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Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
STORHY“Hydrogen Storage Systems for Automotive Application”
Integrated Project n° 502667
Volker Strubel
Josef Zieger
Sitra Colom
Guido Bartlok
Jiri Muller
Georg Mair
Florent Montignac
Angelika Bertalanic
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
1. Project ObjectivesStorHy – General Project Information
“Hydrogen Storage Systems for Automotive Application”Integrated Project n° 502667 within the EU FP6
Co-ordinator: MAGNA STEYR Fahrzeugtechnik AG & Co KGTime frame: 2004 – 2008 (4,5 years)Official project start: March 1st, 2004Budget: € 18.7 mEU contribution: € 10.7 mWebsite: www.storhy.net
34 partners from 13 European countries (5 OEMs, 14 research institutes and 15 supplier companies)
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Gas:700 bar Technologies
Source: Dynetek
Liquid:LightweightFree-form Tank
Solid:Advanced Alanates
Source: IFE
1. Project ObjectivesStorHy – Overall Structure
Users:Vehicle Requirements
Source: BMWSource: PSA Source: Daimler ChryslerSource: Daimler Chrysler
Safety Aspects and Requirements
Multi-Criteria Evaluation
Source: SP Cryo
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
1. Project ObjectivesHydrogen Storage: Consumer Expectations
Public Acceptance of Hydrogen Applications –Study by DC
Main conditions for consumer acceptance of FC vehicles*
Driving range
Refuelling process
High safety level
Vehicle costs
Communication / education
*Excerpt only!
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Consumer Expectations
TechnicalRequirements
Unit StorHyTargets 2010
Driving range > 400 km – 600 km
Driving performance
Usable space
Refuellingconvenient and safe
Safety
Filling cycles 3*5,000
Vehicle costs Costs of storage system €/ kg H2 Not defined
Hydrogen storage mass kg 6 - 10
System grav. energy density kWh/kgwt.%
2.06
System vol. energy density kWh/lkg H2/100l
1.54.5
Refuelling rate kg H2/min 1.2
Burst pressure 700 bar bar 1,645
Permeation rate H2 Ncm3/h *l EHIP II1
Loss of usable H2 (boil-off) g/h *stored kg H2
1
1. Project ObjectivesStorHy:Hydrogen Storage Requirements
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
International technology watchIncrease of service pressure from 350 bar – 700 bar
700 bar Type III fully wrapped aluminum liner
700 bar Type IV fully wrapped non-load carrying plastic liner
700 bar system prototypes or small series announced inUSA, Japan and Europe
Source: Dynetek
2. Alignment to SRA/DSCompressed Hydrogen Storage:
State-of-the-Art
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Material & microstructure– Modified CrMo steels
Liner material characterization– 5 steels assessed concerning H2
embrittlement700 bar design & calculation– Analytical + FE calculations for
composite thickness + optimized modulus (fibre type) + winding path
Vessel testing– Ambient T cycling < 15,000 cycles– Burst factor: > 2.35– Other EIHP-II tests were performed
successfully
Technical data:• Mass of vessel: 40 kg• Internal volume: 39 l• H2 storage capacity: 3.85 wt.%• Operating pressure: 700 bar• H2 mass stored: 1.6 kg
700 bar Type III vessel with metallic liner made by deep drawing
Source: Faber
Source: FaberSource: AL
2. Alignment to SRA/DSStorHy: 700 bar C-H2 Vessels
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Polymeric material & microstructure– Development of specific PA6 formation
(permeation / mechanical elasticity / processability)
Liner material characterization:Permeation of PA polymer liner assessedat 700 bar f (T, p):– Material level: Pe ∼1*10-16mol/(Pa.s.m) – Vessel level: ongoing
700 bar vessel design & calculation– Analytical + FE calculations
for composite thicknessVessel testing– Ambient T cycling > 15,000 cycles– Burst factor: 2.2
Technical data:• Mass of vessel: 29 kg• Internal volume: 37 l• H2 storage capacity: 5.2 wt.%• Operating pressure: 700 bar• H2 mass stored: 1.6kg
Source: CEA
Source: CEA/Ullit
700 bar Type IV vessel with rotomoulded plastic liner
2. Alignment to SRA/DSStorHy: 700 bar C-H2 Vessels
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
2. Alignment to SRA/DSStorHy: Test Results of C-H2 Vessels
Type III (steel liner)
Type IV (PA liner)
Thermoplastic modular system
Burst test Passed Close to target Feasibility GF/PP
Cycling test Not passed Passed Not tested yet
Status Cycling behaviour to be improved
Burst behaviour to be improved
Feasibility at 300 bar
Typical failure mechanisms for C-H2 vessels identifiedMeasured proposed for further improvements steps:
R&D activities required for a fundamental understanding of aging & failure behaviour composite and liner materials, advanced modelling and simulation concepts
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
StorHy contribution (excerpt)
Steel liner
Production
Polymer liner
Production:
Rotomolding
Autofrettage
Process
Vessel testing
CF raw materials Impregnation bath
Filament winding Curing
Liner fabrication Composite manufacturing Post processing
Recycling
Polymer liner
Production:
Blowforming
Alu liner
Production
Shreddering
CF Recycling
Dismantling
2. Alignment to SRA/DSC-H2 Storage: Production Steps
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Ring winding head with modular siphon impregnation units and suitable advancement of the path generationIncrease of the lay-down rate (> factor 3)Better exploitation of the fibre performance, which entails weight reduction potentials for pressure vesselsClean work station due to an almost closed systemReduction of resin consumption Almost no hazardous waste
Winner of two Innovation Awards!
Source: IVW
2. Alignment to SRA/DSStorHy: C-H2 Vessel Production –
Improved Winding and Impregnation
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Development of pre-treatment technology– Hybrid shredder (Kema) selected
Development of recycling processes– Fluidised bed process selected– Good quality fibre (similar stiffness
and 50% strength) has been recycledR&D to increase material recycling rate:
– Microwave pyrolysis process in a fluidised bed
– 86% total material recovery achieved (increase from 63% for fluidised bed)
Recycling of a thermoplastic compositevessel by granulation and injection moulding demonstrated (GF/PP COMAT system)
Cyclone
Air Inlet
Electric Pre-heatersFibre
Scrap CFRP
Recovered FluidisedBed
Air distributorplate
300 mmAfterburner
Clean flue gas To energy recovery
Fan
Fluidised Bed RecyclingTwin screw shredder
Recovered CF fibreSource: UNOTT
2. Alignment to SRA/DSStorHy: C-H2 Composite Vessel
Recycling Concepts
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Booster Cooler
High pressure H2
V2
For fast filling, gaseous hydrogen needs to be cooled down to prevent excessive pressure and temperature levelsHydrogen cooler required in the refuelling station!
Source: Linde / Aral
700 bar filling nozzle
Source: Weh
V1
2. Alignment to SRA/DSRefuelling C-H2: State-of-the-Art
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Fast filling demonstrated on vessel levelFilling temperature down to -100°C demonstrated100% filling rate easy to reachGentle cylinder treatment compared to warm filling – but thermal stress for storage components, esp. sealingCooling down to -40 °C seems to be good compromiseDeeper cooling still needs to be evaluated with regard to costs and material exposure
700 bar cold (–40°C) filling test in F-Cell vehicleSafe and optimized filling demonstrated Source: ET, AL, Dynetek, DC, Weh
Technical data:• Filling T: -85°C• Filling time: <2min• Filling rate: 103%• Min. material T: -14°C
Technical data:• Filling T: -40°C• Filling time: 3 min.• Filling rate: 101%• Gas T: 65°C
2. Alignment to SRA/DSStorHy: C-H2 Cold Filling
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Filling nozzle with/without infrared communication interface
Start of commercialization
Break-away device with infrared communications interface
Linear shut-off valve
Advanced C-H2 700 bar filling devicesdeveloped and tested:
Filling nozzle with infrared communication interfaceLinear shut-off valveBreak-away device
Sources: WEH Source: Weh
2. Alignment to SRA/DSStorHy: C-H2 700 bar Filling Devices
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Source: MAGNA STEYR
2. Alignment to SRA/DSCryogenic Liquid Storage System
International technology watchSmall series, automotive, approved L-H2 storage systems with double-walled stainless cylinders
First cylindrical prototypes with lightweight aluminum tank shells
First flat-shaped prototypes with lightweight steel tank shells
Source: Air LiquideSource: Linde
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Moisture, air, oil, etc
Outgassing
Outer Jacket Composite
Hydrogen
Outgassing
Inner Tank Composite
High Vacuum: 10-5 – 10-6mBar
Hydrogen
Liner
Aluminium sheet (outer jacket)
Liner
Liner
Structure and coating concepts for linerGalvanic copper coating
(inner tank)
Lightweight cylindrical tankCarbon fibre composite structure of inner tank and outer jacket
Source: SP Cryo
2. Alignment to SRA/DSStorHy: L-H2 Lightweight Design
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Concept calculation(e.g. showing deformation at 10.8 bar)
Free-form tank system with auxiliary system boxFree-form design
Source: SP Cryo
Free-form tank demonstrator
Vehicle integrationconcepts
Risk analysis (FMEA and FTA)
2. Alignment to SRA/DSStorHy: L-H2 Free-form Design
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Mass comparison of gasoline and L-H2 tank systemsEnergy content equivalent to 10 kg hydrogen
3010 10 10
10 kg
100 kg
40 kg25 kg
65
25
203
0
25
50
75
100
125
150
175
200
Gasoline 38 dm³ LH2 SteelE 68
cylindrical shape
LH2 LightweightStorHy
cylindrical shape
LH2 Lightweight2010
complex shape
Wei
ght [
kg]
Auxiliary System
Tank
Fuel
Source: SP Cryo
2. Alignment to SRA/DSStorHy: L-H2 Weight Reduction Potential
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
CFRP inner tank manufacturing
Inner tank - coating of liner
Post-processing
CFRP outer jacket manufacturing
StorHy contribution (excerpt SP Cryo)
Tensionsheet
Dome &pipes
Source: SP Cryo
Prepreg (e.g. knitting)
Piping
Pre-processing
Insulation
Component production
Valves, Sensor
Alu liner
Assembly
Evacuation of insulation gap
Testing
Welding
CuringImpregnation
2. Alignment to SRA/DSManufacturing process CFRP tank
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
International technology watchIntensive international R&D efforts focus on different types of materials and storage systems
But:None of these materials fulfills automotive targets (storage density, operation temperature etc.) yet!
Source: DoE 2007
• Metal and complex hydrides
• Chemical hydrides
• Nanoporousstructures
2. Alignment to SRA/DSSolid Storage
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Automotive ChallengesScale-up strategies promising, but reversibility not sufficient!
Scale-up strategies promising, but material storage density of 3 wt. % not sufficient
Storage MaterialMagnesium Alanate
• Mg(AlH4)2: Solvent-free and fast synthesis• Deuterised Mg(AlD4)2 for neutron diffraction• Structure of Mg(AlH4)2: Neutron and
synchrotron X-ray diffraction• Details of thermal and isothermal
decomposition of Mg(AlH4 )2
Sodium Alanate• Purification of NaAlH4 and synthesis of
NaAlD4
Catalyst• Improved synthesis of catalyst: Ti13*6THF
First step: Magnesium and Sodium Alanates
Source: FZKSource: IFE
Source: IFE, FZK
2. Alignment to SRA/DSStorHy: Characterisation of Alanates
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Storage MaterialScreening experiments for synthesis and
characterization for new mixed alanates:• Mg-Al-Li-H, Mg-Al-Ca-H, Ca-Al-Li-H, Ca-Al-Na-H• Mg-Al-Li-H, Mg-Al-Ca-H, Mg-Al-Na-H, Mg-Al-K-H• Mg-Al-Li-H, Mg-Al-Ca-H, Ca-Al-K-H
Synthesis and stabilisation of aluminium hydride AlH3 (Alane) – basic research purpose
2. Alignment to SRA/DSStorHy: Screening for new Alanates
Automotive ChallengesNo new reversiblehydrogen storage compound found
No break-through up to now
High material storage density 10.1%, but not reversible!
Simplified method to synthesize AlH3 by milling at liquid nitrogen temperature, compared to wet chemistry
Work in progress to change the stability of AlH3
Second step: Adaptation of work programme
liquid nitrogen
stainless steel
impactorvial
Spex 6750 freezer mill for cryomilling
2000
4000
6000
8000 α'-AlD3 and α-AlD3PND, Kjeller
INT
EN
SIT
Y (a
rb. u
nits
)
2θ(º)
10 20 30 40 50 60 70 80 90 100 110 120 130-800
0
800
Source: IFE, FZK, GKSS
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Concept for upscaling of material production processes
Source: GKSS/TUHH
8 kg alanate Pilot tank (currently manufactured)
Length: 120 cm, Diameter: 22 cmCapacity: 0.4 kg H2,
Design and development of operational prototype solid storage tanksLaboratory tank for 0.5 kg of alanate
Length: 40 cm / Diameter: 6 cm Capacity: 20 g H2
0 10 20 30 40 50 600
1
2
3
4
5
simple preparation from NaH/Alwith TiCl4, 125°C100 bar (STORHY)
preparation from NaAlH4
with Ti-nanoclusters, 100°C, 100 bar(Fichtner et al.)
H2-c
once
ntra
tion
[wt.%
]
Time [min.]
preparation from NaAlH4 with TiCl3, 125°C, 79-88 bar(Sandrock et al.)
2nd absorption
Up-scaling to kg amounts demonstrated at GKSS mechanical processing facility
Evaluation of low cost production routes for complex hydrides using catalysed NaAlH4 as model material
2. Alignment to SRA/DSStorHy: Upscaling of Solid Storage Tank
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Calculated performance of tanks based on lab-scale data (NaAlH4)
5
89
10
1 432
Oil
1236
Ø 10
Ø 6
625
273
2345678
0
50
100
150
200
250
300
350
400
0 200 400 600 800 1000
t in s
310 g
290 s 540 s458 s
5
89
10
1 432
Oil
1236
Ø 10
Ø 6
625
273
2345678
0
50
100
150
200
250
300
350
400
0 200 400 600 800 1000
t in s
310 g
290 s 540 s458 sHyd
roge
n ab
sorb
ed in
g
Less than 10 min. chargingtime expected even in cost-effective design (pilot tank)
Alpha version 100°C
130°C
Simulation based on kinetic data obtained from optimized StorHy material produced in kg scale
HydrideTank
Fuel cell
HydrogenExternal Heat Consumer
Vehicle
Heattransfer medium
Quick coupling
Internal heatexchanger
Concept for fillingHydride tank is cooled by external heat consumer working at approx. 100°C Coupling of hydrogen and heat transfer medium prior to filling
Concept for drivingFuel cell is cooled to 80°C by hydride tank and internal heat exchanger
Source: NCSRD/GKSS/TUHH
2. Alignment to SRA/DSStorHy: Solid Filling
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Bonfire
Assessment of test procedures for C-H2 vessels
Interlaboratory tests at various European test facilitiesValidation of hydrogen sensors
3. Cross-cutting Issues:StorHy: Safety Assessment
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Development of test procedures for C-H2 vessels: Impact test
Polarplot Crashenergy [KJ]
0
50
100
150
200
250
3000 °
30°
60°
90 °
120°
150°
180°
-150°
-120°
-90°
-60°
-3 0°
10%
50%
90%
99%
Source: BAM, Cidaut
Estimation of statistical crash energies
Estimation of energy impacting on storage system in crash models
Vessel impact tests
Assessment of theresidual burst strength
3. Cross-cutting Issues:StorHy: Safety Assessment of C-H2 Storage
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Alanate powder release experiments
560 ms
Ignition by water droplets
30 ms 60 ms
240 msFlame 240 ms 560 msreproduction2005
Spark ignition
Water mist
Pure hydrogen
opening of burst disc
Source: FZK
1. Disk bursts at p = 10 bar
4. Assessment of sound levels
2. Material is released into various environments3. High speed images
3. Cross-cutting Issues:StorHy: Chemical Safety Experiments
of Solid Storage Materials
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Technical performanceTechnical performance
CostsCosts SafetySafety
Social acceptanceSocial acceptanceEnvironmental impactEnvironmental impact
Multi-criteria evaluationFive different evaluation domains addressed Focus on technical and environmental parameters
Source: CEA
3. Cross-cutting Issues:StorHy: Evaluation
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
0.00
1.00
2.00
3.00
4.00
5.00
0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00 20.00Gravimetric energy density [wt.%]
Volu
met
ricen
ergy
dens
ity[k
g H
2/100
l]
StorHy target 6 wt.%
C-H2 Reference System Typ III H2 350 bar
L-H2 Reference System Stainless SteelC-H2 StorHy System Type IV 700
bar (extrap.)
StorHy Target 4.5 kg H2/100 l
L-H2 StorHy System Lightweight Free-form (extrap.)
Solid StorageSystem Reference
C-H2 StorHy 700 bar Swap Rack
Comparison of system storage densities
Solid Storage StorHySystem NaAlH4 (Not yet optimised)
? L-H2 StorHy System Lightweight Cylindrical
C-H2 Referenc 350 bar Swap Rack
4. Future Perspectives StorHy: Evaluation
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Medium-class Car: Fuel cell vehicle with C-H2 storage
Systemmodule
Battery
CoolingSystem
Power el.: 72 kWHydrogen mass: 1.9 kgC-H2 storage: 350 barMax. speed: 150 km/hRange: 150 km
Today:Driving range lower than 400 kme.g. F-Cell 2002
Power: 60/85 kWHydrogen mass: 4 kgC-H2 storage: 700 barMax. speed: 174 km/hRange: >400 km
Tomorrow:Driving range of 400 km to 500 km by 700 bar C-H2 storage systemse.g. F600 Hygenius Concept Car
Source: DCSource: DC
Source: DC
4. Future Perspectives Hydrogen Storage in different
Vehicle Concepts
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Delivery van: FC City Car with range extender
Power el. 28 kWMax. speed: 95 km/hFC power 5 kWBattery: 15 kWh Hydrogen C-H2@350bar: 1,6 kg Range H2: 70 km Range Battery: 80 km
Today: Tomorrow:
Power 28 kWMax. speed: 95 km/hFC power: 10 kWBattery: 15 kWh Hydrogen C-H2@700bar: 2,7 kgRange H2: 170 kmRange Battery: 80 km
Source: PSA
Source: PSA
4. Future Perspectives Hydrogen Storage in different
Vehicle Concepts
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Power: 191 kW (260 bhp)Hydrogen mass: > 8 kg L-H2 storage: Stainless steel
Cylindrical Range H2: > 200 km + Range Gasoline: > 500 km
Today: Tomorrow:
Monofuel (L-H2)
- Highly efficient hydrogen ICE - Lightweight cryogenic storage
+
Power: > 100 kW (136 bhp)Hydrogen mass: > 7 kgL-H2 storage: Lightweight
Free-form shapeRange H2: > 500 km
Source: BMWSource: MAGNA STEYR
Bi-Fuel (L-H2 + Gasoline)
Hydrogen ICE with L-H2 Storage
4. Future Perspectives Hydrogen Storage in different
Vehicle Concepts
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
C-H2 storageStorage densities of ~4.5 wt.% and ~2.4 kg H2/100 l are achievable on system levelStorHy results regarding C-H2 vessels close up to worldwide R&DFurther optimisation requires fundamental understanding of ageing and failure behaviour of composite and liner materials, modelling and simulation concepts StorHy results on filling components and production conceptsshow promising advanced solutions Further cost reduction requires new industrialisation concepts for mass production and new CF fibresHigher storage densities and further cost reduction require change of Regulations, Codes & Standards as well as new vehicle platforms (e.g. compatible with single cylinder storage concepts)New advanced safety approach necessary in the future, e.g. basedon Probabilistic Safety Assessment
4. Future Perspectives StorHy: Preliminary Conclusions
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
L-H2 storageStorage densities up to 14 wt.% and 4 kg H2/100 l are achievable on system level for metal design, even up to 18 wt.% using advanced composite materialsStorHy results demonstrate a free form tank design with improved conformability to better enable vehicle integration StorHy results show promising advanced solutions beyond worldwide R&D, but still further R&D efforts are required for industrialisation and system validation Substantial cost reduction is indispensableLightweight L-H2 storage systems show considerable potential in combination with new H2 ICE Further L-H2 specific challenges, such as boil-off and permeation, have to be addressed
4. Future Perspectives StorHy: Preliminary Conclusions
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Solid Storage (1)Up to now, storage densities of ~2 wt.% are achieveable on system level with complex hydrides on alanate basisAt present, no solid storage material fulfils the major targets for automotive applicationsStorHy tank development demonstrates feasibility of a fast heat removal using lightweight complex hydridesStorHy safety study shows minimised explosion in case of hydrogen releaseStorHy up-scaling results show high potential for mass productionof complex light weight hydrides at low costs
4. Future Perspectives StorHy: Preliminary Conclusions
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Solid Storage (2)Further research for novel storage materials with improved storage densities, kinetics and thermodynamic behaviour as well as for advanced system components, e.g. heat exchanger, is still requiredAutomotive solutions are not realistic in the medium termStationary or marine applications have more potentials for a market entry in the near future
4. Future Perspectives StorHy: Preliminary Conclusions
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
General conclusionsBeyond StorHy, further R&D activities are proposed for:
In-depth system/vehicle validation in demonstration projectsIndustrialisation and cost reduction conceptsSafety assessment and new advanced safety approachesOptimisation of Regulations, Codes & Standards (e.g design requirements for pressure vessels)New storage concepts, such as pressure tanks with new high performance tensile fibres, hybrid tanks (pressure / cryogenic /solid storage), etc.User-oriented fundamental research on solid storage materials, their safety and technical development of solid storage tanks
4. Future Perspectives StorHy: Preliminary Conclusions
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
4. Future Perspectives StorHy Dissemination
More information?Join the
StorHy Dissemination Event:“Hydrogen Storage Perspectives of the Future”
Date: June 2008
Further information shortly on www.storhy.net!Or contact: volker.strubel@magnasteyr.com
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Backup only!Backup only!
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Inner tank- Inner vessel- Level measurement- Pipework- Cryogenic shut-off valves- Inner tank support
Outer jacket- Outer vessel- Thermal insulation- Refueling interface- Outer support
Auxiliary System Box- Shut-off valves- Control valve- Safety relief valves- Sensors (p, T, H2)- Heat exchanger
Back upL-H2 Storage System
Source: MAGNA STEYR
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Back upC-H2 Storage System
Source: Dynetek
Low pressure
connection
High pressure
connection
Pressure regulator
High pressure vessel
Electrical connections
SensorsValves,FittingsSolenoid
valve
Venting pipe
Fixing
Fully wrappedcylinder &
metallic liner
Type 3
Fully wrappedcylinder &
non-load carrying(plastic) liner
Type 4
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Back upC-H2 Storage Reference System
Source: SP Users
Source: Dynetek
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Back upL-H2 Storage Reference System
Source: SP Users
Source: Magna Steyr
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Back upSolid Storage Reference System
Source: SP UsersSource: DC
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Material & microstructure– Extruded multi-layer based PA
Liner material characterization– 8 multilayer polymers assessed: f (p,T)– Permeation: 2*10-18mol/(Pa.s.m) -> OK
700 bar vessel design & calculation– Optimized end cap design– CF/PA 700 bar system– GF/PP 200 bar system
CF for this thermoplastic composite not available yet!Vessel testing (GF/PP)– Burst pressure = 460 bar
Technical data (CF/PA design):• Mass of vessel: 10.9 kg• Internal volume: 9 l• H2 storage capacity: 3.5 wt.%• Design pressure: 700 bar• H2 mass stored: 0.4 kg
Back upStorHy: 700 bar C-H2 Vessels
700 bar modular system with extruded plastic liner and thermoplastic composite
Source: COMAT
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Type Measure Effort ContributionIV
IV
IV
III
III/IV
III/IV
III/IV
III/IV
III/IV
Improve burst behavior (design, process)
Low 100% burst
Temperature cycling + burst Low Reliability of Type IV
Evaluate tightness after thermal & mechanical ageing (=> depending on permeation results)
Low Improved permeationreliability of Type IV
Low / high temperature exposure risk Medium Safety
Innovative manufacturing concepts High Weight, costs
Improve cycling behaviour Medium Cycling feasibility
Long term behavior (creep…) Medium Safety
Improve design requirements (safety factors) High Weight, costs
New innovative fibers High Weight, costs
Reliable and low cost components Medium Weight, costs, reliability
Back upStorHy: Recommendations for C-H2
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Back upStorHy: C-H2 Vessel Production -
Quality Survey during Autofrettage
0
0,2
0,4
0,6
0,8
1
0 0,2 0,4 0,6 0,8 1
Normalized strain
Nor
mal
ized
inte
rnal
pre
ssur
e
autofrettage pressure (yileding of metal liner)
test pressure
nominal working pressure (15°C)
Example:Typ III (CNG) cylinder = metal liner with full CF/Epoxy wrapping
burst pressure
fibre
bre
ak
residual strain of wrapping after autofrettage
0,0 0,2 0,4 0,6 0,8 1,00,0
0,2
0,4
0,6
0,8
1,0
Nor
mal
ised
val
ues
Normalised autofrettage pressure
AE accumulation
strain intensity
10987654321
“Defect”type III
(cylinder 5)
Defect type II
(cylinder 4)
Defect type II
(cylinder 3)
Defect type I
(cylinder 2)
Defect type I
(cylinder 1)
AE criterion
10987654321
“Defect”type III
(cylinder 5)
Defect type II
(cylinder 4)
Defect type II
(cylinder 3)
Defect type I
(cylinder 2)
Defect type I
(cylinder 1)
AE criterion
Source: BAM
AE Quality Survey Concepts:
Successful in detecting every manufacturing defect by at least 2 of 10 developed AE-criteria!see:
Acoustic Emission (AE)
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Development of test procedures for C-H2 vessels: Bonfire test
Source: BAM
Concept of modular testing
Bonfire tests ofcylinders
Test ofPressure Relief Devices (PRD)
pBurst
p0
Time t in [sec]
Pres
sure
or b
urst
pre
ssur
e p
in [M
Pa]
tBurst 0
pBurst
tIgnition
Burst pressure line as a function of the filling
tBurst max
insufficient PRD
well adjusted PRD
Rupture
Rupture
m << m0
Evolution of pressure in a gas receptacle with PRD
m0
m < m0
m > m0
Validation of combination
Back upStorHy: Safety Assessment of C-H2 Storage
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Interlaboratory tests to evaluate C-H2 testing facilities
Source: BAM
BAM
WUT
Faber
ALTests performed at BAM, WUT, Faber and ALTests show relevance of influence of testing facilities on life-time of C-H2 vessels
ParisWroclaw
Udine
ParisWroclaw
Udine
Test cylinder
Adapter
Tool kit
MeasuringDevice
Sensors
Back upStorHy: Safety Assessment of C-H2 Storage
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Tests of optical fibre sensors for detecting defects of C-H2 vesselsSensor technologies
– Fibre Bragg gratings– Microbending optical fibres
Cycling tests– Type III: detectable increase in local deformation– Type IV: correlation of optical signals and CF fibre
fatigue level to be demonstratedBurst test (for type IV)
– Linear deformation of vessel– Detection depends on sensor localization
Source: WUT
Back upStorHy: On-board Monitoring System
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Training Course ‘StorHy TRAIN-IN 2006’One week full time training course on hydrogen storage technologies
Date: September 25th - 29th, 2006
Location: University of Applied Sciences, Ingolstadt, GermanyOver 80 participants from 20 countries(students, PhD students, scientists, researchers and company representatives)
25 theoretical and practical lectures, hardware exhibitions and excursions
Very good feedback by participants
All lecture handouts and results onlineon www.storhy.net
Back-upStorHy Training Course
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Cost reduction of C-H2 storage systems
Source: DC
Back upStorHy: Cost Estimation
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Magnesium Alanate:Fundamental work on synthesis, structural and thermal propertiesallowed a complete characterization of this promising complex hydride. However, the unfavourable thermodynamic properties of this material made the Mg-Alanate not suitable for hydrogen storage.
Sodium Alanate:Fundamental work carried out with this material in order to improve the kinetics allowed gaining insight into the reaction upon cycling under hydrogen. Indeed, XAS studies explained why the capacity decreases after some dehydrogenation / hydrogenation cycles and why the kinetics slow down at the same time. This knowledge in turn allowed a cost-effective production method of Al-based hydrogen storage material.
Back upStorHy: Work on Alanates
Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October
Complex mixed Alanates:The following systems {[MgH2 + Al + LiH] and [MgH2 + LiAlH4]} are extremely lightweight compounds, with a potential to achieve high gravimetric storage densities for hydrogen. (MgH2 + LiAlH4) appear as the most promising systems in terms of the formation of a newphase and the subsequent decomposition kinetics. However, further work is necessary to identify and isolate this new phase in order to conclude on the suitability of the material for hydrogen storage.
Back upStorHy: Work on mixed Alanates
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