Presentation DEM24-2 Data Analysis of Early Fuel Cell Market Demonstrations Fuel Cell Seminar Palm Springs, CA November 17, 2009 Jen Kurtz, Todd Ramsden, Keith Wipke, Sam Sprik NREL/PR-560-47192 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.
Fuel Cell & Infrastructure Data Collection, Processing, & Analysis Demonstrations Objectives Methodology Results National Renewable Energy Laboratory 2 Innovation for Our Energy Future
Government Funded Early Fuel Cell Markets • Funding sources include DOD Defense Logistics Agency, DOE American Recovery and Reinvestment Act (ARRA), and DOE Interagency Agreement (IAA) • Diverse collection of early market fuel cell applications, project partners, and end users • Expected fuel cell deployment: >1,000 units • Fuel cell applications cover fuel cell forklifts, backup power, micro-CHP, APU, and portable power National Renewable Energy Laboratory 3 Innovation for Our Energy Future
Government Funded Fuel Cell Early Market Deployments – Separated by Funding Source & Application Government Funded Early Market Fuel Cell Count 1400 DoD Forklift Projected Quantities Subject to Change ARRA Forklift IAA Backup 1200 ARRA Backup ARRA Stationary 1000 800 FC Count 600 400 200 0 2009 Q1 2009 Q2 2009 Q3 2009 Q4 2010 Q1 2010 Q2 2010 Q3 2010 Q4 2011 Q1 Install Quarter Created: Nov-12-09 4:40 PM National Renewable Energy Laboratory 4 Innovation for Our Energy Future
Government Funded FC Early Market Project Sites Project partners include DOE, DoD, FC developers, H 2 suppliers, and end users Many site locations to be determined. Quantity and sites are subject to change. DOE is fund source for ARRA & IAA sites. National Renewable Energy Laboratory 5 Innovation for Our Energy Future
Early Fuel Cell Market Data Analysis Objectives • Independent technology assessment ; focused on fuel cell system and hydrogen infrastructure: performance, operation, and safety. • Leverage data processing and analysis capabilities from the fuel cell vehicle Learning Demonstration project and DoD Forklift Demo. • Establish a baseline of real-world fuel cell operation and maintenance data and identify technical/market barriers. • Support market growth of fuel cell technologies by reporting on technology features relevant to the value proposition • Report on technology to fuel cell and hydrogen communities, R&D, and stakeholders Composite • Aggregated data across Data • Individual data analyses for multiple systems, sites, Products each FC system and site and teams (CDPs) Detailed • Identify individual • Publish analysis results Data contribution to CDPs without revealing Products • Only shared with partner proprietary data (DDPs) who supplied data National Renewable Energy Laboratory 6 Innovation for Our Energy Future
Data Flow Bundled data 1 delivered Internal analysis to NREL quarterly completed quarterly Project Team NREL HSDC Results Partner/Site Data Processing & Analysis Data Products Operation Data Evaluating secure data transfer options such as mail and secure FTP CDPs DDPs every 6 months 2 ; used for CDP review CDPs every 6 months 3 1) Data templates are created for each different application/report and are common to all partners in an application. 2) Data exchange may happen more frequently based on data, analysis, & collaboration 3) Results published via NREL Tech Val website, conferences, and reports National Renewable Energy Laboratory 7 Innovation for Our Energy Future
Data Reporting – Fuel Cell Forklift Example • Fuel cell forklift application represents a significant early market opportunity for fuel cells • 40 fuel cell forklifts in operation at DLA’s Defense Depot, Susquehanna Pennsylvania • 9 months of detailed data available, including over 10,000 hydrogen fills • Available data provides a real-world understanding of fuel cell forklift operations • Data from this forklift installation and upcoming future installations will be used to develop Composite Data Products on early market deployments of fuel cell forklifts National Renewable Energy Laboratory 8 Innovation for Our Energy Future
Data on Deployments and Usage Amount of Hydrogen Dispensed (Total = 6169 kg) 3000 2500 Hydrogen Dispensed [kg] 2000 1500 Forklift Fueling by Quarter 1000 3500 Total Fuelings = 7931 500 3000 0 2009Q1 2009Q2 2009Q3 2500 cdpFL04 Created: Nov-06-09 7:56 AM Number of Fuelings 2000 Vehicle Hours: All OEMs, Gen 1 and Gen 2 Through 2009 Q2 35 1500 Total Vehicle Hours = 100,284 30 Number of Vehicles In Service 25 1000 Retired 20 500 15 10 0 5 2009 Q1 2009 Q2 2009 Q3 cdpFL03 0 Created: Nov-06-09 7:35 AM Total Vehicle Hours Created: Aug-26-09 04:13 PM National Renewable Energy Laboratory 9 Innovation for Our Energy Future
Data on Deployments and Usage (cont.) Average Ambient Trip Temperature: DOE Fleet Max Op = 140.0 o F 60 50 Time at Fuel Cell Stack Power Levels: DOE Fleet 40 26.9 % trips above 28 o C 30 Temperature [ o C] 20 50 10 0 1.4 % trips below 0 o C All time 40 -10 Time with 0 speed Operating Time [%] -20 Min Op = -5.8 o F -30 30 0 2 4 6 8 10 12 Trip Frequency [%] Created: Aug-14-09 4:47 PM Segmented Trips/Hour Histogram: DOE Fleet 30 20 25 10 20 Frequency [%] 15 0 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% 95-100% >100% 10 Created: Aug-26-09 2:15 PM % Max Fuel Cell Power (Gross) 5 0 0-1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 >8 Trips/Hour* *Trips/Hour based on 50 hour segments Created: Aug-26-09 2:14 PM spanning stack operating period National Renewable Energy Laboratory 10 Innovation for Our Energy Future
Data on Fuel Cell Value Proposition Time to Fill - Dispenser Data 1600 Average Time = 3.49 min 1400 1200 1000 Number of Fills 800 600 400 200 0 / 0 1 2 3 4 5 6 7 8 9 10 53 Time [min] cdpFL06 Created: Nov-06-09 7:56 AM / FC Backup: Reliability & Availability 100 95 90 85 80 % 75 25th & 75th % 70 median outlier 65 60 Reliability Availability Created: Jul-30-09 10:18 AM National Renewable Energy Laboratory 11 Innovation for Our Energy Future
Data on Fuel Cell Technology Durability: Projected Hours to Low Fuel Cell Power Limit 30 Gen1 (> 200 operation hrs) Gen1 (< 200 operation hrs) Gen2 (> 200 operation hrs) 25 Gen2 (< 200 operation hrs) 20 27% Gen1 > 2000 projected hrs 9% Gen2 > 2000 projected hrs % Stacks 15 10 5 0 0-200 400 600 800 1000 1200 1400 1600 1800 2000 >2000 Projected Hours 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 specific high current. 4. Stacks with less than 200 operation hours are in separate groups because the projection is based on operation data and with operation Created: Sep-11-09 8:57 AM hours greater than 200 the degradation rate tends to flatten out. National Renewable Energy Laboratory 12 Innovation for Our Energy Future
Understanding H2 Tank Cycle Life in FC Forklifts • Need to better understand expected H2 tank filling cycles Operating Time between Fuelings 800 in forklift applications 700 • Data currently being Average = 4.1 hours 600 collected can inform that discussion 500 Count • Can aggregate data 400 on operating hours 300 per fill and per shift to 200 better predict tank 100 cycling 0 0 2 4 6 8 10 12 • Tank life is important Op Time between Fuelings [hours] Created: Nov-13-09 3:42 PM Excludes Data > 12 hours. Data reflects site operations and not necessarily total available runtime. factor in business case if shorter than the life of the lift National Renewable Energy Laboratory 13 Innovation for Our Energy Future
Tank Cycling: Forklift Operations Per Shift & Per kg Histogram of Operating Hours Per Lift Accumulated Operating Hours 9 25% 8 20% 0-1 7 1-2 2-3 15% 6 3-4 Number of Forklifts 4-5 5-6 10% 5 6-7 >7 4 5% 3 0% 2 Per Shift Per kg 1 Range of Average Operating Hours Per Lift By Fleet 8 0 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Op Hours 7 cdpFL02 Created: Nov-06-09 7:35 AM 6 5 Hours 4 3 2 1 0 Per Shift Per kg National Renewable Energy Laboratory 14 Innovation for Our Energy Future
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