VEHICLE-TO-GRID DEMONSTRATION OF A
FUEL-CELL LOCOMOTIVE
Melanie D. Johnson*
US Army Corps of Engineers
ERDC-CERL
Fuel Cell Seminar
San Antonio, TX
18-21 October 2010
* Coauthors: A. R. Miller, K. S. Hess,
T. L. Erickson, J. L. Dippo, and T.
Lambrecht
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HYBRID-FUELCELL SWITCH LOCOMOTIVE
Sponsorship from the
Defense Logistics
Agency
Product of partnership
with Vehicle Projects,
and BNSF Railway
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WHY A HYBRID:
The Duty Cycle of a Switch Locomotive
Mean* = 75 kW
*Mean power computed over 20-h interval
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SWITCH LOCOMOTIVE PROJECT OUTCOMES
Reduce both air and noise pollution near rail yards.
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Successful test of locomotive in production switch applications, 150 hours
of service
Zero emissions in urban rail yard
Provide contingency mobile backup power
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FC Locomotive has the ability to supply power to the grid
Can provide 200 kW continuously for contingency or emergency
operations
Quiet, clean, and mobile power generation
Contribute to Army energy goals
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Reduce fossil fuel consumption
Enhance energy security
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FUEL CELL LOCOMOTIVE: Systems Overview
31 July 2008, BNSF Topeka System Maintenance Terminal
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FUEL CELL LOCOMOTIVE: Systems Overview
Fuel cell
power plant
Radiators
240 kW cont. net fuel cell prime
mover
70 kg hydrogen at 350 bar at roofline
Traction battery allows transients
above 1 MW
Traction
battery
Hydrogen
tanks
9 thousand kg extra ballast to bring to
130 tonne
Ballast
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FUEL CELL LOCOMOTIVE: Systems Overview
Radiator module
Fuel cell power plant
Power electronics
Hydrogen storage
Battery ventilation
module
Ballast
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IMPACT TESTING
700,000 lb consist with
last car braked
• Test conducted by Transportation Technology Center, Inc, in
Pueblo, CO
• Passed tests at 5.1 mph at full gas pressure (3.8 mph with fuel
cell operating)
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PERFORMANCE DEMONSTRATION:
Power in Rail yard
Power Output from Fuel Cell Power Plant
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FUEL COSTS:
Hydrogen from Southern California Pipeline
Mean cost of diesel fuel currently is around $2.95/gal
1 kg hydrogen is equivalent to approx. 1 gal of fossil fuel in
energy content
Hydrogen from the Air Products’ LA pipeline costs $2-3/kg
Based on energy content, hydrogen fuel cost today is equiv to
diesel fuel ($2-3/gal)
This comparison does not include the operating and infrastructure
cost request to compress hydrogen to the required 350 bar.
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PERFORMANCE DEMONSTRATION:
Rail yard Results
Parameter
Value
Gross power operating range
0 – 300 kW
Mean observed net power
87 kW
Mean fuel usage
5.6 kg / h
Useable onboard H2 storage @ 20 deg C
63.5 kg
Mean refueling interval
11.3 h
Balance of plant parasitic losses
17 %
Mean power plant thermodynamic efficiency
50 – 51 %
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VEHICLE TO GRID:
Power Export Demonstration
• Performed at US Army Defense Generator and Rail Center
located on Hill AFB
• Provided the sole source of power to the heavy-rail repair
and rebuild shop
• Shop executes engine rebuilding, rewinding of traction
motors, chassis repair
• Vehicle-to-grid testing performed on base during 6 days
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VEHICLE TO GRID:
Power Export Demonstration Results
• DC output converted to 3-Ph 440 V by off-board AV-900
• Inverter limited grid input to 250 kW (larger inverter would
allow 1.5 MW for 5 min)
• Mean facility power requirement was 65 kW
• Hydrogen fuel consumption was 3.4 kg/h
• With onboard storage, run time is 16 h
• Tube trailer would give run time of 82 h
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CONCLUSIONS
• Locomotive is complete and has ~ 150 h operating time
• Zero emissions in the urban rail yard
• Good worker acceptance (silent in cab, good throttle response,
nil vibration)
• With hydrogen from LA pipeline, energy cost would be
comparable to or lower than diesel: ~ $2-3/gal equivalent
• Vehicle-to-grid demonstration successfully completed at Army
facility
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FC Locomotive Roadmap
Switcher
Road-Switcher
Freight Locomotive
Engineering Study
FY07 - 08 Funds:
FY09 funds:
(1) Power: ½ power
module, 250 kW
(1) Advanced battery
FY11 and later:
(2) Advanced 700-bar H2
storage (420 kg)
(1) Power: 6 power modules, 3.0
MW (4000 hp)
FY10 funds:
(2) H2 storage: Similar to roadswitcher’s but carried in tender;
range 700 miles
(2) H2 storage: 350 bar
(70 kg)
Develop standard, unitary
power module (500 kW)
Commuter Locomotive (DOT)
Hybrid; 4 power modules, 2.0 MW
(2700 hp); metal-hydride storage
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Thank you!
Any Questions?
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