1. Fuel Cell Vehicle
Projects in Texas
October 21, 2010
Presented by Richard Thompson
UT – Center for Electromechanics

2. Presentation Topics
• Hydrogen Fuel Cell 22’ Shuttle Bus
– Vehicle Computer Modeling and Performance
Evaluation
• Hydrogen Fueling Infrastructure in Austin, TX
• DOD Hydrogen Fuel Cell Utility Vehicles
• Upcoming program - Hydrogen Fuel Cell 35’
Transit Bus Demostration in Austin, TX

3. PEM Fuel Cell Plug-In Hybrid Bus Specifications
Vehicle Fuel Cell Shuttle Bus
Bus Manufacturer Ebus
Year Model 2007
Hybrid Type Series - Charge depleting
Length/Width/
6.7m / 2.3 m / 2.8 m
Height
Ground Clearance 20 cm
Wheel Base 3.7 m
GVWR 8845 kg
Passengers 22 seated
Power Plant and
Manufacturer
19.1 kW PEM Fuel Cell / Ballard Ni-Cad Batteries
Fuel 12 kg - 350 Bar Hydrogen
Fuel Storage 2X 5000 psi Roof Mounted Tanks
Saft / STM5-100MRE
Energy Storage
NiCD Batteries - 60 kWh
Propulsion
Induction Motor / Reliance Electric
Motor/Manufacturer
Nominal/Peak
75 kW / 130 kW for 1 min
power
Nominal/Peak
400 Nm / 700 Nm for 1 min
torque
Ballard 19 kW Fuel Cell Stack
Transmission Chain Drive/rear differential Overnight Battery Charger – automatically
Regenerative
Braking
yes controlled by vehicle computer

4. Completed a Nine Month Test Program
• Ebus 22’ Shuttle Bus
– Two hydrogen tanks
– 60 kWh NiCD Batteries
– 19.1 kW Ballard Fuel Cell Stack
– 40 mile range on batteries alone
– 180 to 200 mile range with fuel cell
and batteries
– Has regenerative braking for
improved fuel economy
• Test Program
– Monitored vehicle performance, for example
– hydrogen consumption and fuel cell power output
– battery’s charge/discharge energy
– Monitored maintenance issues

5. Vehicle Evaluation funded by USDOT
• Bus operated over 3 different routes in Austin, TX
– PRC Campus Route:
• Flat, Low speed (<25 mph)
– Great Hills Route:
• Very hilly (10%+ grades), medium speed
(25 – 35 mph)
– Jollyville Parmer Route:
• Moderate grades, high speed (35 – 45 mph)
• Covered 8000 miles over nine months

6. How Efficient are Fuel Cell Plug-in Hybrid Vehicles?
• Fuel cells are > 50% efficient, compared to < 40% for diesel Gasoline engines can
also be converted to run
engines
on Hydrogen
• We averaged about 22 mpg (diesel equivalent energy) • Cost less than FCs
• With batteries only we got over 35 mpg, but limited range • 38% - 40% efficiency
• Very low emissions
• HICE vehicles/engines
are available, but
limited

7. Recorded Evaluation Data
• Daily Manual Logs • Traction Battery Recharging Manual
– Mileage Log
– Ambient temperature
– Voltage and SOC (before and after)
– Hydrogen pressure and temperature
– Duration of charge
– Traction battery voltage and SOC
– Amp-hours into each battery
– Auxiliary battery voltage
– Driver efficiency • Hydrogen Refueling Manual Log
– Vehicle faults and maintenance items – Bus tank pressure and temperature (before and after)
– Pressure of temperature of each tube (before and after)
– Amount of hydrogen used to refuel is then calculated
• Data acquisition monitors • Critical performance criteria of the
164 parameters onboard Ebus are computed and logged into
the bus categorized as: a daily demo and analysis
– Traction System spreadsheet. These criteria
– Item (On/Off) include:
– Temperatures – Mileage
– Trip Information – Battery energy usage (including recharging events)
– Auxiliary 12 V Battery – Traction motor propulsion and regenerative energy
– Hybrid System – Hydrogen consumption
– Overnight Charger – Fuel cell energy output
– Accumulated amp-hours – Fuel cell run time
– Charge Information – Fuel cell, traction motor, and battery efficiencies
– Charge States and Codes – Overall vehicle fuel economy (kWh/km)

8. Vehicle Modeling using PSAT
(Powertrain System Analysis Toolkit)
• All electric vehicle
– Deep cycle lead-acid
batteries
– Advanced state of the art
batteries
• Fuel cell vehicle
• Fuel cell hybrid vehicle
– Plug-in fuel cell
– Fuel cell dominant hybrid

9. Modeling goal was to be able to predict vehicle
performance for any given route
• Matched vehicle’s
net energy
consumption
within 5%
• Approach helps
others make better
choices on
emerging vehicle Slope change with
hydrogen consumption
technologies due to fuel cell operation
• Avoids the “build
and test” approach

10. Hydrogen Fueling Infrastructure in Austin, TX
• Skid-mounted hydrogen fueling station for
vehicles
• Generates hydrogen from natural gas
• Integrated system includes
– fuel processor, which converts natural gas to
hydrogen gas,
– pressure swing absorption unit, which purifies
the hydrogen
– hydrogen compressor
– storage tanks
– hydrogen dispensing system
H2-rich gas High Pressure • First permanent fueling station in
Storage
Texas
– Public outreach and education
Pressure • Provides excellent learning
Water
Reformer Shift
Swing
Absorption Pure H2 platform
Reactor
Utility
Water
• Provides High-purity H2 for
Compressor additional vehicles (50 kg/day)
Methane Dispenser
Pure H2
Integrated Hydrogen Supply
System

11. DOD Extended Range Utility Vehicle Program
• DOD requested extended range
capability on a single tank of
hydrogen gas
• Surpass the range of vehicles
with
– current lead-acid batteries
– advanced state-of-the art batteries
• Vehicle platform for the hydrogen
propulsion retrofit is the all- • Vehicle takes advantage of
electric, Columbia ParCar SUV-LN readily available, commercial
– 3.7 kg of hydrogen in a 5 ksi (350 bar) components
composite tank
– 8.5 kW fuel cell
– Ultracapacitors for improved
acceleration and vehicle efficiency,
regenerative braking

12. Utility Vehicle Layout with H2 Storage
Hydrogen
Storage
3.73 Kg
Boost Converter
(to 48Vdc Motor)
Fuel Cell
Module Controller/Data Ultracapacitor
8kW Acquisition Modules
20-40Vdc NI Compact Rio 4X 16V 500F

13. DOD Extended Range Utility Vehicle Program
Motor Power (continuous/peak) 6.7 kW/12.9 kW
Motor Current (continuous/peak) 150 Amps/500 Amps
Drive Ratio 10.35
Fuel Cell Power 8.5 kW
Fuel 3.7 kg H2 @ 350 Bar
Energy Storage System 4 x 16V 500F Ultracapacitor
Energy Storage Voltage Range 58V - 42V
Delivered Energy from UC ESS 27.8 Whr
All-Electric • Extended range testing was completed
(40 mile range)
To • 309 miles on one fueling of H2
Hydrogen
Fuel Cell • Average fuel economy of 90 mpg –
(> 300 mile range) gasoline equivalent
(same as mi/kg-hydrogen)
Date Trip Distance AVG Economy AVG Fuel Cell Efficiency
[mi] [mi/kg] [%]
10/07/10 1 15.10 79.16 41.20%
10/08/10 2 14.70 79.60 41.70%
10/08/10 3 12.04 79.16 42.53%
10/08/10 4 15.59 81.67 41.40%
10/11/10 5 45.14 88.15 42.23%
10/11/10 6 52.90 95.35 40.86%
10/12/10 7 42.44 94.95 42.54%
10/12/10 8 30.83 94.25 41.37%
10/13/10 9 41.70 91.93 42.66%
10/13/10 10 38.96 87.81 41.58%

14. Proterra Bus to Begin Passenger Service in Austin/Cap Metro - Early 2011
(Currently in Columbia, SC)
35’ Transit Bus
Fuel Cell / Plug-in Battery Hybrid Bus
Ground-up Design
Regenerative Braking
37 Passengers
Up to 10 mpg diesel energy equivalent

15. Proterra Fuel Cell Plug-in Hybrid Bus

16. Sponsors and Supporting Partners
• US Department of Energy
• US Department of Transportation
• Texas H2 Coalition
• Houston Advanced Research Center (HARC)
• Center for Transportation and the Environment (CTE)
• Texas Commission on Environmental Quality (TCEQ)
• Texas State Energy Conservation Office (SECO)
• Gas Technology Institute
• The University of Texas at Austin
• Columbia Parcar
• Hydrogenics