Hybrid Electric Hydrogen Fueled Buses In Transit Service

Hybrid Electric Hydrogen Fueled Buses In Transit Service David M. Mazaika, Paul B. Scott March 20, 2007 12302 Kerran Street Poway, California 92064 www. isecorp. com pscott@isecorp. com or 858 -413 -1742 NHA

Transit Buses are ideal for hydrogen implementation • Due to capability to carry 30 -60 kg hydrogen, ranges to over 500 km are attainable • Transit schedules maximize the use of the vehicle, to 16 hours/day, hence buses have optimal utilization • Large numbers of passengers quickly become familiar with the quiet, clean operation of these electric vehicles, become enthusiastic supporters of hydrogen vehicle innovations • Although vehicles are expensive, the cost is amortized favorably over a large base of hours used, passengers carried. Arguably, the most “bang for the buck” in hydrogen fueled transport! • Transit bus operation is predominately in city centers, where quiet and clean operation is most needed! NHA 20 March 2007 Page 2

ISE Provides Hybrid Electric Buses Diesel Hybrid Bus Highest fuel economy of any commerciallyavailable heavy-duty vehicle drive system Fuel Cell Bus First fuel cell bus used in revenue service in California; nearly 50, 000 miles Gasoline Hybrid Bus First ARB-certified bus hybrid drive system; now in high rate production (100 in 2005) Hydrogen Hybrid Bus Lower cost near-zero emission alternative to fuel cell buses; started revenue service in December 2004 – over 50, 000 mi in service

High Efficiency, Zero Emission Fuel Cell Bus • • • NHA 20 March 2007 Joint Venture established with Thor Industries to develop a series of fuel cell buses Equipped with UTC Fuel Cells 60 k. W PEM fuel cell Fuel Cell Subsystem Operates at Over 50% Net Efficiency Battery Hybrid Drive System Improves Efficiency ~30% Achieves 10 -16 km/kg H 2 (16 km/kg Average in Palm Springs Service) First Fuel Cell Bus in Revenue Service at Sunline Transit, AC Transit Page 4

California Incentives • 2000 - Zero Emission Bus (ZEB) program from CARB, required FCB demonstrations at all diesel fleets of over 200 in size, resulting in fleets of 3 FCBs at VTA (San Jose) and ACT • In October 2006 CARB Re-affirmed ZEB program: – Advanced demo - 12 buses required in Bay area in 2009, – In 2011, 2012 15% of purchases to be FCBs (diesel and alternative path) • Governor is accelerating programs for reduction in transport carbon use, 10% reduction in next 13 yrs NHA 20 March 2007 Page 5

Hydrogen Fueled Transit Buses Source Operator m/kg H 2 Thor/ISE/UTC Sun. Line, AC Transit – Oakland/Berkeley -- Revenue Service 7 -10 m/kg (30’ bus) Daimler/Ballard (36 buses) CUTE Program - 12 Cities, over one million km 3. 5 km/kg (Madrid) Gillig/Ballard (3 buses) VTC (Santa Clara – San Jose) In operation Spring ’ 05 - MAN – Bavarian FCB, New MAN (hybrid) FCB, HICE buses Nurnberg, Erlangen, Furth, 1996 -2001; Munich Airport: May 2004 -, Berlin 2006 HICE, 12 liter engine; FCHB 68 k. W FC + Ni. MH battery storage, 9 km/kg ISE/Ford HHICE - New Flyer chassis, Prototype serving Sun. Line Transit 4 m/kg AC Transit/ISE/Van Hool/UTC (4 buses) Van Hool chassis, AC Transit and Sun. Line Transit 5 -8 m/kg, 300 m Range Toyota – Hino (>8 buses? ) Vehicles served Aachi Exposition Reported 300 km range, 2 x 90 kw FC, Ni-MHi batteries NHA 20 March 2007 Page 6

Worldwide – H 2 Bus programs • Berlin – four HICE buses introduced for 2006 World Cup, more coming • China – Two prototype buses, intent to have FC buses serving 2008 Olympics • Canada – BC Transit solicitation for HFC buses to serve 2010 Winter Olympics (20 buses) • London – solicitation for 10 H-buses to serve London route starting in 2008, hundreds by 2012 Olympics? • + … USA… NHA 20 March 2007 Page 7

USDOT FTA NFCBP • Starting 5 years ago, Cal. Start, other consortia started to lobby for a national FCB program, • In 2005 SAFETEA-LU (Safe, Accountable, Flexible, Efficient Transportation Equity Act: A Legacy for Users) was signed NFCBP (National Fuel Cell Bus Program) ($49 M federal, 50% cost share) • NFCBP goals include facilitating the development of commercially viable FCB technologies, improving efficiency and reducing petroleum consumption • 2 years since passing the bill, announced programs directly involve over a dozen firms spread over USA, Canada, no funds have been negotiated yet. NHA 20 March 2007 Page 8

ISE Fuel Cell Bus Programs 2007 • 4 Hybrid buses operate in California, fifth in Connecticut • Expect to intensify operations, “accelerated testing” program awaits funding • New designs under discussion for Sun. Line Transit, VTA, WMATA, Transport for London, BC Transit – all hybrid electric but using different fuel cells, drive systems, chassis designs. • Continued interest in the NZEV – HHICE bus NHA 20 March 2007 Page 9

HHICE -- Bridging to a Fuel Cell Future Hydrogen Hybrid Bus Gasoline Hybrid Bus NHA 20 March 2007 Hybrid Fuel Cell Bus Page 10

HYDROGEN HYBRID ICE BUS CONFIGURATION Control System Ford V 10 H 2 Engine Energy Storage Accessories Generator Drive Motor Inverter NHA 20 March 2007 Page 11

Energy Flow BATTERIES or ULTRACAPS SIEMENS ELFA SYSTEM DUO-Inverter 1 GENERATOR CGB FUEL 420 to 720 VDC Nominal MOTOR 1 M 2 ENGINE GEN MOTOR 2 AUXILIARY 120 k. W DUO-Inverter 2 ACCESSORIES BRAKING RESISTORS AC 230 VAC Air Conditioning NHA 20 March 2007 M PS AIR Motor Power Steering Air Compressor Page 12

HHICE Bus - Winnipeg Cold Weather Testing NHA 20 March 2007 Page 13

Refueling at Red River College (Electrolytic Hydrogen) NHA 20 March 2007 Page 14

HHICE Bus Experience • Winter and summer testing (-27 to +45 o. C), given dry fuel temperature is not a problem! • The bus now has over 50, 000 miles – mostly in revenue service. • Range is 210 -280 miles – needs to be better! • Average fuel consumption 4 -5 mi/kg • Transit maintenance staff love it – much more accessible than a fuel cell bus! • Engine component reliability has been an issue, notable improvement over the year • Durability issue remains a major concern, • Fuel supply also a major issue! NHA 20 March 2007 Page 15

A Glimpse – Tomorrow’s HICE NOx Emissions vs. Standards NHA 20 March 2007 Page 16

Fuel Cell Hybrid System Layout Hydrogen Storage A/C Unit Fuel Cell Cooling Fuel Cell Power Plant Electronics Cooling Energy Storage System Drive System NHA 20 March 2007 DC/DC & Inverter System Page 17

Fuel Cell Hybrid System Architecture NHA 20 March 2007 Page 18

Fuel Cell Hybrid Bus Status • • NHA 20 March 2007 The 1 st Fuel Cell Hybrid Bus delivered to AC Transit in Oct, 2005 The 2 nd Fuel Cell Hybrid Bus delivered to Sun. Line Transit early Nov and unveiled at the 2005 Fuel Cell Seminar The 3 rd & 4 th Fuel Cell Hybrid Bus delivered to AC Transit in late Dec, 2005 Buses involved in multiple public demonstrations Daily service with AC Transit, Sun. Line transit Fuel cell durability still a concern Batteries (Zebra) cause multiple service outages, limit bus availability Page 19

AC Transit - 9 months experience with new FCHB • Official introduction ceremony in early March, 2006 • One bus is used primarily for shows (such as for the visit of the President – see right) with occasional returns to revenue service • 50, 000 miles revenue service in aggregate (3 buses), • Software issues mostly resolved, serious battery issue, • Bus operation was limited by limited FC warranty hours, accelerated life-test beginning as part of NFCB program NHA 20 March 2007 Page 20

Sun. Line FCB Experience – one year • Used the FC bus double shifts the first two months, now alternating shifts with HHICE bus on Route 50 • 30, 000 miles • hot weather operation awaited resolution of A/C problem, motor failures – now resolved with additional insulation NHA 20 March 2007 Page 21

Announced ISE Involvement in USDOT National Fuel Cell Bus Programs • AC Transit/Sun. Line Accelerated Life-test, bus improvements • Sun. Line Transit, Single New Flyer Bus with UTC FC • Massachusetts Port Authority/Logan Airport – with Nuvera FC • Washington Metro Transit – New Flyer Bus with Ballard FC NHA 20 March 2007 Page 22

A Hydrogen Pathway to Sustainable Mobility NHA 20 March 2007 Page 23

HHICE/FCHB + Wind Hydrogen = Carbon Free Transport! NHA 20 March 2007 Page 24

In Summary: • Hydrogen hybrid buses, fuel cell and HHICE, are in daily revenue service – total of over 120, 000 mi logged in USA, (+ some 1 Million mi for CUTE) • New programs planned in Europe, Canada, USA, • Future single bus programs with new FCs, buses in 2007 -8, + extended California ARB Advanced Demonstration Program NHA 20 March 2007 Page 25