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DaimlerChrysler Readying 2nd-Generation F-Cell Test Vehicle; Targeting 2012-2015 for Commercial Intro
25 July 2006
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| The second-generation B-Class F-Cell. |
DaimlerChrysler estimates that the marketing of hydrogen fuel-cell drive systems will begin sometime between 2012 and 2015, according to a recent fuel-cell workshop held by the company in Germany.
DaimlerChrysler is thus readying its second-generation of F-Cell B-Class fuel-cell test vehicles—announced last year (earlier post)—with an eye toward the beginning of series production with that marketing timeframe in mind.
A total of 60 DaimlerChrysler A-Class vehicles with fuel-cell powertrains are currently in use worldwide, being driven by various customers at six locations in Europe, Asia and the United States.
Representing the largest fuel-cell fleet test to date, all relevant measured values are sent on a daily basis via radio and the Internet to the DaimlerChrysler researchers and developers in Nabern and Ulm.
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| The F600 HYGENIUS |
Compared to the current A-Class F-Cell, the second-generation B-Class F-Cell vehicles feature a number of improvements that are essential in order to bring the technology further toward the series-production stage and which have been installed as prototypes in the F 600 HYGENIUS research vehicle. (Earlier post.)
The most important innovations in the fuel cell drive for the F 600 HYGENIUS include:
A newly developed fuel tank that stores hydrogen at 700 bar rather than the previous 350 bar, thereby enabling the vehicle to hold four kilograms of hydrogen and travel a distance of more than 400 kilometers on one tank.
A new membrane technology for the fuel cells and a new humidification system consisting of hollow fibers. Both of these innovations allow for precise heat and water management, which means that water in liquid form no longer collects in the stack. Such water accumulations freeze in the winter and make cold starts difficult. However, the F 600 HYGENIUS starts easily even at temperatures as low as minus 25 degrees Celsius.
A new electric drive unit on the rear axle in the form of a permanently excited synchronous motor that is both smaller and more powerful than its predecessor from the F-Cell.
A lithium-ion battery that produces 30 kilowatts of power in continuous operation and 55 kilowatts at peak loads—twice the output of the nickel metal hydride batteries previously used.
New bipolar plates that are no longer made of graphite but instead consist of metal foils only 0.15 millimeters thick. The metal improves the conductivity and robustness of the fuel cells, and the thinner foils make the stack around 40% smaller than before.
A new electric turbocharger that supplies air (oxygen) to the fuel cells. This turbocharger is three times smaller and seven times lighter than the previously used screw-type compressor.
Together with other innovations, the new technology package is responsible for the improved fuel economy of the F 600 HYGENIUS, which consumes the energy equivalent of only 2.9 liters of diesel fuel per 100 kilometers. The research vehicle’s fuel cell system operates efficiently—in the partial load range, it has an efficiency rating of 60%, according to DaimlerChrysler.
A further goal of the F 600 HYGENIUS test drives is to develop an optimal operating strategy for future B-Class F-Cell vehicles. Questions explored in this research include:
Would it make sense to operate the vehicle only with the stack or only with the high-voltage battery?
Under what conditions and performance demands should the booster function be activated, whereby energy for the electric motor is supplied by both the fuel cell and the battery?
What are the best situations and points in time to shift the vehicle from one mode to the other?
In which charge stage and driving situation should the motor be used as a generator and the battery be recharged?
The stack that will be used in the B-Class F Cell and—as a double pack—in the successor model to the Citaro fuel cell bus will include a series of innovations from the F 600 HYGENIUS.
The most important technological innovations that DaimlerChrysler will take from the F 600 HYGENIUS are:
The 700-bar tanks for storing hydrogen, in order to increase the full-tank range from today’s 160 kilometers to more than 400 kilometers (249 miles).
The electric drive motor. This permanently energized synchronous motor, which stands out through its light and compact design, has a maximum power output of 85 kilowatts and achieves a maximum torque of 350 Nm.
The lithium-ion battery.
The technically simplified humidification and de-humidification system consisting of hollow fiber modules that lends second-generation stacks freeze-start capability.
The all-new fuel cell stack for the B Class F Cell also generates 40% more output and has a higher power/weight ratio.
Two other innovations from the F 600 HYGENIUS will be gradually introduced to new fuel cell fleets. First of all, the bipolar plates in the fuel cells will be made of metal foils in the future, allowing for more space-saving installation than today’s graphite plates. Secondly, a light electric compressor—rather than the heavy screw-type compressor—will be used to supply air to the stacks.
DaimlerChrysler’s H2 argument. DaimlerChrysler defined three objectives for ”sustainable mobility”:
Maximum efficiency and thus minimal energy consumption by vehicle drive systems;
Diversification of primary energy sources used for transport applications and a greater share of fuels from renewable sources in the energy mix; and
Further emission reductions (in view of the effect of greenhouse gases as well), leading to the long-term goals of zero emissions and complete CO2 neutrality.
Hydrogen has proved to be the ideal secondary energy source for achieving the above-mentioned objectives. That’s because when hydrogen is used as fuel for fuel-cell vehicles, it leads to energy efficiency in the resulting drive system that is nearly twice as high as that achieved by the most modern gasoline and diesel engines. Such fuel cell powertrains therefore offer tremendous gains in efficiency that cannot be achieved even with improved concepts for combustion engines, which DaimlerChrysler is also working on.
Even if the primary energy source and the process used to produce the hydrogen are taken into consideration, fuel-cell drives are still superior to all combustion engine concepts when it comes to emissions as well. Fuel-cell vehicles that run on pressurized hydrogen are by their very nature always zero-emission when in motion. If the hydrogen is obtained from a renewable energy source, the entire utilization chain is also free of emissions.
Petroleum’s nearly complete dominance as the primary energy source for today’s motor-vehicle fuels cannot be maintained over the long term. There are several reasons for this, including the finite nature of this fossil resource, its very high price at present (which is not expected to decrease significantly), and the fact that much of the world’s crude oil reserves are in politically unstable regions. In light of this situation, most oil-consuming countries have made it their goal to break dependence on petroleum, which is why they are increasingly demanding and supporting alternative primary energy sources for use in the production of fuels. Such sources include natural gas, wind power, and biomass.
It is very difficult to forecast the course fuel prices will take. Only two or three years ago, for example, practically no expert would have predicted that the price of crude oil would be more than $75 per barrel in 2006—at that time a barrel of crude was selling for just $25. Nevertheless, over the next few years we can expect further increases in the prices of fuels obtained from fossil energy sources; the only thing not certain is how large the increases will be.
Supplies of crude oil will also continue to dwindle, and the need to exploit lower-yielding sources of crude oil, such as oil shale and oil sand (considered too costly in the past), will by itself lead to higher prices. Then of course there is the factor of politics in oil-producing regions, which has a major impact on prices.
At the same time, there are several factors in favor of techniques for producing fuels from renewable sources. For one thing, solar energy and wind power, at least, are essentially inexhaustible resources, which means scarcity can never play a role in their prices. And the technological advancements that will be achieved in the future with today’s emerging techniques for producing energy from renewable sources will mean greater efficiency, which in turn will reduce production costs. This development can be clearly seen in techniques for generating electricity from wind power. In general, fuels obtained from fossil energy sources will become more expensive in the future, while prices for fuels from renewable sources will tend to fall. And the greater efficiency of fuel cell drives will help to reduce overall vehicle operating costs.
—DaimlerChrysler
July 25, 2006 in Fuel Cells, Hydrogen | Permalink | Comments (46) | TrackBack (0)
Comments
Posted by: Harvey D. | July 26, 2006 at 07:44 AM
Who killed the electric car? GM. Why? The folks at GM soon discovered that the electric vehicles were incompatible with their current combustion engine production system, and thus by promoting electric cars this would be tantamount to a person writing their own death warrant. This is the dillemma that all companies face: when new technology emerges - when "creative destruction" lurks - in the horizon many don't know what steps to take. For example, Microsoft would not support network dependent or browser based system platforms since its entire model is based on selling OS software and applications. So the folk selling or leasing software on the web has a totally different system and posses a real threat to Microsoft; Microsft in the past used its monopoly power to kill such innovations.
Back to the car industry. Hybrid systems look as if they'll be the bridge to fuel cells. By the way a fuel cell is a battery while the storage hybrid system is a battery so you can swap the two with minimal changes to other parts of the vehicle. As for hydrogen, it might make more sense to use that hydrogen to manufacture transportable fuels like ethers(DME) or alcohols, and then use these to power fuel cells rather than struggle to store hydrogen.
Posted by: alan njeru | July 26, 2006 at 08:41 AM
Actauly the new tanks also have more room thus they now store 4 kg instead of the old 1.6 kg tank. thats not 2x thats 2.5x capacity increase.
The faqct is they are making fast progress and its STILL targeted for a 2012 2015 timeline so its very likely to meet that target.
Cost wise the fuel is getting cheaper to make. Capacity wise they can now store enough fuel on the car. Cost wise they are replacing the most expensive parts of the fuel cell and strasticaly cutting its material costs AND they are getting the designs ready for mass production ablity and thus getting the production costs way down too. Oh and ys they have greatly improved the eff of the fuel cell car itself so it needs alot less fuel anyway.
And I will be captain obvious as soo many seem to be clueless... the h2 car as envisioned right there will be a fully battery ev car for short ranges depending on battery capacity.. in short for short trips it is an ev car so shut up and sit down.
Posted by: wintermane | July 26, 2006 at 09:28 AM
Joep:
You are right, no credibility to car makers, politicians, and oil companies. Mild hybrids are 15 years overdue, America oil independence is 20 years overdue, cellulosic ethanol is 10 years overdue at least. Oil companies made a move to Iogen quite a long time ago, and then abandoned it when oil prices drop. The reason is probably that oil companies know better then anybody else that there are a lot of oil around, for many decades to come. It wouldn’t be cheap, but this is exactly what they want. It does not mean that we should senselessly waste precious resource and does not diversify the raw stock. Regional oil independence is quite possible to North America, but it was not done due to lack of will – both from American people and their politicians. I am not sure anything serious will be done at this (number 4?) oil crisis.
Yet there are some bright spots. Toyota; and not only for Prius, but for their notorious philosophy of constant improvement to all even smallest details. Clean Air Act, and most recently – clean-up of diesel engine emissions. So it is possible to do something big. What is lacking is strong will and clear vision. I do not see either.
Posted by: Andrey | July 26, 2006 at 09:30 AM
The taxation question is interesting. If hydrogen becomes a widespread road fuel, it can be taxed like gasoline is today. If plug-in electricity provides more and more of our road energy, then we need a non-fuel based revenue stream to make up the money needed to maintain our roads. Depending on how much road energy gets diverted from road-specific sources (petroleum or alternative liquid fuels, hydrogen) to non-road-specific sources (grid electricity, home generated electricity/hydrogen from renewables, or NG combined heat/power/H2 home appliances), this problem will go from a small one to a large one.
As Andrey points out, increased yearly registration fees are one way. Making them variable by the weight class of the vehicle is already done, and can be stressed further. A mileage-based system is also possible, but I can foresee both practical obstacles as well as cultural ones: People have some expectation of privacy when it comes to car use, and might feel uncomfortable with (and object to) strict reporting of their mileage figures.
An option I would add to the above would be to vary the registration fee according to the zipcode or area where the car is registered. Cars registered to addresses in urban centers can be charged more, on account of their taking up more in-demand urban roadway space. Cars registered to rural areas pay somewhat less. The insurance industry already uses zip-codes for certain premium-setting purposes. People with more than one home might be able to cheat by registering their car in the less-costly locale. To some extent, increased inforcement can cut down on this. To some extent, we'll just have to live with the fact that a small number of people will continue to cheat.
Another option I would like to suggest is the increased application of tolls on major limited-access highways/freeways. Those are the most expensive roads to build and maintain, and the easiest to toll. EZ-Pass type transponder systems can virtually eliminate the practical burdens associated with toll collection. The newest toll-lanes in New Jersey can collect tolls as cars zip by at 55 MPH!
Under this plan, customers who want convenience can have their transponders associated with their credit cards or billing addresses. Those who want privacy should be able to buy pre-paid anonymous transponders with up-front cash. Out of town users can go to the few remaining cash lanes.
Zipcode based fees and increased highway tolling are two alternatives to add to the mix. The public might prefer these approaches or prefer an odometer-based one, as Andrey envisions, or a mix. I'd just like to come up with the maximum number of alternatives for us all to consider.
All this is apart from a scheme of externalities taxation, which could be applied across the energy sector. Pollution, cost of foreign entaglements, climate-change mitigation, and all sorts of things can be priced right into the cost of a barrel of oil or ton of coal. That might increase electricity costs in certain markets. It could also affect the price of hydrogen, if FCVs even become big, depending on where the hydrogen came from. But a revenue-neutral approach -- cutting the lower-bracket tax rates -- can mitigate the undesireable social impacts of that.
Posted by: NBK-Boston | July 26, 2006 at 09:40 AM
EV's are a disruptive technology, and there is no doubt that the oil companies, auto companies and government(s) are not anxious for change. Everyone wants to maintain a status quo they benefit from.
The threat to oil companies is pretty clear. In addition to potential lost profit, how do you capture a market for electricity that is produced by solar and wind in every backyard? And as someone pointed out, they depend on people to stop at fueling stations to buy other stuff -- that is where the profits of those operations are, not in the gasoline.
Auto companies would produce the EV's in a second if they would be profitable enough, but they have two challenges. 1) With fewer moving parts and simpler design, how can you maintain high prices per vehicle? Competitors can make them in their garages out of off the shelf parts and bodies supplied by many companies (A la Telsa?). 2) How do you downsize the manufacturing facities and personnel? Production of electric motors is not going to take the production capacity of V8 multi-valve, fuel injected, 6 speeed transmission vehicles. Our corporate and economic mindset is growth, not real downsizing (layoffs yes, but not less income). That is why IBM dragged its feet on MiniComputers and then PC's until the handwriting was on the wall. Car companies will do the same, but adjust when they feel the heat.
As for Government, they are always for the status quo. That is where their constituencies live. That includes oil and auto companies that fund political campaigns and pay corporate taxes, and employees who work for them. Changing the game is hard to imagine, much less embrace. In addition, what happens if we do shift to renewable energy and computer-box-on-wheel cars? Prices come down, costs come down, tax revenue comes down, and (God forbid) we have deflation? The bankers can't have that. We measure our well being in GDP, and the Fed has a 2% inflation target.
This change is frightening. But it is coming, and fast. Farmers are quickly figuring out that they can make as much money planing a wind turbine as they can growing crops, and they can grow crops too. That will bring overinvestment in renewable energy just as the dot.com boom did for internet and fiber optic companies. The electric providers then need a place to sell their product and what better than EV's? This won't happen overnight, but maybe over a decade. As Betty Davis said, "Fasten your seatbelts, it's going to be a bumpy night."
Posted by: JM | July 26, 2006 at 09:42 AM
JM: if you check their sites. BP,Total and Shell are already moveing into the renewable energy sector, both in generation and development of technology. It's going to take decades for gasoline cars to go away and in the meantime these companies will be shifting with the times (unlike Exxon).
Posted by: Neil | July 26, 2006 at 10:44 AM
So many responses personalizing big business and government. But these are large, impersonal systems. They don't 'care,' they 'operate.' Personalizing them is like using an animist belief system to explain nature. While poetic, its power to improve comprehension and assist change is minimal. These systems don't 'fear' EVs, etc. they simply ignore them because they're not a part of them, e.g. of the oil/energy to new vehicle design process, etc. That in itself is enough.
Never underestimate the power of ignorance & it's ability to halt change for the better. At any level.
So: how will you fix this?
Posted by: Ron Fischer | July 26, 2006 at 10:46 AM
It will be fixed by their lower profits from high fuel consumption vehicle sales and competition from companies like Tesla. This is only brought about by high gas prices which I suspect are only going higher. Eventually climate change will be an influence as well but it will still take some time for the public to votes on this issue. That's my hunch anyway...
Posted by: marcus | July 26, 2006 at 11:42 AM
Interesting article and equally interesting discussion. I think you are all making valid points. I like the notion that a car with an electric motor could be cheaper to build and maintain. Maybe that allows for smaller companies to jump into the mix and put Ford and GM out of business.
Have there been any articles about plug-in hybrids that also utilize photovoltaics? Sure would be great to drive to work and let the car sit in the sun all day and get just enough of a charge to get home.
Posted by: chris | July 26, 2006 at 11:51 AM
Ron,
I don't care if the big companies make money, as long as they provide value. I am a beleiver in the market system. Challenges from Tesla and the other EV startups will force change. It won't happen over night, but the power or profits (or losses) will get us there. Conspiracies don't hold up forever.
Posted by: JM | July 26, 2006 at 11:53 AM
Neil,
My response to Ron applies to your comment as well. I am happy that Big Oil is investing in renewables. That just greases the wheels of progress, it does not stop them.
Posted by: JM | July 26, 2006 at 11:57 AM
Interestingly, 'the system' in London is driving (no pun intended!) the EV market there. London has high driving fees for non-EV vehicles, but not for EVs. The consequence is that London is turning into the biggest EV car market in the world, and more companies are making cars for that market all the time.
The interesting thing about London is they didn't necessarily say EVs are the way, they are just making it really expensive to drive anything else.
Posted by: John McConnell | July 26, 2006 at 12:32 PM
LNG has 2.5 times the amount of energy compared to CNG at 350 bar, how about Liquid Hydrogen compared to Compressed Hydrogen.
Posted by: Max Reid | July 26, 2006 at 02:12 PM
Joep writes:
Where one business disappears , including the jobs, another new business will fill the gap and create new jobs. That is; when big oil is gone and the distribution centres and supporting infrastructure , you will have a boom in the industry and infrastructure that is necessary for supplying the new technology and everything that is related. You will have a shift in jobs, not a complete loss in jobs.Counterexample: the radial tire. They took no more labor to make, but they lasted twice as long as bias-ply; jobs were lost from the tire sector of the economy.
People spent the money on other things, though this was less apparent. Ditto the effect from replacement of petroleum. I am certain that one of the second-order effects of that will be fewer jobs in the military, as less money for terrorists combines with less importance of Middle East oil to make ideological groups and nations both find their local affairs more compelling.
Posted by: Engineer-Poet | July 26, 2006 at 08:28 PM
He said that if you took all the cars parked at a smallish airport, it would take 5 nuclear reactors and enough water to supply a small city just to run them.
Ulf Bossel has long been staunchly anti-hydrogen, but he is a knowledgable scientist. I strongly doubt that he made a statement that is so grossly far from the mark and so easy to refute.
Five nuclear reactors represents about five gigawatts of power. A rough figure for energy consumption in EVs is 750 watt-hours per mile; the average car in the US racks up about 12,000 miles per year. That comes to 8000 kwh per vehicle. There are 84,000 hours in a year, so one EV in average use draws an average of 100 watts. (Obviously much more than that when it's running, but averaged over all the time it's parked, it's aout 100 watts.) So five nuclear power plants would support 50 million EVs.
Typical estimates for a hydrogen FC vehicle running on electrolytic H2 are that it is one third as efficient as a battery EV. So instead of 50 million EVs, our five nukes would support 17 million H2 FCVs. That's some "smallish airport". Let's see about the other part of the statement--water consumed.
It takes about 50 kWh to produce one kg of H2 by electrolysis. 5 GW will produce 100 tons of H2 per hour from 900 tons of water. There are 3,600 seconds in an hour, so we're looking at a quarter of a ton of water per second. That's a modest brook, three feet wide by one foot deep, flowing at the pace of a slow walk. Hmmm, a very small city.
Posted by: Silverthorn | July 26, 2006 at 11:21 PM
Oops! I'm off by a factor of 10: 8760 hours in a year, not 84,000, so average power per EV is more like 1kW, not 100w. So 5 nukes supports 5 million EVs, not 50 million, or 1.7 million H2 FCVs, not 17 million. Still rather a large parking lot for a smallish airport.
Bossel may be right that we'll never see H2 FCVs, but if so, it will be because there are more economical alternatives, not because it's technically infeasible.
Posted by: Silverthorn | July 26, 2006 at 11:29 PM
You're off by a factor of 3 on the energy consumption; EV's typically use around 200-300 WH/mile, not 750.
Figure 300 as a safety factor. 12,000 miles @ 300 Wh/mi is 3600 kWh/year, or an average of 411 watts. Each gigawatt of powerplant would run 2.4 million electric cars.
That's a rather large city's worth.
Posted by: Engineer-Poet | July 27, 2006 at 05:02 AM
An important thing to remember that alot of nitwits are totaly missing is the type 4 reactor produces more electricity then older types AND a huge amount of h2 all while using only the same amount of nuke fuel as the old designs. That is why everyone is so interested in them.
Posted by: wintermane | July 27, 2006 at 10:20 AM
Show me a type 4 reactor in operation, then.
Posted by: Engineer-Poet | July 27, 2006 at 09:03 PM
DME developments in CHina:
Since DME has an advantage of decomposition at lower temperature than methane and LPG, R&D for hydrogen source for fuel cell has been carried out.
If you would like to know more on the latest DME developments, join us at upcoming North Asia DME / Methanol conference in Beijing, 27-28 June 2007, St Regis Hotel. The conference covers key areas which include:
DME productivity can be much higher especially if
country energy policies makes an effort comparable to
that invested in increasing supply.
By:
National Development Reform Commission NDRC
Ministry of Energy for Mongolia
Production of DME/ Methanol through biomass
gasification could potentially be commercialized
By:
Shandong University completed Pilot plant in Jinan and
will be sharing their experience.
Advances in conversion technologies are readily
available and offer exciting potential of DME as a
chemical feedstock
By: Kogas, Lurgi and Haldor Topsoe
Available project finance supports the investments
that DME/ Methanol can play a large energy supply role
By: International Finance Corporation
For more information: www.iceorganiser.com
Posted by: Cheryl Ho | May 23, 2007 at 09:26 PM
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A combination of multi-fuel PHEVs + pure EVs would use existing + future liquid fuel + existing facilities + existing electricity distribution networks and would avoid the very high cost associated with building and maintaining new hydrogen production and distribution facilities.
For the longer term, we could certainly move away from liquid fuels towards cleaner sustainable EVs.
Contrary to liquid fuel, clean electricity can be produced indefinately in sufficient quantity from the sun, wind, waves, hydro and even nuclear, if and where required.
Except for special applications, why should we use electricity (or other sources of energy) to produce hydrogen and then reconvert hydrogen into electricity for the drive trains? Double and triple energy conversion is non effcient and should be avoided. Secondly, EVs produce less GHG than any other form of vehicles.