Advanced Fuel Cell Technology
next

 

M E E T I N G   R E P O R T

The EDTA Conference in Vancouver:
Both Mice and Lions Roared
December 6-8, 2005

Nigel Fitzpatrick
Azure Dynamics
Vancouver, BC, Canada

On the opening day of the Electric Drive Transportation Association Conference & Exposition 2005, I could have ridden on one of Vancouver’s electric trolley buses to reach the waterfront conference center but went in by car on the first day, only correcting this on the second and third days.

Pierre Elliot Trudeau once said that Canada’s relationship with the United States is like being “a mouse in bed with an elephant…no matter how friendly…one is affected by every twitch and grunt.”1 Now and then the elephant will see the mouse and smile, as in the case of the extraordinary rescue by Canada of six U.S. citizens from Iran in 1980 when Congress struck a gold medal in Ambassador Ken Taylor’s honor.2

EDTA is the Electric Vehicle Association of the Americas reborn. This organization was as a sister to the European and Asian organizations that together make up the World Electric Vehicle Organization. The EDTA conference is a world class meeting, and a place to show new developments in anticipation of the 2010 Winter Olympics that are coming to Vancouver and Whistler.

Associated with this year’s conference was a seminar, “Electric Mobility in Canada,” that encompassed rail and road transportation and was co-hosted by Al Cormier of The Centre for Sustainable Transportation (www.cstctd.org) and Pierre Lavallée of CEVEQ (www.ceveq.qc.ca).

The objective was to consider forming a consortium of Canadian interests involved in electric mobility.

We began with presentations by Cameron Marr of Bombardier Transportation (Cameron.marr@ca.transport.bombardier.com) on electric rail systems such as the SkyTrain used in Vancouver and Singapore; Dawn Soulis of Toyota Canada (dsoulis@toyota.ca) spoke about the rapid progress of Toyota’s hybrids; and Aaron Lamb of BC Transit (aaron_lamb@bctransit.com) described the six New Flyer fuel cell hybrid buses in operation and a plan to place 20 more of them into service in Whistler.

Richard Gilbert (richardgilbert1@csi.com) then re- minded us that five of Canada’s leading cities made efficient use of electricity with either trolley buses or guided ground transport and then showed the relative merits of hydrogen, hybrids and tethered electric and plug in electric vehicles. Gilbert’s numbers showed that grid-connected electric transportation used a third of the primary energy that a hydrogen fuel cell would use and also held out hope for future plug-in hybrids which could potentially use electricity more efficiently than the hydrogen route through a fuel cell.

The Whistler fuel cell project deserves some detail. It is important to bear in mind the long lead time in both ordering and building big transit buses. To order a hybrid fuel cell bus you need to place your order at least three years before you want it. Indeed, New Flyer in Winnipeg already has a four-year backlog for ordinary hybrid buses. The geography of Whistler is totally unsuitable for grid-connected vehicles, and plug-in hybrids are not ready. The proven feasible choices are regular diesel, natural gas and hybrid. BC Transit has made a bold decision to see if it is feasible to deploy fuel cell hybrid vehicles.

The cost of the Whistler project would total $89 million including funds to operate for four years, there are budget check points, but BC Transit hopes to be able to award contracts by June. The buses are tightly specified and are required to seat 39 and with standees to carry 60; have a partial or complete low floor; have a range of 500km; be fuel cell hybrids; have 5000psi storage and operate at -20°C, etc. It is hoped to have the first bus in operation in 2008 and then have the fleet begin service in 2009 to be ready for the 2010 Winter Olympics. The plan is to issue the request for proposals by March 31st and to place a contract by June if the specifications can be met.

At noon the exposition had opened downstairs and the “ride and drive’ had begun. Vehicles that were there included the Honda and Ford fuel cell vehicles, various light vehicle hybrid products, a Purolator hybrid delivery truck and a New Flyer hybrid bus.

There were a remarkable number of Toyota Prius taxis visible from the hotel doors. When hybrids first arrived in BC in 2000 we were delighted to find that the provincial government gave an immediate provincial sales tax rebate and their insurance company, ICBC, gave a second one. According to BC’s Minister of the Environment Barry Penner, whom we shall meet later at the close of the conference, one taxi driver in the provincial capital, Victoria, took the risk of trying a Prius as a taxi and then bragged about it. Today virtually all the taxis in Victoria are hybrids. Canada’s highest mileage Prius, a 2001 model, has reached over 400,000km.

At the “Electric Mobility in Canada” lunch the president of EDTA, Bryan Wynne (bwynne@elect ricdrive.org), spoke and drew us all together.

Diving deeply into the exposition in quest of fuel cell stories, I found one immediately. You may be aware that one can buy a quiet submarine with a “fuel cell range extender” from Germany or Italy (http://cns.miis.edu/research/sub-marines/italy/export.htm). Danny Epp (depp@itiselectric.com) worked on the discontinued Ballard submarine project and today was standing with two Dynasty low-speed vehicles. He is now the general manager of Dynasty’s Hybrid Division and is putting together a project to extend the range of the Dynasty vehicle with a small fuel cell. He is presently analyzing the Nexa® power module from Ballard for this application. If funding is attained, the first deployment of this technology would likely be on the UBC campus where a couple of Dynasty electric vehicles already operate. If Epp could do this for an underwater application then, we will see reliable progress close to an already existing hydrogen fueling station: part of the Hydrogen Highway™ in BC.

At the Ballard stand, Emerson Gallagher (emerson. gallagher@ballard.com) showed me the scale of a vehicle fuel cell stack. The Nexa® that Danny Epp may use is smaller, but as you will find at the end of the article, that Cellex has identified a market which will mean it will be available in significant volumes in the next two years.

Opposite the Ballard stand I met Mike McAuley of UQM (mmcauley@uqm.com), which is supplying Ballard with efficient brushless DC motors for their air compressors. McAuley spoke of the growth in orders for their smaller motors. The conversation reminded me that a key need of all electric drive vehicles is the need to efficiently power ancillaries related to steering brakes, air conditioning and power steering.

Right next door I met Ashley Ainsworth of Electrovaya (aainsworth@electrovaya.com) which is under contract to NASA to supply a Li-ion battery for the international space station. They also have an agreement with Microsoft to develop a battery capable of powering a laptop from 8 to 16 hours. The company is one of those who were announced at the conference as players in the Hybrid Consortium (www.hybridconsortium.org.) which consists of component suppliers who are pursuing the quest for “plug-in hybrids” i.e., hybrids which can also accept wall electricity in the way that most developmental hybrids did until Toyota broke away from the herd with the Prius. Hybrids today stay away from damaging deep-discharge cycles as they had to get to market with a reasonable cost. Li-ion promises to better able undergo deep discharge without damage.

Another member of the Hybrid Consortium was present in Ken Fielding, the CEO of Delta-Q (kfielding@delta-q.com), which specializes in battery charging. Delta-Q hopes for a piece of the action in the plug-in hybrid world.

Bypassing the Toyota and Lexus stands I reached the eP-ICEBEAR which does the same job as a Zamboni®, and is billed as the “world’s first fuel cell powered ice refinisher”. This machine (pictured on January’s cover) is a fuel cell hybrid from Resurfice Corp. (www.Resurfice.com), represented by Rick Schlupp. The fuel cell is a 2-5 kW unit from Nuvera claiming an efficiency of 52% DC efficiency at the beginning of life and usefully designed to operate at -20°C. Nuvera was represented by Gus Block, (block.g@nuvera.com). Bruce Wood of ePower Synergies Inc. (BEWood@ePowerSynergies.com), who did the electrical integration, rode in the seat. Dynetek of Calgary provided the hydrogen tanks for this vehicle as they do for many of the hydrogen and natural gas vehicles around the world.

Is there a market and is this an application for a fuel cell? There is certainly a demand for cleaner machines. The Winter Olympics in 2006 in Turin will use a pure electric Zamboni as did the Winter Olympics in Squaw Valley, California, in 1960, the first Olympics to use Frank Zamboni’s electric machine3. Indoor air quality concerns mean there is a move away from natural gas machines here in BC. Indeed, earlier this month5 the Delta council approved spending $190,000 on the first of six new battery-powered machines that are planned before 2012.

Here we have an interesting case to study. There has been a reliable clean electric ice resurfacer since Zamboni introduced one and they are sweeping to success2. Rinks in this province are switching to them. If we go back to the numbers Richard Gilbert gave us in the “Electric Mobility” seminar, we may double the use of electricity if we use a fuel cell. This change is inevitably not good for climate change emissions.

This application would make sense if the hydrogen refueling system and fuel cell allowed a reduction in overall cost of the operation. We will put this discussion “on ice” until we hear the presentations on fuel cell commercialization right at the end of the meeting!

Johnson Controls and Saft have announced a joint venture to work together on batteries for hybrid vehicles. I found only NiMH literature at the stand.

Right next door Cobasys (www.cobasys.com) was displaying an open liquid cooled NiMHax(R) 336-70 battery that has seen service on 14,001lb GVW hybrid trucks. And this battery was right beside its next application, the chassis of a series hybrid shuttle bus shown by Azure Dynamics and manned by Mark Federle (mfederle@ azuredynamics.com).

On the second day I arrived in time to hear news of the buzz of the opening session where, in a question to John Tak of Fuel Cells Canada (jtak@fuelcellscanada.ca), Ed Innes of Manitoba Hydro (jeinnes@hydro.mb.ca) suggested that it was more efficient to put electricity straight into a car than to pass through hydrogen on the way.

I started in a session on military needs but had the luck to move to a session where I hoped to find some of the plug-in buzz in a presentation by Toyota’s Mary Nickerson who talked primarily on market perception of the hybrid. Nickerson joined Dawn Soulis, who had spoken for Toyota the day before, in showing that hybridization could apply to all fuels.

Then the buzz happened again! At the end of this Toyota presentation a questioner gave his name as Ed Schreyer, Canada’s former Governor General. Schreyer has been an electric vehicle champion since he was the Premier of Manitoba. I’ve only seen him once before and that, strangely, was in December 1983 at an electric vehicle and battery conference in Ottawa. He asked why it was that Toyota wants to stop its development halfway up the hill and not go on to plug-in hybrids. Mary Nickerson replied that Toyota is focused on well-to-wheel energy use and is studying plug-in hybrids.

Stephen Brydon (Stephen.Brydon@gov.bc.ca) was speaking for the BC government in another session and I wondered if he would also give more information on the Whistler fuel cell bus plan that Aaron Lamb had described. Brydon reminded the audience that while transportation emissions made up 25% of total GHG in Canada, in British Columbia the number was 40%. This leads to a strong focus on transportation. For example, the BC government has more hybrids than any other provincial government. BC also has the largest hybrid incentives in place in Canada (www.rev.gov.bc.ca/ctb/publications/bulletins/sst_085.pdf).

BC Transit had begun to evaluate hybrid buses and was the first bus property in Canada to have them in operation with six buses for Kelowna. These are New Flyer Buses with the GM Hybrid System. There were five Ford hybrid fuel cell vehicles in operation already in BC (www.vfcvp.gc.ca).

Brydon also briefly touched on the BC Transit offer to purchase 20 fuel cell buses for revenue service in Whistler from 2009 onwards. This was in the context of an overall plan described at www.hydrogeneconomy.gc.ca.

I caught the end of a presentation by John Neufeld of Transport Canada (NEUFELJ@tc.gc.ca) as he was showing a film of the crash testing of low-speed vehicles into a solid wall at 50km/hr. The film and the accelerations recorded on the dummies in the vehicles vividly showed that further work was needed, and the implication was that these vehicles should be separated from other traffic, as indeed they are in gated communities.

At lunch I met Roger Ludwick, R&D planning officer at Manitoba Hydro, (rlludwick@hydro.mb.ca) who gave me some of the background on the interest they have in plug-in hybrids. His budget is supporting a project to demonstrate a Prius hybrid with an extra battery. Ludwick confirmed there was stronger interest in Manitoba for the direct use of electricity for vehicles than hydrogen. Manitoba Hydro is one of the first Canadian utilities to introduce a plug-in hybrid vehicle into its fleet. The vehicle is a Toyota Prius which is being modified to allow a plug-in capability for a 30-mile electric range. The project is to research the operational impacts that a PHEV would impose on the Manitoba Hydro electric system and to evaluate the vehicle operation in Manitoba’s harsh weather conditions. A lithium-ion battery pack will be installed in the Prius after removing the original battery system. Appropriate elect- ronics also will be installed in the car to manage the electric driving mode and kick-in of the gasoline mode. Conversion to PHEV will be completed early in 2006.

In the afternoon I attended a session entitled “Hybrid Technology Advances: Components’ Suppliers’ Perspective” by Menahem Anderman (menahem@advanceautobat.com). He gave an overview of progress and interestingly differentiated between micro hybrids and medium hybrids by saying the former needed less than 5 seconds of charge and the latter needed more than 10 seconds, thereby necessitating a battery.

Gitanjali Dasgupta (gdasgupta@electrovaya.com) then added to my knowledge of the work at Electrovaya with slides supplemented by interactive markings aided by the laptop using a Scribbler® Battery described at www.electrovaya.com.

Marc Wiseman described the global perspective of Ricardo (www.ricardo.com) and, as we have come to expect, stressed the continuing low-cost improvements in the efficiency of engines and, in the context of hybrid electric systems, asked how one gets to less than 100 parts per million failures.

V. Evan House of AltairNano (ehouse@altairnano.com) described a team of people who were formerly part of GM/Delphi. They are operating in Reno, Nevada and Anderson, Indiana. As well as their understanding of pack development, they are doing ground work on new chemistries. One example is a lithium titanate spinel that is safe up to 350°C. It can be recharged in less than 10 minutes and will have a longer battery life. Besides being inherently safe it is a green design and added promise to the Li-ion thrust of the conference.

Before the evening reception there was a panel of speakers who were organized by Bob Stempel, the chairman of ECD and former CEO of GM. In this session there was a flurry of interest in the Toyota presentation by Trent Boman of Toyota (trent_boman@toyota.com) who, in the question period, backed up his slides to one on the relative emissions of tonnes of carbon dioxide over 150,000 km ( the lifetime of the vehicle). It showed that a hybrid emitted 29.7 tonnes and hydrogen from natural gas produced 35.6 tonnes. If the hydrogen were produced with the U.S. power mix, then 93.7 tonnes of carbon dioxide would result.

Elizabeth Munger of Honda (emunger@ earthlink.net) went the other way and presented hydrogen as the ultimate goal. This may well have triggered Gordon Dower of The Ridek Corp. (dower@whidbey.com) to cite Joseph J. Jerome’s “The Hype about Hydrogen” that claims electric vehicles are more efficient than hydrogen vehicles.

The meeting adjourned to the reception. I did have a brief chat with Paul Scott of ISE Corp. (pscott@isecorp.com) on his view of the debates on hydrogen and hybrids. Scott has put together a number of hydrogen vehicles and is fairly positive about the reliability of hydrogen buses from the work he has done in California.

On the third morning I was mostly in meetings in the solutions for heavy-duty vehicles.

Mitch Jackson of FedEx spoke of leading beneficial climate change impact from hybridization of medium-duty trucks where all fleets in the U.S. total 772,000 vehicles between 14,001 and 19,500lbs GVW. While long-term technology goals are needed, there are near-term solutions at hand. It is fuel economy that is first in his mind. FedEx has, of course, just received the prestigious BlueSky Award for its work in introducing commercial delivery vehicle hybrids (www.fedex.com/us/about/news/pressreleases/bluesky.html?link=4) .

The next speaker was Bobby Maher of Maxwell who addressed the use of ultracapacitors with fuel cells for fork trucks, mentioning their work with both General Hydrogen and Hydrogenics in this respect. They could deliver 40kW using a fuel cell of only 14kW peak power.

Then David Deacon (ddeacon@azuredynamics.com) showed the commonality of components between combustion and fuel cell hybrids and plug-in hybrids and stressed that the commercial hybrid vehicle market was capable of reducing costs for all future options. Within three years in the courier delivery market paybacks of between 2.2 years and 3.5 years were within sight. But the key was for government to help the early adopters such as FedEx and Purolator who had taken the lead.

Serge Viola of Purolator (sviola@purolator.com) concluded the session. In Canada, Purolator has the largest share of the courier market. He had analyzed his fleet and found that there were about 3000 trucks with 14,001lb GVW that were suitable for hybridization. Currently he was operating hybrid trucks in the center of Toronto and had ordered 115 further vehicles from Azure. Some would be deployed in Toronto but other centers such as Montreal, Ottawa and Vancouver would also have trucks.Viola spoke then of his hydrogen fuel cell project with a Hydrogenics fuel cell. The next generation would be with a fuel cell, a battery, and possibly also ultracapacitors. He was also looking at a hydraulic hybrid.

At the break I spoke to Maja Veljkovic (Maja.Veljkovic@nrc-cnrc.gc.ca) director general, National Research Council of Canada’s Institute for Fuel Cell Innovation who support not only fuel cell activities (including, of course, SOFC as well as PEM) across Canada but related technologies. Recently the NRC environmental chamber we spoke of in an earlier issue has been testing hybrid trucks between -400C and +400C.

Velijkovic headed in to speak on her hydrogen fueling station in the “Fueling and Infrastructure “ meeting. I went into “Accelerating Commercial Fleet Adoption” and heard Dennis Rogoza (DRogoza@FleetChallenge.ca) and Windell Mitchell (windell.mitchell@metrokc.gov) of the King County Department of Transportation discuss the key issues that face fleets looking to make changes.

Rogoza spoke of the need to ensure that vehicles met the performance specifications of the user. Cost, of course, is a major factor. Mitchell outlined a list of strategies for successfully expanding the hybrid electric vehicle market. He also presented a list of decision-making criteria for evaluating the purchase of hybrid electric vehicles. In 2003 King County was selected to be the lead public agency in the U.S. to solicit a national contract that all local governments could use to purchase hybrid electric vehicles. The goal was to purchase 30,000 hybrid vehicles over a three-year period.

Honda’s Elizabeth Munger kindly hosted all at an excellent lunch. Afterwards I bumped into a smiling Andy Frank, director, Future Automotive Technology at UCDavis (aafrank@ucdavis.edu). Frank is the famed champion of “plug-in hybrids“which we have heard Toyota say at this meeting they are exploring and in which Manitoba Hydro is showing great enthusiasm.

The final technical session I attended was on “Commercialization: Progress and Challenges” where all the presentations were fuel cell related.

Stephen Kukucha showed there was now good durability, low temperature start capability and falling costs. There are now 39 Ballard-powered buses in revenue service with over 90% availability with some fuel cells having operated for 3000 or more hours.

Ron Harmer, vice president, technical services of BC Transit covered the ground of the Whistler bus program that we had heard from Aaron Lamb. It’s good to hear things twice! As I listened to Harmer I realized that the specification of 500km per day we saw earlier would be a real challenge for a Li-ion electric bus, even a plug-in version to match ZEV capability.

Perhaps a plug-in hybrid might suffice? Let’s quickly examine whether this makes sense. The target in this field is to be able to match the curb weight of an equivalent natural gas bus and with the same number of passengers New Flyer sells one with CW: 27,300lb. (12,380kg) and GVWR: 38,670lb. (17,540kg).

If, say, the bus is half loaded with passengers to 15,000 kg, then, at 0.2 Wh/kg.km5, the lower boundary of a number of electric vehicles explored by Elton Cairns in the past, we would need 300kWh of battery for every 100km range. Even at the 20Wh/kg targeted by Electrovaya the battery would weigh in at a challenging 1,500kg. Clearly, deep-cycled plug-in hybrids would not be a shoo-in for this duty cycle. The competition here then is with natural gas and hybrid buses with small batteries. That latter can provide short ZEV capability and silence where needed.

Whistler’s renewable energy will give a better GHG result than we heard from Trent Boman of Toyota. Potentially then the FCHEV bus project for Whistler stands up to sustainability scrutiny. Ron Harmer identified that a Request for Interest for the buses would be posted the following week at www.bcbid.gov.bc.ca/open.dll/welcome.

Julie Doherty, manager of government relations at Methanex (jdoherty@methanex.com) described the progress with the direct methanol fuel cell (DMFC) and particularly spoke of its use for laptops which allows one to operate for 10-12 hours on a cartridge. The product was now passing through the approval process for use on planes. Doherty was followed by Michael Tosca of United Technology Corp. One unique challenge UTC has is to make the fuel cell revenues they have visible inside a $37 billion corporation and Tosca was optimistic.

Kevin Harris of Hydrogenics (kharris@hydro genics.com) said that for the last three years costs had fallen by 50% per year and the complexity of systems is being reduced. Durability is rising to thousands of hours and for stationary applications tens of thousands were being achieved. Useful incentives were appearing in the U.S. and $1000/kW was now available. He identified they are selling products to and support military and pre-commercial markets with new emphasis and clear priority on three target commercial markets – datacentre backup, telecom backup, and material handling. There is continued development on a single common PEMFC technology platform now supplemented with separate product development teams dedicated to each market.

The final presentation was a last-minute entry in the Thursday afternoon session. Adrian Corless of Cellex (Acorless@cellexpower.com) said one warehouse running on hydrogen fork trucks could use up to 500kg of hydrogen per day. There are 6000 centres that have this kind of volume. Beta sales are 2006, volume sales are 2008. The fork trucks would use Ballard Nexa® fuel cell stacks.

The fork truck fuel cell business case works because the vehicles are preferred in continuous use and sit idle for battery charging. Reduced capital costs pay for the switch to fuel cells and this market tolerates much higher fuel cell prices than would the light vehicle market. The ice-cleaning machine is less of a good example; it field tests Nuvera cell stacks, but ice cleaning machines are not in continuous operation and normally rest for longer than they are used. But there are exceptions in multi-rink facilities as necessarily happens at the Olympics.

Hydrogenics and General Hydrogen (www.generalhydrogen.com) are tackling the fork truck market also, and it’s becoming clear that these companies have the potential to roar along with Cellex.

The technical sessions were over. The final session was to be the closing ceremony and for that Brian Wynne needed BC Minister of the Environment Barry Penner to arrive. Unfortunately, the Minister had started a long day at the COP11 Climate Change Conference in Montreal and arrived a little later than expected. Wynne joined the CEO of Azure Dynamics, D. Campbell Deacon (cdeacon @azuredynamics.com), to welcome Penner at the first hybrid electric shuttle bus to appear in BC. Then the EDTA conference came to an orderly close after Wynne presented the E-Visionary Award to Environment Minister Penner to recognize British Columbia’s leadership in alternative energy technology.

Were there other companies that roared besides the fork truck fuel cell suppliers? The small plug-in hybrid roar from Manitoba fitted the admissions from Toyota that hydrogen is not the best option for GHG in the average world of the U.S. light vehicle and that they are looking at plug-in hybrids. This endorsed the new small Li-ion battery companies here such as AltairNano and Electrovaya whose products may contest the indoor applications for fuel cells.

But there were larger company lions roaring! BC Transit is pursuing a case in Whistler where fuel cell buses are a viable option and Methanex is making DMFC happen. Ballard has a solid position in buses and is feeding cell stacks to both Cellex and General Hydrogen. Hydrogenics parallels in both buses and fork trucks.

Toyota, of course, was roaring. In our report of EVS 20 in December 2003, when a Toyota speaker was asked who made the Li-ion battery he was testing, he had said, “We do.” With the potential increase in cycle life, power and energy density it is likely that Toyota will be well positioned if plug-in hybrids are economically viable.

Readers will no doubt recall that the combined global hydrogen by-product from the production of chlorine and sodium chlorate works out to be 1,607,000 annual tonnes of hydrogen. The fork truck market and perhaps the ice rinks can use this GHG-free hydrogen. Do your own calculation on whether there is enough left over for cars to reverse the numbers presented by Toyota’s Trent Boman.

As one would expect, the fuel cell and battery business is made up of niches, and the fork truck opportunity is a large niche! Indeed, Cellex gave the number for this market as greater than $6 billion.

Once again good dialogue and discussion led to progress and the conference was a successful conclusion to 2005.




Footnotes

1. http://www.mapleleafweb.com/features/economy/us-canada/sleeping-elephant.html.

2. http://en.wikipedia .org /wiki/Iran_hostage_crisis

3. http://www.zamboni.com/news/news.html

4. “In the world of Zambonis, natural gas is out, battery power is in.”  Vancouver Sun December 10th

5. Cairns, E.J., Hietbrink, E. H., “Electrochemical Power for Transportation”, Comprehensive Treaty on Electrochemistry, Volume 3, edited, Bockris, J. O’M, Conway, B.E., Yeager, E., White, E., Plenum, 1981

     top ^
next
Tech-Etch