Fuel Cells Vehicles

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Fuel Cells Vehicles Hydrogen

• Anthony Eggert - Assoc. Director
• Hydrogen Pathways Project
• ITS-Davis
• June 3, 2003

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And the topics for today are.

• Brief History of Fuel Cells
• Fuel Cell/System Basics
• Why Fuel Cell Vehicles?
• Hydrogen and The Utopian Vision
• The Messy Transition
• Where do we go from here?

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What is a fuel cell?

• A fuel cell is an electrochemical energy
  conversion device that combines hydrogen and
  oxygen in the presence of an electrolyte to
  produce electricity and water

4
Background
Worlds First Fuel Cell
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Fuel Cells - Background

• Invented 1839 - Sir William Grove

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In the Beginning.

• Sir William Grove
• 1839 first fuel cell result of experiments to
  reverse electrolysis of water
• 1842 bank of 50 cells he called a gaseous
  voltaic battery
• Key finding need a notable surface of
  reaction to produce sufficient power

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20th Century Developments

• 1932-1959 - Francis T. Bacon
• H2/O2 with alkaline electrolyte
• Porous gas diffusion nickel electrodes
• 1959 demonstrated 5 kW system
• 1959 Allis-Chalmers Manufacturing
• Demonstrated 20 HP fuel cell powered tractor

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1959 AC D12 Tractor

• Propane / O2
• 1008 cells
• 15 kW

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1966 Methanol Fuel Cell Truck
Harry Dwyer
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Fuel Cells - Background

• Invented 1839 - Sir William Grove
• 1950s Francis Bacon - 6kW cell

• 1960s Apollo Space Program

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The 20th Century Takes Off

• Gemini (early 1960s)
• PEM fuel cells by GE
• 3 units 1 kW
• Apollo (mid-1960s)
• AFCs by Pratt Whitney (now UTC)
• 3 x 1.42 kW units (110 kg/unit)
• Space Shuttle (1970s)
• AFCs by UTC
• 3 x 12 kW units (90 kg total)

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Fuel Cells - Background

• Invented 1839 - Sir William Grove
• 1950s Francis Bacon - 6kW cell

• 1960s Apollo Space Program
• 1987 DOE Fuel Cells for Transportation Program
• Nov 2000 California FCP

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Fuel Cell Basics
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Fundamentals IC Engine

• Combined chemical reaction
• H2 0.5O2 ? H2O
• (for pure hydrogen combustor)

• Details
• Mixed, uncontrolled reaction process
• Resulting work is in the form of heat that must
  then be converted into mechanical energy

(Source Ballard Power Systems)
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Fundamentals Fuel Cell Stack

• Combined chemical reaction
• H2 0.5O2 ? H2O
• (for pure hydrogen fuel reaction)

• Details
• Reactions are separated in space
• Resulting work is in the form of useable
  electrical energy

(Source Ballard Power Systems)
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Simplified Fuel Cell

• Anode
• H2 2H 2e-
• Cathode
• ½ O2 2H 2e- H2O
• Overall Cell Reaction
• H2 ½ O2 H2O
• Theoretical voltage
• 1.229 V _at_ 1 atm, 25 C

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Fuel Cell Systems
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Major Systems

• Direct / Indirect
• Fuel (Anode)
• Air (Cathode)
• Water
• Thermal management
• Power electronics
• Control

IFC Fuel Cell System for Cars
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No moving parts? Please.

• Air compressor / blower
• Electric motor
• Radiator fans
• Coolant pumps
• Power steering pump
• A/C compressor
• Etc.

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Fuel Cell Systems

• Direct hydrogen system
• Fuel reformer system

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Fuel Options

• Hydrogen
• Compressed (5000 psi or more?)
• Liquefied
• Advanced storage (hydrides, nanotubes, etc.)
• Methanol
• Liquid storage with on-board reforming
• Gasoline (or designer hydrocarbon)
• Liquid storage with on-board processing

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Direct Hydrogen
(Source Institute of Transportation Studies,
UCD)
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IMFC System Diagram
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IHFC System Diagram
H2O from Tank
For cooling
Fuel Reformer System
Gas Tank
Mix/Preheat
ATR and Cleanup
H/C
H2O from Tank
Fuel Cell Stack
Air Preheat
Anode
Burner
Radiator
Exhaust
Cathode
Compressor
Condenser
Exhaust to ATM
ATM air
H/C
Water and Thermal Management System
Compressor
Air Supply System
ATM air
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Direct Hydrogen
(Source Institute of Transportation Studies,
UCD)
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Direct H2 System Diagram
HYDROGEN FUEL STREAM
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Direct H2 System Diagram
AIR STREAM
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Direct H2 System Diagram
WATER AND THERMAL MANAGEMENT
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Balance of Plant Details

• Air Supply System
• Provides oxygen to stack cathode
• Nitrogen in air is unused
• Uses an electric motor, current draw from fuel
  cell stack
• An expander can be used to recover energy from
  stack exhaust gas

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Balance of Plant Details

• Water and Thermal Management System
• Radiator cools stack, maintains 800C
• Condenser extracts liquid water for
  humidification needs
• Stack inlet conditioning
• Cooling of the cathode inlet air by means of
  water injection
• Water injection also acts to ensure
  humidification of the cathode
• Humidification of the anode inlet stream

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Thermal Systems
Or If fuel cells are so efficient, how come they
have such big radiators?
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Where Does the Energy Go?
IC Engine
Fuel Cell
Electrical Energy 50 Exhaust Energy
5 Coolant 45
Mechanical Energy 33 Exhaust Energy
33 Coolant 33
Heat to be dissipated by radiator!
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Heat Rejection
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Overall Heat Transfer
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Heat Rejection
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How can we increase Q?
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How can we increase Q?
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How can we increase Q?
Pacific Northwest National Laboratory
10,000 to 35,000 watts/m2-C Pressure drop 1-2
psi
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How can we increase Q?
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Air / Cathode Operation
(Source Institute of Transportation Studies,
UCD)
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To Pressurize, or Not.?

• The question is analogous to supercharging a
  gasoline ICE is it worth it?
• Although pressurizing improves performance, the
  cost is increased parasitic load
• For example, a 100 kW PEMFC pressurized to 3 bar
  with a Lysholm compressor requires 20 kW of power

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Stack Air Supply WTM
PNet
Pradiator
Pcondenser
PGross
Radiator
Cathode
Exhaust to ATM
Condenser
Pair_supply
H/C
Water and Thermal Management System
Air Supply System
ATM air
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DH efficiency slide
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Powertrain Efficiency
60
FUEL CELL SYSTEM
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Pass. Car Average Power
HSDI DIESEL
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G-DI ENGINE
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PERCENT THERMAL EFFICIENCY
20
10
0
0
20
40
60
80
100
120
PERCENT LOAD
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DH - FUDS
Air Supply
WTM
96 KJ
615 KJ
412 KJ
Hotel
A/C Motor
FC Stack
Trans
Total Fuel (H2) 13367 KJ (LHV)
527 KJ ? 91
1567 KJ ? 78
5076 KJ Stack Loss 712 KJ Aux Loss ? 62
Stack only ? 53.6 Stack - Aux
5379 KJ ? 38.2 TTW
FUDS Cycle
Note ? Energy Out / Energy In
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IM - FUDS
Air Supply
WTM
147 KJ
755 KJ
412 KJ
Hotel
A/C Motor
FP
FC Stack
Trans
Total Fuel (MeOH) 20523 KJ (LHV)
526 KJ ? 91
1590 KJ ? 78.8
6544 KJ ? 68.1
5167 KJ Stack Loss 1313 KJ Aux Loss ? 63
Stack only ? 53.6 Stack - Aux
5383 KJ ? 26.2 TTW
FUDS Cycle
Note ? Energy Out / Energy In
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IH - FUDS
Air Supply
WTM
163 KJ
1698 KJ
412 KJ
Hotel
A/C Motor
FP
FC Stack
Trans
Total Fuel (C8H18) 27070 KJ (LHV)
527 KJ ? 91
1567 KJ ? 79
11923 KJ ? 56
5400 KJ Stack Loss 1861 KJ Aux Loss ? 64.3
Stack only ? 49.3 Stack - Aux
5379 KJ ? 19.9 TTW
FUDS Cycle
Note ? Energy Out / Energy In Air Supply
is for both stack / FP
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Fuel Cell Vehicles Hydrogen
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FCVs On the Road
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FCVs Continued
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Whats the Problem?

• People love their cars
• Gas is cheap
• IC Engines more powerful and efficient than ever
• New vehicle emissions have decreased dramatically!

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Whats the Problem?

• Vehicle emissions have decreased
• However
• Mobility has increased
• Motor vehicles responsible for
• ½ Of smog forming VOCs and NOx
• Up to 90 of CO found in urban air
• More than 50 of hazardous pollutants
• Increased concern over human induced global
  warming
• Concern over single fuel dependence (petroleum)

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The Utopian Vision

• Potential
• Increased energy efficiency
• Zero tailpipe emissions
• Zero GHGs (?)
• Energy diversity
• On the road today!

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Why Fuel Cells Vehicles?

• Fuel cell vehicles have the potential
• Increased energy efficiency?
• Reduced criteria emissions
• CO, HC, NOx, NMOG

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FCVMP Simulation Results

• NOTE The results in Figure 1 assume the
  vehicles are fully warmed
• REFERENCE A fully warmed up vehicle achieving a
• fuel economy of 25mpg (9.41L/100km) would equate
  to 1350 Wh/mile,
• fuel economy of 35mpg (6.72L/100km) would equate
  to 960 Wh/mile.

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Why Fuel Cells Vehicles?

• Fuel cell vehicles have the potential
• Increased energy efficiency?
• Reduced criteria emissions
• CO, HC, NOx, NMOG

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Why Fuel Cells Vehicles?
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Emissions Warranty
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Why Fuel Cells Vehicles?
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Why Fuel Cells Vehicles?

• Fuel cell vehicles have the potential
• Increased vehicle fuel efficiency?
• Reduced criteria emissions
• CO, HC, NOx, NMOG
• Reduction in greenhouse gas emissions (CO2)
• Energy Diversity (i.e. decreased dependence on
  single fuel source)
• Increased design freedom and reduced platform
  requirements

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Why Fuel Cells Vehicles?
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The Messy Reality

• Significant Technical Hurdles Remain
• Onboard Hydrogen Storage Capacity
• Cold Weather Performance
• Reliability/Durability
• Financial challenges significant
• Components
• Fuel
• COST, COST, COST!!!

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Coming down the cost curve
Where we are today
700
Portable power (1K)
600
Premium power
500
FUEL CELL SYSTEM COST /KW
DGS
400
UNIT COST (/KW)
300
Home Power
200
Automotive
100
0
2014
2002
2004
2006
2008
2010
2012
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Portable Power
Portable power
Photo courtesy of Ballard Power Systems
100 watt portable fuel cell
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Distributed Generation
Distributed power stations
Photo courtesy of Ballard Power Systems
250 kW distributed cogeneration power plant
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Home Power
Home power
Photo courtesy of Plug Power
5 kW home cogeneration power plant
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What about the fuel?
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Hydrogen is the fuel now what?

• Where does it come from?
• Who pays for it?
• How do we start?

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Where does it come from?

• Central Plant Production
• Piped, Trucked H2
• Feedstock primarily NG
• Onsite
• SMR from NG
• Onsite Electrolysis
• Electricity Source?
• Others

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Where will hydrogen come from?
Where will the hydrogen come from?
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The Utopian Vision - Renewable Hydrogen
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The Messy Reality - Hydrogen costs
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Hydrogen is the fuel now what?

• Where does it come from?
• Who pays for it?
• How do we start?

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Fuel Infrastructure Costs

• 10-year negative cash flow
• (10 of California stations)
• Hydrogen 235 million

• Estimates highly sensitive to key assumptions
• Continued heavy investment needed to complete
• Similar costs (X10) for nationwide infrastructure

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10 yr Negative cash flow
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Financing the Early Infrastructure

• Public benefits (less pollution GHGs, quiet,
  fuel flexibility, electricity)
• Long-term profit potential ?
• User benefits?

• Fuel infrastructure, production, and delivery
  costs risks
• Vehicle development early production costs

?
Important incentive role for government
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To Do List Technical Challenges

• Components
• Air compressor
• Stack material cost/performance
• Systems
• System integration
• Thermal management
• Water management
• Reliability/durability

• Fuel
• Hydrogen storage
• Infrastructure

VOLUME WEIGHT COST
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Summary

• FCVs and H2 offer great potential
• Reduced pollution and GHGs
• Energy diversity
• Significant hurdles remain
• Technical
• Financial
• The transition is bound to be messy!

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I believe fuel cells could end the 100-year
reign of the internal combustion engine... It
will be a winning situation all around -
customers will get an efficient power source,
communities will get zero emission
transportation, and automakers will get a major
business opportunity. William Clay Ford,
Jr. Chairman and CEO, Ford Motor
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Thank You
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Extra Slides
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Gasoline Safety

• "A new source of power... called gasoline has
  been produced by a Boston engineer. Instead of
  burning the fuel under a boiler, it is exploded
  inside the cylinder of an engine...
• "The dangers are obvious. Stores of gasoline in
  the hands of people interested primarily in
  profit would constitute a fire and explosive
  hazard of the first rank. Horseless carriages
  propelled by gasoline might attain speeds of 14,
  or even 20 miles per hour. The menace to our
  people of this type hurtling through our streets
  and along our roads and poisoning the atmosphere
  would call for prompt legislative action even if
  the military and economic implications were not
  so overwhelming...the cost of producing
  gasoline is far beyond the financial capacity
  of private industry...In addition, the
  development of this new power may displace the
  use of horses, which would wreck our
  agriculture.
• Walter F. Stewart, Congressional Record statement
  from 1875 in "Hydrogen as a Vehicular Fuel,"
  Chapter 3 of K.D. Williamson, Jr. and Frederick
  J. Edeskuty, Recent Developments in Hydrogen
  Technology. Vol. n, CRC Press, 1986, p. 132.

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Example Onboard Fuel Storage
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Example Onboard Fuel Storage

• Certifications (including-not limited to)
• USA FMVSS 304 Meets and Exceeds Criteria
• USA NGV 2-98 Approved
• International ISO CD 11439
• Canada/Australia/UK CSA B51-97 Part 2
• Complies to NFPA 52 (National Fire Protection
  Association)
• Germany TUV Approved

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Onboard Fuel Storage Testing

• Burst Test at 3 x safety factor of the working
  pressure
• Bonfire Test for fire resistance and PRD/TRD
  release
• Pressure Cycling Test from 10 to 125 of the
  working pressure
• Drop Test
• Penetration Test
• Environmental Testing
• Chemical Resistance Testing
• Flaw Tolerance Test
• Shock and Vibration Testing
• Pendulum Impact Test

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Vehicle Comparisons
87
Vehicle Comparisons
88
Vehicle Comparisons
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Hindenburg!
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FCV Safety Demo-lition Derby
Sunday!
Sunday!
Sunday!
Ford FCV
F-Cell