Commercial Vehicles and Extreme Fast Charging Research ... · NMC . Li-ion batteries typically...
Transcript of Commercial Vehicles and Extreme Fast Charging Research ... · NMC . Li-ion batteries typically...
Commercial Vehicles and Extreme Fast Charging Research Needs Workshop 2019
Golden, Colorado
August 27–28, 2019
The National Renewable Energy Laboratory (NREL) hosted the workshop, which was sponsored by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy's Vehicle Technologies Office.
Table of Contents
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Extreme Fast Charging: Perspectives from Cummins
Tritium: High Power Charging for Electric Vehicles
Xcel Energy: Slides for Discussion
Black & Veatch: High Power Charging Siting & Power Delivery
Eaton: EV Fast-Charging Barriers and Opportunities
NREL | 2
Extreme Fast Charging: Perspective from Cummins John Kresse
27 August 2019
Extreme fast charging …
… Advantages for fleets
… Cummins experience
… Challenges
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Fleet Advantages 1
A commercial vehicle is part of an overall system, this includes: the fueling or charging infrastructure, the duty cycle and the driver
Depending on battery sizing, fast charging can improve route flexibility and the impact of higher battery use due to high accessory (esp. cab heating) losses
• However, if a fast charging infrastructure enables the battery to be downsized, route flexibility may be reduced
1Ethan May and Kellie Hwang, “IndyGo Red Line electric buses weren’t going far enough on a charge, so they’re getting a tech fix”, Indianapolis Star, May 23, 2019.
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Fueling rate class 8 diesel class 8 EV
J1772 L2 150 kW 350 kW 500 kW 1 MW
fueling rate (miles / minute) 150 - 300 0.15 1 2.5 4 8 Max charging rates typically only available from 15-80% SOC
While even the extreme fast chargers are more than an order of magnitude slower compared to a diesel pump, these chargers provide significant flexibility to a fleet operator compared to the highest power SAE J1772 level 2 overnight charging
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Cummins support of Wireless Advanced Vehicle Electrification (WAVE) drayage truck project2
Class 8 drayage truck integrated to a WAVE 500 kW wireless inductive charging system Extreme fast charging system enables high truck utilization: in this case,
the objective is to operate 20 hours a day, multiple round trips/day
2 Wireless Extreme Fast Charging for Electric Trucks (WXFC-Trucks) DOE Cooperative Agreement No. DE-EE0008360
Image used with permission of PACCAR Inc.
15 minute fast charge events
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Challenge: batteries Today, support of extreme fast charging requires a battery that either has large
capacity or higher cell cost / reduced energy density • NMC Li-ion batteries typically support (continuous) charge C rates of 0.7 - 1
- Extreme fast charging can only be fully utilized with large batteries • LTO Li-ion batteries support much higher charge rates but have much higher
cost and limited energy density • There are some power-oriented NMC batteries that have higher cost and less
energy density than energy-oriented NMC but can be an acceptable balance High C rate charge cycles can have a negative impact on battery life
Industry need: continuous 3-4C rate battery with good energy density, low cost, that can support 4k charge cycles with acceptable life
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Challenge: operational costs A total cost of ownership (TCO)
study3 found a major contributor for MD EV delivery trucks is grid electricity cost:
• $0.10/kW-h, payback period for an EV is 3½ years 30
35
40
45
50
55
Demand charges varies across all utilities operating in the State ($/KW)
Demand Charge ($/KW)
• $0.20/kW-h, payback period is 5 years 15
20
25
Because of time-of-use and demand charges, the average cost of electricity can more than double for fast charging compared to slow overnight charging
0
5
10
AZNY NECA MACO IL GA NC
Demand Charge-Average of all utilities maximum charge Demand Charge- Maximum charge across all utilities
States
Source: National Renewable Energy Laboratory (NREL)
VT
3 Cummins Electric Truck with Range Extending Engine (ETREE) DOE Cooperative Agreement No. DE-EE0007514
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Challenge: optimizing fleet choices With expensive assets (trucks, charging infrastructure), impact of grid
electricity (cost, availability), and need to ensure fleet missions are accomplished at best TCO, how should each fleet structure & use their eco-system?
• E.g., should a fleet purchase trucks with large batteries with overnight charging or small batteries with robust fast charging network?
• Etc.
This requires (multiple) high fidelity simulation tools with integrated grid, fleet, charging systems and truck modeling capability which can model TCO sensitivity with several independent variables Ultimately, a fleet may need gold standard tools that help with:
• Buying decisions for their eco-system • Operational decisions
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Other challenges Infrastructure costs, impact to grid and where to site chargers Interoperability / lack of standardization
• Pantograph (multiple) • Wireless (multiple) – even with development of SAE J2954 • Automated conductive
Availability and cost of high amperage vehicle side connectors Battery thermal management during extreme high power charging EMI – EMC prediction & mitigation
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Range Extenders (REx) vs. Extreme Fast Charging Infrastructure
An ubiquitous DCFC infrastructure limits the usefulness of a series PHEV • The infrastructure eliminates “range anxiety” so there’s little need for REx
However, the opposite may be true • Until a fleet has access to a reliable fast charging network, the proper
range extender can alleviate both range, and infrastructure, “anxiety”
Cummins ETREE Series PHEV equipped with a 130 kW range extender 10
Extreme Fast Charging
For many commercial fleets, extreme fast charging is a requirement to move electric vehicles from niche to mainstream
But, the challenges must be overcome • Impact on electricity grid including time-of-day and demand charges • Battery technology (charge rate support, impact on battery life) • Others: interoperability, battery thermal management, on-vehicle wiring,
infrastructure costs
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Q+A
1313
High Power Charging for Electric Vehicles
James Kennedy CTO / Founder
Quick Facts: Tritium
Charging Infrastructure
More convenience EV’s can charge anywhere – currently
Optimal Vehicle Charging Locations
70% Home
15% Work
10% Public
5% Corridor
12kW
12-25kW
50kW
350 - 500kW
More convenience EV’s can charge anywhere – future?
Optimal Vehicle Charging Locations
20% Home 12kW
12-25kW 20% Work
20% Public 50kW
40% Corridor / “Petrol Station” 350 - 500kW
European Automotive OEM Network Announced Nov 2017 – 40% built already • IONITY network: Volkswagen (incl Porsche & Audi), Ford Europe, BMW,
Daimler/Mercedes • 400+ sites across Europe within the next 18 months – expected to only be 10% of final
network • Each site consists of:
• 1250kVA MV (10/20kV) transformer, metering, and switchgear • 6x 350kW charging heads + parking spaces, expandable to 500kW • Liquid-cooled charging cables • Site power management control (since total charging head power is greater than site
power) • Telemetry, remote access, firmware updates, billing system, DC metering equipment
European Automotive OEM Network Being built now
European Automotive OEM Network Challenges • Utility connection time
• High workload per site • Long timeframes
• Site Footprint • Installations into existing truck stops on Autobahn network • Total site footprint area is quite restricted at many sites
• Regulatory • German DC meter law
• Site earthing design • MV fault • Lightning strike
Slides for Discussion Beth Chacon Director, Grid Storage & Emerging Technology
August 28th 2019
About Xcel Energy Serving eight states • 3.6 million electricity customers • 2 million natural gas customers
Nationally recognized leader: • Wind energy • Energy efficiency • Carbon emissions reductions • Innovative technology
Xcel Energy Priorities
Our Carbon-free Energy Future Xcel Energy Carbon Goals Compared to 2 C Scenarios
2005 2020 2030 20500%
-20%
-40%
-60% Range of Scenarios Likely to Achieve 2 C
-80%
-100%
2018 2030 2050 38% 80% 100% Achieved Goal Carbon-free Goal
Perc
ent C
arbo
n Em
issi
on R
educ
tion
Goals align with Paris climate
targets to limit warming to 2 C
Strategic Electrification A solution for reducing carbon economy-wide
Xcel Energy EV strategy: • Making EV adoption easier • Creating charging infrastructure • Establishing rates and technology to encourage
charging on low-cost, low-carbon energy
~2 million EVs projected in Xcel Energy territories by 2035
EV Residential TOU Snapshot
• Highest usage 9pm-9am • Due to off-peak pricing • On peak - $.21/kwh (summer) • Off peak - $04/kwh
* Mean usage is mean energy used (in Wh) during 15-minute interval,averaged across all customers in the program. 6
What does Extreme Charging Mean? Peak Load kW
Peak loads for various customer
50 E-buses
20 Story Building facilities
5A High School
Supermarket
0 500 1000 1500 2000 2500 3000
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Timeline for Connecting Service
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Timeline for Connecting Service, cont.
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Copyright Pipistrel
Copyright Proterra
High-Power Charging Siting & Power Delivery Paul Stith Director, Strategy & Innovation
NREL Extreme Fast Charging Workshop Transformative Technologies
August 28, 2019
About Black & Veatch
Employee-owned, global leader in building Critical Human Infrastructure in Energy, Water,Telecommunications and Government Services. Since 1915, we have helped our clients improve the lives of people in more than 100 countries through consulting, engineering, construction, operations and program management.
11,000+ $3.5 Billion Safety Performance in revenue in 2018 0.37 Recordable Incident Rate Professionals
0.06 Lost Time Incident Rate
Power Water Telecom Oil & Gas
.
Transformative Technologies @ Black & Veatch
As of January 25, 2019 Source: Tesla As of September 6, 2018 Source: Electrify America https://www.tesla.com/supercharger https://www.electrifyamerica.com/locations
Over 1,400 High-Power Sites 250KW+
New York MTA Transit on-route & depot charging facilities. Proterra & New Flyer Pilot.
Scaling DistributedClean Energy
Infrastructure
Electric Vehicle Infrastructure Energy Storage Networks Hydrogen Infrastructure
Emerging Distributed Technology Autonomous, Connected Vehicle
Infrastructure
We build complex networks faster
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High-Power Charging: Impacts on SiteDesign & Approach What does it mean for Infrastructure Planning&Investments
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Site Design, Power Delivery, Cost of Energy Multiple Low Voltage Transformers -> Medium
Voltage Utility Service
Switch Gear Capacity Strategy
Centralized Power Conversion
DC Power Utility Delivery
Infrastructure Sharing & Equipment Compounds
Automation, Cooling, Cables, Connectors
Designs and costs shaped by new technologies and utility service provisioning Enabling High Capacity Corridor, Ports,
Depot & Aviation FBO Fueling
Sharing Solutions Across On-Road, Off-Road, Aviation & Marine Applications 5
Step Change in Charging Infrastructure Requirements High Power Corridor Charging
High Utilization Vehicles
Urban Charging Hubs & Depots
High power On-route
Capital Requirements
Facility and Network Roadmaps
Optimize for least regret investments while scaling to meet requirements
High Capital Requirements & Schedules Require Planning,Risk Management and Technology Flexibility
Transit Bus: ~250KWh Over-Road Coach ~500KWh –
750KWh or more per day
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Modular Electrical Design Approach • Develop roadmaps for network capacity and Example (5) pod system diagram:
site deployments
2,500A 277/480V switch board
12.5kV 277/480V transformer (2 MVA)
Pod 1
600kW power unit
600kW power unit
eVTOL
Medium-voltage switch gear 600A 12.5kV
Pod 3
600kW 600kW
600kW power unit
dispenser dispenser dispenser 600kW
eVTOL eVTOL
Pod 5
Utility primary service Pod 2 Pod 4
• Integration with utility planning processes(power requirements, network density, grid support, etc.)
• Distributed energy and resilience • Plan for electrical infrastructure ahead of fleet
ramp up per location • Understanding opportunities for power
sharing with buildings, other vehicle chargingand the role of energy storage
• Reducing cost of energy, storage andrenewables integration options
Source: Black & Veatch – National Institute of Aerospace (NIA), under contract with the National Aeronautics and Space Approach allows for least regret investment Administration (NASA) Urban Air Mobility Study
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Pilot While Planning for Scale (Pilot ENTIRE Sites)
“Businesses (& Fleets) that do not electrify will be at a competitive disadvantage…”
Black & Veatch – EVS30 “Priming the U.S. Grid for High-Power Charging”
> Modular, least regret infrastructure investment program (Fleets & Facilities)
Stakeholder Alignment & Program Goals • Existing Project History • Concurrent, Future Projects
• Building Load Integration • Cost of Energy, Renewable Content • Resilience requirements • Future Proofing Infrastructure
• Project & Program Timeline • Project & Program Budget • Total Cost of Operation
> Fleets, Agencies, Utilities, Cities, Vehicle OEMs, Clean Energy,Community Interests, Project Execution Team, Funding & ROI
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Infrastructure: Understanding Schedule & Whole Costs The most expensive Electric Fleet is one that can’t charge
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$0
$50,000
$100,000
$150,000
$200,000
$250,000
Corridors, Pilot Fleet Sites: High Power ChargingDeployments Scenarios
Transformer
Switch Gear
Land Use
Commissioning
Cable/Conduit/Trenching
Charger Relative, Per Charger Costs
1 4 16
Number of Chargers
All-In Costs for High Power Charging Facilities 11
$-
$1,000,000
$2,000,000
$3,000,000
$4,000,000
$5,000,000
$6,000,000
Full Electrication: Scaling Up Requires Significant Capital
Relative, Per Charger Costs
1 4 16 48 100 200
Substation
Feeder
Transformer
Switch Gear
Land Use
Commissioning
Cable/Conduit/Trenching
Charger
Number of Chargers
All-In Costs for High Power Charging Facilities 12
High-Power Site Development – Potential Grid Upgrades
Potential Grid Upgrades Required, Typical Scenarios & Land Use
Example ranges – all power delivery scenarios are specific to a location, feederaccess, existing, in queue projects and utility operating / power provisioning standards
AND available land / right of ways
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High-Power Site Development Schedules Base Case Power Delivery Schedule: No Grid Upgrades Required
Project Phase Typical Ranges (Months) Engineering / Design 0.50 - 2.00 Permitting / Land Use 0.50 - 3.00 Construction 1.75 - 2.50 Commissioning 0.25 - 0.50 Total Project Schedule 3.00 - 8.00
Assumes 1-2 megawatt load, power is available on site, new utility service andtransformer, 480v supply, existing utility right of way, limited to no building
load integration. May include service extension.
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Power Delivery, Grid Upgrade Schedules Potential Grid Upgrades Required, Schedule Impacts
Potential Power Delivery Upgrades Typical Ranges (Months) Supply Conductor (Service Extension) 0 - 2 Medium Voltage (Service Provisioning) 0 - 5 Feeder Re-Conductor 6 - 36 Feeder Additional Conductor 6 - 36 New Feeder 9 - 48 Substation Upgrade Required 18 - 36 New Substation Required 24 - 48
Example ranges – all power delivery scenarios are specific to a location, feederaccess, existing, in queue projects and utility operating / power provisioning standards
AND available land / right of ways
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Scenario Assumptions (Ultra Fast quickly surpass thresholds!)
Ports Power (MW)
Medium Voltage
Feeder Upgrade
New Feeder
Substation
1 0.125 4 0.50
16 2.00 48 6.00
100 12.50 200 25.00
125KW Per Charger, Medium voltage grid supply for 4MW and larger
configurations, 1 Mile of Feeder, New Substation
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Driving PredictableOutcomes: Costs & Schedules Working with EPCs, Utilities and Stakeholders
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Electric Utility Coordination Key Points • Early engagement and utility coordination at an account and engineering level is
highly encouraged to fully understand requirements and feasible power deliveryschedules.
• Utilities will generally not release site specific power delivery capabilities withoutexpressed intent to develop a location.
• With increased power levels, the scope and location of distribution grid upgrades increases, so does the intensity of land use, right of way and permitting requirements.
• An important aspect of utility coordination is the ability to leverage existingrelationships coupled with engineering know how.
• Relationships, combined with knowledge of utility engineering and business practicescan reduce utility service fees and significantly accelerate service delivery for high-power electric vehicle charging.
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Influence & Expenditure Curve:Ability to Influence Total Installed Cost
Low
High
Design: Conceptual and Detailed
Procurement
Construction
Startup
Complete Time Start
Proposal
Impa
ct p
er D
olla
r Spe
ntAb
ility
to in
fluen
ce c
ost
DO IT! -EARLIER IS BETTER
Basic guideline: $1 spend in Engineering = $10 spent in procurement - $100 spent in Construction
Electric Vehicle Infrastructure 101 – Controlling Project Costs • Change and Risk are expensive
• Quality information drives design certainty • Design certainty drives deployment cost certainty • Develop execution strategies to reduce risk • Plan for unknowns
• Project delays are expensive, vehicles that can’t charge and expedited construction are more expensive!
• Entire power delivery per facility • Understand and manage entire supply chain • Understand all required approvals (internal/external) • Understand and plan for contracts and legal process
> Site feasibility, power delivery, equipment lead times, design approvals
Paul Stith Director, Strategy & Innovation, Transformative Technologies
@Black_Veatch [email protected] @BVSII +1 913-458-8747
Additional Electrification Resources (click to download) REPORTS & BRIEFINGS PRESENTATIONS
To request whitepapers “Priming the U.S. Grid for High-Power Charging” and “Understanding and De-Risking Power Delivery” email [email protected].
Black & Veatch 22
© 2019 Eaton. All rights reserved..
Today & Tomorrow:
EV Fast-Charging Barriers and Opportunities
David Ganger, Ph.D., P.E.
Eaton Research Labs
8/28/2019
To improve the quality of life and the
environment through the use of power
management technologies and services.
New Reported Segment (2018)
$500M investment
Electrical Systems & Services
eMobility Vehicle Electrical Products
Aerospace
Hydraulics
Industrial Sector ($8.5 B, 2018) Electrical Sector ($13.1 B, 2018)
3© 2019 Eaton. All rights reserved..
Utility Equipment
Transformers Protection
Distribution
Equipment
Software
Distribution Equipment
Panelboards &
Switchgear Protection
Monitoring &
Metering
Energy Storage
Electric Vehicle
Supply Equipment
Chargers
Energy Management
Microgrid
Controls
Metering
Today: Barriers to Adoption of Extreme Fast-Charging
Technology Barriers
• Thermal • High voltage • Automation
management architecture • Cooling
• Battery charge rate • Safety concerns
Market Barriers
• Infrastructure costs • Developing standards
& regulations
.
Tomorrow: Site- and Feeder-level Controls
Mobility HIP NODES
Exploring the Effects of Electrification An IoT Based Demand Response Solution
Controllable Loads
Potential Users
Utilities Load aggregators Virtual power plants
Values
- Coordination of grid-service-enabled assets
© 2019 Eaton. All rights reserved. Eaton Confidential. 5
.
Tomorrow: Extreme Fast Charging - DCaaS
600 Vac
1000 Vdc
1000Vdc
AC
Distribution
DC
Distribution
© 2019 Eaton. All rights reserved. Eaton Confidential. 6
7© 2019 Eaton. All rights reserved. Eaton Confidential..