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

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SocKeiJenRamOctHon

Fuel Cell Vehicle and Infrastructure Demonstration Status and Results

NREL/PR-560-44266
National Renewable Energy Laboratory 2 

Outline

• Objectives and Partners• NREL’s Role in the Project and M• How to Access Complete Results• Analysis Results• Summary
National Renewable Energy Laboratory 3 

Fuel Cell Vehicle Learning DemoProject Objectives and Targets

Objectives

– Validate H

2 FC Vehicles and Infrastruct

– Identify Current Status and Evolution of 

• Assess Progress Toward Technology Readi• Provide Feedback to H

2 Research and Deve

Solar Electrolysis S

Performance Measure 2009 2015

Fuel Cell Stack Durability 2000 hours 5000 hoursVehicle Range 250+ miles 300+ milesHydrogen Cost at Station $3/gge $2-3/gge

Key Targets
National Renewable Energy Laboratory 4 

Industry Partners: 4 Automaker/Energy-SupSignificant Number of Gen 2 Vehicles Now 

Gen 1 Gen 1

Gen 1 & 2

Gen 2

Gen 2 

Gen 1

122
National Renewable Energy Laboratory 5 

DOE Learning Demo Fleet Has S69,000 Vehicle Hours and 1.5 Mil

Gen 2 vehicle introduction now 

appears as the 2nd bulge at 

low hours/miles
National Renewable Energy Laboratory 6 

Majority of Project’s Fixed InfrastructVehicles Has Been Installed – Examp

Recent station addition:

Santa Monica Blvd. (Shell) 

16 stations now deployed

Mobile Refueler

Sacramento, CA

Steam Methane Reforming

Oakland, CA

Total of >60,000 kg H2 

produced or dispensed
National Renewable Energy Laboratory 7 

Refueling Stations Test Performance in VarLearning Demo Comprises ~1/4 of all US St

16

Oct-09-2008

6

51

SF Bay Area

Los Angeles Area

7

Detroit Area
National Renewable Energy Laboratory 8 

Extremely Large Data Sets Have Resulted in NREL-Developed Data Processing Tools

Composite 

Data 

Products

Detailed 

Data 

Products

NREL

HSDC

Data Flow

Through September 2008:

270,000 individual vehicle trips

60 GB of on-road data

http://www.nrel.gov/h

Individual Team Disc
National Renewable Energy Laboratory 9 

NREL Web Site Provides Direct Access to AData Products (53), Reports, and Presentati

Dyno Range (2) Window-Sticker Range (3) On-Road 

0

50

100150200250300

Vehicle Range (miles)

Vehicle Range1

Created: Feb-27-07 4:49 PM

(1) Range is based on fuel economy and usable hydrogen on-board the vehicle. One data point for each make/mod(2) Fuel economy from unadjusted combined City/Hwy per DRAFT SAE J2572.(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.

http://www.nrel.gov/hydrogen/cdp_to

http://www.nrel.gov/hydrogen/proj_learning_demo.html
National Renewable Energy Laboratory 10 

0

10203040506070

All OEMs

Efficiency (%) 

Fuel Cell System1 Efficiency

2 at ~25% Net Po

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.

Gen 1 Baseline Dyno Tests Validated High EPower Point – Gen 2 Efficiency Results Pub

Steady-State Efficiency 

at 1⁄4 power on dyno: 

52.5% to 58.1%

High-e

match

FCV 
National Renewable Energy Laboratory 11 

05

101520253035404550

%Time at Power Levels: DOE Fleet

% Time at Power Level

0-5%

5-10%

10-15%

15-20%

20-25%

25-30%

30-35%

35-40%

40-45%

45-50%

50-55%

55-60%

60-65%

65-70%

70-75%

75-80%

80

% Fuel Cell Power (Gross) of Max Created: Aug-28-08 5:48 PM

18.4%-43.7% of operating time at idle(Vehicle Speed = 0 & F.C. Power > 0)

While Most of FC Time is Spent aBulk of Energy is at 20-50% Pow

~50% time 

at <5% FC 

power

02468

10

% Energy by Power levels: DO

% Energy

0-5%

5-10%

10-15%

15-20%

20-25%

25-30%

30-35%

35-40%

40-45%

45-50%

50-55%

55-60%

60-65%

6

% Fuel Cell Power (Gross) of M

Created: Aug-28-08 5:48 PM
National Renewable Energy Laboratory 12 

0

100200300400500600700

Specific Power (W/kg)

FC System Specific Power (W/kg)

2010 and 2015 DOE MYPP Target1 

Created: Sep-17-08 10:30 AM (1) Fuel cell system includes fuel cell stack and BOP but excludes H2 storage, power electronics, and ele

Fuel Cell System Specific Power Dramatic Improvement from Gen 
National Renewable Energy Laboratory 13 

0

100200300400500600700

Power Density (W/L)

FC System Power Density (W/L)

2010 and 2015 DOE MYPP Target1 

Created: Sep-17-08 10:29 AM (1) Fuel cell system includes fuel cell stack and BOP but excludes H2 storage, power electronics, and ele

Fuel Cell System Power Density ~Same Between Gen 1 and 2
National Renewable Energy Laboratory 14 

Dyno (1) Window-Sticker (2) 

0

1020304050607080

Fuel Economy (miles/kg H2)

Fuel Economy

Created: Sep-22-08 11:51 AM

(1) One data point for each make/model. Combined City/Hwy fuel economy per DRAFT SAE J2572.(2) Adjusted combined City/Hwy fuel economy (0.78 x Hwy, 0.9 x City).(3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(4) Calculated from on-road fuel cell stack current or mass flow readings.

Ranges of Fuel Economy from Dyand On-Road Data Similar for Ge
National Renewable Energy Laboratory 15 

Dyno Range (2) Window-Sticker Range (3) On-

0

50

100150200250300

Vehicle Range (miles)

Vehicle Range1

Created: Sep-22-08 11:51 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 SAE J2572.(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 Dyno RUsable H2 Fuel Stored On-Board

Gen 2 Vehicle Range Shows Significant 

Improvement with 700 bar Storage

250-mile 2008 

milestone met
National Renewable Energy Laboratory 16 

0 200 400 600 

220230240250260270280290300

Voltage

Voltage vs. Ope

Created: Oct-09-08 3:01 PM

2

2. FC Stack voltage decay estimate using 

robust, improved segmented linear fit

instead of linear fit (follows non-linear decay trends & early voltage decay)

0 200 400 600 

Vehicle12 Stack1Vehicle15 Stack1Vehicle17 Stack1Vehicle19 Stack1Vehicle16 Stack2

EcoCars

EcoC

Created: Oct-09-08 1:20 PM Stacks sorted by Stack Weight

3

FleetStack

3. Fleet weighted average using FC Stack 

operating hour projections and weights (based on data and confidence in fit)

Improved Method for Calculating Time to 10% Voltage Drop for Sta

1

1. FC Stack voltage & current polarization fit 

Note, 10% voltage drop is a DOE target/metric, not an indicator of end-of-life
National Renewable Energy Laboratory 17 

0

200400600800

10001200140016001800200022002400

2006 Target2009 Target

Actual Operating Hours Accumulated To-Date Projected Hou

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

Time (Hours)

DOE Learning Demonstration Fuel Cell Stack Durabi

Based on Data Through 2008 Q2

Created: Sep-03-08 10:36 AM

(1) Range bars created using one data point for each OEM. Some stacks have accumulated hours beyond 10% vo(2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individual stack (3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OEM's flee(4) Projection using on-road data -- degradation calculated at high stack current. This criterion is used for assessing  may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membra(5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = averag The shaded green bar represents an engineering judgment of the uncertainty on the "Avg Projection" due to dat Projections will change as additional data are accumulated.(6) Projection method was modified beginning with 2008 Q2 data.

Some Gen 1 FC Stacks Have Now AcSignificant Number of Hours Without 

(DOE Milestone)

More 

to 

proje
National Renewable Energy Laboratory 18 

0

5 10 15 

05

1015202530354045

Frequency (%)

Trip Length (miles)

Trip Length: DOE Fleet

Created: Sep-03-08 11:06 AM

2001 NHTS DaASCII.csv Sou

Learning Demo FCVs Tend to Take Ma<1 Mile Than Compared to National Av

Large number of short driving trips 

could cause life of Learning Demo 

Fuel Cells to be shorter than if 

driven by average consumer

Further investigation necessary before 

strong conclusions can be drawn about 

trip length affects on FC life
National Renewable Energy Laboratory 19 

0-1 hr 1-6 hr 6-12 hr 12-18hr 18-24hr 1-7days 7-

0

102030405060

% Trips

Time

Time between Trips: DOE Fleet

0-10 min 10-20 min 20-30 min 

0

1020304050

% Trips

Tim

0-60 min Breakdo

Created: Sep-03-08 11:06 AM

>1/3 trips occur 

within 10 min of 

previous trip

Examining Time Between Trips ShowExperiencing Large Number of Hot St

>50% trips occur 

within 1 hour of 

previous trip
National Renewable Energy Laboratory 20 

Range of Average Ambient TempDuring Vehicle Operation

0

2

4

6

8 

-30-20-10

0

102030405060

0.9 % trips below 

25.1 % trips abov

Frequency [%]

Temperature [oC]

Average Ambient Trip Temperature: All OEMs

Created: Sep-03-08 10:41 AM

Fuel cell vehicles are operating in 

some extreme temperature 

conditions. 2nd gen vehicle tests 

will determine ability to start in 

cold temperatures.
National Renewable Energy Laboratory 21 

350bar 

0

0.010.020.030.040.050.060.070.080.09

0.1

Mass H2 per Liter (kg/L)

Mass of Hyd

Created: Aug-19-08 11:39 AM

1Targets are set for advanced materials-based hydrogen storage tec

350bar 700bar 0

123456789

Weight Percent Hydrogen (%)

Weight Percent Hydrogen

2015 DOE MYPP Target12010 DOE MYPP Target12007 DOE MYPP Target1

Created: Aug-19-08 11:39 AM

1Targets are set for advanced materials-based hydrogen storage technologies.

700 bar On-Board H2 Storage SystemPotential for Improved Performance O

2nd Gen Vehicle Storage 

Data Collected; 

Allows a Comparison of 

350 bar vs. 700 bar
National Renewable Energy Laboratory 22 

More Detailed Data Reporting Allows a Comand Volume of H2, Pressure Vessel, and BO
National Renewable Energy Laboratory 23 

On-Site Natural Gas Reforming On-Site El

0

1020304050607080

2010 MYPP Target2015 MYPP Target

2012 MYPP Target2017 MYPP Target

Production Efficiency (LHV %)

Hydrogen Production Conversion Efficiency1

Average Station EfficiencyQuarterly Efficiency DataHighest Quarterly Efficiency

Created: Sep-24-08 4:17 PM

1Production conversion efficiency is defined as the energy of the hydrogen out of the process (on an LHV basis) divided by the sum 

process from the feedstock and all other energy as needed. Conversion efficiency does not include energy used for compression, s

On-Site Production Efficiency from NReformation and Electrolysis Compa
National Renewable Energy Laboratory 24 

0

100200300400500600700

WTW GHG Emissions (g CO2-eq/mi)

Learning Demonstration Fuel Cycle Well-to-Wheels Greenhouse G

Baseline Conventional Mid-Size Passenger Car2Baseline Conventional Mid-Size SUV2

Average WTW GHG Emissions (Learning Demo)Minimum WTW GHG Emissions (Learning Demo)WTW GHG Emissions (100% Renewable Electricity)WTW GHG Probability Based on Learning Demo3

Created: Sep-24-08 4:19 PM

On-Site Natural Gas Reforming On-Site Electr

1. Well-to-Wheels greenhouse gas emissions based on DOE's GREET model, version 1.8b. Analysis uses default GREET valueproduction conversion efficiency, and electricity grid mix. Fuel economy values are the Gen 1 and Gen 2 window-sticker fuel econversion efficiency values are the production efficiency data used in CDP #13.2. Baseline conventional passenger car and light duty truck GHG emissions are determined by GREET 1.8b, based on the EPA gasoline mid-size passenger car and mid-size SUV, respectively. The Learning Demonstration fleet includes both passenger c3. The Well-to-Wheels GHG probability distribution represents the range and likelihood of GHG emissions resulting from the hyeconomy data and monthly conversion efficiency data from the Learning Demonstration.4. On-site electrolysis GHG emissions are based on the average mix of electricity production used by the Learning Demonstratgrid-based electricity and renewable on-site solar electricity. GHG emissions associated with on-site production of hydrogen felectricity source. GHG emissions from a 100% renewable electricity mix would be zero, as shown. If electricity were supplied emissions would be 1296 g/mile.

Learning Demonstration Vehicle GreenhousUsing Actual Production Efficiencies and F
National Renewable Energy Laboratory 25 

Hydrogen Quality Index Close to TargSome High Inert Gas Measurements

Ref. Elec. Del. Ref. Elec. Del. Re

99.7

99.75

99.8

99.85

99.9

99.95

100

Calculated H2 Index (%)

H

2 Calculated Quality Index by Year and Production Me

OODSC

Created: Sep-22-08 1:41 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, and Year 3 is 2007Q3-2008Q2

Year 1 Year 2 
National Renewable Energy Laboratory 26 

0 1 2

3

4

5

6

Particulates 

μg/L

H

2 Impurities

Data Range SAE J2719 APR2008 Guideline Measured Less T

0 500 1000 1500 2000 

(N2+He+Ar) 

He 

(Ar+N2) 

0

5 10 15 20 25 

H2O 

Total HC 

O2 

CO2 

CO 

NH3 

μmol/mol (ppm)

0 10 20 30 40 50 

Total S* 

nmol/mol (ppb)

Created: Sep-22-08 1:41 PM Data is from Learning Demonstration and California Fuel Cell Partnership testing

*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

Hydrogen Impurities Sampled froStations to Date

High i

lim
National Renewable Energy Laboratory 27 

Ref. Elec. Del. Ref. Elec. Del. Re

0

10203040506070

Total S* (nmol/mol)(ppb)

Total S* (nmol/mol)(ppb)

H

2 Impurities by Year and Production Method

On-Site NG ReformOn-Site ElectrolysDelivered (Data RaSAE J2719 APR20MeasuredLess Than or Equ

Created: Sep-22-08 1:42 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, and Year 3 is 2007Q3-2008Q2*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

Year 1 Year 2 

Hydrogen Impurities by Year and Method – Total Sulfur

Most s

continue 
National Renewable Energy Laboratory 28 

0 0.5 1 1.5 2 2

0

50

100150200250300350400450

Amount F

Number of Fueling Events

Histogram of FAll Light Duty 

Average = 2.24

Created: Sep-02-08 4:21 PM

0 2 4 6 8 10 12 14 16 18 20 0

200400600800

10001200140016001800

Time (min)

Number of Fueling Events

Histogram of Fueling Times

All Light Duty Through 2008Q2

Average = 3.23

 % <5 = 88

Created: Sep-02-08 4:21 PM

Actual Vehicle Refueling Times and A

11,500 Events: Measured by Stations 

Average time: 3.23 min

88% of refueling events took <

Average fill amount: 2.24 kg

Includes Communication and 

Non-Communication Fills
National Renewable Energy Laboratory 29 

0 0.2 0.4 0.6 0.8 1 1.2 1.4 

0

100200300400500600700800

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

All Light Duty Through 2008Q2

5 minute fill of5 kg at 350 bar

3 minute fill o5 kg at 350 b

11594 Events

Average = 0.80 kg/min

25% >1 kg/min

2006 Tech V2010 MYPP 

Created: Sep-02-08 4:10 PM

Actual Vehicle Refueling Rates fr

Events: Measured by Stations or 

Average rate: 0.80 kg/min

25% of refueling events exceeded 1 kg/min

Includes Communication and 

Non-Communication Fills
National Renewable Energy Laboratory 30 

0 0.2 0.4 0.6 0.8 1 1.2 1.4 

0

100200300400500600700

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

Comm vs Non-Comm Fills - All Light Duty Through 200

5 minute fill of5 kg at 350 bar

3 minute fill o5 kg at 350 b

Fill Type Avg (kg/min) %>1 ------------- ------------------ -------Comm 0.94 36%Non-Comm 0.68 17%

CommNon-Comm2006 Tech V2010 MYPP 

Created: Sep-02-08 4:59 PM

Non-Comm Has a

Peak at ~0.2 kg/min Comm Fills C

Achieve Hig

Fill Rates

Communication H2 Fills AchievinHigher Fill Rate than Non-Comm
National Renewable Energy Laboratory 31 

0 0.2 0.4 0.6 0.8 1 1.2 1.4 

0

50

100150200250300350

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

All Light Duty by Year Through 2008Q2

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 0.86 28%

20052006200720082006 Tech V2010 MYPP 

Created: Sep-02-08 4:21 PM

Examining Refueling Data by Yea0.2 kg/min Rate Phased Out

Includes Communication and 

Non-Communication Fills
National Renewable Energy Laboratory 32 

Summary

• Learning Demo project is ~60% complete

– 122 vehicles and 16 stations deployed– 1.5 million miles traveled, 60,000 kg H

2 produce

– 270,000 individual vehicle trips analyzed– Project to continue through 2010 with additiona

• Many new results in the Fall 2008 compos

– 50 new/updated results, 3 unchanged for a tota– Several Gen 1 vs Gen 2 vehicle comparisons– Hydrogen production efficiency related results– Vehicle greenhouse gas estimates using actua

efficiencies

– Fuel cell system W/kg and W/L– Hydrogen impurity breakdown by year and prod

• All results available on web site• Roll-out of 2nd generation vehicles continue

– Most of remaining vehicles to be deployed this – Additional 700 bar stations coming online soon
National Renewable Energy Laboratory 33 

Questions and Discussion

Project Contact: Keith Wipke, National Renew

303.275.4451 keith_wipke n

All public Learning Demo papers and presentations are 

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

Systems Integration & Analysis

Basic Research & Applied R&D

DELIVERY

FUEL CELLS

STORAGE

PRODUCTION

Education

Market Transformation Market Transformation

Market Transformation

Technology 

Validation

Safety, Codes & StandardsManufacturing R&D

@