Toyotas Approach to Fuel Cell Vehicles

June 25, 2014

Toyota Motor Corporation
1
The first automobiles
Steam-powered vehicle (1769)
Electric vehicle (1899)
Gasoline vehicle (1886)
Benz Patent-Motorwagen
Price 2,750 marks (approx. $1,000)
Engine Single-cylinder horizontal
984 cc/400 rpm/0.9 hp
Max. speed 16 km/h
Weight 313 kg
Source: Toyota Automobile Museum; Wikipedia
2
The electric engine starter
Electric engine starter (1911)
Source: Cadillac 1912 Instruction Book
Manual engine starter
3
The assembly line
Advent of mass production (1913)
Price reductions due to
innovations in production
methods
$290 (1924)
$780 (1910)
Ford Model T assembly line
Ford Model T
$850 (1908)
(Rival companies: $1,800)
Sources: Ford Motor Company; Wikipedia; Utah Division of State History;
Amerika jidosha kogyo no kenkyu (Setsuo Kotani, 2001)
4
The road network in the U.S.
Sources: U.S. Department of Transportation Federal Highway Administration;
Cato Handbook on Policy, 6
th
Edition
Interstate Highways (Dwight D. Eisenhower National System of Interstate and Defense Highways)
Built under the Federal-Aid Highway Act of 1956
Combined length of approx. 66,000 km, at a total cost of 25 billion dollars over 13 years
Funded with Highway Trust Fund (Gasoline tax in 1956: 3 cents/gallon)
5
History of gasoline
Lucas gusher, Spindletop Hill,
Texas (1901)
Drive-in gas station (1913)
Sources: Sekiyu no seiki (Daniel Yergin, Yoshiki Hidaka, Naotake Mochida,1991);
The Paleontological Research Institution, Gulf Oil
1901: Oil fields discovered in Texas
1907: First gas station opens in the U.S.
1913: Thermal cracking allows greater quantities of gasoline to be obtained from petroleum
1929: 300,000 stores selling gasoline in the U.S.
6
The age of gasoline-powered automobiles
1950
Electric
vehicles
1900
Year
Gasoline-powered
vehicles
Steam-powered
vehicles
N
u
m
b
e
r

o
f

a
u
t
o
m
o
b
i
l
e
s

Mass
production
Electric
engine
starter
Lincoln Highway Federal-Aid Highway Act
of 1956
Development of thermal
cracking process
Gas stations spread
The first gas station
Increased demand for gasoline
Roads
Fuel
Gasoline-powered automobiles
Steam, electricity, and
gasoline-powered automobiles
Horse-drawn cart
The simultaneous development of technologies, roads and fuel
gave rise to the age of gasoline-powered automobiles
7
What the automobile has achieved
Enhanced mobility (for people and for goods)
Freedom and convenience (anytime, anywhere)
Mobile personal spaces
Economic,
social, and cultural growth
New possibilities
created by enhanced mobility
=
8
Problems caused by gasoline-powered automobiles
Concern over future oil supply
Increase in
number of
vehicles
Surge in
fossil fuel
consumption
Air pollution
CO
2
emissions leading to
global warming
Growth of global
industry and
technology in the
20th century
9
Crude oil supply forecast
Developing non-conventional resources
will increase the global oil supply
Source: IEA; ExxonMobil
Others
Biofuels
Crude and condensate resources
Crude oil
(conventional oil fields)
Tight oil
Oil sands
Liquid natural gas
Deep-sea oil fields
Remaining
resources
Cumulative
production
through 2040
(units: million oil-equivalent
barrels/day)
(trillion barrels)
Global liquids supply by type
10
Increase in distance traveled
1985 $1= 250
GDP and distance traveled by region (1950-1997)
North America
Western Europe
Eastern Europe
Australia and New Zealand
Former Soviet Union
Central Asia
South Asia
Latin America
Middle East and Africa
Africa
Asia Pacific
World
25,000
20,000
15,000
10,000
5,000
0
$0 $5,000 $10,000 $15,000 $20,000 $25,000
Per capita GDP in 1985
D
i
s
t
a
n
c
e

t
r
a
v
e
l
e
d

p
e
r

p
e
r
s
o
n

p
e
r

y
e
a
r

(km) 1997
1950
Distance traveled has increased due to economic growth
Source: WBCSD Mobility 2001
11
The world in 2050
Global population of 9.6 billion
70% of the worlds population living in cities
Global and urban population
Source: OECD
Environmental
Outlook
Global GDP
Source: U.N. Dept. of
Economic and Social
Affairs
Global GDP to increase more than threefold
Rapid increase in overall/urban population and economy leading to
Intensified environmental problems
(climate change, global warming, air pollution)
Global population
Urban population
P
o
p
u
l
a
t
i
o
n

10
8
6
4
2
0
(billion)
12
What is a sustainable mobility society?
One that allows us all to move freely
in comfort and safety,
in an environment-friendly, sustainable manner
13
A sustainable society
A society which uses diverse energy sources, with electricity and hydrogen infrastructures
EVs/PHVs
Electricity
storage
facilities
Thermal
power
generation
Power generation units
Automotive fuel
Hydrogen
tanks
Biomass
Wastewater
Photovoltaic
generation
Wind power
Renewable
Energy
Fossil Fuels
Electricity Grid
Hydrogen Grid
Hydrogen-Electricity
Conversion
High-volume,
long-term storage
Electrolysis
Industry
Electricity
Energy Flow
Hydrogen
Fossil fuels
FCVs/FC buses
Urban/
residential
HVs
Refineries/chemical plants
Chemical
plants
Urban/
residential
Urban/
residential
14
Toyotas environmental principles
Driving real and positive change by popularizing
these vehicles
Developing efficient, low-emission vehicles
Embracing diverse energy sources
15
Primary energy sources, automotive fuels and powertrains
Primary energy
source
Automotive fuel Powertrain
Oil
C
o
n
s
e
r
v
e

D
i
v
e
r
s
i
f
y

Coal
Plants
Electricity
Hydrogen
Diesel
Conventional
and hybrid
vehicles
EVs
FCVs
PHVs
Natural gas
Uranium
Hydro, solar,
geothermal electricity
generation
Gasoline
Biofuels
Gaseous fuels
Synthetic fuels
16
Hybrid vehicle lineup
Toyota has introduced hybrid models in all vehicle categories
Compact
Medium
Large
SUV
Minivan
Commercial
As of May 2014
17
Hybrid vehicle sales
As of May 2014 1997 1999 2001 2009 2011 2003 2005 2007 2013
A
n
n
u
a
l

s
a
l
e
s

(
m
i
l
l
i
o
n
s
)

1.2
1.4
0
0.2
0.4
0.6
0.8
1
0
1
2
3
4
5
6
7
8
9
C
u
m
u
l
a
t
i
v
e

s
a
l
e
s

(
m
i
l
l
i
o
n
)

HV global sales
2012: Achieved 1 million annual units sales for the first time
Dec. 2013: Cumulative sales passed 6 million units
3 million units
2 million units
1 million units
4 million units
5 million units
6 million units
2014
18
Development of hybrid technology
Hybrid technology underpins Toyotas PHVs, EVs and FCVs
EV
HV
PHV
FCV
Motor
Fuel tank
PCU
Battery
Engine
Generator
Motor
Fuel
tank
PCU
Battery
Engine
Generator
Motor
Fuel
tank
PCU
Battery
Engine
Motor
Hydrogen
tank
PCU
Battery
Engine
19
Characteristics of alternative fuels
The strengths of individual alternative fuels
Electricity

Hydrogen

Biofuel

Natural gas

Well-to-wheel CO
2
Poor
to Excellent
Poor
to Excellent
Poor
to Excellent
Good
Supply volume Excellent Excellent Poor Good
Cruising range Poor Excellent Excellent Good
Fueling/charging time Poor Excellent Excellent Excellent
Dedicated infrastructure Good Poor Excellent Good
Internal combustion
engines
Internal combustion
engines
FCV EV
20
Fuel diversity and uses
EVs: Short-distance, HVs & PHVs: Wide-use, FCVs: Medium-to-long distance
Short-distance
commuter vehicles
Travel distance
Fuel Electricity Gasoline, diesel, biofuels, CNG, synthetic fuels, etc. Hydrogen
Home delivery
vehicles
EVs
HVs
PHVs
FC buses
FCVs
V
e
h
i
c
l
e

s
i
z
e

Passenger cars
Route buses
Personal mobility
EVs
HV/PHVs
FCVs
Home delivery
trucks
Full-size trucks
21
The importance of PHVs
Electricity
Gasoline
Next-generation electric vehicles for widespread use
PHVs can be used safely and without limitations, at all times
22
Pros and cons of EVs
EVs are appropriate for short-distance commuting and fleet use
Shorter range
High battery costs
Long charging time
Need for quick charger infrastructure
Zero emissions when driven
Quiet
Rechargeable from household outlet
Advantages Disadvantages
23
About hydrogen
Hydrogen is found in abundance in water and fossil fuels

It is colorless, odorless, and tasteless at room temperature and normal
atmospheric pressure; it is extremely light and diffuses rapidly

It is a reactive element with numerous chemical/fuel uses; fuel cells
increase the electricity generation efficiency of hydrogen
24
Primary uses of hydrogen
Thanks to past experience and recent research,
hydrogen can be used as safely as gasoline or natural gas
Hydrogen has been used for over 200 years
Urban areas: gas lamps
In homes: utility gas (water/coal gas)
In manufacturing: fertilizer (ammonia), oil refining (desulfurization, etc.)
As an automotive fuel
25
Advantages of hydrogen
Zero CO
2
emissions during use, helping to achieve a low-carbon society
Can be obtained from a variety of primary energy sources
From fossil fuels such as natural gas, as well as from unused sewage sludge
From water using natural energy sources such as solar or wind energy
Higher energy density than batteries, and is easier to transport and store; can be
used to resolve uneven distribution of regional energy, and to compensate for
fluctuations in supply from renewable energy sources
Wide range of uses, from home to automotive fuel and power generation
26
We believe hydrogen will be
a leading energy source in
the future
27
Toyotas FCV development to date
1992: Start of development
A Toyota FCV took part in a parade in Osaka. The vehicle
featured a fuel cell stack and metal hydride hydrogen tank.
1996: Parade in Osaka
EVS13 in Osaka (Oct.1996)
Toyotas FCV development started in 1992.
28
Toyotas FCV development to date
Max speed 155 km/h
Range
830 km
(10-15 test
cycle)
Occupancy 5
Max pressure of tank 70 MPa
Fuel cell output 90 kW
World-first limited sale in the U.S. and Japan
Achieves vehicle type certification from the Japanese government
Range and cold start capabilities improved
Toyota has leased over fuel cell 100 vehicles to date, and these
have driven over 2 million km in the U.S. and Japan
2002: FCHV (Dec 2002-)
2005: FCHV (July 2005-)
2008: FCHV-adv (June 2008-)
Toyota
FCHV-adv
(2008)
29
Advantages of FCVs
Energy diversification
Hydrogen can be produced from a
variety of primary energy sources
Zero emissions
Zero CO
2
emissions during driving
Driving pleasure
Smooth start and good acceleration
at low and medium speeds
Smooth and quiet operation
Low refueling time (approx. 3 min.)
Cold-start capability (-30C)
Performance
High cruising range (approx. 700 km
under JC08 cycle; Toyota measurements)
Power supply capabilities 4-5 times greater
than EVs; can supply power to an average
household for more than a week
Large power supply capability for emergencies
30
The potential of FCVs
FCVs are ideal eco-cars
31
FCVs contribute to a sustainable mobility society by:
contributing to the diversity of automotive fuels
only emitting water vapor during driving
offering the convenience of existing gasoline-engine automobiles

Fuel cell system development
The new fuel cell system is smaller and performs better
Top-level
Size reduction
3.0 kW/L
Key system components can be placed under seats
Output power over 100 kW
Over twice the output power
density of the Toyota FCHV-adv
32
High-pressure hydrogen tank development
High-pressure hydrogen tank performance
has increased while costs have decreased
Top-level
Different materials and
manufacturing process used
5.7 wt%
Reduced costs
Number of tanks per vehicle halved from
four to two
Tank storage density improved by approx.
20% compared to Toyota FCHV-adv
(70MPa)
(70MPa)
33
Fuel cell system development
Significant progress has been made in fuel cell system development
Use of boost converter Fewer cells, smaller motor
No humidifier Enhanced reliability; reduced size, weight, and cost
Motor Power control unit Battery Fuel filler
Hydrogen tank Fuel cell
stack
Boost converter
34
Fuel cell system cost reduction
Design
Production technology
Limited sales
Mass production
Resolve technical issues
Market entry Widespread use
Reduce cost
Costs down to 5%
of FCHV-adv costs
(2015)
Further
cost
reductions
FCHV-adv
(2008)
Fuel cell system costs have decreased significantly, and will
continue to decrease.
35
Toyotas FCV sedan: exterior (as of June 25, 2014)
36
Toyotas FCV sedan: Japan sales (as of June 25, 2014)
Going on sale before April 2015
(in the summer of 2015 in the U.S. and Europe)
Sold at Toyota and Toyopet dealerships
Approximately 7 million yen
(Initially, sales will be focused on dealerships in areas where hydrogen infrastructure is
being developed)
(Approximate MSRP; excludes consumption tax; U.S./European pricing not yet decided)
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