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1 Technical Report NREL/TP-560-46679 September 2009 Controlled Hydrogen Fleet Infrastructure Demonstration and Validation Project Fall 2009 Composite Data Products Final Version September 11, 2009 Keith Wipke, Sam Sprik, Jennifer Kurtz, and Todd Ramsden and

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Page 1: Controlled Hydrogen Fleet and Infrastructure Demonstration .../67531/metadc... · 1 Technical Report NREL/TP-560-46679 September 2009. Controlled Hydrogen Fleet Infrastructure Demonstration

1

Technical ReportNREL/TP-560-46679September 2009

Controlled Hydrogen Fleet InfrastructureDemonstration and Validation ProjectFall 2009

Composite Data ProductsFinal Version September 11, 2009

Keith Wipke, Sam Sprik, Jennifer Kurtz, and Todd Ramsden

and

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2

Disclaimer and Government License

This work has been authored by Midwest Research Institute (MRI) under Contract No. DE-AC36-99GO10337 with the U.S. Department of Energy (the “DOE”). The United States Government (the “Government”) retains and the publisher, by accepting the work for publication, acknowledges that the Government retains

a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for Government purposes.

Neither MRI, the DOE, the Government, nor any other agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use

would not infringe any privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not constitute or imply its endorsement, recommendation, or favoring by the Government or any agency thereof. The views and opinions of the authors and/or presenters expressed herein do not necessarily state or reflect those of MRI, the DOE, the Government, or any agency

thereof.

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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

Fall 2009Composite Data Products

September 11, 2009

Keith Wipke, Sam Sprik, Jennifer Kurtz, Todd Ramsden

Controlled Hydrogen Fleet and Infrastructure Demonstration and Validation Project

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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 Gen20200400600800

1000120014001600180020002200240026002800

2006 Target

2009 Target

Actual Operating Hours Accumulated To-Date Projected Hours to 10% Voltage Degradation

Tim

e (H

ours

)

DOE Learning Demonstration Fuel Cell Stack Durability:Based on Data Through 2009 Q2

Max Hrs Accumulated (1)(2) Avg Hrs Accumulated (1)(3) Projection to 10% Voltage Degradation (4)(5)(6)

Max ProjectionAvg Projection

Created: Sep-09-09 10:48 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.

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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

Vehi

cle

Ran

ge (m

iles)

Vehicle Range1

2015 Target2009 Target Gen 1 Gen 2

Created: Aug-27-09 3:32 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

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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

Pow

er D

ensi

ty (W

/L)

FC System (Including Hydrogen Storage) Power Density (W/L)

2010 and 2015 FreedomCAR Research Goal1

Gen 1 Gen 2

Created: Sep-08-09 10:32 AM (1) Fuel cell system includes fuel cell stack, BOP and H2 stroage, but excludes power electronics, battery storage, and electric drive.

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National Renewable Energy Laboratory 7 Innovation for Our Energy Future

0

50

100

150

200

250

300

350

400

Spec

ific

Pow

er (W

/kg)

FC System (Including Hydrogen Storage) Specific Power (W/kg)

2010 and 2015 FreedomCAR Research Goal1

Gen 1 Gen 2

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

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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

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

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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

Fuel

Eco

nom

y (m

iles/

kg H

2)

Fuel Economy

Gen 1 Gen 2

Created: Aug-27-09 3:32 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

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National Renewable Energy Laboratory 10 Innovation for Our Energy Future

0

5

10

15

20

25

Ope

ratin

g Ti

me

[%]

Operating Time at Fuel Cell Stack Voltage Levels: DOE Fleet

<50%50-55%

55-60%60-65%

65-70%70-75%

75-80%80-85%

85-90%90-95%

95-100%>100%

% Max Fuel Cell Stack Voltage

All timeTime at low current

Created: Aug-14-09 4:47 PM

CDP#7: Fuel Cell Voltage

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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 [%]

Effic

ienc

y [%

]

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

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

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National Renewable Energy Laboratory 12 Innovation for Our Energy Future

0

1

2

3

Num

ber o

f Rep

orts

Safety Reports - Vehicle Operation

Tank ScratchTraffic AccidentH2 Leak - During FuelingH2 Alarm - Fuel SystemH2 Alarm - Passenger Compartment

Created: Aug-10-09 3:08 PM

CDP#9: Safety Reports – Vehicles

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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

ght P

erce

nt H

ydro

gen

(%)

Weight Percent Hydrogen

2015 DOE MYPP Target1

2010 DOE MYPP Target1

2007 DOE MYPP Target1

Created: Aug-19-08 11:39 AM1Targets are set for advanced materials-based hydrogen storage technologies.

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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 pe

r Lite

r (kg

/L)

Mass of Hydrogen Per Liter

2015 DOE MYPP Target1

2010 DOE MYPP Target1

2007 DOE MYPP Target1

Created: Aug-19-08 11:39 AM1Targets are set for advanced materials-based hydrogen storage technologies.

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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

Num

ber o

f cyc

les

Hydrogen Tank Cycle Life1

All OEMs

2015 DOE MYPP Target2

2010 DOE MYPP Target2

2007 DOE MYPP Target2 Gen 1 Gen 2

Created: Sep-17-08 10:29 AM

1Data reported reference NGV2, HGV2, or EIHP standards.2Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based technologies.

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National Renewable Energy Laboratory 16 Innovation for Our Energy Future

On-Site Natural Gas Reforming On-Site Electrolysis0

10

20

30

40

50

60

70

80

2010 MYPP Target2015 MYPP Target

2012 MYPP Target

2017 MYPP Target

Prod

uctio

n Ef

ficie

ncy

(LH

V %

)

Hydrogen Production Conversion Efficiency1

Average Station Efficiency

Quarterly Efficiency Data

Highest Quarterly Efficiency

Efficiency Probability Distribution2

Created: Sep-01-09 10:32 AM

1Production conversion efficiency is defined as the energy of the hydrogen out of the process (on an LHV basis) divided by the sum of the energy into the productionprocess from the feedstock and all other energy as needed. Conversion efficiency does not include energy used for compression, storage, and dispensing.2The efficiency probability distribution represents the range and likelihood of hydrogen production conversion efficiency based on monthly conversion efficiency datafrom the Learning Demonstration.

CDP#13: On-Site Hydrogen Production Efficiency

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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)

Num

ber o

f Fue

ling

Even

ts

Histogram of Fueling Rates350 vs 700 bar Fills - All Light Duty Through 2009Q2

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% 17847700 bar 0.62 3% 3792

350 bar700 bar2006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone

Created: Aug-31-09 12:59 PM

CDP#14: Fueling Rates – 350 and 700 bar

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National Renewable Energy Laboratory 18 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*

Freq

uenc

y [%

]

*Trips/Hour based on 50 hour segmentsspanning stack operating period

Created: Aug-26-09 2:14 PM

CDP#16: Fuel Cell Stack Trips Per Hour Histogram

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National Renewable Energy Laboratory 19 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

Trip

s/H

our*

Statistics of Trips/Hour vs Operating Hour: DOE Fleet

*Trips/Hour based on 50 hour segmentsspanning stack operating period

Data Range25th & 75th PercentilesGroup MedianOutlier

Created: Aug-26-09 2:14 PM

CDP#17: Statistics of Trips/Hour vs. Operating Hour

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National Renewable Energy Laboratory 20 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

Avg Fuel Rate (kg/min)

Num

ber o

f Fue

ling

Even

ts

Histogram of Fueling RatesAll Light Duty Through 2009Q2

5 minute fill of5 kg at 350 bar

3 minute fill of5 kg at 350 bar

21854 EventsAverage = 0.78 kg/min

24% >1 kg/min

2006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone

Created: Aug-14-09 10:09 AM

CDP#18: Refueling Rates

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National Renewable Energy Laboratory 21 Innovation for Our Energy Future

0-10 10-30 30-60 60-360 >3600

5

10

15

20

25

30

35

Time [min]

Trip

Fre

quen

cy [%

]

Time Between Trips with Ambient Temperature: DOE Fleet

<0oC0-10oC10-24oC24-40oC>40oC

Created: Aug-26-09 2:15 PM

CDP#19: Time Between Trips & Ambient Temperature

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National Renewable Energy Laboratory 22 Innovation for Our Energy Future

0 50 100 150 200 250 300

Non-Event

Near Miss

Incident

Number of Reports

Seve

rity

Total Infrastructure Safety Reports by Severityand Report Type Through 2009 Q2

Alarms OnlyAutomatic System ShutdownElectrical IssueEquipment MalfunctionFalse Alarm/MischiefH2 Release - Minor, NO IgnitionH2 Release - Significant, NO IgnitionManual System ShutdownNon-H2 ReleaseSite Power OutageStructural IssueSystem Trouble, not Alarm

Created: Sep-01-09 8:38 AM

An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame

CDP#20: Safety Reports – Infrastructure

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National Renewable Energy Laboratory 23 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

26.9 % trips above 28 oC

Trip Frequency [%]

Tem

pera

ture

[o C]

Average Ambient Trip Temperature: DOE Fleet

Created: Aug-14-09 4:47 PM

CDP#21: Range of Ambient TemperatureDuring Vehicle Operation

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National Renewable Energy Laboratory 24 Innovation for Our Energy Future

0

5

10

15

20

25

30

35

Num

ber

of V

ehic

les

Total Vehicle Hours

Vehicle Hours: All OEMs, Gen 1 and Gen 2

In ServiceRetired

100,284Total Vehicle Hours =

Through 2009 Q2

Created: Aug-26-09 04:13 PM

CDP#22: Vehicle Operating Hours

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National Renewable Energy Laboratory 25 Innovation for Our Energy Future

05

1015202530354045

Num

ber

of V

ehic

les

Total Vehicle Miles

Vehicle Miles: All OEMs Combined, Gen 1 and 2

In ServiceRetired

Total Vehicle Miles Traveled = 2,318,038

Through 2009 Q2

Created: Aug-26-09 04:13 PM

CDP#23: Vehicles vs. Miles Traveled

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National Renewable Energy Laboratory 26 Innovation for Our Energy Future

2,318,038

-

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

Vehi

cle

Mile

s Tr

avel

ed

Cumulative Vehicle Miles: All OEMs, Gen 1 and Gen 2

Created: Aug-26-09 04:13 PM

Through 2009 Q2

CDP#24: Cumulative Vehicle Miles Traveled

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National Renewable Energy Laboratory 27 Innovation for Our Energy Future

60

49

-

20

40

60

80

100

120

140

160

Cum

ulat

ive

Vehi

cles

Dep

loye

d/Re

tired

1

Vehicle Deployment by On-Board Hydrogen Storage Type

700 bar on-road350 bar on-roadLiquid H2 on-road700 bar retired350 bar retiredLiquid H2 retired

Created Feb-23-2009 1:20 PM (1) Retired vehicles have left DOE fleet and are no longer providing data to NREL Created Aug-26-2009 4:21 PM

140

(1) Retired vehicles have left DOE fleet and are no longer providing data to NREL

CDP#25: Vehicle H2 Storage Technologies

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National Renewable Energy Laboratory 28 Innovation for Our Energy Future

0

5

10

15

20

0

20

40

60

80

100

120

140

Num

ber o

f Sta

tions

Mas

s of

Hyd

roge

n (1

000

kg)

Calendar Quarter

Cumulative Hydrogen Produced or Dispensed Through 2009 Q2

Cumulative HydrogenNumber of Stations

Created 2009-Aug-27 1:09 pm

CDP#26: Cumulative H2 Produced or Dispensed

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National Renewable Energy Laboratory 29 Innovation for Our Energy Future

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.99.7

99.75

99.8

99.85

99.9

99.95

100

Cal

cula

ted

H2 In

dex

(%)

H2 Calculated Quality Index by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineCalculated Data

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

CDP#27: Hydrogen Quality Index

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National Renewable Energy Laboratory 30 Innovation for Our Energy Future

0 2 4 6 8 10 12 14 16 18 20

Particulates

µg/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

µmol/mol (ppm)

0 10 20 30 40 50 60 70 80

Total S*

nmol/mol (ppb)Created: Aug-31-09 4:39 PM Data is from Learning Demonstration and California Fuel Cell Partnership testing

*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

CDP#28: Hydrogen Fuel Constituents

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National Renewable Energy Laboratory 31 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

10

20

30

40

50

60

70

Tota

l S* (

nmol

/mol

)(ppb

)

Total S* (nmol/mol)(ppb)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 32 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

0.5

1

1.5

2

Tota

l HC

( µm

ol/m

ol)(p

pm)

Total HC (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 33 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

5

10

15

20

25

Tota

l Hal

ogen

ates

(µm

ol/m

ol)(p

pm)

Total Halogenates (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 34 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

2

4

6

8

10

12

14

16

18

20

22

Part

icul

ate

Con

cent

ratio

n ( µ

g/L)

Particulate Concentration (µg/L)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:41 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 35 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

5

10

15

20

25

30

35

40

O2( µ

mol

/mol

)(ppm

)

O2(µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 36 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

500

1000

1500

2000

2500

N2 ( µ

mol

/mol

)(ppm

)

N2 (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 37 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

500

1000

1500

2000

2500

3000

N2+H

e+A

r (µm

ol/m

ol)(p

pm)

N2+He+Ar (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 38 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

5000

10000

15000

20000

25000

30000

Part

icul

ate

Size

(µm

)

Particulate Size (µm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:41 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 39 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

50

100

150

200

250

300

He

( µm

ol/m

ol)(p

pm)

He (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 40 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

5

10

15

H2O

( µm

ol/m

ol)(p

pm)

H2O (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 41 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

0.05

0.1

0.15

0.2

Form

ic a

cid

( µm

ol/m

ol)(p

pm)

Formic acid (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 42 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

0.02

0.04

0.06

0.08

0.1

Form

alde

hyde

(µm

ol/m

ol)(p

pm)

Formaldehyde (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 43 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

0.2

0.4

0.6

0.8

1

CO

( µm

ol/m

ol)(p

pm)

CO (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 44 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

1

2

3

4

5

6

7

8

9

CO

2 ( µm

ol/m

ol)(p

pm)

CO2 (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

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National Renewable Energy Laboratory 45 Innovation for Our Energy Future

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

500

1000

1500

2000

2500

3000

Cal

culta

ted

Tota

l Con

stitu

ents

(µm

ol/m

ol)(p

pm)

Calcultated Total Constituents (µmol/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 GuidelineCalculated Data

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

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National Renewable Energy Laboratory 46 Innovation for Our Energy Future

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

500

1000

1500

2000

2500

Ar+

N2 ( µ

mol

/mol

)(ppm

)

Ar+N2 (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

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National Renewable Energy Laboratory 47 Innovation for Our Energy Future

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

1

2

3

4

5

6

NH

3 ( µ

mol

/mol

)(ppm

)

NH3 (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

50

100

150

200

Ar (µm

ol/m

ol)(p

pm)

Ar (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

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National Renewable Energy Laboratory 48 Innovation for Our Energy Future

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

1

2

3

4

5

6

NH

3 ( µ

mol

/mol

)(ppm

)

NH3 (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method

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National Renewable Energy Laboratory 49 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

Avg Fuel Rate (kg/min)

Num

ber o

f Fue

ling

Even

ts

Histogram of Fueling RatesComm vs Non-Comm Fills - All Light Duty Through 2009Q2

5 minute fill of5 kg at 350 bar

3 minute fill of5 kg at 350 bar

Fill Type Avg (kg/min) %>1 ------------- ------------------ -------Comm 0.92 36%Non-Comm 0.66 13%

CommNon-Comm2006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone

Created: Sep-02-09 11:32 AM

CDP#29: Fueling Rates Communication and Non-Communication Fills

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National Renewable Energy Laboratory 50 Innovation for Our Energy Future

0 50 100 150 200 250

AdjustmentCheck Only

OtherRepair

Replacement

Maintenance: Average Labor Hours Per Station Since InceptionThrough 2009 Q2

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 EventsHours

Comparison of Scheduled/Un-Scheduled Maintenance

Created: Aug-17-09 12:25 PM

CDP#30: Infrastructure Maintenance

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National Renewable Energy Laboratory 51 Innovation for Our Energy Future

0

5

10

15

20

25

Num

ber o

f Sta

tions

Reporting Period

Online Stations

Existing Stations

Retired Stations

Created Aug-27-09 1:03pm

CDP#31: Number of Online Stations

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National Renewable Energy Laboratory 52 Innovation for Our Energy Future

0

1

2

3

4

5

6

7

8

Delivered Compressed H2

Natural Gas On-site Reforming

Electrolysis Delivered Liquid H2

# of

Sta

tions

Production Technology

Infrastructure Hydrogen Production Methods

Existing Stations

Retired Stations

Created Aug-27-09 1:03pm

CDP#32: Infrastructure Hydrogen Production Methods

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National Renewable Energy Laboratory 53 Innovation for Our Energy Future

CDP#33: Percentage of Theoretical Range Traveled Between Refuelings

0 10 20 30 40 50 60 70 80 90 1000

1

2

3

4

5

6

7

8

9

10

11

12Range Histogram: All OEMs

Percentage of chassis dyno range1 b/w refuelings

Perc

enta

ge o

f Ref

uelin

gs

0 10 20 30 40 50 60 70 80 90 1000

25

50

75

100

Cum

ulat

ive

Perc

enta

ge

Created: Aug-26-09 9:40 AM

Total refuelings2 = 22470

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.

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National Renewable Energy Laboratory 54 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

OEM

s Win

dow

-Stic

ker

2 W

indo

w-S

ticke

r 2

On-

Roa

d 3

On-

Roa

d 3

Dyn

o 1

Created: Aug-31-09 9:26 AM

1. Calculated using the combined City/Hwy fuel economy from dyno testing (non-adjusted)and usable fuel on board.2. Applying window-sticker correction factors for fuel economy: 0.78 x Hwy and 0.9 x City.3. Using fuel economy from on-road data (excluding trips > 1 mile, consistent with other data products).

CDP#34: Effective Vehicle Range

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National Renewable Energy Laboratory 55 Innovation for Our Energy Future

05Q2 05Q3 05Q4 06Q1 06Q2 06Q3 06Q4 07Q1 07Q2 07Q3 07Q4 08Q1 08Q2 08Q3 08Q4 09Q1 09Q20

2

4

6

8

10

12

14

16

18

20

22

Reporting Period

Num

ber o

f Sta

tions

Infrastructure Safety Trend and Number of Stations Through 2009 Q2

Number of StationsAvg Refuelings Between Safety Reports

Created: Sep-01-09 8:40 AM

0

100

200

300

400

500

600

Avg

# o

f Ref

uelin

gs B

etw

een

Safe

ty R

epor

ts

7 1132 34

88 102 115

4768

124101

57 5473

51

146

530

CDP#35: Average Refuelings Between Infrastructure Safety Reports

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National Renewable Energy Laboratory 56 Innovation for Our Energy Future

05Q2 05Q3 05Q4 06Q1 06Q2 06Q3 06Q4 07Q1 07Q2 07Q3 07Q4 08Q1 08Q2 08Q3 08Q4 09Q1 09Q20

5

10

15

20

25

30

35

40

45

50

Reporting Period

Num

ber o

f Rep

orts

Type of Infrastructure Safety Reports by Quarter Through 2009 Q2

IncidentNear MissNon-EventNumber of StationsAvg # Reports/Station

Created: Sep-01-09 8:40 AM

An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame

CDP#36: Type of Infrastructure Safety Report By Quarter

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National Renewable Energy Laboratory 57 Innovation for Our Energy Future

0 50 100 150 200 250 300

Non-Event

Near Miss

Incident

Number of Reports

Seve

rity

Primary Factors of Infrastructure Safety ReportsThrough 2009 Q2

Calibration/Settings/ Software ControlsDesign FlawElectrical Power to SiteEnvironment (Weather, Power Disruption, Other)False AlarmInadequate Training, Protocol, SOPInadequate/ Non-working EquipmentMaintenance RequiredMischief, Vandalism, SabotageNew Equipment MaterialsNot Yet DeterminedOperator/Personnel ErrorSystem Manually Shutdown

Created: Sep-01-09 8:38 AM

An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame

CDP#37: Primary Factors of Infrastructure Safety Reports

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National Renewable Energy Laboratory 58 Innovation for Our Energy Future

0 2 4 6 8 10 12 14 16 18 200

500

1000

1500

2000

2500

3000

Time (min)

Num

ber o

f Fue

ling

Even

ts

Histogram of Fueling TimesAll Light Duty Through 2009Q2

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)

Created: Aug-14-09 10:40 AM

CDP#38: Refueling Times

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National Renewable Energy Laboratory 59 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

Amount Fueled (kg)

Num

ber o

f Fue

ling

Even

tsHistogram of Fueling AmountsAll Light Duty Through 2009Q2

Average = 2.14 kg

Created: Aug-14-09 10:40 AM

CDP#39: Refueling Amounts

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National Renewable Energy Laboratory 60 Innovation for Our Energy Future

CDP#40: H2 Tank Level at Refueling

Tank Levels: DOE Fleet

14%

FE

Created: Aug-26-09 9:40 AM

Total refuelings1 = 24859

1. Some refueling events not recorded/detected due to data noise or incompleteness.

Median Tank Level (At Fill) = 41%

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.

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National Renewable Energy Laboratory 61 Innovation for Our Energy Future

CDP#41: Refueling Tank Levels - Medians

FE

Tank Level Medians (At Fill): DOE Fleet, All Vehicles

Created: Aug-26-09 9:40 AM

Total refuelings1 = 24859

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.

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National Renewable Energy Laboratory 62 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 = 20939% of fills b/t 6 AM & 6 PM: 90.2%

1. Fills between 6 AM & 6 PM

2. The outer arc is set at 12 % total Fill.

3. Some events not recorded/detected due to data noise or incompleteness.

AM PM

Created: Aug-26-09 9:40 AM

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National Renewable Energy Laboratory 63 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 Fill

s in

a D

ay

DayCreated: Aug-26-09 9:40 AM

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National Renewable Energy Laboratory 64 Innovation for Our Energy Future

Driving Start Time - Day: DOE Fleet

9%

3

12

9

6

Total Driving3 Events = 273900% of driving trips b/t 6 AM & 6 PM: 85.6%

1. Driving trips between 6 AM & 6 PM

2. The outer arc is set at 12 % total Driving.

3. Some events not recorded/detected due to data noise or incompleteness.

AM PM

% of NHTS trips b/t 6 AM & 6 PM: 81.5%

DOE FleetNHTS

Created: Aug-25-09 2:28 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

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National Renewable Energy Laboratory 65 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 Driv

ing

Trip

s in

a D

ay

Day

DOE FleetNHTS

Created: Aug-25-09 2:28 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

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National Renewable Energy Laboratory 66 Innovation for Our Energy Future

0

10

20

30

40

50

Time at Fuel Cell Stack Power Levels: DOE Fleet

Ope

ratin

g Ti

me

[%]

0-5%

5-10%

10-15

%

15-20

%

20-25

%

25-30

%

30-35

%

35-40

%

40-45

%

45-50

%

50-55

%

55-60

%

60-65

%

65-70

%

70-75

%

75-80

%

80-85

%

85-90

%

90-95

%

95-10

0%>10

0%

% Max Fuel Cell Power (Gross)

All timeTime with 0 speed

Created: Aug-26-09 2:15 PM

CDP#46: Fuel Cell System Operating Power

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National Renewable Energy Laboratory 67 Innovation for Our Energy Future

0 5 10 15 20 250

5

10

15

20

25

30

35

40

45

Trip

Fre

quen

cy [%

]

Trip Length [miles]

Trip Length: DOE Fleet

DOE FleetNHTS

Created: Sep-04-09 12:13 PM2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001

CDP#47: Trip Length

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CDP#48: Primary Factors Affecting Learning Demo Fleet Fuel Cell Degradation

DOE Fleet

High Current TimeHot StartsStarts/hour

Low Voltage TimeHigh Voltage Time

Cold StartsShort Trips

0 Speed TripsHot Ambient Temp

H*

H*

1) On-going fuel cell degradation study using Partial Least Squares (PLS) regression model for combined Learning Demonstration Fleet.

2) DOE Fleet model has a low percentage of explained decay rate variance.

Created: Feb-21-08 9:32 AM

H*: Factor group associated with high decay rate fuel cell stacksL**: Factor group associated with low decay rate fuel cell stacks

Due to differences among teams, the DOE Fleet Analysis results are spread

out and concrete conclusions are difficult to draw.

Individual team analyses (CDP#49) focused on patterns within a fleet.

DOE Fleet

High Current TimeHot StartsStarts/hour

Low Voltage TimeHigh Voltage Time

Cold StartsShort Trips

0 Speed TripsHot Ambient Temp

H*

H*

1) On-going fuel cell degradation study using Partial Least Squares (PLS) regression model for combined Learning Demonstration Fleet.

2) DOE Fleet model has a low percentage of explained decay rate variance.

Created: Feb-21-08 9:32 AM

H*: Factor group associated with high decay rate fuel cell stacksL**: Factor group associated with low decay rate fuel cell stacks

Due to differences among teams, the DOE Fleet Analysis results are spread

out and concrete conclusions are difficult to draw.

Individual team analyses (CDP#49) focused on patterns within a fleet.

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National Renewable Energy Laboratory 69 Innovation for Our Energy Future

CDP#49: Primary Factors Affecting Learning Demo Team Fuel Cell Degradation

Team 1

High Voltage TimeLow Current Time

Short TripsLow Speed

Team 2

Team 3

Team 4

Low Current TimeLong Trips

Warm Ambient TempZero Speed

Current Transients

High Voltage TimeLow Current Time

Short TripsLow Speed

Current Transients

1) On-going fuel cell degradation study using Partial Least Squares (PLS) regression model for each team’s Gen 1 fleet.

2) Teams’ PLS models have a high percentage of explained decay rate variance, but the models are not robust and results are scattered.

3) Factor groups associated with stacks that are opposite to the identified groups here are not specified.

H*

Starts/HourZero SpeedShort Trips

Low Voltage TimeHigh Current TimeCurrent Transients

Cold StartsHot Ambient Temp

High Speed

H*

H*

H*

H*

H*: Factor group associated with high decay rate fuel cell stacks

Created: Mar-09-09 9:06 AM

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National Renewable Energy Laboratory 70 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 = 20939% of fills b/t 6 PM & 6 AM: 9.8%

1. Fills between 6 PM & 6 AM

2. The outer arc is set at 12 % total Fill.

3. Some events not recorded/detected due to data noise or incompleteness.

PM AM

Created: Aug-26-09 9:40 AM

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National Renewable Energy Laboratory 71 Innovation for Our Energy Future

Driving Start Time - Night: DOE Fleet

3%

3

12

9

6

Total Driving3 Events = 273900% of driving trips b/t 6 PM & 6 AM: 14.4%

1. Driving trips between 6 PM & 6 AM

2. The outer arc is set at 12 % total Driving.

3. Some events not recorded/detected due to data noise or incompleteness.

PM AM

% of NHTS trips b/t 6 PM & 6 AM: 18.4%

DOE FleetNHTS

Created: Aug-25-09 2:28 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

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National Renewable Energy Laboratory 72 Innovation for Our Energy Future

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20

50

100

150

200

250

300

350

400

450

500

Avg Fuel Rate (kg/min)

Num

ber o

f Fue

ling

Even

tsHistogram of Fueling Rates

All Light Duty by Year Through 2009Q2

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 0.79 26%

200520062007200820092006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone

Created: Aug-14-09 3:32 PM

CDP#52: Refueling Data by Year

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National Renewable Energy Laboratory 73 Innovation for Our Energy Future

0

2

4

6

8

10FC Energy by Power Levels: DOE Fleet

FC E

nerg

y [%

]

0-5%

5-10%

10-15

%

15-20

%

20-25

%

25-30

%

30-35

%

35-40

%

40-45

%

45-50

%

50-55

%

55-60

%

60-65

%

65-70

%

70-75

%

75-80

%

80-85

%

85-90

%

90-95

%

95-10

0%>10

0%

% Fuel Cell Power (Gross) of Max

Cum

ulat

ive

%

0

20

40

60

80

100

Created: Aug-26-09 2:15 PM

CDP#53: Fuel Cell System Energy within Power Levels

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National Renewable Energy Laboratory 74 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

Trip

Fre

quen

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

rips

Time

0-60 min Breakdown: DOE Fleet

Created: Aug-14-09 5:36 PM

CDP#54: Time Between Trips

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National Renewable Energy Laboratory 75 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]

Trip

Fre

quen

cy [%

]

Energy in Trip: DOE Fleet

Net batterycharge in trip

BatteryVehicle MotorFC

Created: Aug-26-09 2:15 PM

CDP#55: Fuel Cell System Energy

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National Renewable Energy Laboratory 76 Innovation for Our Energy Future

0 5 10 15 20 25 30 35 400

2

4

6

8

10

12

14

16

18

20

22

Trip

Fre

quen

cy [%

]

Daily Distance [miles]

Daily Distance: DOE Fleet

DOE FleetNHTS

Created: Sep-04-09 12:13 PM

Cumulative Frequency@ 20 miles

DOE Fleet: 48.4%NHTS: 27.2%

Cumulative Frequency@ 40 miles

DOE Fleet: 68.1%NHTS: 52.9%

2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001

CDP#56: Daily Driving Distance

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National Renewable Energy Laboratory 77 Innovation for Our Energy Future

CDP#57: H2 Storage System Mass and Volume Breakdown

Average Breakout of H2 Storage System Volume

73%

24%

3%

Average Breakout of H2 Storage System Mass

3.26%

23%

73%

9%

35% 56%

H2 Volume (%)Pressure Vessel Volume (%)Balance of Plant Volume (%)

72%

3.33%

24%

H2 Mass (%)Pressure Vessel Mass (%)Balance of Plant Mass (%)Created: Aug-19-08 9:14 AM

350 bar

700 bar

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National Renewable Energy Laboratory 78 Innovation for Our Energy Future

CDP#58: Fuel Cell System Power Density

0

100

200

300

400

500

600

700

Pow

er D

ensi

ty (W

/L)

FC System Power Density (W/L)

2010 and 2015 DOE MYPP Target1 Gen 1 Gen 2

Created: Sep-17-08 10:29 AM (1) Fuel cell system includes fuel cell stack and BOP but excludes H2 storage, power electronics, and electric drive.

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CDP#59: Fuel Cell System Specific Power

0

100

200

300

400

500

600

700

Spec

ific

Pow

er (W

/kg)

FC System Specific Power (W/kg)

2010 and 2015 DOE MYPP Target1 Gen 1 Gen 2

Created: Sep-17-08 10:30 AM (1) Fuel cell system includes fuel cell stack and BOP but excludes H2 storage, power electronics, and electric drive.

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0 10 20 30 40 50 60 70 80 90 1000

10

20

30

40

50

60

70

Production Capacity Utilization1 [%]

Prod

uctio

n C

onve

rsio

n Ef

ficie

ncy

2 [%]

Monthly Production Conversion Efficiency vs Utilization

Electrolysis DataElectrolysis Fit3

Electrolysis Fit ConfidenceNatural Gas DataNatural Gas Fit3Natural Gas Fit Confidence

Created: Aug-27-09 4:42 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 = 0.86) & low correlation with natural gas data (R2 = 0.034)

CDP#60: On-Site Hydrogen Production Efficiency vs. Capacity Utilization

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National Renewable Energy Laboratory 81 Innovation for Our Energy Future

On-Site Compression Energy 0

5

10

15

20

25

30

35

40

45

50

Com

pres

sion

Ene

rgy

(MJ/

kg)

On-Site Compression Efficiency0

10

20

30

40

50

60

70

80

90

100

2010 MYPP Compression Target

2015 MYPP Compression Target

Com

pres

sion

Eff

icie

ncy

(%)

On-Site Hydrogen Compression Efficiency1 and Energy Use

Average Station Compression Efficiency

Quarterly Compression Efficiency Data

Highest Quarterly Compression Efficiency

Average Station Compression Energy

Quarterly Compression Energy Data

Lowest Quarterly Compression Energy

Created: Aug-27-09 4:14 PM

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, 11.0% of the energycontained in the hydrogen fuel isrequired for the compressionprocess.

CDP#61: Refueling Station Compressor Efficiency

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National Renewable Energy Laboratory 82 Innovation for Our Energy Future

0

100

200

300

400

500

600

700

WTW

GH

G E

mis

sion

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

Created: Sep-08-09 4:21 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 1245 g/mile.

CDP#62: Learning Demonstration Vehicle Greenhouse Gas Emissions

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National Renewable Energy Laboratory 83 Innovation for Our Energy Future

14%

14%

19%

21%

By Number of EventsTotal Number of Events = 2291

22%12%

17%

20%

By Labor HoursTotal Hours = 11119

system control & safetycompressorreformerelectrolyzerdispenserothervalves & pipingelectricalstorage

Created: Aug-17-09 2:56 PM

Hydrogen Fueling Station Maintenance

CDP#63: Hydrogen Fueling Station Maintenance by System

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National Renewable Energy Laboratory 84 Innovation for Our Energy Future

3%5%

33%58%

Fuel Cell Vehicle Events (11075)

19%

7%

49%

24%

Fuel Cell Vehicle Labor (11849 hours)

Vehicle (non-powertrain)Fuel Cell SystemPowertrainBattery

4%10%

11%

13%

24%

38%

Fuel Cell System Events (3704)< 1%

28%

27% 11%

12%

21%

Fuel Cell System Labor (5856 hours)

Thermal ManagementAir SystemControls, Electronics, SensorsFuel SystemFuel Cell StackOther

Created: Aug-18-09 2:25 PM

Fuel Cell Vehicle Maintenance Events and Labor Hours

CDP#64: Fuel Cell Vehicle Maintenance by System

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National Renewable Energy Laboratory 85 Innovation for Our Energy Future

0

2

4

6

8

10

12

14

1015

Cyc

le

UD

DS

Cyc

le

US0

6 C

ycle

HW

FET

Cyc

le

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

Trip

Fre

quen

cy [%

]

Created: Sep-08-09 3:29 PM

CDP#65: Percent Idle in Trip with Comparison to Standard Drive Cycles

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National Renewable Energy Laboratory 86 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]

Ope

ratio

n Ti

me

[%]

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)

Created: Sep-09-09 7:39 AM

CDP#66: FCV Speed with Comparison to Standard Drive Cycles

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National Renewable Energy Laboratory 87 Innovation for Our Energy Future

0

5

10

15

20

25

30

35

40

45

Stac

k C

ount

Fuel Cell Stack Operation Hours: Gen1

Gen1

0-200 40

060

080

010

0012

0014

0016

0018

0020

00>2

000

Gen1 Hours

32% of stacks in operation

In Op1

Retired2

Other3

0

5

10

15

20

25

30

35

40

45

Stac

k C

ount

Fuel Cell Stack Operation Hours: Gen2

Gen2

0-200 40

060

080

010

0012

0014

0016

0018

0020

00>2

000

Gen2 Hours

65% of stacks in operation

In Op1

Retired2

Other3

Created: Sep-09-09 10:48 AM

1) Stack currently accumulating hours2) Stack removed for low performance3) Stack not currently accumulating hours, but not removed because of low performance

CDP#67: Fuel Cell Stack Operation Hours

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National Renewable Energy Laboratory 88 Innovation for Our Energy Future

0-5 10 15 20 25 30 35 40 >400

5

10

15

20

25

30

Stac

k C

ount

% FC Power Drop

FC Power Drop During Operation Period: Gen1

Gen1

68% of In Op stackshave > 10% power drop

In Op1

Retired2

Other3

0-5 10 15 20 25 30 35 40 >400

5

10

15

20

25

30

Stac

k C

ount

% FC Power Drop

FC Power Drop During Operation Period: Gen2

Gen2

95% of In Op stackshave > 10% power drop

In Op1

Retired2

Other3

Created: Sep-09-09 10:48 AM

1) Stack currently accumulating hours2) Stack removed for low performance3) Stack not currently accumulating hours, but not removed because of low performance

CDP#68: Power Drop During Fuel Cell Stack Operation Period

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National Renewable Energy Laboratory 89 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

ower

(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 4 points in segment.

Gen1 Data Range25th & 75th PercentilesGroup MedianOutlier

Created: Sep-09-09 10:48 AM

CDP#69: Max Fuel Cell Power Degradation –Gen 1

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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

ower

(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 4 points in segment.

Gen2 Data Range25th & 75th PercentilesGroup MedianOutlier

Created: Sep-09-09 10:48 AM

CDP#70: Max Fuel Cell Power Degradation –Gen 2

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0-200 400 600 800 1000 1200 1400 1600 1800 2000 >20000

5

10

15

20

25

30

27% Gen1 > 2000 projected hrs9% 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)

Created: Sep-09-09 10:48 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

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National Renewable Energy Laboratory 92 Innovation for Our Energy Future

-20 0 20 40 60-20

-10

0

10

20

30

40

50

60

Ambient Air Temperature [deg C]

Tank

Tem

pera

ture

[deg

C]

Tank vs. Ambient Air Temps Prior to Refueling

Freq

uenc

y

50

100

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-40 -20 0 20 400

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Delta Temperature [deg C]

Cou

nt

Delta Temperature: Tank minus Ambient

Delta Temp HistogramNormal Distribution Fit

0

0.05

0.1

Den

sity

Mean= -3.896Std Dev= 5.775

Created: Sep-09-09 11:11 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

CDP#72: Difference Between Tank and Ambient Temperature Prior to Refueling

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National Renewable Energy Laboratory 93 Innovation for Our Energy Future

10 15 20 25 300

200

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2000Fuel Cell Stack Projected Hours as a Function of Voltage Drop

% Voltage Drop

Proj

ecte

d H

ours

2,3

Gen 1 Average ProjectionsGen 1 Average Projection to 10% Voltage Degradation1

Gen 2 Average ProjectionsGen 2 Average Projection to 10% Voltage Degradation1

Created: Sep-11-09 8:57 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

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