Controlled Hydrogen Flee

Infrastructure Demonstrati

Validation Project:

Fall 2006 Progress Upd

Keith Wipke, Cory Welch, Holly Thomas, 

Sigmund Gronich, John Garba

EVS-22

October 26, 2006

Yokohama, Japan

1NREL, 2US Dept. of Energy

This presentation does not contain any proprietary or confid

NREL/PR-560-40765
Disclaimer and Government Lic

This work has been authored by Midwest Research Institute (MRIDE-AC36-99GO10337 with the U.S. Department of Energy (the “DStates Government (the “Government”) retains and the publisher, 

for publication, acknowledges that the Government retains a non-irrevocable, worldwide license to publish or reproduce the publish

allow 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 us

any 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/o

herein do not necessarily state or reflect those of MRI, the DOE, tagency thereof. 
Outline

• Project Objectives and Overview

• Industry Partners; H2 vehicles and s

• Process and Methodology

• Key Fall 2006 Results

– Vehicles

• Net fuel cell system efficiency• Fuel economy and range

• Fuel cell durability• Safety • High-level vehicle metrics

– H2 Refueling Infrastructure

• Refueling Rates• H2 station impurities

• Summary and Future Results
Project Objectives and 

• Objectives

– Validate H

2 FC Vehicles and Infrastruct

– Identify Current Status of Technology a

– Assess Progress Toward Technology R

– Provide Feedback to H

2 Research and 

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

Key Targets

Hydrogen refueling station, Chino, CA Photo: NREL
Teams are Fielding 

Four Main Types of Veh

Validation also includes FCV Sprinter vans
Number of Learning Demo Vehicles 

3 H2 Storage Technologies 

On-Board Hydrogen Storage Methods

-

10203040506070

Q205 Q305 Q405 Q106 

# of Vehicles (All Teams)

5,000 psi tanks 10,000 psi tanks Liqu

Created 25-Aug-2006

~1/2 of project vehicles have 

Additional vehicles will include 

systems and some additiona
Representative Hydrogen R

Infrastructure Supporting V

LAX refueling station

Hydrogen and gasoline station, WA DC

DTE/BP Power Park, Southfield, MI
Refueling Stations from All Four T

Vehicle/Infrastructure Performance in V

Northern California

Southern California 

09-22-06

Additional Planned Stations (3)

Additional Planned Stations (4)

SE Michigan 

Ad

Additional Planned Stations (2)
Providing Data Analysis and Res

the Public and for the Industry P

Raw Data, 

Reports

Hydrogen Secure Data 

Center (HSDC)

• Located at NREL: Strictly Controlled Access• Detailed Analyses, 

Data Products, Internal Reports

Co

• P

agres

D

• coor

• N

inf

Data is delivered to 

NREL’s Hydrogen 

Secure Data Center 

(HSDC) on CD/DVDs

Data protected in HSDC for 5 years 

after data is developed under 

EPACT 2005, Sec. 810
Five Quarters of Data Analyze

Current Status of Data Reporting to the Hydrogen Secur

On-Road Data Received -- Running Tot

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-05

Jan-06

Feb-06

Mar-06

Apr-06

May-06

Jun-06

Jul

0

A

MB of Data

MB of data# trips

Through September, 2006:

76,000 individual vehicle trips

27 GB of on-road data
PUBLISH

Analysis Calculations and Result

NREL-Developed GUI – Fleet Analysi
Quantity of Project Results Co

Increase; Public Updates Every 

Dyno (1) Window-Sticker (2) On-Road (3)(4) 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/model.(1) One data point for each make/model. Combined City/Hwy fuel economy per DRAFT SAEJ2572.(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.

0

50

100150200250300

All OEMs

Vehicle Range (miles)

Vehicle Range(1)

2015 Target2009 Target

Created: 21-Feb-2006 (1) Calculated from combined City/Hwy fuel economy (dyno test) per DRAFT SAE J2572 and usable fuel on board.

Safety Incidents - Vehicle Operation

0123456789

10

'05 Q2

'05 Q3

'05 Q4

Num ber of Incidents

Passenger Compartment H2 alarm H2 release

Created 21-Feb-2006

Safety Incidents - Infrastructure

2005 Q2 - Q4

Calibration/SettingsElectricalH2 Leak/Unplanned VentNon-H2 Leak

Mischief, Vandalism

Environmental 

(Weather, Power 

Disruption, etc.)

Unconfirmed/False 

Alarm

0 1 2 3 4 5 6 7 8 910 Calibration/Settings

H2 Leak/Unplanned

Vent Mischief, Vandalism

Unconfirmed/False

Alarm

General Category

Created 21-Feb -200 6 Num ber of Incidents

On-Board Hydrogen Storage Methods

-

10203040506070

Q205 Q305 Q405

# of Vehicles (All Teams)

5,000 psi tanks 10,000 psi tanks Liquid H2

Created 16-Feb-2006

0123456789

All OEMs

Weight Percent Hydrogen (%)

Weight Percent Hydrogen

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.

0

0.010.020.030.040.050.060.070.080.09

0.1

All OEMs

Mass H2 per Liter (kg/L)

M ass 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.

99.98499.98699.98899.99099.99299.99499.99699.998

100.000

Hydrogen Purity (%)

Hydrogen Purity Sampled from Stations(1)

Range of Reported DataISO FDTS 14687-2 Target

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

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 

NH3 

μmol/mol (ppm)

0 5 10 15 20 25 30 35 40 45 50

Total S Compounds* 

nmol/mol (ppb)

Created: Jun-01-06 11:02 AM *Includes SO2, COS, and 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 1.8 0

5

10152025303540

Refueling Rate (kg H2/minute)

# of Refuelin g Events

Histogram of Vehicle Refueling Rates

5 minute fill of5 kg at 350 bar

3 minute fill of5 kg at 350 bar

2006 Tech Val Milestone2010 MYPP Adv Storage Materials Target

Created: 21-Feb-2006

-30-20-10

0

1020304050

Degrees Celsius

Ambient Temperature During Operation

All OEMs

Created: 16-Feb-2006

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

Vehicle M iles: All OEM 's Combined

through Q4 2005

05

10152025

0-1500

1500-3000

3000-4500

4500-6000

6000-7500

7500-9000

9000-10500

10500-12000

12000-13500

>13500

Total Vehicle Miles

Number of Vehicles

Total Vehicle M iles Traveled = 196,405

Created: 28-Feb-2006

Cumulative Vehicle Miles Traveled: All OEMs

-

50,000

100,000150,000200,000250,000

Q205 Q305 Q405

Vehicle Miles Traveled

Created: 16-Feb-2006

Cumulative Hydrogen Produced or Dispensed

All Teams Combined

0

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

Q2 2005 Q3 2005 Q4 2005

Reporting Calendar Quarter

Mass of Hydrogen (kg)

Created 21-Feb-2006

Dyno (1) Window-Sticker (2) On-Road (3)(4) 0

1020304050607080

Fuel Economy (miles/kg H 2)

Fuel Economy

Created: Aug-25-06 10:45 AM

(3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(1) One data point for each make/model. Combined City/Hwy fuel economy per DRAFT SAEJ2572.(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.

0 10 20 30 40 50 60 70 80 90 100

Vehicle Range Factors

Percentage of chassis dyno range1

.

All O EM s

W indow-Sticker 2

On-Road 3

Dyno 1

Created: Aug-30-06 3:09 PM

1. Calculated using the combined city/hwy fuel economy from dyno testing (non-adjusted) and usable fuel on board2. Applying window-sticker correction factors for fuel economy: 0.78 x Hwy and 0.9 x City3. Using fuel-economy from on-road data (excluding trips > 1 mile, consistent with other data products)

0 10 

0

102030405060708090

100

Percentage of refuelings

PercCum

Created: Aug-30-06 3:09 PM

Total 

1. Rang2. Some 

Safety Incidents - Infrastructure

2005 Q2 - 2006 Q2

ElectricalNon-H2 Leak

Failed/Broken 

Equipment

Mischief, Vandalism

Calibration/ Settings/ 

Maintenance

Environment (Weather, 

Power Disruption, etc.)

H2 Leak/Unplanned 

Vent

Unconfirmed/False 

Alarm

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

Electrical

Failed/Broken

Equipment

Calibration/

Settings/

Maintenance

H2

Leak/Unplanned

Vent

General Category

Created 30-Aug-06 Number of Incidents

0 

Adjustment

Check Only

Other

Repair

Replacement

0 

Adjustment

Check Only

Other

Repair

Replacement

0% 10

# of Events

Hours

Created: Aug-30-06 3:04 PM

25 Composite Data Products Have Now 

Been Published, Including Updating 10 of the 

16 Published in Spring 2006

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 

NH3 

μmol/mol (ppm)

0 5 10 15 20 25 30 35 40 45 50

Total S Compounds* 

nmol/mol (ppb)

Created: Jun-01-06 11:02 AM *Includes SO2, COS, and H2S.

0123456789

Weight Percent Hydrogen (%)

Created: 23-Feb-2006

1Some near-term 

0

0.010.020.030.040.050.060.070.080.09

0.1

All OEMs

Mass H 2 per Liter (kg/L)

M ass 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.

-

10203040506070

Q205 

# of Vehicles (All Teams)

Created 25-Aug-2006

05

10152025

0-100

1

Number of Vehicles

Created: 25-A ug-06

National Hydrogen 

Association Conference

March 13, 2006

EVS-22 Conf

October 26, 

Dyno 

0

50

100150200250300

Vehicle Range (miles)

Created: Oct-03-06 8:07 AM

(1) Range is base(2) Fuel econom(3) Fuel econom(4) Excludes trip(5) Fuel econom

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 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/mol (ppm)

0 10 20 30 40 50 60 70 80 90 100

Total S* 

nmol/mol (ppb)

Created: Sep-26-06 3:47 PM *Calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

Controlled System Tests Ve

Fuel Cell System Conversion 

0

10203040506070

All OEMs

Efficiency (%) 

Fuel Cell System1 Efficiency

2 at ~25% Net Pow

Created: Aug-29-06 4:09 PM

1 Gross stack power minus fuel cell system auxiliaries, per DRAFT SAEJ2615.2 Ratio of DC output energy to the lower heating value of the input fuel (hydrogen).

Excludes power electronics and electric drive.

In-Vehicle Fue

Efficiencies Ra

52.5% and 58.1%

Results obtained from DOE targe

steady-state vehicle chassis 

dynamometer tests at 

roughly 1⁄4 power
Dynamometer and On-Road Fu

from Learning Demonstration 

Dyno (1) Window-Sticker (2) On

0

1020304050607080

Fuel Economy (miles/kg H 2)

Fuel Economy

Created: Aug-25-06 10:45 AM

(3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/mode(1) One data point for each make/model. Combined City/Hwy fuel economy per DRAFT (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.
Dyno Range (2) Window-Sticker Range (3) On-R

0

50

100150200250300

Vehicle Range (miles)

Vehicle Range1

Created: Oct-03-06 8:07 AM

(1) Range is based on fuel economy and usable hydrogen on-board the vehicle. One data point for each (2) Fuel economy from unadjusted combined City/Hwy per DRAFT SAEJ2572.(3) Fuel economy from EPA Adjusted combined City/Hwy (0.78 x Hwy, 0.9 x City).(4) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(5) Fuel economy calculated from on-road fuel cell stack current or mass flow readings.

Vehicle Range Based on Fuel 

and Usable H2 Fuel Stored O

Data indicate i

capable of b

neces
Effective Vehicle Range Redu

Dyno Range by On-Road Fuel 

0 10 20 30 40 50 60 70 

Vehicle Range Factors

Percentage of chassis dyno range1

.

All OEMs

On-Road 3

Created: Aug-30-06 3:09 PM

1. Calculated using the combined city/hwy fuel economy from dyno testing (non-adjuste2. Applying window-sticker correction factors for fuel economy: 0.78 x Hwy and 0.9 x C3. Using fuel-economy from on-road data (excluding trips > 1 mile, consistent with othe

Real-world on-road fuel economy is 

63-75% of dyno fuel economy

This translates directly into a 

25-37% reduction in effective 

real-world range

Vehicle Range Factor =

(on-road fuel economy) / (dyno fuel economy)
Learning Demo Data Show 

Refueling Behavior as % of T

0 10 20 30 40 50 60 70 

0

102030405060708090

100

Range Histogram: All OEMs

Percentage of chassis dyno range1 b/w refueli

Percentage of refuelings

PercentageCumulative Percentage

Created: Aug-30-06 3:09 PM

Total refuelings

2 = 2048

1. Range calculated using the combined city/hwy fuel economy from dyno testing (not 2. Some refueling events are not detected/reported due to data noise or incompletene

95% of refueling

<65% of dyno 

50% of refueling

<35% of dyno 
Max Hrs Accumulated (1)(2) Avg Hrs Accum

0

200400600800

Time (Hours)

DOE Learning Demonstration:

Fuel Cell Stack Hours Accumulated Through August 2

Created: Oct-05-06 4:32 PM

(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 individu(3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OE

Learning Demo Fuel Cell Sta

Accumulated Through Augu

Accumulation of FC stack operating hours 

takes significant calendar time, due to 

real-world nature of data accumulation

Example

1000 hours = 

1000 hours = 
0 500 1

100120140160180200220240

ST

Predicted Voltage at 300A

Voltage vs. Opera

938 hrs

ThreNom

13 m

V

0 500 1

Created: 28-Feb-2006

Limited Data Necessitated Projectin

10% Fuel Cell Stack Voltage De

0 50 100 150 200 250 300 350

200250300350

Time (stack oper hrs) = 164

Current (A)

Voltage (V)

Stack Degradation Analysis: Vehicle16-Stack2

2400 data points per curve fit

0 100 200 300 400 500 600 100

150200

STACK Operating Time (hrs)

Predicted Voltage (V)

Predicted (Curve Fit) Voltage vs. time for Vehicle16-Stack2

Technique Makes Performance 

Projection Based on All Available 

FC Data; Includes Reporting 

Confidence in Results 0 500 

100120140160180200220240

S

Predicted Voltage at 300A

Voltage vs. O

ThNo

1

0 500 

Note: 10% 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.
Hours Accumulated To-Dat

Projected Hours to 10% Stack Voltag

0

200400600800

10001200140016001800200022002400

2006 Target2009 Target

Actual Operating Hours Accumulated To-Date Projected Hours 

Max Hrs Accumulated (1)(2) Avg Hrs Accumulated (1)(3) Projection to 1

Time (Hours)

DOE Learning Demonstration Fuel Cell Stack Durabili

Based on Data Through August 2006

Created: Oct-05-06 4:32 PM

(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 (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 p may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membran(5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = average  The shaded green bar represents an engineering judgment of the uncertainty due to data and methodology limitat as additional data are accumulated.
Safety Incidents - Vehicle Operation

0123456789

10

'05 Q2

'05 Q3

'05 Q4

'06 Q1

Number of Incidents

H2 Leak - StackH2 Leak - Fuel SystemH2 Leak While FuelingPassenger Compartment H2 alarm

Created: 8/28/2006

Safety Incidents – Veh

Strong vehicle safety record 

indicates very few start-up 

issues and no fundamental 

safety problems with the vehicles
0 0.2 0.4 0.6 0.8 1 1.2 1.4 

0

50

100150

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Vehicle Fueling Rates (Thru 2006Q2)

5 minute fill of5 kg at 350 bar

3 minute fill 5 kg at 350 b

2006 Tech V2010 MYPP 

Created: Aug-29-06 4:47 PM

Actual Vehicle Refueling Rates from >2

Measured by Stations or by Veh

Future analyses 

communication 

fills on fill rates 

Average rate: 0.69 kg/min

Median: 0.72 kg/min

18% of refueling events exceeded 1kg/min
0 1 2 3 4 5 6 

Particulates 

μg/L

H2 Impurities

Data Range SAE J2719 Measured Less Than or Eq

0 50 100 150 200 250 300 3

(N2 + He + Ar) 

0 1 2 3 4 5 6 

H20 

Total HC 

O2 

CO2 

CO 

NH3 

μmol/mol (ppm)

0 10 20 30 40 50 60 7

Total S* 

nmol/mol (ppb)

Created: Sep-26-06 3:47 PM *Calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

Hydrogen Impurities Sampled from All Sta

On-Site Reformation, Electrolysis, and 

High d

uncerta
Range of Ambient Tempe

During Vehicle Operat

-30-20-10

0

1020304050

Degrees Celsius

Ambient Temperature During Operation

All OEMs

Created: 16-Feb-2006

Fuel 

ab

te

Future 

to s
Vehicle Operating Hours an

Traveled Distribution

Vehicle Hours: All OEM's Combined

05

10152025

0-100

100-200

200-300

300-400

400-500

500-600

600-700

700-800

800-900

>900

Total Vehicle Hours

Number of Vehicles

Through Q2 2006

Created: 25-Aug-06

Total Vehicle Hours = 19,324

Vehicle Miles: All 

02468

1012141618

0-1500

1500-3000

3000-4500

4500-6000

6000-7500

7

Total Veh

Number of Vehicles

Total M 

Through 

Created: 25-Aug-06

The bulge of op

traveled is no

New Gen 1 v

introduced, but 

left with Gen 
Summary

• First 5-quarters of project completed

– 63 vehicles now in fleet operation– 9 stations in operation to support project vehicle

– No major safety problems encountered

– Total of 25 composite data products published 

• Project has identified current technical stat

program targets

– Will track improvements from 2nd generation sta

introduced mid-way through project

• Future public results will include:

– 6-month updates to existing composite data pro– Fuel cell cold start-up times– H2 production cost and efficiency

– Other composite data products created based o
Questions and Discus

Contact: Keith Wipke, National Renewa

303.275.4451 keith_wipke@n

All public Learning Demo papers and presentations are a

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