direct hydrogen pem fuel cell powertrain manufacturing

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Austin Power Engineering LLC 1 Cameron St Wellesley, MA 02482 USA www. AUSTINPOWERENG.com [email protected] © 2019 Austin Power Engineering LLC Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing Cost Analysis for Heavy Duty Truck Applications Yong Yang President November 7, 2019

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Page 1: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

Austin Power Engineering LLC1 Cameron St

Wellesley, MA 02482USA

[email protected]

© 2019 Austin Power Engineering LLC

Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing Cost Analysis for Heavy Duty

Truck Applications

Yong Yang

President

November 7, 2019

Page 2: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

1

Austin Power Engineering LLC is an independent technology consulting company that focuses mainly on bottom-up technical cost modeling.

Source: Dr. Rajesh Ahluwalia of ANL

HT/LT Radiators

Demister

Electric Motor

PEFC

Stack

AirExhaust

Humidified Air

HT Coolant

Enthalpy

Wheel

LT Coolant

Purge Valve

Recirculation Pump

LT Coolant Pump

HT Coolant Pump

Fan

Ejector

Pressure RegulatorMembrane

Humidifier

Dilution Mixer

Air Filtration

Hydrogen

Tank

Air Bypass

HT/LT Radiators

Demister

Electric Motor

PEFC

Stack

AirExhaust

Humidified Air

HT Coolant

Enthalpy

Wheel

LT Coolant

Purge Valve

Recirculation Pump

LT Coolant Pump

HT Coolant Pump

Fan

Ejector

Pressure RegulatorMembrane

Humidifier

Dilution Mixer

Air Filtration

Hydrogen

Tank

Air Bypass

Demister

Electric Motor

PEFC

Stack

AirExhaust

Humidified Air

HT Coolant

Enthalpy

Wheel

LT Coolant

Purge Valve

Recirculation Pump

LT Coolant Pump

HT Coolant Pump

Fan

Ejector

Pressure RegulatorMembrane

Humidifier

Dilution Mixer

Air Filtration

Hydrogen

Tank

Hydrogen

Tank

Air Bypass

Cathode pinTop cover

Insulator case

Spring plate

Anode can

Anode

Cathode

Separator

Cathode lead

Safety vent

Gasket

Insulator

Terminal plate

CID

2019 YY

Hydrogen

Electrolysis

Hydrogen

StorageFuel Cell

Battery

2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

Hydrogen & Fuel Cell Manufacturing Cost Modeling

2014 2015 2016 2017 2018 2019

Arthur D Little / TIAX Austin Power Engineering

Introduction Overview

Page 3: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

22019 YY

Have been working on various EV powertrain manufacturing cost analysis since 2002.

Introduction Company Overview

Electric Powertrains

- Full battery powertrain

- Hybrid battery powertrain

- Fuel cell powertrain

Battery Packs

- Lithium ion battery

- Lithium metal solid electrolyte battery

- NiMH battery

Power Electronics

- Battery BMS

- Inverters

- Traction motors

Regenerative/Active

Suspension System

Electric Turbo Chargers

On-board Fly Wheel

Energy Storage System

Range-extension IC Engines

Onboard Hydrogen Storage

Systems

- Compressed H2 tanks

- MH H2 tanks

- Chemical H2 tanks

- Cryo-compressed H2 tanks

- MOF H2 tanksThermal-electrical Generator

(Exhaust Heat Recovery)

Page 4: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

Approach Project Scope

32019 YY

Fuel Cell

System

Hydrogen

Storage

System

Hybrid

Battery

System

Inverter

Motor

Included in

the analysis

Not

included in

the analysis

Conduct a bottom-up manufacturing cost analysis of a 160 kW class 8 truck fuel cell power system.

Class 8 Fuel Cell Truck

Fuel cell power: 160 kWnet /

197kWGross

Battery power: 350 kW

Battery energy: 16 kWh

Motor power: ~500 kW

H2 storage: 60 kg (Six tanks)

H2 storage tank: Cryo-compressed

Range: 300 miles

Test Wt. Fuel Cell Battery

lbs kW kW

Class 1 Class 1: < 6,000 lbs Not eval. Not eval. Not eval.

Class 2 Van Class 2: 6,001 - 10,000 lbs 7588 147 6

Class 3 Service Class 3: 10,001 - 14,000 lbs 11356 165 4

Class 3 School Bus Class 3: 10,001 - 14,000 lbs 11512 180 76

Class 3 Enclosed Van Class 3: 10,001 - 14,000 lbs 12166 149 62

Class 4 Walk-in, Multi-Stop Class 4: 14,001 - 16,000 lbs 15126 166 59

Class 5 Utility Class 5: 16,001 - 19,500 lbs 16860 253 8

Class 6 Construction Class 6: 19,501 - 26,000 lbs 22532 170 30

Class 7 School Bus Class 7: 26,001 - 33,000 lbs 29230 145 56

Class 8 Constrction 37429 139 57

Class 8 Refuse 45291 273 94

Class 8 Nikola One 50870 300 446

Class 8 Tractor Trailer 54489 247 95

Class 8 Line Haul 70869 363 47

ANL Analysis Assumption/Results

Class 8: >33,001 lbs

Light

Duty

Medium

Duty

Heavy

Duty

Class and Vocation PHA Vehicle Class Definaion

* Data from Argon National Lab research papers, 21st Century Truck, DOE

Page 5: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

4

Approach Manufacturing Cost Modeling Methodology

This approach has been used successfully for estimating the cost of various technologies for commercial clients and the DOE.

Technology

Assessment

Manufacturing

Cost Model

Scenario

Analyses

Verification &

Validation

• Literature research• Definition of system and component diagrams• Size components• Develop bill-of-materials (BOM)

• Define system value chain• Quote off-shelve parts and materials• Select materials• Develop processes• Assembly bottom-up cost model •Develop baseline costs

• Technology scenarios• Sensitivity analysis • Economies of Scale• Supply chain & manufacturing system optimization• Life cycle cost analysis

• Cost model internal verification reviews• Discussion with technical developers• Presentations to project and industrial partners• Audition by independent reviewers

Membrane

8.0%

Stack

Conditioning

2.7%

Seal

8.4%

Balance of Stack

2.4%

Bipolar Plate

26.1%

GDL

5.1%

Electrode

41.0%

Stack Assembly

6.3%

2019 YY

Anode Ink

Anode Side

Catalyst Layer

Membrane

Processes

Cathode Side

Catalyst Layer

Cathode Ink

Hot Press

Lamination

Purchased GDL

Purchased GDL

Pt

Pt

Nafion®

Ionomer

99.9% 98.5%

99.9% 98.5%

99% 98.5%

100% 98.5%99% 98.5%

99% 98.5%

100% 100%

100% 100%

100% 100%

100% 100%

100% 100%

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

3-Year TCO 5-Year TCO 10-Year TCO 15-Year TCO

To

tal

Co

st

of

Ow

ers

hip

($

)

PEMFC Plug Hybrid Vehicle

Full Battery Electric Vehicle

Page 6: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

5

Combining performance and cost model will easily generate cost results, even when varying the design inputs.

2019 YY

Process Simulation

Energy requirements

Equipment size/ specs

Product Costs

Product cost (capital,

O&M, etc.)

Conceptual Design

System layout and

equipment requirements

Capital Cost EstimatesSite Plans

Safety equipment, site

prep, land costs

High and low volume

equipment costs

Air (POX only)

Nat. Gas

Water

Fuel

Reformer PSA

H2-rich gas

H2-poor gas

Catalytic

Burner

HeatCold

Water

99.99% pure H2

Low

Pressure

Storage

Medium

Pressure

Storage

High

Pressure

Storage

Flow

cntrlr

Flow

cntrlrFlow

cntrlr

Dispenser

To Vehicle

CO2

H2O

Compressor with intercoolers

Cooling

Tower

Process cost

Material cost

Tape Cast

Anode

Powder Prep

Vacuum

Plasma

Spray

Electrolyte

Small Powder

Prep

Screen

Print

Cathode

Small Powder

Prep

Sinter in Air

1400CSinter in Air

Forming

of

Interconnect

Shear

Interconnect

Vacuum

Plasma

Spray

Slurry

Spray

Screen

Print

Slurry Spray

Slip Cast

Finish Edges

Note: Alternative production processes appear in gray to the

bottom of actual production processes assumed

Braze

Paint Braze

onto

Interconnect

Blanking /

Slicing

QC Leak

Check

Interconnect

Fabrication

Electrolyte CathodeAnode

Stack Assembly

Fuel Station Perimeter

Electrolyzer or SMR,

High-Pressure

Compressor

H2 High Pressure

Cascade Storage

System

Gaseous Fuel

Dispensing Islands

Underground Piping with shared conduit

Vent

Building

Covered Fueling Island

CNG High Pressure

Cascade Storage System

Fire Detector

Walls with minimum fire rating of 2 hours

Wall openings (doors & windows)

Building intake vents

Adjoining property that can be built on

Public sidewalks, parked vehicles

Streets

Railroad tracks

Other flammable gas storage

5 ft

25 ft

50 ft

10 ft

15 ft

10 ft

15 ft

10 ft

Minimum set-back distances for hydrogen and/or natural gas

storage (more stringent gas noted if relevant)

Property of:

TIAX LLC

1061 De Anza Blvd.

Cupertino, CA 95014

Task 5 CNG/Hydrogen Fueling

Site Plan - Fueling Station

Hydrogen and CNG fueling station

SIZE DWG BY DWG NO REV

A Stefan Unnasch B0228 - S0022 1

SCALE 1" = 8 ft 5 Jan 2004 SHEET 1 OF 110 ft

Security FenceNG line in

ft

ft

ft

ft

ft

ft

ft

ft

Process Cost Calcs

Material

Process

$0

$1

$2

$3

$4

$5

$6

$7

$8

$9

$10

Lapp

ing

CM

P

Wet

ther

mal O

xida

tion

Spin

Coa

ting

Wet

Etching

SiO

2

DC S

putte

ring

Ni

RF S

putte

ring

E

Spin

Coa

ting

Stepp

er

DC S

putte

ring

Ag

Stripp

ing

Spin

Coa

ting

Stepp

er

Dry

Etchi

ng S

iO2

DRIE

Si

Wet

Etching

SiO

2

Dry

Etchi

ng N

I

Wafe

r C

ost

($)

Approach Manufacturing Cost Modeling Methodology

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

3-Year TCO 5-Year TCO 10-Year TCO 15-Year TCO

To

tal

Co

st

of

Ow

ers

hip

($

)

PEMFC Plug Hybrid Vehicle

Full Battery Electric Vehicle

Page 7: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

6

Stack and system component in-depth analysis on technology progress and supply chain optimization:

2019 YY

Approach In-depth Analysis

Economies of Scale Analysis

0

1

2

3

4

5

6

2010 2020 2030 2040 2050

Tota

l cap

acit

y (G

W)

Fuel cell penetration in UK genset market

Successful PFCC

Fuel cell breakthrough achieved in 2024

Bass Diffusion Model Analysis

Stack and BOP components

• MEA

• GDL/MPL

• Bipolar plates

• Compressor/expender

• H2 circulation pump

• Humidifier

• Radiator

In-depth analysis

Technology progress

• Breakthrough innovation

• Technology improvement

in short and long term

• Design simplification

Supply chain optimization

• Raw material

• Off-the-shelf Component

• Fabrication process

• Utilization in other industry

• Challenges

OEM evaluation

• Market share

• Production capacity

• Annual revenue

• Product cost

Page 8: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

7

We assume class 8 truck has an annual production volume of 10,000 units.

Manufacturing Assumptions

System Components Class 8 Truck

Vehicle production volume

(unit/year)10,000

Stack source

Assume two 80 kWnet stacks at the

annual production volume of 20,000

units

H2 storage system production

volume

10 kg x 6 cryo-compressed H2 tanks

at the annual production volume of

60,000 units

Battery source

16 kWh lithium-ion battery pack at the

annual production volume of 10,000

units

2019 YY

Page 9: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

8

The 160 kWnet direct hydrogen PEM fuel cell system configuration:

PEMFC System 160 kWnet PEM Fuel Cell System Preliminary System Design

2019 YY

Hydrogen

PT PR

Air

Air Filter

Air pre-cooler

Compressor

Air Flow MeterPT

Stack

Membranehumidifier

M

Exhaust

Demister

Bypass valve

PT PR

Air

Air Filter

Air pre-cooler

Compressor

Air Flow MeterPT

Membranehumidifier

M

Exhaust

Bypass valve

PT PR

Diverter valve

Solenoid valve

Jet Pump

Over pressure cut-off valve

H2 Exhaust

Motorized valve

H2 fi lter

PT PR

Solenoid valve

Jet Pump

Over pressure cut-off valve

H2 fi lter

Motorized valve

PT

PR

Diverter valve

Coolant pump

Coolant tank

High temperature coolant loop

High temperatureradiator

Stack

PT

PR

Diverter valve

Coolant pump

Coolant tank

Low temperature coolant loop

Low temperatureradiator

Demister

v

v

Page 10: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

9

System and material assumptions for the cost estimation:

System Assumptions PEM Fuel Cell System Preliminary Design

2019 YY

Stack Components Unit Current System Comments

Production volume systems/year 10,000 Baseline

System net power kW 160

System gross power kW 197

# of stacks in the system # 2

Stack’ net power kW 80

Stacks’ gross power kW 98.5

Cell power density mW/cm2 1,200 DOE 2018

System Voltage (rated power) Volt 250

Platinum price $/tr.oz. $1,500 Estimated, DOE 2018

Pt loading mg/cm2 0.35 DOE 2018

Membrane type Reinforced PFSA

Membrane thickness micro meter 14

GDL layerNon-woven carbon paper with

MPL layer

GDL thickness micro meter 110 @50 kPa pressure

MPL layer thickness micro meter 45

MEA gasket material PET

MEA gasket thickness micro meter 100

Bipolar plate type Gold dot coated SS316 Treadstone; Near term

Bipolar plate base material Thickness micro meter 100

Seal material EPDM

Page 11: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

10

The bottom-up cost approach will be used to accurately capture the manufacturing costs for each fabrication step.

True-value-mapping analysis virtualizes costs in each fabrication step, which breaks down costs into materials, labor, capex, utility, maintenance, etc.

2019 YY

BUY

MAKE

Anode

Ink

Anode Side

Catalyst Layer

Membrane

Processes

Cathode Side

Catalyst Layer

Cathode

Ink

Hot Press

Lamination

Die Cut

MEA

MEA Continuous Fabrication Process

Purchased

GDL

Purchased

GDL

Pt

Pt

Nafion®

Ionomer

Stack

Assembly

Bipolar

Plate

Purchased

Hardware

Gasket

Stack Fabrication Process

Frame

Seal

Molding

Viton

Viton

Sheet

Metal

Process Yield

Material Utilization

99.9% 98.5%

99.9% 98.5%

99% 98.5%

100% 98.5%99% 98.5%

99% 98.5%

100% 100%

100% 100%

100% 98.5% 99% 95%

99% 95%

100% 100%

100% 100%

100% 100%

100% 100%

100% 100%

100% 100%

100% 100%

99% 95%

99.9% 100%

Testing

99.5% 100%

System Assumptions Process Assumptions

Page 12: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

11

The class 8 truck fuel cell stack costs approximately $64/kW.

Class 8 Truck Stack Cost ($64/kWnet)Stack ComponentsClass 8 Truck Stack

Cost ($/kW)1,2

Anode GDL $2.8

Anode $9.3

Electrolyte $6.0

Cathode $17.1

Cathode GDL $2.8

MEA Assembly $3.6

Cooling Plates $14.9

Seals $3.6

End Plates $0.7

Electrical insulators $0.1

Anode Current Collector $0.1

Cathode Current

Collector$0.1

End-stack heaters $0.8

Compression band $0.1

Fixings & fasteners $0.1

Ventilated Stack

Enclosure$0.3

Stack assemlby $0.8

Stack conditioning $0.4

Stack Total Cost ($/kW) $63.6

1. Results may not appear to calculate due to rounding of the component cost results.

2. Actual stack production volume: 20,000 stacks/yr.

PEMFC System Stack Costs

2019 YY

4%

15%

9%

27%

4%

6%

23%

6%

1%0%

0% 0% 1% 0% 0% 1%1%

1%

Anode GDL Anode Electrolyte Cathode Cathode GDL

MEA Assembly Cooling Plates Seals End Plates Electrical insulators

Anode Current Collector Cathode Current Collector End-stack heaters Compression band Fixings & fasteners

Ventilated Stack Enclosure Stack assemlby Stack conditioning

Page 13: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

12

Class 8 Truck System Cost ($115/kWnet)

The class 8 truck fuel cell system costs approximately $115/kW at the production volume of 10,000 systems/year.

System ComponentsClass 8 Truck System

Cost ($/kW)

Stack $63.58

Air management $29.56

Water management $2.27

Thermal management $5.35

Fuel management $5.16

System controller $0.93

Sensors $1.44

Miscellaneous $1.94

System assembly $4.55

Total: $114.78

1. Assumed 15% markup to the automotive OEM for BOP components

2. Results may not appear to calculate due to rounding of the component cost

results.

PEMFC System Costs

2019 YY

55%

26%

2%

5%

4%1%1% 2% 4%

Stack Air management Water management

Thermal management Fuel management System controller

Sensors Miscellaneous System assembly

Page 14: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

13

The cryo-compressed hydrogen tank has advantages in gravimetric density, volumetric density, and cost.

Cryo-Compressed H2 Storage System Configurations

2019 YY

• US Department of Energy Hydrogen Storage Cost

Analysis, 2013, TIAX; Cost is based on 500,000

units/year

• System level analysis of hydrogen storage options, R. K.

Ahluwalia, 2010

• Cryo-compressed hydrogen storage, BMW 2012

Cryo-

compressed

H2 Tank

Page 15: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

14

The cryo-compressed hydrogen tank design is referenced in studies TIAX conducted on hydrogen storage1.

1. S. Lasher and Y. Yang, “Cryo-compressed and Liquid Hydrogen System Cost Assessments”,

DOE Merit Review, 2008

2. R.K. Ahluwalia, i.e. “Cryo-compressed hydrogen storage: performance and cost review”

Februrary, 2011

Cryo-Compressed Hydrogen Storage System Schematic1, 2

The single tank design has a usable hydrogen storage capacity of 10.1 kg.

Key ParametersSystem Volume

• Storage: 151L

• Vessel: 224L

System Weight: 144.7kg

• LH2 storage: 10.7kg (usable 10.1 kg)

• CH2 storage: 2.8kg

Tank

• Carbon fiber: Toray T700S

• Carbon fiber / resin ratio: 0.68 : 0.32

(weight)

• Translational strength factor: 81.5%

• Safety factor: 2.25

• Carbon fiber composite layer

thickness: 12 mm

• Liner: 3mm Al

• Vacuum gap: 40 mm with 40 layers of

MLVI

• Outer Shell: 3 mm thick SS304

• Gravimetric capacity: 7.1 wt%

• Volumetric capacity: 44.5 kg/m3

Cryo-Compressed H2 Storage System Configurations

2019 YY

Page 16: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

15

Assumptions for the hydrogen storage tank design are based on the literature review and third-party discussions.

Stack Components Unit Class 8 Truck

Production volume tanks/year 60,000

Usable hydrogen Kg 10.1

Total H2 in the tank Kg 10.7

Tank type III

Tank max pressure PSI 5,000

# of tanks Per System 6

Safety factor 2.25

Tank length/diameter ratio 3:1

Liner material Al

Liner thickness mm 3

Carbon fiber type Toray T700S

Carbon fiber cost $/lbs 12

Carbon fiber vs. resin ratio 0.68:0.32

Carbon fiber translational

Strength factor81.5%

Carbon fiber composite layer

thicknessmm 12

Vacuum gap mm 40

# of MLVI layer 40

Outer layer SS304

Outer layer thickness mm 3

Compressed H2 Storage System Specifications

2019 YY

Page 17: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

16

A vertically integrated manufacturing process is assumed for the tank and BOP components.

Compressed H2 Storage System Manufacturing Process

2019 YY

Extrude and Spin

Cylinder

Spin Seal

One End

Boss

Fabrication

Inner Liner Device

Assembly

Spin Seal

2nd End

Vacuum Leak Inspection

Al Liner

Fabrication

Pressure

liner

Liner

Surface

Gel Coat

CF

PrePreg

Filament

Winding

Cure /

Cool

down

Ultrasonic

Inspection

Carbon FiberGel

CF Layer

Fabrication

Liner Support &

Piping Assembly

Cut the MIL into Required

Shape

Laminate Multiple

Insulation Layer

Attach the MIL onto

Composite Tank

SS Outer Tank Body Welding

(One End)

Outer Tank Assembly

Tank Insulation Vacuum

Processing

Final System

Inspection

SS Outer Tank

Cylinder Rolling

SS Outer Tank Dome

Stamping

Insulation Layer Piping

Assembly

SS Outer Tank Body Welding

Vessel Shell

Fabrication

Final

Assembly

Insulation

Fabrication

Page 18: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

17

Class 8 Truck H2 Storage System Cost ($12.4/kWh)

In the cryo-compressed hydrogen storage system, the top three cost drivers are the carbon fiber composite layer, cryogenic valves, and system control valves.

System Components

Class 8 Truck

System Cost

($/kWh)

H2 0.10

Al liner 0.45

CF layer 2.88

Insulation 0.39

Vacuum shell 0.69

Balance of vessel 0.24

Fuel receptacle 1.27

Cryogenic valves 1.24

HX 0.24

Electronic control 2.52

Vent & release device 1.06

Tank frame, piping& fitting,

fasteners 0.18

Assembly & testing 1.12

Total: 12.37

Compressed H2 Storage System Cost

2019 YY

• Cryo-compressed H2 tank production volume: 60,000

tanks/year (10,000 systems/year)

1% 4%

23%

3%

6%

2%

10%10%

2%

20%

9%

1%

9%

H2 Al linerCF layer InsulationVacuum shell Balance of vesselFuel receptacle Cryogenic valvesHX Electronic controlVent & release device Tank frame, piping& fitting, fasteners

Page 19: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

18

We use a 16 kWh lithium ion hybrid battery pack in the fuel cell truck powertrain.

2019 YY

Specifications

Battery pack energy 16 kWh

Battery module Output 350 kW

Cell size (Ah) 55

# of cells in pack 80

# of cells in module 20

# of modules in pack 4

Anode active material Graphite/Si

Cathode active material NMC622

PEMFC Hybrid Energy Storage Lithium Ion Battery Pack

Pack

Illustration Only

Page 20: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

19

We analyze the cells, modules, and pack cost using bottom-up approach.

2019 YY

PEMFC Hybrid Energy Storage Battery Cell-to-Pack Cost

Cell

Module

Pack

Mixing

Filtration

Coating

Drying

Calendering

Mixing

Filtration

Coating

Drying

Calendering

Cathode Anode

Cathode active

material

Conductive

materials

Binder

Current

Collector

(Al)

Anode active

material

Binder

Current

Collector

(Cu)

Punching Punching

Stacking

Tab Welding

Pouch

Stamping

Cell Seal (top

and one side)

Hi-pot Testing

Labeling

Separator

Vacuum

Drying

Room Temp.

Aging

Formation

De-gassing,

2nd Seal

Grading &

Sorting

Filling

Electrolyte

and 1st Seal

Cathode tab

Anode tab

Aluminum

lamination

film

High Temp.

Aging

OCV Testing

OQC

Pack

Materials

ScalingMaterial

Scaling

Al Fin Cell Center

FrameCell

Repeat (20 cells for 4modules)

End Unit with

Cell Monitoring

PCB Board

Thermal

Management

System

Structure

Protection

System

Battery

Management

System+ +

Page 21: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

20

The hybrid lithium ion battery pack costs $169/kWh. Cells, cell module assembly, and battery management system have higher cost contributions.

Battery System Cost ($169 /kWh)

The 16 kWh lithium-ion battery system costs $2,700 per pack at the annual production volume of 10,000 packs.

Cost Category Pack Cost ($/kWh)

Cells $125.00

Cell Module Assembly $16.50

Battery Thermal

Management System $4.89

Battery Structure

Protection System $9.54

Battery Management

System $12.84

Total ($/kWh)$168.76

2019 YY

PEMFC Hybrid Energy Storage Battery Pack Cost

74%

10%

3%

6%

7%

CellsCell Module AssemblyBattery Thermal Management SystemBattery Structure Protection SystemBattery Management System

Page 22: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

21

PEM fuel cell system, onboard hydrogen storage, and hybrid battery cost approximately $46,050 for class 8 fuel cell truck.

2019 YY

Conclusions

Cost CategoryClass 8 Fuel Cell

Truck

Fuel Cell System (160 kWnet) $18,365

H2 Storage system (60 kg H2) $24,985

Hybrid Battery Pack (16 kWh) $2,700

Total: $46,050

CommentsProduction volume:

10,000/yr

40%

54%

6%

Fuel Cell System (160 kWnet)

H2 Storage system (60 kg H2)

Hybrid Battery Pack (16 kWh)

Fuel Cell + H2 Tank + Battery Cost ($169 /kWh)

Page 23: Direct Hydrogen PEM Fuel Cell Powertrain Manufacturing

22

Thank You!

Contact: Yong Yang

Austin Power Engineering LLC

1 Cameron St,Wellesley, MA 02482

+1 781-239-9988+1 401-829-9239

[email protected]

2019 YY