Review of the Research Program of the FreedomCAR and Fuel Partnership First Report (2005) / Chapter Skim
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3 Vehicle Subsystems
3 Vehicle Subsystems
Pages 50-85
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From page 50... ...
utilized in more efficient power plants in lighter vehicles having reduced power requirements while maintaining equivalent utility and safety. DOE envisions that the path to achieving the long-term goals of the FreedomCAR and Fuel Partnership involves a transition from improved gasoline- and diesel-fueled ICE vehicles, to a greater utilization of gasoline- and diesel-fueled hybrid electric vehicles (HEVs)
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From page 51... ...
Hybrid electric vehicles require compact, efficient, and low-cost power electronics and energy storage systems as well as other advanced electrical components to make vehicle costs and weights competitive with conventional vehicles. Many of the same technologies also are applicable to fuel cell vehicles since fuel cell vehicles will be basically electric vehicles with various degrees of hybridization.
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From page 52... ...
Even though hybrid electric vehicles are currently on the market, the projected cost savings due to higher fuel mileage will probably not offset the higher initial cost of the vehicle at foreseeable fuel prices. This implies that further cost reductions may be necessary for the hybrid vehicles to gain widespread acceptance and have a significant impact on fleet fuel mileage.
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From page 53... ...
With approximately 16 million new vehicles sold in the United States every year, improving the energy efficiency of vehicles sold now will have near-term and growing impact on the petroleum consumption of the entire vehicle fleet. FreedomCAR's transition strategy to hydrogen-fueled vehicles envisions a sequence of improved ICEs, increasing use of advanced ICE hybrid vehicles and hydrogen-fueled ICE hybrid vehicles, and -- ultimately -- a transition to hydrogen-fueled fuel cell vehicles (DOE, 2004a)
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From page 54... ...
It is well known, however, that current diesel engines will not meet future emission standards. Therefore, to reduce fuel consumption through the more widespread introduction of diesel engines into the market, advances must be made in emission reduction technologies.
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The operating paradigm of the program is to expand the fundamental understanding of combustion, aftertreatment, and controls phenomena in a precompetitive research environment and then let industry address cost as it works to incorporate the new technologies into vehicle power plants. The individual project topic areas within each research focus are shown in Figure 3-1.
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From page 56... ...
During this last year the ACEC technical team has shifted the emphasis of its research programs. If the current diesel engine combustion process were left unaltered, the conversion efficiency for the nitrogen oxides (NOx)
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From page 57... ...
To capitalize on these synergies in the combustion engines and emissions technical area, the FreedomCAR and Fuel Partnership is collaborating with the 21st Century Truck Partnership, a partnership of DOE, DOD, EPA, and DOT and 15 industrial partners. The combined budget for advanced combustion for both the FreedomCAR and Fuel Partnership and the 21st Century Truck Partnership for FY04 was $54.4 million.
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From page 58... ...
The advanced combustion and emissions control technical team has demonstrated new understanding of the LTC process, including HCCI, and has achieved low-temperature operation in running engines. New understanding of phenomena occurring at the spray nozzle tip, where fuel atomization and air entrainment begin, has been obtained through x-ray imaging, and the boundaries of clean, injection-driven combustion are being expanded.
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From page 59... ...
In accordance with the mission of the FreedomCar and Fuel Partnership to "examine precompetitive, high-risk research," the ACEC technical team is encouraged to identify breakthrough and innovative technologies that could provide long-term solutions to the CIDI emissions problems and to begin to anticipate, analyze, and
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From page 60... ...
Recommendation. Increased emphasis should be placed on novel emission control technologies, and the advanced combustion and emission controls technical team should plan for, analyze, and seek solutions for emission problems associated with emerging fuels, fuel infrastructure, and propulsion systems.
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. Peak efficiency occurs at about 25% rated power.
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The results of the development efforts are communicated among the technical teams and may ultimately be integrated into the program of an individual developer of automotive fuel cells. Technology Issues The PEM fuel cell is based on compartmentalized hardware (cells)
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From page 63... ...
DOE leadership, along with the technical teams, must be alert and make needed changes to the roadmap as they are required. A number of critical technical issues that are shared by the entire fuel cell industry must eventually be resolved if the overall program goals are to be achieved.
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From page 64... ...
Since catalyst performance is related to operating conditions, gas distribution, and membrane interactions, the technical teams must continue to coordinate and enhance their activities. The 2004 Annual DOE Merit Review, held in Philadelphia in May 2004, reports initial progress in these key areas of more durable membranes and lower catalyst loadings.1 The inadequate lifetime and performance characteristics of today's vehicular fuel cell systems can be contrasted with those of stationary applications that use nearly the same technology.
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From page 65... ...
In its present form, the model should be useful for tracking cost changes with design modifications, for establishing goals for component cost, and for prioritizing cost reduction targets. However, the committee found that TIAX predictions had not yet been validated against the cost of existing entire fuel cell systems, making such predictions speculative.
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From page 66... ...
It should be pointed out that although the program is sound on numerous fronts, its success is highly dependent on communication and cooperation among the members of the fuel cell technical teams. Fortunately, communication between different parts of EERE, as well as among EERE managers at the various technical teams, is well established, though in some cases not formalized.
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From page 67... ...
HYDROGEN STORAGE Hydrogen storage activities are organized within the DOE Hydrogen Fuel Initiative (HFI) , with oversight by the hydrogen storage technical team of the FreedomCAR and Fuel Partnership.
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From page 68... ...
Compressed hydrogen and liquid hydrogen, followed by chemical hydrides, come closer to meeting the goal than do the complex metal hydrides or carbon. The hydrogen storage technical team has developed a roadmap of tasks, milestones, and go/no-go decision points to guide the R&D and evaluation of these alternatives.
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69 S .Satyapal,S 20 $18 $16 $15 2004.
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Reversible storage would permit charging the system with hydrogen on-board the vehicle and eliminate recovery and reprocessing of the spent fuel material. Findings and Recommendations The hydrogen storage technical team is newly formed and received significant funding only in FY05.
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From page 71... ...
In view of the risk posed to the entire hydrogen program by the need for a viable hydrogen storage system, the hydrogen storage technical team and the FreedomCAR and Fuel Partnership leadership team should report annually to all program participants, DOE, and Congress on the state of hydrogen storage technology worldwide relative to the goals and targets of the program. ELECTRICAL ENERGY STORAGE The FreedomCAR and Vehicle Technologies (FCVT)
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From page 72... ...
As noted in FCVT's multiyear plan, a primary goal of the energy storage program is to develop by 2010 an electric drive train that includes a battery with a 15-year life at 300 Wh of available energy, discharge power of 25 kW for 18 s, and a $20/kW cost (DOE, 2004a)
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From page 73... ...
A go/ no-go decision based on the performance data will be made in FY06. Further understanding and control of thermal abuse is being done through battery thermal management studies at the National Renewable Energy Laboratory (NREL)
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74 Long Term 400 200 600 200 300 2:1 40 EV Battery Commercial- ization 300 150 460 150 230 2:1 40 s s 18 5 Cell Power for for Fuel Vehicle Low 25 25 250 s s 10 10 Power for for High 40 35 500 s s 10 10 (Power-Assist) Power for for HEV Low 25 20 300 s s 10 2 for for P-HEV 18 18 4.5 700 s Storage 2 s min 2 5 for for for M-HEV 13 8 3 2.6 300 s 2 for Electrochemical 42-volt Stop Start 6 N/A 2.4 250 for Unit kW W/kg kW W/kg kW -1 kW W/L Wh Wh/kg Wh/L h kWh Targets load kW 3 Technical s s at pulse rate rate 3-5 power accessory rate energy ratio power-discharge, DOD/30 power-regeneration, DOD/10 energy -- C/3 density density -- C/3 power/specific energy 80% 20% discharge discharge energy TABLE Target Discharge Specific Regenerative Specific Engine-off Recharge Power Available Specific Energy Specific Total
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75 +85 to 10 100 40 DOD 80% at +50 to 1,000 10 <150 40 min TBD 2004. 90 for TBD 15 5 32 26 400 440 50 17, max s V 2 x +52 +66 discharge.
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From page 76... ...
An EV represents an alternative route to achieving the primary goal of the FreedomCar and Fuel Partnership: energy independence and an environmentally friendly transportation system. The development of high-energy batteries is consistent with DOE's goal of investing in high-risk technologies.
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From page 77... ...
Recommendation. In view of the potential benefits of a high-energy-density DLC in hybrid vehicles, the energy storage technical team, in conjunction with the electrical and electronics system technical team, should maintain an activity that explicitly monitors progress of international DLC research programs and should consider funding research in advanced DLC technologies.
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From page 78... ...
. Program Status and Progress Within the restricted goals established for the EE systems, the EE technical team has built on the results of the motor and electronics development in the PNGV program.
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The FreedomCAR and Fuel Partnership and INEEL have benchmarked the commercially available DLCs and identified their potential for HEVs (see discussion of DLCs in the section on electrical energy storage)
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To date the interaction among the technical teams has been informal and infrequent. The quarterly meetings among technical team chairs and the USCAR FreedomCAR directors address operational issues, not the tactical issues necessary for specifying interface tasks.
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From page 81... ...
The widespread application of lightweight materials and innovative manufacturing processes are necessary to attain this goal. The FreedomCAR and Fuel Partnership has set a vehicle weight reduction target of 50 percent, adding the criterion "affordable cost." These objectives in weight and cost are not dissimilar to those in the predecessor PNGV program and thus allow continuation of the materials programs already in place.
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From page 82... ...
, all these materials achieve the weight savings, but usually at a very significant cost penalty compared with current materials. Thus, while there are some major technical obstacles to the extensive application of these lightweight materials, the paramount challenge to the program is achieving cost parity, or "affordability." The difficulty of achieving affordability cannot be overemphasized, and all the large research programs should include a roadmap showing how to reach the cost target.
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From page 83... ...
Recommendations The materials technical team has the benefit of several years' experience and obviously operates very cooperatively. It has clearly benefited from the earlier NRC reviews of the PNGV program and encompasses in its R&D portfolio all the opportunities for weight reduction afforded by current and future materials.
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From page 84... ...
Recommendation. The materials technical team should provide technical materials input to other technical teams -- for example, electronics, the hydrogen onboard supply system, magnets, motors, fuel cell structural issues -- where such input would be useful.
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From page 85... ...
, EE Technical Team, FreedomCAR and Fuel Partner ship. Washington, D.C.: Office of Energy Efficiency and Renewable Energy.
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