TABLE 7.3 Major Cost Elements in a Budget Roadmap

Cost Element

Capital Costs

O&M Costs

Vehicle production costs

Production facilities

Testing facilities

Base vehicle costs

Fuel cell power train costs

Raw materials

Labor costs (skilled, manual, supervisory)

Facility operating costs (utilities, insurance, etc.)

Facility maintenance costs

Retailing costs

Hydrogen supply costs

Fueling station land and building costs

H2 supply technology (SMRs; coal gasification)

Delivery system hardware (local or remote)

Feedstocks (natural gas, electricity, etc.)

Labor costs

Delivery costs

Other operating costs

Supply-related facility maintenance costs

NOTE: SMR = steam methane reformer.

TABLE 7.4 Projected Cumulative Infrastructure Requirements in 2020, 2035, and 2050 for the Hydrogen Success (Case 1) Scenario

Infrastructure Items

2020

2035

2050

Capital Cost (billion 2005 dollars)

Physical Units

Capital Cost (billion 2005 dollars)

Physical Units

Capital cost (billions 2005 dollars)

Physical Units

Hydrogen production plants:

 

 

 

 

 

 

Natural gas on-site SMR stations

$2.6

2,110

$34

22,000

$122

79,000

Central coal plants with CO2 capture and sequestration

0

0

$18.2

20

$80

79

Central biomass plants

0

0

$13.5

93

$19

131

Central natural gas SMR

0

0

0

0

0

0

 

$2.6

 

$66

 

$221

 

Total production plant capital cost

 

 

 

 

 

 

Refueling stations

$2.6

2,110

$25

56,000

$74

180,000

Delivery system (dollars and pipeline miles)

0

0

$48

39,000

$120

80,000 H2 pipelines; 5,000 CO2 pipelines

Total cumulative capital costs

$2.6

 

$139

 

$415

 

some of these costs would be borne by government programs during the transition period required for fuel cell vehicles to become competitive in the marketplace.

To estimate these costs, the results of the Case 1 scenario described in Chapter 6 were utilized. That scenario represents the committee’s best estimate of the maximum practicable number of HFCVs that could be deployed in the United States by 2020 (and beyond). The committee first estimated the annual expenditures required to deploy the number of vehicles specified per year in that scenario. The vehicle production costs of Table 7.3 are captured in the estimated retail price of HFCVs developed in Chapter 6, and used here in the budget roadmap. The annual capital expenditures for infrastructure to supply hydrogen to those vehicles also were estimated, as well as the O&M costs of the infrastructure each year. The analysis of transition costs for this case ends in 2023, which is the breakeven year, after which HFCVs compete economically with conventional vehicles Hydrogen Success scenario (see Chapter 6).

Building the infrastructure needed to fuel HFCVs will be a substantial construction program in itself, aside from research and technology development. Table 7.4 shows the cumulative number of hydrogen production plants, refueling stations, and distribution pipelines, as well as their cumulative capital costs at several points in time. The committee’s projected cumulative investment for hydrogen infrastructure



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