A national laboratory of the U.S. Department of Energy Office of Energy Efficiency & Renewable Energy National Renewable Energy Laboratory Innovation for Our Energy Future Strategy for the Integration of Subcontract Report NREL/SR-540-38720� Hydrogen as a Vehicle Fuel into September 2005 � the Existing Natural Gas Vehicle � Fueling Infrastructure of the � Interstate Clean Transportation � Corridor Project � April 22, 2004 — August 31, 2005 Gladstein, Neandross & Associates � Santa Monica, California � NREL is operated by Midwest Research Institute ● Battelle Contract No. DE-AC36-99-GO10337 Strategy for the Integration of Subcontract Report NREL/SR-540-38720 Hydrogen as a Vehicle Fuel into September 2005 the Existing Natural Gas Vehicle Fueling Infrastructure of the Interstate Clean Transportation Corridor Project April 22, 2004 — August 31, 2005 Gladstein, Neandross & Associates Santa Monica, California NREL Technical Monitor: R. Parish Prepared under Subcontract No. LCM-4-44175-01 National Renewable Energy Laboratory 1617 Cole Boulevard, Golden, Colorado 80401-3393 303-275-3000 • www.nrel.gov Operated for the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy by Midwest Research Institute • Battelle Contract No. DE-AC36-99-GO10337 NOTICE This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. 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Box 62 Oak Ridge, TN 37831-0062 phone: 865.576.8401 fax: 865.576.5728 email: mailto:[email protected] Available for sale to the public, in paper, from: U.S. Department of Commerce National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 phone: 800.553.6847 fax: 703.605.6900 email: [email protected] online ordering: http://www.ntis.gov/ordering.htm This publication received minimal editorial review at NREL Printed on paper containing at least 50% wastepaper, including 20% postconsumer waste Table of Contents Table of Contents................................................................................................................. i Index of Tables and Figures................................................................................................ ii Executive Summary........................................................................................................... iv Introduction and Background ..............................................................................................1 Scope of Work .....................................................................................................................4 Opportunities and Challenges to the Integration of Hydrogen into the ICTC.....................7 Criteria for Selection..........................................................................................................18 Prospective Targets for NG-H2 Demonstrations................................................................22 Integration of ICTC NG-H2 Sites into Existing Hydrogen Development Efforts .............30 Hydrogen Reformation from Natural Gas .........................................................................32 Potential Site Issues ...........................................................................................................34 Site Specific Recommendations ........................................................................................37 Vehicle Integration Issues..................................................................................................38 Projected Program Costs....................................................................................................43 Next Steps ..........................................................................................................................45 Conclusion .........................................................................................................................48 Bibliography ......................................................................................................................51 Appendix A - Leading Programs to Promote Hydrogen Vehicles ....................................52 Appendix B - Possible Funding Sources for Hydrogen Vehicle and Infrastructure Projects.........................................................................................................................60 Appendix C - California Fuel Cell Partnership Map of Current Hydrogen Vehicle & Station Development Projects......................................................................................66 Appendix D - Map of Current Hydrogen Vehicle & Station Development Projects with Proposed ICTC Hydrogen Demonstration Projects Added .................................67 i Index of Tables and Figures List of Figures Figure 1: USA Waste in Fresno.........................................................................................23 Figure 2: Harris Ranch.......................................................................................................29 Figure 3. Sunline Transit’s fuel cell powered Z-Bus at its hydrogen fueling station ........50 Figure 4: SCAQMD Hydrogen Fueling Station Projects ..................................................53 List of Tables Table 1: Constituents in Natural Gas................................................................................ 10 Table 2: Average LNG Composition for California Vehicle Fuel ................................... 11 Table 3: Energy Densities of Comparative Fuels ............................................................. 13 Table 4: Weight to Volume Ratios for Hydrogen............................................................. 13 Table 5: Comparable Energy Content............................................................................... 14 Table 6: Hydrogen Costs & Transportation Fuel Equivalents.......................................... 17 Table 7: Projected Costs for HCNG Vehicle Demonstration Project............................... 44 Table 8: SCAQMD “Five Cities” Funders ....................................................................... 52 Table 9: South Coast AQMD Projects.............................................................................. 52 Table 10: California Fuel Cell Partnership Projects ......................................................... 54 Table 11: DOE Hydrogen Fleet and Infrastructure Demonstration.................................. 57 ii List of Acronyms and Abbreviations AFV alternative fuel vehicle ASME American Society of Mechanical Engineers ATR autothermal reformation Btu British thermal unit CA 99 California State Highway 99 CaFCP California Fuel Cell Partnership CAP Clean Air Power CARB California Air Resources Board CH4 methane CHG compressed hydrogen gas CNG compressed natural gas CO2 carbon dioxide CTI Collier Technologies, Inc. CVITM Constant Volume InjectionTM CWI Cummins Westport, Inc. DOE U.S. Department of Energy GGE gasoline gallon equivalents GNA Gladstein, Neandross & Associates H2 hydrogen HCNG fuel blend of hydrogen and natural gas ICE internal combustion engine ICTC Interstate Clean Transportation Corridor kg kilogram LCNG liquefied/compressed natural gas LHG liquid hydrogen gas LNG liquefied natural gas MDAQMD Mojave Desert Air Quality Management District NG-H2 natural gas/hydrogen NMHC non-methane hydrocarbons NOx nitrogen oxides NREL National Renewable Energy Laboratory PEM proton exchange membrane PM particulate matter psi pounds per square inch psig pounds per square inch gage SCAQMD South Coast Air Quality Management District SMR steam methane reformer TRU transportation refrigeration units WI Westport Innovations iii Executive Summary The U.S. Department of Energy (DOE) funds research and development that reduces U.S. dependence on imported petroleum and promotes better air quality. The work described in this report was supported through DOE’s National Renewable Energy Laboratory (NREL). NREL has contracted with Gladstein, Neandross & Associates (GNA) to survey opportunities to integrate hydrogen into the natural gas vehicles and fueling stations of the Interstate Clean Transportation Corridor (ICTC). The ICTC is an existing network of over 600 heavy-duty trucks and 20 fueling stations in California and Nevada that are fueled by liquefied natural gas (LNG). This project is intended to lay the groundwork for natural gas-hydrogen fueling infrastructure along the existing ICTC to facilitate the introduction and commercialization of hydrogen vehicles along this route. The objective of this study is to evaluate whether the existing vehicle stock and