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Fuel Cell Vehicle Projects in Texas
October 21, 2010
Presented by Richard ThompsonUT – Center for Electromechanics
Presentation Topics
• Hydrogen Fuel Cell 22’ Shuttle Bus– Vehicle Computer Modeling and Performance
Evaluation
• Hydrogen Fueling Infrastructure in Austin, TX
• DOD Hydrogen Fuel Cell Utility Vehicles
• Upcoming program - Hydrogen Fuel Cell 35’ Transit Bus Demostration in Austin, TX
PEM Fuel Cell Plug-In Hybrid Bus Specifications
Vehicle Fuel Cell Shuttle Bus
Bus Manufacturer Ebus
Year Model 2007
Hybrid Type Series - Charge depletingLength/Width/Height 6.7m / 2.3 m / 2.8 m
Ground Clearance 20 cm
Wheel Base 3.7 m
GVWR 8845 kg
Passengers 22 seated
Power Plant and Manufacturer 19.1 kW PEM Fuel Cell / Ballard
Fuel 12 kg - 350 Bar Hydrogen
Fuel Storage 2X 5000 psi Roof Mounted Tanks
Energy Storage Saft / STM5-100MRENiCD Batteries - 60 kWh
Propulsion Motor/Manufacturer Induction Motor / Reliance Electric
Nominal/Peak power 75 kW / 130 kW for 1 min
Nominal/Peak torque 400 Nm / 700 Nm for 1 min
Transmission Chain Drive/rear differentialRegenerative Braking yes
Ballard 19 kW Fuel Cell Stack
Ni-Cad Batteries
Overnight Battery Charger – automatically controlled by vehicle computer
Completed a Nine Month Test Program
• Ebus 22’ Shuttle Bus– Two hydrogen tanks – 60 kWh NiCD Batteries– 19.1 kW Ballard Fuel Cell Stack– 40 mile range on batteries alone– 180 to 200 mile range with fuel cell
and batteries– Has regenerative braking for
improved fuel economy
• Test Program– Monitored vehicle performance, for example
– hydrogen consumption and fuel cell power output– battery’s charge/discharge energy
– Monitored maintenance issues
Vehicle Evaluation funded by USDOT
• Bus operated over 3 different routes in Austin, TX– PRC Campus Route:
• Flat, Low speed (<25 mph)– Great Hills Route:
• Very hilly (10%+ grades), medium speed (25 – 35 mph)
– Jollyville Parmer Route: • Moderate grades, high speed (35 – 45 mph)
• Covered 8000 miles over nine months
How Efficient are Fuel Cell Plug-in Hybrid Vehicles?
• Fuel cells are > 50% efficient, compared to < 40% for diesel engines
• We averaged about 22 mpg (diesel equivalent energy)• With batteries only we got over 35 mpg, but limited range
Gasoline engines can also be converted to run on Hydrogen• Cost less than FCs• 38% - 40% efficiency• Very low emissions• HICE vehicles/engines
are available, but limited
Recorded Evaluation Data
• Daily Manual Logs– Mileage– Ambient temperature– Hydrogen pressure and temperature– Traction battery voltage and SOC– Auxiliary battery voltage– Driver efficiency– Vehicle faults and maintenance items
• Traction Battery Recharging Manual Log
– Voltage and SOC (before and after)– Duration of charge– Amp-hours into each battery
• Hydrogen Refueling Manual Log– Bus tank pressure and temperature (before and after)– Pressure of temperature of each tube (before and after)– Amount of hydrogen used to refuel is then calculated
• Data acquisition monitors 164 parameters onboard the bus categorized as:
– Traction System– Item (On/Off)– Temperatures– Trip Information– Auxiliary 12 V Battery– Hybrid System– Overnight Charger– Accumulated amp-hours– Charge Information– Charge States and Codes
• Critical performance criteria of the Ebus are computed and logged into a daily demo and analysis spreadsheet. These criteria include:
– Mileage– Battery energy usage (including recharging events)– Traction motor propulsion and regenerative energy– Hydrogen consumption– Fuel cell energy output– Fuel cell run time– Fuel cell, traction motor, and battery efficiencies– Overall vehicle fuel economy (kWh/km)
Vehicle Modeling using PSAT(Powertrain System Analysis Toolkit)
• All electric vehicle– Deep cycle lead-acid
batteries– Advanced state of the art
batteries
• Fuel cell vehicle
• Fuel cell hybrid vehicle– Plug-in fuel cell– Fuel cell dominant hybrid
Modeling goal was to be able to predict vehicle performance for any given route
• Matched vehicle’s net energy consumption within 5%
• Approach helps others make better choices on emerging vehicle technologies
• Avoids the “build and test” approach
Slope change with hydrogen consumption
due to fuel cell operation
Hydrogen Fueling Infrastructure in Austin, TX
• Skid-mounted hydrogen fueling station for vehicles
• Generates hydrogen from natural gas• Integrated system includes
– fuel processor, which converts natural gas to hydrogen gas,
– pressure swing absorption unit, which purifies the hydrogen
– hydrogen compressor– storage tanks– hydrogen dispensing system
• First permanent fueling station in Texas
– Public outreach and education• Provides excellent learning
platform• Provides High-purity H2 for
additional vehicles (50 kg/day)Pure H2
Integrated Hydrogen Supply System
Reformer
PressureSwing
Absorption
Compressor
High PressureStorage
Dispenser
Utility Water
Methane
H2-rich gas
Pure H2WaterShift
Reactor
Pure H2Integrated Hydrogen Supply System
Reformer
PressureSwing
Absorption
Compressor
High PressureStorage
Dispenser
Utility Water
Methane
H2-rich gas
Pure H2WaterShift
ReactorReformer
PressureSwing
Absorption
Compressor
High PressureStorage
Dispenser
Utility Water
Methane
H2-rich gas
Pure H2WaterShift
Reactor
DOD Extended Range Utility Vehicle Program
• DOD requested extended range capability on a single tank of hydrogen gas
• Surpass the range of vehicles with– current lead-acid batteries– advanced state-of-the art batteries
• Vehicle platform for the hydrogen propulsion retrofit is the all-electric, Columbia ParCar SUV-LN– 3.7 kg of hydrogen in a 5 ksi (350 bar)
composite tank– 8.5 kW fuel cell– Ultracapacitors for improved
acceleration and vehicle efficiency, regenerative braking
• Vehicle takes advantage of readily available, commercial components
Utility Vehicle Layout with H2 Storage
Ultracapacitor Modules
4X 16V 500F
Boost Converter(to 48Vdc Motor)
Controller/Data Acquisition
NI Compact Rio
Fuel Cell Module
8kW20-40Vdc
Hydrogen Storage3.73 Kg
DOD Extended Range Utility Vehicle Program
All-Electric(40 mile range)
ToHydrogenFuel Cell
(> 300 mile range)
Date Trip Distance [mi]
AVG Economy [mi/kg]
AVG Fuel Cell Efficiency[%]
10/07/10 1 15.10 79.16 41.20%10/08/10 2 14.70 79.60 41.70%10/08/10 3 12.04 79.16 42.53%10/08/10 4 15.59 81.67 41.40%10/11/10 5 45.14 88.15 42.23%10/11/10 6 52.90 95.35 40.86%10/12/10 7 42.44 94.95 42.54%10/12/10 8 30.83 94.25 41.37%10/13/10 9 41.70 91.93 42.66%10/13/10 10 38.96 87.81 41.58%
• Extended range testing was completed• 309 miles on one fueling of H2
• Average fuel economy of 90 mpg –gasoline equivalent(same as mi/kg-hydrogen)
Motor Power (continuous/peak) 6.7 kW/12.9 kWMotor Current (continuous/peak) 150 Amps/500 AmpsDrive Ratio 10.35Fuel Cell Power 8.5 kWFuel 3.7 kg H2 @ 350 BarEnergy Storage System 4 x 16V 500F UltracapacitorEnergy Storage Voltage Range 58V - 42VDelivered Energy from UC ESS 27.8 Whr
Proterra Bus to Begin Passenger Service in Austin/Cap Metro - Early 2011(Currently in Columbia, SC)
35’ Transit BusFuel Cell / Plug-in Battery Hybrid BusGround-up DesignRegenerative Braking37 PassengersUp to 10 mpg diesel energy equivalent
Proterra Fuel Cell Plug-in Hybrid Bus
Sponsors and Supporting Partners
• US Department of Energy• US Department of Transportation• Texas H2 Coalition• Houston Advanced Research Center (HARC)• Center for Transportation and the Environment (CTE)• Texas Commission on Environmental Quality (TCEQ)• Texas State Energy Conservation Office (SECO)• Gas Technology Institute• The University of Texas at Austin• Columbia Parcar• Hydrogenics