Accumulation Has Decr

Last Year, But Vehicles Still Added 550,

Cumulative Vehicle Miles: All OEMs, Gen 1 and G

Through 2010 Q2

2 000 0002,250,000 2,500,000 2,750,000 3,000,000 

eled

1 000 0001,250,000 1,500,000 1,750,000 2,000,000

le Miles Trav

250,000 500,000 750,000 

1,000,000

Vehicl

-

NREL CDP24

National Renewable Energy Laboratory 15 

Created: Sep-07-10 10:10 AM

NREL CDP24
Driving Behavior (Timing) in Last 6 

Much More Similar to U.S. National 

Driving by Time of Day

12

Total D

% of driving trips b/t 6 AM & 6 PM: 85.3% 

Total D

% of driving trips b/t 6 AM & 6 PM: 77 1% 

9%

12

% of NHTS trips b/t 6 AM & 6 PM: 81.5%

Total D

% of driving trips b/t

6 AM

&

6 PM: 77.1% 

9

3

7%

1. Driving trips between 6 AM & 6 PM

6

2. The outer arc is set at 12 % total Driving.3. Some events not recorded/detected due to data noise or incompleteness.

AM PM

2001 NHTS DASCII S 

National Renewable Energy Laboratory 16 

NREL cdp_fcev_44

Created: Sep-02-10 12:48 PM

ASCII.csv So
More Weekend Driving Observed in 

Months 

– Still Much Less than Nati

25

Driving by Day of Week

2015

Trips in a Day

10

% of 

S

M

T W d Th F i 

05

National Renewable Energy Laboratory 17 

Sun

Mon

Tues

W

e

d Thur

Fri 

NREL cdp_fcev_45 Day

Created: Sep-01-10 1:52 PM

2001 NHTS DASCII.csv Sou
Learning Demo Next Steps

• C tl l i J l Currently analyzing 

J

uly 

– D b 2010 d t Decem

ber 2010

d

a

t

a

• Spring 2011 CDPs published in March, presented a

May

• Publish one or two more Learning Demo CDP sets • Begin receiving fueling data from Burbank station a

Gen 1

Gen 2

Gen 2

Gen 1

Gen

2

(CHIP)

• Partners scheduled to provide data through Septem

National Renewable Energy Laboratory 18 

• Participating in many other demonstration and pre-c

activities outside of this project
Other Relevant U.S. Activities

GM 

– LOU for Hawaii Hy g dro

gen Initi

Gen 1

Gen 2

National Renewable Energy Laboratory 19 
Other Relevant U.S. Activities 

State of California Supp g ortin

g 11 H2 

• 11 H

2 station awards announced 

 8 new stations, 3 upgrades Air Products planning 8 stations: 7 n

all in Southern CA

 Linde 

p g lannin

g 3 stations: 1 new, 2 

Southern CA (9) Northern 

National Renewable Energy Laboratory 20 

Data from APC/UCI from both

Stations to come to NREL
NREL Also Publishes Results from 

Multi

p pp le A lications

National Renewable Energy Laboratory 21 
Number of Fuel Cell Units Being Ev

and Providin

g Data to NREL

700

HSDC - Fuel Cell Systems

500600

sUnderstanding of

300400

ber of Systems 

Much has been learned about FC FC bus and car performance Understanding of MHE & Back-up less mature, but rapidly emerging

200300

Numb

0

100

FCB FCEV MHE BU

National Renewable Energy Laboratory 22 
Each Fuel Cell Application Has Diff

Re

q p uirements and O

peration

FCB, 

BU, 88 43,006

Hours

MHE, 

19 831

BU, 12

Hydrogen Amou

FCEV, 

106,413

MHE

F

8

FCEV

19,831

MHE, 

251,177

FCEV, 

90,865

FCB, 

438,903

Miles

Hydrogen Fill

FCEV, 

FC27

MHE, 

36,468

National Renewable Energy Laboratory 23 

2,872,533
Forklifts Acquire Data Very Rapidly –

Data from 5 Years of Cars, 2 Years of Fo

National Renewable Energy Laboratory 24 
Fueling Rates Vary By Application, Prim

by Constraints on Pressure, Volume, Tim

National Renewable Energy Laboratory 25 
Summary

• Project has completed ~6 years of validation• Vehicle operation Vehicle operation: 114 000 hours 2 87 million 

: 114,000 hours, 2.87 million 

436,000 trips

• H2 station operation: 134,000 kg produced or 

27,000 fuelings

• DOE Key Technical Targets Met: FC Durabili

• Data reporting and analysis continues throug

Data reporting and analysis continues throug

of this year

• New CA fueling p stations planned for inclusion 

NREL infrastructure analysis as they come onprovide data

National Renewable Energy Laboratory 26 
Contact Info. and Web Reso

Project Contact: Keith Wipke, National Renewable Energy L

303.275.4451 keith.wipke nrel.gov @

NREL’s Renewable H2 Station Now 

Over 250 kg H2 and can dispense at 3

National Renewable Energy Laboratory 27 

All public Learning Demo and FC Bus Evaluation papers and presentation

online at http://www.nrel.gov/hydrogen/proj_tech_validation.ht