Austin Power Engineering LLC1 Cameron St
Wellesley, MA 02482USA
© 2019 Austin Power Engineering LLC
Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing Cost Analysis for Heavy Duty
Truck Applications
Yong Yang
President
November 7, 2019
1
Austin Power Engineering LLC is an independent technology consulting company that focuses mainly on bottom-up technical cost modeling.
Source: Dr. Rajesh Ahluwalia of ANL
HT/LT Radiators
Demister
Electric Motor
PEFC
Stack
AirExhaust
Humidified Air
HT Coolant
Enthalpy
Wheel
LT Coolant
Purge Valve
Recirculation Pump
LT Coolant Pump
HT Coolant Pump
Fan
Ejector
Pressure RegulatorMembrane
Humidifier
Dilution Mixer
Air Filtration
Hydrogen
Tank
Air Bypass
HT/LT Radiators
Demister
Electric Motor
PEFC
Stack
AirExhaust
Humidified Air
HT Coolant
Enthalpy
Wheel
LT Coolant
Purge Valve
Recirculation Pump
LT Coolant Pump
HT Coolant Pump
Fan
Ejector
Pressure RegulatorMembrane
Humidifier
Dilution Mixer
Air Filtration
Hydrogen
Tank
Air Bypass
Demister
Electric Motor
PEFC
Stack
AirExhaust
Humidified Air
HT Coolant
Enthalpy
Wheel
LT Coolant
Purge Valve
Recirculation Pump
LT Coolant Pump
HT Coolant Pump
Fan
Ejector
Pressure RegulatorMembrane
Humidifier
Dilution Mixer
Air Filtration
Hydrogen
Tank
Hydrogen
Tank
Air Bypass
Cathode pinTop cover
Insulator case
Spring plate
Anode can
Anode
Cathode
Separator
Cathode lead
Safety vent
Gasket
Insulator
Terminal plate
CID
2019 YY
Hydrogen
Electrolysis
Hydrogen
StorageFuel Cell
Battery
2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
Hydrogen & Fuel Cell Manufacturing Cost Modeling
2014 2015 2016 2017 2018 2019
Arthur D Little / TIAX Austin Power Engineering
Introduction Overview
22019 YY
Have been working on various EV powertrain manufacturing cost analysis since 2002.
Introduction Company Overview
Electric Powertrains
- Full battery powertrain
- Hybrid battery powertrain
- Fuel cell powertrain
Battery Packs
- Lithium ion battery
- Lithium metal solid electrolyte battery
- NiMH battery
Power Electronics
- Battery BMS
- Inverters
- Traction motors
Regenerative/Active
Suspension System
Electric Turbo Chargers
On-board Fly Wheel
Energy Storage System
Range-extension IC Engines
Onboard Hydrogen Storage
Systems
- Compressed H2 tanks
- MH H2 tanks
- Chemical H2 tanks
- Cryo-compressed H2 tanks
- MOF H2 tanksThermal-electrical Generator
(Exhaust Heat Recovery)
Approach Project Scope
32019 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 160 kW class 8 truck fuel cell power system.
Class 8 Fuel Cell Truck
Fuel cell power: 160 kWnet /
197kWGross
Battery power: 350 kW
Battery energy: 16 kWh
Motor power: ~500 kW
H2 storage: 60 kg (Six tanks)
H2 storage tank: Cryo-compressed
Range: 300 miles
Test Wt. Fuel Cell Battery
lbs kW kW
Class 1 Class 1: < 6,000 lbs Not eval. Not eval. Not eval.
Class 2 Van Class 2: 6,001 - 10,000 lbs 7588 147 6
Class 3 Service Class 3: 10,001 - 14,000 lbs 11356 165 4
Class 3 School Bus Class 3: 10,001 - 14,000 lbs 11512 180 76
Class 3 Enclosed Van Class 3: 10,001 - 14,000 lbs 12166 149 62
Class 4 Walk-in, Multi-Stop Class 4: 14,001 - 16,000 lbs 15126 166 59
Class 5 Utility Class 5: 16,001 - 19,500 lbs 16860 253 8
Class 6 Construction Class 6: 19,501 - 26,000 lbs 22532 170 30
Class 7 School Bus Class 7: 26,001 - 33,000 lbs 29230 145 56
Class 8 Constrction 37429 139 57
Class 8 Refuse 45291 273 94
Class 8 Nikola One 50870 300 446
Class 8 Tractor Trailer 54489 247 95
Class 8 Line Haul 70869 363 47
ANL Analysis Assumption/Results
Class 8: >33,001 lbs
Light
Duty
Medium
Duty
Heavy
Duty
Class and Vocation PHA Vehicle Class Definaion
* Data from Argon National Lab research papers, 21st Century Truck, DOE
4
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%
2019 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
5
Combining performance and cost model will easily generate cost results, even when varying the design inputs.
2019 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 EstimatesSite 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
Cathode
Small Powder
Prep
Sinter in Air
1400CSinter in Air
Forming
of
Interconnect
Shear
Interconnect
Vacuum
Plasma
Spray
Slurry
Spray
Screen
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
$10
Lapp
ing
CM
P
Wet
ther
mal O
xida
tion
Spin
Coa
ting
Wet
Etching
SiO
2
DC S
putte
ring
Ni
RF S
putte
ring
E
Spin
Coa
ting
Stepp
er
DC S
putte
ring
Ag
Stripp
ing
Spin
Coa
ting
Stepp
er
Dry
Etchi
ng S
iO2
DRIE
Si
Wet
Etching
SiO
2
Dry
Etchi
ng N
I
Wafe
r C
ost
($)
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
6
Stack and system component in-depth analysis on technology progress and supply chain optimization:
2019 YY
Approach In-depth Analysis
Economies of Scale Analysis
0
1
2
3
4
5
6
2010 2020 2030 2040 2050
Tota
l cap
acit
y (G
W)
Fuel cell penetration in UK genset market
Successful PFCC
Fuel cell breakthrough achieved in 2024
Bass Diffusion Model Analysis
Stack and BOP components
• MEA
• GDL/MPL
• Bipolar plates
• Compressor/expender
• H2 circulation pump
• Humidifier
• Radiator
In-depth analysis
Technology progress
• Breakthrough innovation
• Technology improvement
in short and long term
• Design simplification
Supply chain optimization
• Raw material
• Off-the-shelf Component
• Fabrication process
• Utilization in other industry
• Challenges
OEM evaluation
• Market share
• Production capacity
• Annual revenue
• Product cost
7
We assume class 8 truck has an annual production volume of 10,000 units.
Manufacturing Assumptions
System Components Class 8 Truck
Vehicle production volume
(unit/year)10,000
Stack source
Assume two 80 kWnet stacks at the
annual production volume of 20,000
units
H2 storage system production
volume
10 kg x 6 cryo-compressed H2 tanks
at the annual production volume of
60,000 units
Battery source
16 kWh lithium-ion battery pack at the
annual production volume of 10,000
units
2019 YY
8
The 160 kWnet direct hydrogen PEM fuel cell system configuration:
PEMFC System 160 kWnet PEM Fuel Cell System Preliminary System Design
2019 YY
Hydrogen
PT PR
Air
Air Filter
Air pre-cooler
Compressor
Air Flow MeterPT
Stack
Membranehumidifier
M
Exhaust
Demister
Bypass valve
PT PR
Air
Air Filter
Air pre-cooler
Compressor
Air Flow MeterPT
Membranehumidifier
M
Exhaust
Bypass valve
PT PR
Diverter valve
Solenoid valve
Jet Pump
Over pressure cut-off valve
H2 Exhaust
Motorized valve
H2 fi lter
PT PR
Solenoid valve
Jet Pump
Over pressure cut-off valve
H2 fi lter
Motorized valve
PT
PR
Diverter valve
Coolant pump
Coolant tank
High temperature coolant loop
High temperatureradiator
Stack
PT
PR
Diverter valve
Coolant pump
Coolant tank
Low temperature coolant loop
Low temperatureradiator
Demister
v
v
9
System and material assumptions for the cost estimation:
System Assumptions PEM Fuel Cell System Preliminary Design
2019 YY
Stack Components Unit Current System Comments
Production volume systems/year 10,000 Baseline
System net power kW 160
System gross power kW 197
# of stacks in the system # 2
Stack’ net power kW 80
Stacks’ gross power kW 98.5
Cell power density mW/cm2 1,200 DOE 2018
System Voltage (rated power) Volt 250
Platinum price $/tr.oz. $1,500 Estimated, DOE 2018
Pt loading mg/cm2 0.35 DOE 2018
Membrane type Reinforced PFSA
Membrane thickness micro meter 14
GDL layerNon-woven carbon paper with
MPL layer
GDL thickness micro meter 110 @50 kPa pressure
MPL layer thickness micro meter 45
MEA gasket material PET
MEA gasket thickness micro meter 100
Bipolar plate type Gold dot coated SS316 Treadstone; Near term
Bipolar plate base material Thickness micro meter 100
Seal material EPDM
10
The bottom-up cost approach will be used to accurately capture the manufacturing costs for each fabrication step.
True-value-mapping analysis virtualizes costs in each fabrication step, which breaks down costs into materials, labor, capex, utility, maintenance, etc.
2019 YY
BUY
MAKE
Anode
Ink
Anode Side
Catalyst Layer
Membrane
Processes
Cathode Side
Catalyst Layer
Cathode
Ink
Hot Press
Lamination
Die Cut
MEA
MEA Continuous Fabrication Process
Purchased
GDL
Purchased
GDL
Pt
Pt
Nafion®
Ionomer
Stack
Assembly
Bipolar
Plate
Purchased
Hardware
Gasket
Stack Fabrication Process
Frame
Seal
Molding
Viton
Viton
Sheet
Metal
Process Yield
Material Utilization
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% 98.5% 99% 95%
99% 95%
100% 100%
100% 100%
100% 100%
100% 100%
100% 100%
100% 100%
100% 100%
99% 95%
99.9% 100%
Testing
99.5% 100%
System Assumptions Process Assumptions
11
The class 8 truck fuel cell stack costs approximately $64/kW.
Class 8 Truck Stack Cost ($64/kWnet)Stack ComponentsClass 8 Truck Stack
Cost ($/kW)1,2
Anode GDL $2.8
Anode $9.3
Electrolyte $6.0
Cathode $17.1
Cathode GDL $2.8
MEA Assembly $3.6
Cooling Plates $14.9
Seals $3.6
End Plates $0.7
Electrical insulators $0.1
Anode Current Collector $0.1
Cathode Current
Collector$0.1
End-stack heaters $0.8
Compression band $0.1
Fixings & fasteners $0.1
Ventilated Stack
Enclosure$0.3
Stack assemlby $0.8
Stack conditioning $0.4
Stack Total Cost ($/kW) $63.6
1. Results may not appear to calculate due to rounding of the component cost results.
2. Actual stack production volume: 20,000 stacks/yr.
PEMFC System Stack Costs
2019 YY
4%
15%
9%
27%
4%
6%
23%
6%
1%0%
0% 0% 1% 0% 0% 1%1%
1%
Anode GDL Anode Electrolyte Cathode Cathode GDL
MEA Assembly Cooling Plates Seals End Plates Electrical insulators
Anode Current Collector Cathode Current Collector End-stack heaters Compression band Fixings & fasteners
Ventilated Stack Enclosure Stack assemlby Stack conditioning
12
Class 8 Truck System Cost ($115/kWnet)
The class 8 truck fuel cell system costs approximately $115/kW at the production volume of 10,000 systems/year.
System ComponentsClass 8 Truck System
Cost ($/kW)
Stack $63.58
Air management $29.56
Water management $2.27
Thermal management $5.35
Fuel management $5.16
System controller $0.93
Sensors $1.44
Miscellaneous $1.94
System assembly $4.55
Total: $114.78
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.
PEMFC System Costs
2019 YY
55%
26%
2%
5%
4%1%1% 2% 4%
Stack Air management Water management
Thermal management Fuel management System controller
Sensors Miscellaneous System assembly
13
The cryo-compressed hydrogen tank has advantages in gravimetric density, volumetric density, and cost.
Cryo-Compressed H2 Storage System Configurations
2019 YY
• US Department of Energy Hydrogen Storage Cost
Analysis, 2013, TIAX; Cost is based on 500,000
units/year
• System level analysis of hydrogen storage options, R. K.
Ahluwalia, 2010
• Cryo-compressed hydrogen storage, BMW 2012
Cryo-
compressed
H2 Tank
14
The cryo-compressed hydrogen tank design is referenced in studies TIAX conducted on hydrogen storage1.
1. S. Lasher and Y. Yang, “Cryo-compressed and Liquid Hydrogen System Cost Assessments”,
DOE Merit Review, 2008
2. R.K. Ahluwalia, i.e. “Cryo-compressed hydrogen storage: performance and cost review”
Februrary, 2011
Cryo-Compressed Hydrogen Storage System Schematic1, 2
The single tank design has a usable hydrogen storage capacity of 10.1 kg.
Key ParametersSystem Volume
• Storage: 151L
• Vessel: 224L
System Weight: 144.7kg
• LH2 storage: 10.7kg (usable 10.1 kg)
• CH2 storage: 2.8kg
Tank
• Carbon fiber: Toray T700S
• Carbon fiber / resin ratio: 0.68 : 0.32
(weight)
• Translational strength factor: 81.5%
• Safety factor: 2.25
• Carbon fiber composite layer
thickness: 12 mm
• Liner: 3mm Al
• Vacuum gap: 40 mm with 40 layers of
MLVI
• Outer Shell: 3 mm thick SS304
• Gravimetric capacity: 7.1 wt%
• Volumetric capacity: 44.5 kg/m3
Cryo-Compressed H2 Storage System Configurations
2019 YY
15
Assumptions for the hydrogen storage tank design are based on the literature review and third-party discussions.
Stack Components Unit Class 8 Truck
Production volume tanks/year 60,000
Usable hydrogen Kg 10.1
Total H2 in the tank Kg 10.7
Tank type III
Tank max pressure PSI 5,000
# of tanks Per System 6
Safety factor 2.25
Tank length/diameter ratio 3:1
Liner material Al
Liner thickness mm 3
Carbon fiber type Toray T700S
Carbon fiber cost $/lbs 12
Carbon fiber vs. resin ratio 0.68:0.32
Carbon fiber translational
Strength factor81.5%
Carbon fiber composite layer
thicknessmm 12
Vacuum gap mm 40
# of MLVI layer 40
Outer layer SS304
Outer layer thickness mm 3
Compressed H2 Storage System Specifications
2019 YY
16
A vertically integrated manufacturing process is assumed for the tank and BOP components.
Compressed H2 Storage System Manufacturing Process
2019 YY
Extrude and Spin
Cylinder
Spin Seal
One End
Boss
Fabrication
Inner Liner Device
Assembly
Spin Seal
2nd End
Vacuum Leak Inspection
Al Liner
Fabrication
Pressure
liner
Liner
Surface
Gel Coat
CF
PrePreg
Filament
Winding
Cure /
Cool
down
Ultrasonic
Inspection
Carbon FiberGel
CF Layer
Fabrication
Liner Support &
Piping Assembly
Cut the MIL into Required
Shape
Laminate Multiple
Insulation Layer
Attach the MIL onto
Composite Tank
SS Outer Tank Body Welding
(One End)
Outer Tank Assembly
Tank Insulation Vacuum
Processing
Final System
Inspection
SS Outer Tank
Cylinder Rolling
SS Outer Tank Dome
Stamping
Insulation Layer Piping
Assembly
SS Outer Tank Body Welding
Vessel Shell
Fabrication
Final
Assembly
Insulation
Fabrication
17
Class 8 Truck H2 Storage System Cost ($12.4/kWh)
In the cryo-compressed hydrogen storage system, the top three cost drivers are the carbon fiber composite layer, cryogenic valves, and system control valves.
System Components
Class 8 Truck
System Cost
($/kWh)
H2 0.10
Al liner 0.45
CF layer 2.88
Insulation 0.39
Vacuum shell 0.69
Balance of vessel 0.24
Fuel receptacle 1.27
Cryogenic valves 1.24
HX 0.24
Electronic control 2.52
Vent & release device 1.06
Tank frame, piping& fitting,
fasteners 0.18
Assembly & testing 1.12
Total: 12.37
Compressed H2 Storage System Cost
2019 YY
• Cryo-compressed H2 tank production volume: 60,000
tanks/year (10,000 systems/year)
1% 4%
23%
3%
6%
2%
10%10%
2%
20%
9%
1%
9%
H2 Al linerCF layer InsulationVacuum shell Balance of vesselFuel receptacle Cryogenic valvesHX Electronic controlVent & release device Tank frame, piping& fitting, fasteners
18
We use a 16 kWh lithium ion hybrid battery pack in the fuel cell truck powertrain.
2019 YY
Specifications
Battery pack energy 16 kWh
Battery module Output 350 kW
Cell size (Ah) 55
# of cells in pack 80
# of cells in module 20
# of modules in pack 4
Anode active material Graphite/Si
Cathode active material NMC622
PEMFC Hybrid Energy Storage Lithium Ion Battery Pack
Pack
Illustration Only
19
We analyze the cells, modules, and pack cost using bottom-up approach.
2019 YY
PEMFC Hybrid Energy Storage Battery Cell-to-Pack Cost
Cell
Module
Pack
Mixing
Filtration
Coating
Drying
Calendering
Mixing
Filtration
Coating
Drying
Calendering
Cathode Anode
Cathode active
material
Conductive
materials
Binder
Current
Collector
(Al)
Anode active
material
Binder
Current
Collector
(Cu)
Punching Punching
Stacking
Tab Welding
Pouch
Stamping
Cell Seal (top
and one side)
Hi-pot Testing
Labeling
Separator
Vacuum
Drying
Room Temp.
Aging
Formation
De-gassing,
2nd Seal
Grading &
Sorting
Filling
Electrolyte
and 1st Seal
Cathode tab
Anode tab
Aluminum
lamination
film
High Temp.
Aging
OCV Testing
OQC
Pack
Materials
ScalingMaterial
Scaling
Al Fin Cell Center
FrameCell
Repeat (20 cells for 4modules)
End Unit with
Cell Monitoring
PCB Board
Thermal
Management
System
Structure
Protection
System
Battery
Management
System+ +
20
The hybrid lithium ion battery pack costs $169/kWh. Cells, cell module assembly, and battery management system have higher cost contributions.
Battery System Cost ($169 /kWh)
The 16 kWh lithium-ion battery system costs $2,700 per pack at the annual production volume of 10,000 packs.
Cost Category Pack Cost ($/kWh)
Cells $125.00
Cell Module Assembly $16.50
Battery Thermal
Management System $4.89
Battery Structure
Protection System $9.54
Battery Management
System $12.84
Total ($/kWh)$168.76
2019 YY
PEMFC Hybrid Energy Storage Battery Pack Cost
74%
10%
3%
6%
7%
CellsCell Module AssemblyBattery Thermal Management SystemBattery Structure Protection SystemBattery Management System
21
PEM fuel cell system, onboard hydrogen storage, and hybrid battery cost approximately $46,050 for class 8 fuel cell truck.
2019 YY
Conclusions
Cost CategoryClass 8 Fuel Cell
Truck
Fuel Cell System (160 kWnet) $18,365
H2 Storage system (60 kg H2) $24,985
Hybrid Battery Pack (16 kWh) $2,700
Total: $46,050
CommentsProduction volume:
10,000/yr
40%
54%
6%
Fuel Cell System (160 kWnet)
H2 Storage system (60 kg H2)
Hybrid Battery Pack (16 kWh)
Fuel Cell + H2 Tank + Battery Cost ($169 /kWh)
22
Thank You!
Contact: Yong Yang
Austin Power Engineering LLC
1 Cameron St,Wellesley, MA 02482
+1 781-239-9988+1 401-829-9239
2019 YY