Fuel Cell Range Extender for Electric Vehicles
I’m always happy when I get a note from 2GreenEnergy super-supporter Gary Tulie from his home in Buckinghamshire, England, if only because it gives me an opportunity to go find another pic of his beautiful county, just north and west of London. He writes:
Ceres Power is getting to a very interesting state of development. Their solid oxide fuel cell is very robust and low cost, and can run on compressed natural gas (methane) with around 60% gas to electricity efficiency. This offers a very attractive range extender option for electric vehicles, especially for cold climates where battery range is substantially compromised by the need for heat – which can be obtained off the back end of the fuel cell. Emissions would be around 25% those of an internal combustion engine with no NOx or particulate pollution. Ceres are rapidly approaching full commercialisation for both static and range extender applications.
There is no doubt that range-extenders will play an important role in the development of electric vehicles for at least the next decade, and this sounds like a great solution. Thanks, and cheerio. 🙂
Craig,
I suppose I should declare I made money from trading the shares of Ceres Power Holdings plc.
Ceres is one of hundreds, if not thousands, of companies trying to develop better ESD ( electric Storage Device).
Solid Oxide Fuel Cell technology, like all fuel cell technology is another approach to the problem of low emission transport. Solid oxide fuel cells convert energy by oxidizing fuel, in this case methane, but hydrogen is also commonly used.
Fuel cells technology can use various electrolyte material, but the most difficult challenge for this type of technology is to overcome the problems associated with high operating temperatures, mechanical and chemical compatibility issues.
It’s good to see you’ve changed you mind about the value of Fuel Cell technology (You do understand Ceres technology isn’t a battery ?).
The Ceres fuel cell produces less emissions than fossil fuel, using biogas, ethanol, methane or hydrogen, although with the exception of hydrogen, this technology still produces emissions.
Ceres list the target emission reduction as opposed to gasoline at 70 %, and prototypes have achieved 50-60 % in trials. Although Ceres has attracted investment from Nissan of Japan, the biggest identified customer of this technology are companies like China’s Weichai group who are developing technology for Fuel Cell Buses.
Weichai is a large investor and shareholder.
The concept of using fuel cells as a “range extender” for electric cars, in my opinion, is a bit unrealistic.
I don’t believe the added weight and complication of a fuel cell “range extender” to an electric car, is really practical. Why not just add more batteries, or a small gas powered engine ? The emission output would be, at best, only marginally different.
The additional weight of a fuel cell range extender would drastically reduce an EV’s performance and the additional cost would be a deterrent to consumers as would be refueling. Why not just buy Toyota’s superior HFCV, which would be cheaper and more reliable ?
I’m afraid like Buckinghamshire itself, this technology is only ‘beautiful’ in some parts. On closer examination, it’s a bit like your picture of Buckinghamshire, idyllic, except if you discover yourself in Southcourt, Aylesbury, Buckinghamshire, then you may reconsider your definition of “beautiful ! 🙂
Marcopolo, do you have any idea of the weight of a fuel cell system like that of Ceres per kW? I would have thought a 5 kW system would be relatively light.
Given the Ceres system uses low cost coated steel looks like it could be relatively modest in cost.
I would expect a 5kW fuel cell to be capable of adding around 20 miles of range each hour, so if setting out on a long journey in a car with a nominal 150 mile range, would extend this to around 210 miles, and what’s more, maintain that 210 miles range even in winter when the battery only range might drop to little more than 100 miles due to the need for heating, and for warming the battery.
Hi Gary,
The weight of a Fuel cell used in a vehicle depends on the type of fuel. Hydrogen fuels used in vehicles are required to have extensive safety strength in case of accidents etc.
Vehicle construction and design must be reinforced to allow for these requirements. Hyundai estimates adding 5 kw fuel vehicle fuel cell would approx $35000 to the cost of the vehicle (the fuel cell alone costs $20000).
I’m not sure about the weight, but judging by the spec’s for the Toyota Mirai, the additional weight is considerable weight is considerable.
Hyundai, Toyota and Honda all have battery/Fuel hybrid cell models but the costs of construction are high and not easily reduced by mass unit savings.
In effect, what you are suggesting is technically feasible but very expensive and could be easily rendered obsolete by improving battery technology or mass adoption of vehicles like the Toyota or Honda products.
For large fixed route vehicles, like buses fuel cells a less of a problem and a more competitive technology (cooling, refueling etc).
Marcopolo,
May I ask the age of the report you read in which the Hyundai put the cost of a 5 kW fuel cell system at $35,000?
I can believe that cost for classic systems based on old type fuel cells made up of exotic alloys and ceramics including precious metals (platinum), especially if hydrogen is used as the fuel with all the high pressure expensive containment that entails.
The Ceres Power system is different – with the material cost dominated by a common grade of magnetic stainless steel, and using low cost manufacturing processes – screen printing of a doped Cerium Oxide ink (again low cost). A 2014 report externally audited suggested that 5 kW complete modules would be deliverable at under $1000 per kW at fairly modest production volumes. The system runs around 100 centigrade cooler than other systems, hence the suitability of steel.
Since 2014, Ceres have substantially improved their product – achieving 2 to 3 times as much power per cell, and pushing net system efficiency from about 45% to 60% which will have a further cost reducing effect.
It seems to me that modules could fairly soon be produced in volume at around $500 per kW so a 5 kW system as a range extender would cost around $2500 to produce and maybe $3000 to buy. Add on a suitable tank for LPD or CNG – both widely available, and you might well get the entire system for under $4000.(Hydrogen can be used but does not need to be).
As for weight – the latest cell stacks produce 500W per liter, so a 10 liter cell stack could suffice (probably smaller by the time they hit the mass market). Assuming the cell stack is 50% steel, that would put weight at around 35 kg not counting the fuel system.
If I am anything like right in these assumptions, then I would say such a fuel cell stack would be a very attractive option as a range extender – not greatly more expensive than a high quality 5 kW engine driven generator with about twice the fuel efficiency.