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Title: Final Report: Mass Production Cost Estimation of Direct H2 PEM Fuel Cell Systems for Transportation Applications (2012-2016)

Abstract

This report summarizes project activities for Strategic Analysis, Inc. (SA) Contract Number DE-EE0005236 to the U.S. Department of Energy titled “Transportation Fuel Cell System Cost Assessment”. The project defined and projected the mass production costs of direct hydrogen Proton Exchange Membrane fuel cell power systems for light-duty vehicles (automobiles) and 40-foot transit buses. In each year of the five-year contract, the fuel cell power system designs and cost projections were updated to reflect technology advances. System schematics, design assumptions, manufacturing assumptions, and cost results are presented.

Authors:
ORCiD logo [1];  [1];  [1];  [1]
  1. Strategic Analysis Inc., Arlington, VA (United States)
Publication Date:
Research Org.:
Strategic Analysis Inc., Arlington, VA (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Fuel Cell Technologies Office (EE-3F)
Contributing Org.:
Argonne National Laboratory; National Renewable Energy Laboratory
OSTI Identifier:
1346414
Report Number(s):
DOE-StrategicAnalysis-5236-1
DOE Contract Number:
EE0005236
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
08 HYDROGEN; fuel cells; proton exchange membrane (PEM) fuel cells; transportation fuel cells; manufacturing cost estimation; automotive power systems; transit bus power system

Citation Formats

James, Brian David, Huya-Kouadio, Jennie Moton, Houchins, Cassidy, and DeSantis, Daniel Allen. Final Report: Mass Production Cost Estimation of Direct H2 PEM Fuel Cell Systems for Transportation Applications (2012-2016). United States: N. p., 2016. Web. doi:10.2172/1346414.
James, Brian David, Huya-Kouadio, Jennie Moton, Houchins, Cassidy, & DeSantis, Daniel Allen. Final Report: Mass Production Cost Estimation of Direct H2 PEM Fuel Cell Systems for Transportation Applications (2012-2016). United States. doi:10.2172/1346414.
James, Brian David, Huya-Kouadio, Jennie Moton, Houchins, Cassidy, and DeSantis, Daniel Allen. Thu . "Final Report: Mass Production Cost Estimation of Direct H2 PEM Fuel Cell Systems for Transportation Applications (2012-2016)". United States. doi:10.2172/1346414. https://www.osti.gov/servlets/purl/1346414.
@article{osti_1346414,
title = {Final Report: Mass Production Cost Estimation of Direct H2 PEM Fuel Cell Systems for Transportation Applications (2012-2016)},
author = {James, Brian David and Huya-Kouadio, Jennie Moton and Houchins, Cassidy and DeSantis, Daniel Allen},
abstractNote = {This report summarizes project activities for Strategic Analysis, Inc. (SA) Contract Number DE-EE0005236 to the U.S. Department of Energy titled “Transportation Fuel Cell System Cost Assessment”. The project defined and projected the mass production costs of direct hydrogen Proton Exchange Membrane fuel cell power systems for light-duty vehicles (automobiles) and 40-foot transit buses. In each year of the five-year contract, the fuel cell power system designs and cost projections were updated to reflect technology advances. System schematics, design assumptions, manufacturing assumptions, and cost results are presented.},
doi = {10.2172/1346414},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Thu Sep 01 00:00:00 EDT 2016},
month = {Thu Sep 01 00:00:00 EDT 2016}
}

Technical Report:

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  • This report is the third annual update of a comprehensive automotive fuel cell cost analysis. It contains estimates for material and manufacturing cost of complete 80 kWnet direct hydrogen proton exchange membrane fuel cell systems suitable for powering light duty automobiles.
  • This report estimates fuel cell system cost for systems produced in the years 2006, 2010, and 2015, and is the second annual update of a comprehensive automotive fuel cell cost analysis.
  • This report estimates fuel cell system cost for systems produced in the years 2007, 2010, and 2015, and is the first annual update of a comprehensive automotive fuel cell cost analysis.
  • This report is the fourth annual update of a comprehensive automotive fuel cell cost analysis. It contains estimates for material and manufacturing costs of complete 80 kWnet direct-hydrogen proton exchange membrane fuel cell systems suitable for powering light-duty automobiles.
  • PEMFC technology for transportation must be competitive with internal combustion engine powertrains in a number of key metrics, including performance, life, reliability, and cost. Demonstration of PEMFC cost competitiveness has its own challenges because the technology has not been applied to high volume automotive markets. The key stack materials including membranes, electrodes, bipolar plates, and gas diffusion layers have not been produced in automotive volumes to the exacting quality requirements that will be needed for high stack yields and to the evolving property specifications of high performance automotive stacks. Additionally, balance-of-plant components for air, water, and thermal management are beingmore » developed to meet the unique requirements of fuel cell systems. To address the question of whether fuel cells will be cost competitive in automotive markets, the DOE has funded this project to assess the high volume production cost of PEM fuel cell systems. In this report a historical perspective of our efforts in assessment of PEMFC cost for DOE is provided along with a more in-depth assessment of the cost of compressed hydrogen storage is provided. Additionally, the hydrogen storage costs were incorporated into a system cost update for 2004. Assessment of cost involves understanding not only material and production costs, but also critical performance metrics, i.e., stack power density and associated catalyst loadings that scale the system components. We will discuss the factors influencing the selection of the system specification (i.e., efficiency, reformate versus direct hydrogen, and power output) and how these have evolved over time. The reported costs reflect internal estimates and feedback from component developers and the car companies. Uncertainty in the cost projection was addressed through sensitivity analyses.« less