Status of Hydrogen Station and Fleet Demonstration

at Penn State

Joel R. Anstrom, Ph.D.

February 2007

Director of Hybrid and Hydrogen Vehicle Research Center at the Pennsylvania Transportation Institute

Hydrogen Station/Fleet Demonstration Background

• Emergence of a renewable hydrogen economy is a major component of a long-term U.S. energy security strategy

• DOE interim goals: (until renewable hydrogen infrastructure in place)

– Produce hydrogen locally from natural gas– Target costs and efficiencies competitive with gasoline– Store hydrogen on-board vehicles

• APCI and DOE cost-shared H2 station goals for transportation:– Demonstrate commercial cost viability of H2 station– Deliver hydrogen that meets performance criteria– Demonstrate hydrogen station/fleet at Penn State

starting Summer 2006

Hydrogen Station/Fleet Demonstration Background (continued)

• Partners to demonstrate hydrogen station and fleet:– Air Products and Chemicals, Inc. (APCI)– Centre Area Transportation Authority (CATA) – Penn State Pennsylvania Transportation Institute– Penn State Office of Physical Plant– Collier Technologies

• APCI Hydrogen Station 50% DOE cost share, total $8M

• Funding for startup, training, and one year operation of first HCNG bus, HCNG van, and FCV:

– 2004 Pennsylvania Department of Environmental Protection Energy Harvest Grant - $248,000

– 2004 Pennsylvania Department of Community and Economic Development - $248,000

• Funding for 6-7 more vans, a hydrogen HEV, two add’l years of operation – 2006 Pennsylvania Department of Environmental Protection Alternative Fuels

Incentive Grant - $273,278– 2006 Pennsylvania Department of Community and Economic Development

$273,278

ppt00 5

Storage

Feedstocks Fueling Station Vehicles

H2

Electrolysis

NG

Compression

H2 Storage

H2 Fueling Station at Penn State

H2 GeneratorH2 Generator

APCI CATA buses

HCNG Blend

H2 CNG Blending

OPP Vans

PTI FCV

H2

Compression

Hydrogen Station Description

Hydrogen Station Description (continued)

• APCI Hydrogen station capacity - 4 kg/hr, ~100 kg/day

• 24 car fills/day or 1 bus fill/day on hydrogen

• 3-4 bus fills/day on 30-35% H2 in CNG blend (HCNG)

• Fueling Plan (5 day/week, year round, cold climate):

– 2 H2 car fills/day at 0.6 kg (1.2 kg H2)

– 1-2 van fills/day of HCNG blend (2-4 kg H2)

– 1 bus fills/day of HCNG blend (26 kg H2)

– Plus future Penn State hydrogen research requirements

• Note: >40% load on hydrogen reformer required to prevent frequent shutdown/startup cycles

Hydrogen Demonstration ElementsPartner - Contribution

• Air Products and Chemicals Inc. (APCI) – develop and support hydrogen station

• Centre Area Transportation Authority (CATA) – operate up to 3 HCNG buses on campus route

• PSU Office of Physical Plant (OPP) – operate up to 8 HCNG vans on campus

• PSU Pennsylvania Transportation Institute (PTI) – manage demonstration, collect data, integrate/operate electric vehicle with PEM fuel cell

• Collier Technologies – perform HCNG engine conversions, training, and support

CATA HCNG buses PTI PEM fuel cell car

APCI H2 station at Penn State

OPP HCNG vansPTI H2ICE HEV

APCI Hydrogen Station

• Reform 100 kg H2 per day from natural gas

• Store 1500 gal of liquid H2

• Dispense H2 at 5000 psi with communication fill to CFCP standard

• Blend and dispense 30% H2 by volume HCNG at 3600 psi open loop fill

• Status: Operational

HCNG Bus

• Chassis: 40’ New Flyer CNG passenger bus

• Engine: 11 liter Daewoo converted by Collier Tech

• Fuel Capacity: ~ 1600 l @ 3600 psi of HCNG

• Operation: campus transit

• Fuel Consumption: ~3 mpg Diesel equivalent

• Fueling: daily

• Status: 1st bus conversion and testing completed, entering revenue service

HCNG Van

• Chassis: E 250 Ford utility van

• Engine: 4.6 l V8, 30% H2 in HCNG

• Fuel Capacity: ~80 l at 3600 psi of HCNG

• Operation: campus work van

• Fuel consumption: ~8 mpg gas equivalent

• Fueling: random 24/7

• Status: 1st van conversion and testing completed, in service

• 6-7 additional vans beginning conversion.

Hydrogen Fuel Cell Vehicle

• PSU Converted GM EV1 electric vehicle chassis

• 1.2 kW Ballard Nexa PEM Fuel Cell

• 26 l (0.6 kg) hydrogen tank, 5000 psi

• Operation: test mule and grid power generation

• Fueling: twice daily

• Fuel consumption: ~70 mpg gas equivalent

• PSU designed power electronics: drive, braking, FC voltage boost, charge, and vehicle-grid power

• Status: operational with ongoing tuning and refinement of drive electronics and fuel cell boost converter

HCNG CATA bus operates on Loop Route consuming

majority of hydrogen, fuels

daily

Seven HCNG OPP vans operate on campus, fuel

at random

PTI and APCI collect data on vehicles and

station

Fuel cell vehicle and H2ICE HEV

travel on campus, fuel

daily

PSU Hydrogen Demonstration Funding and Status as of 2/07

• H2 station on-line with liquid tank, blend unit, high pressure storage, and dispensers

• CNG reformer on-line and producing hydrogen

• Funding secured for first bus, 7-8 vans, Fuel Cell Vehicle, H2ICE HEV, and three years of hydrogen fleet operation.

• HyLion FCV filling on H2 and tuning drive system

• First HCNG van in service. Additional vans beginning conversion to HCNG.

• Bus enter regular service on CNG and testing on HCNG.

Contact Information

Joel R. Anstrom

Pennsylvania Transportation Institute

201 Transportation Research Bldg.

University Park, PA 16802

jra2@psu.edu

(814) 863-8904