Fuel Cell Range-Extended Electric Van Case Study

Case Study Fuel cell power systems

Intelligent Energy led a technology integration project

to develop zero-emission, fuel cell range-extended

electric vans for the light duty vehicle market. The project

delivered the technical and economic feasibility of bringing

a range-extended zero emission solution to market via the

integration of Intelligent Energy’s high-efficiency, air-cooled

PEM fuel cells into an existing electric vehicle. A range

extended zero emissions solution has the advantage of

offering extended operational range and fast refuelling,

whilst retaining the advantages of zero emissions and near

silent operation.

Utilising a base electric vehicle powered by a factory-fitted

electric driveline, Intelligent Energy’s hydrogen fuel cell

provides power to recharge the battery, or support the

vehicle’s auxiliary loads. This significantly increased the

range of the battery-only base electric vehicle from

approximately 170km to over 300km.

Developed with direct input from fleet operators,

the fuel cell electric van is capable of extending

continuous operation, improving productivity

and reducing the daily dependency on lengthy

downtime for battery charging.

© Intelligent Energy Limited 2015. All Rights Reserved. The Intelligent Energy name, logo, and other trade brands/names referenced herein are trademarks or registered trademarks of Intelligent Energy Ltd or its group companies. Disclaimer: The information contained in this publication is intended only as a guide and is subject to change as a result of the constant evolution of the Intelligent Energy’s business and its technology. This publication and its contents (i) are not definitive or contractually binding; (ii) do not include all details which may be relevant to particular circumstances; and (iii) should not be regarded as being a complete source of information. To the fullest extent permitted by law, Intelligent Energy offers no warranty as to the accuracy of the content of this publication, shall not be liable for the content of this publication and no element of this publication shall form the basis of any contractual relationship with a third party or be used by any third party as the basis for its decision to enter into a contractual relationship with Intelligent Energy. Published by: Intelligent Energy Ltd, Charnwood Building, Holywell Park, Ashby Road, Loughborough LE11 3GB (Registered in England with company number: 03958217). Printed April 2016. (43498)

Fuel Cell Range Extended Electric Vehicle (REEV) System Specification

Technology Air Cooled (AC) Proton Exchange

Membrane (PEM) Fuel Cell

Performance Rated net power 7.8kW

Output voltage 70V – 150V

Rated current 150A

Emissions Water vapour

Fuel Composition Gaseous hydrogen to ISO14687:2 Grade D

Supply pressure 0.45bar.g

Fuel consumption Less than 90 slpm at rated power

Fuel storage 1.8kg at 35MPa

Refuelling time Less than 5 minutes

Environmental Storage temperature -40ºC to +85ºC

Operational temperature 0ºC to +30ºC nominal

(wider envelope with de-rated performance)

Altitude 0 to 1000m

Physical Mass 44kg

Volume 100L

Additional sub-systems Hydrogen storage DC/DC converter

Powertrain Specification

Powertrain Fuel cell and high voltage battery hybrid coupled to

electric driveline

Motor power 80kW AC synchronous motor

Motor torque 254Nm

Battery 24kWh Li-ion

Vehicle Specification

Payload volume 3.7m3

Payload mass 670kg

CO2 emissions 0g/km

Range > 300km (NEDC)

+44 (0) 1509 271 271 sales@intelligent-energy.com intelligent-energy.com

Key benefits of Fuel Cell Electric Delivery Vans

• Zero tailpipe emissions

• Significantly increased range compared

to battery-only alternative

• Similar refuelling time to a conventional

diesel vehicle, so less than 5 minutes

• Quiet operation

• Retain payload space

Key benefits of Intelligent Energy’s

Fuel Cells Systems

• High system efficiency

• Continuous system health monitoring

and predictive servicing

• CAN control interface

• Low-cost and power-dense fuel cell design

with robust metal construction

• Reduced balance-of-plant components with

no requirement for pre-stack humidification

• Modular system design with integration flexibility

• Transferrable powertrain technology suitable

for a variety of motive applications