U.S. Fuel Cell Electric Vehicle Demonstration Proj 

ect 2010 Sta

KeiJenRam

Oct

FueSan NREL

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

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

• Project Goals• V hi l d H2 St ti D l t St 

Vehicle and H2 Station Deployment Sta

• Performance Compared to Targets

• Highlights of Latest Vehicle and Infrastr

Highlights of Latest Vehicle and Infrastr

Analysis Results and Progress

• Conclusions and Future work

National Renewable Energy Laboratory 2 

Two Teams Concluded Their Proj

Three are Continuin

g g throu

gh 20

Ford/BP and Chevron/Hyundai-Kia Concl

Gen 1 Gen 2 

Daimler, GM, and Air Products Continue to 

Vehicles/Stations within Project throu

G 1

Gen 1

j 

Gen 

1

Gen 2

Gen 2

National Renewable Energy Laboratory 4 
Vehicle Status: All 350 bar Vehic

Onl

y g 700 bar Vehicles Continuin

g

160 

ed1

Vehicle Deployment by On-Board Hydrogen 

700 b

d

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 (2) Two project teams concluded in Fall/Winter 2009 Created Sep-07-2010 8:43 AM

NREL CDP25 
Fueling Station Status: Stations that C

Operate are Mostly Delivered Compre

10

Learning Demonstration Hydrogen Stat

7894567

tationsOperatin

OperatinHistorica

1234

# of StHistorica

01

Delivered Compressed 

H2

Natural Gas On-Site 

Reforming

On-Site Electrolys

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. Markers show the cumulative stations op
Out of 24 Project Stations, 15 Are Stil

(2/3 outside of DOE project)

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

58

Los Angeles Area

National Renewable Energy Laboratory 7 

Aug-10-2010

15
Evaluation Against 3 Primary 

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

Max Team Projected Hours to 

10% Voltage Degradation 1807 hours 2521 ho

Average Fuel Cell Durability Projection 821 hours 1062 ho

Max Hours of O

peration 2375 h 1261

h by a Single FC Stack to Date 2375

hours 1261

ho

Driving Range 103-190 miles 196-254 m

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

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 

Electroly

$10.00 - $1

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 

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

Distributed electrolysis at 1500kg/day: $4.90-$5.70 (2009)
What are the Differences Betwee

S

p g rin

g 2010 and Fall 2010 Result

80 Spring 2010 Results

• Most comprehensive set we ever published• Includes durability range fuel economy etc

16 Fall 2

• No “new” CDPs, but 

Includes durability, range, fuel economy, etc. published CDPs wit

• Covers data from all 4 Learning Demo 

teams + CHIP project over 5 year period

• Majority of these will now stay static, serving 

as a historical record of Gen 1 & Gen 2

published CDPs wit

• Results on most rec

economy, not yet podata accumulated (i

• Covers data from 2 

National Renewable Energy Laboratory 9 

as

a historical record of Gen 1 & Gen

2

comparisons.

project

• Emphasized change

through use of gray 
Quantified Gen 2 Fuel Cell Syste

Im

provement from Gen 1

26002800 Actual Operating Hours Accumulated To-Date Projected Hou

DOE Learning Demonstration Fuel Cell Stack Durabi

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 G

0

200400600

Max Hrs Accumulated1,2 Avg Hrs Accumulated1,3 Projection 

(1) Range bars created using one data point for each OEM. Some stacks have accumulated hours beyond (2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individua(3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OE(4) Projection using on-road data -- degradation calculated at high stack current. This criterion is used for ass may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as (5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = 

The shaded projection bars represents an engineering judgment of the uncertainty on the "Avg Projectio

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 Projectio

 Projections will change as additional data are accumulated.(6) Projection method was modified beginning with 2009 Q2 data, includes an upper projection limit based o

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

*
Fuel Cell Stack Operation Hours 

Show Differences Between Gen 1 

40

Fuel Cell Stack Operation Hours: Gen1

Gen1 In Op1

R ti d

2

40

Fuel Cell Stack 

G

3035

24% of stacks in operation

R

etire

d

2

Other

3

3035

3

2025

Stack Count 20

25

Stack Count 

1015

S

1015

S

05

0 

200 

400 

600 

800 

1000

1200

1400

1600

1800

2000

05

0 

200 

400 

600 

800 

10

National Renewable Energy Laboratory 11 

Gen1 Hours 

NREL CDP67

Created: Mar-23-10 10:39 AM

1) Stack currently accumulating hours2) Stack removed for low performance3) Stack not currently accumulating hours, but not 

 Some project teams concluded in Fall/Winter 20
Completed Final Analysis of Gen 

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 P

g

flattens out after 

~200 hours 

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)

4050607080

% Power From limited Gen 2 data 

received so far, trend of 

flattening after 200 

hours appears similar

Ge

of 

National Renewable Energy Laboratory 12 

30 0 100 200 300 400 500 600 700 800 

Stack 

1) Normalized by 2) Each segmen Box not draw

NREL CDP70 Created: Mar-23-10 10:39 AM
Developed Methodology for Trac

S

y g stem Volta

ge Transients

1) Define a voltage transient cycle 2) Find volta

dV1

dV2

dT dTss

dVss

tage

Cycle Definition:

dV >= 10% Nom Stack V 540

560580600

g

ge in Trip

time

voltdV 10% Nom Stack

V

dTss >= 10 secdVss <= 5% Nom Stack V

480500520

g

FC Voltag

600620

50 

460

3) Categorize and collect voltage 

transient c

ycle details

480500520540560580

voltage

C Voltage in Trip

voltage

y

Cycle Categories

National Renewable Energy Laboratory 13 

0 500 

440460

Created: Mar-01-10 3:33 PM

FC

(a) (b) (c) (d) (e)

v

time
Quantified Transient Cycle Reduction 

Gen 1 and Gen 2 FC Systems

1520

%]

Number of Cycles1 per Trip Mile

5060

%]

Number of Cy

5

1015

Trip Frequency [% 203040

Trip Frequency [%

0

2

4

6

8 10 12 14 16 18 20

0

Cycle Per Mile

T

0

2

4

6

8 

0

10

Cy

T

Range of Fleet Average Cycle1 per Mile Range of Fleet 

203040

er Mile

Range of Fleet Average Cycle per Mile

4567

per Min

Range of Fleet 

Significant 

reduction in 

transients 

b d

G 1 G 2

0

1020

Cycle pe

G 1 

1234

Cycle 

o

bserve

d

p

National Renewable Energy Laboratory 14 

Gen1 Gen

2

Gen1 

NREL CDP74

Created: Mar-22-10 4:46 PM 1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta 
Characterized Fuel Cell Transien

C

ycle Cate

gory

3035

Transient Cycle1 Count by Category2

2530

DownUp Cycle1 dV/dT

4050

y gy

10152025

Frequency [%] 101520

Frequency [%]

102030

Frequency [%]

05

DownUp

SlowUp

SlowDown

SlowDownUp

DownSSUp

0 5 10 15 20 25 30 35 40 0

5

dV/dt

0 

0

10

SlowDown Cycle1 dV/dT SlowDownUp Cycle1 dV/dT 

Type: The 

slow down, 

fast up are the 

most common

304050

ncy [%]

SlowDown Cycle dV/dT

30405060

ncy [%]

SlowDownUp Cycle dV/dT

6080

100

ncy [%]

most common

transients

0 5 10 15 20 25 30 35 40 0

1020

Frequen

0 5 10 15 20 25 30 35 40 0

102030

Frequen

0 

0

2040

Frequen

National Renewable Energy Laboratory 15 

0 5 10 15 20 25 30 35 40

dV/dt

0 5 10 15 20 25 30 35 40

dV/dt

0 

NREL CDP76

Created: Mar-22-10 4:46 PM 1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta 

2) Cycle categories based on cycle up and down times. A slow up or down transient has  SS = Steady State, where the time change is >= 10 seconds and the voltage change 
Average Hydrogen Per Fill Has In

24%

, 

 But Based on Much Smalle

900

1000

Histogram of Fueling Amounts

Vehicle and Infrastructure

700800900

tsNee

500600

of Fueling Event

Average = 2.13 kg

Nee

200

iden

is 

25,464 fills

300400

Number og g

1 730 fill

0 1 2

3

4

5

0

100200

Average = 2.65 kg

1,730 fill

s

National Renewable Energy Laboratory 16 

0 1 2

3

4

5

NREL cdp_fcev_39 Amount Fueled (kg)

Created: Sep-15-10 9:35 AM
Fueling Times Also Increased: +2

3500

Histogram of Fueling Times

Vehicle and Infrastructure

 2006 MYPP Tech  2012 MYPP Tech 

Th h 2009Q4

25003000

ts

Through 2009Q4

 After 2009Q4

2000

of Fueling Event Average = 3.26 min 86% <5 min

10001500

Number o

0 1 2

3

4

5

6

7

0

500 Average = 4.17 min 77% <5 min

National Renewable Energy Laboratory 17 

0 1 2

3

4

5

6

7

NREL cdp_fcev_38 Time (min)

Created: Sep-15-10 9:35 AM
Putting Those Together: 

Avera

g g e Refuelin

g Rate Decreas

1800

Histogram of Fueling Rates

Vehicle and Infrastructure

 20 20

Th 

120014001600

ts5 kg in

Th

 Af

800

10001200

of Fueling Event

5 kg in

5 minutes 

25464 Events

Average = 0.77 kg/min

23% >1 kg/min

400600800

Number o 5 kg 

3 minu

1730 Events

Average = 0.66 kg/min

3% >1 kg/min

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

0

200400 g

National Renewable Energy Laboratory 18 

0

0.2

0.4

0.6

0.8 1 1.2 1.4 1

NREL cdp_fcev_18 Avg Fuel Rate (kg/min)

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

Continues to Improve as Demonstrat

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 

entage of Refue Refuelings after 2009Q41 = 31

 Median distance between 

5

Perce

0 50 100 150 200 

0

Distance between refuelings [Miles]

2

National Renewable Energy Laboratory 19 

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 

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

Last Year, But Vehicles Still Added 55

Cumulative Vehicle Miles: All OEMs, Gen 1 

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 20 

Created: Sep-07-10 10:10 AM

NREL CDP24
Based on Limited Number of Fuelings in La

Higher Level of Tank at Refueling Observed

Tank Levels: DOE Fleet

Median Tank Level (At Fill) = 42% Median Tank Level (At Fill) = 48% 

14%

13%

E

1. Some refueling events not recorded/detected due to data noise or inco2. The outer arc is set at 20% total refuelings.

National Renewable Energy Laboratory 21 

NREL cdp_fcev_40

g

3. If tank level at fill was not available, a complete fill up was assumed.

Created: Sep-02-10 12:47 PM
Driving Behavior in Last 6 Month

Much More Similar to National Av

Driving by Time of Day

12

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

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

9%

12

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

% 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

2A

National Renewable Energy Laboratory 22 

NREL cdp_fcev_44

Created: Sep-02-10 12:48 PM

A
More Weekend Driving Observed 

Months 

– Still Much Less than Na

25

Driving by Day of Week

2015

Trips in a Day

10

% of 

S

M

T W d Th F 

05

National Renewable Energy Laboratory 23 

Sun

Mon

Tues

W

e

d Thur

F

NREL cdp_fcev_45 Day

Created: Sep-01-10 1:52 PM

20A
Summary

• Project has completed >5 full years of ope• Vehicle operation: 114 000 hours 2 87 m

Vehicle operation: 114,000 hours, 2.87 m

436,000 trips

• H2 station operation: 134,000 kg produce

27,000 refuelings

• DOE Key Technical Targets Met: FC Dura• Two of the OEMs will be continuing opera

Two of the OEMs will be continuing opera

vehicles through end of 2011; progress w

• Future work: Additional collaboration with 

OEM teams to make analyses useful for teevolution and preparation for 2014-2015 mNew CA fueling stations planned for inclus

National Renewable Energy Laboratory 24 

• New CA fueling stations planned for inclus

results as they come online
Questions and Discussion

P j t C t t K ith Wi k N ti l R Projec

t

Con

tac

t: 

K

eith Wi

p

ke, 

N

ational Renew

303.275.4451 keith.wipke n

All public Learning Demo papers and presentations are 

@

National Renewable Energy Laboratory 25 

All public Learning Demo papers and presentations are 

online at http://www.nrel.gov/hydrogen/proj_tech_valida