All Composite Data Products: National FCEV …All Composite Data Products: National FCEV Learning...
Transcript of All Composite Data Products: National FCEV …All Composite Data Products: National FCEV Learning...
NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency & Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
Contract No. DE-AC36-08GO28308
Technical Report NREL/TP-5600-53152 November 2011
All Composite Data Products: National FCEV Learning Demonstration With Updates Through October 5, 2011 Keith Wipke, Sam Sprik, Jennifer Kurtz, Todd Ramsden, Chris Ainscough, and Genevieve Saur
NOTICE This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof.
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All Composite Data Products: National FCEV Learning Demonstration
With Updates Through
October 5, 2011
Keith Wipke, Sam Sprik,
Jennifer Kurtz, Todd
Ramsden, Chris
Ainscough, Genevieve
Saur
NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
CDP#1: Hours Accumulated and
Projected Hours to 10% Stack Voltage Degradation
Gen1 Gen2 Gen1 Gen2 Gen1 Gen20
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
2006 Target
2009 Target
Actual Operating Hours Accumulated To-Date Projected Hours to 10% Voltage Degradation
Tim
e (
Ho
urs
)
DOE Learning Demonstration Fuel Cell Stack Durability:Based on Data Through 2009 Q2
Max Hrs Accumulated1,2
Avg Hrs Accumulated1,3
Projection to 10% Voltage Degradation4,5,6
Max Projection
Avg 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 10% voltage degradation.(2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individual stack in "real-world" operation.(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 progress against DOE targets, may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membrane failure.(5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = average nominal projection. The shaded projection bars represents an engineering judgment of the uncertainty on the "Avg Projection" due to data and methodology limitations. Projections will change as additional data are accumulated.(6) Projection method was modified beginning with 2009 Q2 data, includes an upper projection limit based on demonstrated op hours.
National Renewable Energy Laboratory 2 Innovation for Our Energy Future
CDP#2: Vehicle Range
Dyno Range (2) Window-Sticker Range (3) On-Road Range (4)(5)0
50
100
150
200
250
300
Veh
icle
Ran
ge (
miles)
Vehicle Range1
2015 Target
2009 Target
Gen 1
Gen 2
NREL CDP02
Created: Mar-10-10 1:18 PM
(1) Range is based on fuel economy and usable hydrogen on-board the vehicle. One data point for each make/model.(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.
National Renewable Energy Laboratory 3 Innovation for Our Energy Future
CDP#3: Fuel Cell System Power Density,
Including Hydrogen Storage
0
50
100
150
200
250
300
350
400
Po
wer
Den
sit
y (
W/L
)
FC System (Including Hydrogen Storage) Power Density (W/L)
2010 and 2015 FreedomCAR Research Goal1
Gen 1
Gen 2
NREL CDP03NREL CDP03NREL CDP03NREL CDP03
Created: Sep-08-09 10:32 AM (1) Fuel cell system includes fuel cell stack, BOP and H2 storage, but excludes power electronics, battery storage, and electric drive.
National Renewable Energy Laboratory 4 Innovation for Our Energy Future
CDP#4: Fuel Cell System Specific Power,
Including Hydrogen Storage
0
50
100
150
200
250
300
350
400
Sp
ecif
ic P
ow
er
(W/k
g)
FC System (Including Hydrogen Storage) Specific Power (W/kg)
2010 and 2015 FreedomCAR Research Goal1
Gen 1
Gen 2
NREL CDP04NREL CDP04
Created: Aug-28-09 8:42 AM (1) Fuel cell system includes fuel cell stack, BOP and H2 storage, but excludes power electronics, battery storage, and electric drive.
National Renewable Energy Laboratory 5 Innovation for Our Energy Future
CDP#5: Fuel Cell Start Times from
Sub-Freezing Soak Conditions
12 hr Equilibrium 12 hr Equilibrium0
100
200
300
400
500
600
Time to Drive Away Time to Max FC Power
Tim
e [
s]
Fuel Cell Vehicle Start Time from Sub-Freezing Soak Condition1
NREL CDP05NREL CDP05
Created: Sep-08-09 10:54 AM
(1) Learning Demo soak temperature for freeze tests were between -9 and -20 oC
(2) 2010 & 2015 DOE MYPP Cold Start Up Time Target: 30 seconds to 50% of rated power from -20 oC (soak duration not specified).
National Renewable Energy Laboratory 6 Innovation for Our Energy Future
CDP#6: Fuel Economy
Dyno (1) Window-Sticker (2) On-Road (3)(4)0
10
20
30
40
50
60
70
80
Fu
el E
co
no
my (
miles/k
g H
2)
Fuel Economy
Gen 1
Gen 2
NREL CDP06
Created: Mar-10-10 1:18 PM
(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.
National Renewable Energy Laboratory 7 Innovation for Our Energy Future
CDP#7: Fuel Cell Voltage
0
5
10
15
20
25
Op
era
tin
g T
ime [
%]
Operating Time at Fuel Cell Stack Voltage Levels: DOE Fleet
<50%
50-55%
55-60%
60-65%
65-70%
70-75%
75-80%
80-85%
85-90%
90-95%
95-100%>100%
% Max Fuel Cell Stack Voltage
All time
Time at low current
NREL CDP07
Created: Mar-09-10 4:13 PM
National Renewable Energy Laboratory 8 Innovation for Our Energy Future
CDP#8: FC System Efficiency
0 10 20 30 40 50 60 70 80 90 1000
10
20
30
40
50
60
Net System Power [%]
Eff
icie
ncy [
%]
Fuel Cell System1 Efficiency
2
Eff. at 25% Pwr Eff. at 100% Pwr ------------------- -------------------Gen1 51 - 58% 30 - 54%Gen2 53 - 59% 42 - 53%
DOE Target at 25% Power
DOE Target at 100% Power
Gen 1 Efficiency Range
Gen 2 Efficiency Range
NREL CDP08NREL CDP08
Created: Sep-02-09 11:27 AM
1 Gross stack power minus fuel cell system auxiliaries, per DRAFT SAE J2615. Excludes power electronics and electric drive.
2 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 high power linearly extrapolated
due to steady state dynamometer cooling limitations.
National Renewable Energy Laboratory 9 Innovation for Our Energy Future
CDP#9: Safety Reports – Vehicles
0
1
2
3
Nu
mb
er
of
Re
po
rts
Safety Reports - Vehicle Operation
Tank Scratch
Traffic Accident
H2 Leak - During Fueling
H2 Alarm - Fuel System
H2 Alarm - Passenger Compartment
Created: Aug-15-11 1:56 PM
NREL cdp_fcev_09
Created: Aug-15-11 1:56 PM
NREL cdp_fcev_09
National Renewable Energy Laboratory 10 Innovation for Our Energy Future
CDP#10: Storage Weight % Hydrogen
350bar 700bar0
1
2
3
4
5
6
7
8
9
Weig
ht
Perc
en
t H
yd
rog
en
(%
)
Weight Percent Hydrogen
2015 DOE MYPP Target1
2010 DOE MYPP Target1
2007 DOE MYPP Target1
NREL CDP10NREL CDP10
Created: Aug-19-08 11:39 AM
1Targets are set for advanced materials-based hydrogen storage technologies.
National Renewable Energy Laboratory 11 Innovation for Our Energy Future
CDP#11: Volumetric Capacity of H2 Storage
350bar 700bar0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
Mass H
2 p
er
Lit
er
(kg
/L)
Mass of Hydrogen Per Liter
2015 DOE MYPP Target1
2010 DOE MYPP Target1
2007 DOE MYPP Target1
NREL CDP11NREL CDP11
Created: Aug-19-08 11:39 AM
1Targets are set for advanced materials-based hydrogen storage technologies.
National Renewable Energy Laboratory 12 Innovation for Our Energy Future
CDP#12: Vehicle Hydrogen Tank Cycle Life
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
Nu
mb
er
of
cycle
s
Hydrogen Tank Cycle Life1
All OEMs
2015 DOE MYPP Target2
2010 DOE MYPP Target2
2007 DOE MYPP Target2
Gen 1
Gen 2
NREL CDP12NREL CDP12
Created: Sep-17-08 10:29 AM
1Data reported reference NGV2, HGV2, or EIHP standards.
2Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based technologies.
National Renewable Energy Laboratory 13 Innovation for Our Energy Future
CDP#13: On-Site Hydrogen Production
Efficiency
On-Site Natural Gas Reforming On-Site Electrolysis0
10
20
30
40
50
60
70
80
2010 MYPP Target
2015 MYPP Target
2012 MYPP Target
2017 MYPP Target
Pro
du
cti
on
Eff
icie
ncy (
LH
V %
)
Hydrogen Production Conversion Efficiency1
Average Station Efficiency
Quarterly Efficiency Data
Highest Quarterly Efficiency
Efficiency Probability Distribution2
NREL CDP13
Created: Mar-09-10 3:16 PM
1Production conversion efficiency is defined as the energy of the hydrogen out of the process (on an LHV basis) divided by the sum of
the energy into the production process from the feedstock and all other energy as needed. Conversion efficiency does not includeenergy used for compression, storage, and dispensing.2The efficiency probability distribution represents the range and likelihood of hydrogen production conversion efficiency based on
monthly conversion efficiency data from the Learning Demonstration.
National Renewable Energy Laboratory 14 Innovation for Our Energy Future
CDP#14: Fueling Rates – 350 and 700 bar
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
500
1000
1500
2000
2500
Avg Fuel Rate (kg/min)
Nu
mb
er
of
Fu
elin
g E
ven
ts
Histogram of Fueling Rates350 vs 700 bar Fills - All Light Duty Through 2009Q4
5 minute fill of
5 kg at 350 bar
3 minute fill of
5 kg at 350 bar
Fill Type Avg (kg/min) %>1 Count------------- ------------------ ------- --------350 bar 0.82 29% 19659700 bar 0.63 4% 5590
350 bar
700 bar
2006 MYPP Tech Val Milestone
2012 MYPP Tech Val Milestone
NREL CDP14
Created: Mar-09-10 3:10 PM
National Renewable Energy Laboratory 15 Innovation for Our Energy Future
CDP#15: H2 Production Cost vs. Process
0
2
4
6
8
10
12
14
16
Projected Early Market 1500 kg/day Hydrogen Cost1
$/k
g
Natural Gas Reforming2
Electrolysis2
2015 DOE Hydrogen Program Goal Range3
Median
25th & 75th Percentile
10th & 90th Percentile
Created: Jan-19-10 11:08 AM
(1) Reported hydrogen costs are based on estimates of key cost elements from Learning Demonstration energy company partners and represent thecost of producing hydrogen on-site at the fueling station, using either natural gas reformation or water electrolysis, dispensed to the vehicle. Costsreflect an assessment of hydrogen production technologies, not an assessment of hydrogen market demand.(2) Hydrogen production costs for 1500 kg/day stations developed using DOE’s H2A Production model, version 2.1. Cost modeling represents thelifetime cost of producing hydrogen at fueling stations installed during an early market rollout of hydrogen infrastructure and are not reflective of thecosts that might be seen in a fully mature market for hydrogen installations. Modeling uses default H2A Production model inputs supplemented withfeedback from Learning Demonstration energy company partners, based on their experience operating on-site hydrogen production stations. H2A-based Monte Carlo simulations (2,000 trials) were completed for both natural gas reforming and electrolysis stations using default H2A values and10th percentile to 90th percentile estimated ranges for key cost parameters as shown in the table. Capacity utilization range is based on the capabilitiesof the production technologies and could be significantly lower if there is inadequate demand for hydrogen.(3) DOE has a hydrogen cost goal of $2-$3/kg for future (2015) 1500 kg/day hydrogen production stations installed at a rate of 500 stations per year.
Key H2 Cost Elements and Ranges
Input Parameter Minimum
(P10) Maximum
(P90)
Facility Direct Capital Cost $10M $25M
Facility Capacity Utilization 85% 95%
Annual Maintenance & Repairs $150K $600K
Annual Other O&M $100K $200K
Annual Facility Land Rent $50K $200K
Natural Gas Prod. Efficiency (LHV) 65% 75%
Electrolysis Prod. Efficiency (LHV) 35% 62%
NREL CDP15
National Renewable Energy Laboratory 16 Innovation for Our Energy Future
CDP#16: Fuel Cell Stack Trips Per Hour
Histogram
0-1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 >80
5
10
15
20
25
30Segmented Trips/Hour Histogram: DOE Fleet
Trips/Hour*
Fre
qu
en
cy [
%]
*Trips/Hour based on 50 hour segments
spanning stack operating period
NREL CDP16
Created: Mar-09-10 4:13 PM
National Renewable Energy Laboratory 17 Innovation for Our Energy Future
CDP#17: Statistics of Trips/Hour vs.
Operating Hour
0
1
2
3
4
5
6
7
8
9
10
0-250 250-500 500-750 750-1000 1000-1250 1250-1500 1500-1750 1750-2000Stack Op Hour Groups
Tri
ps/H
ou
r*
Statistics of Trips/Hour vs Operating Hour: DOE Fleet
*Trips/Hour based on 50 hour segments
spanning stack operating period
Data Range
25th & 75th Percentiles
Group Median
Outlier
NREL CDP17
Created: Mar-09-10 4:13 PM
National Renewable Energy Laboratory 18 Innovation for Our Energy Future
CDP#18: Refueling Rates
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
200
400
600
800
1000
1200
1400
1600
1800
Avg Fuel Rate (kg/min)
Nu
mb
er
of
Fu
elin
g E
ven
ts
Histogram of Fueling RatesVehicle and Infrastructure
5 kg in
5 minutes
5 kg in
3 minutes
25464 EventsAverage = 0.77 kg/min
23% >1 kg/min
6,219 Events
Average = 0.65 kg/min
5% >1 kg/min
2006 MYPP Tech Val Milestone
2012 MYPP Tech Val Milestone
Through 2009Q4
After 2009Q4
NREL cdp_fcev_18
Created: Aug-30-11 3:02 PM
National Renewable Energy Laboratory 19 Innovation for Our Energy Future
CDP#19: Time Between Trips & Ambient
Temperature
0-10 10-30 30-60 60-360 >3600
5
10
15
20
25
30
35
Time [min]
Tri
p F
req
uen
cy [
%]
Time Between Trips with Ambient Temperature: DOE Fleet
<0oC
0-10oC
10-24oC
24-40oC
>40oC
NREL CDP19
Created: Mar-09-10 4:13 PM
National Renewable Energy Laboratory 20 Innovation for Our Energy Future
CDP#20: Safety Reports – Infrastructure
0 50 100 150 200 250 300
Non-Event
Near Miss
Incident
Number of Reports
Severi
ty
Total Infrastructure Safety Reports by Severityand Report Type Through 2009 Q4
Alarms Only
Automatic System Shutdown
Electrical Issue
Equipment Malfunction
False Alarm/Mischief
H2 Release - Minor, NO Ignition
H2 Release - Significant, NO Ignition
Manual System Shutdown
Non-H2 Release
Site Power Outage
Structural Issue
System Trouble, not Alarm
NREL CDP20
Created: Mar-11-10 2:45 PM
An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame
National Renewable Energy Laboratory 21 Innovation for Our Energy Future
CDP#21: Range of Ambient Temperature
During Vehicle Operation
0 2 4 6 8 10 12-30
-20
-10
0
10
20
30
40
50
60
1.4 % trips below 0 oC
Max Op = 140.0 oF
Min Op = -5.8 oF
28.2 % trips above 28 oC
Trip Frequency [%]
Tem
pera
ture
[oC
]
Average Ambient Trip Temperature: DOE Fleet
NREL CDP21
Created: Mar-09-10 4:12 PM
National Renewable Energy Laboratory 22 Innovation for Our Energy Future
CDP#22: Vehicle Operating Hours
0
5
10
15
20
25
30
35
Nu
mb
er o
f V
eh
icle
s
Total Vehicle Hours
Vehicle Hours: All OEMs, Gen 1 and Gen 2
In Service
Retired (1)
146,584Total Vehicle Hours =
Through 2011 Q2
Created: Sep-01-11 11:37 AM
(1) Retired vehicles have left DOE fleet and are no longer providing data to NRELSome project teams concluded in Fall/Winter 2009
NREL cdp_fcev_22
National Renewable Energy Laboratory 23 Innovation for Our Energy Future
CDP#23: Vehicles vs. Miles Traveled
0
5
10
15
20
25
30
35
40
Nu
mb
er
of
Ve
hic
les
Total Vehicle Miles
Vehicle Miles: All OEMs, Gen 1 and 2
In Service
Retired (1)
Total Vehicle Miles Traveled = 3,394,302
Through 2011 Q2
Created: Sep-01-11 11:37 AM
NREL cdp_fcev_23 (1) Retired vehicles have lef t DOE f leet and are no longer providing data to NRELSome project teams concluded in Fall/Winter 2009
National Renewable Energy Laboratory 24 Innovation for Our Energy Future
CDP#24: Cumulative Vehicle Miles Traveled
3,394,302
-250,000 500,000 750,000
1,000,000 1,250,000 1,500,000 1,750,000 2,000,000 2,250,000 2,500,000 2,750,000 3,000,000 3,250,000 3,500,000 3,750,000
Ve
hic
le M
ile
s T
rav
ele
d
Cumulative Vehicle Miles: All OEMs, Gen 1 and Gen 2
Created: Sep-01-11 11:37 AM
Through 2011 Q2
NREL cdp_fcev_24
National Renewable Energy Laboratory 25 Innovation for Our Energy Future
CDP#25: Vehicle H2 Storage Technologies
4
83
45
38
-
20
40
60
80
100
120
140
160
180
Cu
mu
lati
ve V
eh
icle
s D
ep
loyed
/Reti
red
1
Vehicle Deployment by On-Board Hydrogen Storage Type
700 bar on-road
350 bar on-road
Liquid H2 on-road
700 bar retired
350 bar retired
Liquid H2 retired
(1) Retired vehicles have left DOE fleet and are no longer providing data to NREL(2) Two project teams concluded in Fall/Winter 2009Created Aug-25-11 9:32 AM
170
NREL cdp_fcev_25
(2)
National Renewable Energy Laboratory 26 Innovation for Our Energy Future
CDP#26: Cumulative H2 Produced or Dispensed
0
20
40
60
80
100
120
140
160
Mass o
f H
yd
rog
en
(1
000 k
g)
Calendar Quarter
Cumulative Hydrogen Produced or Dispensed Through 2011 Q2
NREL cdp_fcev_26
Created Sep-7-11 11:15 AM
*
*Some project teams concluded in Fall/Winter 2009
147,500 kg of hydrogen produced or dispensed since project inception
National Renewable Energy Laboratory 27 Innovation for Our Energy Future
CDP#27: Hydrogen Quality Index
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.99.7
99.75
99.8
99.85
99.9
99.95
100
Calc
ula
ted
H2 In
dex (
%)
H2 Calculated Quality Index by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Calculated Data
NREL CDP27
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
National Renewable Energy Laboratory 28 Innovation for Our Energy Future
CDP#28: Hydrogen Fuel Constituents
0 2 4 6 8 10 12 14 16 18 20
Particulates
g/L
H2 Fuel Constituents
Data Range SAE J2719 APR2008 Guideline Measured Less Than or Equal To (Detection Limited)
0 500 1000 1500 2000 2500 3000
(N2+He+Ar)
He
(Ar+N2)
0 5 10 15 20 25 30 35 40
H2O
Total HC
O2
CO2
CO
NH3
mol/mol (ppm)
0 10 20 30 40 50 60 70 80
Total S*
nmol/mol (ppb)NREL CDP28
Created: Mar-10-10 11:05 AM Data is from Learning Demonstration and California Fuel Cell Partnership testing*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).
National Renewable Energy Laboratory 29 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen
Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
1
2
3
4
5
6
NH
3 (
mo
l/m
ol)
(pp
m)
NH3 (mol/mol)(ppm)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
50
100
150
200
Ar
(m
ol/m
ol)
(pp
m)
Ar (mol/mol)(ppm)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
500
1000
1500
2000
2500
Ar+
N2 (
mo
l/m
ol)
(pp
m)
Ar+N2 (mol/mol)(ppm)
Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
500
1000
1500
2000
2500
3000
Calc
ult
ate
d T
ota
l C
on
sti
tuen
ts (
mo
l/m
ol)
(pp
m)
Calcultated Total Constituents (mol/mol)(ppm)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Calculated Data
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
1
2
3
4
5
6
7
8
9
CO
2 (
mo
l/m
ol)
(pp
m)
CO2 (mol/mol)(ppm)
Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
0.2
0.4
0.6
0.8
1
CO
(
mo
l/m
ol)
(pp
m)
CO (mol/mol)(ppm)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
0.02
0.04
0.06
0.08
0.1
Fo
rmald
eh
yd
e (
mo
l/m
ol)
(pp
m)
Formaldehyde (mol/mol)(ppm)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
0.05
0.1
0.15
0.2
Fo
rmic
acid
(
mo
l/m
ol)
(pp
m)
Formic acid (mol/mol)(ppm)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
5
10
15
H2O
(
mo
l/m
ol)
(pp
m)
H2O (mol/mol)(ppm)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
50
100
150
200
250
300
He (
mo
l/m
ol)
(pp
m)
He (mol/mol)(ppm)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
5000
10000
15000
20000
25000
30000
Part
icu
late
Siz
e (
m)
Particulate Size (m)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
500
1000
1500
2000
2500
3000
N2+
He+
Ar
(m
ol/m
ol)
(pp
m)
N2+He+Ar (mol/mol)(ppm)
Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
500
1000
1500
2000
2500
N2 (
mo
l/m
ol)
(pp
m)
N2 (mol/mol)(ppm)
Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
5
10
15
20
25
30
35
40
O2(
mo
l/m
ol)
(pp
m)
O2(mol/mol)(ppm)
Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
2
4
6
8
10
12
14
16
18
20
22
Part
icu
late
Co
ncen
trati
on
(
g/L
)
Particulate Concentration (g/L)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
5
10
15
20
25
To
tal H
alo
gen
ate
s (
mo
l/m
ol)
(pp
m)
Total Halogenates (mol/mol)(ppm)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
0.5
1
1.5
2
To
tal H
C (
mo
l/m
ol)
(pp
m)
Total HC (mol/mol)(ppm)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
(This slide contains 18 graphs (1 for each constituent): view in slide-show mode)
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
10
20
30
40
50
60
70
To
tal S
* (n
mo
l/m
ol)
(pp
b)
Total S* (nmol/mol)(ppb)Non-H
2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)
On-Site Electrolysis (Data Range)
Delivered (Data Range)
SAE J2719 APR2008 Guideline
Measured
Less Than or Equal To (Detection Limited)
NREL CDP28
Created: Mar-10-10 11:07 AM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).
Year 1 Year 2 Year 3 Year 4 Year 5
National Renewable Energy Laboratory 30 Innovation for Our Energy Future
CDP#29: Fueling Rates Communication and
Non-Communication Fills
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
500
1000
1500
2000
2500
Avg Fuel Rate (kg/min)
Nu
mb
er
of
Fu
elin
g E
ven
ts
Histogram of Fueling RatesComm vs Non-Comm Fills - All Light Duty Through 2009Q4
5 minute fill of
5 kg at 350 bar
3 minute fill of
5 kg at 350 bar
Fill Type Avg (kg/min) %>1 ------------- ------------------ -------Comm 0.86 30%Non-Comm 0.66 12%
Comm
Non-Comm
2006 MYPP Tech Val Milestone
2012 MYPP Tech Val Milestone
NREL CDP29
Created: Mar-09-10 3:08 PM
National Renewable Energy Laboratory 31 Innovation for Our Energy Future
CDP#30: Infrastructure Maintenance
0 20 40 60 80 100 120 140 160 180 200
Adjustment
Check Only
Other
Repair
Replacement
Maintenance: Average Labor Hours Per Station Since InceptionThrough 2009 Q4
Scheduled
Un-Scheduled
0 5 10 15 20 25 30 35 40
Adjustment
Check Only
Other
Repair
Replacement
Maintenance: Average Number of Events Per Station Since Inception
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
# of Events
Hours
Comparison of Scheduled/Un-Scheduled Maintenance
NREL CDP30
Created: Mar-10-10 9:30 AM
National Renewable Energy Laboratory 32 Innovation for Our Energy Future
CDP#31: Number of Online Stations
7
12
6
0
5
10
15
20
25
Nu
mb
er
of
Sta
tio
ns
Reporting Period
Cumulative Stations
Continuing Outside of Project
Retired Stations
Current Project Stations
NREL cdp_fcev_31
Created Aug-15-11 2:52 PM
National Renewable Energy Laboratory 33 Innovation for Our Energy Future
CDP#32: Infrastructure Hydrogen Production
Methods
0
1
2
3
4
5
6
7
8
9
Compressed Liquid Pipeline Reforming Electrolysis
Nu
mb
er
of
Sta
tio
ns
Learning Demonstration Hydrogen Stations by Type
Operating Outside of Project
Operating Within Project
Historical 2005-2009*
NREL cdp_fcev_32
Created Sep-6-11 3:02 PM
Delivered On-Site Production
*Some project teams concluded Fall/Winter 2009. Markers show the cumulative stations operated during the 2005-2009 period
National Renewable Energy Laboratory 34 Innovation for Our Energy Future
CDP#33: Percentage of Theoretical Range
Traveled Between Refuelings
0 10 20 30 40 50 60 70 80 90 1000
1
2
3
4
5
6
7
8
9
10
11
12
13Range Histogram: All OEMs
Percentage of chassis dyno range1 between refuelings
Perc
en
tag
e o
f R
efu
elin
gs
0 10 20 30 40 50 60 70 80 90 1000
25
50
75
100
Cu
mu
lati
ve P
erc
en
tag
e
NREL CDP33
Created: Mar-23-10 10:53 AM
Total refuelings2 = 25811
1. Range calculated using the combined City/Hwy fuel economy from dyno testing (not EPAadjusted) and usable fuel on board.2. Some refueling events are not detected/reported due to data noise or incompleteness.
National Renewable Energy Laboratory 35 Innovation for Our Energy Future
CDP#34: Effective Vehicle Range
0 10 20 30 40 50 60 70 80 90 100
Gen1
Gen2
Vehicle Range Factors
Percentage of chassis dyno range1.
All O
EM
s Win
do
w-S
ticker
2
Win
do
w-S
ticker
2
On
-Ro
ad
3
On
-Ro
ad
3
Dyn
o 1
NREL CDP34
Created: Mar-10-10 1:25 PM
1. Calculated using the combined City/Hwy fuel economy from dyno testing (non-adjusted)and usable fuel on board.2. Applying window-sticker correction factors for fuel economy: 0.78 x Hwy and 0.9 x City.
3. Using fuel economy from on-road data (excluding trips < 1 mile, consistent with other data products).
National Renewable Energy Laboratory 36 Innovation for Our Energy Future
CDP#35: Average Refuelings Between
Infrastructure Safety Reports
0
2
4
6
8
10
12
14
16
18
20
22
24
Nu
mb
er
of
Sta
tio
ns
Infrastructure Safety Trend and Number of Stations Through 2009 Q4
05Q2
05Q3
05Q4
06Q1
06Q2
06Q3
06Q4
07Q1
07Q2
07Q3
07Q4
08Q1
08Q2
08Q3
08Q4
09Q1
09Q2
09Q3
09Q4
Number of Stations
Avg Refuelings Between Safety Reports
0
100
200
300
400
500
600
Avg
# o
f R
efu
elin
gs B
etw
een
Safe
ty R
ep
ort
s
7 1132 34
88102
115
4768
124101
57 5473
51
138
447
121
198
NREL CDP35
Created: Mar-23-10 2:43 PM Reporting Period
National Renewable Energy Laboratory 37 Innovation for Our Energy Future
CDP#36: Type of Infrastructure Safety Report
By Quarter
0
10
20
30
40
50
Nu
mb
er
of
Rep
ort
s
Type of Infrastructure Safety Reports by Quarter Through 2011 Q2
05Q2
05Q3
05Q4
06Q1
06Q2
06Q3
06Q4
07Q1
07Q2
07Q3
07Q4
08Q1
08Q2
08Q3
08Q4
09Q1
09Q2
09Q3
09Q4
10Q1
10Q2
10Q3
10Q4
11Q1
11Q2
Incident
Near Miss
Non-Event
Avg # Reports/Station
NREL cdp_fcev_36
Created: Aug-30-11 2:54 PM
Reporting PeriodAn INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame
National Renewable Energy Laboratory 38 Innovation for Our Energy Future
CDP#37: Primary Factors of Infrastructure
Safety Reports
0 50 100 150 200 250 300
Non-Event
Near Miss
Incident
Number of Reports
Severi
ty
Primary Factors of Infrastructure Safety ReportsThrough 2009 Q4
Calibration/Settings/ Software Controls
Design Flaw
Electrical Power to Site
Environment (Weather, Power Disruption, Other)
False Alarm
Inadequate Training, Protocol, SOP
Inadequate/ Non-working Equipment
Maintenance Required
Mischief, Vandalism, Sabotage
New Equipment Materials
Not Yet Determined
Operator/Personnel Error
System Manually Shutdown
NREL CDP37
Created: Mar-11-10 2:45 PM
An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame
National Renewable Energy Laboratory 39 Innovation for Our Energy Future
CDP#38: Refueling Times
0 1 2 3 4 5 6 7 8 9 100
500
1000
1500
2000
2500
3000
3500
Time (min)
Nu
mb
er
of
Fu
elin
g E
ven
ts
Histogram of Fueling TimesVehicle and Infrastructure
Average = 3.26 min86% <5 min
Average = 4.47 min
70% <5 min
2006 MYPP Tech Val Milestone (5 kg in 5 min)
2012 MYPP Tech Val Milestone (5 kg in 3 min)
Through 2009Q4
After 2009Q4
NREL cdp_fcev_38
Created: Aug-30-11 3:05 PM
National Renewable Energy Laboratory 40 Innovation for Our Energy Future
CDP#39: Refueling Amounts
0 1 2 3 4 5 6 70
100
200
300
400
500
600
700
800
900
1000
Amount Fueled (kg)
Nu
mb
er
of
Fu
elin
g E
ven
ts
Histogram of Fueling AmountsVehicle and Infrastructure
Average = 2.13 kg
Average = 2.67 kg
Through 2009Q4
After 2009Q4
NREL cdp_fcev_39
Created: Aug-30-11 3:07 PM
National Renewable Energy Laboratory 41 Innovation for Our Energy Future
CDP#40: H2 Tank Level at Refueling
Through 2009Q4
After 2009Q4
Tank Levels: DOE Fleet
14%
FE
14%
NREL cdp_fcev_40
1. Some refueling events not recorded/detected due to data noise or incompleteness.
2. The outer arc is set at 20% total refuelings.
3. If tank level at fill was not available, a complete fill up was assumed.
Median Tank Level (At Fill) = 42% Total refuelings1 = 27113
Created: Aug-16-11 3:35 PM
Total refuelings1 = 9034Median Tank Level (At Fill) = 50%
National Renewable Energy Laboratory 42 Innovation for Our Energy Future
CDP#41: Refueling Tank Levels - Medians
FE
Tank Level Medians (At Fill): DOE Fleet, All Vehicles
NREL CDP41
Created: Mar-09-10 4:14 PM
Total refuelings1 = 27113
1. Some refueling events not recorded/detected due to data noise or incompleteness.
2. If tank level at fill was not available, a complete fill up was assumed.
National Renewable Energy Laboratory 43 Innovation for Our Energy Future
CDP#42: Refueling by Time of Day
Through 2009Q4
After 2009Q4
Refueling by Time of Day
9%
3
12
9
6
Total Fill3 Events = 22657% of fills b/t 6 AM & 6 PM: 89.7%
1. Fills between 6 AM & 6 PM
2. The outer arc is set at 12 % total Fill.
3. Some events not recorded/detected due to data noise or incompleteness.
AM PM
10%
NREL cdp_fcev_42
Created: Aug-16-11 3:36 PM
Total Fill3 Events = 9054% of fills b/t 6 AM & 6 PM: 88.5%
National Renewable Energy Laboratory 44 Innovation for Our Energy Future
CDP#43: Refueling by Day of Week
Sun Mon Tues Wed Thur Fri Sat0
5
10
15
20
25Refueling by Day of Week
% o
f F
ills
in
a D
ay
Day
Through 2009Q4
After 2009Q4
NREL cdp_fcev_43
Created: Aug-16-11 3:36 PM
National Renewable Energy Laboratory 45 Innovation for Our Energy Future
CDP#44: Driving Start Time – Day
Driving by Time of Day
9%
3
12
9
6
Total Driving3 Events = 295222% of driving trips b/t 6 AM & 6 PM: 85.3%
1. Driving trips between 6 AM & 6 PM
2. The outer arc is set at 12 % total Driving.
3. Some events not recorded/detected due to data noise or incompleteness.
AM PM
7%
% of NHTS trips b/t 6 AM & 6 PM: 81.5%
Through 2009Q4
After 2009Q4
NHTS
NREL cdp_fcev_44
Created: Aug-24-11 4:28 PM
Total Drive3 Events = 36839% of driving trips b/t 6 AM & 6 PM: 74.5%
2001 NHTS Data Includes Car, Truck, Van, & SUV day trips ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
National Renewable Energy Laboratory 46 Innovation for Our Energy Future
CDP#45: Driving by Day of Week
Sun Mon Tues Wed Thur Fri Sat0
5
10
15
20
25Driving by Day of Week
% o
f T
rip
s in
a D
ay
Day
Through 2009Q4
After 2009Q4
NHTS
NREL cdp_fcev_45
Created: Aug-24-11 4:28 PM
2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
National Renewable Energy Laboratory 47 Innovation for Our Energy Future
CDP#46: Fuel Cell System Operating Power
0
10
20
30
40
50
Time at Fuel Cell Stack Power Levels: DOE Fleet
Op
era
tin
g T
ime [
%]
0-5%
5-10
%
10-1
5%
15-2
0%
20-2
5%
25-3
0%
30-3
5%
35-4
0%
40-4
5%
45-5
0%
50-5
5%
55-6
0%
60-6
5%
65-7
0%
70-7
5%
75-8
0%
80-8
5%
85-9
0%
90-9
5%
95-1
00%
>100
%
% Max Fuel Cell Power (Gross)
All time
Time with 0 speed
NREL CDP46
Created: Mar-09-10 4:21 PM
National Renewable Energy Laboratory 48 Innovation for Our Energy Future
CDP#47: Trip Length
0 5 10 15 20 250
5
10
15
20
25
30
35
40
45
Tri
p F
req
uen
cy [
%]
Trip Length [miles]
Trip Length: DOE Fleet
DOE Fleet
NHTS
NREL CDP47
Created: Mar-09-10 4:16 PM
2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
National Renewable Energy Laboratory 49 Innovation for Our Energy Future
CDP#48: Primary Factors Affecting Learning
Demo Fleet Fuel Cell Degradation
DOE Fleet
High Current Time
Hot Starts
Starts/hour
Low Voltage Time
High Voltage Time
Cold Starts
Short Trips
0 Speed Trips
Hot Ambient Temp
H*
H*
1) On-going fuel cell degradation study using Partial Least Squares (PLS)
regression model for combined Learning Demonstration Fleet.
2) DOE Fleet model has a low percentage of explained decay rate variance.
Created: Feb-21-08 9:32 AM
H*: Factor group associated with high decay rate fuel cell stacks
L**: Factor group associated with low decay rate fuel cell stacks
Due to differences among teams, the
DOE Fleet Analysis results are spread
out and concrete conclusions are difficult
to draw.
Individual team analyses (CDP#49)
focused on patterns within a fleet.
NREL CDP48
National Renewable Energy Laboratory 50 Innovation for Our Energy Future
CDP#49: Primary Factors Affecting Learning
Demo Team Fuel Cell Degradation
National Renewable Energy Laboratory 51 Innovation for Our Energy Future
Team 1
High Voltage Time
Low Current Time
Short Trips
Low Speed
Team 2
Team 3
Team 4
Low Current Time
Long Trips
Warm Ambient Temp
Zero Speed
Current Transients
High Voltage Time
Low Current Time
Short Trips
Low Speed
Current Transients
1) On-going fuel cell degradation study using Partial Least Squares (PLS)
regression model for each team’s Gen 1 fleet.
2) Teams’ PLS models have a high percentage of explained decay rate
variance, but the models are not robust and results are scattered.
3) Factor groups associated with stacks that are opposite to the identified
groups here are not specified.
H*
Starts/Hour
Zero Speed
Short Trips
Low Voltage Time
High Current Time
Current Transients
Cold Starts
Hot Ambient Temp
High Speed
H*
H*
H*
H*
H*: Factor group associated with high decay rate fuel cell stacks
Created: Mar-09-09 9:06 AM
NREL CDP49
CDP#50: Refueling by Time of Night
Refueling by Time of Night: DOE Fleet
3%
3
12
9
6
Total Fill3 Events = 22657% of fills b/t 6 PM & 6 AM: 10.3%
1. Fills between 6 PM & 6 AM
2. The outer arc is set at 12 % total Fill.
3. Some events not recorded/detected due to data noise or incompleteness.
PM AM
NREL CDP50
Created: Mar-09-10 4:14 PM
National Renewable Energy Laboratory 52 Innovation for Our Energy Future
CDP#51: Driving Start Time – Night
Driving Start Time - Night: DOE Fleet
4%
3
12
9
6
Total Driving3 Events = 295222% of driving trips b/t 6 PM & 6 AM: 14.7%
1. Driving trips between 6 PM & 6 AM
2. The outer arc is set at 12 % total Driving.
3. Some events not recorded/detected due to data noise or incompleteness.
PM AM
% of NHTS trips b/t 6 PM & 6 AM: 18.4%
NREL CDP51
DOE Fleet
NHTS
NREL CDP51
Created: Mar-09-10 4:15 PM
2001 NHTS Data Includes Car, Truck, Van, & SUV day trips ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
National Renewable Energy Laboratory 53 Innovation for Our Energy Future
CDP#52: Refueling Data by Year
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
100
200
300
400
500
600
700
Avg Fuel Rate (kg/min)
Nu
mb
er
of
Fu
elin
g E
ven
ts
Histogram of Fueling RatesAll Light Duty by Year Through 2009Q4
5 minute fill of
5 kg at 350 bar
3 minute fill of
5 kg at 350 bar
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%
2005
2006
2007
2008
2009
2006 MYPP Tech Val Milestone
2012 MYPP Tech Val Milestone
NREL CDP52
Created: Mar-09-10 3:35 PM
National Renewable Energy Laboratory 54 Innovation for Our Energy Future
CDP#53: Fuel Cell System Energy within
Power Levels
0
2
4
6
8
10FC Energy by Power Levels: DOE Fleet
FC
En
erg
y [
%]
0-5%
5-10
%
10-1
5%
15-2
0%
20-2
5%
25-3
0%
30-3
5%
35-4
0%
40-4
5%
45-5
0%
50-5
5%
55-6
0%
60-6
5%
65-7
0%
70-7
5%
75-8
0%
80-8
5%
85-9
0%
90-9
5%
95-1
00%
>100
%
% Fuel Cell Power (Gross) of Max
Cu
mu
lati
ve %
0
20
40
60
80
100
NREL CDP53
Created: Mar-11-10 9:13 AM
National Renewable Energy Laboratory 55 Innovation for Our Energy Future
CDP#54: Time Between Trips
0-1 hr 1-6 hr 6-12 hr 12-18hr 18-24hr 1-7days 7-30days >30days0
10
20
30
40
50
60
Tri
p F
req
uen
cy [
%]
Time
Time between Trips: DOE Fleet
0-10 min 10-20 min 20-30 min 30-40 min 40-50 min 50-60 min0
10
20
30
40
50
% T
rip
s
Time
0-60 min Breakdown: DOE Fleet
NREL CDP54
Created: Mar-09-10 4:16 PM
National Renewable Energy Laboratory 56 Innovation for Our Energy Future
CDP#55: Fuel Cell System Energy
<-0.5 -0.5-0 0-0.5 0.5-1 1-1.5 1.5-2 2-2.5 2.5-3 3-3.5 3.5-4 4-4.5 4.5-5 >50
10
20
30
40
50
60
Energy Consumed [kWh]
Tri
p F
req
uen
cy [
%]
Energy in Trip: DOE Fleet
Net batterycharge in trip
Battery
Vehicle Motor
FC
NREL CDP55
Created: Mar-09-10 4:16 PM
National Renewable Energy Laboratory 57 Innovation for Our Energy Future
CDP#56: Daily Driving Distance
0 5 10 15 20 25 30 35 400
2
4
6
8
10
12
14
16
18
20
Tri
p F
req
uen
cy [
%]
Daily Distance [miles]
Daily Distance: DOE Fleet
DOE Fleet
NHTS
NREL CDP56
Created: Mar-09-10 4:17 PM
Cumulative Frequency@ 20 miles
DOE Fleet: 47.4%NHTS: 27.2%
Cumulative Frequency@ 40 miles
DOE Fleet: 67.2%NHTS: 52.9%
2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
National Renewable Energy Laboratory 58 Innovation for Our Energy Future
CDP#57: H2 Storage System Mass and Volume
Breakdown
73%
24%
3%
Average Breakout of H2 Storage System Volume
3.26%
73%
23%
Average Breakout of H2 Storage System Mass
56%35%
9%
H2 Volume (%)
Pressure Vessel Volume (%)
Balance of Plant Volume (%)
3.33%
72%
24%
H2 Mass (%)
Pressure Vessel Mass (%)
Balance of Plant Mass (%)Created: Aug-19-08 9:14 AM
350 bar
700 bar
NREL CDP57
National Renewable Energy Laboratory 59 Innovation for Our Energy Future
CDP#58: Fuel Cell System Power Density
0
100
200
300
400
500
600
700
Po
wer
Den
sit
y (
W/L
)
FC System Power Density (W/L)
2010 and 2015 DOE MYPP Target1
Gen 1
Gen 2
NREL CDP58NREL CDP58
Created: Sep-17-08 10:29 AM (1) Fuel cell system includes fuel cell stack and BOP but excludes H2 storage, power electronics, and electric drive.
National Renewable Energy Laboratory 60 Innovation for Our Energy Future
CDP#59: Fuel Cell System Specific Power
0
100
200
300
400
500
600
700
Sp
ecif
ic P
ow
er
(W/k
g)
FC System Specific Power (W/kg)
2010 and 2015 DOE MYPP Target1
Gen 1
Gen 2
NREL CDP59NREL CDP59
Created: Sep-17-08 10:30 AM (1) Fuel cell system includes fuel cell stack and BOP but excludes H2 storage, power electronics, and electric drive.
National Renewable Energy Laboratory 61 Innovation for Our Energy Future
CDP#60: On-Site Hydrogen Production
Efficiency vs. Capacity Utilization
0 10 20 30 40 50 60 70 80 90 1000
10
20
30
40
50
60
70
Production Capacity Utilization1 [%]
Pro
du
cti
on
Co
nvers
ion
Eff
icie
ncy
2 [
%]
Monthly Production Conversion Efficiency vs Utilization
Electrolysis Data
Electrolysis Fit3
Electrolysis Fit Confidence
Natural Gas Data
Natural Gas Fit3
Natural Gas Fit Confidence
NREL CDP60
Created: Mar-09-10 3:34 PM
1) 100% production utilization assumes operation 24 hrs a day, 7 days a week2) Production conversion efficiency is defined as the energy of the hydrogen out of the process (on a LHV basis) divided by the sum of the energy into the productionprocess from the feedstock and all other energy as needed. Conversion efficiency does not include energy used for compression, storage, and dispensing.
3) High correlation with electrolysis data (R2 = 0.82) & low correlation with natural gas data (R
2 = 0.060)
National Renewable Energy Laboratory 62 Innovation for Our Energy Future
CDP#61: Refueling Station Compressor
Efficiency
On-Site Compression Energy0
10
20
30
40
50
60
70
Co
mp
ressio
n E
nerg
y (
MJ/k
g)
On-Site Compression Efficiency0
10
20
30
40
50
60
70
80
90
100
2010 MYPP Compression Target
2015 MYPP Compression Target
Co
mp
ressio
n E
ffic
ien
cy (
%)
On-Site Hydrogen Compression Efficiency1 and Energy Use
Average Station Compression Efficiency
Quarterly Compression Efficiency Data
Highest Quarterly Compression Efficiency
Average Station Compression Energy
Quarterly Compression Energy Data
Lowest Quarterly Compression Energy
NREL CDP61
Created: Mar-11-10 9:41 AM
1Consistent with the MYPP, compression efficiency is defined as the energy of the hydrogen out of the process (on an LHV basis ) divided by the sum of the
energy of the hydrogen output plus all other energy needed for the compression process. Data shown for on-site hydrogen prod uction and storage
facilities only, not delivered hydrogen sites.
Compression Energy Requirement:
On average, 11.3% of the energy
contained in the hydrogen fuel is
required for the compression
process.
National Renewable Energy Laboratory 63 Innovation for Our Energy Future
CDP#62: Learning Demonstration Vehicle
Greenhouse Gas Emissions
0
100
200
300
400
500
600
700
WT
W G
HG
Em
issio
ns (
g C
O2-e
q/m
i)
Learning Demonstration Fuel Cycle Well-to-Wheels Greenhouse Gas Emissions1
Baseline Conventional Mid-Size Passenger Car2
Baseline 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
NREL CDP62
Created: Mar-08-10 4:16 PM
On-Site Natural Gas Reforming On-Site Electrolysis(4)
1. Well-to-Wheels greenhouse gas emissions based on DOE's GREET model, version 1.8b. Analysis uses default GREET values except for FCV fuel economy, hydrogen
production conversion efficiency, and electricity grid mix. Fuel economy values are the Gen 1 and Gen 2 window-sticker fuel economy data for all teams (as used in CDP #6);
conversion 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 window-sticker fuel economy of a conventional
gasoline mid-size passenger car and mid-size SUV, respectively. The Learning Demonstration fleet includes both passenger cars and SUVs.
3. The Well-to-Wheels GHG probability distribution represents the range and likelihood of GHG emissions resulting from the hydrogen FCV fleet based on window-sticker fuel
economy 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 Demonstration production sites, which includes both
grid-based electricity and renewable on-site solar electricity. GHG emissions associated with on-site production of hydrogen from electrolysis are highly dependent on
electricity source. GHG emissions from a 100% renewable electricity mix would be zero, as shown. If electricity were supplied from the U.S. average grid mix, average GHG
emissions would be 1330 g/mile.
National Renewable Energy Laboratory 64 Innovation for Our Energy Future
CDP#63: Hydrogen Fueling Station
Maintenance by System
13%
13%
18%
22%
By Number of EventsTotal Number of Events = 2491
20%12%
17%
21%
By Labor HoursTotal Hours = 11430
system control & safety
compressor
reformer
electrolyzer
dispenser
other
valves & piping
electrical
storage
NREL CDP63
Created: Mar-10-10 10:31 AM
Hydrogen Fueling Station Maintenance
National Renewable Energy Laboratory 65 Innovation for Our Energy Future
CDP#64: Fuel Cell Vehicle Maintenance by
System
3%5%
34%
58%
Fuel Cell Vehicle Events (11574)
18%
8%
50%
24%
Fuel Cell Vehicle Labor (12522 hours)
Vehicle (non-powertrain)
Fuel Cell System
Powertrain
Battery
4%10%
12%
13%
23%
39%
Fuel Cell System Events (3916)< 1%
27%
28%11%
11%
22%
Fuel Cell System Labor (6304 hours)
Thermal Management
Air System
Controls, Electronics, Sensors
Fuel System
Fuel Cell Stack
Other
NREL CDP64
Created: Mar-10-10 10:34 AM
Fuel Cell Vehicle Maintenance Events and Labor Hours
National Renewable Energy Laboratory 66 Innovation for Our Energy Future
CDP#65: Percent Idle in Trip with
Comparison to Standard Drive Cycles
0
2
4
6
8
10
12
14
1015 C
ycle
UD
DS
Cycle
US
06 C
ycle
HW
FE
T C
ycle
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Percent Idle in Trip
% Idle
Tri
p F
req
uen
cy [
%]
NREL CDP65
Created: Mar-09-10 4:17 PM
National Renewable Energy Laboratory 67 Innovation for Our Energy Future
CDP#66: FCV Speed with Comparison to
Standard Drive Cycles
0 5 10 15 20 25 30 35 40 45 50 55 60 65 700
5
10
15
20
25
30
35
40
Speed [mph]
Op
era
tio
n T
ime [
%]
Fuel Cell Vehicle Speed
DOE Fleet Speed
DOE Fleet Idle
1015 Cycle (14.1 mph avg)
UDDS Cycle (19.6 mph avg)
HWFET Cycle (48.0 mph avg)
US06 Cycle (48.2 mph avg)
NREL CDP66
Created: Mar-09-10 4:17 PM
National Renewable Energy Laboratory 68 Innovation for Our Energy Future
CDP#67: Fuel Cell Stack Operation Hours
0
5
10
15
20
25
30
35
40
Sta
ck C
ou
nt
Fuel Cell Stack Operation Hours: Gen1
Gen1
0
200
400
600
800
1000
1200
1400
1600
1800
2000
Gen1 Hours
24% of stacks in operation
In Op1
Retired2
Other3
0
5
10
15
20
25
30
35
40
Sta
ck C
ou
nt
Fuel Cell Stack Operation Hours: Gen2
Gen2
0
200
400
600
800
1000
1200
1400
1600
1800
2000
Gen2 Hours
34% of stacks in operation
In Op1
Retired2
Other3
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 removed because of low performance. Some project teams concluded in Fall/Winter 2009
National Renewable Energy Laboratory 69 Innovation for Our Energy Future
CDP#68: Power Drop During Fuel Cell Stack
Operation Period
0 5 10 15 20 25 30 35 400
5
10
15
20
25
30
Sta
ck C
ou
nt
% FC Power Drop
FC Power Drop During Operation Period: Gen1
Gen1
60% of In Op stacks
have > 10% power drop
In Op1
Retired2
Other3
0 5 10 15 20 25 30 35 400
5
10
15
20
25
30
Sta
ck C
ou
nt
% FC Power Drop
FC Power Drop During Operation Period: Gen2
Gen2
85% of In Op stacks
have > 10% power drop
In Op1
Retired2
Other3
NREL CDP68
Created: Mar-23-10 10:39 AM
1) Stack currently accumulating hours2) Stack removed for low performance3) Stack not currently accumulating hours, but not removed because of low performance. Some project teams concluded in Fall/Winter 2009
National Renewable Energy Laboratory 70 Innovation for Our Energy Future
CDP#69: Max Fuel Cell Power Degradation – Gen 1
30
40
50
60
70
80
90
100
110
120
130
0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000Stack Op Hour Segments(2)
% P
ow
er(
1)
Max Fuel Cell Power Loss vs Op Hours: Gen1
1) Normalized by fleet median value at 200 hours.
2) Each segment point is median FC power (+-50 hrs).
Box not drawn if fewer than 3 points in segment.
Gen1Data Range
25th & 75th Percentiles
Group Median
Outlier
NREL CDP69
Created: Mar-23-10 10:39 AM
National Renewable Energy Laboratory 71 Innovation for Our Energy Future
CDP#70: Max Fuel Cell Power Degradation – Gen 2
30
40
50
60
70
80
90
100
110
120
130
0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000Stack Op Hour Segments(2)
% P
ow
er(
1)
Max Fuel Cell Power Loss vs Op Hours: Gen2
1) Normalized by fleet median value at 200 hours.
2) Each segment point is median FC power (+-50 hrs).
Box not drawn if fewer than 3 points in segment.
Gen2Data Range
25th & 75th Percentiles
Group Median
Outlier
NREL CDP70
Created: Mar-23-10 10:39 AM
National Renewable Energy Laboratory 72 Innovation for Our Energy Future
CDP#71: Projected Hours to OEM Low Power
Operation Limit
0-200 400 600 800 1000 1200 1400 1600 1800 2000 >20000
5
10
15
20
25
30
27% Gen1 > 2000 projected hrs17% Gen2 > 2000 projected hrs
Projected Hours
% S
tacks
Durability: Projected Hours to Low Fuel Cell Power Limit
Gen1 (> 200 operation hrs)
Gen1 (< 200 operation hrs)
Gen2 (> 200 operation hrs)
Gen2 (< 200 operation hrs)
NREL CDP71
Created: Mar-23-10 10:39 AM
1. Low fuel cell power limit is dependent on the fuel cell vehicle system and is unique to each company in this Learning Demonstration.2. Acceptable low vehicle performance limit will be determined by retail customer expectations.3. Power projection method based on the voltage degradation techniques, but uses max fuel cell power instead of voltage at a specifichigh current.4. Stacks with less than 200 operation hours are in separate groups because the projection is based on operation data and with operationhours greater than 200 the degradation rate tends to flatten out.
National Renewable Energy Laboratory 73 Innovation for Our Energy Future
CDP#72: Difference Between Tank and
Ambient Temperature Prior to Refueling
-20 0 20 40 60-20
-10
0
10
20
30
40
50
60
Ambient Air Temperature [deg C]
Tan
k T
em
pera
ture
[d
eg
C]
Tank vs. Ambient Air Temps Prior to Refueling
Fre
qu
en
cy
50
100
150
200
250
300
-40 -20 0 20 400
500
1000
1500
2000
Delta Temperature [deg C]
Co
un
t
Delta Temperature: Tank minus Ambient
Delta Temp Histogram
Normal Distribution Fit
0
0.02
0.04
0.06
0.08
Den
sit
y
Mean= -3.751Std Dev= 6.129
NREL CDP72
Created: Mar-11-10 10:24 AM
-This CDP created in support of SAE J2601 related to refueling
-Temperatures are prior to refueling and exclude data within 4 hours of a previous fill
-The plot to the left excludes ambient temperatures less than -5 deg C
National Renewable Energy Laboratory 74 Innovation for Our Energy Future
CDP#73: Fuel Cell Stack Projected Hours as
a Function of Voltage Drop
10 15 20 25 300
200
400
600
800
1000
1200
1400
1600
1800
2000Fuel Cell Stack Projected Hours as a Function of Voltage Drop
% Voltage Drop
Pro
jecte
d H
ou
rs2,3
Gen 1 Average Projections
Gen 1 Average Projection to 10% Voltage Degradation1
Gen 2 Average Projections
Gen 2 Average Projection to 10% Voltage Degradation1
NREL CDP73
Created: Mar-23-10 10:40 AM
(1) 10% Voltage degradation is a DOE metric for assessing fuel cell performance.(2) Projections using on-road data -- degradation calculated at high stack current.(3) Curves generated using the Learning Demonstration average of each individual fleet average at various voltage degradation levels.(4) The projection curves display the sensitivity to percentage of voltage degradation, but the projections do not imply that all stacks will (or do) operate at these voltage degradation levels.(5) The voltage degradation levels are not an indication of an OEM's end-of-life criteria and do not address catastrophic stack failures such as membrane failure.(6) All OEM Gen 2 average fleet projections are higher than Gen1 projections, however due to less operation data for Gen 2, these projections are limited by demonstrated operation hours to minimize extrapolations.
National Renewable Energy Laboratory 75 Innovation for Our Energy Future
CDP#74: Fuel Cell Transient Cycle Count per
Mile and per Minute
0 2 4 6 8 10 12 14 16 18 200
5
10
15
20
Cycle Per Mile
Tri
p F
req
ue
nc
y [
%]
Number of Cycles1 per Trip Mile
0 2 4 6 8 10 12 14 16 18 200
10
20
30
40
50
60
Cycle Per Min
Tri
p F
req
ue
nc
y [
%]
Number of Cycles1 per Trip Minute
Gen1 Gen20
10
20
30
40
Cy
cle
pe
r M
ile
Range of Fleet Average Cycle1 per Mile
Gen1 Gen21
2
3
4
5
6
7
Cy
cle
pe
r M
in
Range of Fleet Average Cycle1 per Min
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 of 5% max stack voltage.
National Renewable Energy Laboratory 76 Innovation for Our Energy Future
CDP#75: Fuel Cell Transient Voltage and
Time Change
National Renewable Energy Laboratory 77 Innovation for Our Energy Future
CDP#76: Fuel Cell Transient Rate by Cycle
Category
0
5
10
15
20
25
30
35
Dow
nUp
Slo
wUp
Slo
wDow
n
Slo
wDow
nUp
Dow
nSSUp
Fre
qu
en
cy [
%]
Transient Cycle1 Count by Category2
0 5 10 15 20 25 30 35 400
5
10
15
20
25
30
dV/dtF
req
uen
cy [
%]
DownUp Cycle1 dV/dT
0 5 10 15 20 25 30 35 400
10
20
30
40
50
dV/dt
Fre
qu
en
cy [
%]
SlowUp Cycle1 dV/dT
0 5 10 15 20 25 30 35 400
10
20
30
40
50
dV/dt
Fre
qu
en
cy [
%]
SlowDown Cycle1 dV/dT
0 5 10 15 20 25 30 35 400
10
20
30
40
50
60
dV/dt
Fre
qu
en
cy [
%]
SlowDownUp Cycle1 dV/dT
0 5 10 15 20 25 30 35 400
20
40
60
80
100
dV/dtF
req
uen
cy [
%]
DownSSUp Cycle1 dV/dT
NREL CDP76
Created: Mar-22-10 4:46 PM1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage.2) Cycle categories based on cycle up and down times. A slow up or down transient has a time change >= 5 seconds. SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.
National Renewable Energy Laboratory 78 Innovation for Our Energy Future
CDP#77: Fuel Cell Transient Voltage
Changes by Cycle Category
0
5
10
15
20
25
30
35
Dow
nUp
Slo
wUp
Slo
wDow
n
Slo
wDow
nUp
Dow
nSSUp
Fre
qu
en
cy [
%]
Transient Cycle1 Count by Category2
0
5
10
15
20
-34
-30
-26
-22
-18
-14
-10 -6 -2 2 6
10
14
18
22
26
30
34
% Voltage Change [%Max Stack Voltage]F
req
uen
cy [
%]
DownUp Cycle1 dV
0
5
10
15
20
-34
-30
-26
-22
-18
-14
-10 -6 -2 2 6
10
14
18
22
26
30
34
% Voltage Change [%Max Stack Voltage]
Fre
qu
en
cy [
%]
SlowUp Cycle1 dV
0
2
4
6
8
10
12
-34
-30
-26
-22
-18
-14
-10 -6 -2 2 6
10
14
18
22
26
30
34
% Voltage Change [%Max Stack Voltage]
Fre
qu
en
cy [
%]
SlowDown Cycle1 dV
0
2
4
6
8
10
12-3
4-3
0-2
6-2
2-1
8-1
4-1
0 -6 -2 2 61
01
41
82
22
63
03
4
% Voltage Change [%Max Stack Voltage]
Fre
qu
en
cy [
%]
SlowDownUp Cycle1 dV
0
5
10
15
20
-34
-30
-26
-22
-18
-14
-10 -6 -2 2 6
10
14
18
22
26
30
34
% Voltage Change [%Max Stack Voltage]F
req
uen
cy [
%]
DownSSUp Cycle1 dV
NREL CDP77
Created: Mar-22-10 4:46 PM1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage.2) Cycle categories based on cycle up and down times. A slow up or down transient has a time change >= 5 seconds. SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.
National Renewable Energy Laboratory 79 Innovation for Our Energy Future
CDP#78: Fuel Cell Transient Cycles Outside
of Specified Voltage Levels
0
5
10
15
20
25
30
35
Dow
nUp
Slo
wUp
Slo
wDow
n
Slo
wDow
nUp
Dow
nSSU
p
Cycle
Fre
qu
en
cy [
%]
Transient Cycle Count by Category4
Total
<LoV Level2
>HiV Level3
tV
Example
0 2 4 6 8 10 12 14 16 18 200
10
20
30
40
50
60
70
80
Count per Mile
Tri
p F
req
uen
cy [
%]
Cycles1 Outside of Voltage Levels
2,3
<LoV Level2
>HiV Level3
NREL CDP78
Created: Mar-22-10 4:46 PM
1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage.2) The low voltage level is 70% Max Stack Voltage3) The high voltage level is 90% Max Stack Voltage4) Cycle categories based on cycle up and down times. A slow up or down transient has a time change >= 5 seconds. SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.
National Renewable Energy Laboratory 80 Innovation for Our Energy Future
CDP#79: Percentage of Trip Time at Steady
State
0 5 10 15 20 25 30 35 40 45 500
2
4
6
8
10
12
14
16
18
% Time
Tri
p F
req
uen
cy [
%]
Percent of Trip Time at Steady State
NREL CDP79
Created: Mar-22-10 4:46 PM1) SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.
National Renewable Energy Laboratory 81 Innovation for Our Energy Future
CDP#80: Miles Between Refuelings
0 50 100 150 200 250 3000
5
10
Perc
en
tag
e o
f R
efu
elin
gs
Distance between refuelings [Miles]2
Distance Driven Between Refuelings: All OEMs
Gen1
Gen2
After 2009Q4
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 of the vehicle.
Gen1
Refuelings1 = 18941
Median distance between refuelings = 56 Miles Gen2
Refuelings1 = 6870
Median distance between refuelings = 81 Miles
Created: Aug-09-11 8:53 AM
Refuelings after 2009Q41 = 8964
Median distance between refuelings = 96 Miles
National Renewable Energy Laboratory 82 Innovation for Our Energy Future
CDP#81: Average Trip Speed
0 5 10 15 20 25 30 35 40 450
2
4
6
8
10
12
14
16
18
20
Tri
p F
req
uen
cy
1 [
%]
Average Trip Speed [mph]
Histogram of Average Trip Speed
179,424 trips
1) Excludes trips <= 1 mile (40.9%)
29,689 trips
Average trip speed of 25.4 mph
1) Excludes trips <= 1 mile (19.4%)2) 2001 NHTS data includes Car, Truck, Van & SUV day trips
Through 2009Q4
After 2009Q4
NHTS Data2
NHTS Avg Speed
NREL cdp_fcev_81
Average trip speed of 23.2 mph
Created: Aug-24-11 4:28 PM
National Renewable Energy Laboratory 83 Innovation for Our Energy Future
CDP#82: Daily FC Operation Hours in
Automotive Application
0 1 2 3 40
20
40
60
80
Hours of Operation Per Day
Days o
f O
pera
tio
n [
%]
Fuel Cell System Operation Hours Per Day
Through 2009Q4
After 2009Q4
0 1 2 3 40
20
40
60
80
Average Hours of Operation Per Day
Fu
el C
ell S
yste
ms [
%]
Average Daily Fuel Cell System Operation Hours
9.9% Fuel Cell Systems Average > 30 mins Daily
17.8% Fuel Cell Systems Average > 30 mins Daily
Through 2009Q4
After 2009Q4
NREL cdp_fcev_82
Created: Aug-24-11 4:41 PM
National Renewable Energy Laboratory 84 Innovation for Our Energy Future
CDP#83: Hydrogen Dispensed by Day of
Week
Sun Mon Tues Wed Thur Fri Sat0
2
4
6
8
10
12
14
16
18
20
Dis
pen
sed
Hyd
rog
en
[%
of
tota
l]
Day of Week
Dispensed Hydrogen per Day of Week
0
3
6
9
12
15
18
21
24
27
30
Avera
ge k
g
All Stations
Individual Stations
NREL cdp_fcev_83
Created: Aug-30-11 3:35 PM
National Renewable Energy Laboratory 85 Innovation for Our Energy Future
CDP#84: Effect of Average Trip Speed on
Fuel Economy
0 5 10 15 20 25 30 35 40 45 50 550
0.2
0.4
0.6
0.8
1
1.2Effect of Average Trip Speed on Fuel Economy
1F
uel E
co
no
my [
no
rmalized
]
Avg Trip Speed [miles/hour]
Average of Fleet Medians
25th to 75th Percentile
NREL cdp_fcev_84
Created: Sep-22-11 1:35 PM
(1) Data after 2009Q4. The data has been normalized to the max of the median curve for each fleet. Data binned every 5 mph for calculating median and percentiles.
National Renewable Energy Laboratory 86 Innovation for Our Energy Future
CDP#85: Effect of Trip Length on Fuel
Economy
0 10 20 30 40 50 60 700
0.2
0.4
0.6
0.8
1
1.2Effect of Average Trip Length on Fuel Economy
1F
uel E
co
no
my [
no
rmalized
]
Trip Length [miles]
Average of Fleet Medians
25th to 75th Percentile
NREL cdp_fcev_85
Created: Sep-22-11 1:35 PM
(1) Data after 2009Q4. The data has been normalized to the max of the median curve for each fleet. Data binned every 5 miles for calculating median and percentiles.
National Renewable Energy Laboratory 87 Innovation for Our Energy Future
CDP#86: Fuel Cell Stack Operation Hours
0 200 400 600 800 1000 1200 1400 1600 1800 2000 >20000
5
10
15
20
25Fuel Cell Stack
4 Operation Hours
FC
Sta
cks [
%]
Operation Hours
25% of FC Stacks > 920 hours
Med
ian
(677 h
ou
rs)
In Service1
Retired2
Not in Service3
NREL cdp_fcev_86
Created: Sep-28-11 9:58 AM
1) Stacks that are in service and accumulating operation hours.2) Stacks retired due to low-performance or catastrophic failure.3) Indicates stacks that are no longer accumulating hours either a) temporarily or b) have been retired for non- stack performancerelated issues or c)removed from DOE program.4) Only includes systems operating after 2009Q4.
National Renewable Energy Laboratory 88 Innovation for Our Energy Future
CDP#87: Fuel Cell Stacks Projected Hours to
10% Voltage Degradation with Two Fits
0 300 600 900 1200 1500 1800 2100 2400 2700 3000 >30000
10
20
30
40
50
60Fuel Cell Stacks
4 Projected Hours to 10% Voltage Degradation
1,7
68
FC
Sta
cks [
%]
Time 0 Fit (In Service)
Time 0 Fit (Retired or Not in Service)2
Weighted Average (Fleet)
0 300 600 900 1200 1500 1800 2100 2400 2700 3000 >30000
10
20
30
40
50
60
2,2
12
Projected Hours to 10% Voltage Degradation 1,3
FC
Sta
cks [
%]
Steady Operation Fit (In Service)5
Steady Operation Fit (Retired or Not in Service)2,
5
Weighted Average (Fleet)
NREL cdp_fcev_87
Created: Sep-28-11 11:12 AM
1) Projection using field data, calculated at high stack current, from operation hour 0 or a steady operation period. Projected hours may differ from an OEM's end-of-life criterion and does not address "catastrophic" failure modes.2) Indicates stacks that are no longer accumulating hours either a) temporarily or b) have been retired for non- stack performance related issues or c) removed from DOE program.3) Projected hours limited based on demonstrated hours.4) Only includes systems operating after 2009Q4.5) Not all stacks have a steady operation fit which is calculated from data after 200 hr break-in period. The steady operation starting hour is an approximation of the period after initial break-in where degradation levels to a more steady rate.
National Renewable Energy Laboratory 89 Innovation for Our Energy Future
CDP#88: Comparison of Fuel Cell Operation Hours
and Projected Hours to 10% Voltage Degradation
0 500 1000 1500 2000
0
500
1000
1500
2000
2500
3000
3500Comparison of Operation Hours and Projected Hours to 10% Voltage Degradation
5
Pro
jecte
d H
ou
rs1,2
,4
Operation Hours
projected hrs = operation hrs
FC System
FC System (Limited)2
FC System (Retired)3
Unity Line
NREL cdp_fcev_88
Created: Sep-28-11 1:39 PM
24% of stacks are
below the unity line
and have operated
past 10% voltage
degradation.
On average, these
stacks have
operated for 1,050
hours.
Stacks above the
unity line have not
operated past 10%
voltage degradation.
1) Indicates the projected hours to a 10% voltage degradation based upon curve fitting data from operation hour 0.2) Projected hours limited based on demonstrated hours.3) Stacks retired due to low-performance or catastrophic failure.4) Each projection has uncertainty based on the confidence intervals of the fit.5) Only includes systems operated after 2009Q4.
National Renewable Energy Laboratory 90 Innovation for Our Energy Future
CDP#89: Fuel Cell Stack Durability as a
Function of Voltage Drop
10 15 20 25 300
500
1000
1500
2000
2500
3000
3500
4000Fuel Cell Stack
6 Durability as a Function of Voltage Drop
4
% Voltage Drop
Pro
jecte
d H
ou
rs2,3
10th/90th Percentile Projections3
Average of Fleet Projections1,5
NREL cdp_fcev_89
Created: Oct-05-11 2:41 PM
1) 10% Voltage degradation is a DOE metric for assessing fuel cell performance not an indication of an OEM's end-of-life criteria.2) Projections using field data and calculated at high stack current.
3) 10th
and 90th
percentiles spans the range of stack projection. The included stacks satisfy a minimum number of operation hours and weighting factor.4) The projected hours vary based on the percentage of voltage degradation, but the projected hours do not imply that all stacks will (or do) operate to these voltage degradation levels.5) Each fleet has one voltage projection value that is the weighted average of the fleet's fuel cell stack projections.6) Only includes systems operated after 2009Q4.
National Renewable Energy Laboratory 91 Innovation for Our Energy Future
CDP#90: Max Fuel Cell Stack Power
Degradation Over Operation
0
20
40
60
80
100
120
0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000
Stack Op Hour Segments2
% P
ow
er
1
Max Fuel Cell Stack3 Power Degradation Over Operation
1) Normalized by fleet median value at 200 hours.
2) Each segment point is median FC power (+-50 hrs). Box not drawn if fewer than 3 points in segment.
3) Only includes systems operated after 2009Q4.
Data Range
25th & 75th Percentiles
Group Median
Outlier
NREL cdp_fcev_90
Created: Sep-23-11 10:14 AM
Median power differencefrom 0 hour segment to1300 hour segment = -18.4%
National Renewable Energy Laboratory 92 Innovation for Our Energy Future