Automotive Fuel Cells

Transcription

1 Automotive Fuel Cells The Road to Emission-Free Mobility Andreas Truckenbrodt AFCC Automotive Fuel Cell Cooperation Corp. Burnaby, Canada March 2011

2 Agenda Introductions Presentation Who is AFCC What is a fuel cell and what are the benefits Batteries and fuel cells Daimler s fuel cell vehicle progress What is the state of fuel cell technological progress How to achieve cost parity Hydrogen fuel and the infrastructure Global hydrogen and fuel cell vehicle programs Canadian Leadership Solutions and success factors Conclusions Tour of AFCC Test and Prototype Manufacturing Facilities

3 Who is AFCC? Daimler and Ford have been partners/shareholders of Ballard Power Systems since 1994/1997 In February 2008, all automotive assets and resources were transferred from Ballard Power Systems to a new, private company called Automotive Fuel Cell Cooperation Corporation (AFCC) We are now the fuel cell stack centre of excellence for Daimler and Ford Responsible for research, product development, and product launch of auto fuel cell stacks Located in Vancouver Canada 230 employees in 2010 (50+% growth since 2008) Joint-venture private company Daimler 50.1% Ford 30.0% Ballard 19.9% (financial investor only) Operational funding provided by Daimler and Ford Goal to make automotive fuel cells a reliable and affordable solution in the 2015 timeframe

4 What are Fuel Cells? Benefits Zero emission - end product is just water and electricity Oil independence through use of hydrogen Efficiency twice as high as internal combustion engine Comfort of pure electrical driving Driving pleasure electric motors deliver high launch torque

5 GHG Reductions Necessary gco 2 /km CAFE LDT 240 AB1493Light Duty Trucks (e.g. M-,R-,GL-Class) CAFE PC AB1493 Passenger Cars Top Runner 2010 Otto ( kg) EU proposal f. CO 2 -legislation EU target 2012: 130 g CO 2 /km 120 g (incl. ecoinnovation 130 g 10 g) Top Runner 2015 * ( kg kg) AB 1493: LDT: 26.8mpg CAFE in2020 combined: 35 mpg (LDT: ca. 33 mpg; LDV: ca. 37mpg) AB 1493: PC: 43, mpg EUin discussion: 105g CO 2 /km (95g+10 g) in Short Shortand andlong-term needs needsdrive drive commercialization in starting in in2015.

6 Well-to-Wheel Emissions Sources: Argonne National Laboratory GREET 1.8a, AEO 2009 & NHA models FCVs must be part of solution to meet GHG reduction goals.

7 Batteries AND Fuel Cells Long Distance Cross Country City Combustion Engine Hybridization Fuel Cell Electric Plug-In / Range Extender Battery Electric No silver bullet solution requires a portfolio approach.

8 Batteries AND Fuel Cells Strengths & Commonalities Battery EV Strengths Sustainable city vehicle Low operational costs Lowest emissions Best energy efficiency of all drivetrains Commonalities Zero emissions Efficient energy use Petroleum independence Dynamic electric drive Low noise Fuel Cell EV Strengths High range Drive performance Short refueling time Technology applies to passenger cars and commercial vehicles

9 Batteries AND Fuel Cells Challenges & Differences Battery EV Challenges Short range Long charging time High battery costs Battery durability High-volume charging infrastructure non-existent Fuel Cell EV Challenges High component costs Stack durability Renewable hydrogen H2 infrastructure non-existent Major benefits, but challenges remain.

10 BEV/FCV Infrastructure McKinsey Study for Europe Hydrogen Infrastructure Battery Charging Infrastructure 1,000-2,000 per vehicle 5% overall cost of FCV Initial cost 3 Billion for sufficient network coverage Average annual investment 2.5 Billion 1,500-2,500 per vehicle Average annual investment 13 Billion over next 40 years but serves ~200 million BEV/PHV vs. ~100 million FCV Cost of hydrogen infrastructure is lower than for BEV/PHV

11 Daimler Fuel Cell Development Concept cars and feasibility studies Fit for daily use / Fleet test Market launch Methanol Necar 3 Necar 5 Necar 2 Passenger cars F600 F-CELL A- Class Necar 4 A-Class F-CELL Hygenius Daimler Fuel Cell Development Advanced B-Class F-CELL Necar 1 Nebus Light+heavy-duty vehicles Fuel Cell Sprinter Fuel Cell Citaro Fuel Cell Sprinter Citaro FuelCell-Hybrid 17 Years of Fuel Cell Vehicle Development

12 Daimler EV Path smart fortwo ed Premiered in nd generation with lithium-ion battery introduced in km range A-Class E-CELL Introduced in seater 200 km range B-Class F-CELL Series production began and 200 leased to customers in km range Volume production forecasted in 2015

13 Daimler Global FCV Deployments California Fuel Cell Partnership MBUSA European Bus Project HyFLEET:CUTE MB NL Berlin National Innovation Program H2 and Fuel Cell Germany Bus Project Beijing China European Zero Regio Project Clean Energy Partnership Germany MBJ JHFC Program Japan DoE Program USA DSEA Sinergy EDB Project Singapore Fuel Cell Cars in total - 2 million kms - 58,000 hrs Citaro Buses - 36 in total - 2,100,000 kms - 137,000 hrs Bus Project STEP Perth, Australia Sprinter Vans - 3 in total - 64,000 kms - 2,400 hrs Stacks from Burnaby have powered more than 200 FC vehicles since 2004

14 Fuel Cell Improvements B-Class F-CELL (2010) compared to A-Class (2004) Longer stack lifetime Increased power (65 100kW) Higher reliability Longer range ( km) Freeze start to -25 C Li-Ion battery AFCC fuel cell stack Size - 40% Power +30% Consumption -30% Range +150% [l] [kw] [l/100km] [km]

15 Temperature/Power Achievements Max operating temp (+20 %) Freeze start Peak power (+80%) Continuous power

16 Fuel Cell Consumption / Range Fuel consumption (-30%) Zero emission energy with one fill (+260 %)

17 Platinum Content Reduction Platinum content Power density

18 Accomplishments & Progress Performance Safety Cost Durability Performance Comfort Freeze start Range Reliability Longevity Package/weight Cost FCVs FCVs must must be better better and and comparable in incost cost to advancedtoice advanced vehicles. ICE vehicles.

19 Cost Goals MIT study Extra cost ($) 10,000 8,000 6,000 4,000 2, ,000 Goal adv Diesel HEV max min gasoline Diesel HEV FCEV PHEV-30 BEV Source: Kromer/Heywood: A comparative assessment of electric propulsion systems in the 2030 US LD vehicle fleet. SAE

20 Cost Parity Achievable Cost parity, with advanced ICE, is achievable by: Volume/economies of scale (4-5x) Technology improvements (3x) Manufacturing processes Supplier development New, cooperative business models Automotive and non-automotive

21 Reducing Costs On Track Stack Architecture Stack Cost at 100,000 units/year Increase power density and reduce active area Reduce platinum by >50% Use alternative materials with no performance impact 250 Cost $/kw Catalyst $25/kW 50 0 Gen 1 Membrane Gen 2 Gen 3 Goal Stack Generation PFSA or hydrocarbon membrane Bipolar Plate Improve forming, joining, and coating for metal plates Improve conductivity, thickness, and processing time for carbon plates Adopt high volume manufacturing technologies

22 Industrialization First to Industry Stack Automotive Fuel Cell System HVBattery CHG PowerTank electronics Electric Motor Transmission AC/Cooling system HV-harness All major fuel cell components are not common to the auto industry: 1) Stack 2) Fuel Cell System 3) Hydrogen Storage 4) Power Electronics (FC specific) During ramp up, competition of suppliers has to be increased, but cooperation with suppliers may be instrumental for success An auto oriented market for fuel cell components must be created

23 Solutions Cost competitiveness (MIT study) Extra cost ($) 10,000 8,000 6,000 max 4,000 min 2, ,000 gasoline Diesel HEV FCEV PHEV-30 BEV Source: Kromer/Heywood: A comparative assessment of electric propulsion systems in the 2030 US LD vehicle fleet. SAE

24 Functional B-Class F-CELL B-Class F-CELL - Main Technical Data Power Effective power fuel cell 80 kw Effective power electric motor 100 kw Maximum torque 320 Nm Capacity accumulator Hydrogen pressure Range & Consumption Range 6.5 Ah 700 bar Consumption adjusted Approx. 2.9 l diesel equivalent/ 100 km CO2-emissions 0g/100 km Approx. 400 km Driving Performance Acceleration km/h 11.4 s Top Speed 150 km/h

25 Next Generation FC Buses Mercedes-Benz Citaro FuelCELL Hybrid Bus AFCC automotive stacks will power new Mercedes Citaro fuel cell bus

26 All Vehicle Applications Passenger cars will drive volume in all FC applications x 202x Gen1 Gen2 Gen3 Gen4 Gen5 Technology Demonstration Customer Acceptance Cost Reduction Market Intro Cost Reduction II High-Volume Series Production A-Class F-Cell B-Class F-Cell Future Generations Buses Future Generations Sprinter Vans

27 H2 The Ultimate Fuel Made from a variety of feedstocks: Water Biomass Coal Natural gas Renewables Transported via pipeline or shipped in containers Natural Gas Hydro-electricity Biogas Hydrogen Renewables By-product Safely produced, stored, transported, used by industry for 50+ yrs The US produces 11 million tonnes / Canada 3 million tonnes of H2 per year mostly to upgrade petroleum for gasoline Affordable - $10/kg, 1 kg/100km, $40 for 400 km range When H2 is used in a fuel cell, there are ZERO emissions!

28 Infrastructure - Germany Germany leads H2 Mobility in Europe H2 infrastructure public/private partnership Will support the commercialization of FCVs from 2015 Strongly anticipate from 2015 onwards hundreds of thousands of fuel cell vehicles could be commercialized.

29 Japan s FCV & H2 Launch Initiative to introduce mass-produced FCVs in 2015; announced in Jan 2011 Led by 3 automakers / 10 energy companies including Toyota, Nissan, Honda, JX Nippon Oil & Energy, Idemitsu Kosan Iwatani, Osaka Gas, Cosmo Oil, Saibu Gas, Showa Shell Sekiyu, Taiyo Nippon Sanso, Tokyo Gas, Toho Gas Hydrogen infrastructure is key: 100 H2 stations will support initial FCVs in Tokyo, Nagoya, Osaka and Fukuoka Local governments will help strategize: initial consumer demand optimal station placement

30 US Eyes Commercial Market California Fuel Cell Partnership, formed in 1999, implementing Commercial Action Plan 300+ FCVs on California roads today 22 active hydrogen stations includes one retail Station rollout will begin in metropolitan areas, then link corridors before nationwide network California retail H2 station clusters in Santa Monica, Irvine, Torrance and Newport Beach By 2017, automakers expect tens of thousands of FCVs in the hands of California consumers 30

31 Canadian Leadership Canada pioneered auto fuel cells in 1980 s We have trained talent and strong academic/research capabilities Demonstration programs - including the Hydrogen Highway - enabled invaluable testing of technology in real-life situations AFCC s strategic partnership with Daimler/Ford has resulted in new JV, jobs and investments Government support will ensure Canada reaps economic and environmental benefits from FCV market adoption Keep momentum building!

32 The Next Auto Revolution Auto industry in a period of unprecedented change Must invent a cleaner, more efficient automobile Cornerstone technology collaboration required: Proprietary solutions not needed for every challenge OEMs can t afford to develop solutions for all challenges Customers won t pay for a custom solution to a generic problem We must solve joint problems jointly

33 Keys to Success Automotive Industry Clean and efficient Reliable Affordable Fuels/Energy Industry Improve fuel conversion Alternative fuels Infrastructure Automakers Can t Do It Alone Customer Define driving behaviour Make vehicle choice Comfort with technology Public Institutions Relevant framework Incentives Research

34 Conclusions FCVs are a no-compromise vehicle - same utility as an ICE Fuel cells have matured to customer readiness commercialization will begin in 2015 H2 and FCV volumes required to meet climate change goals Commitment by OEMs must be joined by other stakeholders

35 The Future is in Our Hands F800 Fuel Cell Research Vehicle

36 Thank you for coming!