The Development of Fuel Cell Vehicles in China

The Development of Fuel Cell Vehicles in China Professor Dr.-Ing. Tong Zhang Vice-Director of Clean Energy Automotive Engineering Center of Tongji University General Manager of Shanghai FCV Powertrain Co, Ltd. September 21 st, 2010 1

Self-Introduction Research Multidisciplinary/ Multi Research Direction School of Automotive Studies Tongji University Clean Energy Automotive Engineering Center of Tongji University Shanghai FCV Powertrain Co, Ltd. Pre-development /Testing /Experiment Joint Laboratory Development Automobile Industry 2

Contents The development of FCV technique in China FCV demonstration programs in China Challenge in the industrialization of FCV in China 3

EV R&D in China 2001-2005 FCV HEV BEV A Study on Policy, Regulations, Standards and Infrastructure Whole Vehicle Technique of FCEV Calibration and Matching of Whole Vehicle FC Engine Whole Vehicle Technique of HEV Calibration and Matching of Whole Vehicle Motor and Transmission Hybrid Technique Whole Vehicle Technique of BEV Calibration and Matching of Whole Vehicle EV Key Components Industry Multi-Energy Drivetrain Control System 电机驱动系统 E-Motor System 电机驱动系统 and Control 电机驱动系统 Unit DC/DC Converter ISA/ISG Technique Power Battery and Battery Pack Management System 4

EV R&D in China 2006-2010 Total Vehicle Vehicle Products (FCV,HEV,BEV,...) Powertrain platform FCV Powertrain Platform HEV Powertrain Platform BEV Powertrain Platform Key Parts Common Tech. Public Platform FC Engine, Power Battery, Super capacitor,... ICE, E-Motor System and Control Unit,... New Materials, New&Common Tech. Infrastructure,... Policy, Regulations, Standards and Demonstration,... 5

Layout of R&D and Industrialization of FCV in China Sunrise Power Tsinghua University Fuel Cell Driving Motor Time Group Suzhou PHYLION Shen-Li High Tech Tongji University Ananda Kinway Technologies Power Battery Power Electronics 6

FCV Powertrain System FCV Powertrain System ~ = DC/AC Driving Motor ~ = = = DC/AC Motor Controller DC/DC Converter Fuel Cell Engine High Pressure Hydrogen Storage Tank Lithium-ion Power Battery Pack 7

FCEV Powertrain System Fuel Cell System (Fuel Cell Engine) Fuel Cell Unit Fuel Cell Stack Fuel Cell System R&D of fuel cell key components R&D of fuel cell engines for vehicles Whole Vehicle Development of FCV On-board Hydrogen Supply System 8

R&D of Fuel Cell Golden Energy Fuel Cell Co., Ltd. Wuhan Uni. Dongyue Group Dalian Jiaotong University PEM Carbon CCM Paper Research on key components of fuel cell Sunrise Power Co,. Ltd Shanghai LingQiao E.P.E.W. Co., Ltd. The Institute of Coal Chemistry (ICC), Chinese Academy of Sciences (CAS). Shanghai Jiao Tong University (Stamped Metal Bipolar Plate) 811 Institute Bipolar Plate Catalyst Central South University Dalian Institute of Chemical Physics (DICP), Chinese Academy of Sciences (CAS) 9

R&D of Fuel Cell Stack Jiangsu Kunshan FuelCell Co. 0~10kW Fuel Cell Stack Shanghai Shen-Li High Tech Co., Ltd.: 0~55kW Dalian Sunrise Power Co,. Ltd.: 0~ 55kW 811 Institute: 0~50kW Based on metal bipolar plate, with high power density 10

R&D of fuel cell engine for vehicles Shanghai Shen-Li High Tech Co., Ltd.: 0~55kW Fuel Cell Engine for Vehicle Dalian Sunrise Power Co,. Ltd.: 0~55kW Shanghai FCV Powertrain Co., Ltd.: 0~90 kw Wuhan University of Technology: 0~50kW 11

R&D on On-board Hydrogen Supply System Hydrogen tank: Aluminium internal bladder, winded with carbon fiber. Schematic Diagram of the Hydrogen supply System Working pressure: 350 bar Filling receptacle One-way Valve Vent Electromagnetic Valve Pressure Reducing Needle Valve Valve Fuel Cell Stack Gas Tank Safety Valve Temperature Sensor Gas Tank Manual Globe Valve (keep open) Pressure Sensor Gas Tank Electromagnetic Valve Compressed Hydrogen Gas Tank Accessory Shenyang Gas Cylinder Safety Technology Co.,Ltd. Storage Tank 12

Power Platform Whole Vehicle Integration FCV Powertrain Platform Technique 2001-2005 Integrating Industry, study, and research. Applying to various vehicle types Key technique of the powertrain system is transferring to OEM s. Technical Platform for Fuel Cell Bus Powertrain System Tsinghua University/ Beijing Sinohytec Co., Ltd. BF6120FCHEV BK6110FCHEV Technical Platform for Fuel Cell Passenger Car powertrain System Tongji University/Shanghai FCV Powertrain Co., Ltd. 13

FCV Powertrain Platform Technique 2001-2005 Reliability test and endurance test on FCV Serie of Start 10 FCEVs Start 3 (S2000) Accumulative total: 102,000 KM, Max. continuous driving range of single vehicle: 29,000 KM Road simulation test equal to 100,000 KM and intensified Chassis Dyno test Intensified road test in VPG equal to 50,000 KM 14

R&D of Fuel Cell Passenger Car 2006-2010 Matching to Roewe platform Roewe of SAIC Powertrain System Technology Platform Matching to VW platform Passat Lingyu of VW Matching to Chery platform Eastar of Chery 15

Fuel Cell Passenger Car Demonstration Operation in Beijing 2008 Olympic Games 20 Passat Lingyu FCVs 68 days of demonstration operation (from July 14th, 2008 to September 19th, 2008) Over 970 driving services Over76,000 KM driving range Over 2,100 person-time, including Olympics traffic control staff, leaders of ministries and commissions, officers and referees of the Olympic Games and global mediapersonnel. 16

Fuel Cell Passenger Car Demonstration Operation in California, USA. 16 Passat Lingyu FCVs 6 months of demonstration operation (from January 1st, 2009 to June 30th, 2009) Assesed uder different working conditions including urban roads, countryroads, highways and comprehensive road conditions Over 37,000 KM driving range, 4,111 KM for single vehicle Monthly public days, test ride and test drive for mediapersonnel 17

FCEV Demonstration Operation on small scale FCEV Demonstration Operation during Expo 2010 Shanghai China 100 fuel cell sightseeing cars (for skywalk in Expo site) 70 fuel cell passenger cars of 5 brands (for Expo Reception Center and Shanghai Municipal Government Reception Office) 6 fuel cell buses (demonstration operation on Expo Avenue in Expo site) 6 months of demonstration operation (from May 1st 2010 to October 31st 2010) 18

FCEV Demonstration Operation during Expo 2010 Shanghai China Fuel Cell Passenger Car Single motor, front wheel drive, fuel cell engine under atmospheric pressure Motor: 42/88 kw, torque 210 Nm Battery: 375v, 7.5Ah, Lithium (manganese) Fuel cell engine: 55 kw (Shen-li, SunrisePower) Parameter Dimensions (mm) Unladen Mass (kg) Wheel base (mm) Seating Capacity (person) Max. Speed (km/h) 0-100km/h Acceleration Time (s) Max. Gradeability (%) Distance per Charge (Km) Value 4,865 1,765 1,422 1,975 2,849 5 150 15 >20 >300 19

FCEV Demonstration Operation during Expo 2010 Shanghai China Fuel Cell Passenger Car Schematic diagram of the powertrain system Shanghai Fuel Cell Vehicle Powertrain Co., Ltd. 20

FCEV Demonstration Operation during Expo 2010 Shanghai China Schematic diagram of the fuel cell engine system Characteristics of Shen-Li fuel cell System: air and hydrogen coming into the fuel cell stack is humidified with water-togas membrane humidifier, using cooling circulating water as humidifier s water resource. Regular replenishment of cooling circulating water is necessary. Shanghai Shen-Li High Tech Co., Ltd. 21

FCEV Demonstration Operation during Expo 2010 Shanghai China Schematic diagram of the fuel cell engine system Characteristics of Sunrise Power fuel cell system: Air is humidified with enthalpy wheel humidifier, using high temperature and humidity tail gas from the cell stack outlet to humidify the air coming through the cell stack inlet. Hydrogen is not humidified. Dalian Sunrise Power Co., Ltd. 22

FCEV Demonstration Operation during Expo 2010 Shanghai China Fuel Cell Bus Double motor coupling, Double high pressure fuel cell engine Motor: 2 x 42/88 kw Battery: 384v, 2 x 40 Ah Battery of Lithium Iron Phosphate Fuel Cell Engine: 2 x 65 kw Parameter Dimensions (mm) Unladen Mass (kg) Wheel Base (mm) Seating Capacity (Person) Max. Speed (km/h) 0-100km/h acceleration time (s) Max. Gradeability (%) Distance per Charge (Km) Value 11,990 2,535 3,450 14,500 5,940 53 > 70 15 >18 >220 23

FCEV Demonstration Operation during Expo 2010 Shanghai China Fuel Cell Bus Schematic diagram of the powertrain system Fuel Cell Auxiliary System 1 330 420v Fuel Cell Stack 1 280 420v DC-DC Converter 1 Accumulator Cell Motor Controller 1 Whole Vehicle Controller Fuel Cell Stack 2 Fuel Cell Auxiliary System 2 280 420v DC-DC Converter 2 330 420v 375-12V DC-DC Converter Motor Controller 2 375-12V DC DC Converter 12V Accumulator Cell 24V Accumulator Cell Shanghai Fuel Cell Vehicle Powertrain Co., Ltd. 24

FCEV Demonstration Operation during Expo 2010 Shanghai China Schematic diagram of the fuel cell engine system Characteristics of Expo Bus Fuel Cell Stack System (Ballard high pressure fuel cell stack): High pressure system with working pressure between 1.76 and 3.2 bar; Air into the cell stack inlet is humidified with spray type humidifier; Hydrogen into the cell stack inlet is humidified with H2 circulation pump; Water content in the tail gas from the cell stack outlet is condense recovered to ensure the balance of humidifier water system. Shanghai Fuel Cell Vehicle Powertrain Co., Ltd. 25

FCEV Demonstration Operation during Expo 2010 Shanghai China Fuel Cell Sightseeing Car Single motor, front wheel drive / Hub motor, four-wheel drive, Electric-electric hybrid / Plug-in Electric-electric hybrid, fuel cell engine under atmospheric pressure Motor: 5/9 kw; 0.8 / 2.2 kw; Battery:128v 7.5Ah; 40 Ah Fuel Cell Engine:7kw Parameter Dimensions (mm) Unladen Mass (kg) Wheel Base (mm) Seating Capacity (Person) Max. Speed (km/h) Max. Gradeability (%) Distance per Charge (Km) Value 4,480 1,650 2,045 1,070/1,160/1,110 3,295 11 40 (20 in Expo site) >10 50/75/100 26

FCEV Demonstration Operation during Expo 2010 Shanghai China Schematic diagram of the powertrain system Shanghai Fuel Cell Vehicle Powertrain Co., Ltd. 27

FCEV Demonstration Operation during Expo 2010 Shanghai China Schematic diagram of the fuel cell engine system characteristics of sightseeing car s fuel cell system (7kw): Air is humidified with gasto-gas membrane humidifier, using high temperature and humidity tail gas from the cell stack outlet to humidify the air coming through the cell stack inlet. Hydrogen is not humidified. Shanghai Fuel Cell Vehicle Powertrain Co., Ltd. 28

Challenge in the industrialization of FCV in China Power Density:250W/kg (Traditional internal combustion engine: 1kW/kg ) Performance of fuel cell engine is still to be improved Life Span: 2000h (Targeted value for commercial application: 5000h ) Low Temp. Starting: -10 (Traditional internal combustion engine: -40 ) Reliability of the System Building of Infrastructure How to supply sufficient hydrogen filling stations and maintenance stations under large-scaled commercial application condition 29

Challenge in the industrialization of FCV in China Domestic application of fuel cell key material (e.g. PEM, catalyst) is currently not mature Industrialization of key components of fuel cell engine Industrialization of key components for related auxiliary system is underdeveloped. Domestic technology of some key components is not mature, e.g. air compressor for fuel cell. Operational parameters of some key components don t match fuel stacks, e.g. flow rate and pressure of humidifier pump doesn t match the fuel cell stacks, lack of back pressure regulating valve with suitable caliber. Relatively high costs of consumable parts, e.g. too expensive chemical filter which need to be replaced regularly (currently ca. 5,000RMB/set) Industrialization of EV key components Supplier chain for EV key components is not established, nor is the technique mature, e.g. electric air-conditioner, electric pump, electric vacuum pump, DCDC, DCL 30

Challenge in the industrialization of FCV in China Cost analysis of basic prototype based on powertrain platform Power Battery Pack 4% DC/DC 3% Motor & Driving System 6% Retarder 5% Other components of the powertrain system 10% Fuel Cell Engine 72% Main reason of the high costs is price of Pt in the catalyst. The Pt-content has currently a downtrend. Great overall costs of fuel cell engine Fuel Cell Stack Cost Proportion Trend of Pt-content Bipolar plate has high processing costs. New technology (e.g. metal stamping, molding) could reduce its costs substantially. 31

The prospect of vehicle powertrain system technique Driving system electrification and hydrogen is development direction of future vehicles. 32

100 % 80 % Industrialization Process of EV Market Forecast Traditional ICEV Advanced IC & Hybrid Vehicle 60 % 40 % Pure Electric & Plug-in Hybrid Vehicle 20 % FCEV 2005 2010 2015 2020 2025 2030 2035 2040 2045 Energy resource diversification, power system electrification and clean emission will boost the development of alternative energy vehicles! 33

Thank you! 34