Austin Power Engineering LLC 1 Cameron St

Wellesley, MA 02482 USA

www.AUSTINPOWERENG.com

yang.yong@austinpowereng.com

© 2015 Austin Power Engineering LLC

PEM Fuel Cell System Manufacturing Cost Analysis for Automotive Applications

Yong Yang

President

November 17, 2015

1 2015 YY

Have been working on fuel cell manufacturing cost modeling for US DOE, UK Carbon Trust, and commercial clients since 2002.

Introduction Overview

2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

US

DOE

TIAX

Chief Manufacturing cost model developer

Austin Power

Chief Manufacturing cost model developer

US DOE

UK Carbon Trust

Commercial Clients

Fuel Cell / Hydrogen Manufacturing Cost Modeling

2014 2015

2

Approach Manufacturing Cost Modeling Methodology

This approach has been used successfully for estimating the cost of various technologies for commercial clients and the DOE.

Technology

Assessment

Manufacturing

Cost Model

Scenario

Analyses

Verification &

Validation

• Literature research • Definition of system and component diagrams • Size components • Develop bill-of-materials (BOM)

• Define system value chain • Quote off-shelve parts and materials • Select materials • Develop processes • Assembly bottom-up cost model •Develop baseline costs

• Technology scenarios • Sensitivity analysis • Economies of Scale • Supply chain & manufacturing system optimization • Life cycle cost analysis

• Cost model internal verification reviews • Discussion with technical developers • Presentations to project and industrial partners • Audition by independent reviewers

Membrane

8.0%

Stack

Conditioning

2.7%

Seal

8.4%

Balance of Stack

2.4%

Bipolar Plate

26.1%

GDL

5.1%

Electrode

41.0%

Stack Assembly

6.3%

2015 YY

Anode Ink

Anode Side

Catalyst Layer

Membrane

Processes

Cathode Side

Catalyst Layer

Cathode Ink

Hot Press

Lamination

Purchased GDL

Purchased GDL

Pt

Pt

Nafion®

Ionomer

99.9% 98.5%

99.9% 98.5%

99% 98.5%

100% 98.5%99% 98.5%

99% 98.5%

100% 100%

100% 100%

100% 100%

100% 100%

100% 100%

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

3-Year TCO 5-Year TCO 10-Year TCO 15-Year TCO

To

tal

Co

st

of

Ow

ers

hip

($

)

PEMFC Plug Hybrid Vehicle

Full Battery Electric Vehicle

3

Combining performance and cost model will easily generate cost results, even when varying the design inputs.

2015 YY

Process Simulation

Energy requirements

Equipment size/ specs

Product Costs

Product cost (capital,

O&M, etc.)

Conceptual Design

System layout and

equipment requirements

Capital Cost Estimates Site Plans

Safety equipment, site

prep, land costs

High and low volume

equipment costs

Air (POX only)

Nat. Gas

Water

Fuel

Reformer PSA

H2-rich gas

H2-poor gas

Catalytic

Burner

HeatCold

Water

99.99% pure H2

Low

Pressure

Storage

Medium

Pressure

Storage

High

Pressure

Storage

Flow

cntrlr

Flow

cntrlrFlow

cntrlr

Dispenser

To Vehicle

CO2

H2O

Compressor with intercoolers

Cooling

Tower

Process cost

Material cost

Tape Cast

Anode

Powder Prep

Vacuum

Plasma

Spray

Electrolyte

Small Powder

Prep

Screen

Print

Cathode

Small Powder

Prep

Sinter in Air

1400CSinter in Air

Forming

of

Interconnect

Shear

Interconnect

Vacuum

Plasma

Spray

Slurry

Spray

Screen

Print

Slurry Spray

Slip Cast

Finish Edges

Note: Alternative production processes appear in gray to the

bottom of actual production processes assumed

Braze

Paint Braze

onto

Interconnect

Blanking /

Slicing

QC Leak

Check

Interconnect

Fabrication

Electrolyte CathodeAnode

Stack Assembly

Fuel Station Perimeter

Electrolyzer or SMR,

High-Pressure

Compressor

H2 High Pressure

Cascade Storage

System

Gaseous Fuel

Dispensing Islands

Underground Piping with shared conduit

Vent

Building

Covered Fueling Island

CNG High Pressure

Cascade Storage System

Fire Detector

Walls with minimum fire rating of 2 hours

Wall openings (doors & windows)

Building intake vents

Adjoining property that can be built on

Public sidewalks, parked vehicles

Streets

Railroad tracks

Other flammable gas storage

5 ft

25 ft

50 ft

10 ft

15 ft

10 ft

15 ft

10 ft

Minimum set-back distances for hydrogen and/or natural gas

storage (more stringent gas noted if relevant)

Property of:

TIAX LLC

1061 De Anza Blvd.

Cupertino, CA 95014

Task 5 CNG/Hydrogen Fueling

Site Plan - Fueling Station

Hydrogen and CNG fueling station

SIZE DWG BY DWG NO REV

A Stefan Unnasch B0228 - S0022 1

SCALE 1" = 8 ft 5 Jan 2004 SHEET 1 OF 110 ft

Security FenceNG line in

ft

ft

ft

ft

ft

ft

ft

ft

Process Cost Calcs

Material

Process

$0

$1

$2

$3

$4

$5

$6

$7

$8

$9

$10

Lapp

ing

CM

P

Wet

ther

mal

Oxida

tion

Spin

Coa

ting

Wet

Etc

hing

SiO

2

DC S

putte

ring

Ni

RF S

putte

ring

E

Spin

Coa

ting

Stepp

er

DC S

putte

ring

Ag

Stripp

ing

Spin

Coa

ting

Stepp

er

Dry

Etc

hing

SiO

2

DRIE

Si

Wet

Etc

hing

SiO

2

Dry

Etc

hing

NI

Wafe

r C

ost

($)

Approach Manufacturing Cost Modeling Methodology

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

3-Year TCO 5-Year TCO 10-Year TCO 15-Year TCO

To

tal

Co

st

of

Ow

ers

hip

($

)

PEMFC Plug Hybrid Vehicle

Full Battery Electric Vehicle

Approach Scope

4 2015 YY

Fuel Cell

System

Hydrogen

Storage

System

Hybrid

Battery

System

Inverter

Motor

Included in

the analysis

Not

included in

the analysis

Conduct a bottom-up manufacturing cost analysis of a 80kW light-duty vehicle fuel cell power system which includes a fuel cell system, a hydrogen storage tank , and a hybrid NIMH battery pack.

We published various fuel cell vehicle powertrain configurations manufacturing cost analysis in the past years.

Approach Scope

5 2015 YY

Specifications 2012 FCS 2013 FCS 2014 FCS 2015 FCS

PEM fuel cell

system •65 kWe •80 kWe •80 kWe •80 kWe

On-board hydrogen

storage

-Compressed H2 -5,000 psi -Single tank -5.6 kg usable H2

-Compressed H2 -5,000 psi -Single tank -5.6 kg usable H2

-Cryo-compressed H2 -Single tank -10 kg usable H2

-Compressed H2 -10,000 psi -Two tanks -5.6 kg usable H2

Hybrid battery pack -Li-ion battery -16 kWh

-Li-ion battery -1.2 kWh

-Li-ion battery -1.2 kWh

-NiMH battery -1.6 kWh

Comments Plug-in hybrid fuel cell vehicle

hybrid fuel cell

vehicle

hybrid fuel cell

vehicle

hybrid fuel cell

vehicle

6

The 80 kWnet direct hydrogen PEM fuel cell system configuration is referenced in previous and current studies conducted by Argon National Laboratory (ANL).

PEMFC System 80 kWnet PEM Fuel Cell System Preliminary System Design

1. R. K. Ahluwalia, X. Wang, “Fuel cells systems analysis,” 2013 DOE Hydrogen and

Fuel Cells Program Review, Washington DC, May13-16, 2013.

80 kWnet Fuel Cell System Schematic1

Key Parameters Stack

• 3M NSTFC MEA

• 25 mm supported membrane

• 0.153 mg/cm2 Pt

• Power density: 834mW/cm2

• Metal bipolar plates

• Non-woven carbon fiber GDL

Air Management

• Honeywell type compressor

/expender

• Air-cooled motor / Air-foil bearing

Water Management

• Cathode planar membrane humidifier

with pre-cooler

• No anode humidifier

Thermal Management

• Micro-channel HX

Fuel Management

• Parallel ejectors

2015 YY

7

Based on ANL’s stack performance analysis, we make the following system and material assumptions for the cost estimation.

System Assumptions 80 kWnet PEM Fuel Cell System Preliminary Design

Stack Components Unit 2012 2013 2014 2015

Production volume systems/ye

ar 500,000 500,000 500,000 500,000

Stacks’ net power kW 65 80 80 80

Stacks’ gross power kW 72 88 89.4 88

Cell power density mW/cm2 930 984 692 834

Peak stack temp. Degree C 90 87 92.3 100

Peak stack pressure Bar 2.5 2.5 2.5 2.5

Cell Voltage Volt 0.67 0.676 0.695 0.67

System Voltage (rated

power) Volt 300 300 300 300

Platinum price $/tr.oz. $1,475 $1,100 $1,100 $2,000

Pt loading mg/cm2 0.15 0.196 0.153 0.153

Membrane type Reinforced Nafion® Reinforced 3M

PFSA

Reinforced 3M

PFSA

Reinforced 3M

PFSA

Membrane thickness micro meter 20 25 25 25

GDL layer None-woven carbon

paper

None-woven carbon

paper

None-woven

carbon paper

None-woven

carbon paper

GDL thickness micro meter 185 185 185 185

MPL layer thickness micro meter 40 40 40 40

Bipolar plate type

76Fe-20Cr-4V with

nitridation surface

treatment

76Fe-20Cr-4V with

nitridation surface

treatment

SS316L with

Treadstone

Coating

SS316L with

Treadstone

Coating

Bipolar plate base

material Thickness micro meter 100 100 100 100

Seal material Viton® Viton® Viton® Viton®

2015 YY

8

We use Pt price at $2,000/troz which is the similar to highest Pt price in the history.

System Assumptions 80 kWnet PEM Fuel Cell System Pt Price

2015 YY

2015 Study

Current Price

9

The 80 kWnet PEM fuel cell stack costs approximately $30/kW. Electrodes, bipolar plates, and seals are the top three cost drivers.

80 kWnet PEM Fuel Cell Stack Cost

($30/kWnet)

Stack

Components

2015 Stack

Cost ($/kW) Comments

Membrane $1.06 PFSA ionomer

($75/kg)

Electrode $15.37 Pt ($2,000/troz)

GDL $1.50 No-Woven carbon

paper

Bipolar Plate $7.16 Treadstone Coating

metallic plates

Seal $2.14 Viton

BOS $0.58

Manifold, end plates,

current collectors,

insulators, tie bolts,

etc.

Final Assembly $1.47 Robotic assembly

Stack

Conditioning 0.60 2 Hours

Total stack2 $29.88 1. Stack assembly cost category included MEA assembly and stack

QC; QC included visual inspection, and leak tests for fuel, air, and

coolant loops.

2. Results may not appear to calculate due to rounding of the

component cost results.

80 kWnet PEMFC System Stack Costs

2015 YY

4%

51%

5%

24%

7%

2%5% 2%

Membrane

Electrode

GDL

Bipolar Plate

Seal

BOS

Final Assembly

Stack Conditioning

10

80 kWnet PEM Fuel Cell System Cost

($4,742/system)

The 80 kWnet PEM fuel cell system costs $59/kW at the mass production volume. Stack, air management, and thermal management are the top three cost drivers.

System

Components

2015

System

Cost ($/kW)

Comments

Stack $29.9

Water

management $1.6

Cathode side

humidifier, etc.

Thermal

management $5.0

HX, coolant pump,

etc.

Air

management $10.1 CEM, etc.

Fuel

management $4.8 H2 pump, etc.

Balance of

system $3.9

Sensors, controls,

wire harness, piping,

etc.

System

assembly $3.9

Total system1, 2 $59.3

1. Assumed 15% markup to the automotive OEM for BOP components

2. Results may not appear to calculate due to rounding of the component cost

results.

80 kWnet PEMFC System System Costs

2015 YY

50%

3%8%

17%

8%

7%

7%

Stack

Water management

Thermal management

Air management

Fuel management

Balance of system

System assembly

11

The 700 bar compressed hydrogen tank design is referenced in studies TIAX conducted on hydrogen storage1.

700 bar Compressed Hydrogen Storage System Schematic1, 2

Key Parameters

System Volume

• CH2 storage: 5.6kg usable H2

• System pressure: 700 bar

• # of tanks: 2

Tank

• Carbon fiber: Toray T700S

• Carbon fiber / resin ratio: 0.68 : 0.32

(weight)

• Translational strength factor: 63%

• Safety factor: 2.25

• Al liner

• Glass fiber projection layer

Compressed H2 Storage System Configurations

2015 YY

Compressed

Gaseous

Hydrogen

Tank

Fill

System

Control

Module

Refueling

Interface

Hydrogen Line

to Fuel Supply Module**

Data & Comm. Line

to Fuel Cell Stack

Hydrogen Line

Data & Comm. Line

Filling

Station

Interface

Solenoid Valve

(Normally Closed)

Ball Valve

Primary

Pressure Regulator

Pressure

Relief

Device

Pre

ssu

re

Tra

nsd

ucer

Tem

pera

ture

Tra

nsd

ucer

Pressure

Relief

Valve

Check Valve

Check Valve

in Fill Port

In-Tank Regulator Compressed

Gaseous

Hydrogen

Tank

Solenoid Valve

(Normally Closed)

Ball Valve

Primary

Pressure Regulator

Pressure

Relief

Device

Pre

ssu

re

Tra

nsd

ucer

Tem

pera

ture

Tra

nsd

ucer Pressure

Relief

Valve

1. E. Carlson and Y. Yang, “Compressed hydrogen and PEM fuel

cell system,” Fuel cell tech team freedomCar, Detroit, MI,

October 20, 2004.

2. S. Lasher and Y. Yang, “Cost analysis of hydrogen storage

systems - Compressed Hydrogen On-Board Assessment –

Previous Results and Updates for FreedomCAR Tech Team”,

January , 2007

12

Assumptions for the hydrogen storage tank design were based on calculations, literature reviews, and third-party discussions.

Stack Components Unit Current System Comments

Production volume systems/year 500,000 High Volume

Usable hydrogen Kg 5.6

Recoverable H2 in the tank Kg 6.0

Tank type IV With Al liner

Tank pressure PSI 10,000

# of tanks Per System 2

Safety factor 2.25

Tank length/diameter ratio 3:1

Carbon fiber type Toray T700S

Carbon fiber cost $/lbs 12

Carbon fiber vs. resin ratio 0.68:0.32 Weight

Carbon fiber translational

Strength factor 63%

Damage resistant outer layer

material S-Glass

Could be replaced

by cheaper E-glass

S-Glass cost $/lbs 7

Impact resistant end dome

material Rigid Foam

Rigid foam cost $/kg 3

Liner material Al

Compressed H2 Storage System Specification

2015 YY

13

A vertically integrated manufacturing process was assumed for the tank and BOP components.

Spin

Rolling

Pressure

liner

Liner

Surface

Gel Coat

CF

Filament

Winding

Cure /

Cool

down

Ultrasonic

Inspection

Glass

Fiber

Out Layer

Winding

End

Domes

Assembly

Pressure

Test

Dimension

Weight

Inspection

Cure /

Cool

down

BOP

Assembly

Boss

Machining

Final

Inspection

Al

Stock

Al Carbon Fiber

Glass

Fiber

Rigid

Foam

BOP

Components

Gel

• In-tank primary pressure regulator

• Valves & sensors

• Filling interface

• Pressure release devices

• Piping & fitting

Major Tank Components Major BOP Components

• Aluminum End Boss

• Al liner

• Carbon fiber composite layer

• Glass fiber composite layer

• End domes (rigid foam)

Compressed H2 Storage System Manufacturing Process

2015YY

14

CH2 Storage System Cost ($3,794/system)

In the 700 bar compressed hydrogen storage system, the carbon fiber composite layers, in-tank regulators, system control valves are the top three cost drivers.

System Components

2015 CH2

Cost

($/kWh)

Liner $ 0.19

Carbon Fiber $ 12.47

Glass Fiber $ 0.85

Foam $ 0.26

Bosses $ 0.21

Regulator $ 2.68

Fill Port $ 0.54

Valves $ 1.61

Sensors $ 0.64

Pipe&Fitting $ 0.47

Assembly $ 0.24

Inspections $ 0.12

Misc $ 0.05

Total $ 20.33

Compressed H2 Storage System Cost

2015 YY

1%

62%

4%

1%1%

13%

3%

8%

3% 2%1%1%0%

Liner

Carbon Fiber

Glass Fiber

Foam

Bosses

Regulator

Fill Port

Valves

Sensors

Pipe&Fitting

15

A NiMH battery pack will provide hybridization of a fuel cell vehicle which improves fuel economy as well as having the function as a startup battery. There are 34 6.5Ah-7.2V NiMH battery modules in the battery pack.

2015 YY

Specifications

Battery pack voltage 245 V

Battery pack dimension 190 x 850 x 495

mm

Battery pack weight 52 kg

Battery pack energy 1.6 kWh

Number of NiMH battery modules in the

pack 34

NiMH battery module nominal voltage 7.2 V

NiMH battery module nominal capacity

6.5 Ah

NiMH battery module Output 1,350 W

Anode active material AB5

Cathode active material Ni(OH)2

http://afvsafetytraining.com/erg/Toyota-Camry-

HV-2007-11.pdf

http://www.peve.jp/en/product/np2/index.html

Battery Pack

Battery Module

PEMFC Hybrid Energy Storage Nickel Metal Hydride (NiMH) Battery Pack

16

The hybrid NiMH battery pack costs $611/kWh. Battery modules, battery management system, and sensors have higher cost contributions.

Battery System Cost ($611 /kWh)

The 1.6 kWh lithium-ion battery system cost $978 per pack at the mass production volume (500,000 packs/year).

Cost Category 2015 Pack Cost

($/kWh)

6.5 Ah modules $347

Module stack (w/o)

module $6

Battery management

system $91

Sensors, fuses, switches $70

Thermal management

system $28

Enclosure $32

Misc. $19

Assembly and Testing $17

Total ($/kWh) $611

2015 YY

PEMFC Hybrid Energy Storage Battery Pack Cost

57%

1%

15%

11%

5%

5%3% 3%

6.5 Ah modules

Module stack (w/o) module

Battery management system

Sensors, fuses, switches

Thermal management system

Enclosure

17

PEM fuel cell system, onboard hydrogen storage, and hybrid battery cost approximately $10,070 per vehicle.

• The mass production manufacturing cost of the 80 kWnet PEMFC stack is estimated to be $30/kW.

• The mass production OEM cost of the 80 kWnet PEMFC system is estimated to be $59/kW

• The 5.6 kg 2-tank compressed on-board hydrogen storage system is estimated to be $20/kWh at the mass production.

• The hybrid NiMH battery (1.6kWh) costs $978 per pack or $611/kWh.

2015 YY

Conclusion

Cost Category 2012 Pack Cost

($/pack)

2013 Pack Cost

($/pack)

2014 Pack

Cost ($/pack)

2015 Pack

Cost ($/pack)

80 kWe Fuel Cell $4,0301 $4,256 $4,713 $4,742

5.6 Kg Useable H2

Storage $3,058 $3,028 $4,5672 $3,794

Hybrid Battery Pack $4,4973 $1,034 $790 $978

Total: $11,585 $8,318 $10,070 $9,514

Comments FC-PHEV FC-HEV FC-HEV FC-HEV

1. 65kWe fuel cell system

2. 10 kg useable hydrogen.

3. 16 kWh li-ion battery pack

18

The PEM fuel cell middle size passenger vehicle purchase price is approximately $27,089 at the mass production volume.

Component Category

PEMFC

Hybrid

($/unit)

Comments

Glider Glider 7,000 Mid-size passenger vehicle

Power Chain

PEMFC 4,742 Bottom-up costing

H2 storage 3,794 Bottom-up costing

Battery system 978 Bottom-up costing

Traction motor1 1,200 Motor + controller + transmission

Power electric1 840 Battery charger, main inverter, DC/DC

converter, auxiliary inverter, etc

Power chain sub-

total 11,554

Total vehicle manufacturing cost 18,554

Markup2 46% Corporation cost & profit, dealer cost,

shipping cost, tax

Purchase price for consumer 27,089

1. The DOE advanced power electronics & electric motors (APEEM) team reported the power electronics cost

$7/kW and the motor cost $10/kW in 2012.

2. Automobile Industry Retail Price Equivalent and Indirect Cost Multipliers, EPA, 2009

2015 YY

Conclusion Vehicle Costs

19

Comparing a PEM FC vehicle with a middle size passenger electric vehicle which both have a drive range approximately 250 miles.

Conclusions Cost Comparing with Battery

2015 YY

EV Battery Pack Cost 80kWh EV Battery Pack

Cost ($)

80kW PEMFC System*

Cost ($)

$100 /kWh $8,000

$9,514

$150 /kWh $12,000

$200 /kWh $16,000

$250 /kWh $20,000

$300 /kWh $24,000

•* Includes an 80kWe PEMFC, a CH2 storage tank, and a 1.6 kWH NiMH battery

•** Assume the hydrogen to electricity efficiency is 50%

Energy (kWh) Total Energy (kWh) Cost ($/kWh)

EV battery 80kWh 80 kWh $100~300/kWh

PEMFC System* (Chemical

Energy + Electric Energy)

185 kWh (Chemical)

1.6 kWh (Electric) 186.6 kWh $51 /kWh

PEMFC System* (Converted

Chemical Energy** +

Electric Energy)

92.5 kWh (Converted

Chemical)

1.6 kWh (Electric)

94.1 kWh $101 /kWh

20

Thank You!

Contact: Yong Yang

Austin Power Engineering LLC

1 Cameron St, Wellesley, MA 02482

781-239-9988 978-263-0397

yang.yong@austinpowereng.com www.austinpowereng.com

2015 YY