| Lab near
Rochester leads the effort
HONEOYE FALLS - This quiet village
60 miles east of Buffalo is working on the solution to high gas prices
and U.S. reliance on foreign oil.
At the end of a shady street here
is General Motors' lab for fuel cells, a technology in which it is a global
leader. In the site's two low-slung buildings, some 300 engineers and technicians
make an engine that runs on hydrogen instead of gasoline - without noise,
pollution or greenhouse gasses.
The fuel cell, a chemical reactor
that generates electricity, is still regarded as a futuristic technology.
Unlike gas-electric hybrid vehicles, it represents a top-to-bottom change
in vehicle technology. It won't be available in many cars until 2020, the
Energy Department predicts.
But the fuel cell that GM has developed
here in Monroe County is further along than you might think. The technology
is on track to be road-worthy in five years, engineers say.
"We can say the first hurdle has
been met . . . you can drive cars with them," says Matthew Fronk, GM's
chief engineer for fuel cell systems. "The last step is how do we drive
down costs . . . that's what we're focusing on now."
What's lacking are large-scale fuel
sources for hydrogen and the filling stations to distribute it. But spiking
gasoline prices make the alternatives look more practical.
"When gas was a buck and a quarter,
it was "Yeah, fuel cells are prety neat,' " Fronk said. "When fuel starts
to be $3 a gallon, there starts to be a pull from the public: "Is there
something different that can be better?' "
Fronk's team has made about 25 working
fuel cells that power prototype vehicles, six of which are tooling around
Washington, D.C., to demonstrate to policy makers. Another, a converted
Opel Zafira minivan, Fronk has driven at 100 mph on a German test track.
"They can be designed to be very snappy," he says.
Another working fuel cell vehicle
was unveiled here by Sen. Hillary Rodham Clinton in April, a pick-up truck
for use at the Army's base in Ft. Belvoir, Va. Fronk expects more such
technology demonstration projects to roll out as his group refines cost
and performance. Though still too heavy and expensive to be commercially
viable, "I can see a path to that," Fronk says.
The location of GM's fuel cell lab
in Western New York stems from the automaker's long history of electrical
research and development in the Rochester area. The lab in Honeoye Falls
opened in 1999, relocating the fuel cell development group from a smaller
site near Rochester, the company says. Delphi Corp., GM's former parts
arm, also maintains a fuel cell research center in the area, but for a
different technology that provides auxiliary power.
The Buffalo area also has a stake
in future auto technology. A state-funded demonstration project will have
two hydrogen-burning cars in use in 2006, with a fueling station at the
University at Buffalo's north campus in Amherst. The demonstration project,
backed by the state Energy Research and Development Authority, aims to
boost hydrogen fueling technology.
The project envisions converted Toyota
Prius cars with modified gasoline engines burning hydrogen, a less efficient
technology than fuel cells, but one that's seen as an interim step.
"I'm very excited at what the folks
at Honeoye Falls are doing," said Willard E. "Skip" Hauth, vice president
of American Wind Power & Hydrogen LLC on Grand Island, the state's
contractor on the Buffalo hydrogen demonstration project. "When they get
going, they're going to need (fueling stations.)"
In addition, the industrial gas company
Praxair designs hydrogen fueling stations at its site in the Town of Tonawanda.
And hydrogen itself is produced cheaply as a byproduct of chemical plants
in Niagara Falls, which use hydroelectric power to split hydrogen from
water.
With all this hydrogen technology
around, would it make sense to mass-produce fuel cells in Western New York
someday?
"To be determined," Fronk says. "Don't
scratch anything off the list."
Even among big automakers, GM's fuel
cell development site in Monroe County is a rarity. Ford and DaimlerChrysler
both hired an outside company, Ballard Power Systems, to develop fuel cells
for their prototypes.
With its own fuel cell, and a goal
of 2010 to have it ready for mass production, GM is pushing the technology
harder than most automakers. Too hard, critics say. To them, the automaker's
strategy amounts to a long-shot bet, at the expense of shorter-term fixes
like smaller conventional cars and hybrid gas-electric vehicles.
"Fuel cells are a fine holy grail,"
said Rich Kassel, leader of the clean fuels project at the Natural Resources
Defense Council in New York City. "But between now and then, there's a
lot that auto companies could do increase fuel efficiency, and they should
do it."
The environmental group criticizes
the industry and the Bush administration for what it calls weak fuel economy
standards. Bush proclaimed a $1.2 billion hydrogen fuel development initiative
in 2003, what critics call a ploy to draw attention from today's gas-guzzling
technology.
A fuel cell car by itself doesn't
solve fossil fuel problems. Much hydrogen today comes from natural gas,
in a process that emits the greenhouse gas carbon dioxide. To make future
cars truly pollution free, hydrogen producers will have to invest in clean
electric-generating capacity to split hydrogen from water.
However, rising prices for gasoline
bring hydrogen closer to economic practicality. The Energy Department recently
raised its target price for hydrogen to be a viable motor fuel, from $1.50
per gallon-equivalent of gasoline to $2-$3, reflecting expectations of
continued upward pressure on gas prices. Price parity remains far off -
a kilogram of hydrogen, about the energy equivalent of a gallon of gas,
costs $8 to $10 in most areas where its sold for industrial use. But like
hydrogen fueled cars, hydrogen itself is expected to come down in price
with advances in large-scale production.
"There's all different options to
make hydrogen - nuclear, hydro, wind and solar, as well as reforming natural
gas," Fronk said. "Almost any community can make it, based on what their
natural resources are."
Fuel costs and environmental politics
aren't the concern of his fuel cell lab. The engineers here build the guts
of the chemical reactor that generates power, along with its computerized
control system. Other GM sites in Michigan, California and Germany are
working on hydrogen fuel tanks and electric motors. When the country is
ready for a pollution free, gasoline-less vehicle, the GM engineers say
they'll have one - or perhaps sooner than that.
"I'd say hydrogen storage (and) infrastructure
is a little behind fuel cell technology," Fronk said. "Maybe two years
ago fuel cells were behind, but we've made good progress."
A glass display case in front of
Fronk's office shows off the progress. It holds a copy of the fuel cell
used in prototype cars today, a box the size of a suitcase that generates
73 kilowatts, or the equivalent of 98 horsepower. Beside it stand GM's
earlier generation fuel cells - bulkier, lower powered, and made of heavier
materials. The automaker has 152 fuel cell patents and 350 more pending,
largely from work performed in Western New York.
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