Strategy | Energy | Sustainability
Hydrogen Fuel Cells for Heavy Duty, Road and Rail Applications
Future Powertrain Conference 2019
27 February 2019
Guy Bates, Consultant - Low Carbon Transport
E4tech perspective: Strategy | Energy | Sustainability
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• International consulting firm, offices in UK and Switzerland
• Focus on sustainable energy, including electrified vehicles
• 21 years old this year, always independent
• Deep expertise in technology, business and strategy, market assessment, techno-economic modelling, policy support…
• A spectrum of clients from start-ups to global corporations
E4tech’s annual Fuel Cell Industry Review
www.FuelCellIndustryReview.com
Drivers for hydrogen – National policy and decisions by local authorities
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• Strong measures to decarbonise transport drives a mix of technologies, including hydrogen
• Focus is on passenger cars and heavy duty; non-road mobile machinery may not be exempt
• Low Emission Zones
• Remove diesels by 2025
• Discount on car sharing; free bike sharing and public transportation
• Financial support to replace petrol or dieselcommercial vehicles
Paris London
• Low Emissions Zone (LEZ); not met EU Air Quality targets hence Central London Ultra LEZ in 2019
• Pollution charge: pre-‘Euro 4’ vehicles
• Single deck buses to be ZE (FC or BEV)by 2020
• Double deck ZEV by 2025
Birmingham
• Clean Air Zone(CAZ) expected in 2020
• FC bus fleet and refuelling station
• EV and LPG taxi initiatives
• Birmingham Cycle Revolution: 5% of trips 2023
• Creation of Green Travel Districts
Fuel cells offer EV benefits – Favour heavy duty applications
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1 Battery-hydrogen hybrid to ensure sufficient power2 Split in A- and B-segment LDVs (small cars) and C+-segment LDVs (medium to large cars)
based on a 30% market share of A/B-segment cars and a 50% less energy demand
Source: Hydrogen Council (2017)
• Fuel must be decarbonised: hydrogen or electricity
• Fuel cell power decouples from hydrogen energy– unlike batteries
• Hydrogen has a higher energy density
• Benefit from EV acceleration and regeneration
• Neither very hot nor cold conditions strongly affect performance
• Hydrogen fuelling is fast; the model is familiar to oil companies and service station providers
Heavy duty truck example – An equivalent powertrain comparison
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Diesel Hydrogen truck2 (FCET) Battery Electric Truck3 (BET)
“Tank” size 80 Gallons 60 kg H2 320kWh
Additional powertrain cost - <$100,0004 >$100,0003
Additional powertrain weight - <20004 kg >2,5004 kg
Range per fuelling ~9001 km ~4802 km ~1901,3 km
Refuelling interval <1 /day 1-2/day Multiple times a day
Refuelling time 5 minutes ~20 minutes [40 minutes] ~1 hour minimum (depends on charger) [5 hours]
(1) Based on figures from “Analysis of long haul battery electric trucks in EU - 2018”(2) Based on Toyota’s “Beta” prototype. Refuelling @ 2.63 kg H2/min and 60 kg tank (DOE, 2015).(3) Based on the Nikola ONE & https://www.arb.ca.gov/msprog/actruck/docs/HDBEVefficiency.pdf(4) Based on figures from H2FC Supergen conference 2019
• Batteries can’t do it all
• A typical haulage daily run, 800km, a FCET will refuel in 40 minutes, most similar to diesel
Heavy duty truck example – Current and future hydrogen refuelling price
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Tank: 40 kg H2Range: 3801 km
Current price: £10/kg H2 Industrial SMR scale
price: £2/kg H2Fills per duty cycle: 2.1
£840 per duty cycle w/current
prices
Tank: 80 gallonsRange: 900 km
Price: diesel in UK 2019 ~ £1.30/Litre.
Fills per duty cycle: 0.9£350 per duty
cycle
£168 per duty cycle w/future industrial prices
Hydrogen fuel cell truck
Diesel
• Initially, fuel costs will be relatively high
• Hydrogen costs can approach fossil fuel parity with high utilisation electrolysers and cheap renewable electricity, (other options exist)
(1) Based on Toyota’s “project portal - Alpha” prototype.
Fuel cells are scalable and modular – Offer initial design flexibility
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• PEM fuel cells are preferred for transport applications, and use hydrogen
• A fuel cell - Multiple repeated layers sandwiched together to provide the right power
• Stacks are optimised for a particular operation – e.g. Toyota Mirai stack (370 cells, 114kW)
• Reasonable sales are required for economical production – e.g. Toyota expecting 30,000 units by 2020
• Several stacks can be integrated in series for higher power
Information and images from Toyota Global Newsroom - https://newsroom.toyota.co.jp/en/corporate/23722307.html
Toyota Mirai fuel cell stack
PEM fuel cell assembly
Case study – Project Portal “Alpha” & “Beta”
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• Bespoke fuel cell design would have been costly
• Two Mirai fuel cell stacks power the truck –12kWh battery, 500kW and 1,796Nm torque
• 10 more “Beta” prototype semi-trucks for drayage in California
• Gross weight capacity is more than 36.2 tonnes and “Beta’s” estimated driving range is >480km per fill
• Consistent operating routes allow for straightforward refuelling
• In excess of 10,000 miles of operation achieved already
Information and images from Toyota Global Newsroom - https://newsroom.toyota.co.jp/en/corporate/23722307.html
Further examples – Buses, trains, ships and more trucks
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Buses
• Availability is improving
• Costs are reducing
• Europe is leading, Asia is set to overtake
• ICE commonality - 10-15 min refuelling, 300-450km range
Marine
• Continues the trend for fuel cells in heavy duty applications
• Ferries for short distance
• Power for hotel loads
• Different fuels for different technologies
Trains
• Passenger trains are now in operation in Germany; more are on order
• UK and other nations are showing interest
• An alternative to overhead electric lines or diesel power, they have a 1000km range
More trucks!
• 800 Nikola Tre orders by Anheuser Busch
• 1000 Hyundai orders for Swiss supermarkets (for tax benefit)
• Stack power of 30kW in China is designed around the subsidy sweet-spot; increase to 60kW
Information and images from the 2018 Fuel Cell Industry Review - http://www.fuelcellindustryreview.com/
In summary
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• An energy system transition is coming
• Heavy duty and off-highway is a major contributor to emissions and air quality problems
• Batteries can’t do it all. Fuel cells offer EV benefits and a comparable operation of duty cycle
• Hydrogen fuel costs are able to reach parity with fossil fuels
• Technology costs are dropping, and the modular and scalable nature of fuel cells gives flexibility
• Heavy-duty hydrogen fuel cell examples across the sector
• A realistic, zero emission solution
E4tech: Strategy | Energy | Sustainability
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