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Implementation of
Hydrogen Fuel Cell
Vehicles
Richard T Jacobsen
Vivek Utgikar
October 25, 2007
Fuel Cell Fundamentals
_ electrons (e-) +
Anode Cathode
proton
transport
(H+)
H2 O2
Electrolyte
Anodic Reaction Cathodic Reaction
H2 2 H+ + 2 e- Electrodes and Catalyst 1/ O + 2 H+ + 2 e- H O
2 2 2
2
Hydrogen Powered Vehicles
Auto companies poised to move from
proof of concept to production of fuel cell
vehicles
Proof of Concept
Higher hydrogen storage pressures—
10,000psi—Longer ranges—400 miles
Fuel cell packaging, less hand assembly
Freeze-start performance
Profitability far in the future
Hydrogen Vehicles from global
auto makers
General Motors
Daimler-Chrysler
Ford Motor Company
Honda
Toyota
Hyundai
Others……..
General Motors
General Motors
GM has placed a very high priority on fuel cells
and hydrogen as the long-term power source and
energy carrier for automobiles. We see this
combination as the best way to simultaneously
increase energy independence and security,
remove the automobile as a source of emissions,
and allow automakers to create better vehicles
that customers will want to buy in high volumes.
General Motors (cont.)
GM’s fuel cell program is focused on four areas:
Developing a fuel cell propulsion system that can compete head-to-
head with internal combustion engine systems – on performance,
durability and cost.
Demonstrating our progress publicly to let key stakeholders
experience firsthand the promise of this technology.
Collaboratingwith energy companies to ensure that safe,
convenient, and affordable hydrogen is available to our customers,
enabling rapid transformation to fuel cell vehicles.
Working with governments worldwide to ensure that appropriate
market conditions and incentives are in place to enable a successful
market introduction and subsequent sustainable market expansion.
General Motors (cont.)
We are targeting to design and experimentally prove a system
that has the performance, durability, and cost -- assuming scale
volumes -- of today’s engine systems by 2010. We have made a
major commitment to this effort and have spent more than $1
billion to date. Additionally, to achieve our ultimate vision of a
hydrogen economy and hydrogen fuel cell-based transportation,
about 700 GM scientists and engineers are working around the
world on research and development activities in places like the
U.S., Germany, and Japan. As a result, we are making great
progress in developing the necessary technologies and are
increasingly confident we will reach our goal.
GM Sequel
GM Sequel (cont.)
Compressed hydrogen Sequel’s sophisticated
Gasoline-equivalent fuel efficiency
is about 39 mpg, or 5.7 liters per 100 km
by-wire system replaces
the mechanical and
Technology: Fuel cell and by-wire hydraulic linkages of
Overview: The Sequel, about the size of a
conventional vehicles
Cadillac SRX, is the first fuel cell vehicle with electrical wires and
that achieves 0-60 mph in under 10 actuators. This means
seconds and has a 300-mile range. fewer parts to wear out,
Other benefits include: and because by-wire
Unequaled control on snow and ice, or systems work like a fast
uneven terrain computer, Sequel has
42-percent more torque for unparalleled enhanced accelerating,
acceleration braking and overall
Shorter braking distance than an equal handling.
size vehicle
GM Chevy Equinox
Fuel Cell
Compressed hydrogen
Technology: Fuel cell
Overview: Enabled by GM’s fourth-
generation fuel cell propulsion
system, the Equinox Fuel Cell is a
fully-functional crossover vehicle,
engineered for 50,000 miles of life.
Importantly, the Equinox Fuel Cell is GM announced in September 2006 that it
able to start and operate in sub- will build more than 100 Chevrolet Equinox
freezing temperatures during its Fuel Cell vehicles and will begin placing
50,000-mile life. It is expected to meet them with customers in the fall of 2007, as
all applicable 2007 U.S. Federal part of a comprehensive deployment plan
Motor Vehicle Safety Standards, and dubbed “Project Driveway." Designed to
is equipped with a long list of gain comprehensive learnings on all aspects
standard safety features while of the customer experience, Project
Driveway constitutes the first meaningful
providing all of the environmental market test of fuel cell vehicles anywhere
benefits of hydrogen fuel cell and will be targeted in three geographic
technology. The Equinox has a 200 areas: California, the New York metropolitan
mile range. area and Washington D.C.
GM HydroGen3
• The vehicle, the latest in the HydroGen
series, is based on the Zafira, a popular
five-passenger vehicle from our Opel
division in Germany.
• Range - 249 miles/400 km (liquid
storage); 168 miles/270 km
(compressed)
• Top Speed – 99 mph/160 km
• Liquid hydrogen powers the fuel cell
stack, which supplies electricity to a
battery, powering the vehicle and
emitting only clean water.
• GM and Shell are partnering on a
Technology: Hydrogen Fuel Cell demonstration program in Washington
D.C., with a fleet of GM’s HydroGen3
Overview: The HydroGen3 fuel cell fuel cell vehicles.
vehicle marks another important
milestone along the way to fitting • GM partnered with FedEx in Japan
passenger cars with an environmentally under the Japan Hydrogen and Fuel
compatible, resource-saving, fuel cell Cell Demonstration Project.
propulsion system. • The HydroGen3 is part of the Clean
Energy Partnership in Berlin.
GM Hy-Wire
Technology: Fuel cell and by-
wire
Overview: Named for its
combination of hydrogen fuel
cell and drive-by-wire
technology, the Hy-wire
incorporates the features
This drivable prototype envisioned in the AUTOnomy
combines zero-emissions concept vehicle. All of its
with world-class fuel propulsion and control systems
economy and the ability to are contained within an 11-inch-
switch bodies to meet thick skateboard-like chassis,
different needs. maximizing the interior space for
five occupants and their cargo.
GM AUTOnomy
Technology: Fuel cell
and by-wire (concept)
Overview: Designed
from the ground up
around a fuel cell
propulsion system, the
AUTOnomy is the first
to combine fuel cells
with x-by-wire
technology, which
allows steering, braking
amd other vehicle Through the combination of fuel cell
systems to be controlled and x-by-wire technology, design is no
electronically, rather longer restricted to conventional
than mechanically. configurations.
GM Chevy Volt
GM will announce plans to produce a hydrogen-fueled version of the Volt concept
vehicle introduced in January at the Detroit auto show. Like the original Volt, it would
be a plug-in powered by a lithium ion battery, but the battery would be mated with a
hydrogen fuel cell system rather than a small gasoline engine.
The plug-in hydrogen Volt would have a 300-mile range with combined battery and
hydrogen power. No petroleum products would be consumed and the vehicle would be
emissions-free.
www.detroitnews.com
Daimler-Chrysler
Jeep Commander 2
The Jeep Commander 2, a luxury-class Sport Utility Vehicle (SUV) powered
by a fuel cell, demonstrates that this environment-friendly drive concept is also
suitable for larger vehicles. The tank of this SUV is filled with methanol from
which hydrogen is reformed on board the vehicle.
Natrium
The Natrium car is based on the Chrysler Town & Country minivan. It is
powered by sodium borohydride (NaBH4), a white salt whose molecules are
relatively rich in hydrogen. With the help of a chemical catalyst, elementary
hydrogen is produced, which provides the energy for the fuel cell. The
Natrium has an operating range of 500 km and accelerates from 0 to 100 km/h
in 16 seconds. It has a top speed of 129 km/h.
Hermes Sprinter
In 2001, DaimlerChrysler launched a cooperation with the Hamburg
delivery company Hermes Versand Service to test the fuel cell Mercedes-
Benz Sprinter in everyday commercial operation. The Mercedes-Benz van
is fueled by gaseous hydrogen; it has a range of about 150 kilometers and
reaches a speed of 120 km/h with its 55 kW electric motor. The fuel cell
technology does not restrict the load space of this van. In its first year of
operation, the Sprinter covered more than 16,000 kilometers and supplied
4,200 clients.
Mercedes-Benz A-Class "F-Cell"
Christened "F-Cell", 60 of these
cars from the world's first small
series of fuel-cell-powered
passenger cars were operated by
customers in cooperative ventures
in Europe, the USA, Japan and
Singapore. From 2002 to 2007,
several customers took part in this
project to test 60 F-cell A-Classes
under everyday operating conditions in their respective geographic areas. One of
these customers is the car pool of the Federal Chancellery in Berlin, Germany.
Dr. Ewold Seeba, Director of Department 1 in the Chancellor’s Office, said, “If
we don’t start trying to reconcile our demand for universal mobility with the need
to protect the climate, we’ll have no globally applicable alternative to the car in
the coming decade. In other words, we should be taking steps now to prepare
new technologies for market launch. The future needs pioneers.”
Mercedes-Benz A-Class "F-Cell―
(cont.)
In the "F-Cell", the entire fuel cell system is
accommodated in the sandwich floor of the long-
wheelbase Mercedes-Benz A-Class. The
development of fuel cell technology will be
furthered mainly in practical operation involving
extensive field testing.
Ford Motor Company
Ford
Ford first began working on hydrogen technology in the early 1990s.
Ford’s first hydrogen fuel cell vehicle, released in 2001, was based
on a lightweight aluminum sedan body, which also was used in the
development of the company’s first hydrogen-powered internal
combustion engine.
The company currently has a fleet of 30 hydrogen-powered Focus
fuel cell vehicles on the road as part of a worldwide, seven-city
program to conduct real-world testing of fuel cell technology. The
fleet has accumulated more than 300,000 miles since its inception.
With this fleet on the ground, a great deal of information that can be
integrated into future fuel cell vehicle propulsion systems is being
generated in different local environmental conditions.
Ford’s FreedomCAR
Creating a Hydrogen-Powered Transportation System
The "Freedom" in FreedomCAR represents the following:
Freedom from petroleum dependence
Freedom from pollutant emissions
Freedom to choose the vehicle you want
Freedom to drive where you want and when you want
Freedom to obtain fuel affordably and conveniently
The "CAR" in FreedomCAR stands for Cooperative Automotive Research. The
DOE and USCAR (a partnership of Ford Motor Company, DaimlerChrysler, and
General Motors) represent the government and industry in FreedomCAR.
The ultimate vision of FreedomCAR is a transportation system powered by
hydrogen.
Ford’s FreedomCAR (cont.)
Demonstrating Hydrogen's Potential
The demonstration program begins this year with the goal of validating hydrogen-
powered vehicles and infrastructure in real-world operating conditions. We expect
to participate in the demonstration with Ford Focus Fuel Cell Vehicles as the
cornerstone of our participation.
To ensure that interim progress towards improving energy efficiency continues,
FreedomCAR also has active research programs in battery development,
lightweight materials, clean combustion and power electronics.
Currently, there are seven technical teams working on the FreedomCAR project:
Advanced Combustion and Emissions Control
Electrochemical Storage
Electrical and Electronics
Fuel Cells
Hydrogen Storage and Vehicle Interface
Materials
Systems Engineering and Analysis
Ford Hydrogen Vehicles
Ford Edge Hydrogen Vehicle
Fuel Cell Powered Ford Explorer
Ford’s Hydrogen Fuel Cell Focus 2009 Hydrogen Ford Fusion
Ford Airstream Concept
A shiny, hydrogen-powered PHEV funmobile
The HySeries Drive is battery-powered, with
plug-in capability and has a hydrogen fuel
cell as an on-board charger. Ford estimates a
combined city/highway gasoline equivalent
fuel economy rating of 41 mpg. On all-
electric power, the Airstream concept can go
25 miles. Add some hydrogen (ahh, if only it
were so easy), and you can go another 280
miles. The fuel cell, made by Ballard, turns
on automatically when the battery charge
dips below 40 percent. With the on-board
charger (110/220 VAC), the battery pack can
be refilled at home. Ford says the HySeries HYSERIES DRIVE™ FORD CONCEPT FEATURES
Drive is 50 percent smaller and less complex BATTERY-POWERED, PLUG-IN HYBRID WITH A
than conventional fuel cell system and HYDROGEN FUEL CELL
should have more than double the lifetime.
www.autobloggreen.com
Other Automakers
Honda FCX
The FCX Concept is a key stage in
Honda's development of fuel cell
technology and will be the basis for
a totally new fuel cell vehicle which
the company is currently developing.
Limited marketing of this new
vehicle is on target to begin in 2008
in Japan and the U.S. and the focus
will be to deliver a new dimension in
environmentally friendly driving
pleasure not found with petrol-
engine vehicles. This allows gravity to assist in discharging the water
that is produced, resulting in a major improvement in
water drainage - key to high-efficiency fuel stack
To meet Honda's objectives for performance - and achieving a higher output from a
significant gains in both
environmental and driving smaller package.
performance, the FCX Concept is This new fuel cell stack is 20 percent smaller and 30
equipped with a V Flow fuel cell percent lighter than the current FCX FC Stack, yet its
platform. In previous fuel cell stacks power output is 14kW greater. The drive motor has
the hydrogen and the water formed been positioned coaxially with the gearbox for a
in electricity generation flowed
horizontally, this vehicle features a more compact design, with output increased by
vertical-flow design. 15kW.
Honda FCX (cont.)
Overall, the power plant is about 180kg lighter than that of the current FCX
and about 40 percent smaller in volume. The V Flow fuel cell platform also
has allowed the designers to create an elegant, low-riding, sedan form that
would have been difficult to achieve in a conventional fuel cell vehicle. The
result is improved energy efficiency and performance along with a more
spacious interior.
Low-temperature startup has also been significantly improved, enabling cold-
weather starts at temperatures 10°C lower than the current FCX- as low as
minus 30°C.
As an auxiliary power source, the FCX Concept carries a compact, high-
efficiency lithium ion battery, contributing to increased power output and a
more compact power plant. These efficiency improvements to major power
plant components give the vehicle a travel range approximately 30 percent
greater than the current FCX.
Limited marketing of a totally new fuel cell vehicle based on the FCX Concept
model is to begin in Japan and the US in a couple of years.
Toyota FCHV-5
Toyota announced that an improved
version of its FCHV fuel cell hybrid
vehicle successfully completed a 560
km road test by traveling from Osaka to
Tokyo on a single fueling of hydrogen.
The entire trip was completed with the
air conditioner on and with no need to
stop for refueling.
The FCHV used in the trip is 25% more fuel efficient than earlier versions, due
to improvements in the high-performance Toyota FC Stack fuel cell and to
improvements in the control system for managing fuel cell output and battery
charging/discharging. It also features 70Mpa high-pressure hydrogen tanks
capable of storing approximately twice the amount of hydrogen as the previous
FCHV’s 35Mpa high-pressure hydrogen tanks. These improvements make it
possible to achieve a single-fueling cruising distance of approximately 750km.
Hyundai i-Blue Concept
The i-Blue demonstrates a
significant step toward
commercialization of
Hyundai fuel-cell vehicles,
noting that for the first time
its fuel-cell prototype is
embodied in a 2+2
crossover vehicle instead of
an SUV. The i-Blue is
powered by a 100 kW (134
hp) motor powered by a
fuel cell. The automaker
said it is capable of running
nearly 375 miles per
refueling and has a
maximum speed of 102.5
mph.
www.edmunds.com
Hydrogen Vehicles
HYDROGEN CARS HYDROGEN CARS (cont.) HYDROGEN CARS (cont.)
Audi A2H2 Car GM Electrovan Nissan X-Trail FCV
BMW HR2 Race Car GM H2H Hummer SUT Peugeot 207 Epure
BMW Hydrogen 7 GM Hy-wire Concept Suzuki Ionis Mini
Daihatsu Tanto FCHV GM HydroGen Minivan Think FC5 Car
Fiat Panda Concept GM Sequel Concept Think Nordic Car
Ford Airstream Concept Honda FCX Toyota FCHV SUV
Ford Explorer Fuel Cell Hyundai i-Blue Toyota Fine-T (Fine-X)
Ford Flexible Series Edge Hyundai Tucson FCEV Volkswagen HyMotion
Ford Focus FCV Kia Sportage FCEV
Ford Model U Mazda 5 Premacy RE OTHER H2 VEHICLES
Ford Super Chief Truck Mazda RX-8 RE
Giugiaro Vadho Mercedes B-Class F-Cell ETH Zurich PAC-Car II
GM Chevy Equinox FC Mercedes F600 Hygenius Intelligent Energy ENV
GM Chevy Volt Peugeot Citroen Quark
Mitsubishi Nessie SUV
Quantum Aggressor
www.hydrogencarsnow.com
Hydrogen Implementation
Source: General Motors Corporation
Home Hydrogen Unit = Just another home appliance?
Hydrogen Implementation
Vancouver
Hydrogen
highway
infrastructure
In operation by
2010 Winter
Olympics
35
Hydrogen Implementation
March 2007--
California
Hydrogen highway
infrastructure
24 existing stations
170 stations in
operation by 2010
Over 167 cars in
operation Image take from California
Fuel Cell Partnership:
www.cafcp.org/fuel-vehl_map.html
Updated 3/2007
36
Hydrogen Implementation
Liquid Fuels
Carbon sequestration is less necessary
Costs are competitive with gasoline production
Combining carbon and hydrogen using proven
processes with credible cost data
• Synfuels from coal--Separating C from flue gases of
coal plants—Fischer–Tropsch reaction
• Synfuels based on the olefin molecule—gas and
diesel fuel
• Gasification of carbon in fossil fuels—react with H2
37
Hydrogen Implementation
Storing Hydrogen for the future
Metal Hydrides—powdered or granulated
metals, e. g. magnesium hydride
Complex Hydrides—aluminum, boron,
sodium, magnesium
Carbon nanotubes
Porous-walled, hollow glass microspheres
38
Supplier and Consumer Concerns
Safety?
Efficiency?
Costs of buying and selling?
Solution: Well designed and optimized
engineered systems.
39
Design of Hydrogen Systems
Requires accurate properties of hydrogen
Custom experimental measurements are
generally not practical
All thermodynamic properties from an
Equation of State (EOS)
All transport properties from a separate
formulation
EOS and transport formulations accurately
represent published experimental data
40
Questions?
Source: General Motors Corporation
41
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