Fuel Cell Market Transformation

Transcription

1 DOE Recovery Act Projects to Enable Fuel Cell Market Transformation Sara Dillich DOE Energy Efficiency & Renewable Energy Fuel Cell Technologies Program Washington, DC Reginald Tyler DOE Golden Field Office Fuel Cell Technologies Program Golden, CO Matthew Simon Energetics Incorporated Science & Technology Division Washington, DC 2010 Fuel Cell Seminar and Exposition (October 20, 2010)

2 Outline Goals and Objectives ARRA Projects Lessons Learned Supporting Activities Projects Status and Challenges Going Forward 2

3 Goals & Objectives ARRA: American Recovery & Reinvestment Act DOE Fuel Cell Technologies Project Goals Accelerate the commercialization and deployment of fuel cells and fuel cell manufacturing, installation, maintenance, and support services Create new jobs as well as save existing ones Spur economic activity Invest in long-term economic growth 3

4 Recovery Act Funding for Fuel Cells More than $40 million from the 2009 American Recovery and Reinvestment Act to fund 12 projects to deploy up to 1,000 fuel cells FROM the LABORATORY to DEPLOYMENT: DOE funding has supported R&D by all of the fuel cell suppliers involved in these projects. Residential and Small Commercial CHP Auxiliary Power COMPANY AWARD APPLICATION Delphi Automotive $2.4 M Auxiliary Power FedEx Freight East $1.3 M Lift Truck GENCO $6.1 M Lift Truck Jadoo Power $2.2 M Portable MTI MicroFuel Cells $3.0 M Portable Approximately $54 million in cost-share funding from industry participants for a total of about $96 million. Nuvera Fuel Cells $1.1 M Lift Truck Plug Power, Inc. (1) $3.4 M CHP Plug Power, Inc. (2) $2.7 M Back-up Power Univ. of N. Florida $2.5 M Portable ReliOn, Inc. $8.5 M Back-up Power Sprint Nextel $7.3 M Back-up Power Sysco of Houston $1.2 M Lift Truck 4

5 ARRA Deployment Status Fuel Cell Deployment Numbers as of October, 2010 Application Number of Operational Fuel Cells Projected Additional Fuel Cell Deployments (FY11 & FY12) APU - 1 CHP - 6 Back-up Power 24 Up to 500 Lift Truck 206* Up to 500 Portable Power - 3** TOTAL 230 Up to 1000** * An additional 70 fuel cell lift trucks have been delivered, but not yet deployed, for a total of 300 delivered. ** Number does not include the 75 portable fuel cells MTI MicroFuel Cells will be sending to field testers. 5

6 ARRA Progress & Accomplishments Fuel Cell Powered Lift Trucks Deployed First All 12 project grants in place 276 fuel cell lift trucks delivered; 206 deployed Siting and permitting activities are in process More than 20 fuel cell backup stations operational 36 jobs created or retained Over 51% of funds have been spent Hydrogen Safety Panel is reviewing project Safety Plans and scheduling site visits * All bullet points are as of October,

7 Lessons Learned for Market Transformation Siting and Permitting Tackle NEPA requirements first Facilitate national guidelines Codes and Standards Identify and address safety concerns that may impact commercial acceptance of fuel cell systems Provide technical basis for codes and standards Unanticipated Events (e.g. project terminations) Have back-up strategies in place 7

8 Deployment Map for ARRA Fuel Cell Units 21 states will have fuel cell units funded under the Recovery Act 10 states already have fuel cells in operation States with ARRA fuel cells currently in operation Future ARRA fuel cell deployment states 8

9 ARRA Hydrogen Fuel Cell Data NREL Data Collection Fuel Cell & Infrastructure Data sent to NREL s Hydrogen Secure Data Center Data includes operation, maintenance, safety, and hydrogen production See talk by Jen Kurtz (NREL) in the Track 4 Near Term Fuel Cell Markets III session on Wednesday, October 20 th at 5:30 pm National Renewable Energy Laboratory: 9

10 NREL Data Analysis Fuel Cell Deployments ARRA Projects DOE/DoD Projects DATA DATA performance, durability, run time, fuel use, etc. Individual ARRA or DOE/DoD project partner who supplied data Public CDPs are shared with project partners who supplied data to review and ensure proprietary data is not shared Composite Data Products Aggregated data across multiple systems, sites, and teams Publish analysis results without revealing proprietary data Composite Data Products (CDPs) Detailed Data Products (DDPs) Detailed Data Product Individual data analyses for each FC system and site Identify individual contribution to CDPs Only shared with partner who supplied data NREL Early Fuel Cell Market Transformation analysis results: 10

11 Hydrogen Safety Lifecycle Analysis of Tanks at Sandia National Laboratory Addressing cyclic fatigue of steel tanks to provide technical basis for code language for H 2 powered industrial trucks (CSA HPIT1) Quantifiable data being collected for crack initiation, crack growth, leak before-burst, etc. Developing unified design methodologies for high cycle-life tanks Next Steps: Risk analysis of indoor refueling and operation in support of NFPA-2 requirements development (a) (b) (c) 11

12 Hydrogen Safety Activities include: Hydrogen Safety Panel * Review of all project safety plans Provide feedback to project teams on safety plans Visit select ARRA sites Comprehensive Safety Evaluation Report: sitespecific safety issues, recommendations, lessons learned, etc. Comprehensive Final Summary Report * Provides expertise and guidance to DOE to assist with identifying safety-related technical data gaps, best practices and lessons learned 12

13 Auxiliary Power Unit (APU) Status & Challenges Delphi Automotive Systems Objective: Develop a 3- to 5-kW solid oxide fuel cell (SOFC) APU for heavy-duty commercial Class 8 trucks Partners: Electricore, Inc., PACCAR, Inc., TDA Research, Inc. Status Completed initial system and subsystem vibration testing and analysis Starting in 2011 the unit will begin the one year onvehicle demonstration Challenges Robustness: Must be durable enough to withstand road vibrations while attached to truck frame Fuel Quality: SOFC stack must be compatible with diesel fuel Design Requirements: Restrictions on size, weight and location of unit if attached to a Class 8 truck 13

14 Combined Heat and Power (CHP) Status & Challenges Plug Power Objectives Evaluate the performance of 12 high temperature, natural gas fueled, 5-kW PEM, micro-chp fuel cell units Test 6 units in laboratory setting Install and test 6 units at residential and light commercial end user locations Partners: Sempra Energy, National Fuel Cell Research Center (NFCRC) at University of California Irvine Status Units undergoing durability testing Manufacturability improvements have reduced build time by more than 55% Site selection has been initiated for customer testing in CA Challenges Fuel Quality: Fuel cell must be compatible with using natural gas as a fuel Safety & Market: Fuel cell use in residential and light business sectors not yet established in the U.S. 14

15 Back-up Power (Telecommunications) Status ReliOn Objective Deploy PEM hydrogen fuel cell (HFC) systems into the telecommunications and utility networks for backup power Partners: Air Products & Chemicals, Inc., AT&T, PG&E Status Surveys completed for 441 potential sites Permitting completed on 45 sites Constructed and commissioned 24 AT&T sites Selected and approved 9 PG&E sites Continuing permitting process for remaining (up to 150) sites 15

16 Back-up Power (Telecommunications) Status Sprint Nextel Objectives Deploy 5 kw PEM HFCs to demonstrate their technical and economic viability Provide 72 hours of on-site fuel storage to provide backup power for critical cell tower sites Partners: Air Products & Chemicals, Inc., Altergy Systems, Black & Veatch Corporation, Burns & McDonnell Engineering Co., Ericsson Services, Inc., ReliOn, Inc. Status Site selection process underway At least 210 site surveys have been completed to date Up to 260 new sites and 70 retrofit sites planned Design of hydrogen fuel storage is underway 16

17 Back-up Power (Telecommunications) Challenges Permitting & Siting Lack of national consensus on requirements for the application. Each AHJ has different requirements and priorities Hydrogen Delivery Deployment sites are often remote and difficult to access Coordinating delivery schedule of hydrogen to sites across a wide range of locations is difficult 17

18 Back-up / Prime Power DoD Status & Challenges Plug Power Objectives Demonstrate the market viability of low temperature, 6-kW PEM FC powered by liquid petroleum gas (LPG) Provide clean and reliable primary and emergency backup power (72 hours or more) Partners: Army Corps of Engineers Construction Engineering Research Laboratory (CERL), Warner Robins AFB, Fort Irwin Status All 20 sites have been selected (10 sites at Warner Robins AFB, and 10 sites at Fort Irwin) An economically viable fuel cell start up has been determined (hydrogen start up with LPG for extended run time) In process of completing NEPA requirements for selected sites Challenges Cost & System Reliability: Units must compete with incumbent back-up technologies U.S. Market: There is a lack of market penetration and familiarity with using fuel cells for back-up 18

19 Fuel Cell Powered Lift Trucks Status FedEx Freight East, GENCO, Nuvera Fuel Cells, Sysco of Houston Objective Deploy PEM HFC systems as battery replacements in electric lift trucks (Class 1 3) Partners: Air Products & Chemicals, Inc., H.E.B. Grocery Co., Linde North America, Plug Power, Inc., Coca Cola Co., Kimberly Clark, Sysco, Wegmans, Whole Foods Market Status FedEx Freight East has deployed 35 FC powered lift trucks at their distribution facility in Springfield, MO GENCO has deployed 59 FC powered lift trucks at Wegmans (additional 70 delivered to Kimberly Clark and Whole Foods) Nuvera Fuel Cells has deployed 14 FC powered lift trucks at H.E.B. Grocery Co. in San Antonio, TX Sysco of Houston has deployed 98 FC powered lift trucks at their distribution facility in Houston, TX GENCO will be deploying additional (up to 228) FC powered lift trucks at Coca Cola, Kimberly Clark, Sysco, Wegmans and Whole Foods Performance data is already being collected from the lift trucks 19

20 Fuel Cell Powered Lift Trucks Nuvera Fuel Cells Hydrogen Pathways NG Steam Reformer FedEx Freight East, GENCO*, and Sysco of Houston Liquid H 2 Storage * GENCO Deployment Sites City, State Planned Number of Fuel Cell Lift Trucks Coca Cola Charlotte, NC 40 Kimberly Clark Graniteville, SC 25 Sysco Philadelphia, PA 95 Wegmans Pottsville, PA 136 Whole Foods Landover, MD 61 20

21 Fuel Cell Powered Lift Trucks Challenges Safety Codes and standards development for hydrogen storage and dispensing operations lag deployments Misconceptions regarding the risks associated with using hydrogen as a fuel 21

22 Portable Power Status Jadoo Power, MTI MicroFuel Cells, University of North Florida Jadoo Power Objective: Develop a 1 kw, propane fueled, SOFC generator for first responders and major racecar events Partners: Delphi Automotive, Inc., NASCAR Media Group, City of Folsom, CA Status: Completed preliminary analyses on desulfurizer, propane interface and power needs MTI MicroFuel Cells Objective: Demonstrate a 1 W, direct methanol fuel cell (DMFC) consumer electronics power pack Status: Beginning the field testing phase of the portable fuel cell generators (75 units will be sent out for early market testing) University of North Florida Objective: Integrate and miniaturize the components of a 20 W, DMFC portable power system for mobile computing Partners: University of Florida Gainesville, FL Status: Had a successful proof-of-concept design, and has begun further testing 22

23 Portable Power Challenges U.S. Market: Not yet established for portable power; significant competition from overseas industries Fuel Quality: Propane and methanol must be compatible with the fuel cell Portability: FAA regulations need to be modified to allow methanol fuel cartridges to be carried on commercial airlines 23

24 Going Forward By 2013 Up to 1,000 fuel cells will be deployed in commercial scale applications due to ARRA funds trumping DOE funded deployments at scale in the last 10 years! 21 states will have operational fuel cells funded through the Recovery Act NREL data collection and analysis will provide basis for business case for early market fuel cells Effects of ARRA funding on fuel cell market transformation will be assessed 24

25 For More Information ARRA Recovery Project Websites U.S. Recovery Act website: DOE EERE: ARRA Recovery Project Contacts Sara Dillich Reginald Tyler Matthew Simon 25

26 New Hires Planned DOE Fuel Cell Team Member job to be posted soon Check and s/index.html for more information Additional capabilities (potential new hires) solicited: Financial/market/policy & analysis expertise Safety, codes and standards support Hydrogen fuel R&D Chief Engineer 26

27 Other ARRA Related Presentations Scott Kliever, Sysco Food Services of Houston, Inc. Early Market Success Stories Roundtable Wednesday, October 20 th at 8:00 am Steven Shaffer, Delphi Corporation Solid Oxide Fuel Cell Development at Delphi Track 1 SOFC Stack Development Wednesday, October 20 th at 2:30 pm Jennifer Kurtz, National Renewable Energy Laboratory ARRA Fuel Cell Deployment and Operation Data Track 4 Near Term Fuel Cell Markets III Wednesday, October 20 th at 5:30 pm 27