commercial vehicles and extreme fast charging research ... · nmc . li-ion batteries typically...

Commercial Vehicles and Extreme Fast Charging Research Needs Workshop 2019

Golden, Colorado

August 27–28, 2019

The National Renewable Energy Laboratory (NREL) hosted the workshop, which was sponsored by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy's Vehicle Technologies Office.

Table of Contents

3

16

25

35

57

Extreme Fast Charging: Perspectives from Cummins

Tritium: High Power Charging for Electric Vehicles

Xcel Energy: Slides for Discussion

Black & Veatch: High Power Charging Siting & Power Delivery

Eaton: EV Fast-Charging Barriers and Opportunities

NREL | 2

Extreme Fast Charging: Perspective from Cummins John Kresse

27 August 2019

Extreme fast charging …

… Advantages for fleets

… Cummins experience

… Challenges

2

Fleet Advantages 1

A commercial vehicle is part of an overall system, this includes: the fueling or charging infrastructure, the duty cycle and the driver

Depending on battery sizing, fast charging can improve route flexibility and the impact of higher battery use due to high accessory (esp. cab heating) losses

• However, if a fast charging infrastructure enables the battery to be downsized, route flexibility may be reduced

1Ethan May and Kellie Hwang, “IndyGo Red Line electric buses weren’t going far enough on a charge, so they’re getting a tech fix”, Indianapolis Star, May 23, 2019.

3

Fueling rate class 8 diesel class 8 EV

J1772 L2 150 kW 350 kW 500 kW 1 MW

fueling rate (miles / minute) 150 - 300 0.15 1 2.5 4 8 Max charging rates typically only available from 15-80% SOC

While even the extreme fast chargers are more than an order of magnitude slower compared to a diesel pump, these chargers provide significant flexibility to a fleet operator compared to the highest power SAE J1772 level 2 overnight charging

4

Cummins support of Wireless Advanced Vehicle Electrification (WAVE) drayage truck project2

Class 8 drayage truck integrated to a WAVE 500 kW wireless inductive charging system Extreme fast charging system enables high truck utilization: in this case,

the objective is to operate 20 hours a day, multiple round trips/day

2 Wireless Extreme Fast Charging for Electric Trucks (WXFC-Trucks) DOE Cooperative Agreement No. DE-EE0008360

Image used with permission of PACCAR Inc.

15 minute fast charge events

5

Challenge: batteries Today, support of extreme fast charging requires a battery that either has large

capacity or higher cell cost / reduced energy density • NMC Li-ion batteries typically support (continuous) charge C rates of 0.7 - 1

- Extreme fast charging can only be fully utilized with large batteries • LTO Li-ion batteries support much higher charge rates but have much higher

cost and limited energy density • There are some power-oriented NMC batteries that have higher cost and less

energy density than energy-oriented NMC but can be an acceptable balance High C rate charge cycles can have a negative impact on battery life

Industry need: continuous 3-4C rate battery with good energy density, low cost, that can support 4k charge cycles with acceptable life

6

Challenge: operational costs A total cost of ownership (TCO)

study3 found a major contributor for MD EV delivery trucks is grid electricity cost:

• $0.10/kW-h, payback period for an EV is 3½ years 30

35

40

45

50

55

Demand charges varies across all utilities operating in the State ($/KW)

Demand Charge ($/KW)

• $0.20/kW-h, payback period is 5 years 15

20

25

Because of time-of-use and demand charges, the average cost of electricity can more than double for fast charging compared to slow overnight charging

0

5

10

AZNY NECA MACO IL GA NC

Demand Charge-Average of all utilities maximum charge Demand Charge- Maximum charge across all utilities

States

Source: National Renewable Energy Laboratory (NREL)

VT

3 Cummins Electric Truck with Range Extending Engine (ETREE) DOE Cooperative Agreement No. DE-EE0007514

7

Challenge: optimizing fleet choices With expensive assets (trucks, charging infrastructure), impact of grid

electricity (cost, availability), and need to ensure fleet missions are accomplished at best TCO, how should each fleet structure & use their eco-system?

• E.g., should a fleet purchase trucks with large batteries with overnight charging or small batteries with robust fast charging network?

• Etc.

This requires (multiple) high fidelity simulation tools with integrated grid, fleet, charging systems and truck modeling capability which can model TCO sensitivity with several independent variables Ultimately, a fleet may need gold standard tools that help with:

• Buying decisions for their eco-system • Operational decisions

8

Other challenges Infrastructure costs, impact to grid and where to site chargers Interoperability / lack of standardization

• Pantograph (multiple) • Wireless (multiple) – even with development of SAE J2954 • Automated conductive

Availability and cost of high amperage vehicle side connectors Battery thermal management during extreme high power charging EMI – EMC prediction & mitigation

9

Range Extenders (REx) vs. Extreme Fast Charging Infrastructure

An ubiquitous DCFC infrastructure limits the usefulness of a series PHEV • The infrastructure eliminates “range anxiety” so there’s little need for REx

However, the opposite may be true • Until a fleet has access to a reliable fast charging network, the proper

range extender can alleviate both range, and infrastructure, “anxiety”

Cummins ETREE Series PHEV equipped with a 130 kW range extender 10

Extreme Fast Charging

For many commercial fleets, extreme fast charging is a requirement to move electric vehicles from niche to mainstream

But, the challenges must be overcome • Impact on electricity grid including time-of-day and demand charges • Battery technology (charge rate support, impact on battery life) • Others: interoperability, battery thermal management, on-vehicle wiring,

infrastructure costs

11

12

Q+A

1313

High Power Charging for Electric Vehicles

James Kennedy CTO / Founder

Quick Facts: Tritium

Charging Infrastructure

More convenience EV’s can charge anywhere – currently

Optimal Vehicle Charging Locations

70% Home

15% Work

10% Public

5% Corridor

12kW

12-25kW

50kW

350 - 500kW

More convenience EV’s can charge anywhere – future?

Optimal Vehicle Charging Locations

20% Home 12kW

12-25kW 20% Work

20% Public 50kW

40% Corridor / “Petrol Station” 350 - 500kW

European Automotive OEM Network Announced Nov 2017 – 40% built already • IONITY network: Volkswagen (incl Porsche & Audi), Ford Europe, BMW,

Daimler/Mercedes • 400+ sites across Europe within the next 18 months – expected to only be 10% of final

network • Each site consists of:

• 1250kVA MV (10/20kV) transformer, metering, and switchgear • 6x 350kW charging heads + parking spaces, expandable to 500kW • Liquid-cooled charging cables • Site power management control (since total charging head power is greater than site

power) • Telemetry, remote access, firmware updates, billing system, DC metering equipment

European Automotive OEM Network Being built now

European Automotive OEM Network Challenges • Utility connection time

• High workload per site • Long timeframes

• Site Footprint • Installations into existing truck stops on Autobahn network • Total site footprint area is quite restricted at many sites

• Regulatory • German DC meter law

• Site earthing design • MV fault • Lightning strike

James KennedyCTO / Founder

james@tritium.com.au

+61 7 3147 8513

www.tritium.com.au

Slides for Discussion Beth Chacon Director, Grid Storage & Emerging Technology

August 28th 2019

About Xcel Energy Serving eight states • 3.6 million electricity customers • 2 million natural gas customers

Nationally recognized leader: • Wind energy • Energy efficiency • Carbon emissions reductions • Innovative technology

Xcel Energy Priorities

Our Carbon-free Energy Future Xcel Energy Carbon Goals Compared to 2 C Scenarios

2005 2020 2030 20500%

-20%

-40%

-60% Range of Scenarios Likely to Achieve 2 C

-80%

-100%

2018 2030 2050 38% 80% 100% Achieved Goal Carbon-free Goal

Perc

ent C

arbo

n Em

issi

on R

educ

tion

Goals align with Paris climate

targets to limit warming to 2 C

Strategic Electrification A solution for reducing carbon economy-wide

Xcel Energy EV strategy: • Making EV adoption easier • Creating charging infrastructure • Establishing rates and technology to encourage

charging on low-cost, low-carbon energy

~2 million EVs projected in Xcel Energy territories by 2035

EV Residential TOU Snapshot

• Highest usage 9pm-9am • Due to off-peak pricing • On peak - $.21/kwh (summer) • Off peak - $04/kwh

* Mean usage is mean energy used (in Wh) during 15-minute interval,averaged across all customers in the program. 6

What does Extreme Charging Mean? Peak Load kW

Peak loads for various customer

50 E-buses

20 Story Building facilities

5A High School

Supermarket

0 500 1000 1500 2000 2500 3000

7

Timeline for Connecting Service

8

Timeline for Connecting Service, cont.

9

Copyright Pipistrel

Copyright Proterra

High-Power Charging Siting & Power Delivery Paul Stith Director, Strategy & Innovation

NREL Extreme Fast Charging Workshop Transformative Technologies

August 28, 2019

About Black & Veatch

Employee-owned, global leader in building Critical Human Infrastructure in Energy, Water,Telecommunications and Government Services. Since 1915, we have helped our clients improve the lives of people in more than 100 countries through consulting, engineering, construction, operations and program management.

11,000+ $3.5 Billion Safety Performance in revenue in 2018 0.37 Recordable Incident Rate Professionals

0.06 Lost Time Incident Rate

Power Water Telecom Oil & Gas

.

Transformative Technologies @ Black & Veatch

As of January 25, 2019 Source: Tesla As of September 6, 2018 Source: Electrify America https://www.tesla.com/supercharger https://www.electrifyamerica.com/locations

Over 1,400 High-Power Sites 250KW+

New York MTA Transit on-route & depot charging facilities. Proterra & New Flyer Pilot.

Scaling DistributedClean Energy

Infrastructure

Electric Vehicle Infrastructure Energy Storage Networks Hydrogen Infrastructure

Emerging Distributed Technology Autonomous, Connected Vehicle

Infrastructure

We build complex networks faster

3

High-Power Charging: Impacts on SiteDesign & Approach What does it mean for Infrastructure Planning&Investments

4

Site Design, Power Delivery, Cost of Energy Multiple Low Voltage Transformers -> Medium

Voltage Utility Service

Switch Gear Capacity Strategy

Centralized Power Conversion

DC Power Utility Delivery

Infrastructure Sharing & Equipment Compounds

Automation, Cooling, Cables, Connectors

Designs and costs shaped by new technologies and utility service provisioning Enabling High Capacity Corridor, Ports,

Depot & Aviation FBO Fueling

Sharing Solutions Across On-Road, Off-Road, Aviation & Marine Applications 5

Step Change in Charging Infrastructure Requirements High Power Corridor Charging

High Utilization Vehicles

Urban Charging Hubs & Depots

High power On-route

Capital Requirements

Facility and Network Roadmaps

Optimize for least regret investments while scaling to meet requirements

High Capital Requirements & Schedules Require Planning,Risk Management and Technology Flexibility

Transit Bus: ~250KWh Over-Road Coach ~500KWh –

750KWh or more per day

6

Modular Electrical Design Approach • Develop roadmaps for network capacity and Example (5) pod system diagram:

site deployments

2,500A 277/480V switch board

12.5kV 277/480V transformer (2 MVA)

Pod 1

600kW power unit

600kW power unit

eVTOL

Medium-voltage switch gear 600A 12.5kV

Pod 3

600kW 600kW

600kW power unit

dispenser dispenser dispenser 600kW

eVTOL eVTOL

Pod 5

Utility primary service Pod 2 Pod 4

• Integration with utility planning processes(power requirements, network density, grid support, etc.)

• Distributed energy and resilience • Plan for electrical infrastructure ahead of fleet

ramp up per location • Understanding opportunities for power

sharing with buildings, other vehicle chargingand the role of energy storage

• Reducing cost of energy, storage andrenewables integration options

Source: Black & Veatch – National Institute of Aerospace (NIA), under contract with the National Aeronautics and Space Approach allows for least regret investment Administration (NASA) Urban Air Mobility Study

7

Pilot While Planning for Scale (Pilot ENTIRE Sites)

“Businesses (& Fleets) that do not electrify will be at a competitive disadvantage…”

Black & Veatch – EVS30 “Priming the U.S. Grid for High-Power Charging”

> Modular, least regret infrastructure investment program (Fleets & Facilities)

Stakeholder Alignment & Program Goals • Existing Project History • Concurrent, Future Projects

• Building Load Integration • Cost of Energy, Renewable Content • Resilience requirements • Future Proofing Infrastructure

• Project & Program Timeline • Project & Program Budget • Total Cost of Operation

> Fleets, Agencies, Utilities, Cities, Vehicle OEMs, Clean Energy,Community Interests, Project Execution Team, Funding & ROI

9

Infrastructure: Understanding Schedule & Whole Costs The most expensive Electric Fleet is one that can’t charge

10

$0

$50,000

$100,000

$150,000

$200,000

$250,000

Corridors, Pilot Fleet Sites: High Power ChargingDeployments Scenarios

Transformer

Switch Gear

Land Use

Commissioning

Cable/Conduit/Trenching

Charger Relative, Per Charger Costs

1 4 16

Number of Chargers

All-In Costs for High Power Charging Facilities 11

$-

$1,000,000

$2,000,000

$3,000,000

$4,000,000

$5,000,000

$6,000,000

Full Electrication: Scaling Up Requires Significant Capital

Relative, Per Charger Costs

1 4 16 48 100 200

Substation

Feeder

Transformer

Switch Gear

Land Use

Commissioning

Cable/Conduit/Trenching

Charger

Number of Chargers

All-In Costs for High Power Charging Facilities 12

High-Power Site Development – Potential Grid Upgrades

Potential Grid Upgrades Required, Typical Scenarios & Land Use

Example ranges – all power delivery scenarios are specific to a location, feederaccess, existing, in queue projects and utility operating / power provisioning standards

AND available land / right of ways

13

High-Power Site Development Schedules Base Case Power Delivery Schedule: No Grid Upgrades Required

Project Phase Typical Ranges (Months) Engineering / Design 0.50 - 2.00 Permitting / Land Use 0.50 - 3.00 Construction 1.75 - 2.50 Commissioning 0.25 - 0.50 Total Project Schedule 3.00 - 8.00

Assumes 1-2 megawatt load, power is available on site, new utility service andtransformer, 480v supply, existing utility right of way, limited to no building

load integration. May include service extension.

14

Power Delivery, Grid Upgrade Schedules Potential Grid Upgrades Required, Schedule Impacts

Potential Power Delivery Upgrades Typical Ranges (Months) Supply Conductor (Service Extension) 0 - 2 Medium Voltage (Service Provisioning) 0 - 5 Feeder Re-Conductor 6 - 36 Feeder Additional Conductor 6 - 36 New Feeder 9 - 48 Substation Upgrade Required 18 - 36 New Substation Required 24 - 48

Example ranges – all power delivery scenarios are specific to a location, feederaccess, existing, in queue projects and utility operating / power provisioning standards

AND available land / right of ways

15

Scenario Assumptions (Ultra Fast quickly surpass thresholds!)

Ports Power (MW)

Medium Voltage

Feeder Upgrade

New Feeder

Substation

1 0.125 4 0.50

16 2.00 48 6.00

100 12.50 200 25.00

125KW Per Charger, Medium voltage grid supply for 4MW and larger

configurations, 1 Mile of Feeder, New Substation

16

Driving PredictableOutcomes: Costs & Schedules Working with EPCs, Utilities and Stakeholders

17

Electric Utility Coordination Key Points • Early engagement and utility coordination at an account and engineering level is

highly encouraged to fully understand requirements and feasible power deliveryschedules.

• Utilities will generally not release site specific power delivery capabilities withoutexpressed intent to develop a location.

• With increased power levels, the scope and location of distribution grid upgrades increases, so does the intensity of land use, right of way and permitting requirements.

• An important aspect of utility coordination is the ability to leverage existingrelationships coupled with engineering know how.

• Relationships, combined with knowledge of utility engineering and business practicescan reduce utility service fees and significantly accelerate service delivery for high-power electric vehicle charging.

18

Influence & Expenditure Curve:Ability to Influence Total Installed Cost

Low

High

Design: Conceptual and Detailed

Procurement

Construction

Startup

Complete Time Start

Proposal

Impa

ct p

er D

olla

r Spe

ntAb

ility

to in

fluen

ce c

ost

DO IT! -EARLIER IS BETTER

Basic guideline: $1 spend in Engineering = $10 spent in procurement - $100 spent in Construction

Electric Vehicle Infrastructure 101 – Controlling Project Costs • Change and Risk are expensive

• Quality information drives design certainty • Design certainty drives deployment cost certainty • Develop execution strategies to reduce risk • Plan for unknowns

• Project delays are expensive, vehicles that can’t charge and expedited construction are more expensive!

• Entire power delivery per facility • Understand and manage entire supply chain • Understand all required approvals (internal/external) • Understand and plan for contracts and legal process

> Site feasibility, power delivery, equipment lead times, design approvals

Paul Stith Director, Strategy & Innovation, Transformative Technologies

@Black_Veatch StithP@bv.com @BVSII +1 913-458-8747

Additional Electrification Resources (click to download) REPORTS & BRIEFINGS PRESENTATIONS

To request whitepapers “Priming the U.S. Grid for High-Power Charging” and “Understanding and De-Risking Power Delivery” email StithP@bv.com.

Black & Veatch 22

© 2019 Eaton. All rights reserved..

Today & Tomorrow:

EV Fast-Charging Barriers and Opportunities

David Ganger, Ph.D., P.E.

Eaton Research Labs

8/28/2019

To improve the quality of life and the

environment through the use of power

management technologies and services.

New Reported Segment (2018)

$500M investment

Electrical Systems & Services

eMobility Vehicle Electrical Products

Aerospace

Hydraulics

Industrial Sector ($8.5 B, 2018) Electrical Sector ($13.1 B, 2018)

3© 2019 Eaton. All rights reserved..

Utility Equipment

Transformers Protection

Distribution

Equipment

Software

Distribution Equipment

Panelboards &

Switchgear Protection

Monitoring &

Metering

Energy Storage

Electric Vehicle

Supply Equipment

Chargers

Energy Management

Microgrid

Controls

Metering

Today: Barriers to Adoption of Extreme Fast-Charging

Technology Barriers

• Thermal • High voltage • Automation

management architecture • Cooling

• Battery charge rate • Safety concerns

Market Barriers

• Infrastructure costs • Developing standards

& regulations

.

Tomorrow: Site- and Feeder-level Controls

Mobility HIP NODES

Exploring the Effects of Electrification An IoT Based Demand Response Solution

Controllable Loads

Potential Users

Utilities Load aggregators Virtual power plants

Values

- Coordination of grid-service-enabled assets

© 2019 Eaton. All rights reserved. Eaton Confidential. 5

.

Tomorrow: Extreme Fast Charging - DCaaS

600 Vac

1000 Vdc

1000Vdc

AC

Distribution

DC

Distribution

© 2019 Eaton. All rights reserved. Eaton Confidential. 6

7© 2019 Eaton. All rights reserved. Eaton Confidential..