Department of Energy Activities for Vehicle and Utility Applications Sigmund Gronich WASHCOG Hydrogen Workshop May 23, 2006

Agenda Vehicle and Infrastructure Learning Demonstration (Chevron/Hyundai, DaimlerChrysler/BP, Ford/BP, GM/Shell) Energy Station Project (Air Products, FCE) Power Park Project (DTE, DaimlerChrysler, BP)

Vehicle and Infrastructure Learning Demonstration (Chevron/Hyundai, DaimlerChrysler/BP, Ford/BP, GM/Shell)

Learning Demonstration Project Objectives and Targets Objectives Validate H 2 FC Vehicles and Infrastructure in Parallel Identify Current Status of Technology and its Evolution Re-Focus H 2 Research and Development Support Industry Commercialization Decision by 2015 Performance Measure2009*2015** Fuel Cell Stack Durability 2000 hours5000 hours Vehicle Range 250+ miles300+ miles Hydrogen Cost at Station $3/gge$2-3/gge * To verify progress toward 2015 targets ** Subsequent projects to validate 2015 targets Key Targets Photo: NREL Hydrogen refueling station, Chino, CA

Teams are Fielding Four Main Types of Vehicles Validation also includes FCV Sprinter vans

Representative Hydrogen Refueling Infrastructure Supporting Vehicles Chino, CA LAX refueling station Photo: H2CarsBiz Photos: DTE DTE/BP Power Park, Southfield, MI Photo:Shell Hydrogen Hydrogen and gasoline station, WA DC

Refueling Stations from All Four Teams Test Vehicle/ Infrastructure Performance in Various Climates Northern California Southern California Mid-Atlantic Florida Ap Additional Planned Stations (3) Additional Planned Stations (4) Additional Planned Stations (2) SE Michigan

Project Produces Results for Both the Public and the Industry Project Teams Raw Data, Reports Hydrogen Secure Data Center (HSDC) Located at NREL: Strictly Controlled Access Detailed Analyses, Data Products, Internal Reports Composite Data Products Pre-agreed upon aggregate data results for public Detailed Data Products Only shared with company which originated the data No confidential information

Dynamometer and On-Road Fuel Economy

Vehicle Range Based on Dyno Results and Usable H2 Fuel Stored On-Board Data indicate improved H 2 storage technologies capable of being packaged in a vehicle are necessary to meet range targets

Summary First year of the 5-year project completed 59 vehicles now in fleet operation Several new refueling stations opened No major safety problems encountered Project has identified current technical status relative to program targets Will track improvements from 2nd generation stacks/vehicles introduced mid-way through project Future public results will include: FC durability, reliability, efficiency, and start-up times H2 production cost, efficiency, and maintenance

Energy Station Project (Air Products, FCE)

Food Mart Factory Power Hydrogen Heat Fuel H2 Fueling Station Waste Treatment NG Grid Store / Dry Cleaner Hydrogen Energy Station Vision HES

Distributed Power and Hydrogen FuelCell Energy DFC-300 Power Heat H2H2H2 50% 15% 20%

UnitsPhase IPhase II Overall Efficiency (Net Power + Hydrogen Product) / (Fuel) LHV 60%66% Power Efficiency Net Power / (Total Fuel – Hydrogen Product) LHV 49% Hydrogen Efficiency (Hydrogen Product – Purification Power) / Hydrogen Product LHV 68%77% Hydrogen Product Nm3/hr ~ 40~ 80 Net Power w/o & w Hydrogen kW ~ 247 / 207~ 300 / 243 Natural Gas Flow Nm3/hr ~ 55~ 74 Projected Performance

Power Park Project (DTE, DaimlerChrysler, BP)

Approach: Process Flow Diagram System Operations Center (not shown): Provides remote monitoring & control, all data acquisition and web access All AC systems connected to common 480 V Bus

Objectives Project Objectives Develop and test a hydrogen co- production facility having stationary fuel cell power and vehicle fueling capability that uses renewable & non- renewable resources (FY04) Employ representative commercial units under real-world operating conditions (FY04) Based on performance data, project experience, and market assessments evaluate the technical and economic viability of the power park system (FY05) DOE Objectives By 2008, validate an electrolyzer (powered by a wind turbine) with capital cost of $600/kWe and efficiency of 68% (incl. compression to 5,000 psi)* By 2008, develop a dist gen PEM fuel cell system that achieves 32% electrical efficiency and 20,000 hours durability at $1500/kW *when built in quantities of 1,000

Objectives Project Objectives Contribute to development of relevant safety standards & codes required for commercialization of hydrogen-based energy systems (FY04) Identify system optimization and cost reduction opportunities including design footprint, co- production, and peak-shaving applications (FY05) Increase public awareness and acceptance of hydrogen-based energy systems (FY04-F09) DOE Objectives Determine the relevant codes, safety standards, and engineering data required for Power Parks Obtain real-world operating data to better understand performance, maintenance, operation, and economic viability of Power Parks

Approach: Project Overview Design, install, and operate an integrated hydrogen co-production facility utilizing:  Electrolytic hydrogen production (2.7 kg/hr, 43 kg/day)  50kW (DC) stationary fuel cell power (320 kWh/day)  5000 psig vehicle dispensing (15 kg/day)  Renewable on-site solar energy (27 kW)  Grid-connected biomass energy Collect, analyze, and report system performance data & lessons learned for an integrated co-production facility operating under real-world conditions Evaluate commercialization opportunities for an advanced Power Park facility

Accomplishments: V alidated electrolyzer with capital cost of $1500/kWe and efficiency of 59% DTE HTP Demonstration Project Electrolyzer Measured running efficiency* 59% (DOE 2008 goal 68%) $1500/kWe (DOE 2008 goal $600/kWe) Off Peak operation (16 hrs/day) - 43 kg/day production 2.7 kg/hr production rate Projected System Performance (manufacturer quote, 2006 prices) Manufacturer rated efficiency 62.25% $700/kWe (DOE 2008 goal $600/kWe) Off Peak operation (16 hrs/day) kg/day production 90 kg/hr production rate * SNL data analysis for steady operatio

Accomplishments: Validated 40kW ‘peak shaving’ PEM fuel cell system Achieved 44% peak fuel cell efficiency Generated 41,034 kWh from installed bank Demonstrated 1500 Hour (6,000 kWh) stack durability at capital cost of $3,000/kW (DC) Determined stack V-I Curves, transient response, and service performance for future improvement Running efficiency (AC) 44% Stack performance, 1500 hr design life

For More Information Sigmund Gronich, Technology Validation Manager