Technical Report NREL/TP-560-41413 April 2007 Controlled Hydrogen Fleet and Infrastructure...

Technical ReportNREL/TP-560-41413

April 2007

Controlled Hydrogen Fleet and Infrastructure Demonstration and Validation Project

Spring 2007 Composite Data ProductsMarch 8, 2007

K. Wipke, S. Sprik, H. Thomas, and C. Welch

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3

Controlled Hydrogen Fleet and Infrastructure Demonstration and

Validation Project

Spring 2007 Composite Data Products

3/8/07

Keith Wipke, Sam Sprik, Holly Thomas, Cory Welch

4

Max Hrs Accumulated (1)(2) Avg Hrs Accumulated (1)(3)0

200

400

600

800

Tim

e (H

ou

rs)

DOE Learning Demonstration:Fuel Cell Stack Hours Accumulated Through 2006 Q4

Created: Feb-28-07 8:27 PM

(1) Range bars created using one data point for each OEM.(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.

CDP#1A: Learning Demo Fuel Cell Stack Hours Accumulated Through 2006 Q4

5

Projected Hours to 10% Voltage Degradation (1)(2)(3)0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2006 Target

2009 Target

Tim

e (H

ou

rs)

DOE Learning Demonstration Fuel Cell Stack Durability:Based on Data Through 2006 Q4

Max ProjectionAvg Projection


(1) 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.(2) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = average nominal projection. The shaded green bar represents an engineering judgment of the uncertainty due to data and methodology limitations. Projections will change as additional data are accumulated.(3) Projections based on limited accumulated stack hours to date. Average stack hours accumulated to-date range between 145 and 379. Maximum stack hours accumulated to-date range between 300 and 642.

CDP#1B: Projected Hours to 10% Stack Voltage Degradation

6

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2006 Target

2009 Target

Actual Operating Hours Accumulated To-Date Projected Hours to 10% Degradation

Max Hrs Accumulated (1)(2) Avg Hrs Accumulated (1)(3) Projection to 10% Degradation (4)(5)

Tim

e (H

ou

rs)

DOE Learning Demonstration Fuel Cell Stack Durability:Based on Data Through 2006 Q4

Max ProjectionAvg Projection


(1) Range bars created using one data point for each OEM.(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 green bar represents an engineering judgment of the uncertainty due to data and methodology limitations. Projections will change as additional data are accumulated.

CDP#1C: Hours Accumulated and Projected Hours to 10% Stack Voltage Degradation

7

Dyno Range (2) Window-Sticker Range (3) On-Road Range (4)(5)0

50

100

150

200

250

300

Veh

icle

Ran

ge

(mile

s)

Vehicle Range1

2015 Target2009 Target


(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.

CDP#2: Vehicle Range

8

Dyno (1) Window-Sticker (2) On-Road (3)(4)0

10

20

30

40

50

60

70

80

Fu

el E

con

om

y (m

iles/

kg H

2)

Fuel Economy


(3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.

(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).

(4) Calculated from on-road fuel cell stack current or mass flow readings.

CDP#6: Fuel Economy

9

0

10

20

30

40

50

60

70

All OEMs

Eff

icie

nc

y (

%)

Fuel Cell System1 Efficiency2 at ~25% Net Power.

DOE Target

Created: Aug-29-06 4:09 PM

1 Gross stack power minus fuel cell system auxiliaries, per DRAFT SAEJ2615.

2 Ratio of DC output energy to the lower heating value of the input fuel (hydrogen).Excludes power electronics and electric drive.

CDP#8: FC System Efficiency

10

CDP#9: Safety Incidents – Vehicles

Safety Incidents - Vehicle Operation

0

5

10

15

20

25

30

35

40

45

50

2005

Q2

2005

Q3

2005

Q4

2006

Q1

2006

Q2

2006

Q3

2006

Q4

Nu

mb

er o

f In

cid

ents

H2 Leak - During FuelingH2 Alarm - StackH2 Alarm - Fuel SystemH2 Alarm - Passenger Compartment

Created: 2/28/07 8:45AM

11

CDP#10: Storage Weight % Hydrogen

0

1

2

3

4

5

6

7

8

9

All OEMs

We

igh

t P

erc

en

t H

yd

rog

en

(%

)

Weight Percent Hydrogen

2015 DOE MYPP Target1



Created: 23-Feb-20061Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based technologies.

12

CDP#11: Volumetric Capacity of H2Storage

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

All OEMs

Ma

ss

H2

pe

r L

ite

r (k

g/L

)

Mass of Hydrogen Per Liter




Created: 23-Feb-20061Emphasis is on advanced materials-based technologies.

13

CDP#12: Vehicle Hydrogen Tank Cycle Life

0

2000

4000

6000

8000

10000

12000

All OEMs

Nu

mb

er

of

cy

cle

s

Hydrogen Tank Cycle Life




Created: 23-Feb-20061Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based technologies.

14

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20

102030405060708090

100110120130140150160170180190200210220230240250260270

Avg Fuel Rate (kg/min)

Nu

mb

er o

f F

uel

ing

Eve

nts

Histogram of Fueling RatesAll Light Duty Through 2006Q4

5 minute fill of5 kg at 350 bar

3 minute fill of5 kg at 350 bar

2006 Tech Val Milestone2010 MYPP Adv Storage Materials Target


CDP#18: Refueling Rates

15

CDP#20: Safety Incidents – Infrastructure

Total Infrastructure Safety Events by Severity and Event Type Through 2006 Q4

0

5

10

15

20

25

30

35

40

45

50

55

60

65

Non-Event Near Miss Incident

Severity

Nu

mb

er o

f E

ven

ts

H2 Release - Significant, NO Ignition

Electrical Issue

Non-H2 Release

Automatic System Shutdown

Equipment Malfunction

Alarms Only

H2 Release - Minor, NO Ignition

Created 07-Mar-2007

16

-30

-20

-10

0

10

20

30

40

50

60

Deg

rees

Cel

siu

s

Ambient Temperature During Operation

All OEMs

Created: Mar-07-07 3:35 PM

CDP#21: Range of Ambient TemperatureDuring Vehicle Operation

17

CDP#22: Vehicle Operating Hours

Vehicle Hours: All OEMs Combined

0

2

4

6

8

10

12

14

16

18

0-10

0

100-

200

200-

300

300-

400

400-

500

500-

600

600-

700

700-

800

800-

900

>900

Total Vehicle Hours

Nu

mb

er o

f V

ehic

les

Through Q4 2006

Created: 28-Feb-07

Total Vehicle Hours = 28,545

Through Q4 2006

Vehicle Hours: All OEMs Combined

0

2

4

6

8

10

12

14

16

18

0-10

0

100-

200

200-

300

300-

400

400-

500

500-

600

600-

700

700-

800

800-

900

>900

Total Vehicle Hours

Nu

mb

er o

f V

ehic

les

Through Q4 2006

Created: 28-Feb-07

Total Vehicle Hours = 28,545

Through Q4 2006

18

CDP#23: Vehicles vs. Miles Traveled

Vehicle Miles: All OEMs Combined

0

2

4

6

8

10

12

14

0-20

00

2000

-400

0

4000

-600

0

6000

-800

0

8000

-100

00

1000

0-12

000

1200

0-14

000

1400

0-16

000

1600

0-18

000

>1800

0

Total Vehicle Miles

Nu

mb

er o

f V

ehic

les

Total Miles Traveled = 573,064

Through Q4 2006

Created: 28-Feb-07

19

CDP#24: Cumulative Vehicle Miles Traveled

Cumulative Vehicle Miles Traveled: All OEMs

-

100,000

200,000

300,000

400,000

500,000

600,000

700,000

2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2006Q3 2006Q4

Veh

icle

Mile

s T

rave

led

Created: 28-Feb-07

20

CDP#25: Vehicle H2 Storage Technologies

On-Board Hydrogen Storage Methods

-

10

20

30

40

50

60

70

80

2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2006Q3 2006Q4

# o

f V

eh

icle

s (

All

Te

am

s)

Liquid H2

10,000 psi tanks

5,000 psi tanks

Created Feb-28-2007

21

Cumulative Hydrogen Produced or Dispensed

0123456789

10111213141516171819202122

Q2 2005 Q3 2005 Q4 2005 Q1 2006 Q2 2006 Q3 2006 Q4 2006

Calendar Quarter

Mas

s o

f H

ydro

gen

(kg

) (t

ho

usa

nd

s)

Created 20-Feb-2007

CDP#26: Cumulative H2 Produced or Dispensed

22

CDP#27: Hydrogen Purity Scatter Plot

99.7399.7499.7599.7699.7799.7899.7999.8

99.8199.8299.8399.8499.8599.8699.8799.8899.8999.9

99.9199.9299.9399.9499.9599.9699.9799.9899.99

100

Hyd

rog

en F

uel

Qu

alit

y In

dex

(%

)

Hydrogen Fuel Quality Index Sampled from Stations(1)

Data RangeDataSAE J2719

Created: Feb-28-07 12:06 PM(1) Includes sampling from both electrolysis and reforming

23

0 1 2 3 4 5 6 7 8 9 10

Particulates

g/L

H2 Impurities

Data Range SAE J2719 Measured Less Than or Equal To (Detection Limited)

0 500 1000 1500 2000 2500 3000

(N2 + He + Ar)

0 5 10 15 20 25 30 35 40

H20 Total HC

O2 CO2 CO

NH3

mol/mol (ppm)

0 10 20 30 40 50 60 70 80 90 100

Total S*

nmol/mol (ppb)Created: Feb-28-07 12:06 PM *Calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

CDP #28: Hydrogen Impurities Scatter Plot

24

CDP#30: Infrastructure Maintenance

0 20 40 60 80 100 120 140 160 180 200

AdjustmentCheck Only

OtherRepair

Replacement

Maintenance: Average Labor Hours Per Station Since Inception

ScheduledUn-Scheduled

0 5 10 15 20 25 30

AdjustmentCheck Only

OtherRepair

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


25

CDP#31: Number of Reporting Stations

Online Stations

0

2

4

6

8

10

12

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2 2006 Q3 2006 Q4

Reporting Period

Nu

mb

er o

f S

tati

on

s

Created 20-Feb-2007

26

CDP#32: Infrastructure Hydrogen Production Methods

Infrastructure Hydrogen Production Methods

0

1

2

3

4

5

DeliveredCompressed H2

Natural Gas On-site Reforming

Electrolysis Delivered LiquidH2

Production Technology

# o

f S

tati

on

s

Created 07-Mar-2007

27

0 10 20 30 40 50 60 70 80 90 1000

10

20

30

40

50

60

70

80

90

100Range Histogram: All OEMs

Percentage of chassis dyno range1 b/w refuelings

Per

cen

tag

e o

f re

fuel

ing

s

PercentageCumulative Percentage


Total refuelings2 = 5480

1. Range calculated using the combined City/Hwy fuel economy from dyno testing (not EPA adjusted) and usable fuel on board.

2. Some refueling events are not detected/reported due to data noise or incompleteness.

CDP#33: Percentage of Theoretical Range Traveled Between Refuelings

28

0 10 20 30 40 50 60 70 80 90 100

Vehicle Range Factors

Percentage of chassis dyno range1.

All

OE

Ms

Win

do

w-S

tick

er 2

On

-Ro

ad 3

Dyn

o 1


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).3. Using fuel economy from on-road data (excluding trips > 1 mile, consistent with other data products).

CDP#34: Effective Vehicle Range

29

Infrastructure Safety Trend and Online Stations

11 10

20

31

104

110

94

0

2

4

6

8

10

12

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2 2006 Q3 2006 Q4

Reporting Period

Nu

mb

er o

f S

tati

on

s

0

20

40

60

80

100

120

Nu

mb

er

of

Re

fue

lin

gs

Number of Online Stations

Average Refuelings Between SafetyEvents

Created 28-Feb-2007

CDP#35: Average Refuelings Between Infrastructure Safety Events

30

CDP#36: Type of Infrastructure Safety Event By Quarter

Type of Infrastructure Safety Event by Quarter Through 2006 Q4

0

2

4

6

8

10

12

14

16

18

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2 2006 Q3 2006 Q4

Reporting Period

Nu

mb

er o

f E

ven

ts

IncidentNear MissNon-EventStations OnlineAverage # Events/Station

Created 07-Mar-2007

31

CDP#37: Primary Factors of Infrastructure Safety Events

Primary Factors of Infrastructure Safety Events Through 2006 Q4

0 10 20 30 40 50 60 70

Total Non-Events

Total Near Miss

Total Incidents

Sev

erit

y

Number Of Events

Calibration/Settings/ Software Controls

Environment (Weather, Power Disruption, Other)

Inadequate/ Non-working Equipment

Not Yet Determined

Mischief, Vandalism, Sabotage

Maintenance Required

Design Flaw

Operator/Personnel Error

Created 07-Mar-2007

32

CDP#38: Refueling Times

0 2 4 6 8 10 12 14 16 18 200

102030405060708090

100110120130140150160170180190200210220230240250

Time (min)

Nu

mb

er o

f F

uel

ing

Eve

nts

Histogram of Fueling TimesAll Light Duty Through 2006Q4


>

33

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 50

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

Amount Fueled (kg)

Nu

mb

er o

f F

uel

ing

Eve

nts

Histogram of Fueling AmountsAll Light Duty Through 2006Q4


CDP#39: Refueling Amounts

Technical Report NREL/TP-560-41413 April 2007 Controlled Hydrogen Fleet and Infrastructure...

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