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FCH 2 JU - MAWP Key Performance Indicators (KPIs)

The Clean Hydrogen JU as the successor of the FCH 2 JU will continue to monitor and report the on-going projects funded by FCH 2 JU. The relevant technology KPIs can be found in the Annexes of the FCH 2 JU MAWP.

 

  • 15 NOVEMBER 2021
MAWP final version_endorsed GB 15062018 (ID 3712421).pdf

Fuel Cell and Hydrogen - Transport Applications

Fuel cell light duty vehicles (including cars)

 

No.

Parameter

Unit

State of the art

 

FCH 2 JU target

 

SoA 2012

International SoA 2017*

Target 2020

Target 2024

Target 2030

1

Fuel cell system durability

h

2,500

4,000

5,000

6,000

7,000

2

Hydrogen consumption

kg/100 km

na

1.2

1.15

1,1

1

3

Availability

%

95

98

98

99

>99

4

Maintenance

EUR/km

na

0.04

0.03

0.02

0.01

5

Fuel cell system cost

EUR/kW

500

100

60

50

40

6

Areal power density

W/cm2

na

1.0

1.5

1.8

2.0

7

PGM loading

g/kW

na

0.4

0.17

0.08

0.05

8

Cell Volumetric power

kW/l

na

5.0

7.3

9.3

10.0

Notes:

                                     
1. Durability of the fuel cell system until 10% power degradation. The typical vehicle lifetime requirement is 6,000-7,000 h of operation

2. Hydrogen consumption for 100 km driven under real life operation using exclusively hydrogen feed

3. Percent of time that the vehicle is able to operate versus the overall time that it is intended to operate, assuming only FC related technical issues

4. Costs for spare parts and labour for the drivetrain maintenance per km travelled over the vehicle's complete lifetime of 6,000 to 7,000 hours

5. Actual cost of the fuel cell system - excluding overheads and profits, assuming 100,000 systems/year as cost calculation basis

6. Power per cell area @ 0.66V: Ratio of the operating power of the fuel cell to the active surface area of the fuel cell

7. Overall loading in Platinum Group Metals at cathode + anode. (to be only used as guidance, not as a development target)

8. Power for single cell (cathode plate, MEA, anode plate) per unit volume, ref: Autostack-core Evo 2 dimensions: cell pitch 1.0 mm and cell area: 595 cm2

*  for cost aspects, when relevant, the European SoA is indicated and labelled with an asterisk

Fuel cell electric buses (e.g. non-articulated type of bus)

No.

Parameter

Unit

State of the art

FCH 2 JU target

SoA 2012

International SoA 2017*

Target 2020

Target 2024

Target 2030

1

Fuel cell system durability

h

10,000

16,000

20,000

24,000

28,000

2

Hydrogen consumption

kg/100 km

9

8.5

8.0

7.5

7.1

3

Availability

%

85

90

90

93

93

4

Yearly operation cost (including labour)

EUR/year

-

-

16,000

14,000

11,000

5

Fuel cell system cost

EUR/kW

3,500

1,500

900

(250 units)

750

(500 units)

600

(900 units)

6

Bus cost

thousand EUR

1,300

650

625

(150 units)

600

(250 units)

500

(300 units)

Notes:

1. Durability of the fuel cell system subject to EoL criterion, fuel cell stack life 10% degradation in power or H2 leak rate as per SAE2578

2. Hydrogen consumption for 100 km driven under operations using exclusively hydrogen feed acc. to SORT 1 and 2 drive cycle

3. Percent amount of time that the bus is able to operate versus the overall time that it is intended to operate for a fleet availability same as diesel buses

4. Costs for spare parts and man-hours of labour for the drivetrain maintenance

5. Actual cost of the fuel cell system - excluding overheads and profits subject to yearly overall fuel cell bus module volume as stated

6. Cost of manufacturing the vehicle. In case of buses for which a replacement of the fuel cell stack is foreseen, the cost of stack replacement is included in the calculation. Subject to yearly volumes per OEM as assumed in Roland Berger FC bus commercialisation study

* for cost aspects, when relevant, the European SoA is indicated and labelled with an asterisk

Fuel cell electric trains (300 passengers, 150 seated)

No.

Parameter

Unit

State of the art

FCH 2 JU target

2012

International SoA 2017*

2020

2024

2030

1

Fuel cell system durability

h

N/A

12,000

20,000

25,000

30,000

2

Hydrogen consumption

kg/100 km

N/A

24 - 34

22 - 32

21 - 30

20 - 28

3

Availability

%

N/A

87

94

97

>99

Notes:

No possibility at this time to estimate train cost, including fuel cell system cost and yearly operation costs targets.

1.Durability of the fuel cell system subject to EoL criterion output voltage at maximum power

2. Hydrogen consumption for 100 km driven under operations using exclusively hydrogen feed

3. Percent amount of time that the train is able to operate versus the overall time that it is intended to operate

* for cost aspects, when relevant, the European SoA is indicated and labelled with an asterisk

Fuel cell electric aircraft

No.

Parameter

Unit

State of the art

FCH 2 JU target

2012

International SoA 2017*

2020

2024

2030

1

Fuel cell system durability

h

2,000

5,000

10,000

15,000

20,000

2

Availability

%

-

-

60

75

90

 

 

 

 

>20,000

20,000

6,000

3,000

3

Fuel cell system cost

EUR/kW

3,500

>10,000

>15,000

10,000

15,000

3,000

5,000

1,500

3,000

4

Gravimetric Power density

kW/kg

-

2

5

2.5
6

3

7

3.5

8

Notes:

No possibility at this time to estimate aircraft production cost at an assumed up-scaled production level.

1. Durability of the fuel cell system until 10% power degradation.

2. Percent amount of time that the aircraft is able to operate versus the overall time that it is intended to operate.

3. Actual cost of the fuel cell system - excluding overheads and profits for mass production volumes.

  • Ram air turbine - emergency system replacement (RAT) (15-50 kW)
  • Propulsion (40 kW)
  • Cabin Loads - APU (5-20 kW)

4. FC Stack & Power converter.

* for cost aspects, when relevant, the European SoA is indicated and labelled with an asterisk

Fuel cell forklifts

No.

Parameter

Unit

State of the art

FCH 2 JU target

2012

International SoA 2017*

2020

2024

2030

1

Vehicle lifetime

h

na

-

20,000

20,000

20,000

2

Hydrogen consumption

kg/h

na

-

6.67

6.3

6.0

3

System electrical efficiency

%

45

-

50

53

55

4

Availability

%

90

-

98

98

98

5

Mean time between failures (MTBF)

h

na

-

750

1,000

1,250

6

Cost of spare parts

EUR/h

na

-

7

5

4

7

Labour

Person h/kh

na

-

10

7

5

8

Fuel cell system cost (10 kW)

EUR/kW

4,000

-

2,500

1,250

450

9

Est. FC system cost @ mass prod.

EUR/kW

na

-

-

1,250

450

Notes:

1. Total number of hours of vehicle operation until end of life (assuming >98% availability in the fleet in heavy duty 3/7 or 3/5 shift operation).

2. Hydrogen consumption for h of operations using exclusively hydrogen feed for Class 1 forklift load cycle @ 10 kW avg. system power output (Begin-of-Life)

3. Percentage (%) of electricity generated by the fuel cell vs. energy contained in the hydrogen delivered to fuel cell (LHV) for Class 1 forklift load cycle @ 10 kW avg. system power output (Begin-of-Life)

4. Percent amount of time that the forklift is able to operate versus the overall time that it is intended to operate.

5. Average time between successive failures leading to downtime (MTBF in the fleet in heavy duty 3/7 or 3/5 shift operation).

7. Costs for spare parts for the system maintenance as percentage of system investment over the vehicle's complete lifetime.

8. Man-hours of labour for the system maintenance per 1,000 h of operations over the vehicle complete lifetime.

9. Actual cost of the fuel cell system - excluding overheads and

10. Estimated fuel cell system cost at an assumed up-scaled production level of 2024: 20,000 units/production & 2030: FC cost level benefits from automotive, bus and truck volumes.

* for cost aspects, when relevant, the European SoA is indicated and labelled with an asterisk

On-board gaseous hydrogen storage tank

No.

Parameter

Unit

State of the art

FCH 2 JU target

2012

International SoA 2017*

2020

2024

2030

1

CAPEX - Storage tank

EUR/kg H2

3,000

1,000

500

400

300

2

Volumetric capacity (at tank system level)

kg/l

0.02

0.023

0.03

0.033

0.035

3

Gravimetric capacity (at tank system level)

%

4

5

5.3

5.7

6

Notes:

1. Total cost of the storage tank, including one end-plug, INCLUDING the in-tank valve injector assembly assuming 100,000 parts/year.

2. Weight of hydrogen that can be stored over the volume of the tank (including in-tank valve injector assembly, tank walls, bosses, plug and the volume for the hydrogen itself).

* for cost aspects, when relevant, the European SoA is indicated and labelled with an asterisk

Hydrogen Refuelling Stations (HRS)

No.

Parameter

Unit

State of the art

FCH 2 JU target

2012

International SoA 2017*

2020

2024

2030

1

Lifetime

years

na

10

12

15

20

2

Durability

years

na

-

5

10

15

3

Energy consumption

kWh/kg

na

10

5

4

3

4

Availability

%

na

95

96

98

99

5

Mean time between failures (MTBF)

days

na

20

48

72

168

6

Annual maintenance cost

EUR/kg

na

-

1.0

0.5

0.3

7

Labour

Person h/kh

na

-

70

28

16

8

CAPEX for the HRS

Thousand EUR/

(kg/day)

7.5

7

4-2.1

3-1.6

2.4-1.3

9

Cost of renewable hydrogen

EUR/kg

13

12*

11

9

6

Notes:

1. Total number of hours of station operation.

2. Time that the HRS without its major components/parts (storage, compressor, pump) being replaced, is able to operate (storage shall be changed when the number of cycle reaches the regulatory limit. Replacement of hydraulic compressor is forecasted between 10 to 15 years).

3. Station energy consumption per kg of hydrogen dispensed when station is loaded at 80% of its daily capacity - For HRS which stores H2 in gaseous form, at ambient temperature, and dispense H2 at 700 bar in GH2 from a source of >30 bar hydrogen.

4. Percent amount of hours that the hydrogen refuelling station is able to operate versus the total number of hours that it is intended to be able to operate (consider any amount of time for maintenance or upgrades as time at which the station should have been operational).

5. Parts and labour based on a 200 kg/day throughput of the HRS. Includes also local maintenance infrastructure. Does not include the costs of the remote and central operating and maintenance centre.

6. Person -hours of labour for the system maintenance per 1,000 h of operations over the station complete lifetime.

7. Total costs incurred for the construction or acquisition of the hydrogen refuelling station, including on-site storage. Exclude land cost & excluding the hydrogen production unit. Target ranges refer to a 200 kg/day station and a 1000kg/day station.

8. Cost for the hydrogen dispensed (at the pump), considering OPEX and CAPEX according to the operator's business model

* for cost aspects, when relevant, the European SoA is indicated and labelled with an asterisk

Fuel Cell and Hydrogen – Energy Applications

Hydrogen production from renewable electricity and other resources

Hydrogen production from renewable electricity for energy storage and grid balancing using alkaline electrolysers

No.

Parameter

Unit

State of the art

FCH 2 JU target

2012

2017

2020

2024

2030

Generic system*

1

Electricity consumption @nominal capacity

kWh/kg

57

51

50

49

48

2

Capital cost

EUR/(kg/d)

(EUR/kW)

8,000

(~3,000)

1,600

(750)

1,250

(600)

1,000

(480)

800

(400)

3

O&M cost

EUR/(kg/d)/yr

160

32

26

20

16

Stack

4

Degradation

%/1000hrs

-

0.13

0.12

0.11

0.10

5

Current density

A/cm2

0.3

0.5

0.7

0.7

0.8

6

Use of critical raw materials as catalysts

mg/W

8.9

7.3

3.4

2.1

0.7

Notes:

*Standard boundary conditions that apply to all system KPIs: input of 6 kV AC power and tap water; output of hydrogen meeting ISO 14687-2 at a pressure of 30 bar. Correction factors may be applied if actual boundary conditions are different.

2. Capital cost are based on 100 MW production volume for a single company and on a 10-year system lifetime running in steady state operation, whereby end of life is defined as 10% increase in energy required for production of hydrogen. Stack replacements are not included in capital cost. Cost are for installation on a pre-prepared site (fundament/building and necessary connections are available). Transformers and rectifiers are to be included in the capital cost.

3. Operation and maintenance cost averaged over the first 10 years of the system. Potential stack replacements are included in O&M cost. Electricity cost are not included in O&M cost.

4. Stack degradation defined as percentage efficiency loss when run at nominal capacity. For example, 0.125%/1000 h results in 10% increase in energy consumption over a 10 year lifespan with 8000 operating hours per year

5. The critical raw material considered here is Cobalt. Other materials can be used as the anode or cathode catalysts for alkaline electrolysers. 7.3 mg/W derives from a cell potential of 1.7 V and a current density of 0,5 A/cm2, equivalent to 6.2 mg/cm2

Hydrogen production from renewable electricity for energy storage and grid balancing using PEM electrolysers

No.

Parameter

Unit

State of the art

FCH 2 JU target

2012

2017

2020

2024

2030

 

Generic system

1

Electricity consumption @nominal capacity

kWh/kg

60

58

55

52

50

2

Capital cost

EUR /(kg/d)

8,000

2,900

2,000

1,500

1,000

(EURkW)

(~3,000)

(1,200)

(900)

(700)

(500)

3

O&M cost

EUR/(kg/d)/yr

160

58

41

30

21

Specific system

4

Hot idle ramp time

sec

60

10

2

1

1

5

Cold start ramp time

sec

300

120

30

10

10

6

Footprint

m2/MW

-

120

100

80

45

Stack

7

Degradation

%/1000hrs

0.375

0.250

0.190

0.125

0.12

8

Current density PEM

A/cm2

1.7

2.0

2.2

2.4

2.5

9

Use of critical raw materials as catalysts PGM

mg/W

-

5.0

2.7

1.25

0.4

10

Use of critical raw materials as catalysts Pt

mg/W

-

1.0

0.7

0.4

0.1

 Notes:

Availability is fixed at 98% (value from the electrolysis study).

1 to 3 and 7 similar conditions as for alkaline technology (previous table)

2. The time from hot idle to nominal power production, whereby hot idle means readiness of the system for immediate ramp-up. Power consumption at hot idle as percentage of nominal power, measured at 15°C outside temperature.

3. The time from cold start from -20°C to nominal power

9. This is mainly including ruthenium and iridium as the anode catalyst and platinum as the cathode catalyst (2.0 mg/cm2 at the anode and 0,5 mg/cm2 at the cathode). The reduction of critical raw materials content is reported feasible reducing the catalysts at a nano-scale.

Hydrogen production from renewable electricity for energy storage and grid balancing using high-temperature SOE

No.

Parameter

Unit

State of the art

FCH 2 JU target

2012

2017

2020

2024

2030

Generic system*

1

Electricity consumption @rated capacity

kWh/kg

na

41

40

39

37

2

Availability

%

na

na

95%

98%

99%

3

Capital cost

EUR/(kg/d)

na

12,000

4,500

2,400

1,500

4

O&M cost

EUR/(kg/d)/yr

na

600

225

120

75

Specific system

5

Reversible efficiency

%

na

50%

54%

57%

60%

6

Reversible capacity

%

na

20%

25%

30%

40%

Stack

7

Production loss rate

%/1000hrs

na

2.8

1.9

1.2

0.5

 Notes:

* Standard boundary conditions that apply to all system KPIs: input of AC power and tap water; output of hydrogen meeting ISO 14687-2 at atmospheric pressure. Correction factors may be applied if actual boundary conditions are different.

From 3 and 4 please refer to table 2.1 ( similar conditions as for alkaline technology)

5. Reversible efficiency is defined as the electricity generated in reversible mode of the electrolyser, divided by the lower heating value of hydrogen consumed.

6. Reversible capacity is defined as a percentage of the electric capacity in fuel cell mode in relation to the electrolyser mode

7. Degradation at thermo-neutral conditions in percent loss of production-rate (hydrogen power output) at constant efficiency. Note this is a different definition as for low temperature electrolysis, reflecting the difference in technology.

Hydrogen production with low carbon footprint from other resources

No.

Parameter

Unit

State of the art

FCH 2 JU target

2012

2017

2020

2024

2030

Hydrogen from raw biogas*

1

System energy use

kWh/kg

62

56

56

55

53

2

System capital cost

EUR/(kg/d)

4,200

3,800

3,100

2,500

1,500

High temp. water splitting*

1

System energy use

kWh/kg

120

110

100

94

88

2

System capital cost

EUR/(kg/d)

4,000

3,500

2,500

1,700

1,400

3

System lifetime

years

0.5

1

2

10

10

Biological H2 production**

1

System hydrogen yield

H2/C

0.60

0.62

0.64

0.65

0.65

2

Reactor production rate

kg/m3

reactor

2

10

40

100

200

3

Reactor scale

m3

0.05

0.5

1

10

10

 Notes:

* The system energy use values include the energy required for heat generation and for producing hydrogen at 30 bar output pressure to meet ISO 14687-2. Correction factors may be applied if the actual boundary conditions are different.

** Concerning Microorganisms e.g. Algae

Fuel Cell and Hydrogen – Energy Applications

Hydrogen storage, handling and distribution

Hydrogen storage and large scale storage

No.

Parameter

Unit

State of the art

FCH 2 JU target

2012

2017

2020

2024

2030

Compressed gas tube trailers

1

Capacity

kg

400

850

1,000

1,000

1,000

2

Capital cost

EUR/kg

550

400

350

350

350

Large scale H2 storage*

1

Chain efficiency

%

-

60

67

70

72

2

Release energy use

kWh/kg

-

13.3

11

10

9.3

3

System capital cost

EUR/kg

1.2

1.1

1.0

0.8

0.6

Notes:

* Storage of at least 10 tones of hydrogen for at least 48 hours, including all necessary conversion steps from clean H2 input to clean H2 output at 30 bar. Correction factors may be applied if actual boundary conditions are different.

 

Residential micro CHP for single family homes and small buildings (0.3 - 5 kW)

No.

Parameter

Unit

 

State of the art

 

FCH 2 JU target

2012

2017

2020

2024

2030

1

CAPEX

EUR/kW

16,000

13,000

10,000

5,500

3,500

2

Lifetime

years of appliance operation

10

12

13

14

15

3

Availability

% of the appliance

97

97

97

97

98

4

Durability of key component (stack)

hrs

25,000

40,000

50,000

60,000

80,000

5

Reliability

MTBF (hrs)

10,000

30,000

50,000

75,000

100,000

6

Electrical efficiency

% LHV

30-60

33-60

35-60

37-63

39-65

7

Thermal efficiency

% LHV

25-55

25-55

30-55

30-55

30-55

8

Maintenance costs

EUR Ct/kWh

40

20

5

3.5

2.5

9

Tolerated H2 content in NG

%

(Volume)

5%

5%

100%

100%

100%

10

Installation volume/unit

l/kW

330

240

230

225

220

 Notes:

1. Cost of manufacturing (labour, materials, utilities) of the m-CHP unit at current production levels (exclude monetary costs, e.g. overheads, profits, rebates, grants, VAT, insurances, taxes, land).

2. Lifetime (years) that the m-CHP unit, with its major components/parts being replaced, e.g stack, is able to operate until the End-of-Life.

3. Ratio of the time that the FC module was able to operate minus downtime divided by the time that was expected to operate. Downtime is the time that the FC is not able to operate-includes time for (un)scheduled maintenance, repairs, overhaul etc

4. Time that a maintained fuel cell stack is able to operate until End-of-Life criterion - as specified by the OEM.

5. Mean time between failure of the FC that render the system inoperable without maintenance or average time between successive failures leading to downtime: time that the FC is not able to operate includes (un)scheduled maintenance, repairs, overhaul etc

6. Electrical efficiency at rated capacity for the FC module as % of electrical output vs energetic content of fuel - Low Heating Value (LHV).

7. Thermal efficiency at rated capacity for the FC module as % of electrical output vs energetic content of fuel - LHV.

8. Operation and maintenance costs per kWh of electricity produced - Including running, overhaul, repair, maintenance labour costs and costs of stack replacement; excluding: fuel cost, insurances, taxes, etc.

9. Percent amount of hydrogen that can blended into the hydrocarbon feed (usually natural gas) allowing normal functioning of the fuel cell module.

10.Volume of fuel cell module as is available for installation in its basic configuration, in l/kWe.

Mid-sized installations for commercial and larger buildings (5 - 400 kW)

No.

Parameter

Unit

State of the art

 

FCH 2 JU target

 

 

2012

 

2017

 

2020

 

2024

 

2030

1

CAPEX

EUR/kW

6,000 - 10,000

5,000 - 8,500

4,500 – 7,500

3,500 - 6,500

1,500 - 4,000

2

Lifetime

years of plant operation

2 - 20

6 - 20

8 - 20

8 - 20

15-20

3

Availability

% of the

plant

97

97

97

97

98

4

Durability of key component (stack)

khrs

25

30x

50

60

80

5

Reliability

MTBF

(hrs)

10,000

20,000

30,000

50,000

80,000

6

Electrical efficiency

% LHV

40-45

41-55

42-60

42-62

50-65

7

Thermal efficiency

% LHV

24-40

24-41

24-42

24-42

30-50

8

Maintenance costs

EUR Ct/kWh

8.6

7.6

2.3

1.8

1.2

9

Tolerated H2 content

in NG

%

(Volume)

50%

50%

100%

100%

100%

10

Land use/ footprint

m2/kW

0.25

0.15

0.08

0.07

0.06

 

Notes:

From 1 to 9 please refer to the definitions of the previous table

10. Base surface (width x depth) occupied by the stationary fuel cell module per unit of rated electrical capacity.

Large scale FC installations, converting hydrogen and renewable methane into power in various applications (0.4 - 30 MW)

No.

Parameter

Unit

State of the art

FCH 2 JU target

2012

2017

2020

2024

2030

1

CAPEX

EUR/kW

3,000­ - 4,000

3,000 - 3,500

2,000 - 3,000

1,500- 2,500

1,200­ - 1,750

2

Lifetime

years of plant operation

n/a

15

25

25

25

3

Availability

% of the plant

98

98

98

98

98

4

Durability of key component (stack)

khrs

15

20-60

20-60

20-60

25-60

5

Reliability

MTBF (hrs)

n/a

n/a*

25,000

30,000

75,000

6

Electrical efficiency

% LHV

45

45

45

45

50

7

Thermal efficiency

% LHV

20

20-40

22-40

22-40

22-40

8

Maintenance costs

EUR Ct/kWh

n/a

2.8-5

3

3

2

9

Start/Stop

characteristics

-

-

4 hrs 0­100%

-

100%/1

min

-

Notes:

* insufficient number of units installed to get statistically supported figure

From 1 to 8 please refer to the definitions of the previous table

9. Time required to reach the nominal fuel cell rated output when starting the system from shut-down mode (at ambient temperature).