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Technical ReportNREL/TP-560-46679September 2009
Controlled Hydrogen Fleet InfrastructureDemonstration and Validation ProjectFall 2009
Composite Data ProductsFinal Version September 11, 2009
Keith Wipke, Sam Sprik, Jennifer Kurtz, and Todd Ramsden
and
2
Disclaimer and Government License
This work has been authored by Midwest Research Institute (MRI) under Contract No. DE-AC36-99GO10337 with the U.S. Department of Energy (the “DOE”). The United States Government (the “Government”) retains and the publisher, by accepting the work for publication, acknowledges that the Government retains
a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for Government purposes.
Neither MRI, the DOE, the Government, nor any other agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use
would not infringe any privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not constitute or imply its endorsement, recommendation, or favoring by the Government or any agency thereof. The views and opinions of the authors and/or presenters expressed herein do not necessarily state or reflect those of MRI, the DOE, the Government, or any agency
thereof.
NREL is a national laboratory of the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy operated by the Alliance for Sustainable Energy, LLC
Fall 2009Composite Data Products
September 11, 2009
Keith Wipke, Sam Sprik, Jennifer Kurtz, Todd Ramsden
Controlled Hydrogen Fleet and Infrastructure Demonstration and Validation Project
National Renewable Energy Laboratory 4 Innovation for Our Energy Future
CDP#1: Hours Accumulated and Projected Hours to 10% Stack Voltage Degradation
Gen1 Gen2 Gen1 Gen2 Gen1 Gen20200400600800
1000120014001600180020002200240026002800
2006 Target
2009 Target
Actual Operating Hours Accumulated To-Date Projected Hours to 10% Voltage Degradation
Tim
e (H
ours
)
DOE Learning Demonstration Fuel Cell Stack Durability:Based on Data Through 2009 Q2
Max Hrs Accumulated (1)(2) Avg Hrs Accumulated (1)(3) Projection to 10% Voltage Degradation (4)(5)(6)
Max ProjectionAvg Projection
Created: Sep-09-09 10:48 AM
(1) Range bars created using one data point for each OEM. Some stacks have accumulated hours beyond 10% voltage degradation.(2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individual stack in "real-world" operation.(3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OEM's fleet.(4) Projection using on-road data -- degradation calculated at high stack current. This criterion is used for assessing progress against DOE targets, may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membrane failure.(5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = average nominal projection. The shaded projection bars represents an engineering judgment of the uncertainty on the "Avg Projection" due to data and methodology limitations. Projections will change as additional data are accumulated.(6) Projection method was modified beginning with 2009 Q2 data, includes an upper projection limit based on demonstrated op hours.
National Renewable Energy Laboratory 5 Innovation for Our Energy Future
Dyno Range (2) Window-Sticker Range (3) On-Road Range (4)(5)0
50
100
150
200
250
300
Vehi
cle
Ran
ge (m
iles)
Vehicle Range1
2015 Target2009 Target Gen 1 Gen 2
Created: Aug-27-09 3:32 PM
(1) Range is based on fuel economy and usable hydrogen on-board the vehicle. One data point for each make/model.(2) Fuel economy from unadjusted combined City/Hwy per DRAFT SAE J2572.(3) Fuel economy from EPA Adjusted combined City/Hwy (0.78 x Hwy, 0.9 x City).(4) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(5) Fuel economy calculated from on-road fuel cell stack current or mass flow readings.
CDP#2: Vehicle Range
National Renewable Energy Laboratory 6 Innovation for Our Energy Future
CDP#3: Fuel Cell System Power Density, Including Hydrogen Storage
0
50
100
150
200
250
300
350
400
Pow
er D
ensi
ty (W
/L)
FC System (Including Hydrogen Storage) Power Density (W/L)
2010 and 2015 FreedomCAR Research Goal1
Gen 1 Gen 2
Created: Sep-08-09 10:32 AM (1) Fuel cell system includes fuel cell stack, BOP and H2 stroage, but excludes power electronics, battery storage, and electric drive.
National Renewable Energy Laboratory 7 Innovation for Our Energy Future
0
50
100
150
200
250
300
350
400
Spec
ific
Pow
er (W
/kg)
FC System (Including Hydrogen Storage) Specific Power (W/kg)
2010 and 2015 FreedomCAR Research Goal1
Gen 1 Gen 2
Created: Aug-28-09 8:42 AM (1) Fuel cell system includes fuel cell stack, BOP and H2 storage, but excludes power electronics, battery storage, and electric drive.
CDP#4: Fuel Cell System Specific Power, Including Hydrogen Storage
National Renewable Energy Laboratory 8 Innovation for Our Energy Future
12 hr Equilibrium 12 hr Equilibrium0
100
200
300
400
500
600
Time to Drive Away Time to Max FC Power
Tim
e [s
]
Fuel Cell Vehicle Start Time from Sub-Freezing Soak Condition1
Created: Sep-08-09 10:54 AM(1) Learning Demo soak temperature for freeze tests were between -9 and -20 oC(2) 2010 & 2015 DOE MYPP Cold Start Up Time Target: 30 seconds to 50% of rated power from -20 oC (soak duration not specified).
CDP#5: Fuel Cell Start Times from Sub-Freezing Soak Conditions
National Renewable Energy Laboratory 9 Innovation for Our Energy Future
Dyno (1) Window-Sticker (2) On-Road (3)(4)0
10
20
30
40
50
60
70
80
Fuel
Eco
nom
y (m
iles/
kg H
2)
Fuel Economy
Gen 1 Gen 2
Created: Aug-27-09 3:32 PM
(1) One data point for each make/model. Combined City/Hwy fuel economy per DRAFT SAE J2572.(2) Adjusted combined City/Hwy fuel economy (0.78 x Hwy, 0.9 x City).(3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(4) Calculated from on-road fuel cell stack current or mass flow readings.
CDP#6: Fuel Economy
National Renewable Energy Laboratory 10 Innovation for Our Energy Future
0
5
10
15
20
25
Ope
ratin
g Ti
me
[%]
Operating Time at Fuel Cell Stack Voltage Levels: DOE Fleet
<50%50-55%
55-60%60-65%
65-70%70-75%
75-80%80-85%
85-90%90-95%
95-100%>100%
% Max Fuel Cell Stack Voltage
All timeTime at low current
Created: Aug-14-09 4:47 PM
CDP#7: Fuel Cell Voltage
National Renewable Energy Laboratory 11 Innovation for Our Energy Future
0 10 20 30 40 50 60 70 80 90 1000
10
20
30
40
50
60
Net System Power [%]
Effic
ienc
y [%
]
Fuel Cell System1 Efficiency2
Eff. at 25% Pwr Eff. at 100% Pwr ------------------- -------------------Gen1 51 - 58% 30 - 54%Gen2 53 - 59% 42 - 53%
DOE Target at 25% PowerDOE Target at 100% PowerGen 1 Efficiency RangeGen 2 Efficiency Range
Created: Sep-02-09 11:27 AM
1 Gross stack power minus fuel cell system auxiliaries, per DRAFT SAE J2615. Excludes power electronics and electric drive.2 Ratio of DC output energy to the lower heating value of the input fuel (hydrogen). 3 Individual test data linearly interpolated at 5,10,15,25,50,75,and 100% of max net power. Values at high power linearly extrapolated due to steady state dynamometer cooling limitations.
CDP#8: FC System Efficiency
National Renewable Energy Laboratory 12 Innovation for Our Energy Future
0
1
2
3
Num
ber o
f Rep
orts
Safety Reports - Vehicle Operation
Tank ScratchTraffic AccidentH2 Leak - During FuelingH2 Alarm - Fuel SystemH2 Alarm - Passenger Compartment
Created: Aug-10-09 3:08 PM
CDP#9: Safety Reports – Vehicles
National Renewable Energy Laboratory 13 Innovation for Our Energy Future
CDP#10: Storage Weight % Hydrogen
350bar 700bar0
1
2
3
4
5
6
7
8
9
Wei
ght P
erce
nt H
ydro
gen
(%)
Weight Percent Hydrogen
2015 DOE MYPP Target1
2010 DOE MYPP Target1
2007 DOE MYPP Target1
Created: Aug-19-08 11:39 AM1Targets are set for advanced materials-based hydrogen storage technologies.
National Renewable Energy Laboratory 14 Innovation for Our Energy Future
CDP#11: Volumetric Capacity of H2 Storage
350bar 700bar0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
Mas
s H
2 pe
r Lite
r (kg
/L)
Mass of Hydrogen Per Liter
2015 DOE MYPP Target1
2010 DOE MYPP Target1
2007 DOE MYPP Target1
Created: Aug-19-08 11:39 AM1Targets are set for advanced materials-based hydrogen storage technologies.
National Renewable Energy Laboratory 15 Innovation for Our Energy Future
CDP#12: Vehicle Hydrogen Tank Cycle Life
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
Num
ber o
f cyc
les
Hydrogen Tank Cycle Life1
All OEMs
2015 DOE MYPP Target2
2010 DOE MYPP Target2
2007 DOE MYPP Target2 Gen 1 Gen 2
Created: Sep-17-08 10:29 AM
1Data reported reference NGV2, HGV2, or EIHP standards.2Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based technologies.
National Renewable Energy Laboratory 16 Innovation for Our Energy Future
On-Site Natural Gas Reforming On-Site Electrolysis0
10
20
30
40
50
60
70
80
2010 MYPP Target2015 MYPP Target
2012 MYPP Target
2017 MYPP Target
Prod
uctio
n Ef
ficie
ncy
(LH
V %
)
Hydrogen Production Conversion Efficiency1
Average Station Efficiency
Quarterly Efficiency Data
Highest Quarterly Efficiency
Efficiency Probability Distribution2
Created: Sep-01-09 10:32 AM
1Production conversion efficiency is defined as the energy of the hydrogen out of the process (on an LHV basis) divided by the sum of the energy into the productionprocess from the feedstock and all other energy as needed. Conversion efficiency does not include energy used for compression, storage, and dispensing.2The efficiency probability distribution represents the range and likelihood of hydrogen production conversion efficiency based on monthly conversion efficiency datafrom the Learning Demonstration.
CDP#13: On-Site Hydrogen Production Efficiency
National Renewable Energy Laboratory 17 Innovation for Our Energy Future
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
500
1000
1500
2000
2500
Avg Fuel Rate (kg/min)
Num
ber o
f Fue
ling
Even
ts
Histogram of Fueling Rates350 vs 700 bar Fills - All Light Duty Through 2009Q2
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
Fill Type Avg (kg/min) %>1 Count------------- ------------------ ------- --------350 bar 0.82 29% 17847700 bar 0.62 3% 3792
350 bar700 bar2006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone
Created: Aug-31-09 12:59 PM
CDP#14: Fueling Rates – 350 and 700 bar
National Renewable Energy Laboratory 18 Innovation for Our Energy Future
0-1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 >80
5
10
15
20
25
30Segmented Trips/Hour Histogram: DOE Fleet
Trips/Hour*
Freq
uenc
y [%
]
*Trips/Hour based on 50 hour segmentsspanning stack operating period
Created: Aug-26-09 2:14 PM
CDP#16: Fuel Cell Stack Trips Per Hour Histogram
National Renewable Energy Laboratory 19 Innovation for Our Energy Future
0
1
2
3
4
5
6
7
8
9
10
0-250 250-500 500-750 750-1000 1000-1250 1250-1500 1500-1750 1750-2000Stack Op Hour Groups
Trip
s/H
our*
Statistics of Trips/Hour vs Operating Hour: DOE Fleet
*Trips/Hour based on 50 hour segmentsspanning stack operating period
Data Range25th & 75th PercentilesGroup MedianOutlier
Created: Aug-26-09 2:14 PM
CDP#17: Statistics of Trips/Hour vs. Operating Hour
National Renewable Energy Laboratory 20 Innovation for Our Energy Future
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
500
1000
1500
Avg Fuel Rate (kg/min)
Num
ber o
f Fue
ling
Even
ts
Histogram of Fueling RatesAll Light Duty Through 2009Q2
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
21854 EventsAverage = 0.78 kg/min
24% >1 kg/min
2006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone
Created: Aug-14-09 10:09 AM
CDP#18: Refueling Rates
National Renewable Energy Laboratory 21 Innovation for Our Energy Future
0-10 10-30 30-60 60-360 >3600
5
10
15
20
25
30
35
Time [min]
Trip
Fre
quen
cy [%
]
Time Between Trips with Ambient Temperature: DOE Fleet
<0oC0-10oC10-24oC24-40oC>40oC
Created: Aug-26-09 2:15 PM
CDP#19: Time Between Trips & Ambient Temperature
National Renewable Energy Laboratory 22 Innovation for Our Energy Future
0 50 100 150 200 250 300
Non-Event
Near Miss
Incident
Number of Reports
Seve
rity
Total Infrastructure Safety Reports by Severityand Report Type Through 2009 Q2
Alarms OnlyAutomatic System ShutdownElectrical IssueEquipment MalfunctionFalse Alarm/MischiefH2 Release - Minor, NO IgnitionH2 Release - Significant, NO IgnitionManual System ShutdownNon-H2 ReleaseSite Power OutageStructural IssueSystem Trouble, not Alarm
Created: Sep-01-09 8:38 AM
An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame
CDP#20: Safety Reports – Infrastructure
National Renewable Energy Laboratory 23 Innovation for Our Energy Future
0 2 4 6 8 10 12-30
-20
-10
0
10
20
30
40
50
60
1.4 % trips below 0 oC
Max Op = 140.0 oF
Min Op = -5.8 oF
26.9 % trips above 28 oC
Trip Frequency [%]
Tem
pera
ture
[o C]
Average Ambient Trip Temperature: DOE Fleet
Created: Aug-14-09 4:47 PM
CDP#21: Range of Ambient TemperatureDuring Vehicle Operation
National Renewable Energy Laboratory 24 Innovation for Our Energy Future
0
5
10
15
20
25
30
35
Num
ber
of V
ehic
les
Total Vehicle Hours
Vehicle Hours: All OEMs, Gen 1 and Gen 2
In ServiceRetired
100,284Total Vehicle Hours =
Through 2009 Q2
Created: Aug-26-09 04:13 PM
CDP#22: Vehicle Operating Hours
National Renewable Energy Laboratory 25 Innovation for Our Energy Future
05
1015202530354045
Num
ber
of V
ehic
les
Total Vehicle Miles
Vehicle Miles: All OEMs Combined, Gen 1 and 2
In ServiceRetired
Total Vehicle Miles Traveled = 2,318,038
Through 2009 Q2
Created: Aug-26-09 04:13 PM
CDP#23: Vehicles vs. Miles Traveled
National Renewable Energy Laboratory 26 Innovation for Our Energy Future
2,318,038
-
250,000
500,000
750,000
1,000,000
1,250,000
1,500,000
1,750,000
2,000,000
2,250,000
2,500,000
Vehi
cle
Mile
s Tr
avel
ed
Cumulative Vehicle Miles: All OEMs, Gen 1 and Gen 2
Created: Aug-26-09 04:13 PM
Through 2009 Q2
CDP#24: Cumulative Vehicle Miles Traveled
National Renewable Energy Laboratory 27 Innovation for Our Energy Future
60
49
-
20
40
60
80
100
120
140
160
Cum
ulat
ive
Vehi
cles
Dep
loye
d/Re
tired
1
Vehicle Deployment by On-Board Hydrogen Storage Type
700 bar on-road350 bar on-roadLiquid H2 on-road700 bar retired350 bar retiredLiquid H2 retired
Created Feb-23-2009 1:20 PM (1) Retired vehicles have left DOE fleet and are no longer providing data to NREL Created Aug-26-2009 4:21 PM
140
(1) Retired vehicles have left DOE fleet and are no longer providing data to NREL
CDP#25: Vehicle H2 Storage Technologies
National Renewable Energy Laboratory 28 Innovation for Our Energy Future
0
5
10
15
20
0
20
40
60
80
100
120
140
Num
ber o
f Sta
tions
Mas
s of
Hyd
roge
n (1
000
kg)
Calendar Quarter
Cumulative Hydrogen Produced or Dispensed Through 2009 Q2
Cumulative HydrogenNumber of Stations
Created 2009-Aug-27 1:09 pm
CDP#26: Cumulative H2 Produced or Dispensed
National Renewable Energy Laboratory 29 Innovation for Our Energy Future
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.99.7
99.75
99.8
99.85
99.9
99.95
100
Cal
cula
ted
H2 In
dex
(%)
H2 Calculated Quality Index by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineCalculated Data
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
CDP#27: Hydrogen Quality Index
National Renewable Energy Laboratory 30 Innovation for Our Energy Future
0 2 4 6 8 10 12 14 16 18 20
Particulates
µg/L
H2 Fuel Constituents
Data Range SAE J2719 APR2008 Guideline Measured Less Than or Equal To (Detection Limited)
0 500 1000 1500 2000 2500 3000
(N2+He+Ar) He
(Ar+N2)
0 5 10 15 20 25 30 35 40
H2O Total HC
O2 CO2 CO
NH3
µmol/mol (ppm)
0 10 20 30 40 50 60 70 80
Total S*
nmol/mol (ppb)Created: Aug-31-09 4:39 PM Data is from Learning Demonstration and California Fuel Cell Partnership testing
*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).
CDP#28: Hydrogen Fuel Constituents
National Renewable Energy Laboratory 31 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
10
20
30
40
50
60
70
Tota
l S* (
nmol
/mol
)(ppb
)
Total S* (nmol/mol)(ppb)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 32 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
0.5
1
1.5
2
Tota
l HC
( µm
ol/m
ol)(p
pm)
Total HC (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 33 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
5
10
15
20
25
Tota
l Hal
ogen
ates
(µm
ol/m
ol)(p
pm)
Total Halogenates (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 34 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
2
4
6
8
10
12
14
16
18
20
22
Part
icul
ate
Con
cent
ratio
n ( µ
g/L)
Particulate Concentration (µg/L)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:41 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 35 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
5
10
15
20
25
30
35
40
O2( µ
mol
/mol
)(ppm
)
O2(µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 36 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
500
1000
1500
2000
2500
N2 ( µ
mol
/mol
)(ppm
)
N2 (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 37 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
500
1000
1500
2000
2500
3000
N2+H
e+A
r (µm
ol/m
ol)(p
pm)
N2+He+Ar (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 38 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
5000
10000
15000
20000
25000
30000
Part
icul
ate
Size
(µm
)
Particulate Size (µm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:41 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 39 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
50
100
150
200
250
300
He
( µm
ol/m
ol)(p
pm)
He (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 40 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
5
10
15
H2O
( µm
ol/m
ol)(p
pm)
H2O (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 41 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
0.05
0.1
0.15
0.2
Form
ic a
cid
( µm
ol/m
ol)(p
pm)
Formic acid (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 42 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
0.02
0.04
0.06
0.08
0.1
Form
alde
hyde
(µm
ol/m
ol)(p
pm)
Formaldehyde (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 43 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
0.2
0.4
0.6
0.8
1
CO
( µm
ol/m
ol)(p
pm)
CO (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 44 Innovation for Our Energy Future
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
1
2
3
4
5
6
7
8
9
CO
2 ( µm
ol/m
ol)(p
pm)
CO2 (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 45 Innovation for Our Energy Future
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
500
1000
1500
2000
2500
3000
Cal
culta
ted
Tota
l Con
stitu
ents
(µm
ol/m
ol)(p
pm)
Calcultated Total Constituents (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineCalculated Data
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
National Renewable Energy Laboratory 46 Innovation for Our Energy Future
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
500
1000
1500
2000
2500
Ar+
N2 ( µ
mol
/mol
)(ppm
)
Ar+N2 (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
National Renewable Energy Laboratory 47 Innovation for Our Energy Future
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
1
2
3
4
5
6
NH
3 ( µ
mol
/mol
)(ppm
)
NH3 (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
50
100
150
200
Ar (µm
ol/m
ol)(p
pm)
Ar (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
National Renewable Energy Laboratory 48 Innovation for Our Energy Future
Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0
1
2
3
4
5
6
NH
3 ( µ
mol
/mol
)(ppm
)
NH3 (µmol/mol)(ppm)Non-H2 Constituents by Year and Production Method
On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)
Created: Aug-31-09 4:40 PM
Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2
Year 1 Year 2 Year 3 Year 4
CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method
National Renewable Energy Laboratory 49 Innovation for Our Energy Future
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
200
400
600
800
1000
1200
1400
1600
Avg Fuel Rate (kg/min)
Num
ber o
f Fue
ling
Even
ts
Histogram of Fueling RatesComm vs Non-Comm Fills - All Light Duty Through 2009Q2
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
Fill Type Avg (kg/min) %>1 ------------- ------------------ -------Comm 0.92 36%Non-Comm 0.66 13%
CommNon-Comm2006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone
Created: Sep-02-09 11:32 AM
CDP#29: Fueling Rates Communication and Non-Communication Fills
National Renewable Energy Laboratory 50 Innovation for Our Energy Future
0 50 100 150 200 250
AdjustmentCheck Only
OtherRepair
Replacement
Maintenance: Average Labor Hours Per Station Since InceptionThrough 2009 Q2
ScheduledUn-Scheduled
0 5 10 15 20 25 30 35 40
AdjustmentCheck Only
OtherRepair
Replacement
Maintenance: Average Number of Events Per Station Since Inception
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
# of EventsHours
Comparison of Scheduled/Un-Scheduled Maintenance
Created: Aug-17-09 12:25 PM
CDP#30: Infrastructure Maintenance
National Renewable Energy Laboratory 51 Innovation for Our Energy Future
0
5
10
15
20
25
Num
ber o
f Sta
tions
Reporting Period
Online Stations
Existing Stations
Retired Stations
Created Aug-27-09 1:03pm
CDP#31: Number of Online Stations
National Renewable Energy Laboratory 52 Innovation for Our Energy Future
0
1
2
3
4
5
6
7
8
Delivered Compressed H2
Natural Gas On-site Reforming
Electrolysis Delivered Liquid H2
# of
Sta
tions
Production Technology
Infrastructure Hydrogen Production Methods
Existing Stations
Retired Stations
Created Aug-27-09 1:03pm
CDP#32: Infrastructure Hydrogen Production Methods
National Renewable Energy Laboratory 53 Innovation for Our Energy Future
CDP#33: Percentage of Theoretical Range Traveled Between Refuelings
0 10 20 30 40 50 60 70 80 90 1000
1
2
3
4
5
6
7
8
9
10
11
12Range Histogram: All OEMs
Percentage of chassis dyno range1 b/w refuelings
Perc
enta
ge o
f Ref
uelin
gs
0 10 20 30 40 50 60 70 80 90 1000
25
50
75
100
Cum
ulat
ive
Perc
enta
ge
Created: Aug-26-09 9:40 AM
Total refuelings2 = 22470
1. Range calculated using the combined City/Hwy fuel economy from dyno testing (not EPAadjusted) and usable fuel on board.2. Some refueling events are not detected/reported due to data noise or incompleteness.
National Renewable Energy Laboratory 54 Innovation for Our Energy Future
0 10 20 30 40 50 60 70 80 90 100
Gen1
Gen2
Vehicle Range Factors
Percentage of chassis dyno range1.
All
OEM
s Win
dow
-Stic
ker
2 W
indo
w-S
ticke
r 2
On-
Roa
d 3
On-
Roa
d 3
Dyn
o 1
Created: Aug-31-09 9:26 AM
1. Calculated using the combined City/Hwy fuel economy from dyno testing (non-adjusted)and usable fuel on board.2. Applying window-sticker correction factors for fuel economy: 0.78 x Hwy and 0.9 x City.3. Using fuel economy from on-road data (excluding trips > 1 mile, consistent with other data products).
CDP#34: Effective Vehicle Range
National Renewable Energy Laboratory 55 Innovation for Our Energy Future
05Q2 05Q3 05Q4 06Q1 06Q2 06Q3 06Q4 07Q1 07Q2 07Q3 07Q4 08Q1 08Q2 08Q3 08Q4 09Q1 09Q20
2
4
6
8
10
12
14
16
18
20
22
Reporting Period
Num
ber o
f Sta
tions
Infrastructure Safety Trend and Number of Stations Through 2009 Q2
Number of StationsAvg Refuelings Between Safety Reports
Created: Sep-01-09 8:40 AM
0
100
200
300
400
500
600
Avg
# o
f Ref
uelin
gs B
etw
een
Safe
ty R
epor
ts
7 1132 34
88 102 115
4768
124101
57 5473
51
146
530
CDP#35: Average Refuelings Between Infrastructure Safety Reports
National Renewable Energy Laboratory 56 Innovation for Our Energy Future
05Q2 05Q3 05Q4 06Q1 06Q2 06Q3 06Q4 07Q1 07Q2 07Q3 07Q4 08Q1 08Q2 08Q3 08Q4 09Q1 09Q20
5
10
15
20
25
30
35
40
45
50
Reporting Period
Num
ber o
f Rep
orts
Type of Infrastructure Safety Reports by Quarter Through 2009 Q2
IncidentNear MissNon-EventNumber of StationsAvg # Reports/Station
Created: Sep-01-09 8:40 AM
An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame
CDP#36: Type of Infrastructure Safety Report By Quarter
National Renewable Energy Laboratory 57 Innovation for Our Energy Future
0 50 100 150 200 250 300
Non-Event
Near Miss
Incident
Number of Reports
Seve
rity
Primary Factors of Infrastructure Safety ReportsThrough 2009 Q2
Calibration/Settings/ Software ControlsDesign FlawElectrical Power to SiteEnvironment (Weather, Power Disruption, Other)False AlarmInadequate Training, Protocol, SOPInadequate/ Non-working EquipmentMaintenance RequiredMischief, Vandalism, SabotageNew Equipment MaterialsNot Yet DeterminedOperator/Personnel ErrorSystem Manually Shutdown
Created: Sep-01-09 8:38 AM
An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame
CDP#37: Primary Factors of Infrastructure Safety Reports
National Renewable Energy Laboratory 58 Innovation for Our Energy Future
0 2 4 6 8 10 12 14 16 18 200
500
1000
1500
2000
2500
3000
Time (min)
Num
ber o
f Fue
ling
Even
ts
Histogram of Fueling TimesAll Light Duty Through 2009Q2
Average = 3.26 min86% <5 min
2006 MYPP Tech Val Milestone (5 kg in 5 min at 350 bar) 2012 MYPP Tech Val Milestone (5 kg in 3 min at 350 bar)
Created: Aug-14-09 10:40 AM
CDP#38: Refueling Times
National Renewable Energy Laboratory 59 Innovation for Our Energy Future
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 50
100
200
300
400
500
600
700
800
900
Amount Fueled (kg)
Num
ber o
f Fue
ling
Even
tsHistogram of Fueling AmountsAll Light Duty Through 2009Q2
Average = 2.14 kg
Created: Aug-14-09 10:40 AM
CDP#39: Refueling Amounts
National Renewable Energy Laboratory 60 Innovation for Our Energy Future
CDP#40: H2 Tank Level at Refueling
Tank Levels: DOE Fleet
14%
FE
Created: Aug-26-09 9:40 AM
Total refuelings1 = 24859
1. Some refueling events not recorded/detected due to data noise or incompleteness.
Median Tank Level (At Fill) = 41%
2. The outer arc is set at 20% total refuelings.3. If tank level at fill was not available, a complete fill up was assumed.
National Renewable Energy Laboratory 61 Innovation for Our Energy Future
CDP#41: Refueling Tank Levels - Medians
FE
Tank Level Medians (At Fill): DOE Fleet, All Vehicles
Created: Aug-26-09 9:40 AM
Total refuelings1 = 24859
1. Some refueling events not recorded/detected due to data noise or incompleteness.2. If tank level at fill was not available, a complete fill up was assumed.
National Renewable Energy Laboratory 62 Innovation for Our Energy Future
CDP#42: Refueling by Time of Day
Refueling by Time of Day: DOE Fleet
9%
3
12
9
6
Total Fill3 Events = 20939% of fills b/t 6 AM & 6 PM: 90.2%
1. Fills between 6 AM & 6 PM
2. The outer arc is set at 12 % total Fill.
3. Some events not recorded/detected due to data noise or incompleteness.
AM PM
Created: Aug-26-09 9:40 AM
National Renewable Energy Laboratory 63 Innovation for Our Energy Future
CDP#43: Refueling by Day of Week
Sun Mon Tues Wed Thur Fri Sat0
5
10
15
20
Fills by Day of Week: DOE Fleet
% o
f Fill
s in
a D
ay
DayCreated: Aug-26-09 9:40 AM
National Renewable Energy Laboratory 64 Innovation for Our Energy Future
Driving Start Time - Day: DOE Fleet
9%
3
12
9
6
Total Driving3 Events = 273900% of driving trips b/t 6 AM & 6 PM: 85.6%
1. Driving trips between 6 AM & 6 PM
2. The outer arc is set at 12 % total Driving.
3. Some events not recorded/detected due to data noise or incompleteness.
AM PM
% of NHTS trips b/t 6 AM & 6 PM: 81.5%
DOE FleetNHTS
Created: Aug-25-09 2:28 PM
2001 NHTS Data Includes Car, Truck, Van, & SUV day trips ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#44: Driving Start Time – Day
National Renewable Energy Laboratory 65 Innovation for Our Energy Future
Sun Mon Tues Wed Thur Fri Sat0
2
4
6
8
10
12
14
16
18
20
Driving Trips by Day of Week: DOE Fleet
% o
f Driv
ing
Trip
s in
a D
ay
Day
DOE FleetNHTS
Created: Aug-25-09 2:28 PM
2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#45: Driving by Day of Week
National Renewable Energy Laboratory 66 Innovation for Our Energy Future
0
10
20
30
40
50
Time at Fuel Cell Stack Power Levels: DOE Fleet
Ope
ratin
g Ti
me
[%]
0-5%
5-10%
10-15
%
15-20
%
20-25
%
25-30
%
30-35
%
35-40
%
40-45
%
45-50
%
50-55
%
55-60
%
60-65
%
65-70
%
70-75
%
75-80
%
80-85
%
85-90
%
90-95
%
95-10
0%>10
0%
% Max Fuel Cell Power (Gross)
All timeTime with 0 speed
Created: Aug-26-09 2:15 PM
CDP#46: Fuel Cell System Operating Power
National Renewable Energy Laboratory 67 Innovation for Our Energy Future
0 5 10 15 20 250
5
10
15
20
25
30
35
40
45
Trip
Fre
quen
cy [%
]
Trip Length [miles]
Trip Length: DOE Fleet
DOE FleetNHTS
Created: Sep-04-09 12:13 PM2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#47: Trip Length
National Renewable Energy Laboratory 68 Innovation for Our Energy Future
CDP#48: Primary Factors Affecting Learning Demo Fleet Fuel Cell Degradation
DOE Fleet
High Current TimeHot StartsStarts/hour
Low Voltage TimeHigh Voltage Time
Cold StartsShort Trips
0 Speed TripsHot Ambient Temp
H*
H*
1) On-going fuel cell degradation study using Partial Least Squares (PLS) regression model for combined Learning Demonstration Fleet.
2) DOE Fleet model has a low percentage of explained decay rate variance.
Created: Feb-21-08 9:32 AM
H*: Factor group associated with high decay rate fuel cell stacksL**: Factor group associated with low decay rate fuel cell stacks
Due to differences among teams, the DOE Fleet Analysis results are spread
out and concrete conclusions are difficult to draw.
Individual team analyses (CDP#49) focused on patterns within a fleet.
DOE Fleet
High Current TimeHot StartsStarts/hour
Low Voltage TimeHigh Voltage Time
Cold StartsShort Trips
0 Speed TripsHot Ambient Temp
H*
H*
1) On-going fuel cell degradation study using Partial Least Squares (PLS) regression model for combined Learning Demonstration Fleet.
2) DOE Fleet model has a low percentage of explained decay rate variance.
Created: Feb-21-08 9:32 AM
H*: Factor group associated with high decay rate fuel cell stacksL**: Factor group associated with low decay rate fuel cell stacks
Due to differences among teams, the DOE Fleet Analysis results are spread
out and concrete conclusions are difficult to draw.
Individual team analyses (CDP#49) focused on patterns within a fleet.
National Renewable Energy Laboratory 69 Innovation for Our Energy Future
CDP#49: Primary Factors Affecting Learning Demo Team Fuel Cell Degradation
Team 1
High Voltage TimeLow Current Time
Short TripsLow Speed
Team 2
Team 3
Team 4
Low Current TimeLong Trips
Warm Ambient TempZero Speed
Current Transients
High Voltage TimeLow Current Time
Short TripsLow Speed
Current Transients
1) On-going fuel cell degradation study using Partial Least Squares (PLS) regression model for each team’s Gen 1 fleet.
2) Teams’ PLS models have a high percentage of explained decay rate variance, but the models are not robust and results are scattered.
3) Factor groups associated with stacks that are opposite to the identified groups here are not specified.
H*
Starts/HourZero SpeedShort Trips
Low Voltage TimeHigh Current TimeCurrent Transients
Cold StartsHot Ambient Temp
High Speed
H*
H*
H*
H*
H*: Factor group associated with high decay rate fuel cell stacks
Created: Mar-09-09 9:06 AM
National Renewable Energy Laboratory 70 Innovation for Our Energy Future
CDP#50: Refueling by Time of Night
Refueling by Time of Night: DOE Fleet
3%
3
12
9
6
Total Fill3 Events = 20939% of fills b/t 6 PM & 6 AM: 9.8%
1. Fills between 6 PM & 6 AM
2. The outer arc is set at 12 % total Fill.
3. Some events not recorded/detected due to data noise or incompleteness.
PM AM
Created: Aug-26-09 9:40 AM
National Renewable Energy Laboratory 71 Innovation for Our Energy Future
Driving Start Time - Night: DOE Fleet
3%
3
12
9
6
Total Driving3 Events = 273900% of driving trips b/t 6 PM & 6 AM: 14.4%
1. Driving trips between 6 PM & 6 AM
2. The outer arc is set at 12 % total Driving.
3. Some events not recorded/detected due to data noise or incompleteness.
PM AM
% of NHTS trips b/t 6 PM & 6 AM: 18.4%
DOE FleetNHTS
Created: Aug-25-09 2:28 PM
2001 NHTS Data Includes Car, Truck, Van, & SUV day trips ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#51: Driving Start Time – Night
National Renewable Energy Laboratory 72 Innovation for Our Energy Future
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
50
100
150
200
250
300
350
400
450
500
Avg Fuel Rate (kg/min)
Num
ber o
f Fue
ling
Even
tsHistogram of Fueling Rates
All Light Duty by Year Through 2009Q2
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
Year Avg (kg/min) %>1 ------- ----------------- -------2005 0.66 16%2006 0.74 21%2007 0.81 26%2008 0.77 23%2009 0.79 26%
200520062007200820092006 MYPP Tech Val Milestone2012 MYPP Tech Val Milestone
Created: Aug-14-09 3:32 PM
CDP#52: Refueling Data by Year
National Renewable Energy Laboratory 73 Innovation for Our Energy Future
0
2
4
6
8
10FC Energy by Power Levels: DOE Fleet
FC E
nerg
y [%
]
0-5%
5-10%
10-15
%
15-20
%
20-25
%
25-30
%
30-35
%
35-40
%
40-45
%
45-50
%
50-55
%
55-60
%
60-65
%
65-70
%
70-75
%
75-80
%
80-85
%
85-90
%
90-95
%
95-10
0%>10
0%
% Fuel Cell Power (Gross) of Max
Cum
ulat
ive
%
0
20
40
60
80
100
Created: Aug-26-09 2:15 PM
CDP#53: Fuel Cell System Energy within Power Levels
National Renewable Energy Laboratory 74 Innovation for Our Energy Future
0-1 hr 1-6 hr 6-12 hr 12-18hr 18-24hr 1-7days 7-30days >30days0
10
20
30
40
50
60
Trip
Fre
quen
cy [%
]
Time
Time between Trips: DOE Fleet
0-10 min 10-20 min 20-30 min 30-40 min 40-50 min 50-60 min0
10
20
30
40
50
% T
rips
Time
0-60 min Breakdown: DOE Fleet
Created: Aug-14-09 5:36 PM
CDP#54: Time Between Trips
National Renewable Energy Laboratory 75 Innovation for Our Energy Future
<-0.5 -0.5-0 0-0.5 0.5-1 1-1.5 1.5-2 2-2.5 2.5-3 3-3.5 3.5-4 4-4.5 4.5-5 >50
10
20
30
40
50
60
Energy Consumed [kWh]
Trip
Fre
quen
cy [%
]
Energy in Trip: DOE Fleet
Net batterycharge in trip
BatteryVehicle MotorFC
Created: Aug-26-09 2:15 PM
CDP#55: Fuel Cell System Energy
National Renewable Energy Laboratory 76 Innovation for Our Energy Future
0 5 10 15 20 25 30 35 400
2
4
6
8
10
12
14
16
18
20
22
Trip
Fre
quen
cy [%
]
Daily Distance [miles]
Daily Distance: DOE Fleet
DOE FleetNHTS
Created: Sep-04-09 12:13 PM
Cumulative Frequency@ 20 miles
DOE Fleet: 48.4%NHTS: 27.2%
Cumulative Frequency@ 40 miles
DOE Fleet: 68.1%NHTS: 52.9%
2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#56: Daily Driving Distance
National Renewable Energy Laboratory 77 Innovation for Our Energy Future
CDP#57: H2 Storage System Mass and Volume Breakdown
Average Breakout of H2 Storage System Volume
73%
24%
3%
Average Breakout of H2 Storage System Mass
3.26%
23%
73%
9%
35% 56%
H2 Volume (%)Pressure Vessel Volume (%)Balance of Plant Volume (%)
72%
3.33%
24%
H2 Mass (%)Pressure Vessel Mass (%)Balance of Plant Mass (%)Created: Aug-19-08 9:14 AM
350 bar
700 bar
National Renewable Energy Laboratory 78 Innovation for Our Energy Future
CDP#58: Fuel Cell System Power Density
0
100
200
300
400
500
600
700
Pow
er D
ensi
ty (W
/L)
FC System Power Density (W/L)
2010 and 2015 DOE MYPP Target1 Gen 1 Gen 2
Created: Sep-17-08 10:29 AM (1) Fuel cell system includes fuel cell stack and BOP but excludes H2 storage, power electronics, and electric drive.
National Renewable Energy Laboratory 79 Innovation for Our Energy Future
CDP#59: Fuel Cell System Specific Power
0
100
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400
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700
Spec
ific
Pow
er (W
/kg)
FC System Specific Power (W/kg)
2010 and 2015 DOE MYPP Target1 Gen 1 Gen 2
Created: Sep-17-08 10:30 AM (1) Fuel cell system includes fuel cell stack and BOP but excludes H2 storage, power electronics, and electric drive.
National Renewable Energy Laboratory 80 Innovation for Our Energy Future
0 10 20 30 40 50 60 70 80 90 1000
10
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60
70
Production Capacity Utilization1 [%]
Prod
uctio
n C
onve
rsio
n Ef
ficie
ncy
2 [%]
Monthly Production Conversion Efficiency vs Utilization
Electrolysis DataElectrolysis Fit3
Electrolysis Fit ConfidenceNatural Gas DataNatural Gas Fit3Natural Gas Fit Confidence
Created: Aug-27-09 4:42 PM
1) 100% production utilization assumes operation 24 hrs a day, 7 days a week2) Production conversion efficiency is defined as the energy of the hydrogen out of the process (on a LHV basis) divided by the sum of the energy into the productionprocess from the feedstock and all other energy as needed. Conversion efficiency does not include energy used for compression, storage, and dispensing.3) High correlation with electrolysis data (R2 = 0.86) & low correlation with natural gas data (R2 = 0.034)
CDP#60: On-Site Hydrogen Production Efficiency vs. Capacity Utilization
National Renewable Energy Laboratory 81 Innovation for Our Energy Future
On-Site Compression Energy 0
5
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35
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45
50
Com
pres
sion
Ene
rgy
(MJ/
kg)
On-Site Compression Efficiency0
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100
2010 MYPP Compression Target
2015 MYPP Compression Target
Com
pres
sion
Eff
icie
ncy
(%)
On-Site Hydrogen Compression Efficiency1 and Energy Use
Average Station Compression Efficiency
Quarterly Compression Efficiency Data
Highest Quarterly Compression Efficiency
Average Station Compression Energy
Quarterly Compression Energy Data
Lowest Quarterly Compression Energy
Created: Aug-27-09 4:14 PM
1Consistent with the MYPP, compression efficiency is defined as the energy of the hydrogen out of the process (on an LHV basis) divided by the sum of theenergy of the hydrogen output plus all other energy needed for the compression process. Data shown for on-site hydrogen production and storagefacilities only, not delivered hydrogen sites.
Compression Energy Requirement:On average, 11.0% of the energycontained in the hydrogen fuel isrequired for the compressionprocess.
CDP#61: Refueling Station Compressor Efficiency
National Renewable Energy Laboratory 82 Innovation for Our Energy Future
0
100
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400
500
600
700
WTW
GH
G E
mis
sion
s (g
CO
2-eq
/mi)
Learning Demonstration Fuel Cycle Well-to-Wheels Greenhouse Gas Emissions1
Baseline Conventional Mid-Size Passenger Car2
Baseline Conventional Mid-Size SUV2
Average WTW GHG Emissions (Learning Demo)
Minimum WTW GHG Emissions (Learning Demo)
WTW GHG Emissions (100% Renewable Electricity)
WTW GHG Probability Based on Learning Demo3
Created: Sep-08-09 4:21 PM
On-Site Natural Gas Reforming On-Site Electrolysis(4)1. Well-to-Wheels greenhouse gas emissions based on DOE's GREET model, version 1.8b. Analysis uses default GREET values except for FCV fuel economy, hydrogenproduction conversion efficiency, and electricity grid mix. Fuel economy values are the Gen 1 and Gen 2 window-sticker fuel economy data for all teams (as used in CDP #6);conversion efficiency values are the production efficiency data used in CDP #13.2. Baseline conventional passenger car and light duty truck GHG emissions are determined by GREET 1.8b, based on the EPA window-sticker fuel economy of a conventionalgasoline mid-size passenger car and mid-size SUV, respectively. The Learning Demonstration fleet includes both passenger cars and SUVs.3. The Well-to-Wheels GHG probability distribution represents the range and likelihood of GHG emissions resulting from the hydrogen FCV fleet based on window-sticker fueleconomy data and monthly conversion efficiency data from the Learning Demonstration.4. On-site electrolysis GHG emissions are based on the average mix of electricity production used by the Learning Demonstration production sites, which includes bothgrid-based electricity and renewable on-site solar electricity. GHG emissions associated with on-site production of hydrogen from electrolysis are highly dependent onelectricity source. GHG emissions from a 100% renewable electricity mix would be zero, as shown. If electricity were supplied from the U.S. average grid mix, average GHGemissions would be 1245 g/mile.
CDP#62: Learning Demonstration Vehicle Greenhouse Gas Emissions
National Renewable Energy Laboratory 83 Innovation for Our Energy Future
14%
14%
19%
21%
By Number of EventsTotal Number of Events = 2291
22%12%
17%
20%
By Labor HoursTotal Hours = 11119
system control & safetycompressorreformerelectrolyzerdispenserothervalves & pipingelectricalstorage
Created: Aug-17-09 2:56 PM
Hydrogen Fueling Station Maintenance
CDP#63: Hydrogen Fueling Station Maintenance by System
National Renewable Energy Laboratory 84 Innovation for Our Energy Future
3%5%
33%58%
Fuel Cell Vehicle Events (11075)
19%
7%
49%
24%
Fuel Cell Vehicle Labor (11849 hours)
Vehicle (non-powertrain)Fuel Cell SystemPowertrainBattery
4%10%
11%
13%
24%
38%
Fuel Cell System Events (3704)< 1%
28%
27% 11%
12%
21%
Fuel Cell System Labor (5856 hours)
Thermal ManagementAir SystemControls, Electronics, SensorsFuel SystemFuel Cell StackOther
Created: Aug-18-09 2:25 PM
Fuel Cell Vehicle Maintenance Events and Labor Hours
CDP#64: Fuel Cell Vehicle Maintenance by System
National Renewable Energy Laboratory 85 Innovation for Our Energy Future
0
2
4
6
8
10
12
14
1015
Cyc
le
UD
DS
Cyc
le
US0
6 C
ycle
HW
FET
Cyc
le
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Percent Idle in Trip
% Idle
Trip
Fre
quen
cy [%
]
Created: Sep-08-09 3:29 PM
CDP#65: Percent Idle in Trip with Comparison to Standard Drive Cycles
National Renewable Energy Laboratory 86 Innovation for Our Energy Future
0 5 10 15 20 25 30 35 40 45 50 55 60 65 700
5
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35
40
Speed [mph]
Ope
ratio
n Ti
me
[%]
Fuel Cell Vehicle Speed
DOE Fleet SpeedDOE Fleet Idle1015 Cycle (14.1 mph avg)UDDS Cycle (19.6 mph avg)HWFET Cycle (48.0 mph avg)US06 Cycle (48.2 mph avg)
Created: Sep-09-09 7:39 AM
CDP#66: FCV Speed with Comparison to Standard Drive Cycles
National Renewable Energy Laboratory 87 Innovation for Our Energy Future
0
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45
Stac
k C
ount
Fuel Cell Stack Operation Hours: Gen1
Gen1
0-200 40
060
080
010
0012
0014
0016
0018
0020
00>2
000
Gen1 Hours
32% of stacks in operation
In Op1
Retired2
Other3
0
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45
Stac
k C
ount
Fuel Cell Stack Operation Hours: Gen2
Gen2
0-200 40
060
080
010
0012
0014
0016
0018
0020
00>2
000
Gen2 Hours
65% of stacks in operation
In Op1
Retired2
Other3
Created: Sep-09-09 10:48 AM
1) Stack currently accumulating hours2) Stack removed for low performance3) Stack not currently accumulating hours, but not removed because of low performance
CDP#67: Fuel Cell Stack Operation Hours
National Renewable Energy Laboratory 88 Innovation for Our Energy Future
0-5 10 15 20 25 30 35 40 >400
5
10
15
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25
30
Stac
k C
ount
% FC Power Drop
FC Power Drop During Operation Period: Gen1
Gen1
68% of In Op stackshave > 10% power drop
In Op1
Retired2
Other3
0-5 10 15 20 25 30 35 40 >400
5
10
15
20
25
30
Stac
k C
ount
% FC Power Drop
FC Power Drop During Operation Period: Gen2
Gen2
95% of In Op stackshave > 10% power drop
In Op1
Retired2
Other3
Created: Sep-09-09 10:48 AM
1) Stack currently accumulating hours2) Stack removed for low performance3) Stack not currently accumulating hours, but not removed because of low performance
CDP#68: Power Drop During Fuel Cell Stack Operation Period
National Renewable Energy Laboratory 89 Innovation for Our Energy Future
30
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130
0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000Stack Op Hour Segments(2)
% P
ower
(1)
Max Fuel Cell Power Loss vs Op Hours: Gen1
1) Normalized by fleet median value at 200 hours.2) Each segment point is median FC power (+-50 hrs). Box not drawn if fewer than 4 points in segment.
Gen1 Data Range25th & 75th PercentilesGroup MedianOutlier
Created: Sep-09-09 10:48 AM
CDP#69: Max Fuel Cell Power Degradation –Gen 1
National Renewable Energy Laboratory 90 Innovation for Our Energy Future
30
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130
0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000Stack Op Hour Segments(2)
% P
ower
(1)
Max Fuel Cell Power Loss vs Op Hours: Gen2
1) Normalized by fleet median value at 200 hours.2) Each segment point is median FC power (+-50 hrs). Box not drawn if fewer than 4 points in segment.
Gen2 Data Range25th & 75th PercentilesGroup MedianOutlier
Created: Sep-09-09 10:48 AM
CDP#70: Max Fuel Cell Power Degradation –Gen 2
National Renewable Energy Laboratory 91 Innovation for Our Energy Future
0-200 400 600 800 1000 1200 1400 1600 1800 2000 >20000
5
10
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30
27% Gen1 > 2000 projected hrs9% Gen2 > 2000 projected hrs
Projected Hours
% S
tack
s
Durability: Projected Hours to Low Fuel Cell Power Limit
Gen1 (> 200 operation hrs)Gen1 (< 200 operation hrs)Gen2 (> 200 operation hrs)Gen2 (< 200 operation hrs)
Created: Sep-09-09 10:48 AM
1. Low fuel cell power limit is dependent on the fuel cell vehicle system and is unique to each company in this Learning Demonstration.2. Acceptable low vehicle performance limit will be determined by retail customer expectations.3. Power projection method based on the voltage degradation techniques, but uses max fuel cell power instead of voltage at a specifichigh current.4. Stacks with less than 200 operation hours are in separate groups because the projection is based on operation data and with operationhours greater than 200 the degradation rate tends to flatten out.
CDP#71: Projected Hours to OEM Low Power Operation Limit
National Renewable Energy Laboratory 92 Innovation for Our Energy Future
-20 0 20 40 60-20
-10
0
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60
Ambient Air Temperature [deg C]
Tank
Tem
pera
ture
[deg
C]
Tank vs. Ambient Air Temps Prior to Refueling
Freq
uenc
y
50
100
150
200
250
-40 -20 0 20 400
1000
2000
Delta Temperature [deg C]
Cou
nt
Delta Temperature: Tank minus Ambient
Delta Temp HistogramNormal Distribution Fit
0
0.05
0.1
Den
sity
Mean= -3.896Std Dev= 5.775
Created: Sep-09-09 11:11 AM
-This CDP created in support of SAE J2601 related to refueling-Temperatures are prior to refueling and exclude data within 4 hours of a previous fill-The plot to the left excludes ambient temperatures less than -5 deg C
CDP#72: Difference Between Tank and Ambient Temperature Prior to Refueling
National Renewable Energy Laboratory 93 Innovation for Our Energy Future
10 15 20 25 300
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1000
1200
1400
1600
1800
2000Fuel Cell Stack Projected Hours as a Function of Voltage Drop
% Voltage Drop
Proj
ecte
d H
ours
2,3
Gen 1 Average ProjectionsGen 1 Average Projection to 10% Voltage Degradation1
Gen 2 Average ProjectionsGen 2 Average Projection to 10% Voltage Degradation1
Created: Sep-11-09 8:57 AM
(1) 10% Voltage degradation is a DOE metric for assessing fuel cell performance.(2) Projections using on-road data -- degradation calculated at high stack current.(3) Curves generated using the Learning Demonstration average of each individual fleet average at various voltage degradation levels.(4) The projection curves display the sensitivity to percentage of voltage degradation, but the projections do not imply that all stacks will (or do) operate at these voltage degradation levels.(5) The voltage degradation levels are not an indication of an OEM's end-of-life criteria and do not address catastrophic stack failures such as membrane failure.(6) All OEM Gen 2 average fleet projections are higher than Gen1 projections, however due to less operation data for Gen 2, these projections are limited by demonstrated operation hours to minimize extrapolations.
CDP#73: Fuel Cell Stack Projected Hours as a Function of Voltage Drop
F1147-E(10/2008)
REPORT DOCUMENTATION PAGE Form Approved OMB No. 0704-0188
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September 2009 2. REPORT TYPE
Technical Report 3. DATES COVERED (From - To)
4. TITLE AND SUBTITLE
Controlled Hydrogen Fleet and Infrastructure Demonstration and Validation Project: Fall 2009; Composite Data Products, Final Version September 11, 2009
5a. CONTRACT NUMBER DE-AC36-08-GO28308
5b. GRANT NUMBER
5c. PROGRAM ELEMENT NUMBER
6. AUTHOR(S) K. Wipke, S. Sprik, J. Kurtz, and T. Ramsden
5d. PROJECT NUMBER NREL/TP-560-46679
5e. TASK NUMBER FC087810
5f. WORK UNIT NUMBER
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) National Renewable Energy Laboratory 1617 Cole Blvd. Golden, CO 80401-3393
8. PERFORMING ORGANIZATION REPORT NUMBER NREL/TP-560-46679
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)
10. SPONSOR/MONITOR'S ACRONYM(S) NREL
11. SPONSORING/MONITORING AGENCY REPORT NUMBER
12. DISTRIBUTION AVAILABILITY STATEMENT National Technical Information Service U.S. Department of Commerce 5285 Port Royal Road Springfield, VA 22161
13. SUPPLEMENTARY NOTES
14. ABSTRACT (Maximum 200 Words) Graphs of composite data products produced by DOE's Controlled Hydrogen Fleet and Infrastructure Demonstration and Validation project through September 2009.
15. SUBJECT TERMS hydrogen; hydrogen demonstration; hydrogen validation
16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT
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