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Hyundai to begin production of ix35 Fuel Cell vehicle in December; targeting 1,000 units by 2015

69253 69252hyu-ix35 fuel cell
ix35 Fuel Cell. Click to enlarge.

In December 2012, Hyundai will begin production of the ix35 Fuel Cell crossover vehicle at its Ulsan manufacturing facility in Korea, with a target of building up to 1,000 vehicles by 2015. Hyundai called the ix35 Fuel Cell its “halo vehicle” in the Blue Drive sub-brand, the badge worn by Hyundai’s cleanest vehicles, including Sonata Hybrid, i20 Blue Drive and BlueOn, Hyundai’s battery-powered i10.

Hyundai has already signed contracts with cities in Denmark and Sweden to lease the ix35 Fuel Cell to municipal fleets. Beyond 2015, Hyundai plans limited mass production of the ix35 Fuel Cell, with a goal of 10,000 units; Hyundai will also introduce the vehicle in Korea and California.

Ix35
ix35 fuel cell powertrain layout. Click to enlarge.

The fuel economy and range of the ix35 Fuel Cell have improved by 10% over the previous-generation model. In a presentation on Hyundai’s fuel cell technology at the US Department of Energy (DOE) Merit Review in May 2012, John Juriga, Director of Powertrain Hyundai / Kia America Technical Center, said that the fuel cell system in the ix35 achieves a power density of more than 640 W/L (DOE target is 650 W/L). Size reduction of the system has been achieved through modularization.

Ix35stack
Exploded view of the ix35 fuel cell stack. Click to enlarge.

The fuel cell stack—which uses a low-cost bipolar plate and gasket material—itself has a power density of 1.65 kW/L. Operating voltage is 50~450V, and maximum cold-start ability is -30 °C (-22 °F).

Unlike other fuel cell vehicles that use compressed air to supply oxygen to the fuel cell stack, Hyundai’s ix35 Fuel Cell uses ambient air. This reduces parasitic loss in the oxygen supply, raising fuel efficiency and reducing power consumption by 50%. For passengers, the elimination of an air compressor reduces noise inside the cabin.

The ix35 Fuel Cell Specifications
Length; width; height 4,410 mm; 1,820 mm; 1,655 mm
Fuel consumption 0.96 kgH2/100 km
Fuel cell output power 100 kW
Battery 24 kW
Fuel storage 700 bar, 5.6 kg
Top speed 160 km/h (100 mph)
Range 588 km
Acceleration 0 to 100 km/h in 12.5 seconds

In addition to the fuel cell stack, the ix35 Fuel Cell uses the same lithium-polymer battery found in the Hyundai Sonata Hybrid. A kinetic energy regeneration system charges the battery when the driver applies the brakes or drives downhill.

69253 69252hyu-ix35 fuel cell engine
Under the hood. Click to enlarge.

The ix35 Fuel Cell is equipped with stop/start technology, which shuts down the fuel cell stack and relies on battery power only when the vehicle is idling, minimizing energy loss in city driving.

Hyundai’s ix35 Fuel Cell offers drivability and performance similar to that of the gasoline-powered ix35. The ix35 Fuel Cell can be filled with hydrogen in only a few minutes. It accelerates from zero to 62 mph in 12.5 seconds, has a top speed of 160 km/h (100 mph) and can travel 588 km (365 miles) without refueling.

Hyundai chose its popular ix35 as the first vehicle for its fuel cell technology. The ix35 is Hyundai’s second-best-selling car in Europe, behind only i30, and was one of the first to display Hyundai’s Fluidic Sculpture design identity.

Hyundai said it was encouraged by the actions of several governments, especially in Europe, that have created detailed roadmaps for building a hydrogen infrastructure and are providing necessary funds. Hydrogen fueling stations exist in several European nations and additional ones are being built and planned. Expansion of fueling stations is also anticipated in Korea and California, and Hyundai will supply its ix35 Fuel Cell to public and private fleets there, as well.

Hyundai’s ix35 Fuel Cell is currently participating in the European Hydrogen Road Tour, organized by the European demonstration programme, H2moves. The Road Tour is a multi-city, pan-European display of hydrogen fuel cell vehicle technology, which has stopped in Paris during the motor show.

The ix35 Fuel Cell is the result of 14 years and significant financial investment in research and development by hundreds of engineers at Hyundai’s fuel cell R&D center in Mabuk, Korea. The car has logged more than 2 million miles of road tests in real-world conditions in Europe, Korea and the US.

Hyundai’s fuel cell program is based at its Eco-Technology Research Institute in Mabuk, Korea, about 45 minutes south of Seoul. The program was launched in 1998 with a roadmap targeting series production of fuel cell vehicles by the end of 2012 and consumer sales by 2015.

The mission of the Mabuk research centre is to create commercially viable, zero-emissions vehicles. The ix35 Fuel Cell achieves that goal, providing a clear choice for public and private fleets.

—Dr. Tae Won Lim, Managing Director of fuel cell R&D

Resources

Comments

A D

These fuelcell cars and suvs are unbeatable, im glad hyunday is starting limited commercialisation. It's gonna be a huge success. The range is very good at 365 miles and it's easy to monitor how much hydrogen is left into the tank contrary to batteries where you never know really what is the state of charge. As soon as there is a hydrogen infrastructure been build then we gonna have big trucking too that will use hydrogen contrary to batteries that can barrelly apply to small cars only and are rejected by consumers. One way or the other someone gonna fing how to do hydrogen in quantities at low cost and onsite. In 2022 approx, i will be on the market for a used vehicle and i hope to buy a first hydrogen car and i will forget are limp previous ice cars were with vibrations, low power and big weight and cost, pollution, hiccups on acceleration, bothersome transmissions, etc. The world will change overnight as soon as hydrogen fuelcell technology will be put on the market.

Davemart

That is around half the energy density of the Toyota fuel cell stack.
Not using compressed air sounds good though.

Brotherkenny4

"As soon as there is a hydrogen infrastructure been build then we gonna have big trucking too that will use hydrogen contrary to batteries that can barrelly apply to small cars only and are rejected by consumers."

This is the point. There will never be a hydrogen infrastructure and the car companies and the oil companies know it. So what offering hydrogen fueled vehicles gives them is the appearance of caring about us and the environment while still having almost insurmountable hurdles available as an easy excuse for the lack of progress and change. Precisely opposite to EVs and PHEVs which already have the infrastructure and truely threaten change away from oil. And, just like drugs and the drug war, alot of people make money off oil and so we will never stop using what is profitable to the masters.

Engineer-Poet

Preach it, Brother Kenny!

Davemart

So here are the facts on the supposedly unsuperable obstacles to hydrogen roll out:
Initial deployment:
'H2Station® CAR-100 provides 70MPa SAE J2601 compliant fast-fill of hydrogen for passenger vehicles with a capacity of up to 100kg/day. All equipment is integrated into a compact station module allowing for easy transport and installation in only two days. This significantly reduces both the investment cost and time from contract to start of operation, which is important when deploying station networks. As fuel sales in a network grows and reach a level feasible for larger stations the CAR-100 can easily be relocated to outskirts of the network.'

http://fuelcellsworks.com/news/2012/09/25/h2-logic-launches-new-h2station%C2%AE-products-for-hydrogen-refueling-of-fuel-cell-powered-material-handling-vehicles-and-passenger-vehicles/

Note that these can be deployed on a rolling basis, so that as hydrogen becomes established in an early adopter area they can move on elsewhere.
100kg/day would be enough to service a couple of hundred vehicles at 30/miles/day.

That sounds an easier roll out to me than a fast charger infrastructure.
The hydrogen for that level of use would be brought in by tanker.

No need to upgrade transmission systems or transformers for a high speed electric charging station.

And:
'The aim is to bring down the cost to that of a natural gas filling station, around 300,000 euros, or $387,500, from around 1 million euros today, said Ulrich Buenger, a coordinator at the European Hydrogen Road Tour 2012, which is funded by industry and the European Commission.'

http://www.mercurynews.com/cars/ci_21628374/hyundai-introduce-worlds-first-production-fuel-cell-electric

Those cost statements are not just figures plucked from the air, but a result of analysis of the components needed to build them.

Europe already has a perfectly adequate infrastructure to deliver LNG for vehicles, and whilst the cost of a hydrogen roll out may for the time being be somewhat higher, vast amounts can be saved on oil import bills, for instance by the use of hydrogen from agricultural and municipal waste.

HarveyD

Many areas may very well end up with three (3) energy sources for road-rail vehicles:

1. Existing gasoline and diesel for ICEVs and diesel-electric locomotives for the next 20+ year transition period.

2. Quick charging stations (fixed wired and wireless) for Electrified (PHEVs and BEVs) cars and light trucks, specially in urban and neighboring areas.

3. Hydrogen stations for FC equipped heavy highway vehicles and adjacent locomotive combined filling stations.

Darius

HarveyD,

#3 Why it shall be hydrohen instead CNG main fuel for heavy city and highway trucks?

Davemart

@darius:
Even after allowing for conversion losses it is quite a bit more efficient to use hydrogen in fuel cells rather than natural gas in a combustion engine.

For City trucks and buses you can also combine it really easily with batteries in hybrids, and still have a totally zero emission vehicle at point of use.

No doubt for the next ten or fifteen years plenty of natural gas trucks will be hitting the road though.

Bear in mind however that in most countries natural gas sells for several times the US price.
The low price of US NG is also probably around half of the sustainable price to cover costs, so the economics of NG in the US are much better than elsewhere and likely more favourable than is sustainable.

Davemart

Here is the pdf with full info on the Hyundai. It also gives their road map.
It is perfectly clear from this that progress has been as projected, and is not some sort of never never thing as the advocates of batteries as a one size fits all nostrum repeatedly and inaccurately say.
http://www.fch-ju.eu/sites/default/files/documents/ga2010/sae-hoon_kim.pdf

Engineer-Poet

Hydrogen does not travel well.  The energy/volume of hydrogen is about 1/3 of methane, with similar viscosity; pipeline pumping losses would be very high.  Liquid hydrogen has a density of about 0.07, so 1 kg of LH2 consumes a volume of about 14 liters.  A US gallon is 3.79 liters, so it would take volume equivalent to about 5 gasoline tankers (even assuming no insulation) to carry the same energy with LH2.  That's a lot more tankers on the road, and a lot more energy needed to move them.

It's fun to speculate about hydrogen made from biomass, but there's nowhere near enough biomass to do the job.

The energy loss with HVDC is about 3%/1000 km, far lower than any gaseous fuel pushed through pipelines.  Transformers and other gear are good for many decades.  I suspect it makes more sense to move electricity 1000 miles and then electrolyze water than it does to pump hydrogen.  Of course, if you've moved electricity all that way you might as well use it as-is and skip the conversion losses (and all the capital equipment).

Power surge demands with high-power chargers are easily managed with things like flywheels.  There just isn't any major handicap for electricity except the gap between the wire and the vehicle in motion on the road.

Davemart

EP:
The efficiency of fuel cells is far greater than petrol engines, so you need to transport a lot less fuel.

We manage perfectly well to pump natural gas, although of course that is rather less corrosive, so the strictures against using pipelines for transport of gaseous fuels hardly seems absolute.
Germany for one also plans to provide a lot of it's hydrogen locally, rather than centrally, so reducing pumping needs.

I have recently found out that more than half of German vehicle miles are for longer journeys, with the differences between that usage pattern and that of the US presumably due to their excellent public transport covering a lot of commuting.
In that case present battery cars would not help much for more than half of the miles travelled, so particularly with electricity at 30 cents/kwh it is hardly surprising that they are keener on fuel cells than battery cars.

'It's fun to speculate about hydrogen made from biomass, but there's nowhere near enough biomass to do the job.'

Please give the figures on which you base this definitive and statement.
Others argue:
'"If you take just 20% of the agricultural and forest residue available in Europe, which can sustainably be taken away from the fields, you can make half of Europe's gasoline demands,"'

http://www.bbc.co.uk/news/business-19179419

Personally I don't know, but you clearly have access to figures which give you confidence to make an absolute statement, so please show on what that confidence is based.

kelly

If GM said this 'folks' could assume it was another taxpayer grant stunt, sorta like we're years beyond the statute of limitations living in the Bush Hydrogen Initiative years.

Is that p@#$k mentoring the latest Republican candidate and voter 'chad' registrations?

Anyway, with Hyundai, who knows..

SJC

Hyundai might want to reform NG to H2 like Tesla did with Superchargers.

HarveyD

Darius...CNG for heavy trucks-buses and locomotives is interesting in USA, specially during the current extremely low cost NG/SG glut. NG price is about 6 to 9 times higher in EU and Asia, making it less advantageous and that high price would go up again if NG was used to power trucks-buses-locomotives etc.

On the under hand, electricity can be produced at very low cost and can be distributed most everywhere with very low lost. The major problem to solve is the high price and current low capacity (140-180 Wh/Kg) e-storage units, specially for long haul heavy vehicles.

Long haul electric trucks and buses would need tonnes of high price batteries to do the 1000+ Km stretch they normally do. PHEV technology with ICE (gasoline, diesel CNG) genset and/or improved FC genset would be better suited, for those vehicles, at the present time?

Bob Wallace

"That sounds an easier roll out to me than a fast charger infrastructure."

Might be. If we were starting from zero with both hydrogen and electricity. But since the electricity infrastructure is at least 90% in place and since we are already installing a large number of fast chargers hydrogen would be starting too deep in the hole to catch up.

Who is going to invest hundreds of billions of dollars in a hydrogen infrastructure when we can drive cheaper per mile on electricty?

Add in the enormous cost of paying for the hydrogen infrastructure and hydrogen as a fuel loses big time.

Davemart

'Who is going to invest hundreds of billions of dollars in a hydrogen infrastructure when we can drive cheaper per mile on electricty?'

You run into hundreds of billions putting a charger in each garage, let alone alongside the road for the 50% of vehicles with no garage.

The other answer to your question at the moment is of course anyone who wants to travel more than 60 miles or so at highway speed without stopping for a recharge and can't afford a Tesla.

Engineer-Poet
The efficiency of fuel cells is far greater than petrol engines
Not even twice as efficient, compared to the 5x increased fuel volume.  Fuel cells powered by RE starting from electricity have lower total efficiency than batteries; it's only if you start from e.g. natural gas or coal that hydrogen fuel cells are better, and you pay high capital costs to get it.
We manage perfectly well to pump natural gas
We do, but we also pay in losses.  The losses for puming hydrogen would be ~2.5x as great per unit energy.  (I tried to find data for the losses in pipeline transport of NG but what turned up was obviously not an η parameter.)
Germany for one also plans to provide a lot of it's hydrogen locally
Generated from what, though?
Please give the figures on which you base this definitive and statement.
For the USA, I'm using The Billion-Ton Vision, mostly.  Figuring an achievable 800 million tons * 18 GJ/ton = 14.4e18 J; converted to H2 at 50%, 7.2e18J or 2e12 kWh/y.  After compression and conversion in the FC (net efficiency, 50%?), 1e12 kWh/y or 114 GW delivered.  My estimate of power demand by vehicles from some years back was 180 GW.  Maybe you can tweak some of these numbers up, but it's still a very close thing with little margin for error (or drought).
Engineer-Poet
Long haul electric trucks and buses would need tonnes of high price batteries to do the 1000+ Km stretch they normally do.
Why should we continue with the silly and wasteful wheel-on-pavement scheme, when such heavy vehicles do most of the damage to pavement?  Build a "lane" of rail, either with overhead electric power or switched ground-mounted third rail.  Steel wheel on steel rail eliminates most of the rolling resistance, and the rails provide guidance.  Link vehicles nose-to-tail (physically or virtually) and you have a train which requires no human intervention except for the lead and in emergencies.  You can put your drivers on their 1000 km haul at 100 kph at 8 PM, and they can sleep until their arrival at the destination at 6 AM.  Change out loads and they'd be home in time for dinner.
Engineer-Poet
You run into hundreds of billions putting a charger in each garage, let alone alongside the road for the 50% of vehicles with no garage.
I don't see it.  The "charger" for a J1772 connection is something I could build with an off-the-shelf microcontroller board, wall-wart power supply and a high-power relay (or solid-state equivalent) for maybe $100, quantity 1.  For the first generation of PHEVs which come with their own J1772 adapter cables (taking 120 VAC 10 A from the wall), I suspect that they'd come in around $20/unit in quantity.

The annual expenditure on motor fuels in the USA is on the order of $500 billion, so even "hundreds of billions" is quite reasonable if it's spread over as little as a decade.  But it won't cost that much; 100 million chargers at an average of $300 apiece (most just cheap home units) is only $30 billion.

Roger Pham

>>>"Who is going to invest hundreds of billions of dollars in a hydrogen infrastructure when we can drive cheaper per mile on electricty?"

The actual cost for sufficient H2-filling stations to cover the entire continental USA by 2015 will be only around 300-500 Millions USD. NOT hundreds of billions. It is an investment that will pay off within a few years, so a lot of people would want to invest in that. Remember how the CD music came to replace the vinyl records? If well marketed, H2-FCV's will gradually replace current-technology vehicles. They will set off a new cool-and-hip trend in consumerism, similar to fashion and fad, this time automotive fashion, just like the minivans took over the station wagons, then the SUV's took over the minivans. After 2015, if you wanna be trendy, hip, cool, and show off that you're "loaded", you will wanna have a supercool H2-FCV parked in your VIP parking space at work, or in your driveway. I know that Kit P is shaking his head, but, sorry, that's how automotive history has always been and how it's gonna be! Owning a car is not just about transportation. It's about a personal statement to the world about who you are...(eg. "look at my super-duper red Corvette...Sure, I can get to work on a Chevette or Citation or a Nova, and I don't need a large-block 400CID 500hp V-8 2-seater to get me to places, but it sure turns heads and get me dates.." :)

And most people surely never wanna buy a car that reflects that they are a penny pincher...No one wants to look cheap in front of their friends, peers, or neighbors...Surely, early adopters with the cash to splurge do not care much about "driving cheaper per mile on electricity?" They wanna show that they're livin' large!

One more important thing I will need to bring up, Bob, is that H2 filling stations can recoup their investments easily because all H2-FCV will need refills at the stations. The situation for e-fast-charge stations is vastly different, because people will charge at home for the most part, and only use e fast charging on occasions...If you wanna have enough e fast charging stations around to satisfy people's only occasional fast charging needs...Good Luck recouping investments on e fast charging stations.

SJC

Car companies can turn $1 of NG into $10 of H2. Cars double their cost including fuel over 10 years. Get the car sale profit up front and the fuel profits over a decade.

Davemart

Thanks for the detailed response, EP.
I really meant it when I said that I have not been able to get a good handle on the amount of energy available from biomass, as it seems that there are a huge number of possible pathways.

To respond to a couple of your points:
Germany for one also plans to provide a lot of it's hydrogen locally

Generated from what, though?

Please give the figures on which you base this definitive and statement.

For the USA, I'm using The Billion-Ton Vision, mostly. Figuring an achievable 800 million tons * 18 GJ/ton = 14.4e18 J; converted to H2 at 50%, 7.2e18J or 2e12 kWh/y. After compression and conversion in the FC (net efficiency, 50%?), 1e12 kWh/y or 114 GW delivered. My estimate of power demand by vehicles from some years back was 180 GW. Maybe you can tweak some of these numbers up, but it's still a very close thing with little margin for error (or drought).

Germany plans to use get hydrogen from just about everything, including, in my view at that latitude ludicrously, solar.
Here is what they are planning for wind though:
http://fuelcellsworks.com/news/2012/08/21/e-on-starts-construction-of-power-to-gas-pilot-plant-in-germany/

A lot of it is biomass though.

The link you give does not consider algae, which is a large, but to my mind dubious, resource.

Using the figures you give, we can actually hit around 70% for conversion and compression now, which is of course a major uplift on the numbers you suggest.

Miles travelled are also falling year on year, not rising.

The main thing though is that we don't need to provide 100% of transport needs, nor anything like it, from biomass for it to be a very useful resource.

It is perfectly reasonable, it seems, to think that we might get a third of our hydrogen from biomass sources.

Engineer-Poet
most people surely never wanna buy a car that reflects that they are a penny pincher.
This accounts for the unpopularity of the Prius, right? (joke!)

The alleged superiority of the H2-FCV is its high range per day and quick refilling, but this doesn't help if the nearest H2 station is 20 miles away, let alone 50.  The safety issues with gas at 700 bar (or more, on the storage/dispensing side) argue for a station cost on the same order as a natural gas station, at $350,000 to 3x that*.  You need these things almost everywhere, so figure at least one per 20-mile square on a rough rectangle 4000 miles by 1500 miles, or 15,000 of them.  Cost:  $5-15 billion.  Until the network has achieved full penetration there are places your H2-FCV can only visit on in-and-out trips, or not at all.  So much for its "advantage" over electric.

What's the cachet in running out on the way to the one H2 station in town and needing a tow?

No one wants to look cheap in front of their friends, peers, or neighbors.
So instead you buy a PHEV, which everyone knows costs more.  You get exclusive use of the reserved parking spaces with the free chargers (another early-adopter perk) and possibly at work also.  On the road, your car has a distinctive badge and the hinged cover for the charging port to set it apart.  You are greener than just about anyone, and truly Sticking It To Big Oil; the H2-FCV people are buying their gas from XOM-branded pumps.  You might visit a filling station 4 times a year, unlike the H2 people who have to work new and cranky high-pressure dispensing systems (which may require an attendant, meaning extra cost and limited hours).

* I see ads for truck stops selling upwards of 100-150,000 gallons per month.  Selling even 50,000 gallons of diesel equivalent of LNG per month at 50¢/gallon premium over cost for amortization, a $350,000 LNG installation would be paid off in about 14 months.  The Henry Hub price of NG is about 1/10 the retail price of ULSD; the gross margin for early adopters appears to be well upwards of $1 per gallon-equivalent, maybe over $2.  There's a much better case to be made for LNG than H2.

Davemart

'The alleged superiority of the H2-FCV is its high range per day and quick refilling'

Nothing alleged about it.
You should have said that 'the fact is that....'

I don't quite know what figures you are trying to analyse, the costs of a full deployment or start up costs.
Clearly any initial deployments won't try to cover the wilds of Montana and so on.

We already know what initial deployment costs will be.
California is spending around $68 million dollars, which will give enough to be going on with.

Obviously further roll out would depend on how that goes.

For some reason you also seem to exclude the possibility of PHEV fuel cell cars, and have passed over the notion that in places like Germany half of all vehicle miles are long distance, so batteries/PHEVs would not help much.

BEVs have, to date and excluding ultra expensive Tesla's, had limited success.
PHEV's are likely to be the way to go for the next ten years as a mass solution.

Replacing the gasoline content of the PHEV with hydrogen, even if from natural gas exclusively, would result in massive savings of CO2 emissions, and save many of the millions of deaths a year from air pollution.

In fact, some proportion at least of the hydrogen would come from non-fossil fuel sources.

I like batteries, and if we can develop a lithium air battery or whatever, that is fine.
Until then I would wish to use the best combination of technologies we can manage, and hydrogen fuel cells can provide capabilities simply beyond the scope of what any battery we have within reach of our technology.

Engineer-Poet
The link you give does not consider algae, which is a large, but to my mind dubious, resource.
Blue-sky, certainly.  You don't bet on such things; I'm pro-nuclear power, but I don't even think of proposing thermochemical hydrogen for FCVs as it's far too speculative.  Hot-water hydrolysis of biomass to sugars is another matter.
Using the figures you give, we can actually hit around 70% for conversion and compression now
Still well short.  There are also competing and perhaps more important uses for that feedstock.
Miles travelled are also falling year on year, not rising.
If your energy projections are based on an ever-deepening economic recession, you're not going to get much political support!
we might get a third of our hydrogen from biomass sources.
Begging the question, what provides the other 2/3?

One reason I am pro-nuclear is that 2/3 of motor fuel can be replaced by electricity in current-generation PHEVs (if nuclear, domestic and zero-emission) and the other 1/3 can be replaced by liquid fuels generated from waste.  Domestic garbage and waste biomass can be hydrolyzed to small molecules, then gasified in supercritical water to yield ready-made synthesis gas.  Syngas makes methanol very easily, which is a good motor fuel.  All this takes is heat, which fission generates cleanly and in abundance.

Using either thorium or fast breeders, fission can supply our full energy needs on the time scale of industrial society.  Processed waste and other biomass can supply the remaining demand for fuels and chemicals without risk of depletion.  That's a full solution, and weather barely affects it.  It's one of the best routes, and also one of the lowest-risk.

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