Strategy | Energy | Sustainability

Hydrogen Fuel Cells for Heavy Duty, Road and Rail Applications

Future Powertrain Conference 2019

27 February 2019

Guy Bates, Consultant - Low Carbon Transport

guy.bates@e4tech.com

E4tech perspective: Strategy | Energy | Sustainability

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• International consulting firm, offices in UK and Switzerland

• Focus on sustainable energy, including electrified vehicles

• 21 years old this year, always independent

• Deep expertise in technology, business and strategy, market assessment, techno-economic modelling, policy support…

• A spectrum of clients from start-ups to global corporations

E4tech’s annual Fuel Cell Industry Review

www.FuelCellIndustryReview.com

Drivers for hydrogen – National policy and decisions by local authorities

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• Strong measures to decarbonise transport drives a mix of technologies, including hydrogen

• Focus is on passenger cars and heavy duty; non-road mobile machinery may not be exempt

• Low Emission Zones

• Remove diesels by 2025

• Discount on car sharing; free bike sharing and public transportation

• Financial support to replace petrol or dieselcommercial vehicles

Paris London

• Low Emissions Zone (LEZ); not met EU Air Quality targets hence Central London Ultra LEZ in 2019

• Pollution charge: pre-‘Euro 4’ vehicles

• Single deck buses to be ZE (FC or BEV)by 2020

• Double deck ZEV by 2025

Birmingham

• Clean Air Zone(CAZ) expected in 2020

• FC bus fleet and refuelling station

• EV and LPG taxi initiatives

• Birmingham Cycle Revolution: 5% of trips 2023

• Creation of Green Travel Districts

Fuel cells offer EV benefits – Favour heavy duty applications

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1 Battery-hydrogen hybrid to ensure sufficient power2 Split in A- and B-segment LDVs (small cars) and C+-segment LDVs (medium to large cars)

based on a 30% market share of A/B-segment cars and a 50% less energy demand

Source: Hydrogen Council (2017)

• Fuel must be decarbonised: hydrogen or electricity

• Fuel cell power decouples from hydrogen energy– unlike batteries

• Hydrogen has a higher energy density

• Benefit from EV acceleration and regeneration

• Neither very hot nor cold conditions strongly affect performance

• Hydrogen fuelling is fast; the model is familiar to oil companies and service station providers

Heavy duty truck example – An equivalent powertrain comparison

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Diesel Hydrogen truck2 (FCET) Battery Electric Truck3 (BET)

“Tank” size 80 Gallons 60 kg H2 320kWh

Additional powertrain cost - <$100,0004 >$100,0003

Additional powertrain weight - <20004 kg >2,5004 kg

Range per fuelling ~9001 km ~4802 km ~1901,3 km

Refuelling interval <1 /day 1-2/day Multiple times a day

Refuelling time 5 minutes ~20 minutes [40 minutes] ~1 hour minimum (depends on charger) [5 hours]

(1) Based on figures from “Analysis of long haul battery electric trucks in EU - 2018”(2) Based on Toyota’s “Beta” prototype. Refuelling @ 2.63 kg H2/min and 60 kg tank (DOE, 2015).(3) Based on the Nikola ONE & https://www.arb.ca.gov/msprog/actruck/docs/HDBEVefficiency.pdf(4) Based on figures from H2FC Supergen conference 2019

• Batteries can’t do it all

• A typical haulage daily run, 800km, a FCET will refuel in 40 minutes, most similar to diesel

Heavy duty truck example – Current and future hydrogen refuelling price

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Tank: 40 kg H2Range: 3801 km

Current price: £10/kg H2 Industrial SMR scale

price: £2/kg H2Fills per duty cycle: 2.1

£840 per duty cycle w/current

prices

Tank: 80 gallonsRange: 900 km

Price: diesel in UK 2019 ~ £1.30/Litre.

Fills per duty cycle: 0.9£350 per duty

cycle

£168 per duty cycle w/future industrial prices

Hydrogen fuel cell truck

Diesel

• Initially, fuel costs will be relatively high

• Hydrogen costs can approach fossil fuel parity with high utilisation electrolysers and cheap renewable electricity, (other options exist)

(1) Based on Toyota’s “project portal - Alpha” prototype.

Fuel cells are scalable and modular – Offer initial design flexibility

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• PEM fuel cells are preferred for transport applications, and use hydrogen

• A fuel cell - Multiple repeated layers sandwiched together to provide the right power

• Stacks are optimised for a particular operation – e.g. Toyota Mirai stack (370 cells, 114kW)

• Reasonable sales are required for economical production – e.g. Toyota expecting 30,000 units by 2020

• Several stacks can be integrated in series for higher power

Information and images from Toyota Global Newsroom - https://newsroom.toyota.co.jp/en/corporate/23722307.html

Toyota Mirai fuel cell stack

PEM fuel cell assembly

Case study – Project Portal “Alpha” & “Beta”

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• Bespoke fuel cell design would have been costly

• Two Mirai fuel cell stacks power the truck –12kWh battery, 500kW and 1,796Nm torque

• 10 more “Beta” prototype semi-trucks for drayage in California

• Gross weight capacity is more than 36.2 tonnes and “Beta’s” estimated driving range is >480km per fill

• Consistent operating routes allow for straightforward refuelling

• In excess of 10,000 miles of operation achieved already

Information and images from Toyota Global Newsroom - https://newsroom.toyota.co.jp/en/corporate/23722307.html

Further examples – Buses, trains, ships and more trucks

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Buses

• Availability is improving

• Costs are reducing

• Europe is leading, Asia is set to overtake

• ICE commonality - 10-15 min refuelling, 300-450km range

Marine

• Continues the trend for fuel cells in heavy duty applications

• Ferries for short distance

• Power for hotel loads

• Different fuels for different technologies

Trains

• Passenger trains are now in operation in Germany; more are on order

• UK and other nations are showing interest

• An alternative to overhead electric lines or diesel power, they have a 1000km range

More trucks!

• 800 Nikola Tre orders by Anheuser Busch

• 1000 Hyundai orders for Swiss supermarkets (for tax benefit)

• Stack power of 30kW in China is designed around the subsidy sweet-spot; increase to 60kW

Information and images from the 2018 Fuel Cell Industry Review - http://www.fuelcellindustryreview.com/

In summary

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• An energy system transition is coming

• Heavy duty and off-highway is a major contributor to emissions and air quality problems

• Batteries can’t do it all. Fuel cells offer EV benefits and a comparable operation of duty cycle

• Hydrogen fuel costs are able to reach parity with fossil fuels

• Technology costs are dropping, and the modular and scalable nature of fuel cells gives flexibility

• Heavy-duty hydrogen fuel cell examples across the sector

• A realistic, zero emission solution

E4tech: Strategy | Energy | Sustainability

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