Fuel Cells as EV Range Extenders:A Near-Term Fuel Cell Solution
1501 Northpoint Parkway, Suite 101West Palm Beach, FL 33407
(561) 868-6720
2
EnerDel is the only company in the USA with the
capability in place to produce large
lithium ion batteries on a mass scale.
EnerFuel is developing
technologies and products that advance the
performance of fuel cells and enable
increased applicability to near
term markets.
NanoEner is developing new,
cutting-edge methods of material deposition and thin
films using Nanotechnology.
Enertech is the 3rd largest Li-Ion
battery producer in Korea. EnerTech ensures the cost of prodution for Li-Ion
batteries are competitive.
Ener1 Family
EnerDel Japan is working on
material & cell chemistry &
manufacturing processing for
lithium batteries.
Indianapolis,Indiana USA
West Palm Beach, Florida USA
Chungju, South Korea
Fort Lauderdale, Florida USAJapan
EnerDel is developing Lithium Ion batteries to improve the cost and performance of electric vehicles.
Ener 1 is the Group HeadNasdaq: HEV
Worldwide HQ:New York, New York USA
European HQ:Paris, France
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• Reduces required fuel cell nominal power
• Reduces required battery size• Eliminates fuel cell transient
operation• Reduces fuel cell required
start-up time
Unique Mix of Technologies Enables Fuel Cell Range Extender
EV Range Extender
HT-PEM Fuel CellHigh efficiency powerHigh energy density
BatteryImmediate powerElectrical energy
storage
Fuel ReformerEliminates need for hydrogen infrastructure
Eliminates reformer transient operationReduces required
reformer size
Eliminates reformate clean-up, Reduces reformer cost
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Small Fuel Tank
Fuel Processor
*
HT-PEM Fuel Cell Battery
Vehicle Propulsio
n
EV Range Extender
GasolineDieselE-85E-100MethanolBiodieselBiobutanolDME(others)
Electric Vehicle Vision
Fuels other than Hydrogen can be used
GridOpportunity Charging Stations
Opportunity: EV Range Extender produces no toxic emissions.Battery can be charged by fuel cell while vehicle is parked.
Opportunity: EV Range Extender produces no toxic emissions.Battery can be charged by fuel cell while vehicle is parked.
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Types of EV Range Extenders
1kW 3kW 10kW
Climate Control / Idle Charge Assisting Charge Sustaining
Cli
mate
Con
trol
/ Id
le •1-3kW fuel cell•Partial range extension
•Cabin heating and cooling
•Battery protection
Ch
arg
e A
ssis
tin
g •3-10kW fuel cell•Range extension
•Cabin heating and cooling
•Battery protection
Ch
arg
e S
ust
ain
ing •>10kW fuel cell
•Unlimited range extension
•Cabin heating and cooling
•Battery protection
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2008 EnerFuel Developed Range Extended EV
95mph max speed
8sec, 0 - 60mph (97kph)
Specification Li-Ion Fuel Cell
Energy Content 20kWh 20kWh
Max Power 80kW (for 10sec) 3kW (continuous)
Weight 200kg (Actual) 80kg (Actual)
Cost $15,000 ($750/kWh)
$5,250 ($1,750/kW or $263/kWh)
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HT-PEM Fuel Cell Module Reduces BOP
Air
Anode
Cathode
H2
Blower / Compressor
Cooling Fan
Gen 2.0 fuel cell module undergoing testing Reactant humidification and cooling system.Radiator much larger than for Piston Engine
HT-PEM LT-PEM
EnerFuel’s HT-PEM Fuel Cell Module Doesn’t Need:• Reactant humidification• Coolant loop / Coolant pumps • Radiator
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BOP and Stack Cost in the System
System Power
Ove
rall
Sys
tem
Co
st
% Stack
% BOP
BOP costs are a higher proportion of system weight, size and cost as fuel cell power is decreased.
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Reduction of BOP Impacts Costs of Lower Power Fuel Cells
500,000 unit annual production of 80kW system
Source: “Cost Analysis of PEM Fuel Cell Systems for Transportation” NREL/SR-560-39104
Percentage of Automotive System Cost
80KW System 5 KW System
500,000 unit annual production of 5kW system
Source: Estimation based on 80KW system
Percentage of Automotive System Cost
= BOP components eliminated in HT-PEM fuel cell (24% of total cost)
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Energy Density of Potential Fuels
4.4
5.9
7.7
9.0
9.9
2.41.9
0.9
0.0
2.0
4.0
6.0
8.0
10.0
12.0
Methanol Ethanol Butanol Conventionalgasoline
U.S.conventional
diesel
Hydrogen5kpsig
Hydrogen10kpsig
LiquidHydrogen
kWh
th/L
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HT-PEM Allows Reformer Integration
Typical Hydrogen Fuel Cell System
Hydrogen
The Problem
Requires Hydrogen Infrastructure
LT-PEM Fuel Cell
Previous Reformer-based Fuel Cell System
Energy
Traditional Fuel
LT-PEM Fuel Cell
Energy
H2
Reformer(Separates Hydrogen)
CO Remov
al
H2H2+CO CO Removal is:• Too Expensive• Too Heavy• Too Complicated• Too Large
Long Start-up Time(5-15 min)
EnerFuel System
Traditional Fuel
EnerFuel HT-PEM Fuel Cell
EnergyReformer(Separates Hydrogen)
H2+COUses Existing Fuel Infrastructure, CO Removal is not necessary
The Solution
The Problem
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• HT-PEM has much lower susceptibility to CO poisoning than LT-PEM
• Allows for simplified and low cost integration with reformers
20 40 60 80 100 120 140 160 180 200 2200
20
40
60
80
100
Relative Activity for Fuels with a Range of CO Levels
Temperature (°C)
Re
lati
ve
Ac
tiv
ity
of
Fu
el C
ell
Ele
ctr
od
e (
%)
10
0 %
= F
ull
Av
aila
ble
Ac
tiv
ity
0.002%
0.01%
0.1%
0.5%
10%
5.0%
1.0%
3.0%
16%
Source: Q. Lietal /Progress in Polymer Science 34 (2009) 449–477
LT-PEM Op. Temp
EnerFuelHT-PEM
Operating Temp
EnerFuel Can Tolerate CO in Reformed Hydrogen
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Electric Vehicle Usage Model
TRIP
Here
There
Daily CommuteConsists of a series of trips
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Inputs to Monte Carlo* Analysis
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Min Median Max
Average Trip Length (mi [km]) 1 [1.6] 10 [16.1] 50 [80.5]
Average Trip Vehicle Speed (mph, [kph]) 15 [24.1] 45 [72.4] 50 [80.5]
Number of Trips per Day 2 4 10
Average Time Between Immediate Trips (h) 0.5 3 8
Vehicle Average Driving Energy Consumption (Wh/mi [Wh/km]) 100 [62] 200 [124] 350 [217]
*Monte Carlo Analysis runs a large number of scenarios to determine the likelihood of potential outcomes.
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Vehicle Energy Needs
TRIPEV
HereThere
EV
Daily CommuteConsists of a series of trips
4.4kWh average trip energy10kWh battery can power 97% of trips
23kWh average commute energy
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1 3 5 100
5
10
15
20
25
30
35
40
45
50
4.7
14.2
23.7
47.4
1.9
5.7
9.5
18.9
Average Energy Provided by FC (kWh) 97% Confidence Level
Fuel Cell Power (kW)
En
erg
y C
on
trib
uti
on
by
Fu
el
Ce
ll f
or
Da
ily
Co
mm
ute
(k
Wh
)
Fuel Cell Adds Range and Could Reduce Battery Pack Size
On average, a 5kW fuel cell stack would add 20kWh of range to the daily commute
A 5kW fuel cell stack could reduce battery pack size by 9kWh with minimal risk of adversely affecting vehicle driving range
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Fuel Cell Reduces Probability of Needing to Charge During Day
0 1 2 3 4 5 6 7 8 9 10 110%
20%
40%
60%
80%
100%
37%
51%
71%
84%
96%
52%
63%
79%
89%
97%
Probability FC + Battery Will Fulfill Daily Commute Energy Needs
20kWh Battery 15kWh Battery
Fuel Cell System Power Output (kW)
20kWh Battery Only
15kWh Battery Only
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Vehicle EfficiencyEfficiency Definitions:
consumed gasoline of gallons
driven milesEfficiency Perceived
consumedenergy electrical eq. gasolineconsumed gasoline of gallons
driven milesEfficiency Vehicle
= 91mpg2.6 L/100km
= 72mpg 3.3 L/100km
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Fuel Cell Lowers EV Driving Range Cost
Assuming 200Wh/mi average drive energy consumption, reformer based 5kW FC system at $1750/kW, battery cost is $750/kWh.
100
219
171$15,000
$23,764
$16,639
0
50
100
150
200
250
300
20kWh Battery 20kWh Battery + 5kW FC10kWh Battery + 5kW FC
Avg
. Veh
icle
Ran
ge
(mi)
$0
$5,000
$10,000
$15,000
$20,000
$25,000
Po
wer
pla
nt
Pri
ce (
$)
Avg. Vehicle Range (mi) Powerplant Price
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<10kW System Enables Related Applications
Stationary, Backup Power,
microCHP
E-Bikes
MaterialHandlingTelecommunications
Related Applications Drive Economies of Scale
<10kWFuel Cell
<10kWFuel Cell
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Conclusions
1. The use of Charge Assisting (3-10kW) fuel cell systema. Provides significant increase on daily vehicle driving rangeb. Reduces the capital cost associated with EV driving rangec. Improves customer satisfaction (reduction of range anxiety)
2. Fuel Cell Range Extender Provides Benefits Other Than Range
a. Capacity to “run while parked”b. Climate controlc. Battery life extension
3. Systems developed in the same power level have other near-term applicationsa. Idle eliminatorsb. Backup powerc. Micro-CHPd. Material Handling
Thank you
Questions and Answers
For more information please contact:
Daniel A. Betts, [email protected]
1501 Northpoint Parkway, Suite 101West Palm Beach, FL 33407
+1 (352) 258-1405