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Transcript of 1 Technical Report NREL/TP-560-48173 May 2010 Controlled Hydrogen Fleet and Infrastructure...
1
Technical ReportNREL/TP-560-48173
May 2010
Controlled Hydrogen Fleet and InfrastructureDemonstration and Validation Project
Spring 2010
Composite Data ProductsFinal Version March 29, 2010
Keith Wipke, Sam Sprik, Jennifer Kurtz, and Todd Ramsden
2
NOTICE
This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United
States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes
any legal 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 privately owned rights. Reference herein to any specific
commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute
or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views
and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any
agency thereof.
Available electronically at http://www.osti.gov/bridge
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fax: 865.576.5728
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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 2010Composite Data Products
March 29, 2010
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
Gen1 Gen2 Gen1 Gen2 Gen1 Gen20
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
2006 Target
2009 Target
Actual Operating Hours Accumulated To-Date Projected Hours to 10% Voltage Degradation
Tim
e (H
ou
rs)
DOE Learning Demonstration Fuel Cell Stack Durability:Based on Data Through 2009 Q2
Max Hrs Accumulated1,2 Avg Hrs Accumulated1,3 Projection to 10% Voltage Degradation4,5,6
Max ProjectionAvg Projection
NREL CDP01Created: Mar-23-10 10:39 AM
(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 projection bars 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 2009 Q2 data, includes an upper projection limit based on demonstrated op hours.
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
NREL CDP02Created: Mar-10-10 1:18 PM
(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
CDP#3: Fuel Cell System Power Density, Including Hydrogen Storage
0
50
100
150
200
250
300
350
400
Po
wer
Den
sity
(W
/L)
FC System (Including Hydrogen Storage) Power Density (W/L)
2010 and 2015 FreedomCAR Research Goal1
Gen 1 Gen 2
NREL CDP03NREL CDP03NREL CDP03NREL CDP03
Created: Sep-08-09 10:32 AM (1) Fuel cell system includes fuel cell stack, BOP and H2 storage, but excludes power electronics, battery storage, and electric drive.
National Renewable Energy Laboratory 7 Innovation for Our Energy Future
0
50
100
150
200
250
300
350
400
Sp
ecif
ic P
ow
er (
W/k
g)
FC System (Including Hydrogen Storage) Specific Power (W/kg)
2010 and 2015 FreedomCAR Research Goal1
Gen 1 Gen 2
NREL CDP04NREL CDP04
Created: Aug-28-09 8:42 AM (1) Fuel cell system includes fuel cell stack, BOP and H2 storage, but excludes power electronics, battery storage, and electric drive.
CDP#4: Fuel Cell System Specific Power, Including Hydrogen Storage
National Renewable Energy Laboratory 8 Innovation for Our Energy Future
12 hr Equilibrium 12 hr Equilibrium0
100
200
300
400
500
600
Time to Drive Away Time to Max FC Power
Tim
e [s
]
Fuel Cell Vehicle Start Time from Sub-Freezing Soak Condition1
NREL CDP05NREL CDP05
Created: Sep-08-09 10:54 AM
(1) Learning Demo soak temperature for freeze tests were between -9 and -20 oC(2) 2010 & 2015 DOE MYPP Cold Start Up Time Target: 30 seconds to 50% of rated power from -20 oC (soak duration not specified).
CDP#5: Fuel Cell Start Times from Sub-Freezing Soak Conditions
National Renewable Energy Laboratory 9 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
NREL CDP06Created: Mar-10-10 1:18 PM
(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 10 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
NREL CDP07Created: Mar-09-10 4:13 PM
CDP#7: Fuel Cell Voltage
National Renewable Energy Laboratory 11 Innovation for Our Energy Future
0 10 20 30 40 50 60 70 80 90 1000
10
20
30
40
50
60
Net System Power [%]
Eff
icie
ncy
[%
]
Fuel Cell System1 Efficiency2
Eff. at 25% Pwr Eff. at 100% Pwr ------------------- -------------------Gen1 51 - 58% 30 - 54%Gen2 53 - 59% 42 - 53%
DOE Target at 25% PowerDOE Target at 100% PowerGen 1 Efficiency RangeGen 2 Efficiency Range
NREL CDP08NREL CDP08
Created: Sep-02-09 11:27 AM
1 Gross stack power minus fuel cell system auxiliaries, per DRAFT SAE J2615. Excludes power electronics and electric drive.2 Ratio of DC output energy to the lower heating value of the input fuel (hydrogen). 3 Individual test data linearly interpolated at 5,10,15,25,50,75,and 100% of max net power. Values at high power linearly extrapolated due to steady state dynamometer cooling limitations.
CDP#8: FC System Efficiency
National Renewable Energy Laboratory 12 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-10-10 2:35 PMNREL CDP09
CDP#9: Safety Reports – Vehicles
National Renewable Energy Laboratory 13 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
NREL CDP10NREL CDP10
Created: Aug-19-08 11:39 AM1Targets are set for advanced materials-based hydrogen storage technologies.
National Renewable Energy Laboratory 14 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
NREL CDP11NREL CDP11
Created: Aug-19-08 11:39 AM1Targets are set for advanced materials-based hydrogen storage technologies.
National Renewable Energy Laboratory 15 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
NREL CDP12NREL CDP12
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 16 Innovation for Our Energy Future
CDP#13: On-Site Hydrogen Production Efficiency
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
NREL CDP13Created: Mar-09-10 3:16 PM
1Production conversion efficiency is defined as the energy of the hydrogen out of the process (on an LHV basis) divided by the sum ofthe energy into the production process from the feedstock and all other energy as needed. Conversion efficiency does not inc ludeenergy used for compression, storage, and dispensing.2The efficiency probability distribution represents the range and likelihood of hydrogen production conversion efficiency base d onmonthly conversion efficiency data from the Learning Demonstration.
National Renewable Energy Laboratory 17 Innovation for Our Energy Future
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
500
1000
1500
2000
2500
Avg Fuel Rate (kg/min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling Rates350 vs 700 bar Fills - All Light Duty Through 2009Q4
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 0.82 29% 19659700 bar 0.63 4% 5590
350 bar700 bar2006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone
NREL CDP14Created: Mar-09-10 3:10 PM
CDP#14: Fueling Rates – 350 and 700 bar
National Renewable Energy Laboratory 18 Innovation for Our Energy Future
CDP#15: H2 Production Cost vs. Process
0
2
4
6
8
10
12
14
16Projected Early Market 1500 kg/day Hydrogen Cost1
$/kg
Natural Gas Reforming2 Electrolysis2
2015 DOE Hydrogen Program Goal Range3
Median25th & 75th Percentile10th & 90th Percentile
Created: Jan-19-10 11:08 AM
(1) Reported hydrogen costs are based on estimates of key cost elements from Learning Demonstration energy company partners and represent thecost of producing hydrogen on-site at the fueling station, using either natural gas reformation or water electrolysis, dispensed to the vehicle. Costsreflect an assessment of hydrogen production technologies, not an assessment of hydrogen market demand.(2) Hydrogen production costs for 1500 kg/day stations developed using DOE’s H2A Production model, version 2.1. Cost modeling represents thelifetime cost of producing hydrogen at fueling stations installed during an early market rollout of hydrogen infrastructure and are not reflective of thecosts that might be seen in a fully mature market for hydrogen installations. Modeling uses default H2A Production model inputs supplemented withfeedback from Learning Demonstration energy company partners, based on their experience operating on-site hydrogen production stations. H2A-based Monte Carlo simulations (2,000 trials) were completed for both natural gas reforming and electrolysis stations using default H2A values and10th percentile to 90th percentile estimated ranges for key cost parameters as shown in the table. Capacity utilization range is based on the capabilitiesof the production technologies and could be significantly lower if there is inadequate demand for hydrogen.(3) DOE has a hydrogen cost goal of $2-$3/kg for future (2015) 1500 kg/day hydrogen production stations installed at a rate of 500 stations per year.
Key H2 Cost Elements and Ranges
Input Parameter Minimum
(P10) Maximum
(P90)
Facility Direct Capital Cost $10M $25M
Facility Capacity Utilization 85% 95%
Annual Maintenance & Repairs $150K $600K
Annual Other O&M $100K $200K
Annual Facility Land Rent $50K $200K
Natural Gas Prod. Efficiency (LHV) 65% 75%
Electrolysis Prod. Efficiency (LHV) 35% 62%
NREL CDP15
National Renewable Energy Laboratory 19 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
30Segmented Trips/Hour Histogram: DOE Fleet
Trips/Hour*
Fre
qu
ency
[%
]
*Trips/Hour based on 50 hour segmentsspanning stack operating period
NREL CDP16Created: Mar-09-10 4:13 PM
CDP#16: Fuel Cell Stack Trips Per Hour Histogram
National Renewable Energy Laboratory 20 Innovation for Our Energy Future
0
1
2
3
4
5
6
7
8
9
10
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
NREL CDP17Created: Mar-09-10 4:13 PM
CDP#17: Statistics of Trips/Hour vs. Operating Hour
National Renewable Energy Laboratory 21 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
Avg Fuel Rate (kg/min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling RatesAll Light Duty Through 2009Q4
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
25464 EventsAverage = 0.77 kg/min
23% >1 kg/min
2006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone
NREL CDP18Created: Mar-09-10 3:18 PM
CDP#18: Refueling Rates
National Renewable Energy Laboratory 22 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
NREL CDP19Created: Mar-09-10 4:13 PM
CDP#19: Time Between Trips & Ambient Temperature
National Renewable Energy Laboratory 23 Innovation for Our Energy Future
0 50 100 150 200 250 300
Non-Event
Near Miss
Incident
Number of Reports
Sev
erit
y
Total Infrastructure Safety Reports by Severityand Report Type Through 2009 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
NREL CDP20Created: Mar-11-10 2:45 PM
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#20: Safety Reports – Infrastructure
National Renewable Energy Laboratory 24 Innovation for Our Energy Future
0 2 4 6 8 10 12-30
-20
-10
0
10
20
30
40
50
60
1.4 % trips below 0 oC
Max Op = 140.0 oF
Min Op = -5.8 oF
28.2 % trips above 28 oC
Trip Frequency [%]
Tem
per
atu
re [
oC
]
Average Ambient Trip Temperature: DOE Fleet
NREL CDP21Created: Mar-09-10 4:12 PM
CDP#21: Range of Ambient TemperatureDuring Vehicle Operation
National Renewable Energy Laboratory 25 Innovation for Our Energy Future
0
5
10
15
20
25
30
35
40
Nu
mb
er o
f Ve
hic
les
Total Vehicle Hours
Vehicle Hours: All OEMs, Gen 1 and Gen 2
In Service
Retired (1)
106,413Total Vehicle Hours =
Through 2009 Q4
Created: Mar-09-10 02:36 PM
(1) Retired vehicles have left DOE fleet and are no longer providing data to NRELSome project teams concluded in Fall/Winter 2009
NREL CDP22
CDP#22: Vehicle Operating Hours
National Renewable Energy Laboratory 26 Innovation for Our Energy Future
05
1015202530354045
Nu
mb
er o
f V
ehic
les
Total Vehicle Miles
Vehicle Miles: All OEMs, Gen 1 and 2
In Service
Retired (1)
Total Vehicle Miles Traveled = 2,580,382
Through 2009 Q4
Created: Mar-09-10 03:16 PM
NREL CDP23 (1) Retired vehicles have lef t DOE f leet and are no longer providing data to NRELSome project teams concluded in Fall/Winter 2009
CDP#23: Vehicles vs. Miles Traveled
National Renewable Energy Laboratory 27 Innovation for Our Energy Future
2,580,382
-
250,000
500,000
750,000
1,000,000
1,250,000
1,500,000
1,750,000
2,000,000
2,250,000
2,500,000
2,750,000
Ve
hic
le M
iles
Tra
ve
led
Cumulative Vehicle Miles: All OEMs, Gen 1 and Gen 2
Created: Mar-09-10 03:16 PM
Through 2009 Q4
NREL CDP24
CDP#24: Cumulative Vehicle Miles Traveled
National Renewable Energy Laboratory 28 Innovation for Our Energy Future
83
40
17
-
20
40
60
80
100
120
140
160
Cu
mu
lati
ve V
ehic
les
Dep
loye
d/R
etir
ed1
Vehicle Deployment by On-Board Hydrogen Storage Type
700 bar on-road350 bar on-roadLiquid H2 on-road700 bar retired350 bar retiredLiquid H2 retired
(1) Retired vehicles have left DOE fleet and are no longer providing data to NRELSome project teams concluded in Fall/Winter 2009Created Mar-09-2010 8:34 AM
144
NREL CDP25
CDP#25: Vehicle H2 Storage Technologies
National Renewable Energy Laboratory 29 Innovation for Our Energy Future
CDP#26: Cumulative H2 Produced or Dispensed
0
5
10
15
20
25
0
20
40
60
80
100
120
140
160
Cu
mu
lati
ve N
um
ber
of S
tati
on
s
Mas
s o
f H
ydro
gen
* (1
000
kg)
Calendar Quarter
Cumulative Hydrogen Produced or Dispensed Through 2009 Q4
Cumulative Hydrogen
Number of Stations
NREL CDP26
Created 2010-Mar-22 2:50pm
*Some project teams concluded in Fall/Winter 2009
National Renewable Energy Laboratory 30 Innovation for Our Energy Future
Ref. Elec. Del. 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
NREL CDP27Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
CDP#27: Hydrogen Quality Index
National Renewable Energy Laboratory 31 Innovation for Our Energy Future
0 2 4 6 8 10 12 14 16 18 20
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)NREL CDP28Created: Mar-10-10 11:05 AM 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 32 Innovation for Our Energy Future
Ref. Elec. Del. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
500
1000
1500
2000
2500
3000
Cal
cult
ated
To
tal C
on
stit
uen
ts (
mo
l/mo
l)(p
pm
)
Calcultated Total Constituents (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
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.
0
2
4
6
8
10
12
14
16
18
20
22
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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4
Year 1 Year 2 Year 3 Year 4 Year 5
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
(This slide contains 18 graphs (1 for each constituent): view in slide-show mode)
Ref. Elec. Del. Ref. 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)
NREL CDP28Created: Mar-10-10 11:07 AM
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, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).
Year 1 Year 2 Year 3 Year 4 Year 5
National Renewable Energy Laboratory 33 Innovation for Our Energy Future
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
500
1000
1500
2000
2500
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 2009Q4
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
Fill Type Avg (kg/min) %>1 ------------- ------------------ -------Comm 0.86 30%Non-Comm 0.66 12%
CommNon-Comm2006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone
NREL CDP29Created: Mar-09-10 3:08 PM
CDP#29: Fueling Rates Communication and Non-Communication Fills
National Renewable Energy Laboratory 34 Innovation for Our Energy Future
0 20 40 60 80 100 120 140 160 180 200
AdjustmentCheck Only
OtherRepair
Replacement
Maintenance: Average Labor Hours Per Station Since InceptionThrough 2009 Q4
ScheduledUn-Scheduled
0 5 10 15 20 25 30 35 40
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
NREL CDP30Created: Mar-10-10 9:30 AM
CDP#30: Infrastructure Maintenance
National Renewable Energy Laboratory 35 Innovation for Our Energy Future
CDP#31: Number of Online Stations
8
10
5
0
5
10
15
20
25
Nu
mb
er
of
Sta
tio
ns
Reporting Period
Cumulative Stations
Existing Stations
Continuing Outside of Project
Retired Stations
NREL CDP31Created Mar-19-10 9:05am
National Renewable Energy Laboratory 36 Innovation for Our Energy Future
CDP#32: Infrastructure Hydrogen Production Methods
0
1
2
3
4
5
6
7
8
9
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 StationsContinuing Outside of ProjectRetired Stations
NREL CDP32Created Mar-19-10 9:05am
National Renewable Energy Laboratory 37 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
12
13Range Histogram: All OEMs
Percentage of chassis dyno range1 between 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
NREL CDP33
Created: Mar-23-10 10:53 AM
Total refuelings2 = 25811
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 38 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
NREL CDP34
Created: Mar-10-10 1:25 PM
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 39 Innovation for Our Energy Future
0
2
4
6
8
10
12
14
16
18
20
22
24
Nu
mb
er o
f S
tati
on
s
Infrastructure Safety Trend and Number of Stations Through 2009 Q4
05Q2
05Q3
05Q4
06Q1
06Q2
06Q3
06Q4
07Q1
07Q2
07Q3
07Q4
08Q1
08Q2
08Q3
08Q4
09Q1
09Q2
09Q3
09Q4
Number of StationsAvg Refuelings Between Safety Reports
0
100
200
300
400
500
600
Avg
# o
f R
efu
elin
gs
Bet
wee
n S
afet
y R
epo
rts
7 1132 34
88102
115
4768
124101
57 5473
51
138
447
121
198
NREL CDP35
Created: Mar-23-10 2:43 PM Reporting Period
CDP#35: Average Refuelings Between Infrastructure Safety Reports
National Renewable Energy Laboratory 40 Innovation for Our Energy Future
0
10
20
30
40
50
Nu
mb
er o
f R
epo
rts
Type of Infrastructure Safety Reports by Quarter Through 2009 Q4
05Q2
05Q3
05Q4
06Q1
06Q2
06Q3
06Q4
07Q1
07Q2
07Q3
07Q4
08Q1
08Q2
08Q3
08Q4
09Q1
09Q2
09Q3
09Q4
IncidentNear MissNon-EventNumber of StationsAvg # Reports/Station
NREL CDP36
Created: Mar-23-10 2:15 PM
Reporting PeriodAn 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 41 Innovation for Our Energy Future
0 50 100 150 200 250 300
Non-Event
Near Miss
Incident
Number of Reports
Sev
erit
y
Primary Factors of Infrastructure Safety ReportsThrough 2009 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
NREL CDP37Created: Mar-11-10 2:45 PM
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 42 Innovation for Our Energy Future
0 2 4 6 8 10 12 14 16 18 200
500
1000
1500
2000
2500
3000
3500
Time (min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling TimesAll Light Duty Through 2009Q4
Average = 3.26 min86% <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)
NREL CDP38Created: Mar-09-10 3:18 PM
CDP#38: Refueling Times
National Renewable Energy Laboratory 43 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
700
800
900
1000
Amount Fueled (kg)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling AmountsAll Light Duty Through 2009Q4
Average = 2.13 kg
NREL CDP39Created: Mar-09-10 3:18 PM
CDP#39: Refueling Amounts
National Renewable Energy Laboratory 44 Innovation for Our Energy Future
CDP#40: H2 Tank Level at Refueling
Tank Levels: DOE Fleet
14%
FE
NREL CDP40Created: Mar-09-10 4:14 PM
Total refuelings1 = 27113
1. Some refueling events not recorded/detected due to data noise or incompleteness.
Median Tank Level (At Fill) = 42%
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 45 Innovation for Our Energy Future
CDP#41: Refueling Tank Levels - Medians
FE
Tank Level Medians (At Fill): DOE Fleet, All Vehicles
NREL CDP41
Created: Mar-09-10 4:14 PM
Total refuelings1 = 27113
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 46 Innovation for Our Energy Future
CDP#42: Refueling by Time of Day
Refueling by Time of Day: DOE Fleet
9%
3
12
9
6
Total Fill3 Events = 22657% of fills b/t 6 AM & 6 PM: 89.7%
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
NREL CDP42Created: Mar-09-10 4:14 PM
National Renewable Energy Laboratory 47 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
DayNREL CDP43Created: Mar-09-10 4:14 PM
National Renewable Energy Laboratory 48 Innovation for Our Energy Future
Driving Start Time - Day: DOE Fleet
9%
3
12
9
6
Total Driving3 Events = 295222% of driving trips b/t 6 AM & 6 PM: 85.3%
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%
NREL CDP44
DOE FleetNHTS
NREL CDP44
Created: Mar-09-10 4:15 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 49 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
NREL CDP45
DOE FleetNHTS
NREL CDP45
Created: Mar-09-10 4:15 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 50 Innovation for Our Energy Future
0
10
20
30
40
50
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
NREL CDP46Created: Mar-09-10 4:21 PM
CDP#46: Fuel Cell System Operating Power
National Renewable Energy Laboratory 51 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
NREL CDP47Created: Mar-09-10 4:16 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 52 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.
NREL CDP48
National Renewable Energy Laboratory 53 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 AMNREL CDP49
National Renewable Energy Laboratory 54 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 = 22657% of fills b/t 6 PM & 6 AM: 10.3%
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
NREL CDP50Created: Mar-09-10 4:14 PM
National Renewable Energy Laboratory 55 Innovation for Our Energy Future
Driving Start Time - Night: DOE Fleet
4%
3
12
9
6
Total Driving3 Events = 295222% of driving trips b/t 6 PM & 6 AM: 14.7%
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%
NREL CDP51
DOE FleetNHTS
NREL CDP51
Created: Mar-09-10 4:15 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 56 Innovation for Our Energy Future
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
Avg Fuel Rate (kg/min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling RatesAll Light Duty by Year Through 2009Q4
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 0.77 23%2009 0.77 22%
200520062007200820092006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone
NREL CDP52Created: Mar-09-10 3:35 PM
CDP#52: Refueling Data by Year
National Renewable Energy Laboratory 57 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
NREL CDP53Created: Mar-11-10 9:13 AM
CDP#53: Fuel Cell System Energy within Power Levels
National Renewable Energy Laboratory 58 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
NREL CDP54Created: Mar-09-10 4:16 PM
CDP#54: Time Between Trips
National Renewable Energy Laboratory 59 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
NREL CDP55Created: Mar-09-10 4:16 PM
CDP#55: Fuel Cell System Energy
National Renewable Energy Laboratory 60 Innovation for Our Energy Future
0 5 10 15 20 25 30 35 400
2
4
6
8
10
12
14
16
18
20
Tri
p F
req
uen
cy [
%]
Daily Distance [miles]
Daily Distance: DOE Fleet
DOE FleetNHTS
NREL CDP56Created: Mar-09-10 4:17 PM
Cumulative Frequency@ 20 miles
DOE Fleet: 47.4%NHTS: 27.2%
Cumulative Frequency@ 40 miles
DOE Fleet: 67.2%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 61 Innovation for Our Energy Future
CDP#57: H2 Storage System Mass and Volume Breakdown
73%
24%
3%
Average Breakout of H2 Storage System Volume
3.26%
73%
23%
Average Breakout of H2 Storage System Mass
56%35%
9%
H2 Volume (%)Pressure Vessel Volume (%)Balance of Plant Volume (%)
3.33%
72%
24%
H2 Mass (%)Pressure Vessel Mass (%)Balance of Plant Mass (%)Created: Aug-19-08 9:14 AM
350 bar
700 bar
NREL CDP57
National Renewable Energy Laboratory 62 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
NREL CDP58NREL CDP58
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 63 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
NREL CDP59NREL CDP59
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 64 Innovation for Our Energy Future
CDP#60: On-Site Hydrogen Production Efficiency vs. Capacity Utilization
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
NREL CDP60Created: Mar-09-10 3:34 PM
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 = 0.82) & low correlation with natural gas data (R2 = 0.060)
National Renewable Energy Laboratory 65 Innovation for Our Energy Future
CDP#61: Refueling Station Compressor Efficiency
On-Site Compression Energy0
10
20
30
40
50
60
70
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
NREL CDP61Created: Mar-11-10 9:41 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, 11.3% of the energycontained in the hydrogen fuel isrequired for the compressionprocess.
National Renewable Energy Laboratory 66 Innovation for Our Energy Future
CDP#62: Learning Demonstration Vehicle Greenhouse Gas Emissions
0
100
200
300
400
500
600
700
WT
W G
HG
Em
issi
on
s (g
CO
2-eq
/mi)
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
NREL CDP62Created: Mar-08-10 4:16 PM
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 1330 g/mile.
National Renewable Energy Laboratory 67 Innovation for Our Energy Future
13%
13%
18%
22%
By Number of EventsTotal Number of Events = 2491
20%12%
17%
21%
By Labor HoursTotal Hours = 11430
system control & safety
compressor
reformer
electrolyzer
dispenser
other
valves & piping
electrical
storage
NREL CDP63Created: Mar-10-10 10:31 AM
Hydrogen Fueling Station Maintenance
CDP#63: Hydrogen Fueling Station Maintenance by System
National Renewable Energy Laboratory 68 Innovation for Our Energy Future
3%5%
34%
58%
Fuel Cell Vehicle Events (11574)
18%
8%
50%
24%
Fuel Cell Vehicle Labor (12522 hours)
Vehicle (non-powertrain)Fuel Cell SystemPowertrainBattery
4%10%
12%
13%
23%
39%
Fuel Cell System Events (3916)< 1%
27%
28%11%
11%
22%
Fuel Cell System Labor (6304 hours)
Thermal Management
Air System
Controls, Electronics, Sensors
Fuel System
Fuel Cell Stack
Other
NREL CDP64Created: Mar-10-10 10:34 AM
Fuel Cell Vehicle Maintenance Events and Labor Hours
CDP#64: Fuel Cell Vehicle Maintenance by System
National Renewable Energy Laboratory 69 Innovation for Our Energy Future
0
2
4
6
8
10
12
14
1015
Cyc
le
UD
DS
Cyc
le
US
06 C
ycle
HW
FE
T C
ycle
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Percent Idle in Trip
% Idle
Tri
p F
req
uen
cy [
%]
NREL CDP65Created: Mar-09-10 4:17 PM
CDP#65: Percent Idle in Trip with Comparison to Standard Drive Cycles
National Renewable Energy Laboratory 70 Innovation for Our Energy Future
0 5 10 15 20 25 30 35 40 45 50 55 60 65 700
5
10
15
20
25
30
35
40
Speed [mph]
Op
erat
ion
Tim
e [%
]
Fuel Cell Vehicle Speed
DOE Fleet SpeedDOE Fleet Idle1015 Cycle (14.1 mph avg)UDDS Cycle (19.6 mph avg)HWFET Cycle (48.0 mph avg)US06 Cycle (48.2 mph avg)
NREL CDP66Created: Mar-09-10 4:17 PM
CDP#66: FCV Speed with Comparison to Standard Drive Cycles
National Renewable Energy Laboratory 71 Innovation for Our Energy Future
0
5
10
15
20
25
30
35
40
Sta
ck C
ou
nt
Fuel Cell Stack Operation Hours: Gen1
Gen1
0
200
400
600
800
1000
1200
1400
1600
1800
2000
Gen1 Hours
24% of stacks in operation
In Op1
Retired2
Other3
0
5
10
15
20
25
30
35
40
Sta
ck C
ou
nt
Fuel Cell Stack Operation Hours: Gen2
Gen2
0
200
400
600
800
1000
1200
1400
1600
1800
2000
Gen2 Hours
34% of stacks in operation
In Op1
Retired2
Other3
NREL CDP67Created: Mar-23-10 10:39 AM
1) Stack currently accumulating hours2) Stack removed for low performance3) Stack not currently accumulating hours, but not removed because of low performance. Some project teams concluded in Fall/Winter 2009
CDP#67: Fuel Cell Stack Operation Hours
National Renewable Energy Laboratory 72 Innovation for Our Energy Future
0 5 10 15 20 25 30 35 400
5
10
15
20
25
30
Sta
ck C
ou
nt
% FC Power Drop
FC Power Drop During Operation Period: Gen1
Gen1
60% of In Op stackshave > 10% power drop
In Op1
Retired2
Other3
0 5 10 15 20 25 30 35 400
5
10
15
20
25
30
Sta
ck C
ou
nt
% FC Power Drop
FC Power Drop During Operation Period: Gen2
Gen2
85% of In Op stackshave > 10% power drop
In Op1
Retired2
Other3
NREL CDP68Created: Mar-23-10 10:39 AM
1) Stack currently accumulating hours2) Stack removed for low performance3) Stack not currently accumulating hours, but not removed because of low performance. Some project teams concluded in Fall/Winter 2009
CDP#68: Power Drop During Fuel Cell Stack Operation Period
National Renewable Energy Laboratory 73 Innovation for Our Energy Future
30
40
50
60
70
80
90
100
110
120
130
0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000Stack Op Hour Segments(2)
% P
ow
er(1
)
Max Fuel Cell Power Loss vs Op Hours: Gen1
1) Normalized by fleet median value at 200 hours.2) Each segment point is median FC power (+-50 hrs). Box not drawn if fewer than 3 points in segment.
Gen1Data Range25th & 75th PercentilesGroup MedianOutlier
NREL CDP69Created: Mar-23-10 10:39 AM
CDP#69: Max Fuel Cell Power Degradation – Gen 1
National Renewable Energy Laboratory 74 Innovation for Our Energy Future
30
40
50
60
70
80
90
100
110
120
130
0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000Stack Op Hour Segments(2)
% P
ow
er(1
)
Max Fuel Cell Power Loss vs Op Hours: Gen2
1) Normalized by fleet median value at 200 hours.2) Each segment point is median FC power (+-50 hrs). Box not drawn if fewer than 3 points in segment.
Gen2Data Range25th & 75th PercentilesGroup MedianOutlier
NREL CDP70Created: Mar-23-10 10:39 AM
CDP#70: Max Fuel Cell Power Degradation – Gen 2
National Renewable Energy Laboratory 75 Innovation for Our Energy Future
0-200 400 600 800 1000 1200 1400 1600 1800 2000 >20000
5
10
15
20
25
30
27% Gen1 > 2000 projected hrs17% Gen2 > 2000 projected hrs
Projected Hours
% S
tack
s
Durability: Projected Hours to Low Fuel Cell Power Limit
Gen1 (> 200 operation hrs)Gen1 (< 200 operation hrs)Gen2 (> 200 operation hrs)Gen2 (< 200 operation hrs)
NREL CDP71Created: Mar-23-10 10:39 AM
1. Low fuel cell power limit is dependent on the fuel cell vehicle system and is unique to each company in this Learning Demonstration.2. Acceptable low vehicle performance limit will be determined by retail customer expectations.3. Power projection method based on the voltage degradation techniques, but uses max fuel cell power instead of voltage at a specifichigh current.4. Stacks with less than 200 operation hours are in separate groups because the projection is based on operation data and with operationhours greater than 200 the degradation rate tends to flatten out.
CDP#71: Projected Hours to OEM Low Power Operation Limit
National Renewable Energy Laboratory 76 Innovation for Our Energy Future
CDP#72: Difference Between Tank and Ambient Temperature Prior to Refueling
-20 0 20 40 60-20
-10
0
10
20
30
40
50
60
Ambient Air Temperature [deg C]
Tan
k T
emp
erat
ure
[d
eg C
]
Tank vs. Ambient Air Temps Prior to Refueling
Fre
qu
ency
50
100
150
200
250
300
-40 -20 0 20 400
500
1000
1500
2000
Delta Temperature [deg C]
Co
un
t
Delta Temperature: Tank minus Ambient
Delta Temp HistogramNormal Distribution Fit
0
0.02
0.04
0.06
0.08
Den
sity
Mean= -3.751Std Dev= 6.129
NREL CDP72Created: Mar-11-10 10:24 AM
-This CDP created in support of SAE J2601 related to refueling-Temperatures are prior to refueling and exclude data within 4 hours of a previous fill-The plot to the left excludes ambient temperatures less than -5 deg C
National Renewable Energy Laboratory 77 Innovation for Our Energy Future
10 15 20 25 300
200
400
600
800
1000
1200
1400
1600
1800
2000Fuel Cell Stack Projected Hours as a Function of Voltage Drop
% Voltage Drop
Pro
ject
ed H
ou
rs2,
3
Gen 1 Average Projections
Gen 1 Average Projection to 10% Voltage Degradation1
Gen 2 Average Projections
Gen 2 Average Projection to 10% Voltage Degradation1
NREL CDP73Created: Mar-23-10 10:40 AM
(1) 10% Voltage degradation is a DOE metric for assessing fuel cell performance.(2) Projections using on-road data -- degradation calculated at high stack current.(3) Curves generated using the Learning Demonstration average of each individual fleet average at various voltage degradation levels.(4) The projection curves display the sensitivity to percentage of voltage degradation, but the projections do not imply that all stacks will (or do) operate at these voltage degradation levels.(5) The voltage degradation levels are not an indication of an OEM's end-of-life criteria and do not address catastrophic stack failures such as membrane failure.(6) All OEM Gen 2 average fleet projections are higher than Gen1 projections, however due to less operation data for Gen 2, these projections are limited by demonstrated operation hours to minimize extrapolations.
CDP#73: Fuel Cell Stack Projected Hours as a Function of Voltage Drop
National Renewable Energy Laboratory 78 Innovation for Our Energy Future
0 2 4 6 8 10 12 14 16 18 200
5
10
15
20
Cycle Per Mile
Tri
p F
req
ue
nc
y [
%]
Number of Cycles1 per Trip Mile
0 2 4 6 8 10 12 14 16 18 200
10
20
30
40
50
60
Cycle Per Min
Tri
p F
req
ue
nc
y [
%]
Number of Cycles1 per Trip Minute
Gen1 Gen20
10
20
30
40
Cy
cle
pe
r M
ile
Range of Fleet Average Cycle1 per Mile
Gen1 Gen21
2
3
4
5
6
7
Cy
cle
pe
r M
in
Range of Fleet Average Cycle1 per Min
NREL CDP74Created: Mar-22-10 4:46 PM 1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage.
CDP#74: Fuel Cell Transient Cycle Count per Mile and per Minute
National Renewable Energy Laboratory 79 Innovation for Our Energy Future
CDP#75: Fuel Cell Transient Voltage and Time Change
National Renewable Energy Laboratory 80 Innovation for Our Energy Future
0
5
10
15
20
25
30
35
DownUp
SlowUp
SlowDown
SlowDownUp
DownSSUp
Fre
qu
ency
[%
]
Transient Cycle1 Count by Category2
0 5 10 15 20 25 30 35 400
5
10
15
20
25
30
dV/dtF
req
uen
cy [
%]
DownUp Cycle1 dV/dT
0 5 10 15 20 25 30 35 400
10
20
30
40
50
dV/dt
Fre
qu
ency
[%
]
SlowUp Cycle1 dV/dT
0 5 10 15 20 25 30 35 400
10
20
30
40
50
dV/dt
Fre
qu
ency
[%
]
SlowDown Cycle1 dV/dT
0 5 10 15 20 25 30 35 400
10
20
30
40
50
60
dV/dt
Fre
qu
ency
[%
]
SlowDownUp Cycle1 dV/dT
0 5 10 15 20 25 30 35 400
20
40
60
80
100
dV/dtF
req
uen
cy [
%]
DownSSUp Cycle1 dV/dT
NREL CDP76Created: Mar-22-10 4:46 PM
1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage.2) Cycle categories based on cycle up and down times. A slow up or down transient has a time change >= 5 seconds. SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.
CDP#76: Fuel Cell Transient Rate by Cycle Category
National Renewable Energy Laboratory 81 Innovation for Our Energy Future
0
5
10
15
20
25
30
35
DownUp
SlowUp
SlowDown
SlowDownUp
DownSSUp
Fre
qu
ency
[%
]
Transient Cycle1 Count by Category2
0
5
10
15
20
-34
-30
-26
-22
-18
-14
-10 -6 -2 2 6
10
14
18
22
26
30
34
% Voltage Change [%Max Stack Voltage]F
req
uen
cy [
%]
DownUp Cycle1 dV
0
5
10
15
20
-34
-30
-26
-22
-18
-14
-10 -6 -2 2 6
10
14
18
22
26
30
34
% Voltage Change [%Max Stack Voltage]
Fre
qu
ency
[%
]
SlowUp Cycle1 dV
0
2
4
6
8
10
12
-34
-30
-26
-22
-18
-14
-10 -6 -2 2 6
10
14
18
22
26
30
34
% Voltage Change [%Max Stack Voltage]
Fre
qu
ency
[%
]
SlowDown Cycle1 dV
0
2
4
6
8
10
12-3
4-3
0-2
6-2
2-1
8-1
4-1
0 -6 -2 2 61
01
41
82
22
63
03
4
% Voltage Change [%Max Stack Voltage]
Fre
qu
ency
[%
]
SlowDownUp Cycle1 dV
0
5
10
15
20
-34
-30
-26
-22
-18
-14
-10 -6 -2 2 6
10
14
18
22
26
30
34
% Voltage Change [%Max Stack Voltage]F
req
uen
cy [
%]
DownSSUp Cycle1 dV
NREL CDP77Created: Mar-22-10 4:46 PM
1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage.2) Cycle categories based on cycle up and down times. A slow up or down transient has a time change >= 5 seconds. SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.
CDP#77: Fuel Cell Transient Voltage Changes by Cycle Category
National Renewable Energy Laboratory 82 Innovation for Our Energy Future
0
5
10
15
20
25
30
35
DownUp
SlowUp
SlowDown
SlowDownUp
DownSSUp
Cyc
le F
req
uen
cy [
%]
Transient Cycle Count by Category4
Total
<LoV Level2
>HiV Level3
tV
Example
0 2 4 6 8 10 12 14 16 18 200
10
20
30
40
50
60
70
80
Count per Mile
Tri
p F
req
uen
cy [
%]
Cycles1 Outside of Voltage Levels2,3
<LoV Level2
>HiV Level3
NREL CDP78Created: Mar-22-10 4:46 PM
1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage.2) The low voltage level is 70% Max Stack Voltage3) The high voltage level is 90% Max Stack Voltage4) Cycle categories based on cycle up and down times. A slow up or down transient has a time change >= 5 seconds. SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.
CDP#78: Fuel Cell Transient Cycles Outside of Specified Voltage Levels
National Renewable Energy Laboratory 83 Innovation for Our Energy Future
0 5 10 15 20 25 30 35 40 45 500
2
4
6
8
10
12
14
16
18
% Time
Tri
p F
req
uen
cy [
%]
Percent of Trip Time at Steady State
NREL CDP79Created: Mar-22-10 4:46 PM
1) SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.
CDP#79: Percentage of Trip Time at Steady State
National Renewable Energy Laboratory 84 Innovation for Our Energy Future
0 50 100 150 200 250 3000
5
10
Per
cen
tag
e o
f R
efu
elin
gs
Distance between refuelings [Miles]2
Distance Driven Between Refuelings: All OEMs
Gen1Gen2
NREL CDP80
Created: Mar-23-10 10:53 AM
Total Refuelings1 = 25811 Gen1 Refuelings = 18941 Median distance between refuelings = 56 Miles Gen2 Refuelings = 6870 Median distance between refuelings = 81 Miles
1. Some refueling events are not detected/reported due to data noise or incompleteness.
2. Distance driven between refuelings is indicative of driver behavior and does not represent the full range of the vehicle.
CDP#80: Miles Between Refuelings