1 Technical Report NREL/TP May 2010 Controlled Hydrogen Fleet and Infrastructure Demonstration and Validation Project Spring 2010 Composite Data Products Final Version March 29, 2010 Keith Wipke, Sam Sprik, Jennifer Kurtz, and Todd Ramsden

2 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. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof. Available electronically at Available for a processing fee to U.S. Department of Energy and its contractors, in paper, from: U.S. Department of Energy Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN phone: fax: Available for sale to the public, in paper, from: U.S. Department of Commerce National Technical Information Service 5285 Port Royal Road Springfield, VA phone: fax: online ordering: Printed on paper containing at least 50% wastepaper, including 20% postconsumer waste

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. Spring 2010 Composite Data Products March 29, 2010 Keith Wipke, Sam Sprik, Jennifer Kurtz, Todd Ramsden Controlled Hydrogen Fleet and Infrastructure Demonstration and Validation Project

National Renewable Energy Laboratory 4 Innovation for Our Energy Future CDP#1: Hours Accumulated and Projected Hours to 10% Stack Voltage Degradation

National Renewable Energy Laboratory 5 Innovation for Our Energy Future CDP#2: Vehicle Range

National Renewable Energy Laboratory 6 Innovation for Our Energy Future CDP#3: Fuel Cell System Power Density, Including Hydrogen Storage

National Renewable Energy Laboratory 7 Innovation for Our Energy Future CDP#4: Fuel Cell System Specific Power, Including Hydrogen Storage

National Renewable Energy Laboratory 8 Innovation for Our Energy Future CDP#5: Fuel Cell Start Times from Sub-Freezing Soak Conditions

National Renewable Energy Laboratory 9 Innovation for Our Energy Future CDP#6: Fuel Economy

National Renewable Energy Laboratory 10 Innovation for Our Energy Future CDP#7: Fuel Cell Voltage

National Renewable Energy Laboratory 11 Innovation for Our Energy Future CDP#8: FC System Efficiency

National Renewable Energy Laboratory 12 Innovation for Our Energy Future CDP#9: Safety Reports – Vehicles

National Renewable Energy Laboratory 13 Innovation for Our Energy Future CDP#10: Storage Weight % Hydrogen

National Renewable Energy Laboratory 14 Innovation for Our Energy Future CDP#11: Volumetric Capacity of H2 Storage

National Renewable Energy Laboratory 15 Innovation for Our Energy Future CDP#12: Vehicle Hydrogen Tank Cycle Life

National Renewable Energy Laboratory 16 Innovation for Our Energy Future CDP#13: On-Site Hydrogen Production Efficiency

National Renewable Energy Laboratory 17 Innovation for Our Energy Future CDP#14: Fueling Rates – 350 and 700 bar

National Renewable Energy Laboratory 18 Innovation for Our Energy Future CDP#15: H2 Production Cost vs. Process

National Renewable Energy Laboratory 19 Innovation for Our Energy Future CDP#16: Fuel Cell Stack Trips Per Hour Histogram

National Renewable Energy Laboratory 20 Innovation for Our Energy Future CDP#17: Statistics of Trips/Hour vs. Operating Hour

National Renewable Energy Laboratory 21 Innovation for Our Energy Future CDP#18: Refueling Rates

National Renewable Energy Laboratory 22 Innovation for Our Energy Future CDP#19: Time Between Trips & Ambient Temperature

National Renewable Energy Laboratory 23 Innovation for Our Energy Future CDP#20: Safety Reports – Infrastructure

National Renewable Energy Laboratory 24 Innovation for Our Energy Future CDP#21: Range of Ambient Temperature During Vehicle Operation

National Renewable Energy Laboratory 25 Innovation for Our Energy Future CDP#22: Vehicle Operating Hours

National Renewable Energy Laboratory 26 Innovation for Our Energy Future CDP#23: Vehicles vs. Miles Traveled

National Renewable Energy Laboratory 27 Innovation for Our Energy Future CDP#24: Cumulative Vehicle Miles Traveled

National Renewable Energy Laboratory 28 Innovation for Our Energy Future CDP#25: Vehicle H2 Storage Technologies

National Renewable Energy Laboratory 29 Innovation for Our Energy Future CDP#26: Cumulative H2 Produced or Dispensed

National Renewable Energy Laboratory 30 Innovation for Our Energy Future CDP#27: Hydrogen Quality Index

National Renewable Energy Laboratory 31 Innovation for Our Energy Future CDP#28: Hydrogen Fuel Constituents

National Renewable Energy Laboratory 32 Innovation for Our Energy Future CDP#28 Supplemental: Hydrogen Constituents by Year and Production Method (This slide contains 18 graphs (1 for each constituent): view in slide-show mode)

National Renewable Energy Laboratory 33 Innovation for Our Energy Future CDP#29: Fueling Rates Communication and Non-Communication Fills

National Renewable Energy Laboratory 34 Innovation for Our Energy Future CDP#30: Infrastructure Maintenance

National Renewable Energy Laboratory 35 Innovation for Our Energy Future CDP#31: Number of Online Stations

National Renewable Energy Laboratory 36 Innovation for Our Energy Future CDP#32: Infrastructure Hydrogen Production Methods

National Renewable Energy Laboratory 37 Innovation for Our Energy Future CDP#33: Percentage of Theoretical Range Traveled Between Refuelings

National Renewable Energy Laboratory 38 Innovation for Our Energy Future CDP#34: Effective Vehicle Range

National Renewable Energy Laboratory 39 Innovation for Our Energy Future CDP#35: Average Refuelings Between Infrastructure Safety Reports

National Renewable Energy Laboratory 40 Innovation for Our Energy Future CDP#36: Type of Infrastructure Safety Report By Quarter

National Renewable Energy Laboratory 41 Innovation for Our Energy Future CDP#37: Primary Factors of Infrastructure Safety Reports

National Renewable Energy Laboratory 42 Innovation for Our Energy Future CDP#38: Refueling Times

National Renewable Energy Laboratory 43 Innovation for Our Energy Future CDP#39: Refueling Amounts

National Renewable Energy Laboratory 44 Innovation for Our Energy Future CDP#40: H2 Tank Level at Refueling

National Renewable Energy Laboratory 45 Innovation for Our Energy Future CDP#41: Refueling Tank Levels - Medians

National Renewable Energy Laboratory 46 Innovation for Our Energy Future CDP#42: Refueling by Time of Day

National Renewable Energy Laboratory 47 Innovation for Our Energy Future CDP#43: Refueling by Day of Week

National Renewable Energy Laboratory 48 Innovation for Our Energy Future CDP#44: Driving Start Time – Day

National Renewable Energy Laboratory 49 Innovation for Our Energy Future CDP#45: Driving by Day of Week

National Renewable Energy Laboratory 50 Innovation for Our Energy Future CDP#46: Fuel Cell System Operating Power

National Renewable Energy Laboratory 51 Innovation for Our Energy Future CDP#47: Trip Length

National Renewable Energy Laboratory 52 Innovation for Our Energy Future CDP#48: Primary Factors Affecting Learning Demo Fleet Fuel Cell Degradation

National Renewable Energy Laboratory 53 Innovation for Our Energy Future CDP#49: Primary Factors Affecting Learning Demo Team Fuel Cell Degradation

National Renewable Energy Laboratory 54 Innovation for Our Energy Future CDP#50: Refueling by Time of Night

National Renewable Energy Laboratory 55 Innovation for Our Energy Future CDP#51: Driving Start Time – Night

National Renewable Energy Laboratory 56 Innovation for Our Energy Future CDP#52: Refueling Data by Year

National Renewable Energy Laboratory 57 Innovation for Our Energy Future CDP#53: Fuel Cell System Energy within Power Levels

National Renewable Energy Laboratory 58 Innovation for Our Energy Future CDP#54: Time Between Trips

National Renewable Energy Laboratory 59 Innovation for Our Energy Future CDP#55: Fuel Cell System Energy

National Renewable Energy Laboratory 60 Innovation for Our Energy Future CDP#56: Daily Driving Distance

National Renewable Energy Laboratory 61 Innovation for Our Energy Future CDP#57: H2 Storage System Mass and Volume Breakdown

National Renewable Energy Laboratory 62 Innovation for Our Energy Future CDP#58: Fuel Cell System Power Density

National Renewable Energy Laboratory 63 Innovation for Our Energy Future CDP#59: Fuel Cell System Specific Power

National Renewable Energy Laboratory 64 Innovation for Our Energy Future CDP#60: On-Site Hydrogen Production Efficiency vs. Capacity Utilization

National Renewable Energy Laboratory 65 Innovation for Our Energy Future CDP#61: Refueling Station Compressor Efficiency

National Renewable Energy Laboratory 66 Innovation for Our Energy Future CDP#62: Learning Demonstration Vehicle Greenhouse Gas Emissions

National Renewable Energy Laboratory 67 Innovation for Our Energy Future CDP#63: Hydrogen Fueling Station Maintenance by System

National Renewable Energy Laboratory 68 Innovation for Our Energy Future CDP#64: Fuel Cell Vehicle Maintenance by System

National Renewable Energy Laboratory 69 Innovation for Our Energy Future CDP#65: Percent Idle in Trip with Comparison to Standard Drive Cycles

National Renewable Energy Laboratory 70 Innovation for Our Energy Future CDP#66: FCV Speed with Comparison to Standard Drive Cycles

National Renewable Energy Laboratory 71 Innovation for Our Energy Future CDP#67: Fuel Cell Stack Operation Hours

National Renewable Energy Laboratory 72 Innovation for Our Energy Future CDP#68: Power Drop During Fuel Cell Stack Operation Period

National Renewable Energy Laboratory 73 Innovation for Our Energy Future CDP#69: Max Fuel Cell Power Degradation – Gen 1

National Renewable Energy Laboratory 74 Innovation for Our Energy Future CDP#70: Max Fuel Cell Power Degradation – Gen 2

National Renewable Energy Laboratory 75 Innovation for Our Energy Future CDP#71: Projected Hours to OEM Low Power Operation Limit

National Renewable Energy Laboratory 76 Innovation for Our Energy Future CDP#72: Difference Between Tank and Ambient Temperature Prior to Refueling

National Renewable Energy Laboratory 77 Innovation for Our Energy Future CDP#73: Fuel Cell Stack Projected Hours as a Function of Voltage Drop

National Renewable Energy Laboratory 78 Innovation for Our Energy Future CDP#74: Fuel Cell Transient Cycle Count per Mile and per Minute

National Renewable Energy Laboratory 79 Innovation for Our Energy Future CDP#75: Fuel Cell Transient Voltage and Time Change

National Renewable Energy Laboratory 80 Innovation for Our Energy Future CDP#76: Fuel Cell Transient Rate by Cycle Category

National Renewable Energy Laboratory 81 Innovation for Our Energy Future CDP#77: Fuel Cell Transient Voltage Changes by Cycle Category

National Renewable Energy Laboratory 82 Innovation for Our Energy Future CDP#78: Fuel Cell Transient Cycles Outside of Specified Voltage Levels

National Renewable Energy Laboratory 83 Innovation for Our Energy Future CDP#79: Percentage of Trip Time at Steady State

National Renewable Energy Laboratory 84 Innovation for Our Energy Future CDP#80: Miles Between Refuelings