System Cost Reduction and Subcomponent Performance Enhancement David L. Wood III Fuel cell electric vehicles (FCEVs) powered by proton-exchange membrane fuel cells (PEFC) and fueled by hydrogen offer the promise of zero emissions with excellent driving range of 300-400 miles and fast refueling times of less than five minutes; two major advantages over battery electric vehicles (BEVs). FCEVs face several remaining major challenges in order to achieve widespread and rapid commercialization. Many of the challenges, especially those from an FCEV system and subsystem cost and performance perspective are addressed in this book. Chapter topics include: His industrial and academic career began in 1995. He was employed by General Motors Corporation and SGL Carbon Group in applied research and development related to automotive and stationary protonexchange fuel cell (PEFC) technology. Later work at Los Alamos National Laboratory (LANL) and Cabot Corporation, focused on elucidation of key chemical degradation mechanisms, development of accelerated testing methods, and component development. Wood III impact of FCEV commercialization new hydrogen infrastructure cost comparisons stack bipolar plate corrosion protective coatings onboard chemical hydride storage new hydrogen sensors simulation of onboard hydrogen storage strategies vehicle air supply systems FCEV energy management optimization of hybrid FCEV powertrains About the Editor David Wood III, is Senior Staff Scientist, Roll-to-Roll Manufacturing Team Lead, Fuel Cell Technologies Program Manager, and UT Bredesen Center Faculty Member at Oak Ridge National Laboratory (ORNL) researching novel electrode architectures, advanced processing methods, manufacturing science, and materials characterization for lithium ion batteries and low-temperature fuel cells. He manages programs and financial operations on hydrogen infrastructure issues, polymer electrolyte fuel cells, and lithium ion batteries. He has been employed at ORNL since 2009. Impacting Rapid Hydrogen Fuel Cell Electric Vehicle Commercialization System Cost Reduction and Subcomponent Performance Enhancement Impacting Rapid Hydrogen Fuel Cell Electric Vehicle Commercialization AUTOMOTIVE Impacting Rapid Hydrogen Fuel Cell Electric Vehicle Commercialization System Cost Reduction and Subcomponent Performance Enhancement TU-001 ISBN: 978-0-7680-8256-2 David L. Wood III 9 P151631_fuel_cells_TU_cover.indd 1 780768 082562 2/15/16 3:11 PM
Preface...xi Introduction: Impacting Rapid Hydrogen Fuel Cell Electric Vehicle (FCEV) Commercialization...xiii Chapter 1: Disruption as a Strategy: Technology Leadership Brief...1 Drivers of Change...1 Obstacles...1 Disruptive Effects of an Automaker Forcing Infrastructure...2 Results...3 Summary and Conclusions...4 References...5 Acknowledgments...5 Chapter 2: Retail Infrastructure Costs Comparison for Hydrogen and Electricity for Light-Duty Vehicles... 7 Methods...9 Number of Hydrogen Stations by Size...11 Number of EVSE Stations by Type...11 Hydrogen Station Costs...13 EVSE Station Costs...14 Results...15 Total Capital Costs per City and Capital Costs per Mile Traveled...15 Total Fuel Costs per Vehicle Mile...19 Discussion: Variability of Results...20 Conclusion...24 Acknowledgments...24 References...24 Appendix...26 EVSE Station Cost...26 A1 Cost Estimates for Level 1 Residential EVSE...26 A2 Cost Estimates for Level 2 Residential EVSE...28 A3 Cost Estimates for Level 2 Commercial...30 A4 Cost Estimates for DC Fast Charge (DCFC)...32 v
vi Chapter 3: Nanometers Layered Conductive Carbon Coating on 316L Stainless Steel as Bipolar Plates for More Economical Automotive PEMFC...35 Experimental...36 Results and Discussion...38 Surface Morphology and Phase Structure...38 AFM and ICR Properties...42 Summary and Conclusions...44 References...45 Acknowledgments...47 Chapter 4: Chemical Hydrides for Hydrogen Storage in Fuel Cell Applications...49 Chemical Hydride Materials...51 Modeling Solid AB Reactor Systems...52 Solid AB Flow Through Reactor (Auger) Design...53 Solid AB Fixed Bed Reactor...56 Modeling Fluid AB Reactor Systems...58 Slurry Reactor...58 Solvated AB Reactor...59 Summary and Conclusions...62 References...62 Acknowledgments...64 Chapter 5: Hydrogen Sensors for Automotive Fuel Cell Applications...65 Automotive Hydrogen Technology and Hydrogen Sensor Safety...66 Hydrogen Sensors in the Vehicle...67 Measuring Hydrogen Automotive Sensor Specification...68 Typical Environmental Load...69 Operating Principle for Hydrogen Detection...70 Typical Challenges in the Measuring Device...71 Change of the Thermal Budget Over Time Positive/ Negative Drift...72 Delamination of Sensor Chip Surface Coating...74 Embrittlement of Surface Coating...76 Kirkendall-Effect at the Bond Pads...77 Present and Future Hydrogen Sensor Development...79 Summary and Conclusions...79 References...80 Acknowledgments...81
Chapter 6: Development of a Vehicle-Level Simulation Model for Evaluating the Trade-off between Various Advanced On-board Hydrogen Storage Technologies for Fuel Cell Vehicles...83 Vehicle Model: HSSIM...84 Fuel Cell Model...88 Model Framework...89 Model Application...91 Conclusions...96 References...97 Acknowledgments...98 Chapter 7: Air Supply System for Automotive Fuel Cell Application...99 Fuel Cell System...100 Air Supply System for Fuel Cell...104 Previous Generation Air Supply System...105 Current Generation Air Supply System...107 Future Generation Air Supply System...110 Comparison of the Three Generations of Air Supply Systems...113 Summary and Conclusions...114 References...115 Acknowledgments...115 Chapter 8: Hybrid Electric System for a Hydrogen Fuel Cell Vehicle and Its Energy Management... 117 Description of the Vehicle...118 Dimensioning of the Powertrain...119 Dimensioning of the Sources...120 Fuel Cell and Battery Models...121 Fuel Cell...121 Battery...122 Energy Management...123 Global Optimization...124 Global Optimization Results...126 Local Optimization...128 Local Optimization Results...130 Conclusion...132 References...132 vii
Chapter 9: Control System for Sensing the Differential Pressure between Air and Hydrogen in a Polymer Electrolyte Fuel Cell (PEFC)...135 System Configuration [9-2]...136 Cathode...137 Anode...137 Modeling of Air Supply System...138 Modeling of Air Supply System [9-2], [9-3], ]9-4]...138 Flow Characteristics around Orifice [9-4]...139 Linearization of Mass Flow Rate around Orifice [9-4]...140 Pressure Dynamics [9-4]...140 Derivation of Linear Model of Air Supply System [9-2], [9-3]...140 Design of Continuous Sliding Mode Control System [9-2], [9-3]...143 Preparation for Configuring Hydrogen/Air Pressure Control System [9-2]...144 Transfer Function from Reference Value to Plant Output in a 2 DOF Control System Using a Minimal Order Observer...144 Application to a Sliding Mode Servo Control System with a Minimal Order Observer..............................145 Configuration of Differential Pressure Control System...146 The Case of Increasing Pressure [9-2]...147 The Case of Air Pressure Displays Higher Response under a Condition of Decreasing Pressure [9-2]...148 The Case of Hydrogen Pressure Displays Higher Response under a Condition of Decreasing Pressure [9-2]...149 Configuration of the System for Controlling the Hydrogen-Air Pressure Difference within a Specified Range...149 Experimental and Simulation Results...150 Conclusion...150 References...150 Chapter 10: Multi-Objective Optimization of Fuel Cell Hybrid Vehicle Powertrain Design Cost and Energy...153 Methodology...154 Case Study...155 PHEV and HEV Single-Objective Optimization...159 PHEV and HEV Multi-Objective Optimization...161 viii
Results and Discussion...164 HEV-FC...164 PHEV-FC...167 Summary and Conclusions...172 References...172 Acknowledgments...174 Appendix...175 About the Editor...177 ix