2009 Test Trek with Fuel Cell and Fridge in Vehicle
Test Trek using Fuel Cell and eco-camper products
As a family of fisherman, we decided to use the Fuel Cell and run a 7 day Test during an “all boys” fishing trip: Dad and 3 of his 4 sons in Queensland.
We usually take a camper trailer or off-road caravan but the boys voted for a quad bike. There are some advantages to a quad bike on deserted beaches and sneaking along estuary edges, something you can’t do in a 4WD. Otherwise, we would have had a “tinnie” behind.
So on this trip, it was “vehicle only” camping with a trailer with a quad bike on it and a storage pod on the front for all the camping gear.
To fully test the Fuel Cell we needed a constant sizeable load. We chose the Waeco 80L fridge/freezer which can be force switched to a “high” power setting and in this setting is “power hungry” constantly.
As a sidenote, we much prefer eutectic based technology because of its energy saving feature of smoothing out power demand and operating at a lower duty cycle. The Autofridge is an excellent example of this technology and at eco-camper we only sell and recommend “Autofridge”. However, the additional eutectic technology comes at a premium, and it is not the most common portable fridge in the market. The Waeco is probably one of the most common fridges available.
We did NOT use the vehicle charging system to charge the batteries so that the Fuel Cell was the only power source for refrigeration, lighting and charging the mobile phone and camera.
The Test started on Saturday 10th October 2009 and concluded on Sunday 18th October, a total of 8 days.
What we wanted to know was whether this technology, unknown to most Australians but common in Europe is suitable for the Australian environment?
We needed a rough and tumble test environment:
- A rough road
- Warm/ hot salty air
- Constant near 24 hour power demand on the batteries by a power hungry freezer.
- No special attention (other than test data)
- Attempt to fail the unit with an artificial high temperature and see if it recovers by itself
- And 3 boys (maybe 4) that can be rough and reasonably hot weather in October on the coast.
We set out for the town of “1770” in Queensland.
For those who want a one page report: Our conclusion is that the Fuel Cell can comfortably handle the freezer load day over day with capacity to spare. It is a “set and forget” solution to 12V power with 2 x 10L cartridges = 23 days of a high power demand freezer load. Page 6 has recommendation.
Our Test Location 1770…. “What an unusual name for a town”
Well, the Town of 1770 (Seventeen Seventy) was named after the year in which Captain James Cook first landed in Queensland . It was only the second landfall made in Australia by the crew of the Endeavour. The town was named to honour this and a monument has since been erected near the place where James Cook and Joseph Banks came ashore.
Regarded as the birthplace of Queensland , 1770 nestles into the western side of Rodds peninsula surrounded on three sides by the Coral Sea and Bustard Bay . With stunning views of Bustard Bay and Round Hill Creek, 1770 is one of the few places on the east coast of Australia where you can watch the sun go down over land without being on a boat or island. Located between Gladstone and Bundaberg, 1770 is a little less than 500km (about six hours drive) from Brisbane.
1770 and its ‘companion town', Agnes Water, are a great place to visit with a marina with daily cruises to the Great Barrier Reef, Fitzroy Reef and Lady Musgrave Island. There are also four national parks (Eurimbula, Round Hill, Deepwater and Mount Colosseum ) nearby for camping and hiking and fishing activities.
The Bustard Heads lighthouse, built in 1868 and standing 102 metres above the sea, is one of only two prefabricated cast iron lighthouses built in Queensland . It is still operational today although it was automated and de-staffed during 1985.
The LARC is an amphibious vehicle that takes tours up and down the coast from 1770. Noticeably PINK!
The Test vehicle with the Fuel Cell in the rear and travelling Quad Bike on one of the local beaches.
Here is our Test setup in the back of an 80 Series Toyota Landcruiser.
The vehicle is not set up with Fridge slides and drawers as we still use the fold down seats when travelling with 6 of us. The camping gear was in the unipod on the trailer carrying the Quad Bike.
In the photo you will see:
- An SFC (Smart Fuel Cell) EFOY 1600 Fuel Cell
- 140Ah AGM battery pack with the batteries on their side. In the photo, the batteries are in a stainless steel storage container underneath the fuel cell and fuel cartridge.
- An 80 Litre Waeco fridge/freezer: set in “high mode” meaning maximum power consumption. Temp setting LOWEST to operate as a freezer for the entire trip.
- A 500 W modified sine wave inverter which is capable of running adaptors for a laptop computer and phone chargers.
- 1 x 10Litre Methanol Fuel Cartridge
- Eco-camper LED light bar
- Eco-camper LED flexi-strip
- Various chargers and appliances
- Fishing Gear for Four
What we left behind (for purposes of test):
- Eco-camper 80W or 120W solar suitcase
We would normally always take solar panels, however for this test, we wanted to see the Fuel cell operate with NO OTHER POWER SOURCE. - Kimberley Kamper
Results
Energy Balance – the battery pack was close to fully charged at the beginning and end of the test.
|
|
No of Days |
Amp Hours |
Operating |
Ave Amps |
Amp |
Duty Factor |
|
|
Energy Consumed |
8 |
502 |
192 |
2.61 |
62.75 |
46.7% |
|
|
Energy Delivered |
8 |
502 |
112 |
4.48 |
62.75 |
|
6.8 Litres Used |
The Waeco Fridge set in the “high” mode and running at coldest temperature (freezer mode) consumed on average 62.75 Amp Hours per Day.
The Fuel Cell is capable of 130 Amp hours per day at maximum rate. To deliver 62.75 Amp Hours, the Fuel Cell is running at a duty factor of 58% & averages 4.48 Amps. Its maximum current observed was 5.1Amps.
Conclusion is that the Fuel Cell can comfortably handle the freezer load day over day with capacity to spare. With 2 x 10L Cartridges, the Fuel Cell would be able to provide power to the Waeco in this configuration for 23-24 Days.
Ease of Operation
The Fuel Cell has a simple one touch start and one touch to “automatic” to charge the battery and provide energy. It could not be any simpler. The controller was candled to see the status of hours used, voltage and current flow for the purposes of this report. The >> button scrolls the display through voltage, current, hours of operation and status.
Attempt to fail the unit
The operating ambient temperature of the fuel cell is 40 degrees Centigrade. On Day 4, we left the vehicle sealed with the fridge running and the Fuel Cell running in a closed vehicle in the sun. The inside temperature rose to the high 30s. The Fuel cell stopped with a message on the controller “Ambient Temp too high”. Once the temperature dropped after we opened the tailgate and circulated air in the vehicle, the Fuel Cell automatically resumed operation.
Exhaust
We ran the small exhaust tube which emits water and a small amount of carbon dioxide (similar to a baby’s breath – we love this marketing description) into the seal point where the lower tailgate joins the floor. The water dropped down onto the seal with a very small amount of water absorption onto the carpet. This didn’t worry us at all.
Travel on Rough Roads with high vibration
We did not find any adverse effect on the unit in difficult road conditions.
Local Modification
After discussion with SFC in Germany in person on the high ambient temperatures in Australia, it was recommended that we modify the Fuel Cell by increasing the air flow. We did this by adding another fan with exit flow and connected it to the units operation 12V supply. It has a small cowling and an additional maglev low power fan to vent the airflow away from the Fuel Cell inlet.
This modification has worked exceptionally well with excellent results in high ambient temperatures.
Here are our other results from the Test Team of Stuart Grant and Robert:
I have guided this team to:
- Prefer tag and release but as you will read with the local bird life, we will sacrifice a modest fish to a great sea hawk.
- Use “yabbies” and “beach worms”.
- Use maximum of 6lb line.
- Love Dolphins, Sting Rays and “friendly” Estuary Sharks.
- Be passionate about the environment and try to disturb as little as possible.
Now for the fun:
|
Robert being persistent |
35cm of Joy for Grant with a Trumpeter |
Feeding a pair of Sea Hawks fresh fish
Our Comparison of the EFOY Fuel Cell and a Honda EU10i
The EFOY Fuel Cell cannot be considered as a replacement for 240V gensets because if you have need for that much power (air conditioning or whatever), the EFOY doesn't generate enough power.
The EFOY Fuel Cell should be regarded as a compact battery charger with these batteries supporting a 12V power supply. When combined with energy efficient 12V devices, the result is far superior to a genset: Quiet, smooth 24 hour power- easy to operate and hassle free.
The Fuel Cell is complimentary to solar panels especially in countries like Australia as there is plentiful sunlight. Solar panels depend on favourable weather conditions, the EFOY doesn't. The combination is bulletproof. If solar is a hassle or you don’t have storage space or setup conditions, just use the EFOY.
It cannot be considered as a replacement for gensets because if you have need for that much power (air conditioning or whatever), the EFOY doesn't generate enough power.
|
|
Honda EU10i |
SFC EFOY 1600 |
|
Weight |
13Kg plus Fuel |
7.6kg plus fuel |
|
Using |
|
|
|
Noise |
55 dB(A) at 7m away |
23 dB(A) at 7m away |
Our Recommendation for Boaties and Campers – simple trouble free refrigeration!
|
The EFOY Fuel Cell combined with a 70AHr AGM battery and the Autofridge Eutectic refrigerator. Benefits are: The Autofridge 75Litre Refrigerator uses eutectic technology. This improves energy efficency as it operates with a smooth temperature control and low duty factor. It can also hold temperature in typical conditions for up to 23 hours if power is lost. The 70 Ahr AGM battery pack is much smaller in capacity than usually required for refrigeration. This smaller capacity reduces weight. AGM batteries are “maintenance free” The SFC EFOY 1600 Fuel Cell and 2 x 10L cartridges (second stored in hold as spare) will automatically charge battery and maintain power supply to the Autofridge With 2 x 10L Fuel Cartridges, our estimate is that the Autofidge would operate for typically 70-75 days in refrigerator mode and half that time as a freezer. The investment would be less than $9,000 The warranty on the Fuel Cell is 3 years or 3,000 hours for registered units. |
The Technology behind EFOY Fuel Cells
The principle behind EFOY fuel cells
The EFOY Fuel Cell transforms chemical energy directly into electrical energy. The transformation is highly efficient and involves no moving parts, making it a particularly effective source of power. A lot of patented innovation has gone into our units, making the EFOY fuel cell a marvel of miniaturization, a lightweight but high-powered, long-lasting performer. SFC’s home-grown technology has positioned EFOY fuel cells to lead the field in fuel-cell systems for mobile applications.
How does an EFOY fuel cell work?
At the heart of every EFOY fuel cell is the stack. The stack actually consists of several cells: an anode, a cathode and a membrane that acts as an electrolyte, separating the anode and the cathode from each other. Positively charged electrical particles (protons) can permeate the membrane. Methanol and water are introduced on the anode side while ambient oxygen enters the cathode side. H+ ions, free electrons and carbon dioxide arise on the anode side. The protons can permeate the membrane while the electrons have to travel an electrical circuit over to the cathode side, thereby producing electrical current. H+ ions and water vapor arise on the cathode side, making EFOY fuel cells an extremely environmentally friendly way to generate electricity.
©SFC Smart Fuel Cell AG
EFOY fuel cells use liquid fuel
Every EFOY fuel cell employs DMFC (Direct Methanol Fuel Cell) technology which transforms methanol directly into electrical current. That's a real advantage, especially for mobile applications, because liquid methanol is easy to transport anywhere in practical EFOY fuel cartridges.
EFOY fuel cells and the hybrid principle
SFC’s hybrid approach is the common denominator among all fuel-cell products, regardless of how they are employed. EFOY fuel cells work in tandem with a battery in nearly every application. It’s the ideal combination of power generation and storage. The battery stores and dispenses energy as needed including start-up and peak loads, while the EFOY fuel cell continually recharges the battery. The result is a fully-charged battery all the time.
Of course EFOY fuel cells operate in tandem with other power generators such as solar modules too. Here, the fuel cell only cuts in if the solar module can’t produce enough power due to poor weather conditions.
EFOY Fuel Cartridges
Power anytime and anywhere – EFOY fuel cartridges keep you mobile! The practical EFOY cartridges contain the fuel for EFOY fuel cells. EFOY fuel cartridges have been designed especially for safe, convenient operation of EFOY fuel cells. Cartridges are available in 5-liter and 10-liter sizes.
Why can I only use EFOY fuel cartridges with EFOY fuel cells?
EFOY fuel cartridges contain ultra-pure fuel that has been specially conceived for EFOY fuel cells. Only original EFOY fuel cartridges may be used on EFOY fuel cells in order to avoid irreversible damage to the unit by invisible chemical impurities such as sulfur, chlorine, sodium, etc. The warranty does not cover damage caused by the use of contaminated fuels!
Tested and proven Security!
Every SFC fuel cartridge carries the TUEV safety seal. SFC fuel cartridges have always been subject to the most stringent safety standards. The containers consist of highly impact-resistant plastic. Containers are subjected to numerous drop and shock tests and have continuously demonstrated a high level of security in these tests.
SFC fuel cartridges are equipped with a safety valve to prevent leakage. The valve will only open if the fuel cartridge is connected to an SFC fuel cell. If the fuel cartridge is removed, the safety valve will hermetically seal ensuring that the user never comes into contact with methanol. This method of fueling is far safer, cleaner and more convenient than gasoline-powered generators.
Want to know more about environmentally friendly methanol?
Ultra-pure methanol is used to power EFOY fuel cells. This has decisive advantages over hydrogen-powered fuel cells:
Hydrogen is normally stored in heavy metal hydride cartridges. Manufacturing and refilling these cartridges is a very costly process. The contents last only a few hours and strict regulations govern the transportation of hydrogen.
Methanol, on the other hand, is sold in safe, convenient fuel cartridges. The cartridges can be replaced during operation within seconds. Charging time, as in the case of rechargeable batteries, is a thing of the past thus guaranteeing continual operation.
Recent reference of long term boating user in UK
Posted by: chriggel at September 28, 2009 7:19 AM
I've been using an EFOY 1200 on my 11m yacht for 3 years now in the UK and it has been a big success. Connected to 300aH of 12v 'leisure' battery the unit powers up silently when the voltage drops to 12.4 and cuts out automatically at 13.5. The boat is on a swinging mooring where the EFOY ensures the batteries are kept in top condition.
It's fit-and-forget. I never have to run the engine for charging even when sailing or at anchor for long periods. In practice 2 gallons of methanol lasts a 3 week cruise.
Downsides are the initial cost and availability of fuel - SFC insist you use their 'ultra-pure' methanol.
I think EFOY has a real niche for coastal cruising where solar is not reliable.
Posted by: Keith at September 28, 2009 4:25 PM
This seems like just what I need for cruising in a lightweight, outboard-powered multihull.
Typically, batteries are sized to store at least 24 hours worth of energy needs. If a fuel cell can cycle on and off automatically and unobtrusively, 24 hours a day, you could easily cut the weight of the battery bank in half. Plus you don't need any heavy high-amperage cables, etc. That is a very significant weight saving!
Want more information?
Go to www.eco-camper.com and follow the links to the range of eco products.
We have
- Solar Suitcases with 4 stage charge control (includes automatic equalisation)
- Intelligent charge booster for car alternators
- Diesel Hot Water Suitcases that can pump froma stream or billabong for near endless hot water
- LED Lighting especially for camping
- 12V Membrane Heaters for under mattresses
- Diesel powered Heaters
- Eutectic Refrigerators
- Storage bags
Call 02 6620 6888
We will be opening our new eco-camper store in Sydney in November 2009 in Potts Point.
Bruce Loxton
Ballina October 20th 2009
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