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Technology Validation: Fuel Cell Bus Evaluations

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Technology Validation: Fuel Cell Bus Evaluations Technology Validation: Fuel Cell Bus Evaluations Leslie Eudy National Renewable Energy Laboratory June 7, 2016 Project ID# TV008 This presentation does not contain any proprietary, confidential, or otherwise restricted information. Overview Timeline and Budget Barriers • Project start: FY03 • A. Lack of current fuel cell • End: Project continuation and vehicle (bus) performance direction determined annually by and durability data DOE • C. Lack of current H2 • FY15 DOE funding: $265K fueling infrastructure performance and • FY16 planned DOE funding: $200K availability data • Total DOE funds received to date: $3.725 M (14 years) Partners • Transit fleets: Operational data, fleet experience Additional funding: U.S. Department • Manufacturers: Vehicle specs, of Transportation (DOT)/Federal data, and review Transit Administration (FTA) • Fuel providers: Fueling data and review 2 Relevance • Validate fuel cell electric bus (FCEB) performance and cost compared to DOE/DOT targets and conventional technologies • Document progress and “lessons learned” on implementing fuel cell systems in transit operations to address barriers to market acceptance Current Targets* Units 2016 Target Ultimate Target Bus lifetime Years/miles 12/500,000 12/500,000 Powerplant lifetime Hours 18,000 25,000 Bus availability % 85 90 Roadcall frequency Miles between 3,500/15,000 4,000/20,000 (bus/fuel cell system) roadcall Hours per day/ Operation time 20/7 20/7 days per week Maintenance cost $/mile 0.75 0.40 Miles per diesel Fuel economy 8 8 gallon equivalent * Fuel Cell Technologies Program Record # 12012, Sep 2012, www.hydrogen.energy.gov/pdfs/12012_fuel_cell_bus_targets.pdf 3 Approach Data Collection/Analysis • NREL third-party Individual Site analysis uses Reports standard protocol for • Documents collecting existing performance data from transit results and partners experience for each transit agency • Includes comparisons Annual FCEB Status • Builds database of to conventional Report (milestone) results technology buses in • Crosscutting analysis • Reports published similar service comparing results and posted on (diesel, CNG, diesel from all sites NREL website hybrid) • Assesses progress CNG = compressed natural gas and needs for continued success • Provides input on annual status for DOE/DOT Targets 4 Approach: NREL Assesses Technology Readiness Levels Manufacturer teams for FCEBs currently operating in the United States Length Fuel Cell Bus OEM Hybrid System Design Strategy Energy Storage TRL Level (ft) System Siemens ELFA integrated Van Hool 40 US Hybrid Fuel cell dominant Lithium-based batteries 7 by Van Hool Siemens ELFA integrated New Flyer 40 Ballard Fuel cell dominant Lithium-based batteries 7 by Bluways ElDorado 40 Ballard BAE Systems Fuel cell dominant Lithium-based batteries 7 Proterra 35 Hydrogenics Proterra integration Battery dominant Lithium-titanate batteries 6 EVAmerica 35 Ballard Embedded Power Battery dominant Lithium-titanate batteries 6 OEM = original equipment manufacturer Data included in presentation 5 Approach: Data Summary for 2016 Specifications for FCEBs included in data summary FCEB Identifier ACT ZEBA SL AFCB Transit agency AC Transit SunLine ACT ZEBA Thousand Palms, Location Oakland, CA CA Number of buses 13 4 Bus OEM Van Hool ElDorado National Bus length/height 40 ft / 136 in. 40 ft / 140 in. Fuel cell OEM US Hybrid Ballard Model PureMotion 120 Fcvelocity–HD6 Power (kW) 120 150 Siemens ELFA, BAE Systems Hybrid system integrated by Van HybriDrive SL AFCB Hool Design strategy FC dominant FC dominant Energy storage—OEM EnerDel A123 Nanophosphate Type Li-ion Li-ion Capacity 17.4 kWh 11 kWh Number of cylinders 8 8 Capacity (kg)/pressure (bar) 40 / 350 50 / 350 OEM = original equipment manufacturer ACT ZEBA = AC Transit Zero Emission Bay Area SL AFCB = SunLine American Fuel Cell Bus FC = fuel cell 6 Accomplishments: Progress Toward Targets Top Fuel Cell Powerplant Exceeds 22,000 Hours Top fuel cell powerplant (FCPP) >22,000 hours, surpassing DOE/DOT 2016 target; 71% of FCPPs (12) over 10,000 hours 30,000 DOE/DOT Ultimate Target: 25,000 25,000 20,000 DOE/DOT 2016 Target: 18,000 15,000 Total Hours Total Average: 11,495 10,000 5,000 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 In-Service FCPPs ACT ZEBA SL AFCB Total hours accumulated on each FCPP as of 2/29/16 7 Accomplishments: Progress Toward Targets Average Bus Availability Improves to 73% Monthly bus availability 100 New Data Ultimate Target: 90% 90 2016 Target: 85% 80 70 60 50 Hybrid system upgrades on two buses 40 Availability (%) Availability 30 20 Previous year AMR 2015 Summary Average availability: 70% Average availability: 73% 10 FCPP Availability: 97% FCPP Availability: 95% 0 ZEBA AFCB Average FC system only Availability = planned operation days compared to actual operation days 8 Accomplishments: Progress Toward Targets Availability Summary: 2015 Data Traction Bus PM Hybrid Maintenance Batteries 2% FCEB Fleet Number % Propulsion 2% 6% 2% Available 4,129 84 FC System FC system 148 3 13% Hybrid propulsion 111 2 Traction batteries 116 2 Available Bus maintenance 325 7 75% PM 89 2 Total days 4,918 100 PM = preventive maintenance Bus Traction PM Maintenance Hybrid Batteries 2% 7% Propulsion 2% Two ZEBA buses were down 2% FC System most of 2015 for FC system 3% issues that were difficult to diagnose; removal of those Available two buses from data brings 84% availability to 84% 9 Accomplishments: Progress Toward Targets Monthly Fuel Economy Compared to Baseline mpDGE = miles per diesel gallon equivalent 9 New Data 8 Target: 8 mpDGE 7 6 5 4 3 Fuel Economy Economy (mpDGE) Fuel 2 2014 Average: FCEB 7.26 2015 Average: FCEB 6.85 Diesel 4.29; CNG 3.43 Diesel 4.28; CNG 3.22 1 ACT ZEBA ACT Diesel (Gillig) SL AFCB SL CNG 0 Drop in fuel economy over time could be due to several factors: degradation of fuel cells, changes in routes used, changes in hybrid system calibration 10 Accomplishments: Progress Toward Targets Reliability: Miles Between Roadcall (MBRC) 25,000 New Data 20,000 Ultimate FC System MBRC Target 2016 FC System MBRC Target 15,000 10,000 Miles between roadcall 5,000 Ultimate Bus MBRC Target 2016 Bus MBRC Target 0 Bus MBRC FC System MBRC – FCEB reliability continues to increase and has surpassed ultimate targets – Maintenance staff becoming more familiar with system, applying new tools to anticipate and fix issues before they fail in service 11 Maintenance Costs per Mile by Month by Mile per Costs Maintenance Accomplishments: Cost per mile Cost per mile Cost per mile $0.60 $0.80 $1.00 $1.20 $1.40 $1.60 $1.80 $0.00 $0.20 $0.40 $0.00 $0.20 $0.40 $0.60 $0.80 $1.00 $1.20 $1.40 $1.60 $1.80 $0.40 $1.00 $1.60 $0.00 $0.20 $0.60 $0.80 $1.20 $1.40 $1.80 Low $0.13 FCEB Diesel Low $0.14 Jan-14 CNG Jan-14 Jan-14 Feb-14 Feb-14 Feb-14 Low $0.32 Mar-14 Mar-14 Mar-14 Apr-14 Apr-14 Apr-14 May-14 May-14 May-14 Jun-14 Jun-14 Jun-14 Progress Toward Targets Targets Toward Progress Jul-14 Jul-14 Jul-14 Unscheduled Aug-14 Aug-14 Aug-14 Unscheduled Unscheduled Sep-14 Sep-14 Sep-14 Oct-14 Oct-14 Oct-14 Nov-14 Nov-14 Nov-14 Dec-14 Scheduled Dec-14 Dec-14 Scheduled Scheduled High $1.03 Jan-15 Jan-15 Jan-15 High $1.74 Feb-15 Feb-15 Feb-15 Mar-15 Mar-15 Mar-15 Apr-15 Apr-15 Apr-15 New Data May-15 May-15 May-15 Jun-15 Jun-15 Jun-15 Jul-15 Jul-15 Jul-15 High $0.58 Aug-15 Aug-15 Aug-15 Sep-15 Sep-15 Sep-15 Oct-15 Oct-15 Oct-15 Nov-15 Nov-15 Nov-15 Dec-15 Dec-15 Dec-15 $0.52 CNG $0.27 Diesel $0.98 Average 2015 FCEB 12 Accomplishments: Progress Toward Targets Maintenance Costs per Mile – Average for Data Periods FCEB Diesel CNG $1.00 $1.00 $1.00 $0.90 $0.98$0.90 $0.90 $0.80 $0. 79 $0.80 $0.80 $0.70 $0.70 $0.70 $0.60 $0.60 $0.60 $0.54 $0.52 $0.50 $0.50 $0.50 $0.40 $0.40 $0.40 Cost mile per Cost $0.32 mile per Cost $0.30 $0.30 $0.27 $0.30 Average Average cost per mile $0.20 $0.20 $0.20 $0.10 $0.10 $0.10 $0.00 $0.00 $0.00 5/12 - 12/15 1/15 - 12/15 7/13 - 12/15 1/15 - 12/15 3/12 - 12/15 1/15 - 12/15 Unscheduled Scheduled – Average cost per mile shown for overall data period and for the past year – Costs tend to rise as buses age and pass warranty period – Average miles for each bus type – FCEB: 91,400; Diesel: 144,500; CNG: 399,000 13 Accomplishments: Progress Toward Targets Maintenance Cost per Mile by System 2.00 Tires New Data 1.80 General air system 1.60 repairs Axles, wheels, and 1.40 drive shaft Lighting 1.20 1.00 HVAC 0.80 Frame, steering, and Cost per mile ($) Cost suspension 0.60 Brakes 0.40 PMI* 0.20 Propulsion-related 0.00 Cab, body, and accessories Propulsion system costs make up 50.6% of total maintenance costs (46.9% in 2014) followed by cab, body, and accessories at 16.5% *PMI = preventive maintenance inspection 14 Accomplishments: Progress Toward Targets Maintenance Cost per Mile by Propulsion Sub-System 1.20 New Data 1.00 0.80 Hybrid System Fuel System 0.60 Cooling Air Intake Cost per ($) mile Cost 0.40 Cranking/Charging Electrical 0.20 FC 0.00 – FC system costs are 18.9% of total maintenance costs (8.3% in 2014) – High cost components results in increased cost per mile – Components with highest cost for 2015 include inverter (Mar), H2 solenoids (Apr, Oct), air compressor (June, Sep), inductor (Oct) 15 Accomplishments and Progress: Responses to Previous Year Reviewers’ Comments • Reporting spare FCPPs with in-service FCPPs makes it challenging to interpret real stack life.
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