HyTRAN - Europa · 2018-10-22 · MOTOR Opcon air compressor. ... ¾Novel micro channel diesel Fuel Processor ¾Novel Twin Screw Air Compressor ¾Balance-of-plant components ... 2006

Hydrogen and Fuel Cell Technologies for Road Transport

Fuel Cell and Hydrogen Joint Undertaking Stakeholders General Fuel Cell and Hydrogen Joint Undertaking Stakeholders General Assembly Assembly –– 2626--27 October 2009, Brussels, Belgium27 October 2009, Brussels, Belgium

HyTRANHydrogen and Fuel Cell Technologies for Road Transport

Dr. Per EkdungeVolvo Technology Corporation



• Program: IP in FP6• Coordinator: VOLVO

• Total budget: 16.8 M€• EU funding: 8.8 M€• Partners: 19• Countries: 7• Duration: 2004-2009

The HyTRAN project

OEM’s Suppliers

CENTRORICERCHEFIAT

CENTRORICERCHEFIAT

Universities/Institutes

http://www.vw.com/index.htm

http://www.imm-mainz.de/v0/vvseitene/vvhome/home.php

http://www.ecn.nl/corp/info.en.html

http://www.imperial.ac.uk/

http://www.envipark.com/script/park.dll?w=551028810&home



HyTRAN ObjectivesThe overall objectives of HyTRAN are to advance the fuel cell technology towards a commercially viable solution in terms of performance and cost by developing components and systems for:

Direct Hydrogen PEM Fuel Cell system, 80 kW power size, with innovative Fuel cell stack and Balance of PlantsAuxiliary Power Unite, APU, Diesel reformat PEM Fuel Cell 5 kWsystem, including microstructuredsteam reformer, clean-up reactor,i stack and Balance of Plants



Panda HyTRAN• Design phase:

Innovative vehicle layoutPowertrain components (innovative twin screw compressor developed by OpconElectric driveline (power electronics)

• FCS integrationAir systemHydrogen lineCooling systemWater management

• Control of an innovative powertrain

FUEL CELLSTACK

INVERTER MOTOREELETTRICO

Architettura elettricaArchitettura elettricaH2

aria ElectricElectric architecturearchitectureair

hydrogen

INVERTER ELECTRIC MOTOR

Opcon air Opcon air compressorcompressor



OpconAir

Compressor

Silencers

Stacks radiator Power electronicradiator

H2 tank60 l @ 350 bar

Nuvera PEM stackswith JM MEA

max 80 kW

Water recoverysystem from exhaust air

CHARACTERISTICSFull power fuel cell vehicle80 kW PEM fuel cellsNew generation Opcon twin screw air

compressorCarbon fiber hydrogen tankAC induction electric motor4 SeatsMax speed 130 km/hRefuelling time < 5 minRange (UDC) > 200 km

CHARACTERISTICSCHARACTERISTICSFull power fuel cell vehicle80 kW PEM fuel cellsNew generation Opcon twin screw air

compressorCarbon fiber hydrogen tankAC induction electric motor4 SeatsMax speed 130 km/hRefuelling time < 5 minRange (UDC) > 200 km



HyTRAN Panda main activities - Year 2009

• Final vehicle validation phaseTest on FIAT tracks for vehicle parameters identificationTest on roller bench for H2 consumption measurementRoad testing in harsh conditions participation to international competitions

• Rally Montecarlo, 26-29 March 2009• EVS Viking Rally, 11-13 May 2009

Tests on the HyNor Roadway in the south of Norway



Obtained results – Year 2009

• Hydrogen consumption: 9 g/km on NEDC cycle (corresponding to 3.6 l/100 km of gasoline equivalent against the fuel consumption of 6.5 l/100 km of the gasoline Panda NP)

• Rally Montecarlo: 1100 km driven without any failure

• Viking Rally: 750 km lenght, 1°place for consumption league and 2° place for final league

Speed/current profile during testNEDC cycle



APU ApplicationTruck driver run electrical on-board equipment during resting, e.g. radio, phone, television, computer, freezer, microwave, air conditioning, cab ventilation, …

At idle, diesel engines run at one of its most inefficient working points

~1.800 hours of idling per year and truck (in USA)

More than 5.000 $ per year and truck

U.S. trucks consume more than one billion gallons of diesel fuel during resting per year

Emission from idling of long haul truck U.S. : NOx: 180 000 tons per year

PM: 5 000 tons per year

CO2: 11 millions ton per year

Upcoming laws restrict the idling time



TP2 technical content

• 5kW Diesel FC-APU for vehicle application• HyTRAN combines technology development and

system integration workNovel micro channel diesel Fuel Processor Novel Twin Screw Air CompressorBalance-of-plant componentsSystem optimization and integrationSystem performance & controlVehicle integration potential, cost

• Tested Lab prototype


Fuel Cell and Hydrogen Joint Undertaking Stakeholders General Fuel Cell and Hydrogen Joint Undertaking Stakeholders General Assembly Assembly –– 2626--27 October 2009, Brussels, Belgium27 October 2009, Brussels, BelgiumSteam reformer prototype (courtesy of IMM)

Functionality of Fuel Cell APU

Preferential oxidation reactor prototype(courtesy of IMM)

Water gas shift reactor prototype(courtesy of IMM)



TP2 system integration work

Idea – simplified schematic

Complete system schematic after several design loops, simulations, sub-system testing and FMEA analysis

Simplified CAD model with black box components

CAD model with real key component models

System testing Final CAD model of the systemSystem built


Fuel Cell and Hydrogen Joint Undertaking Stakeholders General Fuel Cell and Hydrogen Joint Undertaking Stakeholders General Assembly Assembly –– 2626--27 October 2009, Brussels, Belgium27 October 2009, Brussels, BelgiumFuel Cell and Hydrogen Joint Undertaking Stakeholders General Fuel Cell and Hydrogen Joint Undertaking Stakeholders General Assembly Assembly –– 2626--27 October 2009, Brussels, Belgium27 October 2009, Brussels, Belgium

SP8000/WP8300SP8000/WP8300

WP 8300WP 8300Market AnalysisMarket AnalysisSelected resultsSelected results

Leader: Centro Ricerche FIATLeader: Centro Ricerche FIATPartner: Imperial College LondonPartner: Imperial College London



Diesel PEM FC APUs for trucksDiesel PEM FC APUs for trucks

• Strong market drivers for diesel APUs for trucks in California: “idling ban”• The rest of the US and Canada will probably follow soon, with a total market

size of 700,000 units• In Europe, the market is not driven by regulation, but by demand for added

comfort by the driver. Estimated market size: 100,000 units• Potentially competing diesel APU technologies

Internal combustion engines – commercialSolid-Oxide Fuel Cells – prototypes PEM Fuel Cells – prototypes Batteries – but these do not provide the same functionalities; not a directcompetitor

• Each one of these technologies has strengths and weaknesses, and is a different stage of development

• The possible future market uptake has been studied using a dynamic simulation model developed specifically for the project HyTRAN



Diesel FC APU market modelDiesel FC APU market model

Stock of PEM FCAPUs onboard

trucks

APU adoptiondecision

PEM FC APUtechnology

PEM FCtechnology

PEM FCniche/early markets

L1

L2

L3L4

RD&Dinvestment

Incentives

SOFCtechnology

Stock of ICE APUsonboard trucks

Stock of SOFCAPUs onboard

trucks

ICEtechnology

020,00040,00060,00080,000

100,000120,000140,000160,000180,000200,000

2006

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2018

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2022

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2028

2030

unit

s

year

( )

Portable generators

Small niche transport

Small stationary

Net present value

Demand for auxiliary power

Niche market scenarios

Learning curves



Diesel APU results: US marketDiesel APU results: US market

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PEM FC APU stack replacement

PEM FC APU slow niche markets

PEM FC APU stack replacement slow niche markets

PEM FC APU low investment

PEM FC APU stack replacement low investment

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PEM FC APU fuel processor x2

PEM FC APU fuel processor x5

Market uptake scenariosDiesel PEM FC APU economics are quite

good if compared to idling. Once minimum durability of 5,000 hours has been reached, market uptake can start and penetration can be fast. The most sensitive factor though is R&D investment, as underinvestment can slow down the process considerably.

Cost of fuel processor is also important, but affects the final uptake level more than the penetration rate



Diesel APU results: US marketDiesel APU results: US market

Market uptake scenariosDiesel PEM FC APUs, when developed,

are also expected to soon outcompeteICE APUs

However, diesel SOFC APUs can be a much stronger competitor, particularly in the long term. The width of the window of opportunity for diesel PEM FC APUs is strongly influenced by the relative R&D funding compared to SOFC diesel APU technology

0

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uni

ts in

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led

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PEM FC APU (baseline)

PEM FC APU (fuel processor x5)

ICE APU (baseline)

ICE APU (fuel processor x5)

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PEM FC APU (baseline)

PEM FC APU (fuel processor x5)

SOFC APU (baseline)

SOFC APU (fuel processor x5)



Diesel APU results: EU marketDiesel APU results: EU market

0

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PEM FC APU baseline

PEM FC APU fuel processor x2 no incentivePEM FC APU fuel processor x2 incentive 1000 eurPEM FC APU fuel processor x5 no incentivePEM FC APU fuel processor x5 incentive 1500 eur

Market uptake scenariosUptake of diesel PEM FC APUs in Europe may start early, but the weaker market drivers

mean that it would be slower than in the US. Incentives may be required and high capital cost may significantly hinder penetration



HH22 PEM FC powertrains for carsPEM FC powertrains for cars

• Due to the need to cut CO2 emissions, improve atmospheric air quality and move away from oil, ultimately highly efficient, ultra low emission powertrains for cars will be needed

• The electric powertrain seems ideal, but the question is: battery electric or hydrogen fuel cell?

• Comparing the lifecycle costs of the 3 following options provides important indications

Pure battery electric powertrain (BEV)“Pure” hydrogen fuel cell powertrain (hybrid configuration) (FCEV)Hydrogen fuel cell/ battery electric plug-in hybrid (FCHEV)

• The comparison is first done on a generic vehicle platform and generic driving cycle, and then behavioural aspects are also taken into account (i.e.: distributions of average daily distances driven by car types) particularly using the UK as a case study




Lifecycle cost sensitivity of various powertrains for a generic saloon car:

- 80 kWe peak power- 20 kWe mean power (@ 70

mph)

BEV: 25 kW battery

FCHEV: 20 kW fuel cell, 6 kW battery, 50:50 usage

The FCHEV is an important option that should not be overlooked




Data extracted from the UK National Travel Survey

It appears that different types of cars are indeed used differently

This has important implications for the optimum powertrainconfiguration

0

5

10

15

20

25

< 5 < 10 < 15 < 25 < 35 < 50 < 100 < 200 > 200

Perc

ent

Daily distance driven (miles)

Distribution of daily distance driven by car type in the UK

small car small/medium car medium car large car



HH22 PEM FC powertrains for carsPEM FC powertrains for carsDue to both vehicle characteristics and driver behaviour, the percent of miles driven on

electricity only changes across vehicle types for the same battery size

National Travel Survey Small Small / Medium

Medium & Average

Large

Market Segments Super-mini

Lower medium

Multipurpose

Luxury

Equivalent ICE mpg 51 45 40 28

Equivalent ICE gCO2 km-1 150 170 190 275

Peak power required / kW 62.7 71 80 114

Average power required / kW

15.7 17.8 20 29

H2 consumption / MJ mile-1 1.55 1.76 1.98 2.82

Electricity / MJ mile-1 0.77 0.88 0.99 1.41



HH22 PEM FC powertrains for carsPEM FC powertrains for carsPowertrain lifecycle cost as a function of battery size

for the 4 vehicle types considered• Overall lifecycle costs increase with vehicle size

• However, optimum battery size doesn’t change dramatically: 4-8 kWh for a small vehicle, 6-14 kWh for a large vehicle

• The role of PEM FCs increases with the vehicle size, as a higher percent of total mileage is driven on hydrogen



Additional informationAdditional information

The complete analysis for diesel PEM FC APU has been published on:Contestabile, M. (2009). "Analysis of the market for diesel PEM fuel cell auxiliary

power units onboard long-haul trucks and of its implications for the large-scale adoption of PEM FCs" Energy Policy doi:10.1016/j.enpol.2009.03.044.

Results of the powertrain analysis have been presented:Offer G. J., Contestabile M., Howey D., Clague R., Brandon N. P. (2009).

“Techno-economic and behavioural analysis of battery electric, hydrogen fuel cell and hybrid vehicles in a future sustainable road transport system in the UK” Eleventh Grove Fuel Cell Symposium, London, UK

And have been submitted for publication (currently under review)

For further questions: [email protected]

mailto:[email protected]

Documents

HyTRAN - Europa · 2018-10-22 · MOTOR Opcon air compressor. ... ¾Novel micro channel diesel Fuel Processor ¾Novel Twin Screw Air Compressor ¾Balance-of-plant components ... 2006