pl003_satyapal_joint_plenary_2011_o

Hydrogen & Fuel Cells Program Overview Dr. Sunita Satyapal Program Manager 2011 Annual Merit Review and Peer Evaluation Meeting May 9, 2011 Enable widespread commercialization of hydrogen and fuel cell technologies: • Early markets such as stationary power, lift trucks, and portable power • Mid-term markets such as residential CHP systems, auxiliary power units, fleets and buses • Long-term markets including mainstream transportation applications/light duty vehicles Updated Program Plan May 2011 Hydrogen and Fuel Cells Key Goals 2 from renewables or low carbon resources Fuel Cell Market Overview 0 25 50 75 100 2008 2009 2010 USA Japan South Korea Germany Other (M W ) Megawatts Shipped, Key Countries: 2008-2010 North American Shipments by Application Fuel cell market continues to grow • ~36% increase in global MWs shipped • ~50% increase in US MWs shipped • Published several reports • The Business Case for Fuel Cells • State of the States: Fuel Cells in America • 2010 Fuel Cell Market Report http://www.fuelcells.org/BusinessCaseforFuelCells.pdf http://www.fuelcells.org/StateoftheStates.pdf 3FuelCells2000, Pike Research, Fuel Cell Today, ANL Hydrogen & Fuel Cells - Budgets EERE Funding ($ in thousands) Key Activity FY 2010 FY 2012 Request Fuel Cell Systems R&D 75,609 45,450 Hydrogen Fuel R&D 45,750 35,000 Technology Validation 13,005 8,000 Market Transformation 15,005 0 Safety, Codes & Standards 8.653 7,000 Education 2,000 0 Systems Analysis 5,408 3,000 Manufacturing R&D 4,867 2,000 Total $170,297 $100,450 1 Fuel Cell Systems R &D includes Fuel Cell Stack Component R&D, Transportation Systems R&D, Distributed Energy Systems R&D, and Fuel Processor R&D; Hydrogen Fuel R&D includes Hydrogen Production & Delivery and Hydrogen Storage R&D; No Market Transformation in FY 2012; FY 2009 Recovery Act funding of $42M not shown in Table. FY 12 Includes SBIR/STTR funds. $ i n th ou sa nd s EERE Funding for Hydrogen & Fuel Cells 4 Additional $42 M under Recovery Act ~$38 M/year for Basic Energy Sciences 5 Key Challenges The Program has been addressing the key challenges facing the widespread commercialization of fuel cells. Te ch no lo gy B ar ri er s* E co no m ic & In st it ut io na l B ar ri er s Fuel Cell Cost & Durability Targets*: Stationary Systems: $750 per kW, 40,000-hr durability Vehicles: $30 per kW, 5,000-hr durability Safety, Codes & Standards Development Domestic Manufacturing & Supplier Base Public Awareness & Acceptance Hydrogen Supply & Delivery Infrastructure Hydrogen Cost Target: $2 – 4 /gge, (dispensed and untaxed) Technology Validation: Technologies must be demonstrated under real-world conditions. Assisting the growth of early markets will help to overcome many barriers, including achieving significant cost reductions through economies of scale. Market Transformation Hydrogen Storage Capacity Target: > 300-mile range for vehicles—without compromising interior space or performance Balance of Plant ($/kW, includes assembly & testing) Stack ($/kW) Current status: $51/kW vs target of $30/kW Initial Estimate Target $30/kW $51/kW $61/kW$73/kW $94/kW $108/kW Reduced the projected high-volume cost of fuel cells to $51/kW (2010)* • More than 30% reduction since 2008 • More than 80% reduction since 2002 *Based on projection to high-volume manufacturing (500,000 units/year). **Panel found $60 – $80/kW to be a “valid estimate” for 2008 http://hydrogendoedev.nrel.gov/peer_reviews.html Progress – Fuel Cell R&D 2010 2007 6http://www.hydrogen.energy.gov/pdfs/10004_fuel_cell_cost.pdf Demonstrated advanced gas diffusion layer manufacturing processes that have reduced cost by >50% and increased manufacturing capacity by 4X since 2008 (Ballard) Progress – Fuel Cell R&D Progress continues in low and zero Pt catalysts Application Average Automotive 4,046 Backup Power 3,281 Material Handling 13,168 Stationary 16,545 Tracking durability data from multiple companies (NREL) • Demonstrated >10,000 hours for SOFCs (Acumentrics) • Achieved 10,000 simulated start/stop cycles with new catalyst, greatly exceeding target (3M) Durability – Lab Data (Hours) 7 G. Wu, K. L. More, C. M. Johnston, P. Zelenay, Science, 332, 443-7 (2011) • Developed and demonstrated non PGM catalysts (polyaniline/ cyanamide-based catalysts) • Demonstrated more than 6X the performance of Pt using nanosegregated binary and ternary Pt alloy catalysts Tracking durability for diverse applications. Maximum projected durability exceeds some DOE targets. LANL, ORNL, ANL, BNL NREL R. Adzic honored as Brookhaven Natl Lab Inventor of the Year for his work on fuel cell catalysis! High volume projected costs for hydrogen production technologies continue to decrease. Low volume/early market costs are still high. Hydrogen cost range reassessed – includes gasoline cost volatility and range of vehicle assumptions. Progress – Hydrogen Production & Delivery Notes: Data points are being updated to the 2009 AEO reference case. The 2010 Technology Validation results show a cost range of $8- $10/gge for a 1,500 kg/day distributed natural gas and $10- $13/gge for a 1,500 kg/day distributed electrolysis hydrogen station. Projected High-Volume Cost of Hydrogen (Dispensed)—Status ($ /g al lo n ga so lin e eq ui va le nt [g ge ], un ta xe d) H2 threshold cost being updated from $2-$3/gge 8 Hydrogen Delivery: Projected an additional 33% improvement in tube trailer capacity in the last year due to optimized carbon composites vessel design (Lincoln Composites) Demonstrated continued progress in hydrogen cost reduction 9 $/gge H2 Delivered Progress – Hydrogen Production • Increased hydrogen yield by 65% • Reduced production cost to an estimated $4.65/gge delivered Autothermal Reforming of Pyrolysis Oil Photoelectrochemical Conversion (PEC): • Demonstrated potential to exceed 10% solar- to-hydrogen efficiency target >16% observed at lab scale (NREL) Reduced electrolyzer cost by 80% since 2001 • 15% cost reduction in just the last year • Projected high volume capital cost of $350/kW (vs. 2012 target $400/kW) (Proton, Giner) Progress - Hydrogen Storage Tanks can achieve 430 mile range. Focus is on materials R&D but meeting all weight, volume, performance and cost requirements is still challenging. Developed > 420 new materials with potential to store hydrogen at low to moderate pressures Projected Capacities for Complete 5.6-kg H2 Storage Systems 0 2 4 6 8 10 12 14 16 -200 -100 0 100 200 300 400 Temperature for observed H2 release (ºC) O b se rv ed H 2 C ap ac it y, w ei g h t % AB/IL (20% bminCl) LiMgN LiBH4/CA Ca(BH4)2 Mg(BH4)2 LiNH2/MgH2 MgH2 NaAlH4 Li3AlH6/LiNH2 solid AB (NH3BH3) 1,6 naphthyridine AB ionic liq. IRMOF-177 PANI PCN-12 metal hydrides sorbents chemical hydrides carbide-derived C M-B-N-H PANI H2 sorption temperature (ºC) 0-100-200 Mg(BH4)2(NH3)2 Mg(BH4)(AlH4) Mg(BH4)2(NH3)2 Li3AlH6/Mg(NH2)2 Material capacity must exceed system targets DOE system targets LiBH4/MgH2 MOF-74 C aerogel B/C Open symbols denote new mat'ls for FY2009 NaMn(BH4)4 2015 Ultimate AlB4H11 Ca(BH4)2/2LiBH4 Mg-Li-B-N-H Na2Zr(BH4)6 LiMn(BH4)3 Mg(BH4)2(NH3)2 CsC24 CsC24 BC8 AC (AX-21) MPK/PI-6 PCN-6 MD C-foam LiBH4/Mg2NiH4 bridged cat./IRMOF-8 Ti-MOF-16 Bridged cat/AX21 BC8 C123BF8 AC(AX-21) M-doped CA LiAB KAB DADB AlH3 AB/LiNH2 Liq AB:MeAB AB/AT/PS soln AB/Cat. Li-AB Ca(AB)2 Ti(AB)4 AB+AF(Me-Cell) 10 • Validated cryosorbents achieving >8.5 wt.% H2 storage (Texas A&M, SwRI) • Identified potential pathways to reduce carbon fiber and tank cost 11 Collaborations Examples of Cross-Office Collaborative Successes ARPA-E: Focus on creative, high-risk transformational energy research Applied RD&D of innovative technologies Advancing fundamental science knowledge base Using ARPA-E developed catalyst in water splitting device Bandgap tailoring (Stanford) Nano-catalyst support scaffold (Stanford) Standard protocols and benchmarking High Throughput Processes (UCSB) Nanowire based solar fuels generation (CalTech) Alkaline Membranes Solar to Fuels Hub Working Groups PEC, Biological, High T Membranes, Storage Systems Developing novel catalysts (high risk/high impact) Pt monolayer Pd core Mechanistic understanding of catalysts Biological H2 production Materials-based H2 storage Progress - Technology Validation Demonstrations are essential for validating technologies in integrated systems Real-world Validation Vehicles & Infrastructure • 155 fuel cell vehicles and 24 hydrogen fueling stations • Over 3 million miles traveled • Over 131 thousand total vehicle hours driven • 2,500 hours (nearly 75K miles) durability • Fuel cell efficiency 53-59% • Vehicle Range: ~196 – 254 miles (430 miles on separate FCEV) Buses (with DOT) • H2 fuel cell buses have a 42% to 139% better fuel economy when compared to diesel & CNG buses Forklifts • Over 44,000 refuelings at Defense Logistics Agency site CHHP (Combined Heat, Hydrogen and Power) • Achieved 54% (hydrogen + power) efficiency of fuel cell when operating in hydrogen co-production mode • 100 kg/day capacity, renewable hydrogen supply 12 Air Products, Fuel Cell Energy Hydrogen & Fuel Cells for Energy Storage Improved efficiency of renewable H₂ production by matching the polarization curves of PV & electrolyzers to enable direct coupling. Power Conversion OR Direct Coupling Electrolyzers Compression & Storage Generator/ Fuel Cells OR R at io St ac k Po w er /T ot al S ol ar In pu t 13 Direct coupling vs Power Conversion w Max Power Tracking Expanded Facility to test multiple technologies (wind, solar, electrolyzers, fuel cells/ generators, plus H2 refueling) • Optimized power conversion and demonstrated consistent power output across larger range of solar input • Demonstrated up to nearly 20% power improvement at low irradiance DOE RD&D Data Collection & Validation DOT Deployment Accomplishments 0 1 2 3 4 5 6 7 8 9 10 M ile s pe r Di es el G al lo n Eq ui va le nt ACT Diesel ACT FCB SunLine CNG SunLine FCB CTT Diesel CTT FCB Fuel Cell buses: 42% to 139% better fuel economy than conventional buses Applied R&D Reduced cost (80% since 2002) Improved performance NREL National Bus Program ($49 million for 4 years) DOE and DOT support the development and deployment of fuel cell technology DOE – DOT Collaborations NREL 14 Demonstrated: •Doubled fuel economies (8 mpg, >2X compared to diesel buses) •41% increase in average miles between roadcall with new fuel cell system (~8,500 MBRC) •Demonstrated more than 8,000 hr fuel cell durabilityProjections based on the typical diesel baseline of 4 mpg in an average transit duty cycle 14 DOD-DOE Memorandum of Understanding Strengthen coordination and partnerships between DOE and DOD. Shipboard APUs Bio/logistics fuels reforming Aviation APUs Industry working group established Waste-to-Energy DOD-DOE working group formed to identify opportunities. Workshops Held Outcomes & Next Steps Impact 1FCHEA, http://www.fchea.org/index.php?id=14, 2 DOD Estimates 634,000 million BTUs potential energy savings using waste-to-energy CHP2 Potentially reduce NOx emissions by ~900-2,200 tons/yr for aircraft & 1,200-2,000 tons/yr for GSE2 Shipboard fuel cells capable of saving ~11,000-16,000 bbls/ship/yr2 15 Potential Resources near DOD Sites 16 17 Progress – Market Transformation & Recovery Act Deployed more than 630 fuel cells to date for use in forklifts and backup power at several companies including Sprint, AT&T, FedEX, Kimberly Clark, and Whole Foods FROM the LABORATORY to DEPLOYMENT: DOE funding has supported R&D by all of the fuel cell suppliers involved in these projects. DOE: $42 M Cost-share: $54 M Total: $96 M. ARRA JOBS STATUS (Jan 2011) ~50 jobs reported on Recovery.gov • Forklifts • FedEX Freight East, GENCO, Nuvera Fuel Cells, Sysco Houston • Back-up Power • Plug Power, Inc., ReliOn, Inc., Sprint Nextel • Portable Power • Jadoo Power, MTI MicroFuel Cells, Univ. of N. Florida • Auxiliary Power • Delphi Automotive 44 5 75 95 12 3 0 20 40 60 80 100 120 140 160 180 200 2009 2010 U ni ts MT Funding Year Market Transformation Hydrogen and Fuel Cell Deployments* Infrastructure* Buses MHE Stationary EBU* Accomplishments Additional fuel cell lift truck deployments taking place based on ARRA experience and lessons learned! ARRA Material Handling Equipment Data As of 12/31/2010 Hydrogen Dispensed > 18,500 kg Hydrogen Fills > 38,800 Hours Accumulated > 307,400 hrs Durability ~3,000 hrs* Reliability 75% w/MTBF > 100 hrs Data Collection Snapshot (NREL) MORE THAN 500 ADDITIONAL FUEL CELL FORKLIFTS PLANNED E.g., Sysco, H-E-B Grocery, BMW *Average projected hours to 10% voltage drop of all the fleets with a max fleet project of more than 9,500 hours. 25% of systems have more than 2,300 operation hours and one fleet averages more than 2,6000 operation hours. 18 Fuel Cell Technologies Post-doc Program – Up to five positions available to conduct applied research at universities, national laboratories, and other research facilities – Applications are due June 30, 2011 http://www1.eere.energy.gov/education/postdoctoral_fellowships/ Education and Outreach • Developed and disseminated information to educate key stakeholders • Reached > 8,500 teachers • Measured up to 220% increase in knowledge level in 2 years Progress – Safety, Codes & Standards and Education tanks in secondary containment pumps accumulators Safety R&D and Codes & Standards • Exceeded 34,000 hydrogen pressure cycles in steel storage tanks • Quantified effect of barrier walls leading to potential for up to 50% reduction in separation distances • Expanded web-based first responder training (17,000 visits) Tanks with engineered defects are projected to exceed expected life 19 Sandia National Lab Example - The Case for Fuel Cell Forklifts Fuel cell forklifts offer several advantages compared to conventional fork lift technology Preliminary Analysis Compared to conventional forklifts, fuel cell forklifts have: • 1.5 X lower maintenance cost • 8 X lower refueling/recharging labor cost • 2 X lower net present value of total system cost Preliminary Analysis: Comparison of PEM Fuel Cell- and Battery-Powered Forklifts Time for Refueling/ Changing Batteries 4-8 min/day 45-60 min/day (for battery change-outs) 8 hours (for battery recharging & cooling) Labor Cost of Refueling/Recharging $1,100/year $8,750/year NPV of Capital Costs $12,600 ($18,000 w/o incentives) $14,000 NPV of O&M Costs (including fuel) $52,000 $128,000 20 Published Fact Sheets & Case Studies Employment Impacts of Early Markets Preliminary Analysis Gross National Impact of PEMFCs in Forklifts Technology/Market Assumptions: • $1,300/kW initial mfg cost (Battelle), $4,200/kW retail price. • Shipments reach 3,300 annually by 2020 (Greene et. al.) out of ~100,000. • 15,000 FC forklifts in operation by 2020 (<2 percent of Class 1-3 forklifts). • Average of 60 fuel cells/site, 250 site installations by 2020. • Tax credit expires in 2016. Developed user-friendly tool to calculate economic impacts Includes short-term jobs (construction/ expansion of mfg capacity, installation & infrastructure) & on-going jobs (manufacturing, O&M and fuel production & delivery) Select State or Region Type of Fuel Cell Application Average Size of Manufactured Fuel Cell Fuel Cells Manufactured by Year Annual Fuel Cell Production (kW/year) Time Frame (years) Existing Fuel Cell Production Capacity (kW/year) Additional Manufacturing Capacity to be Constructed (kW/year) Sales Price ($/kW) Production Cost ($/kW, initial) Progress Ratio Production Volume for Initial Cost Scale Elasticity Full Scale Production Level (kW/year) Annual Rate of Technological Progress Average Production Cost Over Time Frame ($/kW) Installation Cost ($/kW) Operations & Maintenance Cost ($/kW, annual) 21Argonne National Lab/RCF $0 $10,000 $20,000 $30,000 $40,000 $50,000 $60,000 Es ti m at ed R et ai l P ri ce Comparison of 2008 ORNL Study and 2010 Fuel Cell Cost Estimates 2005 Average 2010 Predicted 2010 Average PEM Stack $/kW 1 kW Back-up Power 5 kW Back-up Power 5 kW Materials Handling 5 kW CHP Methane Early Market Cost Reduction Analysis $0 $1,000 $2,000 $3,000 $4,000 PEM Stack For Back-up Power $/kW 1 kW Back-up Power System 5 kW Back-up Power System 5 kW Materials Handling Unit 5 kW CHP Methane Reforming Not included in 2008 study 2005 and 2010 averages based on estimates supplied by OEMs. 2010 predicted assumed government procurements of 2,175 units per year, total for all market segments. Predictions assumed a progress ratio of 0.9 and scale elasticity of -0.2. 2005 Average 2010 Predicted 2010 Average • 50% or greater reduction in costs • 2008 model generally underestimated cost reductions 22 ORNL Assessing Program Impact - Commercialization DOE funding directly led to ~30 hydrogen and fuel cell technologies in the market. 256 PATENTS resulting from EERE-funded R&D: - 136 fuel cell - 88 H2 production & delivery - 32 H2 storage Source: Pacific Northwest National Laboratory http://www1.eere.energy.gov/hydrogenandfuelcells/pdfs/pathways_success_hfcit.pdf DuPont Proton 3M Quantum Technologies BASF Catalysts LLC Dyanlene, Inc. Examples 23 Nu m be r o f p at en ts PNNL Additional Analysis - Hydrogen Infrastructure 1. Cost reduction from station duplication will require ~120 stations and was based on 3% reduction for a doubling of capacity. 2. Cost of H2 delivered to station is ~$5/kg. 3. Station cost reductions based on ANL Hydrogen Delivery Systems Analysis Model (HDSAM). 4. Current station cost based on current California state funded stations. Capital cost ~ $2.5 million. Cost Reductions for Stations St at io n Delivered H2 Cost Reductions Opportunities Identified by Experts Identified opportunities for reducing infrastructure cost. High-priority opportunities include station designs, streamlining/standardizing permitting process, and financial, policy and partnership support. 24 Preliminary Analysis RFI: Tech. Validation Closes June 1, 2011 RFI: Bus Targets 25 Announcements Areas of Interest • Innovative concepts for: – Stationary fuel cell systems for residential and commercial applications – Combined-heat-hydrogen- and-power (CHHP) co- production fuel cell systems • Technology Validation projects for other markets For more information: http://www1.eere.energy.gov/hydrogenandfuelcel ls/news_detail.html?news_id=16873 http://www07.grants.gov/search/search.do?&mo de=VIEW&oppId=84333 Closes July 1, 2011 Areas of Interest • Solicit feedback on performance, durability and cost targets for fuel cell transit buses • Sponsored by Questions may be addressed to: DOEFCBUSRFI@go.doe.gov Acknowledgements DOE Hydrogen & Fuel Cells Program Federal Agencies Industry Partnerships & Stakeholder Assn’s. • Tech Teams (USCAR, energy companies- FreedomCAR & Fuel • Fuel Cell and Hydrogen Energy Association (FCHEA) • Hydrogen Utility Group • ~ 65 projects with 50 companies Universities ~ 50 projects with 40 universities State & Regional Partnerships • California Fuel Cell Partnership • California Stationary Fuel Cell Collaborative • SC H2 & Fuel Cell Alliance • Upper Midwest H