Fuel Cell Vehicle Developmentat Hyundai-Kia Motors

Byung Ki Ahn & Tae Won LimFuel Cell Vehicle TeamHyundai-Kia Motors

104 Mabuk-Dong, Giheung-Gu, Yongin-SiGyeonggi-Do, Korea

Abstract - Fuel Cell Vehicles, which are driven by electricalpower generated from hydrogen fuel, are becoming a 'hot potato'in the automotive industry. It is now well known that the crudeoil supply will run out in about forty years and the earth needs adifferent type of energy resource that can last indefinitely.'Hydrogen era' is expected to begin in the 2020's, and the biggestmarket for hydrogen fuel cells will certainly be the auto industry.However, the cost of the fuel cell vehicle or the individual parts isfar from being realistic from a mass production standpoint. Everymajor auto maker is trying to reduce the cost and enhancemanufacturability, and we are about to see the promising outcome.Hyundai-Kia Motors has the largest fuel cell research center inKorea and it has developed several different types of FCVs sinceits first launch of Santa Fe FCV in 2000. In this paper, we presentthe basic principles of fuel cells and the history of fuel cell vehicles.In addition, the status of FCV development at Hyundai-KiaMotors will be introduced. Verification programs sponsored byKorean and American governments are presented to show howactively we are collaborating with other fuel cell-relatedcompanies in order to make FCVs commercially available.

I. INTRODUCTION

The assumption that hydrogen can be an energy resource forhouseholds and vehicles has come closer to reality in the latetwentieth century thanks to the energy generating device called'fuel cells'. The basic principle of a fuel cell is opposite to theelectrolysis of water to separate hydrogen and oxygen. Insteadof applying 'electricity' to water to obtain the gasses, in fuelcells electricity is the product from combining hydrogen andoxygen. If pure hydrogen were used in the electrochemicalreaction, the only byproduct is pure water. Therefore, usinghydrogen is very environmentally-friendly. Also, it should benoted that hydrogen is the most abundant element on earth.Fuel cell vehicles (FCVs) have been studied and intensively

developed since late 1980's. The tank-to-wheel efficiency isnot restricted by Carnot cycle and can be as high as 60%, andthis benefit was attractive enough to many major automakers inthe world. Including Toyota which heavily relied on 'hybridvehicles' rather than FCVs, the majority in the automotivebusiness believed that commercial FCVs will be on the streetby as early as 2000.While Prius, Toyota's hybrid car, has become a big hit as a

high gas mileage vehicle, FCVs are still struggling fromunresolved issues. Cost, durability and subzero temperaturestart-up are three of the major obstacles that should be

overcome before FCVs become commercially viable. Inaddition, government regulations to deal with high pressurehydrogen gas need to be set for public usage ofFCVs.Although FCVs seem to have a long way to go until mass

production, it is understood that they will be one of few optionsto substitute internal combustion engines in the long run.Hybrid vehicles still use fossil fuel. Doubling the gas mileagein hybrid cars will reduce fuel consumption but will not be thebest solution for energy crisis. The question is not whetherFCVs will be made with a reasonable price tag, but when itwill happen.In this paper, we will introduce the general aspects and the

history of FCVs as well as FCV development activities atHyundai-Kia Motors. The later part of the paper will beattributed to the introduction to the demonstration programs weare attending domestically and internationally.

II. TECHNOLOGIES

A.PEMFuel Cells and FCVsSince U.S. NASA considered fuel cells a supplementary

power unit for its spacecrafts in the 1960's, several differenttypes of fuel cells have been developed. Typically, protonexchange membrane fuel cells(PEMFCs) are known as anappropriate candidate for automotive applications because oflow operating temperature in the range of 65 80°C. InPEMFCs, while protons move from the anode to the cathodethrough the electrolyte, electrons are bypassed to generateelectrical power. A schematic of a PEMFC is shown in Fig. 1.

e-

AnodeCurrentCollector

AnodeBackinc

HydrogenFlowPic-li

Air (oxygen)Flow Field Water

and Air

CathodeCurrentCollector

I Iik \Cathodei i`:MEA BackingHydrogen /

f tlt.+I-+ c

Fig. 1. Schematic structure of a PEMFC

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The power from the electrochemical reasction in a unit fuelcell is merely enough to light a small electric bulb. To increasethe power that suits an 100 horse power SUV, several hundredcells should be 'stacked'. And two other major systems are tobe equped: balnce of plant(BOP) that feeds oxidant and coolantto the stack; and the fuel processing system(FPS) to providehydrogen rich fuel. When these systems are assembled in avehicle frame, a fuel cell car is completed. It is obvious thatsimilar to electric vehicles, electrical power train systems, abattery unit,and control units are also essential.

f Contr

Fig. 2. Major systems of a FCV

B .Advantages offuel cellsThe most important reason that we should develop fuel cell

vehicles is depletion of the crude oil supply. According toreliable statistics data, crude oil will run out in about fortyyears and natural gas supply will last only seventy some years.Besides, vehicle emission has been criticized as the mainreason of air pollution in large cities. It is thus very reasonablethat major auto makers have been looking for alternative fuelswhich are unlimited and non-pollutant.Another advantage of FCVs is technically proven. Compared

to international engines, FCVs have higher fuel efficiency dueto direct conversion from chemical energy (fuel) to electricalenergy. The overall efficiency including well-to-tank and tank-to-wheel efficiencies can be over 40%, about 15% higher thancurrent hybrid vehicles. Furthermore, the cost of hydrogen fuelis comparable to that of gasoline even at present, which impliesthe huge cost advantage of FCVs when mass production ofhydrogen fuel is possible in the future.It is hard to predict 'how many' FCVs will be on the street by'when'. Automotive World Car Industry Forecast Reportpredicts, however, that 9000 of the vehicles manufactured inthe 2040's will be fuel cell-powered. Other reports forecast thebeginning of the so-called 'hydrogen era' in 2025 2030.

III. MILESTONES

A .FCVDevelopment ofForeign CompaniesSince the possibility of fuel cells in vehicles was shown by

Ballard, a Canadian fuel cell company, and the US nationallaboratories, it became a trend that major auto makers invest

huge research fund to fuel cell technologies. The 'Big 3' werevery anxious to achieve the goal of the mass production ofFCVs before the 21st century began, so were Japan's Toyotaand Honda. But, the time frame has been modified severaltimes, and at present some are skeptical about the future ofFCVs. Good news is, however, no major auto maker hasabandoned its fuel cell program. Rather, some companies suchas Toyota have strengthened FCV programs with a goal ofmass production in 2015.Fig. 3 shows the summary of FCV development of somemajor auto makers. GM still has the goal of 'becoming the firstcar maker selling 1 million FCVs'. Other companies plan togo to the mass production stage between 2010 and 2020. InFig. 3 the blue reverse triangles denote 'test driving'; and thered diamond 'small production', while the black stars refer tomass production.

Honda

Toyota

('02. 2)Lease sale

GM

DCX

Ford

* *02.12: Lease sale (USA, Japan)* '05.12 :20 cars runningV 2012: Production (oal)* '02.12: Lease sale (USA, Japan)* '05.12 :30 cars runningV 2010: Production (oal)* '05.12: 20 cars runningv 2010: Production (goal)

'05.12: 100 cars running* / 2012 Sale's to public (gc

* '05.12: 30 cars running(USA, Canada)

Fig. 3. Trend of auto makers' FCV development

B .FCVDevelopment at Hyundai-Kia MotorsSince Hyundai-Kia Motors presented its first generation FCV

in 2000, several upgraded versions have been introduced.While the first FCV, which used a Santa Fe body frame, hadthe FC stack under the floor and was able to cruise 160km withone fuelling, the next generation FCVs(Tucson and Sportage)extended their driving range to 300km. The maximum speedwas also enhanced from 124km/hr to 150km/hr. Othertechnical milestones we have achieved are as follows:

- Freeze capability: Start at -20°C within 5 minutes- Life: Longer than 1,500 hours- Interior space: Identical to ICE Tucson- Others: Less noise, easier to operate, better R&H

Unlike the first FCV, the second generation FCVs haveauxiliary power source in the form of high voltage lithiumpolymer battery. The fuel cell stack generates 80kW, and thebattery stores as much as 20kW. Hydrogen fuel is compressedup to 350 bars and is stored in three high pressure tanks madeof aluminum and carbon fibers.Another big fuel cell project by Hyundai-Kia Motors is 'Fuel

Cell Bus' program. The first FC bus was manufactured thisyear and was used for a trial operation during the World Cup

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2006 in Germany. The basic body of the FC bus uses a low-step axle based CNG bus that is currently mass-produced. Fuelcell generates a maximum of 160kW, and a pack of supercapacitor can develop up to 80kW when needed. The drivingpower of the vehicle is generated by a 240kW electric motor.

(a) Santa Fe FCV (2000) (b) Tucson FCV (2004)

Fig. 4. Fuel cell powered SUVs by Hyundai-Kia Motors

Fig. 5. The 1St generation fuel cell bus

IV. PROGRAMS

Hyundai-Kia Motors has been participated in manycompetitions and demonstration programs. We attendedMichelin Challenge Bibendum in 2001, 2003 and 2004, and in2004 we had very good ratings in fuel mileage and emission. InApril, 2005, our technology for high gas mileage was provenagain in the EVS21 Monte-Carlo Rally. Hyundai-Kia Motors'FCV was ranked first in the area with 80km/kg(H2).

Our global network extends internationally to Japan andUnited States. Since 2002 we have been a partner of Fuel CellPractice Program in Japan. And California FC Partnership isanother program we have been involved in for the past sixyears.

The biggest program we are currently contributing to isdirected by US Department of Energy(DOE). In DOE's FleetDemonstration Program, Hyundai-Kia Motors is joining UTCPower and Chevron Texaco, providing 32 FC SUVs until 2009.UTC Power develops FC stacks, and Chevron Texaco is incharge of hydrogen fueling stations.We have recently launched a demonstration program in Korea,

too. Ministry of Commerce, Industry and Energy supports a

'Fuel Cell Vehicle Monitoring Project' for the purpose ofintroducing fuel cells to the public and obtaining actual drivingdata of recently developed FCVs. Through this new project, wewill have opportunites to drive 30 SUVs and 4 buses on publicstreets for the next three years. This program is important notonly for FCVs or FC buses but also hydrogen infrastructures. 5fueling stations will be built in 4 different locations in Korea sothat an FCV can run from one station to another withoutadditional fueling.Participating into such programs and projects hasadvantageous effect: Build technical and strategic networkto share information with. On top of that, comparing oneparty's result(or product) with another party's always tendto expedite development of both sides. Hyundai-KiaMotors' FC programs have rapidly grown for the past 5years and will continue to develop. In order to abide byour roadmap to arrive the mass production stage withinnext 10 years, we will make a tremendous effort.

V. CONCLUSION

Fuel cell vehicles have recently gained much attentionbecause of depletion of fossil fuel, environmental issues and soforth. All the major auto makers including Hyundai-KiaMotors are focusing on resolving technical problems for massproduction, and many predict that FCVs will be commerciallyviable by 2020 and be competitive against internal combustionengines by 2030. This paper deals with some general aspectsrelating to fuel cell technology and introduces developmentprograms at Hyundai-Kia Motors. As one of the the largestvehicle manufacturers in the world, Hyundai-Kia Motorsunderstands its responsibility to resolve issues associated withenvironment. In addition, we understand that the future autoindustry will not be discussed without fuel cell vehicles.Hyundai-Kia Motors is now actively participating in variousdmonstration programs, and it will help build network withother fuel cell-related organizations.

ACKNOWLEDGMENT

We would like to thank Ministry of Commerce, Industryand Energy(MOCIE), Ministry of Construction andTransportation (MOCT), and Ministry of Science andTechnology (MOST) for partly supporting our research workthrough various government projects. Our thanks are also dueto National R&D Organization for Hydrogen and Fuel Cell,and to National R&D Organization for Futurisitc Vehicles.

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