DOE Hydrogen DOE Hydrogen Composite Tank ProgramComposite Tank Program

Dr. Neel SiroshDIRECTOR, FUEL STORAGE

GoalsGoals• Optimize and validate commercially viable high

performance pressure storage systems for transportation applications, in line with DOE targets

Objectives:Objectives:• Develop and validate 5,000 psi storage tanks

– Tank efficiency: 7.5 – 8.5 wt%• Validate 5,000 psi in-tank-pressure regulators

– Total storage system efficiency: 5.7 wt%• Develop and validate 10,000 psi storage tanks

– Tank efficiency: 6 - 6.5 wt%• Develop and validate 10,000 psi storage systems

– Quantum Internal Program; total system efficiency: 4.5 wt%• Optimize designs and processes to achieve the DOE

cost targets

DOE Storage TargetsDOE Storage Targets

0.050.11Loss of Usable Hydrogen (grams)

21.50.5Refueling Rate (kg H2 / min)

1,5001,000500Cycle Life (1/4 tank to full)

$2$4$6Cost ($ / kw hr)

2.71.51.2Usable Energy Density (kw hr / L)

321.5Usable Specific Energy (kw hr / kg)

201520102005Parameter

ApproachApproach

• Learn from the successful 100 yr history of pressure vessels (industrial, aerospace, CNG)

• Optimize materials, design, process to improve weight efficiency (5,000 psi tanks)

• Develop & validate volumetrically efficient storage systems (10,000 psi tanks)

• Improve system efficiency (In-tank Regulator, Balance of Plant Components)

• Validate and certify components (Codes & Standards, Regulatory approvals)

• Work towards cost reduction (Technology, Economies of Scale

1900

1910

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1960

1970

1980

1990

2000

2010

Compressed Gases Have Been Around for Over 100 YearsCompressed Gases Have Been Around for Over 100 Years

Industrial Fire

Ext

ingu

ishe

rs

Life Support

AircraftSCUBA

Automotive

Pressures Up To6,000 psi

QUANTUM Compressed Hydrogen StorageQUANTUM Compressed Hydrogen Storage

Pressure Relief Device (thermal)

In Tank Gas Temperature Sensor

Carbon Composite Shell (structural)

Gas Outlet Solenoid

High Molecular Weight Polymer Liner (gas permeation barrier)

Foam Dome (impact protection) Impact Resistant Outer Shell (damage resistant)

In-Tank Regulator

Pressure Sensor (not visible here)

Product BenchmarkingProduct Benchmarking

Mass of Tank to Store 5 Kg of Hydrogen GasMass of Tank to Store 5 Kg of Hydrogen Gas

10,000-psi Composite Tanks

Vent Line Ports

Defueling Port (optional)

Fill PortFilter

Check Valve

Vehicle Interface Bracket with Stone Shield

In Tank Regulator with Solenoid Lock-off

Pressure Relief Device

Manual Valve

Compressed Hydrogen Storage SystemCompressed Hydrogen Storage System

System Level Weight Efficiency

Storage of 5 kg of Hydrogen Gas (Using One Tank)

1.921.55,000 psi Technology

1.621.510,000 psi Technology

Status20102005Usable Specific Energy (kw hr / kg)

Volumetric Efficiency: 5,000 Volumetric Efficiency: 5,000 psi vs psi vs 10,000 10,000 psi psi StorageStorage

1.31.51.2Usable Energy Density (kw hr / L)Status20102005

Cost DriversCost Drivers• Primary driver is material cost

– 40 - 80% is carbon fiber cost– Significant opportunities for cost-reduction

Cos

t Str

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re –

Fibe

r A

Cos

t Str

uctu

re –

Fibe

r B

Introductory Period71-83

Initial Growth Period84-93

Expansion Period94-

Application

Marginal Application Fishing Rod Aircraft Secondary Structure

Application Expanded Tennis Racket Golf Shaft Aircraft Primary Structure

Industrial Uses takeoffEnergy related

Transportation Civil Eng’s & Construction

Remarks High Performance Product Grade VarietyFabrication Development

Cost ReductionLargerScaleStructure

0

5

10

15

20

25

30

1970 1975 1980 1985 1990 1995 2000 2005

Dev

elop

men

t of G

olf S

haft,

Fish

ing

Rod

Industrial Use

Aerospace Use

Recreational Use

Ten

nis R

acke

ts &

Go

lf Sha

fts B

oom

Airc

raft

Busin

ess

Rec

essi

on

Indu

stria

l M

arke

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ke o

ff

Sate

llite

app

licat

ion

Exp

ansi

on

Prim

ary

Stru

ctur

e fo

r A32

0

Prim

ary

Struc

ture

for

B77

7

1000

ton/

year

Sec

onda

ry

Str

uctu

re

for

B75

7 &

B76

7

Carbon Fiber Worldwide Supply

Toray38%

Mistubishi16%

Hexcel5%

Large Tow15%

Others4%

Toho18%

Amoco2%

Taiwan Plastics

2%

Carbon Fiber Market Share

Carbon FiberGlass FiberEpoxyCurativesLiner PolymerFoam DomeFront BossAft Boss1-1/8 AdapterSealsValvePRDMiscellaneous

Carbon FiberGlass FiberEpoxyCurativesLiner PolymerFoam DomeFront BossAft Boss1-1/8 AdapterSealsValvePRDMiscellaneous

Safety & Certification StatusSafety & Certification Status

Certification Certification StatusStatus::

E.I.H.P. / German Pressure Vessel Code DBV P.18FMVSS 304 (modified)

10,000 psi (700 bar)

E.I.H.P. / German Pressure Vessel Code DBV P.18NGV2-2000 (modified)FMVSS 304 (modified)KHK

5,000 psi (350 bar)

NGV2-2000 (modified)DOT FMVSS 304 (modified)

3,600 psi (250 bar)

Approvals / ComplianceStorage Pressure

QUANTUM Participates in:QUANTUM Participates in:

• E.I.H.P ( European Integrated Hydrogen Project) Code Committee• ISO Hydrogen Storage Standard Committee• CSA – America NGV2 Hydrogen TAG

Regulatory ApprovalsRegulatory Approvals

Regulatory Agency Validation Tests

• Hydrostatic Burst • Extreme Temperature Cycle• Ambient Cycle • Acid Environment• Bonfire • Gunfire Penetration• Flaw Tolerance• Accelerated Stress• Drop Test• Permeation• Hydrogen Cycle• Softening Temperature• Tensile Properties• Resin Shear• Boss End Material

• ISO 15869 - International• NGV2 - US/Japan/Mexico• FMVSS 304 - United States• NFPA 52 - United States • KHK - Japan• CSA B51 - Canada• TÜV - Germany

10,000 10,000 psi psi Components AvailabilityComponents Availability

EIHP / TÜVCheck Valves

EIHP / TÜVPRD (thermal)

EIHP / TÜVFittings

EIHP / TÜVFuel Lines

EIHP / TÜVRefueling Receptacle

EIHP / TÜVPressure Transducers

EIHP / TÜVManual Tank Valves

EIHP / TÜVRegulator

EIHP / TÜVTank

ApprovalAvailableComponent

Project TimelineProject TimelinePRODUCTION

350 Bar H2250 Bar CNG 700 Bar H2

Up to 10X Cost Reduction Through Economies of Scale

CONCEPT

700 Bar H2350 Bar H2

Cost Reduced (30%)

700 Bar H2

Cost Reduced (75%)

700 Bar H2 Next Gen Storage

250 Bar CNGDOE Programs

PROTOTYPE350 Bar H2 700 Bar H2250 Bar H2 350 bar Conformable

Cost Reduced (30%)

700 Bar H2

20082004 200620021998 2000

Collaborative WorkCollaborative Work

• Alliance with Thiokol (Material, Design, Testing)• Global alliance with GM (Fuel Cell Enabling

Technologies)• Development Program with NASA / Aerovironment

(Advanced light weight systems)• CRADA with Idaho National Labs (Enhanced

Permeation Barriers)• Collaboration with Oak Ridge National Labs

(Monitoring Systems)

Accomplishments Accomplishments –– Technical ProgressTechnical Progress2002Certified complete 10,000 psi Storage

System (EIHP / TUV)

Validated & shipped

5,000psi tanks(NGV2, EIHP

standards)

Validated & shipped 10,000 psi

tanks(Worlds’ first

10,000 psi tank; EIHP / TUV)

Successfully demonstrated 10,000 psi fast-fill within 3

minutes75 Liter Hydrogen Fast Fill Data

Peak and Average Gas Temperatures

0

20

40

60

80

100

120

0 0.2 0.4 0.6 0.8 1 1.2 1.4Time (Min)

Tem

pera

ture

(ºC

)

0

50

100

150

200

250

300

350

400

Gas temperature near the middle of the container

I/C Sensor Temperature (Averaged)

Tank Psi

Chart 3

(6 wt %)(7.5 & 8.5 wt %) ( 3 wt %)

2003Completed 5,000 psi

tank & in-tank regulator production

optimizations

Achieved 13.36 wt %

tank efficiency (5,000 psi tank;

aerospace)

Achieved >45,000 cycles fatigue life and 30% cost-reduction for

10,000 psi tanks (design, process)

Accomplishments Accomplishments –– Commercial ProgressCommercial Progress2002

Agreement with Hyundai to

Jointly Develop Fuel Cell & Alt Fuel Vehicles

Texas Tech & Virginia Tech in

Future Truck competition with Quantum tanks

GM’s revolutionary Hy-Wire introduced with Quantum tanks

Quantum tanks used in stationary power

application (NEXTEL, Hydrogenics)

2003

Ships Three Portable Refueling

Systems

Production of Storage systems for Toyota

Agreement with Sumitomo for

storage systems Distribution

Supplies storage system to Suzuki

Future Plans / MilestonesFuture Plans / Milestones

• Refueling Strategy (Thermal Management with Fast-Fill) (’04)

• Structural Optimization of Tanks, Liners, Components (’04)

• Materials (Lower Cost Fibers, Strength & Cycle Life Trade-off, Liner Materials) (’05)

• Balance of Plant Components (Valves, Regulators, Filters, Relief Devices, Tubing, Fitting, Sensors, Mounting) (’05)

• Vehicle Hydrogen Safety (Impacts, Crash Statistics) (’05)

• Smart Tanks – Monitoring System to Support Lower Burst Ratio (’05)

ConclusionsConclusions

• 5,000 psi and 10,000 psi compressed storage systems are currently available and successfully deployed on fuel cell vehicles

• DOE 2005 performance targets are achievable• Storage is a significant cost factor in overall fuel cell

system cost• Carbon Fiber and stainless steel hardware costs

represent over 90% of the costs• Design & process improvements to address storage

tank costs are on-going