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Session TA.5 – Demonstration P

Costs, and Market Introduction

This presentation does not contain any proprietary, confidential, or otherwise restricted info

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, opera
National Renewable Energy Laboratory 

2 

NREL is One of 12 U.S. DepaEnergy National Laboratories

Los Alamos 

National 

Laboratory

Lawrence 

Livermore 

National 

Laboratory

Sandia 

National 

Laboratories

Lawrence 

Berkeley 

National 

Laboratory

Idaho

National 

Laboratory

Pacific Northwest 

National 

Laboratory

Argonne 

National 

Laboratory

Natio

Ener

Techno

Labora

Oak Ridge 

National 

Laboratory

Science

Fossil Energy

Nuclear Energy

Nuclear SecurityEnergy Efficiency and Renewable Energy NREL is operated for DOE by the Alliance for Sustainable E

(Midwest Research Institute and Battelle) 
National Renewable Energy Laboratory 

3 

National Renewable Energy Laboratory

National Renewable Energy Laboratory

•Research spans fundamental science to techno•Collaboration with industry and university partn•Research programs linked to market opportuni

• Only national lab ded

energy and energ
National Renewable Energy Laboratory 

4 

Outline

• Who/What is NREL?• Brief Highlights of Select International F

Introduction Plans in:

• Germany• Japan• Korea

• Highlights from United States

• Car, bus, forklift, and others

• Review of Today’s Schedule and Timin
National Renewable Energy Laboratory 

5 

September 2009 OEM Letter of UnderDiscusses Worldwide Introduction, but Focused on 

“Based on current 

to a variety o

conditions, the s

anticipate that from 

significant numb

could be commerc

aimed at a few h

over life cycle o

““The signing OEMs strongly support the idea 

building-up a hydrogen infrastructure in Europe, 

Germany as starting point and at the same tim

developing similar concepts for the market 

penetration of hydrogen infrastructure in othe

regions of the world, with one US market, Japa

and Korea as further starting points.”
National Renewable Energy Laboratory 6 

GermanyNational Innovation Program (NIP) Ov

Preparing Hydrogen and Fuel Cell MarketsNational Innovation Programme (NIP)

1,4 billion €

10-year-programme till 2016 

+ 700 million €

Co‐payment from in

500 million €

for demonstration

+ 200 million €

for R&D

• Preparing hydrogen & fuel cell

markets

• Focus on R&D combined with 

everyday demonstration

• hydrogen & fue

applications and 

transport, statio

supply, special 

Politics Indust

BMVBS / BMWi / BMBF / BMU

in discussion: 180 projects / 

€815 Mio. budget

approved: 69 projects /

€351Mio. budget

Preparing Hydrogen and Fuel Cell MarketsNational Innovation Programme (NIP)

1,4 billion €

10-year-programme till 2016 

+ 700 million €

Co‐payment from ind

500 million €

for demonstration

+ 200 million €

for R&D

• Preparing hydrogen & fuel cell

markets

• Focus on R&D combined with 

everyday demonstration

• hydrogen & fuel 

applications and 

transport, statio

supply, special m

Politics Industr

BMVBS / BMWi / BMBF / BMU

in discussion: 180 projects / 

€815 Mio. budget

approved: 69 projects /

€351Mio. budget
National Renewable Energy Laboratory 7 

GermanyNational Innovation Program (NIP) Fo

NIP: Preparing MarketsTransport:

• 54% of the NIP• incl. H2-production and H2-infrastructure

• extension of vehicle 

cars and buses) and 

starting from key reg

Hamburg)

Stationary applications:

• 36% of the NIP• FC-heating-applications in privately

owned homes

• FC in industrial CHP

Special mark

• 10% of the • critical ene

IT, telecom

• logistics, le

markets

NIP: Preparing MarketsTransport:

• 54% of the NIP• incl. H2-production and H2-infrastructure

• extension of vehicle f

cars and buses) and 

starting from key reg

Hamburg)

Stationary applications:

• 36% of the NIP• FC-heating-applications in privately

owned homes

• FC in industrial CHP

Special mark

• 10% of the • critical ener

IT, telecomm

• logistics, le

markets
National Renewable Energy Laboratory 

8 

JapanToyota Announces $50,000 FCV Poss

“Our targe

money with 

vehicle... Pr

be covered 

th

– Yoshihik
National Renewable Energy Laboratory 

9 

JapanFCV Commercialization Plans Ho

* Precondition: Benefit for FCV users (price/convenience etc.) are secured, and FCVs are widely and smoo

2010 2011 2015 2016 2025 

•Solving technical issues and promotion of review regulations (Verifying & reviewing development progress as needed)

•Verifying utility of FCVs and H2 stations

from socio-economicviewpoint

Year Note: Vertical axis indicates the relative scale bet

Phase 1

Technology

Demonstration

【JHFC-2】

Phase 2

Technology & Market

Demonstration

【Post JHFC】 【Starting Period】

Phase 3

Early Commercialization

【Expansion Period】

H2 Station Number Vehicle Number Determine specifications of commercial type H2 stations Begin building commercial type H2 stations Increase of FC

introduction o

Perio

build

Approx. 1,000 H2 stations

*

Approx. 2 million FCVs

*

•Expanding production and sales of FCVs while maintaining convenience of FCV users•Reducing costs for H2 stations and 

hydrogen fuel•Continuously conducting technology development and review of regulations

Commercialization Scenario for FCVs and H

2 Stat
National Renewable Energy Laboratory 10 

Japan (progress): NREL/SRNL Verified ToyoDriving Range >400-Mile (Without Refueling

Average

trip

distance

(miles)

H2

consumed

(kg)

Remaining

usable H2

(kg)

Calculated

remaining

range

(miles) (miles) (miles)

Vehicle

#1

331.50 4.8255 1.4854 102.04 433.55

Vehicle 431

#2

331.45 4.8751 1.4328 97.41 428.87

0 MPG

30 MPG60 MPG90 MPG
National Renewable Energy Laboratory 11 

KoreaPlans Consistent with Japan and 

“Hyundai-Kia e

small-scale 

FCEVs by 201

about 9000 v

sold in the U

mostly to mu

all manufactur

By 2015, it 

48,000 FCEV

annually in 

number that 

280,000 
National Renewable Energy Laboratory 12 

KoreaHyundai-Kia Roadmap

Source: Todd Su
National Renewable Energy Laboratory 13 

KoreaHyundai-Kia Next Generation for 

Source: Todd Su
National Renewable Energy Laboratory 14 

United States of America

• Fuel Cell Cars – Learning Demonstratio

• Fuel Cell Buses• Fuel Cell Forklifts

• DOE• DOD
National Renewable Energy Laboratory 15 

U.S Fuel Cell Vehicle Learning DemonIndustry Partners and Vehicle Deploy

Gen 1

Gen 1 & 2 Gen 

Gen 2

Gen 1

Gen 2

-

20 40 60 80 

100 120 140 160 

Cumulative Vehicles Deployed/Retired

1

Vehicle Deployment by On-Board Hyd

700 bar on-road350 bar on-roadLiquid H2 on-road700 bar retired350 bar retiredLiquid H2 retired

(1) Retired vehicles have left DOE fleet and are no longer provi

Some project teams concluded in Fall/Winter 2009 Created Mar-09-2010 8:34 AM

NREL CDP25

(CHIP)
National Renewable Energy Laboratory 16 

U.S Fuel Cell Vehicle Learning DemonInfrastructure Status

05

10152025

Number of Stations

Existing StationsContinuing Outside of Retired Stations

NREL CDP31

Created Mar-19-10 9:05am

0123456789

Delivered Compressed 

H2

Natural Gas On-site 

Reforming

Electrolysis Delivered Liquid H2

# of Stations

Production Technology

Infrastructure Hydrogen Production Methods 

Existing StationsContinuing Outside of ProjectRetired Stations

NREL CDP32

Created Mar-19-10 9:05am

Total of 130,000 kg H2

produced or 

dispensed

from the 23 stations
National Renewable Energy Laboratory 17 

U.S. Hydrogen Refueling Stations in O

Feb-18-2010

2

56

SF Bay Area

Detroit 

Los Angeles Area

15
National Renewable Energy Laboratory 18 

80 Public Composite Data Products Have BeNew Results and Updates Every 6 Months

Results presented at:

FC Seminar, NHA, EVS 
National Renewable Energy Laboratory 19 

Verified High Gen 2 Fuel Cell System Maintained (Compared to Gen 1)

0 10 20 30 40 50 60 70 

0

102030405060

Net System Power [%]

Efficiency [%]

Fuel Cell System1 Efficiency2

 Eff. at 25% Pwr Eff. at 100% Pwr ------------------- -------------------Gen1 51 - 58% 30 - 54%Gen2 53 - 59% 42 - 53%

DODOGeGe

NREL CDP08

Created: Sep-02-09 11:27 AM

1 Gross stack power minus fuel cell system auxiliaries, per DRAFT SAE J2615. Excludes power ele2 Ratio of DC output energy to the lower heating value of the input fuel (hydrogen). 3 Individual test data linearly interpolated at 5,10,15,25,50,75,and 100% of max net power. Values at 

 due to steady state dynamometer cooling limitations.
National Renewable Energy Laboratory 20 

Quantified Gen 2 Fuel Cell SysteImprovement from Gen 1

Gen1 Gen2 Gen1 Gen2 G

0

200400600800

1000120014001600180020002200240026002800

2006 Target2009 Target

Actual Operating Hours Accumulated To-Date Projected Hou

Time (Hours)

DOE Learning Demonstration Fuel Cell Stack Durabi

Based on Data Through 2009 Q2

Max Hrs Accumulated1,2 Avg Hrs Accumulated1,3 Projection 

NREL CDP01

Created: Mar-23-10 10:39 AM

(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 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 

*

One Gen 1 stack 

accumulated almost 

2400 hours without 

maintenance
National Renewable Energy Laboratory 21 

Tracked Refueling Rates Over 5 Yof Project

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1

0

100200300400500600700

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

All Light Duty by Year Through 2009Q4

5 minute fill of5 kg at 350 bar

3 minute fill o5 kg at 350 b

Year Avg (kg/min) %>1 ------- ----------------- -------2005 0.66 16%2006 0.74 21%2007 0.81 26%2008 0.77 23%2009 0.77 22%

20202020202020

NREL CDP52

Created: Mar-09-10 3:35 PM
National Renewable Energy Laboratory 22 

Range: Quantified Real-World Improvement Range Between Gen 1 and Gen 2 Vehicles

0 50 100 150 200 

05

10

Percentage of Refuelings

Distance between refuelings [Miles]2

Distance Driven Between Refuelings: All OEMs

NREL CDP80

Created: Mar-23-10 10:53 AM

Total Refuelings1 = 25811

 Gen1 Refuelings = 18941 Median distance between ref Gen2 Refuelings = 6870 Median distance between ref

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 

4
National Renewable Energy Laboratory 23 

U.S. FCV Learning DemonstrPerformance Summary

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 Operation 

by a Single FC Stack to Date 2375 hours 1261 ho

Driving Range 103-190 miles 196-254 mFuel Economy (Window Sticker) 42 – 57 mi/kg 43 – 58 mFuel Cell Efficiency at 1⁄4 Power 51 - 58% 53 - 59Fuel Cell Efficiency at Full Power 30 - 54% 42 - 53Infrastructure Performance Metrics H2 Cost at Station (early market)*

On-site natural gas 

reformation

$7.70 - $10.30

On-site 

Electroly

$10.00 - $1

Average H2 Fueling Rate 0.77 kg/min 

*Outside of this project, DOE independent panels concluded at 500 replicat

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

Distributed electrolysis at 1500kg/day: $4.90-$5.70 (2009)
National Renewable Energy Laboratory 24 

American Recovery and Reinvestme(ARRA) Fuel Cell Early Market Proje

COMPANY

Delphi Automotive 

FedEx Freight East 

GENCO 

Jadoo Power 

MTI MicroFuel Cells 

Nuvera Fuel Cells 

Plug Power, Inc. (1) Plug Power, Inc. (2) 

Univ. of N. Florida 

ReliOn Inc. 

Sprint Comm. 

Sysco of Houston 

Project Objective

Deploy ~1,000 fuel cells to 

accelerate the 

commercialization and 

deployment of fuel cells and 

fuel cell manufacturing, 

installation, maintenance, and 

support services

12 awards with >$40 million ARRA 

& ~$53 million cost share
National Renewable Energy Laboratory 25 

U.S. ARRA Fuel Cell Units in OperaCurrent and Projected Quantities

2009 Q4 2010 Q1 2010 Q2 2010 Q3 2010 Q4 2011 Q1 

0

200400600800

100012001400

Projected Operation Quantities

In Operation Quantity

Calendar Quarter

DOE ARRA1 Funded Early Fuel Cell Markets: Un

APUBackup PowerForkliftStationary

Created: Apr-14-10 4:16 PM 

1000

171 136

Actual Quantities
National Renewable Energy Laboratory 26 

U.S. Department of DefenseFC Forklift Demonstration Overvi

4 Fuel Cell Forklift Demonstration Projects

• DOD’s Defense Logistics Agency uses over 3,00

accomplish its warehousing operations in DOD’s Distribution Centers

• DLA has selected 4 warehouse sites to operate a

multiple hydrogen generation, dispensing and fuetechnologies to power materials handling equipm24-month pilot phase

• DDSP is DLA’s first fuel cell MHE pilot site

• Ribbon cutting: February 10, 2009

Locations:

DDSP: 40 forklifts, delivered (cryogenic) hydrogen, indoor dispDDWG: 20 forklifts, hydrogen via onsite natural gas reformatioDDJC: 20 forklifts, hydrogen via solar electrolysisFt. Lewis: 19 forklifts, 1 bus, wastewater digester gas hydroge

Duration: 2 years of operation at each site

Technology Validation: NREL to perform data analysis to validate 
National Renewable Energy Laboratory 27 

0 500 1000 1500 

01234567

Accumulated Hours on FC Stack

Combined Fleet Through 2009Q4

Number of Forklifts

Stack Hours

Total Combined Fleet St

NREL cdpFL02

Created: Apr-19-10 11:19 AM

Fuel Cell Stack Hours are Accumulin the Forklift Applications (~10X fa

40% of the combine

over 1500 hours o

on their FC s

40% of the combine

over 1500 hours o

on their FC s

These res These resuults are fr lts are fro

o
National Renewable Energy Laboratory 28 

U.S. Fuel Cell Bus DemonstrationPlanned FCB Evaluations for DO
National Renewable Energy Laboratory 29 

U.S. Fuel Cell Bus DemonstraSignificant Fuel Consumption Reduc

Progress• Continued data collection & analysis of five FCBs in real-w

transit agencies

• Documented fuel economy improvement over conventiona

as 2 times (depending on duty cycle)

• Manufacturer has modified FC based on early results to in

reliability. New version installed in all 5 buses beginning i

02468

1012

Miles per gallon (diesel equivalent) ACTFCB ACTDiesel

CTTFCB CTTDieselSunLine FCB SunLine CNG

Mo

• Tw

haho(ro
National Renewable Energy Laboratory 30 

Session TA.5: Early Morning 
National Renewable Energy Laboratory 31 

Session TA.5: Late Morning S
National Renewable Energy Laboratory 32 

Session TA.5: After Lunch an
National Renewable Energy Laboratory 33 

Questions and Discussion

Contact: Keith Wipke, National Renewable En

303.275.4451 keith.wipke n

All public U.S. Technology Validation papers and presentation

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

@