hydrogen fuel cell performance in the key early markets of ... · nrel is a national laboratory of...

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

Hydrogen Fuel Cell Performance in the Key Early Markets of Material Handling Equipment and Backup Power

2013 Fuel Cell Seminar and Energy Exposition Jennifer Kurtz, Sam Sprik, Todd Ramsden, Genevieve Saur, Chris Ainscough, Matt Post, Mike Peters

October 23, 2013 Columbus, Ohio

NREL/PR-5400-60865

2

www.nrel.gov/hydrogen/proj_tech_validation.html

NFCTEC Analysis Approach

National Fuel Cell Technology Evaluation Center

NFCTEC

Analysis and reporting of real-world operation data

3

Objectives

Assess technology o Perform independent technology assessment in real world operation conditions o Focus on fuel cell system and hydrogen infrastructure: performance, operation, and

safety o Leverage data processing and analysis capabilities developed under the fuel cell vehicle

Learning Demonstration project o Evaluate material handling equipment (MHE) and backup power o Analysis includes up to 1,000 fuel cell systems deployed with American Recovery and

Reinvestment Act (ARRA) funds

Support market growth o Provide analyses and results relevant to the markets value proposition o Report on technology status to fuel cell and hydrogen communities and other key

stakeholders such as end users

Assess the technology status in real world operations, establish performance baselines, report on fuel cell and hydrogen

technology, and support market growth by evaluating performance relevant to the markets value proposition

4

28 Backup Power CDPsCount and Category

Infra. Operation (6)

Fuel Cell Operation (5, 7, 8, 9, 11, 12, 13,

15, 16, 17, 21)

0 1 2 3 4 5 6 7 8 9 10 11 120

10

20

30

40

50

60

Average Run Hours Per Month

Perc

ent o

f Sys

tem

s

Monthly Run Time

NREL cdp_bu_16

Created: Apr-02-13 2:43 PM | Data Range: 2009Q3-2012Q4

0 0.5 1 1.5 2 2.5 3 3.5 4 4.50

10

20

30

40

50

60

70

80

Average Starts Per Month

Perc

ent o

f Sys

tem

s

Average Starts Per Month

NREL cdp_bu_17


0 100 200 300 400 500 600 700 800 9000

10

20

30

40

50

60

70System Operation Hours vs. Calendar Days

Calendar Days

Ope

ratin

g H

ours

NREL cdp_bu_21


Ten P

ercen

t Use

Line

Five Perc

ent Use L

ine

Calendar Days = span from first to last use

Fuel Cell Reliability (4, 10)

< 1%

Start Reliability

EStop: 1

No Fuel: 2

System Failure: 5

NREL cdp_bu_10

Created: Apr-03-13 11:21 AM | Data Range: 2009Q3-2012Q4

1788 out of 1796 successful starts

99.6 %

8 failed operations

Unsuccessful Operation Categories

Deployment (1, 2, 3, 14, 19)

FC Unit Locations - Backup Power

0

25

50

75

100

125

Backup Power (393 Sites and 817 FC Units)NREL cdp_bu_19


Number of FCUnits in

State/Site U.S. Grid Outage Stats (18, 20)

0 10 20 30 40 50 60 70 80 90

Median Demonstrated^2

Average Demonstrated^2

Max Demonstrated^2

Median Grid Outage^1

Average Grid Outage^1

Average Hurricane^1

Hours

Continuous System Run Time

Durations demonstrated from ARRA project data

65.5 hours

0.3 hours

0.8 hours

38.5 hours

7.3 hours

86.5 hoursSandy 142.5 hoursIrene 55.5 hoursIsaac 61.4 hours

NREL cdp_bu_18


1) Grid data from Electric Disturbance Event (OE-417) Annual Summaries 2002-20122) Fuel cell operations less than 5 minutes apart have been combined to address intermittent operation. 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 20120

50

100

150

200

250

300

350

23

61

93 85 91 78

149

97

123

307

196

Num

ber o

f Inc

iden

ts

Year

2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 15

20

25

30

35

40

45

50

55

60

Out

age

time

(hr)

Power Outages1 (2002-2012)

Average number of outages per year = 118Average outage time = 42 hours

Number of OutagesAverage Time per Outage

NREL cdp_bu_20


1) Grid data from Electric Disturbance Event (OE-417) Annual Summaries 2002-2012

Cost of Ownership (22, 23, 24, 25, 26, 27,

28)

5

Backup Power Operation Summary 2009 Q12013 Q2

Systems in operation*

Successful starts

Average site capacity in kW

Continuous run hours demonstrated

Start attempts

*Not all systems have detailed data reporting to NREL

Installed capacity in MW

Operation hours

Systems are operating reliably in 23 states. Reasons for unsuccessful starts include an e-stop signal, no fuel, and other system failures.

0

25

50

75

100

125

Number of FCUnits in

State/Site

6

Backup Power Fuel Cell Systems Deployed

0

100

200

300

400

500

600

700

800

900

10 14 14 31 44

204 232

357

494

625 649 658702

807 830 836 842

Backup Power Fuel Cell Systems Deployed

2009

Q3

2009

Q4

2010

Q1

2010

Q2

2010

Q3

2010

Q4

2011

Q1

2011

Q2

2011

Q3

2011

Q4

2012

Q1

2012

Q2

2012

Q3

2012

Q4

2013

Q1

2013

Q2

2013

Q3

Cum

ulat

ive

Syst

ems

1,2

Dep

loye

d

NREL cdp_bu_01

Created: Sep-27-13 1:42 PM | Data Range: 2009Q3-2013Q3 1) Sites may have more than one FC system2) Not all FC systems are supplying operation data

7

Annualized Cost by Runtime

8

8-Hour Annualized Cost of Ownership

9

Analysis of Fuel Cell Backup Power Operation with U.S. Grid Outage from 01/2010 through 08/2013

10

74 MHE CDPsCount and Category

Deployment & Site Overview (1, 40)

Fuel Cell Operation (2, 7, 8, 11, 15,

16, 17, 23, 24, 63) Fuel Cell Reliability (28, 29, 30, 31)

Fuel Cell Safety (26, 27, 53, 56, 57)

Infra. Safety (25, 41, 46, 51, 55)

Infra. Reliability (45, 48, 49, 50)

FC Maintenance (12, 13, 14, 43, 54, 61)

(1) Total cost represents the annualized cost of ownership of Class I, II, and III forklifts on a net present value basis, accounting for capital, operating, and maintenance costs of forklifts, power packs, and infrastructure (labor costs for maintenance and for charging or fueling are included, but labor costs of forklift material handling operations are excluded). Costs are calculated assuming that the material handling operations are ongoing, with equipment replacements made as necessary. Capital, operating, and maintenance costs are assumed toremain constant in real-dollar terms, and capital purchases are discounted using a discount rate representing the time value of money. Fuel cell system costs reflect the current fuel cell tax credit of $3,000/kW or 30% of purchase price. Analysis does not consider the potential productivity increases resulting from the constant power output of fuel cell systems, which may be significant. Costs of ownership of Class II forklifts are expected to be similar for Class I forklifts, though the cost of the lift itself is expected to be higher.

Costs are based on information provided by deployment host partners (end-users) based on a questionnaire developed by NREL, supplemented with data provided by project partners, and are reflective of the material handling operations of these deployments. Where appropriate, fuel cell deployment data were used in place of end-user questionnaire data; in particular, data from CDPs 1, 6, 8, 14, and 22 were used. Cost assessment will be further refined as additional data are available.

Total Cost of Ownership for Class I, II & III Forklifts1

Cost of Ownership (58, 59, 60,64)

Total Cost of Ownership Sensitivity Analysis1

(1) Total cost represents the annualized cost of ownership of Class I, II, and III forklifts on a net present value basis. Fuel cell system costs reflect the current fuel cell tax credit of $3,000/kW or 30% of purchase price. Costs are based on information provided by deployment host partners based on a questionnaire developed by NREL, supplemented with additional data provided by project partners, and are reflective of the material handling operations of these deployments. Where appropriate, fuel cell deployment data were used in place of end-user questionnaire data; in particular, data from CDPs 1, 6, 8, 14, and 22 were used.

Sensitivity analysis shows the ranges in annual per lift cost of ownership resulting from varying key parameters affecting battery and fuel cell forklift cost.

Fuel Cell Durability (32, 33, 34, 38, 39, 73)

< 10000 hours > 10000 hours 0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%Fuel Cell Stacks Projected Hours to 10% Voltage Degradation

Projected Hours to 10% Voltage Degradation 1,3

FC S

tack

s [%

]

In ServiceNot In Service2

NREL cdp_mhe_97


1) Projection using field data, calculated at high stack current, from operation hour 0. Projected hours may differ from an OEM's end-of-life criterion and does not address "catastrophic" failure modes.2) Indicates stacks that are no longer accumulating hours either a) temporarily or b) have been retired for non- stack performance related issues or c) removed from DOE program.3) Projected hours limited based on demonstrated hours.

0 10 20 30 40 50 600

1

2

3

4

5

6

7

8

9

10

Amount Fueled in an Hour [kg]

Freq

uenc

y [%

of t

otal

]

Hydrogen Dispensed Per Hour - ARRA

NREL cdparra_mhe_69


Average: 4.8 kgs per hourMedian: 3.5 kgs per hourMax: 52.5 kgs per hour

Infra. Operation (3, 4, 5, 6, 9, 10, 21, 22, 35,

37, 42, 62, 65, 68, 69, 70, 71)

1 2 3 4 5 6 7 80

10

20

30

40

50

60

70

80

90

100

Station (Sorted By Increasing Max Daily Amount)

Cap

acity

Util

izat

ion

2 [%

]

Station Capacity Utilization

Max Daily20 kg

Max Daily25 kg

Max Daily64 kg

Max Daily99 kg

Max Daily102 kg

Max Daily135 kg

Max Daily293 kg

Max Daily358 kg

42.9%

Average Daily Utilization1

Maximum Daily Utilization

NREL cdparra_mhe_71NREL cdparra_mhe_71


1Maximum quarterly utilization considers all days; average daily utilization considers only days when at least one filling occurred2100% represents maximum daily amount dispensed for each individual site

1 2 3 4 5 6 7 80

50

100

150

200

250


Fills

Per

Day

Station Usage

Maximum Daily Fills

Average Daily Fills1

NREL cdparra_mhe_70


1Average daily fills considers only days when at least one fill occurred

0 5 10 15 20 25 30 35 40 450

2

4

6

8

10

12

Number of Fuelings in an Hour

Freq

uenc

y [%

of t

otal

]

Number of Fuelings Per Hour - ARRA

NREL cdparra_mhe_68


Average: 7.3 per hourMedian: 5.0 per hourMax: 39.0 per hour

11

MHE Operation Summary 2009 Q42013 Q2

Units in operation*

Hydrogen fills

Hydrogen dispensed in kg

Operation hours

Average operation hours between fills

Average fill amount in kg

Average fill time in minutes *One project has completed

Validation of MHE is based on real-world operation data from high-use facilities

12

Study of FC Voltage Degradation Against 10,000 Hours

< 10000 hours > 10000 hours 0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%Fuel Cell Stacks Projected Hours to 10% Voltage Degradation

Projected Hours to 10% Voltage Degradation 1,3

FC S

tack

s [%

]

In ServiceNot In Service2

NREL cdp_mhe_97

Created: Sep-28-13 12:46 PM | Data Range: 2009Q1-2013Q2

1) Projection using field data, calculated at high stack current, from operation hour 0. Projected hours may differ from an OEM's end-of-life criterion and does not address "catastrophic" failure modes.2) Indicates stacks that are no longer accumulating hours either a) temporarily or b) have been retired for non- stack performance related issues or c) removed from DOE program.3) Projected hours limited based on demonstrated hours.

More than 50% of stacks have projected hours to 10% voltage degradation >10,000 hours.

13

Study of Infrastructure Usage by Daily Fills

1 2 3 4 5 6 7 80

50

100

150

200

250


Fills

Per

Day

Station Usage

Maximum Daily Fills

Average Daily Fills1

NREL cdparra_mhe_70

Created: Sep-26-13 10:20 AM | Data Range: 2009Q4-2013Q2

1Average daily fills considers only days when at least one fill occurred

The maximum daily fill count for two sites was >200 fills. Those two sites average nearly 100 fills per day.

14

0

50

100

150

200

250

AIR

SYST

EM

CONT

ROL E

LECT

RONI

CS

DISP

ENSE

R

FITTIN

GS&P

IPING

HYDR

OGEN

COM

PRES

SOR

SENS

ORS

VALV

ES

MTB

F (D

ays)

MTBF by Equipment Category: Infrastructure (Delivered H2 Only)

Median SiteLowest Site

NREL cdparra_mhe_72


Breakdown of MTBF by Key Delivered Hydrogen Infrastructure Categories

Consistent across all sites are failures with control electronics and hydrogen compressors. These two categories have low MTBF.

15

0 25 50 75 100 125 150 175 200 225 250 275 3000

1

2

3

4

5

6

7

8

9

10

Site MTBF1 (Days)

Cou

nt o

f Site

sSite MTBF (Calendar Days In Operation): Infrastructure

NREL cdp_mhe_48

Created: Sep-28-13 12:45 PM | Data Range: 2009Q1-2013Q21. Cumulative Mean Time Between Failure

Infrastructure Reliability Analysis

Infrastructure consistently delivering 250 and 350 bar fills even though the majority of the sites have a MTBF of 25 days or less

Compressor 51%

Control Electronics 20%

Dispenser 19%

Air System 10%

Delivered H2 Maintenance Count by Category 1,330 Maintenance Events

63% unscheduled

16

Breakdown of Failure Modes for Top Four Maintenance Categories for Infrastructure

0 100 200 300 400

HYDROGEN COMPRESSOR

DISPENSER

CONTROL ELECTRONICS

AIR SYSTEM

Event Count

51%*

20%*

19%*

10%*

DATA ERROR

DRIVE OFF

EXCESSIVE NOISE

FAILED CLOSED

HYDROGEN LEAK

INSPECT TROUBLE ALARM OR REPORT

LIGHTNING STRIKE

METAL FATIGUE

MOISTURE INFILTRATION

OUT OF CALIBRATION

PRESSURE LOW

REPLACE FAILED PARTS

TEMPERATURE HIGH

MISC

0 500 1000 1500 2000 2500 3000 3500

HYDROGEN COMPRESSOR

DISPENSER

CONTROL ELECTRONICS

AIR SYSTEM

Labor Hours

58%*

18%*

14%*

9%*

NREL cdp_mhe_52


Failure Modes for Top Four Infrastructure Equipment Categories

* Percentage of total events or hours, reference CDP 66.

MISC includes the following failure modes: ambient temperature too low, broken wire,cavitation, data error, debris infiltration, electrical short, failed closed, false alarm, flow

high, flow low, fluid leak non-hydrogen, fluid leak non_hydrogen, fluidleak_non_hydrogen, inspect trouble alarm or report, maintenance error, manufacturing

defect, metal fatigue, moisture infiltration, network malfunction, operator protocol, other,power outage, pressure high, pressure low, replace failed parts, software bug,

unspecified electronics failure, vandalism, voltage low, other

There are many different failure modes for the top four categories and these modes provide insight for RD&D needs

17

Technical SummaryWhat Weve Learned

Fuel Cell Backup Power Operating reliability in 23 states with

99.7% successful starts. Maximum continuous run time of 65

hours due to an unplanned grid outage.

Fuel Cell Material Handling Equipment Operating with an average availability

of ~98% at eight end-user facilities. Most systems operate at least 6 hours

a day. Cost of ownership comparison

between fuel cell and battery MHE indicate significant cost savings for refueling labor and infrastructure space but much greater cost for hydrogen infrastructure and fuel.

Aggregated data showcase performance over the last two

years in MHE and backup power.

Performance results address a need for published results on

the technology status.

Data analyses develop as systems operate and based on the key performance areas in

the markets.

Backup Slides

19

Published MHE Cost of Ownership Report

Key Findings Cost advantages dependent on

deployment size and use (i.e., multi-shift operation per day)

H2 fuel cell cost advantages in maintenance, warehouse infrastructure space, and refueling labor cost

H2 fuel cell cost disadvantages in infrastructure and fuel cell cost and hydrogen cost

Report Sections Inputs, assumptions, and results for

Class I/II and Class III Sensitivity study Intensive deployment scenario

Cost advantage per unit is ~$2,000/year for the average high-use facility with Class I and II fuel cell lift trucks analyzed by NREL

20

MHE and Infrastructure Safety Report Analyses

6%6%

88%

By Number of IncidentsTotal Incidents = 16

14%

14%

14%

14%

14%

29%

By Number of IncidentsTotal Incidents = 7

Control Electronics

Operator Protocol

Fuel System

Fittings & Piping

FC Stack

Electrical

Dispenser

Compressor Valves

Majority of MHE safety reports (217) are minor hydrogen leaks

(4,480 stack hours per report)

Majority of infrastructure safety reports (82) are hydrogen leaks primarily from the hydrogen compressor and plumbing

(3,587 kg dispensed per report)

Hydrogen Fuel Cell Performance in the Key Early Markets of Material Handling Equipment and Backup PowerNFCTEC Analysis ApproachObjectives28 Backup Power CDPsCount and CategoryBackup Power Operation Summary 2009 Q12013 Q2Backup Power Fuel Cell Systems DeployedAnnualized Cost by Runtime8-Hour Annualized Cost of OwnershipAnalysis of Fuel Cell Backup Power Operation with U.S. Grid Outage from 01/2010 through 08/201374 MHE CDPsCount and CategoryMHE Operation Summary 2009 Q42013 Q2Study of FC Voltage Degradation Against 10,000 HoursStudy of Infrastructure Usage by Daily FillsBreakdown of MTBF by Key Delivered Hydrogen Infrastructure Categories Infrastructure Reliability AnalysisBreakdown of Failure Modes for Top Four Maintenance Categories for InfrastructureTechnical SummaryWhat Weve LearnedBackup SlidesPublished MHE Cost of Ownership ReportMHE and Infrastructure Safety Report Analyses

/ColorConversionStrategy /LeaveColorUnchanged /ColorImageAutoFilterStrategy /JPEG /ColorImageDepth -1 /ColorImageDict > /ColorImageDownsampleThreshold 1.50000 /ColorImageDownsampleType /Bicubic /ColorImageFilter /DCTEncode /ColorImageMinDownsampleDepth 1 /ColorImageMinResolution 150 /ColorImageMinResolutionPolicy /OK /ColorImageResolution 150 /ColorSettingsFile () /CompatibilityLevel 1.7 /CompressObjects /Tags /CompressPages true /ConvertImagesToIndexed true /CreateJDFFile false /CreateJobTicket false /CropColorImages false /CropGrayImages false /CropMonoImages false /DSCReportingLevel 0 /DefaultRenderingIntent /Default /Description > /DetectBlends true /DetectCurves 0.10000 /DoThumbnails false /DownsampleColorImages true /DownsampleGrayImages true /DownsampleMonoImages true /EmbedAllFonts true /EmbedJobOptions true /EmbedOpenType false /EmitDSCWarnings false /EncodeColorImages true /EncodeGrayImages true /EncodeMonoImages true /EndPage -1 /GrayACSImageDict > /GrayImageAutoFilterStrategy /JPEG /GrayImageDepth -1 /GrayImageDict > /GrayImageDownsampleThreshold 1.50000 /GrayImageDownsampleType /Bicubic /GrayImageFilter /DCTEncode /GrayImageMinDownsampleDepth 2 /GrayImageMinResolution 150 /GrayImageMinResolutionPolicy /OK /GrayImageResolution 150 /ImageMemory 1048576 /JPEG2000ColorACSImageDict > /JPEG2000ColorImageDict > /JPEG2000GrayACSImageDict > /JPEG2000GrayImageDict > /LockDistillerParams false /MaxSubsetPct 100 /MonoImageDepth -1 /MonoImageDict > /MonoImageDownsampleThreshold 1.50000 /MonoImageDownsampleType /Bicubic /MonoImageFilter /CCITTFaxEncode /MonoImageMinResolution 1200 /MonoImageMinResolutionPolicy /OK /MonoImageResolution 1200 /Namespace [ (Adobe) (Common) (1.0) ] /NeverEmbed [ true ] /OPM 1 /Optimize true /OtherNamespaces [ > > /FormElements true /GenerateStructure true /IncludeBookmarks true /IncludeHyperlinks true /IncludeInteractive true /IncludeLayers false /IncludeProfiles true /MarksOffset 6 /MarksWeight 0.25000 /MultimediaHandling /UseObjectSettings /Namespace [ (Adobe) (CreativeSuite) (2.0) ] /PDFXOutputIntentProfileSelector /UseName /PageMarksFile /RomanDefault /PreserveEditing true /UntaggedCMYKHandling /LeaveUntagged /UntaggedRGBHandling /LeaveUntagged /UseDocumentBleed false >> ] /PDFX1aCheck false /PDFX3Check false /PDFXBleedBoxToTrimBoxOffset [ 0 0 0 0 ] /PDFXCompliantPDFOnly false /PDFXNoTrimBoxError true /PDFXOutputCondition () /PDFXOutputConditionIdentifier (CGATS TR 001) /PDFXOutputIntentProfile (U.S. Web Coated \050SWOP\051 v2) /PDFXRegistryName (http://www.color.org) /PDFXSetBleedBoxToMediaBox true /PDFXTrapped /False /PDFXTrimBoxToMediaBoxOffset [ 0 0 0 0 ] /ParseDSCComments true /ParseDSCCommentsForDocInfo true /ParseICCProfilesInComments true /PassThroughJPEGImages true /PreserveCopyPage true /PreserveDICMYKValues true /PreserveEPSInfo false /PreserveFlatness false /PreserveHalftoneInfo false /PreserveOPIComments false /PreserveOverprintSettings true /StartPage 1 /SubsetFonts true /TransferFunctionInfo /Apply /UCRandBGInfo /Remove /UsePrologue false /sRGBProfile (sRGB IEC61966-2.1)>> setdistillerparams> setpagedevice

hydrogen fuel cell performance in the key early markets of ... · nrel is a national laboratory of...

Documents