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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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DOE OSTI2024

Assessment of Heavy-Duty Fueling Methods and Components

Building on the successful commissioning and demonstration of NREL's heavy-duty (HD) fast flow research facility under the Innovating Hydrogen Station's Project, researchers advanced R&D activities to the next phase under a new project titled, Assessment of Heavy-Duty Fueling Methods and Components. This Cooperative Research and Development Agreement (CRADA) is led by NREL in partnership with NextEnergy, Argonne National Laboratory, and Chevron with NextEnergy representing a larger group of industry partners that includes AirLiquide, Hyundai, Nel, Nikola, Shell, and Toyota. The CRADA seeks to develop a comprehensive assessment of HD fuel cell electric vehicle fueling protocols and fueling hardware to understand the effects of fueling protocol architectures on station design, vehicle design, functional safety requirements, and the implications on the total cost of ownership (TCO) and techno economic assessment (TEA).

class 8 truck↗
DOE OSTI2025

Regional Analysis for an Economically and Environmentally Viable Transition to Heavy-Duty Vehicles with Alternative Powertrains

The transportation sector is responsible for a significant portion of greenhouse gas emissions. Within the sector, truck freight is responsible for a third of the associated emissions. Alternative powertrains are seen as a viable approach to significantly reduce these emissions. Prior to making a large-scale transition, it is important to consider the following questions: will the power grid support a transition to alternative powertrains?; will the transition truly reduce carbon emissions?; and will the transition impose an unnecessary economic burden on companies within the industry? The answer to these questions, however, can vary by geography, maturity/capacity of the energy distribution network or predicted vehicle load. We focus on the latter two questions, investigating the variation in estimated total cost of ownership and carbon emissions across the United States at the zip code level for both heavy-duty battery electric vehicles and heavy-duty fuel cell electric vehicles. As a benchmark, we compare estimated emissions and costs of alternative powertrain vehicles to that of conventional heavy-duty vehicles powered by diesel internal combustion engines. This work highlights areas with electric grids primed for a transition to alternative powertrain vehicles, such as the Pacific Northwest, and areas that require further infrastructure investment in renewables, such as many of the Mountain states, Missouri, and Florida. Additionally, this work illustrates the current advantages in carbon emissions of battery electric vehicles compared to fuel-cell electric vehicles, while providing insights into required regional investments for narrowing the gap.

Goulet, Nate [ORNL] (ORCID:0000000237314965)↗
DOE OSTI2021

Low-Cost Intermediate-Temperature Fuel-Flexible Protonic-Ceramic Fuel Cell and Stack

Large, centralized power plants are currently the most efficient way to convert fuels such as natural gas to electricity. Fuel cells, however, could become highly efficient generators across a range of sizes from tens of watts to megawatts. In particular, fuel cells with an electrical efficiency of 50% could displace small generators of 25 kilowatts (kW) or less in applications such as remote power, telecommunications, and residential cogeneration. Current 25 kW natural gas generators employing internal combustion engines are typically only 25-30% efficient and expensive to maintain. Furthermore, fuel cells could provide valuable services to the grid, such as the ability to ramp power up or down in response to load conditions. While there are different types of fuel cells, each with their strengths and weaknesses, fuel cells generally are very expensive. For example, lower temperature fuel cells can be started up quickly, but require highly pure hydrogen fuel and expensive catalysts. High-temperature fuel cells can operate on a range of fuels, but they have costly system components and can degrade rapidly.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Powertrain Performance and Total Cost of Ownership Analysis for Class 8 Yard Tractors and Refuse Trucks

Advanced powertrain technologies, specifically fuel cell electric powertrains, have gained attention as viable alternatives for medium- and heavy-duty (M/HD) vehicles. However, it is unclear how these alternative powertrain vehicles stack up against their diesel counterparts in terms of performance and total cost of ownership (TCO). Furthermore, there are vehicle segments within the M/HD sector that have remained unstudied for fuel cell electric applications. This analysis aims to provide a comparative scoping-level TCO and performance analysis for two heavy-duty vocation vehicles (Class 8 U.S. port-side yard tractor and Class 8 U.S.-based refuse truck) for both conventional diesel and heavy-duty fuel cell electric (HDFC) powertrains. The refuse truck analysis also considered compressed natural gas powertrains (CNG) for comparison. The analysis includes seven timeframes (2020, 2025, 2030, 2035, 2040, 2045, and 2050) for comparison. This simplified TCO analysis includes only direct costs (fuel price, glider purchase price, and operating & maintenance costs) and excludes any associated indirect cost (e.g., dwell time costs and other opportunity based costs). Representative drive cycles for each vehicle were based on on-board GPS logged data and chosen by the analysis team to represent average, non-extreme driving conditions. At the time the analysis was performed, the Inflation Reduction Act was not in effect and therefore any potential subsidies and future cost reductions enacted under the Inflation Reduction Act were not included. Based on the operational setpoints used in this analysis, HDFC powertrains for both yard tractors and refuse trucks have the potential to achieve TCO advantages over conventional diesel powertrains (and CNG for refuse truck applications) in the near- to mid-term future while meeting the necessary duty cycle performance requirements. Yard tractors and refuse trucks spend a significant amount of time operating at low speeds, with long durations of idling, and experience numerous start/stop occurrences. These operational characteristics favor fuel cell performance as fuel cells operate with higher efficiencies at lower percentages of total power output. Conversely, conventional diesel and CNG engines are most efficient at higher percentages of total power output. This helps HDFC powered yard tractors and refuse trucks realize improved fuel economy when compared to their diesel counterparts, which helps reduce total fuel costs and therefore, total TCO. The analysis demonstrates that fuel prices play a significant role in determining TCO for each vehicle and should remain an R&D focus area. Overall, under the analysis' specified conditions, HDFC yard tractors have the potential to achieve cost parity with diesel yard tractors as early as 2025. For refuse trucks, HDFC refuse trucks have the potential to achieve cost parity with diesel and CNG refuse trucks in 2030 and 2040, respectively.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

The role of infrastructure to enable and support electric drive vehicles: A Transportation Research Part D Special Issue

Widespread vehicle electrification appears to be necessary to achieve timely and deep reductions in greenhouse gases (GHG) and pollutant emissions as well as petroleum use in the transportation sector. The lack of a sufficient refuelling infrastructure has defeated many past efforts to promote alternatives to petroleum fuels. The papers in this special issue on the “Role of Infrastructure to Enable and Support Electric Drive Vehicles” address the diverse challenges posed by a transition from fossil-fuelled internal combustion engine vehicles to vehicles powered by electric motors and the special role of refuelling/recharging infrastructure in this transition. Electric drive vehicles are herein considered to be plug-in electric vehicles (PEVs), including plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs), and hydrogen fuel cell electric vehicles (FCEVs). BEVs and FCEVs are also known as Zero Emission Vehicles (ZEVs) because their propulsion systems produce no tailpipe emissions.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Market Segmentation Analysis of Medium and Heavy Duty Trucks with a Fuel Cell Emphasis

The medium- and heavy-duty transportation sector is experiencing rapid changes in powertrain technology innovation with recent announcements of battery electric and fuel cell electric trucks being offered. However, the economics of these alternative powertrain vehicles are uncertain and difficult to compare directly. This analysis seeks to bridge the gap of techno-economic analyses for these alternative powertrain vehicles by comparing all of them within the same analytic framework. Specifically, this report evaluates the total cost of ownership (TCO) of six different truck powertrain technologies (diesel, diesel hybrid-electric, plug-in hybrid electric, compressed natural gas, battery electric, and fuel cell electric) for three different truck vocations (Class 8 long haul [750 mile range], Class 8 short haul [300 mile range], and Class 4 parcel delivery), for different Department of Energy technology statuses (2018, 2025, and Ultimate). The TCO framework includes direct costs (purchase price, fuel, operating and maintenance), indirect costs (dwell time costs due to refueling/recharging and payload opportunity costs from forgone revenue due to the truck being weight-limited), but excludes general operation costs (driver wages and benefits, insurance, tire replacements, permits, tolls) that are assumed to be the same across powertrains. The TCO was evaluated for four scenarios that reflect typical business operating conditions. The TCO analysis results highlight that each powertrain technology may have an economic advantage on a TCO basis in certain business operating conditions and depending on fuel price realized. For Class 8 long haul trucks when payload opportunity costs are not incurred, battery electric and fuel cell electric powertrains could be cost competitive with diesel if the 2025 targets are achieved and fuel prices are low. If payload opportunity costs are incurred, battery electric powertrains are not estimated to reach TCO parity with diesel even if Ultimate targets and low electricity prices are realized, indicating a need for significant vehicle lightweighting. In Class 8 short haul commercial applications when payload opportunity costs are not incurred, battery electric, fuel cell electric, and compressed natural gas vehicle powertrains have very competitive TCOs with diesel if the 2025 targets are achieved. In Class 8 short haul commercial applications when payload opportunity costs are incurred, the battery electric vehicle powertrains can achieve TCO parity with diesel only if the Ultimate battery prices are met ($80/kWh). In Class 4 parcel delivery truck operating scenarios where there are no dwell time costs incurred, the plug-in hybrid electric vehicle, battery electric vehicle, and fuel cell electric vehicle could be cost-competitive with diesel and compressed natural gas with current (2018) technology performance and costs. In general, the payload opportunity costs can be a significant driver to TCO for the Class 8 long and short haul commercial vehicle applications while the dwell time costs could be a major TCO cost driver for the Class 4 parcel delivery vehicle if the business scenario realizes those costs.

advanced powertrains↗
DOE OSTI2024

Analysis and Comparison of Different Metrics of DC-DC Converters to Determine Fuel Cell Stack Architectures in Heavy Duty Fuel Cell Vehicle Applications

This paper presents a comparative study of the DC-DC converters used in heavy-duty fuel cell electric vehicles for different input fuel cell stack configurations and voltages in terms of various important metrics including efficiency, cost, weight and power density. Contrary to conventional use of an interleaved boost topology, the analysis presented in this paper demonstrates that improved converter metrics can be achieved for an interleaved buck topology that uses a different input fuel cell stack. An insight to the optimal choice of number of interleaved phases for each metric is also presented. Results presented in the tables and plots convey the findings.

Mukherjee, Subho↗
DOE OSTI2026

Autonomie Simulation Datasets in Support of U.S. DOT-NHTSA Advanced Vehicle Technology Research

Understanding how new vehicle technologies affect fuel economy and energy use is critical to the regulatory work performed by the U.S. Department of Transportation’s National Highway Traffic Safety Administration (NHTSA), which sets Corporate Average Fuel Economy (CAFE) standards under the Energy Policy and Conservation Act of 1975. In order to support this work, Argonne National Laboratory uses Autonomie, a full-vehicle simulation tool, to evaluate advanced powertrain architectures and their effects on vehicle energy consumption and performance. A wide range of vehicle classes has been assessed (i.e., internal combustion engine vehicles, hybrid electric vehicles, plug-in hybrid electric vehicles, battery-electric vehicles, and fuel cell electric vehicles), as well as the effects of various technology improvements such as lightweighting, aerodynamic refinements, and low-rolling-resistance tires. Simulations have been run across multiple drive cycles to capture fuel and electricity use under realistic operating conditions. The resulting datasets include detailed vehicle-level results, model assumptions, and validation reports, all of which have been made publicly available through NHTSA in support of the 2023 notice of proposed rulemaking covering light-duty vehicles for model years 2027 to 2035. These data are critical to stakeholders working in fuel economy regulation, vehicle technology assessment, and energy policy analysis.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

A Comprehensive Simulation Study to Evaluate Future Vehicle Energy and Cost Reduction Potential

Under the umbrella of EERE’s Office of Sustainable Transportation, the U.S. Department of Energy’s (DOE) Vehicle Technologies Office (VTO) and Hydrogen and Fuel Cell Technologies Office (HFTO) seek to develop sustainable, affordable, and efficient technologies for transportation of goods and people. Translating investments in advanced transportation component technologies and powertrains to estimate the potential for vehicle-level fuel savings is critical to understanding DOE’s impact and success in this mission For this study, Argonne National Laboratory (Argonne) simulated technologies funded by VTO and HFTO for light-duty vehicles across the following: Powertrain configurations (conventional, power-split hybrid electric vehicle, extended-range electric vehicle, battery electric drive, and fuel-cell vehicles); Vehicle classes (compact car, mid-size car, small sport utility vehicle [SUV], mid-size SUV, and pickup truck); Fuels (gasoline, diesel, natural gas, hydrogen, and battery electricity). We assessed each technology for five different timeframes: laboratory years 2015 (reference), 2020, 2025, 2030, and 2045. We assumed a delay of 5 years between laboratory year and model year (i.e., the year the technology is introduced into production). Finally, we included uncertainties for both technology performance and cost by considering two cases (note that these cases are not intended as predictions of future performance): Low case , aligned with DOE technology manager estimates of expected original equipment manufacturer (OEM) improvements based on business as usual regulatory and market environments; High case , aligned with aggressive technology advancements based on research and development (R&D) targets developed through support by VTO and HFTO. We estimated the energy and cost impact of different technologies using Autonomie (Argonne undated), a state-of-the-art vehicle system simulation tool developed by Argonne and used to assess the energy consumption, performance, and cost of multiple advanced vehicle technologies. The tool comprises a complete set of vehicle models to assess impacts across a wide range of classes (from light- to heavy-duty), powertrain configurations (from conventional to hybrid electric vehicles [HEVs], fuel cell electric vehicles [FCEVs], plug-in hybrid electric vehicles [PHEVs], and battery electric vehicles [BEVs]), components, and control strategies, including vehicle-level and component-level controls developed and calibrated using dynamometer test data. Autonomie has been used to support a wide range of studies: analyzing various component technologies, sizing powertrain components to meet different vehicle requirements, comparing the benefits of powertrain configurations, optimizing both heuristic and route-based vehicle energy control, and predicting transportation energy use when paired with a traffic modeling tool such as POLARIS. This report documents the assumptions made and the vehicle-level energy consumption benefits and associated technology costs estimated for various types of light-duty vehicles. Details regarding vehicle assumptions and simulation results are available in the spreadsheets accompanying this report.

08 HYDROGEN↗
DOE OSTI2024

Simulation-Based Assessment of Energy Consumption of Alternative Powertrains in Agricultural Tractors

The objectives of this research were to develop simulation models for agricultural tractors with different powertrain technologies and evaluate the energy consumption in typical agricultural operations. Simulation models were developed for conventional, parallel hybrid electric, series hybrid electric, fuel cell hybrid, and battery electric powertrains. Autonomie vehicle simulation software (version 2022) was used for the simulations and the tractor models were simulated in two tilling cycles and in a road transport cycle with a trailer. The alternative powertrains were configured to have at least the same tractive performance as the conventional, diesel engine-powered tractor model. The simulation results showed that the potential of the parallel and series hybrid powertrains to improve energy efficiency depends heavily on the tractor size and the operating cycle conditions. The fuel cell hybrid and battery electric powertrains have a higher potential to reduce energy consumption and emissions but still have inherent technical challenges for practical operation. The battery-powered electric tractor would require improvements in the storage energy density to have a comparable operational performance in comparison to other powertrains. The fuel cell hybrid tractor already provided an adequate operating performance but the availability of hydrogen and refueling infrastructure could be challenging to resolve in the farming context.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

PILBCP-IL Composite Ionomers for High Current Density Performance

Wide-spread commercialization of fuel cell electric vehicles using proton exchange membrane fuel cell (PEMFC) power sources requires that several existing limitations be addressed. These include: (1) a reduction in platinum (Pt) loading in the catalytic electrodes, (2) improvements in reactant and electronic mobility throughout the catalytic electrodes, (3) reduction in the reliance on materials derived from polluting “forever chemicals”, and (4) a significant improvement in the operational longevity of catalytic electrode components. In this project, a team of two universities, Drexel University and Texas A&M University, one national lab, National Renewable Energy Laboratory, and one company, General Motors, collaborated to develop a new cathode ionomer chemistry that would address these limitations and result in an improvement in performance over existing ionomer materials. The key technology developed through this collaborative project was a composite cathode ionomer encompassing an ionic liquid interlayer between Pt catalysts and a sulfonated polymerized ionic liquid block co-polymer (S-PILBCP) that possess the orthogonal properties of protonic conductivity and ionic liquid enhanced kinetics and durability (see schematic in Figure 1). The composite S-PILBCP ionomer eliminates many of the existing issues with perfluorosulfonic acid-based ionomers including active site blocking by sulfonate specific adsorption, restricted O 2 transport through ionomer films, limited humidity tolerance and active area loss for carbon pore confined catalyst particles, and use of polluting “forever chemicals”. Following successful integration of the developed composite ionic liquid into a PEMFC cathode catalyst layer, we demonstrate enhanced performance over Nafion containing cathodes with Pt/C and PtCo/C at both low and high current density. The performance with our composite S-PILBCP ionomer meets the Department of Energy (DOE) targets for light duty vehicle applications

08 HYDROGEN↗
DOE OSTI2021

The Technical and Economic Potential of Hydrogen within the United States

Hydrogen markets have an opportunity to grow as its value as an energy intermediate increases. Hydrogen’s estimated serviceable consumption potential in the United States is 106 MMT/yr which is a ten-fold increase over the current market size. That opportunity is driven primarily by increased demands for metals refining, biofuel and hydrocarbon production, supplementing the natural gas system, seasonal storage for the electricity grid, and fuel cell electric vehicles. The U.S. has many renewable, nuclear, and fossil resources that each could meet that demand itself. The economic potential, which considers both costs to produce hydrogen and willingness of applications to pay for it, is 22 to 41 MMT/yr. The range is impacted by factors that impact the cost to produce including the price of natural gas and the cost of electrolyzers. It is also impacted by competition to provide the same services as hydrogen including electrification.

electrolysis↗
DOE OSTI2023

Enabling a Sustainable Future: Zero-Emission Vehicles Cost Analysis to Inform Decarbonization Pathways

Despite being only 5% of vehicles on the road, medium- and heavy-duty vehicles (MHDVs) are the second largest contributor to transportation emissions (21%) and a major source of local air pollution disproportionally affecting disadvantaged communities. This talk summarizes a cost analysis for zero emissions vehicles (battery electric EVs and hydrogen fuel cell FCEVs) for all medium and heavy duty applications, ranging from large pick-up trucks, to delivery vans, buses, and heavy trucks. Results show that with continued improvements in vehicle and fuel technologies (in line with U.S. Department of Energy targets and vetted with industry), zero-emission vehicles (ZEVs) can reach total-cost-of-driving parity with conventional diesel vehicles by 2035 for all medium- and heavy-duty (MD/HD) vehicle classes without incentives. Assuming economics drives adoption, ZEV sales could reach 42% of all MD/HD trucks by 2030, reflecting lower combined vehicle purchase and operating costs (using real-world payback periods). Two technological solutions - battery electric vehicles (BEVs) and fuel cell electric vehicles (FCEVs) - are viable in multiple market segments, offering alternative pathways for decarbonization: a) BEVs tend to become cost-competitive for smaller trucks before 2030 and for short-haul (<500-mile) heavy trucks before 2035. b) Hydrogen FCEVs tend to become cost-competitive for long-haul (>500-mile) heavy trucks by 2035. Results are very sensitive to technology improvement trajectories, adoption decision-making, and uncertain assumptions about future freight demand, logistics, and vehicle use explored in multiple scenarios.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2024

SAE Government-Industry - Heavy-Duty Policy: Panel Discussion (G203)

Medium- and heavy-duty vehicles are 21% of US transportation greenhouse gas (GHG) emissions and a major source of air pollution. In this talk to present some results exploring how the total cost of driving (TCD) of zero-emission vehicles (ZEVs), including battery electric vehicles and hydrogen fuel cell electric vehicles (EVs and FCEVs), could evolve under alternative scenarios. Results show that with continued improvements in vehicles and fuels, ZEVs can rapidly become viable, potentially reaching TCD parity or better compared to diesel vehicles by 2035 for all market segments. For heavy long-haul trucks, EVs become competitive on a TCD basis at charging costs below $0.18/kWh, while FCEVs become competitive on a TCD basis at hydrogen costs below $5/kg. A full transition to ZEV sales by 2035 results in 65% emissions reductions by 2050 compared to 2019 without supportive policies. Incentives such as the Inflation Reduction Act vehicle purchase credits further accelerate ZEV TCD competitiveness with major adoption opportunities over the next five years.

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗
DOE OSTI2020

Biomass feedstock transport using fuel cell and battery electric trucks improves lifecycle metrics of biofuel sustainability and economy

We report the use of new vehicle technologies such as fuel cell hybrid electric and fully electric powertrains for biomass feedstock supply is an unexplored solution to reducing biofuel production cost, greenhouse gas emissions, and health impacts. These technologies have found success in light-duty vehicle applications and are in development for heavy-duty trucks. This study presents the first detailed stochastic techno-economic analysis and life-cycle assessment of biomass feedstock supply systems with diesel, fuel cell hybrid electric, and fully electric trucks and determines their impacts on biofuel production considering butanol as a representative biofuel. This study finds that fuel cell hybrid electric and fully electric trucks consume less energy relative to the diesel-powered truck regardless of the evaluated circumstances, including payloads of truck (loaded and empty), pavement types (gravel and paved), road conditions (normal and damaged), and road networks (local and highways). The use of fuel cell hybrid and fully electric trucks powered by H 2 -fuel and renewable sources of electricity, respectively, results in a large reduction in cost and carbon footprint, specifically for a long-distance hauling, and minimize other economic and environmental impacts. While the economic advantage of fuel cell hybrid electric vehicle is dependent on the price of H 2 -fuel and road conditions, use reduces the GHG emissions of biobutanol per 100 km-trucking-distance by 0.98-10.9 gCO 2e /MJ. Results show that converting to fully electric truck transport decreases the biobutanol production cost and GHG emissions per 100 km-trucking-distance by 0.4-7.3 cents/L and 0.78 to 9.1 gCO 2e /MJ, respectively. This study establishes the foundation for future investigations that will guide the development of economically, socially, and environmentally sustainable biomass feedstock supply system for cellulosic biorefineries or other goods transportation systems.

09 BIOMASS FUELS↗
DOE OSTI2020

Retail Hydrogen Station Reliability Status and Advances

One of the most vital emerging commercial markets for hydrogen is fuel cell-powered mobility including cars, trucks, and buses. These vehicles are refueled via a network of hydrogen fueling stations, with the highest number of U.S. stations being in California. The numbers of both fuel cell electric vehicles (FCEVs) and hydrogen stations have increased in the last two years, with anecdotal information from FCEV drivers indicating that station reliability is hurting the consumer acceptability of FCEV technologies. Therefore, this study benchmarks the current state of hydrogen station reliability in practice and presents on-going research that is investigating the failures that are contribute to hydrogen station reliability issues. This is accomplished with an analysis of operation, safety, and maintenance data from hydrogen stations and fuel cell electric vehicles to benchmark the maintenance and failure of hydrogen stations and their components. This analysis, of over 5,000 station maintenance events, presents the leading maintenance categories and failure rates, and is a prerequisite to the development of data-driven reliability improvement plans. We present a reliability growth analysis and on-going research into the root causes of failure for dispensers, a particularly failure-prone subsystem.

08 HYDROGEN↗
DOE OSTI2020

Recent developments in catalyst-related PEM fuel cell durability

Cost and durability remain the two major barriers to the widespread commercialization of polymer electrolyte membrane fuel cell (PEMFC)-based power systems, especially for the most impactful but challenging fuel cell electric vehicle (FCEV) application. Commercial FCEVs are now on the road; however, their PEMFC systems do not meet the cost targets established by the U.S. Department of Energy, primarily due to the high platinum loading needed on the cathode to achieve the requisite performance and lifetime. Furthermore, while the activities of a number of commercial Pt-based alloy cathode catalysts exceed the beginning-of-life (BOL) targets, these activities, and the overall cathode performance, degrade via a variety of mechanisms described herein. Degradation is mitigated in current FCEVs by utilizing a cathode catalyst with a lower BOL activity (e.g., much lower transition metal alloy content and larger BOL nanoparticle size), necessitating higher catalyst loadings, and through the utilization of system controls that avoid conditions known to exacerbate degradation processes, such as limiting the fuel cell stack voltage range. The design and development of active and robust materials and eliminating the need for vehicle mitigation strategies would greatly simplify the operating system, allowing for greater transient operation, avoiding large hybridization, and curtailing of fuel cell power. Although system mitigation strategies have provided the near-term pathway for FCEV commercialization, material-specific solutions are required to further reduce costs and improve operability and efficiency. Future material developments should focus on stabilization of the electrode structure and minimization of the catalyst particle susceptibility to dissolution caused by oxide formation and reduction over PEMFC cathode-relevant operating potentials plus minimization of support corrosion. Ex situ accelerated stress tests have provided insight into the processes responsible for material and performance degradation and will continue to provide useful information on the relative stability of materials and benchmarks for robust and stable materials-based solutions not requiring system mitigation strategies to achieve adequate lifetime.

25 ENERGY STORAGE↗
DOE OSTI2024

Heavy-Duty Hydrogen Fueling Station Corridors

In this short technical report, we explore the range of levelized costs of dispensed hydrogen (H2) from hydrogen refueling (or fueling) stations (HRS) for H2 heavy-duty fuel cell electric vehicles (FCEVs) that are feasible in the 2030 timeframe. We explore different scenarios by varying hydrogen delivery distances, HRS sizes, HRS utilization rates, and economies of scale in the Hydrogen Delivery Scenario Analysis Model (HDSAM). Thus, we observe how the contribution to the levelized cost of each supply chain component changes.

DIRECT ENERGY CONVERSION,HYDROGEN↗