advanced fuel cell systems for transport …2019/11/14 · avl list gmbh (headquarters) public...
TRANSCRIPT
![Page 1: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/1.jpg)
AVL List GmbH (Headquarters)
Public
Advanced Fuel Cell Systems for
Transport ApplicationsA3PS Conference, Vienna15th of Nov. 2019
Juergen Rechberger
Global Head of Fuel Cell Development
![Page 2: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/2.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 2Public
Affordable e-Mobility - Application Map
Fuel Cell
Diesel
REV,PHEV
Stop and go Drive Cycle Continuous
Lig
ht
load
Duty
Cycle
Hig
h load
Inter-urban Highway-cycle HighwayCity
BEV
Source: AVL
![Page 3: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/3.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 3Public
w
Fuel Cell in Automotive
Strong momentum for Fuel Cell/H2 driven by commercial vehicles and China
Passenger Car Commercial Vehicle
![Page 4: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/4.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 4Public
Passenger Cars - Fuel CellPowertrain Cost Comparison
55025060
100
200
180
140
300 350 400 450 500
80
120
160
BEV
Power
[kW]
Range
[km]
InnovationZone
Fuel Cell
Source: AVL
Fuel Celladvantage
BEVadvantage
For larger & long range vehicles, FCVs will be lower cost than BEVs
![Page 5: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/5.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 5Public
Renewable Energy Consumption ComparisonBEV, FCEV & ICE with synth. Gasoline
0
20
40
60
80
100
120
140
Energy in Vehicle
Energy at Station
(refilling/charging)
Renewable primary Energy
BEV
FCEV (H2)
ICE Hybrid (Synth. Gasoline)
kW
h/
10
0km
Passenger car, 15kWh/100km mechanical energyBEV: LiIon, 12kW & 100kW ChargeFCEV: PEM/H2, 880bar/-40°C, PEM ELICE: Full Hybrid, PEM EL/Fischer Tropsch
Factor 3-4
20%
Ambient Conditions
Quick chargingIntermediate
energy storage
Latest Gen FC Technology
880bar, -40Cre-filling
PEM ELPipeline distribution
![Page 6: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/6.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 6Public
w
AVL Activities in Fuel Cell
400 engineers in fuel cell powertrain, testing and simulation
PEM Stack EngineeringFuel Cell System Development
PEM + SOFCIntegration & Application
Development
Fuel Cell Test Systems Energy Storage & H2/Synfuel Production
Fuel Cell Simulation Tools
![Page 7: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/7.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 7Public
CELL STACK SYSTEM APPLICATION
AVL Value Chain
PEM Technology
SOFC Technology
![Page 8: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/8.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 8Public
170kW climate chamber PEM system test rig available @HyCentA
New Fuel Cell test center will open in Q1/20:
Space up to 25 test rig
System- subsystem & component test rigs
HD system test rig up to 400kW
1st full scale PEM test rig in operation
AVL Fuel Cell Test Center
![Page 9: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/9.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 9Public
Mission:
Facts:
AVL Fuel Cell Canada registered
Office rented: 8602 Commerce Court, Burnaby
Start of operation: July 2018
Number of engineers: 33 (30 from former Daimler/Ford stack development JV - AFCC, 1 from Ballard)
AVL Fuel Cell Canada
Development of world class PEM Stacks for PC & CV applications
![Page 10: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/10.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 10Public
Fuel Cell System Development
![Page 11: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/11.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 11Public
Technology Challenges
Passenger Car
Commercial Vehicles
![Page 12: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/12.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 12Public
AVL Fuel Cell Concept Car
Vehicle platform VW Passat GTE
Vehicle curb weight 1746 kg
Vehicle gross weight 2182 kg
Battery size 9.9 kWh
Battery power 85 kW
Fuel cell power ~70 kW
e-drive power 100 kW
Hydrogen tank capacity 3.8/5.3 kg
Number of tanks 3/4
Hydrogen refilling time approx.3 min
Hydrogen consumption 0.8 kg /100 km
Driving range >600 km
![Page 13: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/13.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 13Public
AVL Fuel Cell Concept Car
70kW Fuel Cell System
100kW e-Drive
9.9kWh Battery
3 Cylinder H2 Storage
![Page 14: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/14.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 14Public
AVL PEM Fuel Cell Engine
FC Gross Power 70kW
FC Net Power 55-60kW
Efficiency 46-60%
Dynamics T90 <1s
E-Motor 100kW
Lifetime 6.000 hrs
![Page 15: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/15.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 15Public
Modular Fuel Cell Systems for Truck & BusParallel Operation of PEM FC Systems
HYTRUCK Objectives:
Modular Truck fuel cell system
Power density/durability tradeoff
Hydrogen Storage Solution
Key components (stack, DC/DC,…)
HYTRUCK Architecture:
100kW Truck FCS Module (Concept Design)
![Page 16: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/16.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 16Public
Packaging of Fuel Cell Trucks
• 300kW Fuel Cell System will fit into engine space• H2 Tank system very challenging to integrate for long range (>50kg H2)
Example: Short wheel-base tractor (high volume application)
cooling
E-axle
E-axle
cooling
H2 T
ank
Optional – with increased wheel-base only
![Page 17: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/17.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 17Public
Solutions
Increase front area by 60%
Clean up front radiator by moving AC system to the roof
Limit fuel cell power via battery hybridization
Add side cooler and fans
Increase the stack temperature
Solutions for FC Truck Cooling
Using a roof installation for AC system would reduce the pre load for the main radiator and the air side pressure drop
Increase of main radiator front area possible below lights
E-drive cooling system could be implemented
in side radiatorLT
rad
iato
r
EM
Inverter
Eelectric
pump
he
ate
r
E
SOV
HT
rad
iato
r
AC
CO
ND
OC DCT
ICE
Byp
ass
blo
ck
PumpICE
he
ad
TC
MCT
E
Ch
iller
charger
E
electric
pump
HV Battery
HC
3/2 v alv e
![Page 18: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/18.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 18Public
w
35kW PEM REX AVL Design for SOP
35kW PEM REX System - SOP in China 2020
PEM / H2
2019
Max. net. Power 35 kW
Min. Power 10% of max Power
el. Efficiency @max Load
(system/stack level) 42/56%
el. Efficiency Peak
(system/stack level) 58/72%
T90 Time >1s
Start-up Time (20°C, to 90% Load) <3s
Cold Start Temp. -20°C
Freeze Start Time (to 90% Load) < 45s@-20°C
Dimensions 50L
Weight 65kg
GENERIC SPECIFICATION
![Page 19: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/19.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 19Public
Fuel Cell Durability Development
CFD Cell Optimization with Damage Models
Detection and avoidance of Damaging Operating Conditions with THDA
Optimization of Operating Strategy with 1D Damage Models
10.000hr
Baseline
Cell Optimization
Advanced Diagnostics
Advanced Operating Strategies
15.000hr 15.000hr
1
2
3
1
2 3
![Page 20: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/20.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 20Public
AVL PEM Stack Development
KPI AVL Stack TargetsGen0-Baseline
Power [kW] 110 (60-120)
Power Density [kW/L]Compressed cell row w/hardware (no enclosure)
>3
DimensionsCell width x cell length [mm]
130 x 400
Cost indicators:
Performance CONFIDENTIAL
Pt loading [mg/cm2]
CONFIDENTIAL
Lifetime [h](time to 10% power loss)
15,000
Freeze startup capabilityFreeze-thaw tolerance
-30°C (tbc with system)-40°C
![Page 21: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/21.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 21Public
w
Technology Roadmap (PEM)
Power Density improvement driven by cell performance (CCM) and cell design
Cost reduction driven by volume
Today 2025 2030
FC
Syste
m C
ost
Sta
ck P
ow
er D
en
sit
y200€/kW
80€/kW 40€/kW3kW/l
4kW/l
5kW/l
![Page 22: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/22.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 22Public
w
SOFC Range Extender Development
SOFC REX Technology based on biofuels (e.g. eGas) enables extremely WtW efficiencies
+
T-HVAC System 30kW SOFC REX
![Page 23: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/23.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 23Public
w
Fuel Cell Solutions for Rail & Marine
Fuel Cell Adoption/Industrialization has started Rail, Marine & Aviation
3MW Marine PEM Power Unit
200kW PEM modular Rail System
25kW SOFC Marine APU (Diesel)
![Page 24: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/24.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 24Public
Summary
Fuel Cell has economic and ecological advantages in larger & heavier vehicles
Fast refill is a key advantage
H2 will become an important renewable energy carrier
AVL accelerates investments in H2/Fuel Cell Technology
![Page 25: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/25.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 25Public
KEYTECH has received funding from the Austria Research Promotion Agency’s e!MISSIONprogramme under grant agreement No 855237.
HYTRUCK has received funding from the Austrian Climate and Energy Fund’s Energy Model Region programme under grant agreement No 868790.
![Page 26: Advanced Fuel Cell Systems for Transport …2019/11/14 · AVL List GmbH (Headquarters) Public Advanced Fuel Cell Systems for Transport Applications A3PS Conference, Vienna 15th of](https://reader030.vdocument.in/reader030/viewer/2022041005/5eaa0ddfefb567552824e946/html5/thumbnails/26.jpg)
J. Rechberger | Fuel Cell | 15 November 2019 | 26Public