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A method for determining the optimal delivered hydrogen pressure for fuel cell electric vehicles
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Supercritical cryo-compressed hydrogen storage for fuel cell electric buses
Liquid hydrogen (LH 2 ) truck delivery and storage at dispensing sites is likely to play an important role in an emerging H 2 infrastructure. Here, we analyzed the performance of single phase, supercritical, on-board cryo-compressed hydrogen storage (CcH 2 ) with commercially-available LH 2 pump enabled single-flow refueling for application to fuel cell electric buses (FCEB). We conducted finite-element stress analyses of Type 3 CcH 2 tanks using ABAQUS for carbon fiber requirement and Fe-Safe for fatigue life. The results from these analyses indicate that, from the standpoint of weight, volume and cost, 2-mm 316 stainless steel liner is preferred to aluminium 6061 alloy in meeting the required 15,000 charge-discharge cycles for 350–700 bar storage pressures. Compared to the Type 3, 350 bar, ambient-temperature H 2 storage systems in current demonstration FCEBs, 500-bar CcH 2 storage system is projected to achieve 91% improvement in gravimetric capacity, 175% improvement in volumetric capacity, 46% reduction in carbon fiber composite mass, and 21% lower system cost, while exceeding >7 day loss-free dormancy with initially 85%-full H 2 tank.
Life-cycle implications of hydrogen fuel cell electric vehicle technology for medium- and heavy-duty trucks
This study provides a comprehensive and up-to-date life-cycle comparison of hydrogen fuel cell electric trucks (FCETs) and their conventional diesel counterparts in terms of energy use and air emissions, based on the ensemble of well-established methods, high-fidelity vehicle dynamic simulations, and real-world vehicle test data. For the centralized steam methane reforming (SMR) pathway, hydrogen FCETs reduce life-cycle or well-to-wheel (WTW) petroleum energy use by more than 98% compared to their diesel counterparts. The reduction in WTW air emissions for gaseous hydrogen (G.H2) FCETs ranges from 20-45% for greenhouse gases, 37-65% for VOC, 49-77% for CO, 62-83% for NOx, 19-43% for PM10, and 27-44% for PM2.5, depending on vehicle weight classes and truck types. With the current U.S. average electricity generation mix, FCETs tend to create more WTW SOx emissions than their diesel counterparts, mainly because of the upstream emissions related to electricity use for hydrogen compression/liquefaction. Compared to G.H2, liquid hydrogen (L.H2) FCETs generally provide smaller WTW emissions reductions. For both G.H2 and L.H2 pathways for FCETs, because of electricity consumption for compression and liquefaction, spatio-temporal variations of electricity generation can affect the WTW results. FCETs retain the WTW emission reduction benefits, even when considering aggressive diesel engine efficiency improvement.
Fuel Cell Electric Vehicle Durability and Fuel Cell Performance
The objectives of this project are to validate hydrogen fuel cell electric vehicles (FCEVs) in real-world settings and to identify the current status and evolution of the technology. The analysis objectively assesses progress toward targets and market needs defined by the U.S. Department of Energy and stakeholders, provides feedback to hydrogen research and development, and publishes results for key stakeholder use and investment decisions. Fiscal year 2018 objectives focus on analysis and reporting of FCEV driving range, fuel economy, drive and fill behaviors, durability, fill performance, and fuel cell performance. This report specifically addresses the topics of fuel cell stack durability and fuel cell performance.
Hydrogen Fuel Cell Electric Vehicles
A hydrogen fuel cell electric vehicle (FCEV) is two to three times more efficient than a comparable vehicle powered by an internal combustion engine running on gasoline. Because of their efficient operation, FCEVs can travel long distances with less fueling. An FCEV also produces clean tailpipe exhaust, emitting only water vapor and warm air. FCEVs have driving ranges of more than 300 miles per tank of hydrogen. Drivers can fuel their FCEVs in less than five minutes at a dispenser that looks and feels similar to gasoline dispensers except for the high-pressure gaseous connection.1 In addition, FCEVs are propelled by an electric motor, so they are very quiet, have very few moving parts and fewer fluids to change, and have minimal maintenance requirements overall.
Fuel Cell Electric Vehicle Driving and Fueling Behavior
The objectives of this project are to validate hydrogen fuel cell electric vehicles in real-world settings and to identify the current status and evolution of the technology. The analysis objectively assesses progress toward targets and market needs defined by the U.S. Department of Energy and stakeholders, provides feedback to hydrogen research and development, and publishes results for key stakeholder use and investment decisions. Fiscal year 2018 objectives focused on analysis and reporting of fuel cell electric vehicle driving range, fuel economy, drive and fill behaviors, durability, fill performance, and fuel cell performance. This report specifically addresses the topics of driving range, fuel economy, drive and fill behaviors, and fill performance.
Quantitative Risk Assessment for Fuel Cell Electric Bus Hydrogen Storage and Refueling Facility
It is necessary to understand the safety implications and risk mitigation options for fuel cell electric bus fleet deployment, especially for related facilities responsible for operations such as production, storage, compression, and dispensing of hydrogen for use by the buses. In this report, we present a quantitative risk assessment for a potential fuel cell electric bus fleet that was motivated by efforts to improve resilience at the Portland International Airport but can be applicable to a range of hydrogen case studies and use cases. We estimated risk for a facility that produces, stores, compresses, and dispenses hydrogen for the fleet of buses, with a focus on individual risk to people in terms of annual frequency of fatality. We considered the frequency of hydrogen leaks that could result in harmful physical outcomes like jet fires or explosions, and the consequences of those outcomes for people. We created customized fault trees to calculate the frequencies of different sizes of leaks and event sequence diagrams to calculate ignition probabilities for the various leak sizes. We also leveraged the HyRAM+ toolkit to use these inputs to calculate overall risk for the facility, which we separated into one section responsible for producing, storing, and compressing hydrogen, and one section responsible for dispensing the hydrogen to the buses. We found that the dispensing area seemed to have a higher risk than the production/storage/compression area of the facility, largely because of the inclusion of a component with a high leak frequency (the heat exchanger used to cool the hydrogen before entering the vehicle, to prevent overheating and expansion of hydrogen in the onboard tank). For the example production and refueling facility we evaluated and the data we used for the analysis, the leak frequency had a larger impact on the risk differences between the two sections on the facility, compared to the physical outcome consequence, which was slightly different due to the varying fuel conditions, but not substantially different. Actions can be taken to prevent these hazards (e.g., lowering leak frequencies in system components) or to mitigate the consequences if they do occur (e.g., installing barriers to protect people if ignition events occur). The choice of which actions to take depends not only on safety considerations but also on space, time, staffing, feasibility, and financial constraints. Therefore, the quantitative risk assessment approach can help understand relative risk contributions from different components, leak sizes, consequences, and human actions, to prioritize risk reduction strategies and balance these parameters. The outcomes of this report may be useful for a variety of stakeholders working in the hydrogen, transportation, vehicle, and aviation sector, including those responsible for aspects like facility design, operations, and regulations. There is not a single value of risk that determines whether a hypothetical system is “safe” or not. The insights about risk mitigations may be leveraged, and the quantitative risk assessment approach can be applied to other case studies to understand risk priorities and contributions specific to different FCEB and hydrogen facility uses.
Safety Compliance Verification of Fuel Cell Electric Vehicle Exhaust
NREL has been developing compliance verification tools for allowable hydrogen levels prescribed by the Global Technical Regulation Number 13 (GTR-13) for hydrogen fuel cell electric vehicles (FCEVs). As per GTR-13, FCEV exhaust is to remain below 4 vol% H2 over a 3-second moving average and shall not at any time exceed 8 vol% H2 and that this requirement is to be verified with an analyzer that has a response time of less than 300 ms. To be enforceable, a means to verify regulatory requirements must exist. In response to this need, NREL developed a prototype analyzer that meets the GTR metrological requirements for FCEV exhaust analysis. The analyzer was tested on a commercial fuel cell electric vehicle (FCEV) under simulated driving conditions using a chassis dynamometer at the Emissions Research and Measurement Section of Environment and Climate Change Canada and FCEV exhaust was successfully profiled. Although the prototype FCEV Exhaust Analyzer met the metrological requirements of GTR-13, the stability of the hydrogen sensor was adversely impacted by condensed water in the sample gas. FCEV exhaust is at an elevated temperature and nearly saturated with water vapor. Furthermore, condensed water is present in the form of droplets. Condensed water in the sample gas can collect on the hydrogen sensing element, which would not only block access of hydrogen to the sensor but can also permanently damage the sensor. In the past year, the design of the gas sampling system was modified to mitigate against the transport of liquid water to the sensing element. Laboratory testing confirmed the effectiveness of the modified sampling system water removal strategy while maintaining the measurement range and response time required by GTR-13. Testing of the upgraded analyzer design on an FCEV operating on a chassis dynamometer is scheduled for the summer of 2021.
Orange County Transportation Authority Fuel Cell Electric Bus Progress Report (Feb-Jul 2020) [Slides]
This report presents early results from a deployment of fuel cell electric buses (FCEBs) operated by Orange County Transportation Authority (OCTA) in Southern California. The ten FCEBs, produced by New Flyer, feature an electric drive propulsion system powered by a Ballard fuel cell system. The project team is collaborating with the U.S. Department of Energy (DOE) and DOE's National Renewable Energy Laboratory (NREL) to evaluate the buses in revenue service. The goal of this evaluation is to compare the FCEB performance to that of conventional technology and to track progress over time toward meeting the technical targets set by DOE and the Department of Transportation (DOT). The FCEBs were delivered beginning in late-2019, and were placed in service on February 9, 2020. The data period covers February 2020 through July 2020. NREL collects data on ten 2016 model year compressed natural gas (CNG) buses as a baseline comparison at OCTA.
SunLine Transit Agency Fuel Cell Electric Bus Progress Report (Data Period Focus Jan-Jun 2020) [Slides]
This report presents early results from a deployment of fuel cell electric buses (FCEBs) operated by SunLine Transit Agency in the Coachella Valley area of California. The five FCEBs, produced by New Flyer, feature an electric drive propulsion system powered by a Ballard fuel cell system. The project team is collaborating with the U.S. Department of Energy (DOE) and DOE's National Renewable Energy Laboratory (NREL) to evaluate the buses in revenue service. The goal of this evaluation is to compare the FCEB performance to that of conventional technology and to track progress over time toward meeting the technical targets set by DOE and the Department of Transportation (DOT). The FCEBs were delivered beginning in mid-2019. The data period covers January 2020 through July 2020. NREL collects data on five 2019 model year compressed natural gas (CNG) buses as a baseline comparison at SunLine. These new CNG buses were phased into service beginning in April 2020.
AC Transit Fuel Cell Electric Bus Progress Report (Data Period Focus: Jan. 2020 through Dec. 2020) [Slides]
This report presents early results from a deployment of fuel cell electric buses (FCEBs) operated by Alameda Contra-Costa Transit (AC Transit) in the east bay area of California. The ten FCEBs, produced by New Flyer, feature an electric drive propulsion system powered by a Ballard fuel cell system. The project team is collaborating with the U.S. Department of Energy (DOE) and DOE's National Renewable Energy Laboratory (NREL) to evaluate the buses in revenue service. The goal of this evaluation is to compare the FCEB performance to that of conventional technology and to track progress over time toward meeting the technical targets set by DOE and the Department of Transportation (DOT). The FCEBs were delivered beginning in late-2019. The data period covers January 2020 through July 2020. NREL collects data on two different baseline bus fleets for comparison: five 2017 model year diesel buses and five 2016 model year diesel hybrid buses.
Turboexpander: Alternative Fueling Concept for Fuel Cell Electric Vehicle Fast Fill
At the DOE Hydrogen and Fuel Cells Program Annual Merit Review and Peer Evaluation Meeting, NREL presented progress and accomplishments for the 'Turboexpander: Alternative Fueling Concept for Fuel Cell Electric Vehicle Fast Fill' project. This project was awarded through DOE's H2@Scale CRADA Call to investigate the performance of a turboexpander device. A turboexpander is capable of cooling pressurized hydrogen gas as it drops in pressure from the station supply. NREL has designed and is building a proof of concept device using a drag turbine. Test results will be published and will be used in future projects.
GM Light Duty Fuel Cell Electric Vehicle Validation Data
General Motors LLC (GM) completed a multi-phase project with the Department of Energy to validate light-duty fuel cell electric vehicle (FCEV) performance and durability using dynamometer fuel cell system and real-world vehicle performance data. This project began with GM’s Gen 0 Fuel Cell Fleet vehicles with Technology Insertion operating strategies and materials, and extended to GM’s Gen 1 and early Gen 2 commercial-design intent Fuel Cell stacks and Fuel Cell Systems. The intent of this project was to understand how fuel cell materials, system architectures, and operating strategies impact fuel cell stack durability under fully dynamic operating conditions such as those seen in a light duty vehicle application. More than 87,000 hours of system run time were accumulated under this project simulating several vehicle lifetimes under aggressive driver usage conditions. Lessons learned from this demonstration project have helped expedite the development of a commercially viable, zero-petroleum, zero-emission, Fuel Cell propulsion system. Durability test results have enabled a substantial reduction in the precious metal content in the Fuel Cell Stack with each successive generation of stack design. Stack lifetimes between the first and current design iterations have increased nearly tenfold, while the overall precious metal content has been reduced by approximately 85%. The Gen 2 system power density (kW/gPt) is over five times that of the Gen 0 system. In addition, run time voltage degradation as a function of total platinum was reduced by more than an order of magnitude between the first and last phase of this project. GM is proceeding with a low volume production program aided by the results of the durability testing performed under this cooperative agreement.
Comparison of well-to-wheels energy use and emissions of a hydrogen fuel cell electric vehicle relative to a conventional gasoline-powered internal combustion engine vehicle
The operation of hydrogen fuel cell electric vehicles (HFCEVs) is more efficient than that of gasoline conventional internal combustion engine vehicles (ICEVs), and produces zero tailpipe pollutant emissions. However, the production, transportation, and refueling of hydrogen are more energy- and emissions-intensive compared to gasoline. In this research, a well-to-wheels (WTW) energy use and emissions analysis was conducted to compare a HFCEV (Toyota Mirai) with a gasoline conventional ICEV (Mazda 3). Two sets of specific fuel consumption data were used for each vehicle: (1) fuel consumption derived from the U.S. Environmental Protection Agency's (EPA's) window-sticker fuel economy figure, and (2) weight-averaged fuel consumption based on physical vehicle testing with a chassis dynamometer on EPA's five standard driving cycles. The WTW results show that a HFCEV, even fueled by hydrogen from a fossil-based production pathway (via steam methane reforming of natural gas), uses 5%–33% less WTW fossil energy and has 15%–45% lower WTW greenhouse gas emissions compared to a gasoline conventional ICEV. The WTW results are sensitive to the source of electricity used for hydrogen compression or liquefaction.
Risk Assessment of Hydrogen Fuel Cell Electric Vehicles in Tunnels
The need to understand the risks and implications of traffic incidents involving hydrogen fuel cell electric vehicles in tunnels is increasing in importance with higher numbers of these vehicles being deployed. A risk analysis was performed to capture potential scenarios that could occur in the event of a crash and provide a quantitative calculation for the probability of each scenario occurring, with a qualitative categorization of possible consequences. The risk analysis was structured using an event sequence diagram with probability distributions on each event in the tree and random sampling was used to estimate resulting probability distributions for each end-state scenario. Here, the most likely consequence of a crash is no additional hazard from the hydrogen fuel (98.1–99.9% probability) beyond the existing hazards in a vehicle crash, although some factors need additional data and study to validate. These scenarios include minor crashes with no release or ignition of hydrogen. When the hydrogen does ignite, it is most likely a jet flame from the pressure relief device release due to a hydrocarbon fire (0.03–1.8% probability). This work represents a detailed assessment of the state-of-knowledge of the likelihood associated with various vehicle crash scenarios. This is used in an event sequence framework with uncertainty propagation to estimate uncertainty around the probability of each scenario occurring.
Investigation of precooling unit design options in hydrogen refueling station for heavy-duty fuel-cell electric vehicles
Precooling gaseous hydrogen fuel to a cold temperature before refueling a heavy-duty (HD) hydrogen fuel cell electric vehicle (HFCEV) is essential to avoid overheating the vehicle tank, as well as achieving a high state of charge (SOC). Because a large volume of hydrogen is dispensed during each fill, the need for a shorter fill time amplifies the need to precool each load for refueling a HFCEV. Thus, the design and operation of a precooling unit (PCU), as well as the associated capital and operating costs, plays a pivotal role in any plans for heavy-duty hydrogen refueling stations. Here, in this paper, we present a thermodynamic and technoeconomic analysis of a PCU in a gaseous hydrogen refueling station (HRS) for HD HFCEVs. By employing Argonne National Laboratory's hydrogen station cost optimization and performance evaluation (H2SCOPE) model, the refueling of 50 kg of hydrogen on-board type IV tank at ambient temperatures of 15–45 °C and varying fill rates is simulated. The required degree of precooling temperature to obtain either 100% or the maximum possible SOC is obtained from the simulation. Additionally, the simulation results demonstrate that the average flow rate of hydrogen is approximately 40% lower than the maximum flow rate during a typical fill; which motivates further evaluation of the instantaneous hydrogen mass flow rate profile and suggests the scope of improving precooling unit design. Accordingly, a hybrid strategy of precooling hydrogen has been proposed to address the cooling load by sizing the refrigeration unit for the average flow rate of hydrogen, while supplementing the above average peak hydrogen flow cooling load through thermal buffering. The combined technique enables the downsizing of the original PCU capacity by 25–40% and demonstrates a potential cost reduction of the PCU by approximately 30%, which translates to an installed cost reduction of ∼$125,000 per dispenser.
Autonomous Fueling System for Heavy-Duty Fuel Cell Electric Trucks
The motivation for this project stemmed from the challenges associated with rapidly refueling heavy-duty hydrogen fuel cell electric trucks (FCETs). Current manual refueling processes for fast refueling involve large, heavy equipment (e.g., hoses three times heavier than standard) and pose ergonomic risks and potential for equipment damage. The goal was to develop and test an autonomous fueling system to improve ergonomics, enhance safety, increase equipment durability through design improvements, and potentially speed up the fueling process. This project aimed to add to the understanding of autonomous systems in the context of heavy-duty hydrogen refueling, evaluating the technical effectiveness of potential concepts. A successfully developed system would benefit the public by facilitating the adoption of zero-emission heavy-duty transport, reducing reliance on manual labor for a physically demanding task, and potentially improving the safety and efficiency of hydrogen refueling infrastructure. The major accomplishment during the project's active period was the completion of the system-level architecture task. This involved establishing a detailed list of system requirements covering interfaces, environmental conditions, regulatory compliance, industry standards, safety, security, performance capabilities, and optional features. Five key use cases for the autonomous system were also identified. However, due to internal restructuring at Nikola, the necessary resources could not be allocated to continue the project. Consequently, Nikola opted to discontinue the project. The award was mutually terminated by Nikola and the DOE.