1st International Conference on Hydrogen Safety Pisa, Sept. 8-10 2005 Hydrogen Vehicles Road-Map in FIAT Giuseppe Rovera Centro Ricerche Fiat

Fuel Cell Vehicles for Urban Transportation FCV development in Fiat is focused on urban vehicles: City Cars and Buses

The Fiat Fuel Cell Road Map FC Cityclass Torino FC Cityclass Madrid 2002 2006 Hybrid FC Europolis Seicento FC APU Panda Cell Full Power 2000 2004 Seicento Hydrogen FUEL CELL SYSTEM APU FC system II generation FC with Load-follower powertrain Full power FC system Panda fleet III generation FC system BUS CITY CARS Years Doblò FC

Iveco FC Hybrid Cityclass Performance Max Speed 60 km/h Gradeability 20% (@ full load) H2Refuelling Time <15 min Range (urban cycle) 12 h Caratteristiche principali Vehicle Cityclass 12 m Load 72 passengers Total Weight 19 tonn Powertrain architecture Series Hybrid load follower (DC/DC lato FC) Batteries Pb gel (576 Vnom – 50 Ah), or NaNiCl2 (Zebra) Electric Motor AC asinchronous triphase (160 kW – 1000 Nm) PEM Fuel Cell System 60 kWmax H2Tank 9 bottles, total 149 l @ 200 bar

Fiat Seicento Hydrogen Program supported by Ministry of Environment MAIN CHARACTERISTICS Payload Curb weight Ni-Me battery AC Induction Motor PEM Fuel Cell System Powertrain Architecture H2 Tank 4 seats 1150 kg 144 V – 0.9 kWh 15/30 kW, 123 Nm 40 kW max Hybrid Full Performance 68 l @ 350 bar VEHICLE PERFORMANCE Acceleration 0-50 km/h Maximum speed Gradeability @ full load Refuelling time Range (UDC cycle) < 7 s 130 km/h > 20% < 10 min 220 km

NEXT STEP FUEL CELL VEHICLES FLEETS (2006-2010) Toward Hydrogen Mobility The Fiat Road-Map on Automotive Technologies NEXT STEP FUEL CELL VEHICLES FLEETS (2006-2010)

The 3d generation FCV: Panda Hydrogen Program supported by Ministry of Environment Main Features and Vehicle Performance Payload 4 seats Curb Weight 1150 kg Max Speed 150 km/h Acceleration Time (0–50 km/h) 7 s Range (Urban Driving Cycle) > 220 km Gradeability @ full load 23% Refuelling time < 5 min FC Powertrain Architecture Full Power FC Fuel Cell System Nuvera PEM stacks Electric Motor AC Induction Hydrogen Tank 68 l, 1.6 kg H2 @ 350 bar Fiat Panda Hydrogen

The EU- Zero Regio Program FC Vehicles fleet demonstration (2006-2008) Project Goal Set up and test the Hydrogen chain for Transportation, from production to distribution Verify User Acceptance of Fuel Cell Vehicles, and functionality of related infrastructure and services Assess safety, cost issues, socio-economic and environmental impact FRAKFURT MANTOVA CONSORTIUM Regione Lombardia Centro Recerche Fiat Eni Technology City of Mantova Sapio JRC, Ispra IEFE, Bocconi University Lund University Roskilde University Rhein Main Daimler Chrysler Fraport AG Agip Deutschland GmbH Infraserv GmbH & Co. Hoechst KG Linde AG Saviko Consultants TÜV Hessen GmbH

60kW Hybrid Fuel Cell Modular System EUROPOLIS FUEL CELLS 60kW Hybrid Fuel Cell Modular System CRF System: series hybrid Length: 7.4 m. Chassis: superlow (350 mm.) Payload: > 30 passengers Batteries: Ni-Cd / Ni-MeH Range: > 200 km (hybrid mode)

planned Fleet Tests (2008-2010) FUEL CELL VEHICLES planned Fleet Tests (2008-2010) Torino Stazione di rifornimento 2 Europolis FC Hybrid Milano, Mantova, Arese Stazione di produzione e rifornimento 10 Panda Hydrogen 2 Europolis FC Hybrid Genova Stazione di rifornimento Europolis/Panda Napoli Stazione di rifornimento Europolis/Panda Firenze/Siena Stazione di rifornimento Europolis/Panda

IMPROVEMENTS EXPECTED ON FUEL CELL POWERTRAIN (2006-2010) Toward Hydrogen Mobility The Fiat Road-Map on FCV IMPROVEMENTS EXPECTED ON FUEL CELL POWERTRAIN (2006-2010)

NEXT STEP: Improving FC Vehicles (2006-2010) CRF Research Activities are addressing the following priorities: Fuel Cell tecnologies for improved efficiency (>50%), extended performances (-30°C--+50°C ambient, 5000 hrs duration) and lower Cost: - New hydrogen recirculation circuits - Simplified humidification techniques - High temperature membrane (>90°C) - Cooling circuit and materials for low temperature operation (-30°C) - On board diagnosis for enhanced Safety - New generation, high-voltage low-cost Stacks with simplified design, improved catalytic materials and automated assembly Standardisation of Components and subsystems for applications both to Cars and Buses.

Toward Hydrogen Mobility The Fiat Road-Map on FCV HYDROGEN SAFETY

Hydrogen Vehicles Safety User Expectations for Hydrogen Vehicles : No additional tasks or responsibility during vehicle lifecycle, e.g. refuelling or maintenance No additional costs, including maintenance and repair Safety levels equal or better of current vehicles

Priority Investigation Areas HYDROGEN VEHICLES Safety Priority Investigation Areas H2 Leakage Detection and Recovery during Vehicle Refuelling, Stationary and Dynamic Operation. Improved high pressure H2 Storage; integrity status & performance monitoring. Crashworthiness of hydrogen components Automated Emergency interventions, e.g. Hydrogen discharge in case of crash, fire-explosion risk Passive mitigation engineering measures to protect occupants and surroundings from disruptive events such as explosion and fire Other Issues Electrical shock prevention. The Approach includes the development of comprehensive sensing,diagnostics and control technologies, the adoption of engineering based on best practices and consistent experimental data base, exhaustive test and analysis procedures. SOLUTIONS MUST BE RELIABLE, SIMPLE AND COST EFFECTIVE to increase public confidence on Hydrogen safety and reliability “better than current vehicles”