EC Project: HYCHAIN MINITRANS EC Project: HYCHAIN MINITRANS “Development of Innovative Fuel Cell Vehicle Fleets to Drivethe Use of Hydrogen as an Alternative Fuel in Early Markets”

Including highlight of Midibus aspects

Clean Urban Transport for Europe CongressHamburg, Germany, 10 - 11 May, 2006

Mark Kammerer, HYDROGENICS POWER SYSTEMS, Hydrogenics GmbH, Germany

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HYCHAIN MINITRANS - OVERVIEW

Air Liquide FranceProject Coordinator

Feb 1st 2006Project start17.000.000 €EC DG TREN Financing37.653.000 €Total budget

NATIONAL COORDINATORS

Fuel cellFuel cellWheelchairsWheelchairs

H2

Fuel cell Fuel cell scootersscooters

HybridHybridminibusesminibuses

Fuel Cell Fuel Cell portable portable

generatorgeneratorHydrogen Hydrogen infrastructureinfrastructure

Fuel cellFuel cellutility carsutility cars

Fuel cellFuel cellTricyclesTricycles

SMALL TRANSPORT APPLICATIONS

KEY DATA

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Main Projects of the European Partnership “Hydrogen for Transport”

HyLIGHTS - Coordination and Monitoring activities between the Lighthouse Projects

HYCHAIN MINITRANS – EC Context

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HYCHAIN – Regional Initiatives spanning W. Europe

RhôneRhône--AlpesAlpesGrenoble Greater Metropolitan Area

North Rhine WestphaliaNorth Rhine WestphaliaRegion of Region of EmscherEmscher--LippeLippeAmalgamated CommunityAmalgamated Community

CastillaCastilla y Ley LeóónnCities of Soria and Leóón

Emilia RomagnaEmilia RomagnaCity of Modena

RegionsRegions

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Air Liquide GmbH, Hydrogenics GmbH,Masterflex AG, WIN, Wuppertal Institute

Air Liquide Italy, Democenter,Fast, VEM

Air Liquide SA, Axane Fuel Cells,Ascoparg, CEA, INPG, Paxitec, INERIS

Air Liquide E, Besel, Ciemat, CEU, Derbi, Domenech, Iberdrola, Rucker

HYCHAIN Participants

Diverse partners of the HYCHAIN MINITRANS Project

RhôneRhône--AlpesAlpesL’agglomération de Grenoble,Département de l’Isère

EmscherEmscher--LippeLippe RegionRegion12 cities in the Ruhr Area12 cities in the Ruhr Area

CastillaCastilla y Ley LeóónnSoria and Leon

Emilia RomagnaEmilia RomagnaModena

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1. Introduce low power fuel cell vehicle fleets in selected early niche transport markets to enhance public awareness and acceptance of fuel cells in four Regions spanning Western Europe

2. Demonstrate and test a significant number of fuel cell “power modules” from four European fuel cell manufacturers in “mini”transport applications, to achieve a minimum critical mass for early industrialization, gaining a significant reduction of costs.

3. Set up micro-infrastructures for hydrogen refueling including logistics, maintenance services, monitoring, training

4. Address cross-cutting actions such as regulations & standards, costs issues, environmental impact, safety, policy encouragement, etc.

HYCHAIN MINITRANS – MAIN OBJECTIVES

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Aim: Fuel Cells used by the General Public

Obtain CertificationBuild public acceptance

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HYCHAIN MINITRANS – 5 Systems, 158 Vehicles

34 Vehicles40 Vehicles

500 W250 W

30 Vehicles

1 kW

10 Vehicles44 Vehicles 3 H2 Dispensers

2,5 kW 10 kW

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R&D & Design

Industrialization

Manufacturing & Delivery

Operation and maintenance

Project Preparation

Assessment & Dissemination

September 2005 : Negotiations with EC finalized

October 2005 : Project approved by Member States Programme Committee

November 2005 : Consortium Contract signed

January 31st 2006 : Official project Launch and Kick-Off in Brussels

December 2005 : EC Contract signed

HYCHAIN MINITRANS – SCHEDULE

2006 2007 20102008 20092005

End Users Commitment

Demonstration Preparation

LogisticUpdate

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HYCHAIN - Project Organization

Executive BoardProject Coordinator + Regional Coordinators

European Commission

Regional Institutional

partners

Project coordinator

Administrative coordinator

General assembly(All partners)

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Respectful with the environment(emissions or noise)

Service company (maintenance, services, ..)Service company (maintenance, services, ..)Logistic service, post service Logistic service, post service ……

Municipal companies (local service, Municipal companies (local service, ……))

Air Liquide (Germany)Masterflex (Germany)Electronic, integration

Masterflex (Germany)Hawk Bikes (Germany)Multifunctional tricycle

Increased autonomy(min. 150 km),

High efficiency

Flexible(no need of driving license, free of taxes, …)

Power available for additional applications(cooling, lighting …)Low operation cost

Innovative design

HYCHAIN MINITRANS – Cargo Bike

Quick refilling(using hydrogen cartridges)

Air Liquide (Germany)2 Litres Cylinder @ 700 barMasterflex (Germany)Electronic, integration

Masterflex (Germany)250 W Fuel cellHawk Bikes (Germany)Multifunctional tricycle

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20 % reduction in weight, compared to conventionalelectric wheelchairs

For disabled people centers, associations,For disabled people centers, associations,residential homes for elderly, hospitals, airports,residential homes for elderly, hospitals, airports,

museums, and other public spacesmuseums, and other public spaces

Use of renewable hydrogen

Increased autonomy (50%),compared to conventionalelectric wheelchairs

Lower recharging time(less than 5 min)

Besel (Spain)Integration, engineering and testingAir Liquide (France) 1 x 700 bar H2 cylinder

Axane (France)0.5 kW Fuel CellMeyra (Germany)Electric wheelchair

HYCHAIN MINITRANS – Wheelchair

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Cleaner and quieter than conventional combustionengine scooters

Courier service, postal delivery (urban use), municipal police aCourier service, postal delivery (urban use), municipal police and nd others municipal services, individual user in urban spacesothers municipal services, individual user in urban spaces

Besel/Rucker (Spain) Power train, integration,engineering and testing

Air Liquide (France)2 x 2 litres @ 700 barsMES –DEA (Switzerland)1 kW Fuel cell

Derbi (Spain)Original scooter

Battery recharging through the fuel cell operation (no grid recharging)

Higher vehicle performance than electric scooters based on batteries

Fuelled byrenewable hydrogen

HYCHAIN MINITRANS – Scooter

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Shorter recharging time than a conventional electrical systems

Municipal Maintenance ServicesMunicipal Maintenance Services(e.g. garbage disposal, green spaces, cleaning)(e.g. garbage disposal, green spaces, cleaning)

Public Urban transport ; Private companies of transportPublic Urban transport ; Private companies of transport

Air Liquide (France)4 x 20 litres @ 300 barsVEM (Italy)Integration

Axane (France)3 kW Fuel cell systemVEM (Italy)Base vehicle

Lighter weighted and larger filling capacity than similar electrical vehicle with batteries

No emissions

Light maintenance

Detachable generator forauxiliary mobile poweror as range extender,more than 30% increased range

HYCHAIN MINITRANS – Utility Vehicle

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Can use exclusively renewable energies

Public transport, historical areas, natPublic transport, historical areas, naturaural parks, university l parks, university campus, industrial areas, airports, commercial centers, campus, industrial areas, airports, commercial centers, ……

Dynetek (Germany)5.8 kg @ 200 bar H2 StorageHydrogenics (Germany)Electronic and integration

Hydrogenics (Germany)10 kW Fuel CellTecnobus (Italy)Electric Midibus

Hybrid propulsion, cleaner than Diesel

Increased autonomy > 200 km(current standard lead acid battery only 60-80 km)

HYCHAIN MINITRANS – Midi bus

Low recharging time(less than 5 min)

No emissions

Light maintenance

Hybrid propulsion, improved performance over battery only version

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Rationale: small vs. large vehicles

Concept:Start modest scaleKeep it simpleIterate Scale up

Low costsFC size (kW) is proportional to cost, therefore Lower capital investment, minimized financial risk for partners and participantsLow H2 consumption, minimized operation costs Large fleet sizes of smaller vehicles more easily affordable than large

• Large fleets can accelerate the proving of MTBF and fleet issues more quickly than small

Fast progress• More readily available components on the

market (large components tend to need customization)

Similar learningLearning is comparable with small systems as with large

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Fuel Cells in the Community

Optimize existing prototypesObtain necessary certifications

Set up limited series productionSet up H2 infrastructures

Gain fleet field testing dataObtain public acceptance

Kick start business models

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CUTE Congress Hamburg

For the enthusiasts of Fuel Cell Buses largely attending the CUTE conference, a little more about the midi bus portion of theHYCHAIN project…

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Chosen Bus Platform

Modest Scale: “Midi-Bus”Introduce fuel cell to a bus which is already standard electricMinimize modifications to the base bus design

Selected the “Gulliver” (a.k.a. “Oreos 22” in France)manufactured by TECNOBUS s.p.a., Italy

Urban transit bus5.3 m in length6000 kg gross vehicle weightLow speed classification, 25 kW electric motor power22 passengers

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Impressions of the Gulliver

Inner city / pedestrian zone View inside, loaded

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Midi Bus Applications

Historical and environmentally sensitive town centers (narrow or curved roadways, pedestrian zones)“Hyper-center” routes with service including along pedestrian zonesFeeder lines or “Complementary urban transport”, or “Proximity”service for already established transit routesIndustrial, Academic or Hospital CampusesNature parks, Health resortsAirports (crew shuttles, small jet passenger shuttles) Fairgrounds transit, Event VIP shuttlesResidential neighborhoods

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example Midi bus Service

“Stop on Demand” (“Blue Line”)Loop, 3-6 kmNo defined schedule, frequency every 6-12 minutes, average 10 minutesAverage waiting time: 5 minutesStops Blue Line (just wave!)Tariff free for demonstration, or with valid pass card or pre-purchased ticket

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System architecture and energy flow

ENERGY FLOWS FROM STACK TO WHEELS

FUEL CELL SYSTEMAUXILIARIES

air systemwater management

DC / DCCONVERTER

37V - 57V / 72V

Stack37V - 57V

12kW

100%

Air

H2

TRACTION BATTERY PACK 72V

45%

DC / DC CONVERTER

72V / 12V

VEHICLE AUXILIARIES 12V

D.C. MOTOR TRANSMISSION

36%

WHEELS

Tank Compartment

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DC/DC-Converter

HyPM10 H2-Storage

Radiator

First Prototype - Integration and Main Components

Planning Execution

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> 45 % (including DC converter, before batteries)Fuel Cell system average efficiency (expected)

Average < 2.5 kg/100 km (standard drive cycle)H2 Consumption

25 kWPeak Power demand

implementedRegenerative breaking capability

Existing DC Drive Motor

ca. 1 h without fuel cell (standard drive cycle)Autonomy

125 AhCapacity

72 VVoltage

Hybrid System Energy Storage (NiCad Battery Pack)

> 200 km (standard drive cycle)Autonomy

5.8 kg (2 composite tanks of 2.9 kg each)Hydrogen quantity

200 barPressure

Compressed Gas Hydrogen Storage

95 kg, dryFC module mass

De-ionized waterCoolant

65 °CStack operating temperature

≤ 20 kPa, gaugeStack operating pressure

400 to 710 kPa, gaugeGas supply pressure

56 % (LHV basis, excluding radiator fan)Fuel Cell module peak efficiency

13 kW (software limit to 11 kW in Midi bus)Peak Power

10 kWRated continuous power

Fuel Cell System

FC-Hybrid System – Details - 1st Prototype

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On behalf of the HYCHAIN Group…

Thank you for your attention in Hamburg…

The project partners and participants gratefully acknowledge thesupport of the European Commission and the Regions and Municipalities involved.