Fuel Cells AND Batteries - Key Enablers for Zero Emission Vehicles - Dr. Andreas Truckenbrodt AFCC...

Fuel Cells AND Batteries

- Key Enablers for Zero Emission Vehicles -

Dr. Andreas TruckenbrodtAFCC Automotive Fuel Cell Cooperation Corp.

Burnaby, Canada

HFC 2009

June 1, 2009

AFCC: The Centre for Fuel Cell Stack Development for Daimler AG and Ford Motor Company

Automotive Fuel Cell Cooperation


161

104

125

164

196Gasoline ICE

Hybrid (gasoline ICE)

Diesel ICE

Hybrid (Diesel ICE)

Hydrogen ICE (CGH2 out of CNG)

Battery electric vehicle (EU-mix)

Battery electric vehicle (Bio mass)

Battery electric vehicle (Wind power)

Reference: Compact sedan, NEDC (New European Drive Cycle)

Source: European Database EUCAR/CONCAWE/J RC, 2005

Fuel Cell vehicles with Hydrogen and Battery vehicles based on renewable electricity have the highest potential for CO2-emission reductions

Natural-gas ICE (CNG)

-28%

GHG emissions [g CO2 eq/km]

196

141

164 -16%

125 -36%

161 -18%

186 -5%

87 -56%

8 -96%

-100%

104 -46%

14 -93%

9 -95%

Fuel Cell (H2 from CNG)

Fuel Cell (H2 from bio mass)

Fuel Cell (H2 from wind power)

0 50 100 150 200 250

0

161

104

125

164

196Gasoline ICE

Hybrid (gasoline ICE)

Diesel ICE

Hybrid (Diesel ICE)

Hydrogen ICE (CGH2 out of CNG)

Battery electric vehicle (EU-mix)

Battery electric vehicle (Bio mass)

Battery electric vehicle (Wind power)

Reference: Compact sedan, NEDC (New European Drive Cycle)

Source: European Database EUCAR/CONCAWE/J RC, 2005

Fuel Cell vehicles with Hydrogen and Battery vehicles based on renewable electricity have the highest potential for CO2-emission reductions

Natural-gas ICE (CNG)

-28%

GHG emissions [g CO2 eq/km]

196

141

164 -16%

125 -36%

161 -18%

186 -5%

87 -56%

8 -96%

-100%

104 -46%

14 -93%

9 -95%

Fuel Cell (H2 from CNG)

Fuel Cell (H2 from bio mass)

Fuel Cell (H2 from wind power)

0 50 100 150 200 250

0

Well-to-wheel CO2 potential


Fuel Cell Electric

Battery Electric

Combustion Engine

Hybridization

Plug-In/Range Extender

Mobility Scenarios

long distance cross country city

A diverse powertrain portfolio is required to cover all applications

Powertrain portfolio

Automotive Fuel Cell CooperationBoth require infrastructure

Buildup of charging infrastructure

Investment for the charging infrastructure depends on vehicles sales

Investment [€]

Private parking place(50%)

Workplace

Commercial parking

sites

Public parking

Number of vehicles

Buildup H2-Infrastructure

H2-infrastructure requires start-up investments

Investment [€]

Start investfor a minimal-infrastructure

Number of vehicles

Overall costs for infrastructure are similar, though shape is a little different

Automotive Fuel Cell CooperationBoth are approaching near-term commercialization

F-Cell

smart ed

Automotive Fuel Cell CooperationBatteries – Promise and Challenges

• High worldwide sentiment for EV/PHEV’s• Batteries are making good progress technically and

cost-wise• But EV/PHEV’s are not

farther ahead than fuel cells– Many challenges remain– May 27 announcement

Chrysler/DOE: $448 million dollars to develop EV/PHEV – includes $365 million for a 365 vehicle test fleet

– Very few vehicles on the road in customer hands to prove market potential – many are just starting a test fleet phase


Future GenerationsFuture Generations

Generation 1Technology Demonstration

F-Cell

Generation 2Customer Acceptance

B-Class F-Cell

Generation 3Cost Reduction I

Generation 4Market IntroductionCost Reduction II

Passenger CarsLead application



Bus



Sprinter

Generation 5High Volume Series Production

2004

2010

2013

201x

202y

Fuel cell roadmap - The path to commercialization

Fuel cell passenger cars will drive the volume


Gen 1: Technology demonstration From Necar 1 (1994) to F-Cell and Fuel Cell Buses (2004-2008)

JHFC ProgramJapan

Sinergy EDB ProjectSingapore

California Fuel Cell Partnership

DoE Program USA

Bus Project BeijingChina

Clean Energy Partnership

Germany

European Bus Project

HyFLEET:CUTE

Bus Project STEPPerth, Australia

National Innovation Program H2 and Fuel

Cell Germany

European Zero Regio

Project

MBUSAMB NL Berlin

DSEA

MBJ

36 Buses (Citaro) inEurope, Australia,

China

3 SprinterEurope, USA

∼ 2.100.000 km∼ 137.000 h

∼ 64.000 km∼ 2.400 h

60 F-Cell Vehicles in customer operation

∼ 2.000.000 km∼ 58.000 h 100 vehicles since 2004


B-Class F-Cell:

• Higher stack lifetime • Increased power (65kW 100kW)• Higher reliability• Longer range (160km 400km)• Freeze start ability below 0°C• Li-Ion battery

[l]

Size

- 40%

[kW

]

Power

+30%

A-Class F-Cell

[l/10

0km

]

Consumption

-30%

B-Class F-Cell

[km

]

Range

+150%

2004 – 2009Worldwide 90 cars, 39 buses

from 2009Small series production

Generation 2: Full customer acceptance

Fuel cells have also made huge progress

Generation 1: Technology demonstration

Automotive Fuel Cell CooperationStatus of fuel cell technology

PerformanceSafetyComfortFreeze startRange

ReliabilityLongevityPackage/weightCost

Automotive Fuel Cell CooperationFuel cell achievements and challenges

Gen 2: On road 2009

Gen 3: Full scale running prototypes

Power Density

0

0.5

1

1.5

2

2.5

Gen 1 Gen 2 Gen 3 Goal

Stack Generation

Sta

ck P

ow

er D

ensi

ty

Stack Durability

0

50000

100000

150000

200000

250000


Stack Generation

Sta

ck D

ura

bili

ty

Automotive Fuel Cell CooperationFor fuel cells we know how to get the cost down

Goal: Competitive to the incumbent technologies

• Volume increase, economies of scale” (4-5x)

• Technology improvements (3x)

• Supplier development

• New, cooperative business models

Magnitude of the task: factor 15

Stack Cost at 100,000 units/year

0

50

100

150

200

250

300


Stack Generation

Co

st $

/kW

Automotive Fuel Cell CooperationCost driven development goals

Stack• reduce Pt loading from 1 mg/cm2 to 0.2 - 0.3 mg/cm2

– develop improved cathode catalyst material and application technology without negative impact on lifetime

• reduce active stack area– increase catalyst activity at full and part load (fuel economy !)

while reducing Pt loading• reduce bipolar plate cost through high volume manufacturing

technologies (metal plates or carbon plates)• improve membrane performance under dry and hot conditions to

accommodate reduced/eliminated humidifier system concept• improve unit cell/ flow field concept to accommodate

reduced/eliminated hydrogen recirculation system conceptSystem• reduce/eliminate humidifier• reduce/eliminate hydrogen recirculation loop• reduce component cost (compressor,

sensors, valves, tank, power electronics etc.)

cost

per-formance

life-time

Automotive Fuel Cell CooperationSolve joint problems jointly

• Our industry does not need proprietary solutions to every problem

• As the cost of these solutions gets higher and higher, no one company can afford to develop all of them

• Nor will our customers pay the price tag for a custom solution…….to a generic problem

The path to success in the last century probably is not going to be the path to success in this one.

This drives us toward collaboration with other automakers and suppliers on the development of the cornerstone technologies of our collective future.

The path to success in the last century probably is not going to be the path to success in this one.

This drives us toward collaboration with other automakers and suppliers on the development of the cornerstone technologies of our collective future.


… and we'll alwaysmanage branddifferentiation …


Automotive Industry Fuels/Energy Industry

Customer Public Institutions

• improved conv. fuels• alternative fuels• infrastructure

• clean and efficient• reliable• affordable

• choice of vehicle• driving behaviour• "feel comfortable"

• relevant framework• incentives• research

All stakeholders are in charge !

Automotive Fuel Cell CooperationKey Messages

• It is “fuel cells AND batteries”

• Fuel cells work fine - #1 focus is now on cost reduction, and we know how to get there

• The strong commitment from the car manufacturers needs to be joined by the other stakeholders

Fuel Cells AND Batteries - Key Enablers for Zero Emission Vehicles - Dr. Andreas Truckenbrodt AFCC...

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