Fuel Cell System for Transportation -- 2005 Cost Estimate

Abstract

Independent review report of the methodology used by TIAX to estimate the cost of producing PEM fuel cells using 2005 cell stack technology. The U.S. Department of Energy (DOE) Hydrogen, Fuel Cells and Infrastructure Technologies Program Manager asked the National Renewable Energy Laboratory (NREL) to commission an independent review of the 2005 TIAX cost analysis for fuel cell production. The NREL Systems Integrator is responsible for conducting independent reviews of progress toward meeting the DOE Hydrogen Program (the Program) technical targets. An important technical target of the Program is the proton exchange membrane (PEM) fuel cell cost in terms of dollars per kilowatt ($/kW). The Program's Multi-Year Program Research, Development, and Demonstration Plan established $125/kW as the 2005 technical target. Over the last several years, the Program has contracted with TIAX, LLC (TIAX) to produce estimates of the high volume cost of PEM fuel cell production for transportation use. Since no manufacturer is yet producing PEM fuel cells in the quantities needed for an initial hydrogen-based transportation economy, these estimates are necessary for DOE to gauge progress toward meeting its targets. For a PEM fuel cell system configuration developed by Argonne National Laboratory, TIAX estimated the total cost to bemore » $108/kW, based on assumptions of 500,000 units per year produced with 2005 cell stack technology, vertical integration of cell stack manufacturing, and balance-of-plant (BOP) components purchased from a supplier network. Furthermore, TIAX conducted a Monte Carlo analysis by varying ten key parameters over a wide range of values and estimated with 98% certainty that the mean PEM fuel cell system cost would be below DOE's 2005 target of $125/kW. NREL commissioned DJW TECHNOLOGY, LLC to form an Independent Review Team (the Team) of industry fuel cell experts and to evaluate the cost estimation process and the results reported by TIAX. The results of this independent review will permit NREL and DOE to better understand the credibility of the TIAX cost estimation process and to implement changes in future cost analyses, if necessary. The Team found the methodology used by TIAX to estimate the cost of producing PEM fuel cells to be reasonable and, using 2005 cell stack technology and assuming production of 500,000 units per year, to have calculated a credible cost of $108/kW.« less