Slide 1: Ground Support Equipment Demonstration
MT011 Ground Support Equipment Demonstration Jim Petrecky 6/9/16 Copyright 2016, Plug Power Inc.
Slide 2: Overview / Relevance
PLUG POWER kL: OVERVIEW RELEVANCE
Slide 3: Program Overview
Program Overview Cargo Tractor Demonstration Program Timeline • Project Start Date | 1/1/13 • Project End Date | 3/31/17 • Percent Complete | 76% Barriers • Exposure to elements • Airport emissions • Aggressive load profile Budget • Total Funding | $4.996M • DOE Share |$2.497 • Partners Share | 50.0
Slide 4: A Real Economic Alternative
A Real Economic Alternative A real economic alternative to diesel assets Dept. of Energy Objectives • Value prop that makes sense • Higher energy efficiency while • Readily available fuel • Lower petroleum demand meeting • Service organization to maintain asset operation • Lower carbon emissions • S
Slide 5: Hydrogen Economics
Hydrogen Economics Supply Comments Price ($/kg) Trucks Usage Price ($/kg) Method Fuel Only (kg/mo) Fuel + Infra Gaseous - Inefficient, generally $12.00 5 800 $15.75 lower volumes (200 kg) - Generally lower pressure (2400 PSI), partial fills Supply Comments Price ($/kg) Trucks Usage Price ($/kg) Meth
Slide 6: Hydrogen Economics – Liquid
Hydrogen Economics – Liquid Energy Required Shift Power Efficiency Fuel Required Fuel Required Fuel Cost Fuel Cost kW-hr % kW-hr Units of Fuel $/Unit $/Shift Fuel Cell H2 kg $/kg 45% 111 3.3 $5.25 $17.50 50 Diesel Engine Diesel gal $/gal 20% 250 6.6 $2.27 $14.95 However… • When a diesel tractor need
Slide 7: Hydrogen Economics – Onsite H2
Hydrogen Economics – Onsite H2 Energy Required Shift Power Efficiency Fuel Required Fuel Required Fuel Cost Fuel Cost kW-hr % kW-hr Units of Fuel $/Unit $/Shift Fuel Cell H2 kg $/kg 45% 111 3.3 $2.50 $8.33 50 Diesel Engine Diesel gal $/gal 20% 250 6.6 $2.27 $14.95 However… • When a diesel tractor ne
Slide 8: Expansion of GSE Inventory
Expansion of GSE Inventory US Airline GSE Market (late 2009 figures) Belt Loaders Type of Equipment Units % of Market Cumulative Loads from ground level to aircraft storage areas by way of Tow Tractors 27,978 45% 45% conveyer belt Belt Loaders 12,395 20% 65% Pushback Tractor 6,068 10% 75% Ground Pow
Slide 9: Development of a H2 Ecosystem
Development of a H2 Ecosystem H2 Ecosystem Phase 2: Tethered Local Fleet • Busses/Shuttles • Delivery (Package, food, Albany Airport etc.) • Service Vehicle • Postal Trucks • Dispensing Phase 1: Captive Fleet Phase 3: Tethered Regional • Tractors Fleet • Cargo Loaders • Busses • Belt Loaders • Deliv
Slide 10: Coordination
PLUG POWER kL: COORDINATION
Slide 11: Program Team
Program Team Plug Power (Prime | Fuel Cell Integrator | H2 Supply) FedEx (End User) Charlatte Memphis-Shelby Memphis Tennessee County Airport Division of Fire (Tractor OEM) Authority Services 11
Slide 12: Approach
PLUG POWER kL: APPROACH
Slide 13: Defining Requirements
Defining Requirements Vehicle Testing • Testing in Latham • Charlatte CT5E tractor • FedEx Express dollies • Shock testing in Memphis Route Simulations • Worst case start/stop 13 13
Slide 14: Fuel Cell Design
Fuel Cell Design Drop-in-Place Replacement For Battery Fuel Cell • Stack (power) • Battery (transient soak) H2 Tank • Energy (run time) GenDrive Specs • Drawbar: 5,000 lbs. • Towing Capacity: 40,000 lbs. • Voltage: 80VDC • Power: 22 kW • 100% Outdoor Operation Ballast • H2 Storage: 3.6 kg • Weight (
Slide 15: Protection from Airport Emissions
Protection from Airport Emissions Activated Carbon Filter • Donaldson adsorption filter • Removal of oil, hydrocarbon and vapors • Removal of particulate contamination in the air stream No evidence of effect on systems during operation Airport Emissions Constituent Constituent How Created Carbon Dio
Slide 16: Hydrogen Infrastructure
Hydrogen Infrastructure Best scalable, economic solution | Delivered liquid hydrogen • H2 Capacity: 15,000 gallons • Gaseous Storage: 60 kg • Liquid temp: -253 deg C • Gaseous Fueling Pressure: 350 bar • Liquid Pressure: 5 PSI • Dispensing Time: 1 kg/min Liquid Storage Liquid Pumps Vaporizer High Pr
Slide 17: Refueling
Refueling • Turn handle on hose until arrow is pointing away from vehicle • Place hose on fuel cell fueling receptacle • Turn handle 180 deg. clockwise until arrow is pointing at the vehicle • Fueling hose locks and automatically starts flow to the tank 17
Slide 18: Fuel Cell Safety
Fuel Cell Safety • Safety Documentation • GSE System Requirements Document • GSE Safety Concept • Answers to PNNL Hydrogen Safety Team review • DFMEA on all subsystems • Safety HAZOP • Safety Testing • Battery vibration • System vibration • Hydrogen ventilation testing • Hydrogen tank testing (1.25x
Slide 19: H2 Infrastructure Safety
H2 Infrastructure Safety • GenFuel safety documentation • Safety Testing • GenFuel service manual • Factory acceptance test of dispenser – • 3rd party review of infrastructure 1.25x working pressure • GenFuel System Components • Line pressure test • Infrared flame detectors • Safety Code Compliance
Slide 20: All-inclusive Offering
All-inclusive Offering Approach is make the solution transparent to the customer operations: • Tractor operation is equal or better than a battery • Customer does not need to handle hydrogen supply logistics • Operator experience is the same • Asset uptime is guaranteed • Refueling is as easy as fue
Slide 21: Accomplishments
PLUG POWER kL: ACCOMPLISHMENTS
Slide 22: Bench Prototype
Bench Prototype Systems Modeling • Stack Sizing • Battery Sizing • Balance of Plant design Bench Testing Testing Achievements • Automated testing • Graphic interface • Liquid-cooled load banks • Safety sensors/E-stops • Computer-controlled load profile management 22 22
Slide 23: Alpha Prototype
Alpha Prototype • Advanced packaging design • Easy top serviceability of all major components • 150 liter (3.6 kg) H2 tank • Driver-side fueling • Extended Li-Ion battery capacity • Vibration dampening frame • Weatherproofing 23 23
Slide 24: Alpha Prototype
Alpha Prototype • Charlatte CT5E tug, FedEx Express dollies, and 40,000 lbs. of weight • Endurance testing • Software/diagnostics testing 24 24
Slide 25: Environmental / Stress Testing
Environmental / Stress Testing Airport application is 24/7 outdoors Tractors are exposed to the elements Testing at Extremes Environmental Chamber Testing • Designed, tested, stack and battery freeze protection down to -20 deg F • Tested heat rejection up to 108 deg F at nominal stack temp Wind Driv
Slide 26: Statement of Work / Progress
Statement of Work / Progress • Task 1: Definition of Requirements Complete Budget • Task 2: Alpha Prototype Complete Period 1 • Task 3: BTT Beta Builds Complete • Task 4: BTT Testing and Certification Complete • Task 5: Site Preparation Complete Budget • Task 6: Commissioning Complete Period 2 • Tas
Slide 27: Data Collected During Year 1
Data Collected During Year 1 Year 1 Results Performance during Year 1 fell short of demonstration targets • Power: Capable of 5,000 lbs. drawbar capacity • Availability: > 80% • Run time: > 1 shift • Reliability (MTBF – Mean Time Between Failures): > 100 hours • Speed rating: 10 mph • Outdoor operat
Slide 28: Experience Real World Conditions
Experience Real World Conditions Temp Precipitation Humidity Shock and vibe 28
Slide 29: Learning From Year 1
Learning From Year 1 Year 1 Results Tractor handles application load Operating outdoor 24/7 is not a problem Weatherproofing strategy works well Air filtration protects the system from airport hydrocarbon emissions Tractor can operate worst route for full shift without needing to refuel Handful of c
Slide 30: Future Work
PLUG POWER kL: FUTURE WORK
Slide 31: Future Work
Future Work Year 1 Results Tractor Version 2.0 • Replacement of problematic components • Same architecture • For scaling to 20 kW, some components were different than GenDrive productions for forklift trucks • Did not see the same performance; replacements tested for ~ 1 year • FedEx Express more in
Slide 32: Summary
PLUG POWER kL: SUMMARY
Slide 33: Summary
Summary Objectives H2 Infrastructure FC development • Site planning through Q3 2014 • Cost-competitive • Installation in Q4 2013 • More energy-efficient • Hydrogen site permitted in March 2015 • Reduce consumption of diesel • Lower carbon emissions Demonstration • Decreased energy expenditures • Sta
Slide 34: Corporate Headquarters
Corporate Headquarters 968 Albany Shaker Road, Latham, NY 12110 West Coast 15913 E. Euclid Avenue, Spokane, WA 99216 plugpower.com