1. Brief Introduction

The FCB national project office organized a delegation to visit the U.S. and Brazil on 12^th-26^th March 2005. The objectives were to increase understanding of the demonstration for FCBs and hydrogen refueling station in the U.S., learn advanced technology and management, and exchanged information and experiences of FCB project with Brazil. The delegation, headed by Mr. Xu Jing, Director of the National Project, Department of High and New Technology development and Industrialization of MOST, was composed of officials and experts from the MOST, Ministry of Construction, Certification and Accreditation Administration of China, China Automotive Technology and Research Center, National Power Plant Combustion Engineering Research Center (NPCC), Dalian Institution of Chemical Physics, Tongji University and National PMO.

During the two weeks study tour, the delegation respectively visited California Fuel Cell Partnership, the U.S. Department of Energy, General Motor in Washington DC, Shell hydrogen refueling station in Washington DC, ISE, GEF program in EMTU and ethanol filling station in Brazil. They also participated in the “International Partnership for Hydrogen Economy (IPHC) Implementation and Liaison Committee Meeting” held on 23rd-24tth March in Rio de Janeiro, Brazil.

In the visit of the U.S. Department of Energy, Mr. Xu Jing and the delegation met Mr. Garman, the new vice Minister of the DOE. They exchanged the information about the China mid and long term renewable energy plan, and discussed the collaboration program between China and USA. They expressed strong interest on strengthening hydrogen energy and IPHE cooperation. In addition, the next IPHC Implementation and Liaison Committee Meeting will be held in October 2005 in Shanghai China.

Due to the lack of global energy and environmental pollution, not only the developed countries but also the developing countries are all interesting in the development of hydrogen economy. The effective policy will ensure the development of the hydrogen economy. It is necessary to establish the partnership among government, public institution and manufacturer.

Fuel cell is an important element in the hydrogen economy. At the beginning of fuel cell commercialization, the effective national policy has positive effect on stimulating the initial market. On the one hand, it needs the corresponding codes, standards and regulations to support the suppliers and the infrastructure. On the other hand, it is necessary to encourage the early users, for example, preferential tax on fuel cells in the emerging market period.

The production and transportation of hydrogen and infrastructure establishment are expecting the cooperation between government and enterprise, including investment and development. USA as an example, the number of hydrogen filling station will be 11,700 (in 100 Metropolitan Areas, 15% of total filling stations in cities covers 70% of population, and national highways, one station per 25 miles). If the cost of each hydrogen filling station is $10 M, the total cost of the hydrogen infrastructure in USA will be 10-12 billion dollars. It is obvious that is a huge investment.

Although fuel cell technology has attracted great attention from government and suppliers, the real commercialization is still needs time. To realize the commercial target, i.e., 5000-6000 hours duration, competitive cost $50/kW, feasible operation under extreme conditions, etc, more R&D effort should be made. The detail time tables are different in government and enterprise. The public is also needs time to recognize this new technology. The experience in the USA and Brazil on public propaganda is valuable for China Fuel Cell Program. In a word, the effort from government, enterprise and public are all required for fuel cell coming into people’s daily life.

In the intercommunion with the USA and Brazil government, the progress of Fuel Cell Bus Program is understood. The existing issues, the strategy of automotive company and the government policy and long term target are disclosed. It is a successful visit.

2. The U.S. study tour

2.1 California Fuel Cell Partnership (CaFCP)

CaFCP is implemented by government, automotive company, energy supplier, and fuel-cell technological company. It began to formally operate in April 1999 in California, including fuel-cell buses and cars. CaFCP is considered as a significant display of utilization and promotion of various fuel-cell vehicles. Meanwhile CaFCP exchanges experiences among various fuel-cell vehicles demonstration.

Project Procedures:

The Part I of CaFCP was completed in December 2003. The Part II is from 2004 to 2007, focusing on promoting commercialization of fuel-cell vehicle. There are 87 FC cars and 3 FC buses, and 16 hydrogen refueling stations in operation in California. Another 10 hydrogen refueling stations will be in-service performance in 2005 as well, and about 300 FC vehicles will be expected to operate until 2007. The objectives in 2004-2007 periods include:

(1) Develop FC vehicle and hydrogen refueling station
(2) Put forward a draft of cooperation
(3) Training relevant staff
(4) Establish related standards
(5) Exchange information and experiences
(6) Lead capital direction

Some methods are conducted to guarantee communication effectively in the project, for instance, hold monthly discussion, share documents online, quarterly report on in-service performance. In addition, a series of test are conducted such as requirements of fuel infrastructure, vehicle and fuel safety, marketing requirements and customer acceptance etc. CaFCP also holds many actions to increase the understanding of FC technology and benefits among the public, including exhibition, race, introduction in campus, and attend relevant meeting.

Some data are expected to be collected through the project, involving operation and maintenance cost, fuel consumption situation, feasibility, training, public awareness and acceptance, security and expected properties.

Current problems:

FCBs in-service performance have some main problems: the cost of fuel-cell purchase, operation and maintenance are higher than normal bus; lack of relevant capital support; limited driving range; fuel fill difficulty; and reliability, battery life and technological service can not meet commercialization.

The organizer also realizes that some ways can contribute to achieve FCB commercialization, such as, improving FC technology, decreasing FC cost, building up infrastructure, promoting education among the public, training technological staff, and increasing the public awareness etc.

2.1.1 Fuel-cell car in-service performance

The cars in-service performance in CaFCP include F-Cell (Daimler Chrysler), Focus FCV (Ford), HydroGen 3 (General Motor), FCHV-4 (Toyota), FCX (Honda), FCV (Nissan), FCEV (Hyundai) and FC demonstration car (Volkswagen). Every company has their own garage. The delegation rode on several cars running performance.

(1)F-Cell (Daimler Chrysler)

F-Cell came in market in 2002. There are 60 F-cell are in-service performance in Europe, the U.S., Japan and Singapore now. Hydrogen fill pressure 350Bar for onboard hydrogen storage，continue log 150km (equal to diesel vehicle consume 4.2 liter per hundred km), motor output power 65kW， accumulated speed from 0 to 100 km spend 16 second，max speed 140 km/hr.

(2) FCHV (Toyota)

FCHV is hybrid fuel-cell and NIMH battery car. Fuel-cell output power 90kW，motor max output power 80kW，top speed 155km/hr，range per fueling 300km. The accumulated trail distance is over 140 thousand km in Japan and California. Hydrogen is supplied by compressed hydrogen storage tank with max pressure 350 Bar.

(3)X-trail FCV (Nissan)

It is hybrid PEMFC and lithium battery car. Max output power 63KW, motor max output power 85KW. Onboard hydrogen storage pressure 350Bar，top speed 145km/hr，range per fueling 350km.

(4)FCX (Honda)

FCX utilizes Honda’s own FC, which can start FC system at –20oc.

2.1.2 Fuel cell buses program

There are three transit companies who implement FCBs in-service performance in California, including SunLine Transit Agency in Coachella Valley, Santa Clara Valley Transit Authority in Silicon Valley and AC Transit in Northeast San Francisco Bay. The three FCBs in Santa Clara began to operate in March, which aimed to compare pure fuel-cell bus with hybrid FC and battery-powered bus, and to test the safety and vibration.

Bus operational life is average 12 years in California. The objective in 2008 is that zero emission vehicles (ZEV) will be composed of 15% of total new-purchased buses; all new buses will be ZEV in 2010. The ZEV is divided into pure ZEV, partly ZEV, and advanced technology hybrid electric vehicle and fuel-cell vehicle. The program expects to increase FCB to 250 until 2009, 2,500 during 2009-2011, and 25,000 during 2012-2015. There are no related regulations of ZEV technology in California, thus FC vehicle will compete with hybrid electric vehicle in the long-term during the in-service performance.

2.1.3 CaFCP hydrogen refueling station

This station is installed by BP, Chevron Texaco, Exxon Mobil, Shell Hydrogen, Air Products, Praxair together. Some elements were considered during the hydrogen refueling station installation, including hydrogen nozzle, operator training, fuel delivery, immediate communication during hydrogen fill etc.

The station use liquid hydrogen for delivery and storage. The liquid hydrogen need to be gasified firstly; then fill hydrogen at 250-350bar. Capability of filling hydrogen is 100 Kg per day. The station security system includes pressure adjustment system，remote control，infrared braze detector etc.

Hydrogen nozzle features on-line monitoring hydrogen quality to prevent impurity to effect on the cell. It also provides basic data for establishing and unifying hydrogen standards.

CaFCP invented Hydrogen Quality Sampling Adapter (HQSA) that takes a sample at hydrogen nozzle instead of in reserve tank to improve the crucial control of hydrogen quality and avoid impurity to come into onboard hydrogen storage. HQSA can work at 350Bar or 250Bar. The security system includes pressure release equipment、back pressure valve and pressure meter etc. CaFCP took a complete test for this system and utilized it in the station.

Filling machine is used to fill hydrogen for fuel cell vehicle in the station. Vehicle is filled by filling gun that links communication cable and ground wire. Communication test equipment can check the pressure and temperature during hydrogen filling, which monitors the speed of filling hydrogen to guarantee security and hydrogen quantity. Fill machine with screen can show some relevant data, such as total quantity of hydrogen, filling pressure etc.

2.2 General Motor

Considering the potential requirements of vehicle industry development, energy security, reduce petrol use, enhance environmental prevention and material , and economic sustainable development, automotive enterprise realize that it is a crucial problem to develop and commercialize hydrogen fuel-cell vehicle.

Some advantages of hydrogen fuel cell vehicle comparing with petrol vehicle have been shown in General Motor’s marketing research report:

· Reduce 99% petrol consumption
· Decrease 50% energy consumption
· Cut down 50% green house gas emission
· Decrease 95% volatile organic matter emission
· Reduces 99% CO emission
· Decrease 50% nitrogen oxides emission
· No effect on sulfur oxides
· During the hydrogen production, solving CO2 and pressing hydrogen by clean electricity reduce the emission from W-T-W (well to wheel).

2.3 GM-Shell Partnership: Benning Road Station

General Motor cooperated with Shell Hydrogen to set up hydrogen fill infrastructure. The Benning Road Station in Washington is in-service performance of filling hydrogen for fuel-cell vehicle. In this project, Shell Hydrogen and General Motor established complete system from hydrogen production to retailing. The station has a hydrogen storage tank of 1,500 gallon under the ground. At the moment, the station services 6 fuel cell vehicles, which can supply liquid hydrogen and compressed hydrogen. The demonstration for hydrogen fuel-cell vehicle in Washington Area contributes to increase the awareness of policy departments and the public, enhance the participation among government, energy company and vehicle manufacturer for promoting the development of hydrogen energy economy.

2.4. ISE Research-ThunderVolt

ISE Research-Thunder Volt focuses on research electric and hybrid electric vehicle technology. It produces above 100 ThunderVolt hybrid electric buses every year. The buses innovated by ISE include diesel hybrid electric bus, petrol hybrid electric bus, fuel-cell bus and vehicle with hydrogen internal combustion engine. ISE is a professional company who research propulsion system of vehicle. It effectively improves the commercialization of hybrid electric technology. ISE development is worth to be learned by us.

3. Brazil Study Tour

3.1 The Demonstration for FCB Project

EMTU is an authority that takes responsibility on urban transportation management in Brazil. It is charging of 67 cities transit, covering 23 million population, 15 hundred thousand passengers and 10 thousand vehicles per day. EMTU bears responsibility for implement the demonstration for fuel-cell bus project in Brazil that is supported by GEF/UNDP. During the visit, EMTU introduced the project schedule to delegation as the following:

· The first stage: feasibility analysis, completed.
· The second stage: installation of garage and related infrastructure that can contain 200 vehicles, expected to complete in 4-5 years.
· The third stage: pre-commercialization, expected five years.
· The fourth stage: in-service operation that eight FCBs run one million kilo meters in four years; improving technology and reducing cost to make real commercialization; producing FC bus in Brazil; accumulating experiences of hydrogen filling.

Development plan at every stage:

Brazil FCB project is implemented by the Brazil Ministry of Mineral and Energy，EMTU Saint Paul Transit Management Bureau, FINEP (Projects and Studies Financing), GEF and UNDP. The objectives of this project include:

· Demonstration for hydrogen fuel cell bus in Saint Paul and exhibition of hydrogen infrastructure.
· Innovation of FC bus based on Brazil domestic made chassis and body
· Use renewable energy, such as hydroelectric power, ethanol, and biomass electric power (sugercane) to produce hydrogen, promoting FC commercialization.
· Reduce environmental pollution.

In this project, fuel cell, bus, and the equipment of hydrogen production by water electrolysis are supplied by Ballard, Marcopolo and Stuart Energy respectively. Hydrogen fill pressure is expected to be 350 bar. In the first stage, pure fuel cell bus is highlighted and expected to complete in autumn this year.

Mr Xu Jing introduced the China FCB project briefly and exchanged information and experiences with Brazil representatives. The delegation visited EMTU bus garage as well.

3.2 Ethanol Petrol Station

The delegation also visited the ethanol station in Brazil. This station is supplied by Shell, providing diesel, ethanol petrol and pure ethanol fuel. Depending on the customer requirements from the visited station, pure ethanol fuel bus accounts for 3-5%，ethanol petrol fuel vehicle 70%，diesel fuel vehicle 20% (almost heavy-duty vehicles). Ethanol content of ethanol petrol fuel is not over 26%. Brazil government promotes the pure ethanol or ethanol petrol utilization through tax reduction and tax-free. All petrol stations supply ethanol petrol in Brazil. However, pure ethanol fuel vehicles still hold a small percentage in market due to higher price of engine by ethanol. In addition, there is about 75-80% petrol stations can supply pure ethanol fuel in Brazil.