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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)
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. 2016. "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 = 2016,
month = 9
}

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.
  • In partial fulfillment of the Department of Energy (DOE) Contract No. DE-AC02-94CE50389, {open_quotes}Direct-Hydrogen-Fueled Proton-Exchange-Membrane (PEM) Fuel Cell for Transportation Applications{close_quotes}, this preliminary report addresses the conceptual design and packaging of a fuel cell-only powered vehicle. Three classes of vehicles are considered in this design and packaging exercise, the Aspire representing the small vehicle class, the Taurus or Aluminum Intensive Vehicle (AIV) Sable representing the mid-size vehicle and the E-150 Econoline representing the van-size class. A fuel cell system spreadsheet model and Ford`s Corporate Vehicle Simulation Program (CVSP) were utilized to determine the size and the weight of the fuel cellmore » required to power a particular size vehicle. The fuel cell power system must meet the required performance criteria for each vehicle. In this vehicle design and packaging exercise, the following assumptions were made: fuel cell power system density of 0.33 kW/kg and 0.33 kg/liter, platinum catalyst loading less than or equal to 0.25 mg/cm{sup 2} total and hydrogen tanks containing gaseous hydrogen under 340 atm (5000 psia) pressure. The fuel cell power system includes gas conditioning, thermal management, humidity control, and blowers or compressors, where appropriate. This conceptual design of a fuel cell-only powered vehicle will help in the determination of the propulsion system requirements for a vehicle powered by a PEMFC engine in lieu of the internal combustion (IC) engine. Only basic performance level requirements are considered for the three classes of vehicles in this report. Each vehicle will contain one or more hydrogen storage tanks and hydrogen fuel for 560 km (350 mi) driving range. Under these circumstances, the packaging of a fuel cell-only powered vehicle is increasingly difficult as the vehicle size diminishes.« less