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Prospects and Challenges for Fuel Cell Cars for Tomorrow’s mobilityDr. Peter Treffinger / Prof. Horst E. Friedrich / Dr. Karelle CouturierNovember 21st 2007, 2nd International Workshop on Functional Materials for Mobile Hydrogen Storage, Karlsruhe

Folie 2 > Vortrag > AutorDokumentname > 23.11.2004

Functional Materials for Mobile Hydrogen Storage > Treffinger > Karlsruhe > Nov. 21st 2007, slide 2

Institute of Vehicle Concepts

DLR - sites and employeesThe DLR - German Aerospace Research Center

5.100 employees working in 27 research institutes and facilities

at 8 sitesin 7 field offices.

Offices in Brussels, Paris and Washington.

fields of research:aeronautics, space, transport, energy

Köln-Porz

Lampoldshausen

Stuttgart

Oberpfaffenhofen

Braunschweig

Göttingen

Berlin--Adlershof

Bonn

Trauen

HamburgNeustrelitz

Weilheim

Berlin-Charlottenburg

Sankt Augustin

Darmstadt




Outline

Bench mark liquid fuelTomorrow’s vehicle concepts ?

Fuel consumptionDevelopment routes

Tomorrow’s fuels ?Fuel cell cars and hydrogen storages

Operation conditionsSafetyCost

Summary




Bench mark – Storage of conventional liquid fuels

Picture: TI Automotive

Almost free shapableVolumetric efficiency (Volume of Storage / package space) ≈ 90 %Gravimetric efficiency (Mass of fuel / Mass of empty storage) ≈ 4,0Gravimetric energy density ≈ 9,5 kWh/kgSystem weight




Honda IMA

Toyota Fine-X

Bora Hy-Power

Vehicle Concepts

LexusRX400h

HyperCar

F-Cell

A-KlasseB-Klasse

GM Sequel

Audi Q7 hybrid

Two-Mode Hybrid

BMWGM

DaimlerChrysler

Touran Hy-Motion

Toyota Prius

DLR - Hylite




Fuel consumption

MJ/km

source: Y. Baba, H. Ishitani. Well to Wheel Efficiency of Advanced Technology Vehicles in Japanese. Electric Vehicle Symposium. Long Beach, 2003.

velo

city

(km

/ h)

0 200 400 600 800 1000 12000

20

40

60

80

100

120

1400Zeit (s)

velo

city

(km

/ h)

0 200 400 600 800 1000 12000

20

40

60

80

100

120

1400Zeit (s)

velo

city

(km

/ h)

0 200 400 600 800 1000 12000

20

40

60

80

100

120

1400Zeit (s)

velo

city

(km

/ h)

0 200 400 600 800 1000 12000

20

40

60

80

100

120

1400Zeit (s)

Japan 10-15-Mode

US-UDDS

NEFZ

US-Highway

Japan1015US-UDDSNEFZUS-Highway

0,0 0,5 1,0 1,5 2,0 2,5 3,0

gasoline engine

gasoline hybrid

diesel engine

diesel hybrid

FC (CH2)

FC hybrid(CH2)

-36%-30%

-20%

-46%




CO2-emissionsdifferent generic drive trains

sources: DLR. R. Edwards, Well-To-Wheel Analysis, 2003. UBA-H2, Entwicklung einerGesamtstrategie zur Einf. alternat. Kraftstoffe. Pehnt, Ganzheitliche Bilanzierung, 2002. Schweimer, Sachbilanz des Golf A4, Wolfsburg.

0 500 1000 1500 2000 2500 3000 3500

reference gasoline middle class

gasoline start/stop

gasoline micro hybrid

gasoline mild hybrid

gasoline full hybrid

FC vehicle H2 ex Coal

FC vehicle H2 ex CNG

FC vehicle H2 ex CleanCoal

FC vehicle H2 ex REG

cumulated CO2 -emissions (kg/a)

vehicle

fuel production

urban operation

highway operation




CO2 reduction potentials

Ø new cars in Germany 2004 (source: ifeu/KBA)

EU-goal for 2012

ACEA goal for 2008 (KAMA 2009)

100

120

140

160

180

80

CO

2em

issi

ons

of n

ew v

ehic

les

in g

/km

(NEF

Z)

2012 2020 2030

cost optimated mix of technologies lightweight construction, integral, electro hybrid

lightweight construction, integral, gasoline engine

full hybrid

mild hybrid

optimization gasoline engine, second stage

aerodynamic resistance, long term

red. of rolling resistanceoptimization gasoline engine, third stage

efficient gearbox

stop/start, externoptimization gasoline engine, first stage

lightweight construction, first stage

aerodynamic resistance, short term




Roadmap towards sustainability

Movie: Schulé, 2005




Fuel scenario for GermanyHigh-efficient vehicles & liquid bio fuels

2.500

1.500

2.000

1.000

500

02000 2010 2020 2030 2040 2050

PJ/a

Hydrogen

Bio-Ethanol

Natural Gas

Diesel fossil, PC

Gasoline

Electricity

Diesel fossil, Trucks

1st gen biodiesel

2nd gen biodiesel (BtL)

Mrd. Veh-km

500

550

600

700

750PC

50

55

60

65

70

75HT

Kilometers traveled

650

Reduction of CO2 Emissionsby 2nd generation bio-fuels

Reduction of fuel consumption by efficient vehicle concepts

Diversificationbyalternative power trains/fuels

Quelle: DLR




Fuel cell vehicleExample Mercedes-Benz F-600 Hygenius

Sources: Brennstoffzellenantriebe Technischer Status und Ausblick, ATZ 09/2007; www.all4engineers.com, www.daimlerchrysler.com

Permanent excited Synchronous motor(85 kW, 350 Nm)

Wasser-cooled Lithium-Ionen-BatteryFuel cell stack (60 kW)Compressed hydrogen (700 bar) Electrical compressorNew Humidification deviceRange: 400 kmMax speed: 170 km/h

The following data is based on our estimation:Fuel cell stack operation temperature: ~ 80 °C

⇒ Challenge heat rejection (Have a look on front area of vehicle) Hear more on that issue in presentation of VW




--440384440100Number of cells

GM Equinox

-

-

-

Metal

ca. 85 °C

ca. 1,7 bar

93 kW

2005

PEM

St – 18

GM

FCX(2003)

0,9 kW/kg

48 kg

(33 l)

Metal

max. 95 °C

-

43 kW

2003

PEM

Honda

FCHV(7/2005)

-

-

-

-

-

-

90 kW

-

PEM

Toyota

140 kg96 kg-Weight

200420032006Developmentdate (approx.)

Andromeda IIMark 902Labeling

DC F 600 HYgenius

ca. 1 kW/kg

-

Metal

ca. 70-80°C

ca. 1,6 bar

16,5 kW

PEM

DaimlerChrysler

0,6 kW/kg0,9 kW/kgspez. Weight

NuveraBallardManufacturer

PEMPEMStack Type

Fiat Panda Hydrogen

DC F-CellInstalled in vehicle

864x486x200mm³ (84 l)

805x375x250mm³ (75 l)

Dimensions

MetalGraphiteBPP Material

70 – 85 °C65 - 80 °CTemperature

1,6 bar3 barPressure (abs.)

85kW85 kWPower

Data of fuel cell stacks

Sources: Gathered from several sources, publications, web-sites, might be notconsistent.




--440384440100Number of cells

GM Equinox

-

-

-

Metal

ca. 85 °C

ca. 1,7 bar

93 kW

2005

PEM

St – 18

GM

FCX(2003)

0,9 kW/kg

48 kg

(33 l)

Metal

max. 95 °C

-

43 kW

2003

PEM

Honda

FCHV(7/2005)

-

-

-

-

-

-

90 kW

-

PEM

Toyota

140 kg96 kg-Weight

200420032006Developmentdate (approx.)

Andromeda IIMark 902Labeling

DC F 600 HYgenius

ca. 1 kW/kg

-

Metal

ca. 70-80°C

ca. 1,6 bar

16,5 kW

PEM

DaimlerChrysler

0,6 kW/kg0,9 kW/kgspez. Weight

NuveraBallardManufacturer

PEMPEMStack Type

Fiat Panda Hydrogen

DC F-CellInstalled in vehicle

864x486x200mm³ (84 l)

805x375x250mm³ (75 l)

Dimensions

MetalGraphiteBPP Material

70 – 85 °C65 - 80 °CTemperature

1,6 bar3 barPressure (abs.)

85kW85 kWPowerChallenge desorption temperature:If the “HT-PEM” does not happen we would rely on a temperature level for desorption of approx. 90 °C

Challenge desorption temperature:If the “HT-PEM” does not happen we would rely on a temperature level for desorption of approx. 90 °C

Data of fuel cell stacks

Sources: Gathered from several sources, publications, web-sites, might be notconsistent.




H2-Storage Compartment 1


AmbientPEFC-

Stack Case

H2-ComponentCompartment

Ambient

H2-Sensor 1

H2-Sensor 3 in the Passenger Compartment

H2-Sensor 2

Example HyLite® fuel cell system packageSafety concept and hydrogen storage






AmbientPEFC-

Stack Case

H2-ComponentCompartment

Ambient

H2-Sensor 1

H2-Sensor 3 in the Passenger Compartment

H2-Sensor 2

Example HyLite® fuel cell system packageSafety concept and hydrogen storage

Components/function neededStorage (material + heat exchanger + vessel); storing hydrogenCharging line with safety equipment; provide mass flow; operating pressureHydrogen supply line to fuel cell stack with safety equipmentHeating and cooling circuit for desorption and adsorptionEventually: Cold start device

⇒ System mass must consider all components required to fulfill the functions

Components/function neededStorage (material + heat exchanger + vessel); storing hydrogenCharging line with safety equipment; provide mass flow; operating pressureHydrogen supply line to fuel cell stack with safety equipmentHeating and cooling circuit for desorption and adsorptionEventually: Cold start device

⇒ System mass must consider all components required to fulfill the functions




Challenge charging of storage

35 kJ/mol: 5 kg H2 90 MJ5 min: ca. 300 kW

0

1

10

100

1000

2.25 2.75 3.25 3.75 4.25Temperature 1000/T [1/K]

Pres

sure

P [b

ar]

high pressure

lowtemperatur

0.1

Temperature T [°C] 150 100 50 0 -50

1 bar

25 bar85

°C 0 °C

ΔH = -40 kJ/molRΔS

RTΔHln(P) −=

ΔS = -130 J/mol.K ΔH = -35 kJ/mol

ΔH = -30 kJ/mol

ΔH = -25 kJ/mol




Challenge charging of storage

35 kJ/mol: 5 kg H2 90 MJ5 min: ca. 300 kW

0

1

10

100

1000

2.25 2.75 3.25 3.75 4.25Temperature 1000/T [1/K]

Pres

sure

P [b

ar]

high pressure

lowtemperatur

0.1

Temperature T [°C] 150 100 50 0 -50

1 bar

25 bar85

°C 0 °C

ΔH = -40 kJ/molRΔS

RTΔHln(P) −=

ΔS = -130 J/mol.K ΔH = -35 kJ/mol

ΔH = -30 kJ/mol

ΔH = -25 kJ/mol

The station should provide cooling power of several 100 kWI personally believe not on concepts replacing of storages; warranty!

The station should provide cooling power of several 100 kWI personally believe not on concepts replacing of storages; warranty!




Experiments on charging of technical solid statestorages

Variety of storage tanks 40 to 400 Nl H2 capacityCharge/discharge at constant pressureor constant mass flowExternal cooling/heating system (2.25 kW)

Lab scaled tank125 cm3 geometric volumeFulfilled with variety of low temperature metal hydride (AB5, AB2, etc…)Temperature profile and pressure drop in the hydride bed

Commercially available storage tank as bench mark AB5 with annular geometry (300 Nl H2 capacity)Storage of JSW compatible to HyLite vehicle

Sources: DLR, Institute of Technical Thermodynamics, Institute of vehicle concepts

Fuel cell stackHeat management

Air supply system JSW storage

Lab scaled storage

Storage test bench

Fuel cell system test bench




Experiments on charging of technical solid statestorages

Variety of storage tanks 40 to 400 Nl H2 capacityCharge/discharge at constant pressureor constant mass flowExternal cooling/heating system (2.25 kW)

Lab scaled tank125 cm3 geometric volumeFulfilled with variety of low temperature metal hydride (AB5, AB2, etc…)Temperature profile and pressure drop in the hydride bed

Commercially available storage tank as bench mark AB5 with annular geometry (300 Nl H2 capacity)Storage of JSW compatible to HyLite vehicle

H2 loading in a LaNi5 Storage tank: 40 L H2, T=25°C, P=10 bar

0

2

4

6

8

10

12

14

0 100 200 300 400 500 600 700 800 900 1000

Time [s]

H2 l

oadi

ng [g

H2 /

kg

Me]

Simulation

Experiment

Sources: DLR, Institute of Technical Thermodynamics, Institute of vehicle concepts

Fuel cell stackHeat management

Air supply system JSW storage

Lab scaled storage

Storage test bench

Fuel cell system test bench




Challenge dynamic operation

Increase of the effective conductivity of the MeH-Bed with Aluminum

1 kg H2 storage tank

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

01.32

0.113

0.225

0.337

0.448

0.560

0.672

0.783

0.895

0.9107

Al fraction in LaNi5effective conductivity [W/mK]

H2

load

ing

at

5 m

in [

kg]

0

50

100

150

200

250

300

350

400

tota

l mas

se [

kg]

and

volu

me

[L]

of

the

sto

rag

e ta

nkmasse of the container [kg]

masse of Al [kg]

masse of LaNi5 [kg]

volume of the container [L]

H2 loading at 5 min [kg]

DOE 2010: 17 kg - 23 L

Dynamic operationUnderstand heat and mass transfer Develop effective heat and mass transfer employing light weight heat exchange devices

Dynamic operationUnderstand heat and mass transfer Develop effective heat and mass transfer employing light weight heat exchange devices

Source: DLR, Institute of Technical Thermodynamics




Challenge cost

DLR cost model for Li-Ion batteries

Carlson (2005) 500k stacks/a

DLR (2007) 10 stacks

Membrane 4.36 € 165.20 €Electrodes 52.08 € 205.42 €GDL´s 3.43 € 51.36 €Bipolar plates 8.98 € 85.26 €Gaskets 2.32 € 10.05 €Summe 71.17 € 517.29 €

DLR cost investigation of fuel cell stacksDLR (2007) cost consider material cost only




Challenge cost

DLR cost model for Li-Ion batteries

Carlson (2005) 500k stacks/a

DLR (2007) 10 stacks

Membrane 4.36 € 165.20 €Electrodes 52.08 € 205.42 €GDL´s 3.43 € 51.36 €Bipolar plates 8.98 € 85.26 €Gaskets 2.32 € 10.05 €Summe 71.17 € 517.29 €

DLR cost investigation of fuel cell stacksDLR (2007) cost consider material cost only

Cost issue of fuel cell Cost issue of traction batteriesCost issue of solid state storage ?

Cost issue of fuel cell Cost issue of traction batteriesCost issue of solid state storage ?




SummaryLiquid fuel tank is tough bench markMultiple power train technologies are in development the race is going on …Hydrogen competes with other fuels also in long term

Bio fuelsElectricity

Solid state storage faces a lot of challengesReversible capacity of materialCyclabilityAdjustment to operation conditions of fuel cell system (T and p)Refueling effortsIs gravimetric energy density kept when considering all components needed in real operationand finally what‘s about the cost ...

We should discuss today and then go back to work immediately ...

Thank you very much for your attention!

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Prospects and Challenges for Fuel Cell Cars for Tomorrow’s ... › imperia › md › content › gkss › institu… · Prospects and Challenges for Fuel Cell Cars for Tomorrow’s