1 technical report nrel/tp-560-45451 march 2009 controlled hydrogen fleet infrastructure...
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1
Technical ReportNREL/TP-560-45451
March 2009
Controlled Hydrogen Fleet InfrastructureDemonstration and Validation Project
Spring 2009
Composite Data ProductsFinal Version March 13, 2009
Keith Wipke, Sam Sprik, Jennifer Kurtz, and Todd Ramsden
2
Disclaimer and Government License
This work has been authored by Midwest Research Institute (MRI) under Contract No. DE-AC36-99GO10337 with the U.S. Department of Energy (the “DOE”). The United States
Government (the “Government”) retains and the publisher, by accepting the work for publication, acknowledges that the Government retains a non-exclusive, paid-up, irrevocable,
worldwide license to publish or reproduce the published form of this work, or allow others to do so, for Government purposes.
Neither MRI, the DOE, the Government, nor any other agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any 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 any privately owned rights.
Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not constitute or imply its endorsement,
recommendation, or favoring by the Government or any agency thereof. The views and opinions of the authors and/or presenters expressed herein do not necessarily state or reflect
those of MRI, the DOE, the Government, or any agency thereof.
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
Spring 2009Composite Data Products
March 13, 2009
Keith Wipke, Sam Sprik, Jennifer Kurtz, Todd Ramsden
Controlled Hydrogen Fleet and Infrastructure Demonstration and Validation Project
National Renewable Energy Laboratory 4 Innovation for Our Energy Future
CDP#1: Hours Accumulated and Projected Hours to 10% Stack Voltage Degradation
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)(6)
Tim
e (H
ou
rs)
DOE Learning Demonstration Fuel Cell Stack Durability:Based on Data Through 2008 Q4
Max ProjectionAvg Projection
Created: Feb-24-09 1:21 PM
(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 green bar 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 2008 Q2 data.
National Renewable Energy Laboratory 5 Innovation for Our Energy Future
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 Gen 1 Gen 2
Created: Mar-03-09 10:56 AM
(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
National Renewable Energy Laboratory 6 Innovation for Our Energy Future
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
Gen 1 Gen 2
Created: Mar-03-09 10:57 AM
(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.
CDP#6: Fuel Economy
National Renewable Energy Laboratory 7 Innovation for Our Energy Future
0
5
10
15
20
25
Op
erat
ing
Tim
e [%
]
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 timeTime at low current
Created: Feb-26-09 5:56 PM
CDP#7: Fuel Cell Voltage
National Renewable Energy Laboratory 8 Innovation for Our Energy Future
CDP#8: FC System Efficiency
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.
National Renewable Energy Laboratory 9 Innovation for Our Energy Future
0
1
2
3
Nu
mb
er
of
Re
po
rts
Safety Reports - Vehicle Operation
Tank ScratchTraffic AccidentH2 Leak - During FuelingH2 Alarm - Fuel SystemH2 Alarm - Passenger Compartment
Created: Mar-02-09 8:46 AM
CDP#9: Safety Reports – Vehicles
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
Wei
gh
t P
erce
nt
Hyd
rog
en (
%)
Weight Percent Hydrogen
2015 DOE MYPP Target1
2010 DOE MYPP Target1
2007 DOE MYPP Target1
Created: Aug-19-08 11:39 AM1Targets 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
Mas
s H
2 p
er L
iter
(kg
/L)
Mass of Hydrogen Per Liter
2015 DOE MYPP Target1
2010 DOE MYPP Target1
2007 DOE MYPP Target1
Created: Aug-19-08 11:39 AM1Targets 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 o
f cy
cles
Hydrogen Tank Cycle Life1
All OEMs
2015 DOE MYPP Target2
2010 DOE MYPP Target2
2007 DOE MYPP Target2
Gen 1 Gen 2
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
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
ctio
n E
ffic
ien
cy (
LH
V %
)
Hydrogen Production Conversion Efficiency1
Average Station Efficiency
Quarterly Efficiency Data
Highest Quarterly Efficiency
Efficiency Probability Distribution2
Created: Feb-26-09 2:26 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 productionprocess from the feedstock and all other energy as needed. Conversion efficiency does not include energy 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 datafrom the Learning Demonstration.
CDP#13: On-Site Hydrogen Production Efficiency
National Renewable Energy Laboratory 14 Innovation for Our Energy Future
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
2000
Avg Fuel Rate (kg/min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling Rates350 vs 700bar Fills - All Light Duty Through 2008Q4
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
Fill Type Avg (kg/min) %>1 Count------------- ------------------ ------- --------350 bar 0.81 27% 14375700 bar 0.59 3% 2033
350 bar700 bar2006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone
Created: Mar-09-09 3:38 PM
CDP#14: Fueling Rates – 350 and 700 bar
National Renewable Energy Laboratory 15 Innovation for Our Energy Future
0-1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 >80
5
10
15
20
25
30
35Segmented Trips/Hour Histogram: DOE Fleet
Trips/Hour*
Fre
qu
ency
[%
]
*Trips/Hour based on 50 hour segmentsspanning stack operating period
Created: Mar-09-09 9:46 AM
CDP#16: Fuel Cell Stack Trips Per Hour Histogram
National Renewable Energy Laboratory 16 Innovation for Our Energy Future
1
2
3
4
5
6
7
8
9
0-250 250-500 500-750 750-1000 1000-1250 1250-1500 1500-1750 1750-2000Stack Op Hour Groups
Tri
ps/
Ho
ur*
Statistics of Trips/Hour vs Operating Hour: DOE Fleet
*Trips/Hour based on 50 hour segmentsspanning stack operating period
Data Range25th & 75th PercentilesGroup MedianOutlier
Created: Mar-09-09 9:46 AM
CDP#17: Statistics of Trips/Hour vs. Operating Hour
National Renewable Energy Laboratory 17 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
100
200
300
400
500
600
700
800
900
1000
1100
Avg Fuel Rate (kg/min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling RatesAll Light Duty Through 2008Q4
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
16623 EventsAverage = 0.78 kg/min
24% >1 kg/min
2006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone
Created: Feb-25-09 5:24 PM
National Renewable Energy Laboratory 18 Innovation for Our Energy Future
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
Created: Feb-26-09 5:56 PM
CDP#19: Time Between Trips & Ambient Temperature
National Renewable Energy Laboratory 19 Innovation for Our Energy Future
CDP#20: Safety Reports – Infrastructure
0 50 100 150 200 250
Non-Event
Near Miss
Incident
Number of Reports
Sev
erit
y
Total Infrastructure Safety Reports by Severityand Report Type Through 2008 Q4
Alarms OnlyAutomatic System ShutdownElectrical IssueEquipment MalfunctionFalse Alarm/MischiefH2 Release - Minor, NO IgnitionH2 Release - Significant, NO IgnitionManual System ShutdownNon-H2 ReleaseSite Power OutageStructural IssueSystem Trouble, not Alarm
Created: Feb-27-09 8:16 AM
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 20 Innovation for Our Energy Future
0 2 4 6 8 10 12-30
-20
-10
0
10
20
30
40
50
60
1.1 % trips below 0 oC
Max Op = 140.0 oF
Min Op = -2.2 oF
29.6 % trips above 28 oC
Trip Frequency [%]
Tem
per
atu
re [
oC
]
Average Ambient Trip Temperature: DOE Fleet
Created: Feb-26-09 5:56 PM
CDP#21: Range of Ambient TemperatureDuring Vehicle Operation
National Renewable Energy Laboratory 21 Innovation for Our Energy Future
0
5
10
15
20
25
30
35
Nu
mb
er o
f V
ehic
les
Total Vehicle Hours
Vehicle Hours: All OEMs, Gen 1 and Gen 2
In Service
Retired
85,244Total Vehicle Hours =
Through 2008 Q4
Created: Mar-02-09 04:13 PM
CDP#22: Vehicle Operating Hours
National Renewable Energy Laboratory 22 Innovation for Our Energy Future
0
5
10
15
20
25
30
35
40
Nu
mb
er o
f V
ehic
les
Total Vehicle Miles
Vehicle Miles: All OEMs Combined, Gen 1 and 2
In Service
Retired
Total Vehicle Miles Traveled = 1,924,869
Through 2008 Q4
Created: Mar-02-09 04:13 PM
CDP#23: Vehicles vs. Miles Traveled
National Renewable Energy Laboratory 23 Innovation for Our Energy Future
1,924,869
-
250,000
500,000
750,000
1,000,000
1,250,000
1,500,000
1,750,000
2,000,000
2,250,000
Ve
hic
le M
iles
Tra
ve
led
Cumulative Vehicle Miles: All OEMs, Gen 1 and Gen 2
Created: Mar-02-09 04:03 PM
Through 2008 Q4
CDP#24: Cumulative Vehicle Miles Traveled
National Renewable Energy Laboratory 24 Innovation for Our Energy Future
71
48
-
20
40
60
80
100
120
140
160
Cu
mu
lati
ve V
eh
icle
s D
ep
loye
d/R
eti
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
Created Feb-23-2009 1:20 PM (1) Retired vehicles have left DOE fleet and are no longer providing data to NREL Created Feb-27-2009 9:10 AM
140
(1) Retired vehicles have left DOE fleet and are no longer providing data to NREL
CDP#25: Vehicle H2 Storage Technologies
National Renewable Energy Laboratory 25 Innovation for Our Energy Future
0
5
10
15
20
0
10
20
30
40
50
60
70
80
90
100
Nu
mb
er o
f Sta
tio
ns
Mas
s o
f H
ydro
gen
(1
000
kg)
Calendar Quarter
Cumulative Hydrogen Produced or Dispensed Through 2008 Q4
Cumulative Hydrogen
Number of Stations
Created 2009-Mar-06 3:48 pm
CDP#26: Cumulative H2 Produced or Dispensed
National Renewable Energy Laboratory 26 Innovation for Our Energy Future
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
Cal
cula
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 GuidelineCalculated Data
Created: Feb-25-09 1:17 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4
CDP#27: Hydrogen Quality Index
National Renewable Energy Laboratory 27 Innovation for Our Energy Future
0 1 2 3 4 5 6 7 8 9 10
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)Created: Feb-25-09 1:23 PM Data is from Learning Demonstration and California Fuel Cell Partnership testing
*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).
CDP#28: Hydrogen Fuel Constituents
National Renewable Energy Laboratory 28 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.0
1
2
3
4
5
6
NH
3 (
mo
l/mo
l)(p
pm
)
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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. 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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
500
1000
1500
2000
2500
Ar+
N2 (
mo
l/mo
l)(p
pm
)
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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
500
1000
1500
2000
2500
3000
Cal
cult
ated
To
tal I
mp
uri
ties
( m
ol/m
ol)
(pp
m)
Calcultated Total Impurities (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 GuidelineCalculated Data
Created: Feb-25-09 1:17 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
1
2
3
4
5
6
7
8
9
CO
2 ( m
ol/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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
0.2
0.4
0.6
0.8
1
CO
( m
ol/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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
0.02
0.04
0.06
0.08
0.1
Fo
rmal
deh
yde
(m
ol/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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
0.05
0.1
0.15
0.2
Fo
rmic
aci
d (
mo
l/mo
l)(p
pm
)
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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
5
10
15
H2O
( m
ol/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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:17 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
50
100
150
200
250
300
He
(m
ol/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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
5000
10000
15000
20000
25000
30000
Par
ticu
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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. 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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
500
1000
1500
2000
2500
N2 (
mo
l/mo
l)(p
pm
)
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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
5
10
15
20
25
30
35
40
O2(
mo
l/mo
l)(p
pm
)
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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
1
2
3
4
5
6
7
8
9
10
11
Par
ticu
late
Co
nce
ntr
atio
n (
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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
5
10
15
20
25
To
tal H
alo
gen
ates
( m
ol/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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
0.5
1
1.5
2
To
tal H
C ( m
ol/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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4
Year 1 Year 2 Year 3 Year 4Ref. 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/mo
l)(p
pb
)
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 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Feb-25-09 1:18 PM
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, and Year 4 is 2008Q3-2008Q4*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).
Year 1 Year 2 Year 3 Year 4
(This slide contains 18 graphs (1 for each constituent): view in slide-show mode)
National Renewable Energy Laboratory 29 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
200
400
600
800
1000
1200
Avg Fuel Rate (kg/min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling RatesComm vs Non-Comm Fills - All Light Duty Through 2008Q4
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
Fill Type Avg (kg/min) %>1 ------------- ------------------ -------Comm 0.88 32%Non-Comm 0.65 15%
CommNon-Comm2006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone
Created: Feb-25-09 4:26 PM
National Renewable Energy Laboratory 30 Innovation for Our Energy Future
0 20 40 60 80 100 120 140 160 180
AdjustmentCheck Only
OtherRepair
Replacement
Maintenance: Average Labor Hours Per Station Since InceptionThrough 2008 Q4
ScheduledUn-Scheduled
0 5 10 15 20 25 30 35
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
Created: Feb-25-09 7:45 AM
CDP#30: Infrastructure Maintenance
National Renewable Energy Laboratory 31 Innovation for Our Energy Future
0
5
10
15
20
25
Nu
mb
er
of
Sta
tio
ns
Reporting Period
Online Stations
Existing Stations
Retired Stations
Created Feb-26-09 10:09am
CDP#31: Number of Online Stations
National Renewable Energy Laboratory 32 Innovation for Our Energy Future
0
1
2
3
4
5
6
7
8
Delivered Compressed H2
Natural Gas On-site Reforming
Electrolysis Delivered Liquid H2
# o
f S
tati
on
s
Production Technology
Infrastructure Hydrogen Production Methods
Existing Stations
Retired Stations
Created Feb-26-09 10:09am
CDP#32: Infrastructure Hydrogen Production Methods
National Renewable Energy Laboratory 33 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
12Range Histogram: All OEMs
Percentage of chassis dyno range1 b/w refuelings
Per
cen
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
erce
nta
ge
Created: Feb-20-09 12:25 PM
Total refuelings2 = 18799
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 34 Innovation for Our Energy Future
0 10 20 30 40 50 60 70 80 90 100
Gen1
Gen2
Vehicle Range Factors
Percentage of chassis dyno range1.
All
OE
Ms W
ind
ow
-Sti
cker
2 W
ind
ow
-Sti
cker
2
On
-Ro
ad 3
On
-Ro
ad 3
Dyn
o 1
Created: Mar-03-09 11:23 AM
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).
CDP#34: Effective Vehicle Range
National Renewable Energy Laboratory 35 Innovation for Our Energy Future
05Q2 05Q3 05Q4 06Q1 06Q2 06Q3 06Q4 07Q1 07Q2 07Q3 07Q4 08Q1 08Q2 08Q3 08Q40
2
4
6
8
10
12
14
16
18
20
22
Reporting Period
Nu
mb
er o
f S
tati
on
s
Infrastructure Safety Trend and Online Stations Through 2008 Q4
Number of Online StationsAvg Refuelings Between Safety Reports
Created: Feb-27-09 8:18 AM
0
20
40
60
80
100
120
140
160
180
200
Avg
# o
f R
efu
elin
gs
Bet
wee
n S
afet
y R
epo
rts
711
32 34
88
102
117
47
68
124
100
5651
73
49
CDP#35: Average Refuelings Between Infrastructure Safety Reports
National Renewable Energy Laboratory 36 Innovation for Our Energy Future
05Q2 05Q3 05Q4 06Q1 06Q2 06Q3 06Q4 07Q1 07Q2 07Q3 07Q4 08Q1 08Q2 08Q3 08Q40
5
10
15
20
25
30
35
40
45
50
Reporting Period
Nu
mb
er o
f R
epo
rts
Type of Infrastructure Safety Reports by Quarter Through 2008 Q4
IncidentNear MissNon-EventStations OnlineAvg # Reports/Station
Created: Feb-27-09 8:18 AM
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
CDP#36: Type of Infrastructure Safety Report By Quarter
National Renewable Energy Laboratory 37 Innovation for Our Energy Future
0 50 100 150 200 250
Non-Event
Near Miss
Incident
Number of Reports
Sev
erit
y
Primary Factors of Infrastructure Safety ReportsThrough 2008 Q4
Calibration/Settings/ Software ControlsDesign FlawElectrical Power to SiteEnvironment (Weather, Power Disruption, Other)False AlarmInadequate Training, Protocol, SOPInadequate/ Non-working EquipmentMaintenance RequiredMischief, Vandalism, SabotageNew Equipment MaterialsNot Yet DeterminedOperator/Personnel ErrorSystem Manually Shutdown
Created: Feb-27-09 8:16 AM
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
CDP#37: Primary Factors of Infrastructure Safety Reports
National Renewable Energy Laboratory 38 Innovation for Our Energy Future
0 2 4 6 8 10 12 14 16 18 200
500
1000
1500
2000
2500
Time (min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling TimesAll Light Duty Through 2008Q4
Average = 3.30 min87% <5 min
2006 MYPP Tech Val Milestone (5 kg in 5 min at 350 bar) 2012 MYPP Tech Val Milestone (5 kg in 3 min at 350 bar)
Created: Mar-02-09 8:43 AM
CDP#38: Refueling Times
National Renewable Energy Laboratory 39 Innovation for Our Energy Future
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 50
100
200
300
400
500
600
Amount Fueled (kg)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling AmountsAll Light Duty Through 2008Q4
Average = 2.18 kg
Created: Feb-25-09 5:24 PM
CDP#39: Refueling Amounts
National Renewable Energy Laboratory 40 Innovation for Our Energy Future
CDP#40: H2 Tank Level at Refueling
Tank Levels: DOE Fleet
14%
FE
Created: Feb-20-09 12:37 PM
Total refuelings1 = 20639
1. Some refueling events not recorded/detected due to data noise or incompleteness.
Median Tank Level (At Fill) = 40%
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.
National Renewable Energy Laboratory 41 Innovation for Our Energy Future
CDP#41: Refueling Tank Levels - Medians
FE
Tank Level Medians (At Fill): DOE Fleet, All Vehicles
Created: Feb-20-09 12:37 PM
Total refuelings1 = 20639
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 42 Innovation for Our Energy Future
CDP#42: Refueling by Time of Day
Refueling by Time of Day: DOE Fleet
10%
3
12
9
6
Total Fill3 Events = 17237% of fills b/t 6 AM & 6 PM: 91.1%
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
Created: Feb-20-09 12:37 PM
National Renewable Energy Laboratory 43 Innovation for Our Energy Future
CDP#43: Refueling by Day of Week
Sun Mon Tues Wed Thur Fri Sat0
5
10
15
20
Fills by Day of Week: DOE Fleet
% o
f F
ills
in a
Day
DayCreated: Feb-20-09 12:38 PM
National Renewable Energy Laboratory 44 Innovation for Our Energy Future
Driving Start Time - Day: DOE Fleet
9%
3
12
9
6
Total Driving3 Events = 224309% of driving trips b/t 6 AM & 6 PM: 86.9%
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
% of NHTS trips b/t 6 AM & 6 PM: 81.5%
DOE FleetNHTS
Created: Feb-26-09 6:21 PM
2001 NHTS Data Includes Car, Truck, Van, & SUV day trips ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#44: Driving Start Time – Day
National Renewable Energy Laboratory 45 Innovation for Our Energy Future
Sun Mon Tues Wed Thur Fri Sat0
2
4
6
8
10
12
14
16
18
20
Driving Trips by Day of Week: DOE Fleet
% o
f D
rivi
ng
Tri
ps
in a
Day
Day
DOE FleetNHTS
Created: Feb-26-09 6:21 PM
2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#45: Driving by Day of Week
National Renewable Energy Laboratory 46 Innovation for Our Energy Future
0
5
10
15
20
25
30
35
40
45
Time at Fuel Cell Stack Power Levels: DOE Fleet
Op
erat
ing
Tim
e [%
]
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 timeTime with 0 speed
Created: Feb-26-09 6:27 PM
CDP#46: Fuel Cell System Operating Power
National Renewable Energy Laboratory 47 Innovation for Our Energy Future
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 FleetNHTS
Created: Feb-26-09 6:11 PM
2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#47: Trip Length
National Renewable Energy Laboratory 48 Innovation for Our Energy Future
CDP#48: Primary Factors Affecting Learning Demo Fleet Fuel Cell Degradation
DOE Fleet
High Current TimeHot StartsStarts/hour
Low Voltage TimeHigh Voltage Time
Cold StartsShort Trips
0 Speed TripsHot 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 stacksL**: 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.
DOE Fleet
High Current TimeHot StartsStarts/hour
Low Voltage TimeHigh Voltage Time
Cold StartsShort Trips
0 Speed TripsHot 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 stacksL**: 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.
National Renewable Energy Laboratory 49 Innovation for Our Energy Future
CDP#49: Primary Factors Affecting Learning Demo Team Fuel Cell Degradation
Team 1
High Voltage TimeLow Current Time
Short TripsLow Speed
Team 2
Team 3
Team 4
Low Current TimeLong Trips
Warm Ambient TempZero Speed
Current Transients
High Voltage TimeLow Current Time
Short TripsLow 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/HourZero SpeedShort Trips
Low Voltage TimeHigh Current TimeCurrent Transients
Cold StartsHot 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
National Renewable Energy Laboratory 50 Innovation for Our Energy Future
CDP#50: Refueling by Time of Night
Refueling by Time of Night: DOE Fleet
3%
3
12
9
6
Total Fill3 Events = 17237% of fills b/t 6 PM & 6 AM: 8.9%
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
Created: Feb-20-09 12:38 PM
National Renewable Energy Laboratory 51 Innovation for Our Energy Future
Driving Start Time - Night: DOE Fleet
3%
3
12
9
6
Total Driving3 Events = 224309% of driving trips b/t 6 PM & 6 AM: 13.1%
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%
DOE FleetNHTS
Created: Feb-26-09 6:21 PM
2001 NHTS Data Includes Car, Truck, Van, & SUV day trips ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#51: Driving Start Time – Night
National Renewable Energy Laboratory 52 Innovation for Our Energy Future
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
50
100
150
200
250
300
350
400
450
Avg Fuel Rate (kg/min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling RatesAll Light Duty by Year Through 2008Q4
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
Year Avg (kg/min) %>1 ------- ----------------- -------2005 0.66 16%2006 0.74 21%2007 0.81 26%2008 0.78 24%
20052006200720082006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone
Created: Feb-25-09 5:24 PM
CDP#52: Refueling Data by Year
National Renewable Energy Laboratory 53 Innovation for Our Energy Future
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
Created: Feb-26-09 6:12 PM
CDP#53: Fuel Cell System Energy within Power Levels
National Renewable Energy Laboratory 54 Innovation for Our Energy Future
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
Created: Feb-26-09 5:56 PM
CDP#54: Time Between Trips
National Renewable Energy Laboratory 55 Innovation for Our Energy Future
<-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
BatteryVehicle MotorFC
Created: Feb-26-09 6:12 PM
CDP#55: Fuel Cell System Energy
National Renewable Energy Laboratory 56 Innovation for Our Energy Future
0 5 10 15 20 25 30 35 400
5
10
15
20
25
Tri
p F
req
uen
cy [
%]
Daily Distance [miles]
Daily Distance: DOE Fleet
DOE FleetNHTS
Created: Feb-26-09 6:12 PM
Cumulative Frequency@ 20 miles
DOE Fleet: 49.6%NHTS: 27.2%
Cumulative Frequency@ 40 miles
DOE Fleet: 69.1%NHTS: 52.9%
2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#56: Daily Driving Distance
National Renewable Energy Laboratory 57 Innovation for Our Energy Future
CDP#57: H2 Storage System Mass and Volume Breakdown
Average Breakout of H2 Storage System Volume
73%
24%
3%
Average Breakout of H2 Storage System Mass
3.26%
23%
73%
9%
35% 56%
H2 Volume (%)Pressure Vessel Volume (%)Balance of Plant Volume (%)
72%
3.33%
24%
H2 Mass (%)Pressure Vessel Mass (%)Balance of Plant Mass (%)
Created: Aug-19-08 9:14 AM
350 bar
700 bar
National Renewable Energy Laboratory 58 Innovation for Our Energy Future
CDP#58: Fuel Cell System Power Density
0
100
200
300
400
500
600
700
Po
wer
Den
sity
(W
/L)
FC System Power Density (W/L)
2010 and 2015 DOE MYPP Target1 Gen 1 Gen 2
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 59 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
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 60 Innovation for Our Energy Future
0 10 20 30 40 50 60 70 80 90 1000
10
20
30
40
50
60
70
Production Capacity Utilization1 [%]
Pro
du
ctio
n C
on
vers
ion
Eff
icie
ncy
2 [%
]
Monthly Production Conversion Efficiency vs Utilization
Electrolysis Data
Electrolysis Fit3
Electrolysis Fit ConfidenceNatural Gas Data
Natural Gas Fit3
Natural Gas Fit Confidence
Created: Mar-02-09 9:09 AM
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 = 0.87) & low correlation with natural gas data (R2 = 0.018)
CDP#60: On-Site Hydrogen Production Efficiency vs. Capacity Utilization
National Renewable Energy Laboratory 61 Innovation for Our Energy Future
On-Site Compression Energy0
5
10
15
20
25
30
35
40
45
50
Co
mp
ress
ion
En
erg
y (M
J/kg
)
On-Site Compression Efficiency0
10
20
30
40
50
60
70
80
90
100
2010 MYPP Compression Target
2015 MYPP Compression Target
Co
mp
ress
ion
Eff
icie
ncy
(%
)
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
Created: Mar-02-09 8:35 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 theenergy of the hydrogen output plus all other energy needed for the compression process. Data shown for on-site hydrogen production and storagefacilities only, not delivered hydrogen sites.
Compression Energy Requirement:On average, 9.3% of the energycontained in the hydrogen fuel isrequired for the compressionprocess.
CDP#61: Refueling Station Compressor Efficiency
National Renewable Energy Laboratory 62 Innovation for Our Energy Future
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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
Created: Feb-26-09 11:32 AM
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, hydrogenproduction 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 conventionalgasoline 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 fueleconomy 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 bothgrid-based electricity and renewable on-site solar electricity. GHG emissions associated with on-site production of hydrogen from electrolysis are highly dependent onelectricity 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 GHGemissions would be 1241 g/mile.
CDP#62: Learning Demonstration Vehicle Greenhouse Gas Emissions
National Renewable Energy Laboratory 63 Innovation for Our Energy Future
14%
16%
17%
22%
By Number of EventsTotal Number of Events = 1860
11%
19%
17%
22%
By Labor HoursTotal Hours = 9093
system control & safetycompressorelectrolyzerreformerdispenserotherelectricalvalves & pipingstorage
Created: Mar-03-09 3:50 PM
Hydrogen Fueling Station Maintenance
CDP#63: Hydrogen Fueling Station Maintenance by System
National Renewable Energy Laboratory 64 Innovation for Our Energy Future
4%5%
34%57%
Fuel Cell Vehicle Events (9357)
22%
5%
49%
24%
Fuel Cell Vehicle Labor (10216 hours)
Vehicle (non-powertrain)Fuel Cell SystemPowertrainBattery
3%11%
11%
14%
26%
36%
Fuel Cell System Events (3175)< 1%
31%
24%12%
13%
20%
Fuel Cell System Labor (5035 hours)
Thermal ManagementAir SystemControls, Electronics, SensorsFuel SystemFuel Cell StackOther
Created: Mar-09-09 3:16 PM
Fuel Cell Vehicle Maintenance Events and Labor Hours
CDP#64: Fuel Cell Vehicle Maintenance by System