engineering safe and efficient hydride- based technologies ... · • a metal hydride cascade for...

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Engineering Safe and Efficient Hydride- Based Technologies(ESEHBT) David Grant, Gavin Walker, Evangelos Gkanas, Alastair Stuart Materials, Mechanics and Structures Research Division, Faculty of Engineering, University of Nottingham David Book, Rex Harris, Shahrouz Nayebossadri, Lydia Pickering, Yanmeng Chao, School of Metallurgy & Materials University of Birmingham W. Malalasekera (Malal), Salah Ibrahim, Maxim Bragin, Tom Beard Wolfson School of Mechanical and Manufacturing Engineering, Department of Aeronautical and Automotive Engineering, Loughborough University Engineering Safe and Compact Hydrogen Energy Reserves (ESCHER)

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Page 1: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Engineering Safe and Efficient Hydride-Based Technologies(ESEHBT)

David Grant, Gavin Walker, Evangelos Gkanas, Alastair Stuart Materials, Mechanics and Structures Research Division, Faculty of Engineering,

University of Nottingham

David Book, Rex Harris, Shahrouz Nayebossadri, Lydia Pickering, Yanmeng Chao, School of Metallurgy & Materials

University of Birmingham

W. Malalasekera (Malal), Salah Ibrahim, Maxim Bragin, Tom Beard Wolfson School of Mechanical and Manufacturing Engineering,

Department of Aeronautical and Automotive Engineering, Loughborough University

Engineering Safe and Compact Hydrogen Energy Reserves (ESCHER)

Page 2: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

AIMS

• To optimise metal hydride based technologies that are extremely compact but also have a high level of safety.

• Develop a module sized for the smallest application, i.e. daily top-up for a commuter vehicle, with the system able to be expanded by increasing the number of modules to fully charge multiple vehicles for either a community charging point, or for servicing a small fleet of commercial hydrogen vehicles.

• Address design issues related to deployment of the module in the selected applications and integration issues with hydrogen generators, such as effective heat management of the whole system and safety.

Page 3: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

OBJECTIVES

To deliver:

• A Metal Hydride (MH) store with a system capacity of 40 g(H2) L-1. To achieve this, every aspect of the store will be investigated, from the container to the bed formulation, heat transfer and recovery mechanisms, economically viable store materials, container and fabrication methods to demonstrate mass deployment feasibility.

• A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which can deliver 10 g (H2) min-1 for rapid refuelling (scenario A) or can deliver 1 g (H2) min-1 for overnight charge refuelling (scenario B)

• Components for scenarios A or B identified above (electrolyser, MH store, MH compressor, heat recovery system, controls) all within the size of a large chest freezer for installation in a garage or outhouse.

• An investigation of all aspects of safety and hazards within the system, focussing on hydrogen safety, hydride bed exposure and reactions to trauma such as fire and collision.

Page 4: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

1

2

3

4

Contents

5

Introduction to the system

Material Challenges and Targets

Numerical Study on a Two – Stage Metal Hydride

Hydrogen Compressor (MHHC)

Early Results on Models and Materials

Development of modelling capabilities and assessment of safety in hydrogen technologies involving metal hydrides

Page 5: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Introduction to System

Scenario B – trickle charge Target H2 production over 10 hours - 600 g H2 storage capacity of each stage (based on 50 - 55 minute cycle) - 60 g Mass of MH stage 1 – 4.45 kg Mass of MH stage 2 – 4 kg Refuelling time 10 h @ 50-55 minute cycles Required electrolyser production rate 1.875 mol/min.

First Stage MH

Second Stage MH

High Pressure Tank

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3/14

Introduction about the performance of a two-stage MHHC

Low Pressure Hydrogen Supply

Stage 1 Stage 2

High-Pressure

Tank

Heat Transfer

Fluid

Advantages of MHHC over Mechanical Compressors

Simplicity in Design and Operation

Absence of Moving Parts

Safety and Reliability

No Problems Related to Lubrication and Maintenance

Possibility to Consume Waste Industrial Heat Instead of Electricity

Valve 1 Valve 2

Valve 3

Pin

High Delivery Pressure

Pd: Delivery Pressure

Ps: Supply Pressure

Th : Dehydrogenation Temperature

Ts : Hydrogenation Temperature

Coupling Process

Typical Commercial Mechanical

Compressor

Page 7: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Material Challenges and Targets

Tuneable P-c-T properties (High compression ratio in available temperature

range)

High Reversible Hydrogen storage capacity – Reduction of the Amount of the

MH

Fast Kinetics

Low plateau slope

Low hysteresis

Stability during cycling

Scalability of MH alloys synthesis and affordable costs

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Pd

Xmax

lnP

H/MXmin

Ps

Material Selection – Material Combination

Δp

First Stage Hydrogenation

First Stage Dehydrogenation

Second Stage Hydrogenation

Second Stage Dehydrogenation First Stage Second Stage

AB5- Type

LaNi5 – Mm-Ni-

Al

AB2 – Type

Ti-Zr-Mn

AB5 – Type

LaNi5

AB5 – Type

Ca-Mm-Ni

AB2 – Type

Ti-Cr-Mn

AB2 – Type

Ti-Zr-Cr-Fe-V

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Numerical Study of the MHHC

Basic Assumptions and Equations

• H2 and metal are in local thermal equilibrium

• Solid Phase is Isotropic and has uniform porosity

• Hydrogen is treated as an ideal gas from a thermodynamic point of view.

• Heat transfer by Radiation is negligible

• The equilibrium pressure is described by Van’t Hoff Law

• The thermal conductivity and the specific heat of hydride bed are constant

Hydrogenation Process Kinetic Term

Dehydrogenation Process Kinetic Term

( ) ( ) (k ) Qe g g g e

TCp Cp v T T

t

( ) ( ) ((1 )e g pg s psCp C C

(1 )e g sk k k

5

0

1ln [ ( ) tan[ ( ) ] 10

2 2eq s

f

S x SP

RT R x

exp[ ]ln[ ]( )absabs abs s

eq

E pm C

RT P

exp[ ] ( )eqdes

des des s

eq

P pEm C

RT P

φs and φ0 plateau flatness factors

S Hysteresis Factor

Page 10: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Potential alloys

10

Low pressure stage Comments

1) LaNi5 Purchased from Sigma-Aldrich

2) Hydralloy C, TiZr(MnVFe)2

(Ti0.65Zr0.35)1+xMnCr0.8Fe0.2

Purchased from Sigma-Aldrich

Induction melted UoN

High pressure stage Comments

3) Ti0.29V0.14 Mn0.51 (FeCrZr) Purchased from Sigma-Aldrich

4) Ti0.5V0.45Nb0.05Mn Synthesised by Arc melting, UoB

5) Ti1.1Cr1.5Mn0.4V0.1 Synthesised by Arc melting, UoB

6) TiMn1.5V0.45Fe0.1 Synthesised by Arc melting, UoB

7) (Ti0.97Zr0.03)1.2Cr1.6Mn0.4 Synthesised by Arc melting, UoB

Alloys are selected based on the reported enthalpy and entropies values

in the literature to compress hydrogen above 350 bar using a two-stage

MH compressor

Page 11: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

First Stage Alloy

Dehydrogenation Second Stage Alloy Hydrogenation 20 0C

Case 1 LaNi5 100 0C: Peq=20.19bar 130 0C: Peq= 41.29 bar

Zr-V-Mn-Nb (AB2 type) Peq=32.95 bar

Case 2

MmNi4.6Al0.4 100 0C: Peq=56.96 bar Zr-V-Mn-Nb (AB2 type) Peq=32.95 bar

Case 3

LaNi5 100 0C: Peq=20.19bar 130 0C: Peq= 41.29 bar

Ti0.99Zr0.01V0.43

Fe0.99Cr0.05Mn1.5

Peq=31.63 bar

Case 4

MmNi4.6Al0.4 100 0C: Peq=56.96 bar Ti0.99Zr0.01V0.43

Fe0.99Cr0.05Mn1.5

Peq=31.63 bar

Materials Used for the Simulation Study

Page 12: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

8/14 0 500 1000 1500

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

Simulation Results

Experimental Data

Hy

dro

ge

na

tio

n C

ap

ac

ity

(w

t% H

2)

Time (s)

25 0C

50 0C

0 200 400 600 800 1000 1200 1400

-1,0

-0,8

-0,6

-0,4

-0,2

0,0

Experimental Data

Simulation Results

50 0C

Deh

yd

rog

en

ati

on

Cap

acit

y (

wt%

H2

)

Time (s)

25 0C

Validation of the simulation results with the experimental

Material Used for the Validation: LaNi5

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4

0

10

20

30

40

Pre

ss

ure

(b

ar)

Hydrogen uptake (wt%)

30 oC absorption

30 oC desorption

50 oC absorption

50 oC desoprtion

75 oC absorption

75 oC desorption

0,0029 0,0030 0,0031 0,0032 0,0033

0,6

0,8

1,0

1,2

1,4

1,6

1,8

2,0

2,2

2,4

2,6

H=-29.8 kJ/mol

S=104.9 J/Kmol

lnP

(a

tm)

1/T (K)

H=-28.3 kJ/mol

S=102.1 J/Kmol

Page 13: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

High pressure alloys

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

0

20

40

60

80

100

120

140

Pre

ssure

(bar)

Hydrogen uptake (wt%)

27 oC Absorb.

27 oC Desorb.

50 oC Absorb.

50 oC Desorb.

60 oC Absorb.

60 oC Desorb.

Ti-V-Nb-Mn

Sloping plateaux, hysteresis factor (ln Pa/Pd at 27 oC=0.46)

Hydrogen capacity at 27 oC: 1.51 wt%

Plateau width (∆C) significantly decreases with temperature increase

13

4) Ti0.5V0.45Nb0.05Mn: PCI characteristics

3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35

2.5

3.0

3.5

4.0

4.5

5.0

H= -21.74 kJ/mol

S= 100.01 J/Kmol

Habs

= 20.25 kJ/mol

S= 97.77 J/Kmol

lnP

(a

tm)

1/T *103

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9/14

Geometry of the reactors • Both Reactors are 60 % Full with Material to Avoid Lattice Expansion Issues

• For 60g H2 stored per cycle in the High Pressure Tank

LaNi5: 4.45 kg MmNi4.6Al0.4: 4.12 kg

Zr-V-Mn-Nb: 4 kg Ti-Zr-V-Fe-Cr-Mn: 3.42 kg

Hydride

Tank Walls 3 mm

External

Jacket

H2 Supply Filter

Stage 1

Stage 2

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10/14

Mass and Energy Balance During the Coupling Between the Reactors

Total Number of Hydrogen moles in the interconnector anytime

Pressure of Hydrogen in the combined space anytime

Dehydrogenation Kinetics

Hydrogenation Kinetics

t t t des absn n n n

t t t tt t

A B

n R TP

V V

exp[ ]eq t tdes

des des s

eq

P PEm C

RT P

exp[ ] ln( )abs t tabs abs s

eq

E Pm C

RT P

Hydride Stage 1 Hydride Stage 2

ndes nabs

H2 Flow

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Simulation Results Case 1: First Stage (AB5) LaNi5 – Second Stage (AB2) Zr-V-Mn-Nb

0 1000 2000 3000 4000 5000

120

100

80

60

40

S. H Process

Zr-V-Mn-Nb

Dehydrogenation

Zr-V-Mn-Nb

Hydrogenation

LaNi5

Dehydrogenation

Ta

nk

Av

g T

em

pe

ratu

re (0C

)

Time (s)

LaNi5

Hydrogenation

S. H Process

Pin = 15 bar

Tcold

= 20 0C

Thot

= 130 0C

20

0 1000 2000 3000 4000 50000

50

100

150

200

250

300

S.H Process

Ti-V-Mn-Nb

Dehydrogenation

Ti-V-Mn-Nb

Hydrogenation

S.H Process

Pin = 15 bar

Tcold

= 20 0C

Thot

= 130 0C

Tan

k A

vg

Pre

ss

ure

(b

ar)

Time (s)

LaNi5

Hydrogenation

LaNi5

Dehydrogenation

0 1000 2000 3000 4000 50000.0

0.2

0.4

0.6

0.8

1.0

Hy

dro

gen

Co

ncen

tra

tio

n

Time (s)

• Coupling Between 200C (Hydrogenation) and

1300C (Dehydrogenation)

• Time for a full cycle: 70-75 min

• Energy Required: 10-11 kJ

• Maximum Compression Ratio: 22-23:1

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Cycle Time (min) Compression Ratio Energy Penalty (kJ)

Case 1 70-75 22-23:1 10-11

Case 2 65-67 12:1 7.5-8

Case 3 58-60 18-19:1 10-11

Case 4 63-65 10:1 8-9

Comparison of the Performance of all cases

First Stage Second Stage

Case 1 LaNi5 (20 -130 0C) Zr-V-Mn-Nb (20 -130 0C)

Case 2 MmNi4.6Al0.4 (20 -100 0C)

Zr-V-Mn-Nb (20 -100 0C)

Case 3 LaNi5 (20 -130 0C)

Ti0.99Zr0.01V0.43 Fe0.99Cr0.05Mn1.5 (20 -130 0C)

Case 4 MmNi4.6Al0.4 (20 -100 0C)

Ti0.99Zr0.01V0.43 Fe0.99Cr0.05Mn1.5 (20 -100 0C)

Page 18: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Outcomes so far

System 1: LaNi5 (1300C) - ZrVMnNb (200C)

Deliver Pressure after coupling: 36 bar/ Final Pressure: 318 bar

System 2: MmNi4.6Al0.4 (1000C) - ZrVMnNb (200C)

Deliver Pressure after coupling: 43 bar/ Final Pressure: 182 bar

System 3: LaNi5 (1300C) - Ti0.99Zr0.01V0.43 Fe0.99Cr0.05Mn1.5 (20

0C) Deliver Pressure after coupling: 37 bar/ Final Pressure: 280 bar

System 4: MmNi4.6Al0.4 (100

0C) - Ti0.99Zr0.01V0.43 Fe0.99Cr0.05Mn1.5 (200C)

Deliver Pressure after coupling: 49 bar/ Final Pressure: 157 bar

Presentation of a mathematical model and simulation results for a two stage MHHC

Four Different Systems were considered and studied

Future Targets

• Decrease compression cycle time to 50-55 min

• Materials with higher compression efficiency

• Heat Management of the Tanks

• Geometries

Page 19: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Text in here Text in here Text in here

Maximising the kinetics

Thin Hydride Shell Thickness of

Shell 5.48mm

External Jacket

Hydrogen Supply

Filter

External Jacket

Wall Thickness 3mm

Tank’s Wall

Cooling/Heating

Medium

Hydride

External Tank’s Wall

Hydrogen Supply

Filter

Tube 1

Tube 2

Tube 3

Tube 4

Al Foam Packed with the

powder

Co-central Tubes Wall Thickness

3mm

Tube Radius: 5mm

Cooling Tube

Thickness 1,5 mm

Co-central Tubes with Al foam 40 ppi Average Cell Diameter 2.3 mm

Page 20: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Development of modelling capabilities and assessment of safety in hydrogen technologies involving metal hydrides

• Hydrogen fire simulations

• Fundamental modelling and assessment of explosion hazards of hydrogen

• Experiments (University of Sydney)

• Modelling and assessment of explosion hazards of hydrogen

• Experimental testing of dust explosions (FSA GmbH)

Page 21: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

• Dispersion model validation

• RCS framework for hydrogen

• Hydrogen fuelling standards and current potential restrictions on ESCHER project

• Processing of the experimental data for combustion model development

Page 22: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Matsuura et al., Numerical simulation of leaking hydrogen dispersion behaviour in a partially open space, International Journal of Hydrogen Energy, 2008, Volume 33, Issue 1, Pages 240-247

Geometry of the validation case

Page 23: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Sensor readings validation

T. Beard, M. Bragin, W. Malalasekera, S. Ibrahim, “Numerical simulation of hydrogen discharge in a partially enclosed space” submitted to the 12th International Conference on Combustion & Energy Utilisation, Lancaster, 29 Sept – 3 Oct 2014

Page 24: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Contents

• Dispersion model validation

• RCS framework for hydrogen

• Hydrogen fuelling standards and current potential restrictions on ESCHER project

• Processing of the experimental data for combustion model development

24-33 ESCHER Meeting 04 July 7th, 2014

Page 25: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Risk Control Strategy Framework for hydrogen

HSE only regulates safety at the work place

When it comes to regulating residential garages, all of the regulations become suggestions…HSE recommends to follow the same approach as for work spaces

Dangerous Substances and Explosives Atmospheres Regulations (DSEAR) 2002, which implements in the UK ATEX 137 “The User” Directive (Workers at risk)

Control of Major Accident Hazard Regulations 1999 (COMAH), which implements in the UK Seveso II Directive

Equipment and Protective Systems for Use in Potentially Explosive Atmospheres (EPS) 1996

Others: Pressure Equipment, Gas Appliances, Low Voltage, Electromagnetic Compatibility Directives, etc

Page 26: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Dangerous Substances and Explosives Atmospheres

The key requirement of the DSEAR is that risks from dangerous substances are assessed and controlled

DSEAR requires:

Identification of fire and explosion hazards

Classification of areas where explosive atmospheres may exist

Evaluations of risks

Specifications of measures to prevent or mitigate the effects of an ignition

Page 27: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Risk Control Strategy stipulated by DSEAR

Risk Control Strategy stipulated by DSEAR:

Substitution (for less dangerous substance)

Preventing the formation of explosive atmospheres (containment, dilution through effective ventilation)

Preventing the ignition of explosive atmospheres

Zone classification

Mitigating the effects of an explosion (explosion resistant equipment, pressure relief, prevention of flame acceleration and DDT, explosion progression and Domino effect)

Page 28: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Control of Major Accident Hazard

COMAH applies mainly to the chemical industry, but also to storage facilities where threshold quantities of the dangerous substances identified by the Regulations are kept or used.

There are two threshold levels given in the regulations. Sites with quantities exceeding the lower level are known as ‘lower-tier’ sites and those exceeding the upper value as ‘top-tier’ sites.

Threshold values for hydrogen are 5 tonnes and 50 tonnes, which means that this regulation may not even apply to many of the larger hydrogen refuelling stations, let alone a home hydrogen refueller.

Page 29: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Notification of Installations Handling Hazardous Substances

The NIHHS Regulation (1982, 2002) prohibit the handling of certain hazardous substances in quantities equal or exceeding the threshold quantity specified in the regulations unless HSE has been notified.

The threshold quantity for hydrogen is two tonnes…

Page 30: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Equipment and Protective Systems for Use in Potentially Explosive Atmospheres (EPS)

The legal requirements for equipment and protective systems intended for use in potentially explosive atmospheres are given in the ATEX 100A Equipment Directive (sometimes also called the ATEX 95 Directive)

The Directive covers both electrical and non-electrical (mechanical) equipment

The requirements also extend to controlling and regulating devices intended for use outside the explosive atmosphere, but required for, or contributing to, the safe functioning of equipment or protective systems in the explosive atmosphere

Page 31: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Classification of hazardous areas

IEC/EN60079-10 “Electrical apparatus for explosive gas atmospheres. Part 10. Classification of hazardous areas”

Hazardous areas are classified into zones based upon the frequency of the occurrence and duration of an explosive gas atmosphere, as follows:

Zone 0: An area in which an explosive gas atmosphere is present continuously or for long periods (>1000 hours/year)

Zone 1: An area in which an explosive gas atmosphere is likely to occur in normal operation (10-1000 hours/year)

Zone 2: An area in which an explosive gas atmosphere is not likely to occur in normal operation and, if it does occur, is likely to do so only infrequently and will exist for a short period only (1-10 hours/year)

Page 32: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Classification of hazardous areas

Another important consideration is the temperature classification of the electrical equipment. The surface temperature or any parts of the electrical equipment that may be exposed to the hazardous atmosphere should be tested that it does not exceed 80% of the auto-ignition temperature of the specific gas in the area where the equipment is intended to be used

T1 450°C, T2 300°C, T3 200°C, T4 135°C, T5 100°C, T6 85°C

The above table tells us that the surface temperature of a piece of electrical equipment with a temperature classification of T1 will not rise above 450 °C

The auto-ignition for hydrogen is 560 °C so we will require the highest temperature grading T1

Page 33: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Pressure Equipment Regulation/Directive

Pressure Equipment Regulation (PER) 1999 stems from EU Pressure Equipment Directive (PED)

For pressure equipment > 0.5bar above atmospheric pressure

It defines, based on contents, maximum allowable pressure and volume, the conformity procedure, which is then linked to the risk presented in the event of an uncontrollable release of stored energy

PER will apply to MH storage vessels and all associated pipework

Pressure systems should have means for venting and also have to be subjected to a regular inspections

Page 34: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Contents

• Dispersion model validation

• RCS framework for hydrogen

• Hydrogen fuelling standards and current potential restrictions on ESCHER project

• Processing of the experimental data for combustion model development

Page 35: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Hydrogen Refuelling Standard SAE J2601

Establishes guidelines for communicating and non-communicating refuelling

Applies to light duty vehicle fuelling for vehicles with storage capacity from 1 to 10 kg for 70 MPa and 1 to 7.5 kg for 35 MPa

Operating conditions limitations:

Gas temperature in vehicle fuel system < 85 °C

No more than 10 complete stops during refuelling (defined if flow reduces below 1% of the max flow rate)

Leak test should be carried out before any fuelling

But… The SAE J2601 is due for renewable in Autumn 2014

Page 36: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Hydrogen Refuelling Standards ISO 20100

ISO 20100, which is currently under development will include indoor refuelling operation (mainly for warehouses).

Current Technical Specifications (ISO/TS 20100:2008) explicitly exclude residential and home applications

Specific requirements will be provided for H2 systems in enclosures:

ventilation requirements to avoid the development of a flammable atmosphere in case of expectable leaks, even if all electrical equipment is designed for operation in a flammable atmosphere

maximum H2 concentration thresholds will be defined for initiation of safety measures for system shutdown

requirements for hydrogen refueling in a warehouse

Page 37: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Some useful points to consider (ISO/TS 20100:2008)

Installation and equipment design shall minimize the number of connections and other possible points of leakage or release to atmosphere

It is recommended to use joints that are permanently secured and so constructed that they limit the maximum release rate to a predictable value

Page 38: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Hydrogen generators

Hydrogen generators using water electrolysis process shall meet the requirements of ISO 22734-1

During normal fuelling system shutdown, the hydrogen generators using water electrolysis process and the hydrogen generators using fuel processing technologies shall not rely on safety devices to shut down

Actuation of any emergency shutdown device of the fuelling station shall shut down the hydrogen generators using water electrolysis process and the hydrogen generators using fuel processing technologies

Page 39: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Hydrogen compressors

Valves shall be installed such that each compressor can be isolated for maintenance. Where compressors are installed for operation in parallel, each discharge line shall be equipped with a check valve

The inlet pressure shall be monitored by a pressure indicator/switch to avoid a vacuum in the inlet line and consequent ingress of air. This pressure indicator/switch shall cause the compressor to shut down before the inlet pressure reaches atmospheric pressure

The temperature after the final stage of compression, or the temperature after the cooler, where fitted, shall be monitored by an indicator/alarm that shall be arranged to shut down the compressor at a predetermined maximum temperature

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Filters and separators

Filters and, if applicable, separators shall be included if hydrogen is expected to contain function-impairing impurities

The filters and separators shall be sized for the maximum hydrogen gas flow and for the expected impurities in the hydrogen gas, and shall be provided with sufficiently large sumps or collecting tanks

As far as possible, filters and separators should be combined in a single unit

Clogging of the filter insert in the main hydrogen gas flow shall be monitored

Page 41: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Other Relevant Standards

Electrical resistance trace heating (if available) should comply with IEC 60079-30-1

All electrical equipment installed should be suitable for the area classification according to IEC 60079-0 and other applicable parts of 60079 series

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Contents

• Dispersion model validation

• RCS framework for hydrogen

• Hydrogen fuelling standards and current potential restrictions on ESCHER project

• Processing of the experimental data for combustion model development

Page 43: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Turbulence

generating grid

4

5

50

Frame 001 25 Mar 2008 No Data Set

Sydney Combustion Chamber

15

02

03

02

03

0

S1

S2

S3

Obstacle

50

Solid

Vent

IgnitionPoint

Turbulentgeneratingbaffle plates

Fuel/airinlet

Y

Z

X

ESCHER Meeting 03 April 24th, 2014

43-38

Page 44: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Test Case

Large eddy Simulations (LES) were carried

out using an in-house code PUFFIN

Hydrogen/air mixture with equivalence ratio

0.7 is modelled for the current case

The Dynamic Flame Surface Density

(DFSD) model is tested on the case of for

Sydney combustion chamber for hydrogen

explosion and identified to be successful.

Page 45: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Results. Validation

Comparison between sequence of images showing flame structure after ignition. (a) LIF-OH images from experiments. (b) Numerical snapshots for reaction rate contours

generated at 2.2, 2.4, 3.6, 4.2 and 4.4 ms. Equivalence ratio 0.7.

ESCHER Meeting 03 April 24th, 2014

45-38

Page 46: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Results: Overpressure - validation

Time (ms)

Ove

rpre

ssu

re(m

ba

r)

0 1 2 3 4 5 6 7 8 9 100

100

200

300

400

500

600

700

800

Exp

LES

Overpressure time traces of LES simulation compared with experimental data Equivalence ratio 0.7

Page 47: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Results: Range of equivalence ratios

Movies of LES simulation for equivalence ratios 0.4 (left), 0.7 (centre), and 1 (right)

ESCHER Meeting 03 April 24th, 2014

47-38

Page 48: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Turbulence

generating grid

4

5

50

Frame 001 25 Mar 2008 No Data Set

Sydney Combustion Chamber

15

02

03

02

03

0

S1

S2

S3

Obstacle

50

Solid

Vent

IgnitionPoint

Turbulentgeneratingbaffle plates

Fuel/airinlet

Y

Z

X

(a) (b) The two baffle configurations studied here

(a) OOOS. (b) BBBS

Page 49: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Processing of the experimental data I

49-33 ESCHER Meeting 04 July 7th, 2014

The flame front speed of the three fuels through the chamber for both the OOOS and BBBS configurations

Page 50: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Processing of the experimental data II

The flame front length expansion through the chamber for the three fuels at both configurations, plotted to the peak flame front lengths witnessed

Page 51: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Processing of the experimental data III

The flame stretch rate along the explosion chamber for the OOOS configuration

Page 52: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Processing of the experimental data IV

52-33 ESCHER Meeting 04 July 7th, 2014

The flame stretch rate along the explosion chamber for the BBBS configuration

Page 53: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

ESCHER progress

• Store requirements, capacity and scenarios evaluated.

• COMSOL models of stores and compressors completed. Compressors. Initial metal hydride couples analysed

• Exploration of stage 2 metal hydrides for compressor, improving kinetics, compression ratio and reducing hysterisis

• Hydrogen Dispersion model validation against experimental data – completed

• Review of standards related to hydrogen use indoors – started, ongoing

• Fundamental model development (with PUFFIN code): processing of experimental data – started, ongoing

• Progress on schedule

53-33

Page 54: Engineering Safe and Efficient Hydride- Based Technologies ... · • A Metal Hydride cascade for compressing hydrogen from 10 to 350 bar. This will require a compact system which

Collaborations • HSL: Steffan Laden. • ITM Power: Nick Van Dyke • University of Sydney: Asaad Masri • FSA GmbH • GL Industries Ltd • Eminate Ltd Dissemination E.I Gkanas, D.M Grant, A.D Stuart, G.S Walker D.Book, S. Nayebossadri, L. Pickering , Metal Hydrogen Systems MH2014 14th International Symposium on Metal-Hydrogen Systems 20-25th July 2014 T. Beard, M. Bragin, W. Malalasekera, S. Ibrahim, “Numerical simulation of hydrogen discharge in a partially enclosed space” submitted to the 12th International Conference on Combustion & Energy Utilisation, Lancaster, 29 Sept – 3 Oct 2014