FuelCellTechnologiesOfficeU.S.DepartmentofEnergy

AnOverviewoftheFCTOHydrogenStorageProgram’sCompressedGasStorageR&DChallengesandStrategies

U.S.DepartmentofEnergyFuelCellTechnologiesOffice

BrianRiceCourtesyofNedStetson

Fuel Cell Technologies Office |1HydrogenFuelCellVehiclesareNowAvailable!

Initialvehiclerolloutoccurringwithcompressed700barpressurehydrogenstorage

HyundaiTucsonFuelCell ToyotaMirai

PhotoCredit:HyundaiMotor PhotoCredit:ToyotaMotor

HondaClarityPhotoCredit:HondaMotor

AllcurrentcommercialFCEVsusetwo

700barcompositeoverwrappedpressurevesselsforonboardhydrogenstorage

Fuel Cell Technologies Office |2

-

500

1,000

1,500

2,000

2,500

U.S.FuelCellCarSalesandExpertOutlook

2,000

Absolutelyorpartlyagreethat

fuelcellcarssoldorleasedintheU.S.

August2014 May2017

Note:Cumulativenumberofvehiclessold/leased.Source:hybridcars.com

FuelCellCarSalesGrowing

Fuelcellcarswillbetherealbreakthroughforelectricmobility

78%ofexecutives

KPMG,GlobalAutomotiveExecutiveSurvey2017(Jan.2017)

Fuel Cell Technologies Office |3FuelCells:BigleapsinHeavyDutyTruckSpace

ZH2:U.S.ArmyandGMcollaborationFirstofitskind

FuelcellbusesinCAsurpass17Mpassengers

Industrydemonstratesfirstheavydutytruck

Fuelcellelectricdeliveryandparceltrucks– Firstofitskinddemonstration- FedExandUPSstartingdeliveriesthissummer!

Fuel Cell Technologies Office |4FuelCellForkliftOrdersontheRise

Credit:FuelCellEnergy

BMWplantinGreer,SouthCarolina

Over15,000fuelcellforkliftsdeployedoronorderbyindustry

Approx.6millionhydrogenrefuelings todate

MHE:MaterialHandlingEquipment(MHE),TypeIandII*Source:NREL..AnEvaluationoftheTotalCostofOwnershipofFuelCell–PoweredMHE(2013)

AnnualizedCostExample

Fuel Cell Technologies Office |5

GasolineHydrogen@700bar

~7xgasoline

GasolineHydrogen@700bar

~3.5xgasoline

ChallengesforHydrogenasanEnergyCarrier

Hydrogenisalow-densitygasunderallpracticalconditionsonearth

VeryLowEnergyDensity

Evenwhencompressedtohighpressures,H2 haslowenergyby

volumecomparedthanmostotherfuels!

H2 fueltanksonboardvehiclesarelargerthantypicalgasolinetanks

…even withefficiencyofthefuelcellis considered

HydrogeniscurrentlystoredinCompositeOverwrappedPressureVesselsat700bar(~10,000psig)

Fuel Cell Technologies Office |6CurrentStatusvs.RevisedTargets

StorageTargetsGravimetrickWh/kg(kgH2/kgsystem)

VolumetrickWh/L(kgH2/Lsystem)

Costs1$/kWh($/kgH2)

2020 1.5(0.045)

1.0(0.030)

$10($333)

2025 1.8(0.055)

1.3(0.040)

$9($300)

Ultimate 2.2(0.065)

1.7(0.050)

$8($266)

CurrentStatus2

700barcompressed(5.6kgH2,TypeIV,SingleTank)

1.4(0.042)

0.8(0.024)

$15($500)

ThefullsetofH2 storagetargetscanbefoundontheProgram’swebsite:https://energy.gov/eere/fuelcells/downloads/doe-targets-onboard-hydrogen-storage-systems-light-duty-vehicles

1 Projectedat500,000units/year2 FCTODataRecord#15013,11/25/2015:https://www.hydrogen.energy.gov/pdfs/15013_onboard_storage_performance_cost.pdf

Fuel Cell Technologies Office |7MoreChallengesforH2 asanEnergyCarrier

High-pressureH2 storagetanksareexpensiveanddifficulttopackageonboardvehicles

Conventional gasolinetanksarehighlyconformable

High-pressureH2 tanksarelargerandhaverigidcylindricalshapes

https://www.hydrogen.energy.gov/pdfs/15013_onboard_storage_performance_cost.pdf

CarbonFiber62%

ResinMaterials4%FilamentWinding6% OtherManufacturing

Processes3%

Muchhighercosts!

CarbonfibercompositeBalanceofPlantComponents

2020Target UltimateTarget

$2455for5kgH2

$3950for5kgH2

Analysisforasingletankdesign

Fuel Cell Technologies Office |8

LeveragingeffortsoftheInstituteforAdvancedCompositesManufacturingInnovation

InstituteforAdvancedCompositesManufacturingInnovation

Leveragedproject:ThermoplasticCompositeCompressedGasStorageTanks

Cross-Cutting:IACMI-TheCompositesInstitute

• InstituteofManufacturingUSA• ManagedbytheEEREAdvancedManufacturingOffice• TechnologyFocusAreas:

- Vehicles- WindTurbineBlades- CompressedGasStorageVessels- Design,Modeling&Simulation- CompositeMaterials&Processes

• Projectlead:DuPont• Partners:- CompositePrototyping

Center(CPC)- SteelheadComposites- UniversityofDayton

ResearchInstitute(UDRI)• Kick-off:FY2017,Q1