Revolve Technologies Limited. The Integration of Hydrogen in New/Existing Vehicles. Paul Turner, Engineering Director

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1 Revolve Technologies Limited The Integration of Hydrogen in New/Existing Vehicles, Engineering Director

2 RTL History & Background Revolve Technologies Limited (RTL) is a specialist powertrain, engineering and development business located in Brentwood, Essex. The 4,000m² main building houses our engineering teams and vehicle workshops including all support activities, engine build, electrical & electronics build, fabrication, and the model studio. The annex building houses 5 engine test cells Revolve, through our brands Mountune LLC and 1552 wheels, have opened an engineering facility in California primarily to support motorsport and aftermarket engineering opportunities Revolve also operates from satellite facility in Coventry Revolve has a staff of approximately 100 people and serve a number of industries from Motorsport to OEM to MoD to rail to marine etc. Revolve was an early participant in low carbon technology, having now been continuously active in this sector since

3 RTL Low Carbon Vehicles Experience 3

4 Hydrogen Integration in Existing/New Vehicles Hydrogen Dual Fuel Hydrogen injection in diesel engines Replaces significant quantity of diesel with hydrogen Up to 70% hydrogen displacement No difference in performance Sub 50g/km CO2 emissions Vehicle existing emission system No impact to load space** 5 mins refuelling time For a range of vehicle types, particularly large vans, HGV, & farm vehicles 100% Hydrogen Combustion Hydrogen injection in spark ignition engines Up to 45% B.T.E. ZERO emissions Simplified exhaust system, light weight engine, no aftertreatments required No impact to load space 5 mins refuelling time For a range applications vehicles, power generation, auxiliary power module Fuel Cell Range Extender for EV s Electric vehicles provide opportunity for zero emission Range and charging limitations Fuel cell converts hydrogen to electricity Charges battery on-the-go Range depends on hydrogen storage capacity ZERO emissions Only water is emitted 5 mins refuelling time For all electric vehicle types 4

5 Hydrogen Dual Fuel Hydrogen injection into air intake system Diesel acts as ignition source for the hydrogen gas The dual fuel system allows the use of hydrogen as the primary fuel system whenever hydrogen is present above 20 bar Once the pressure drops below this threshold the vehicle automatically switches to the original Diesel system Allowing maximum operator flexibility and continued use between refuelling station. Underbody Installation Side-body Installation Inside Installation 5

6 100% Hydrogen Combustion ZERO Emission Thermal Engine Propulsion System (TEPS) TEPS can be implemented on light, medium and heavy commercial vehicles, and optimised for combustion efficiency, air quality, emissions and overall system cost The system will immediately lower the carbon footprint of internal combustion engine production, negating the need for rare earth materials, and expensive after treatments, and/or additives Complicated and expensive exhaust and emissions hardware and software can be replaced with low cost Hydrogen Selective Catalytic Reduction (H2SCR) catalysts Propulsion system is right sized for power output Low cost zero emission option Current TEPS module 60kW 6

7 Fuel Cell Range Extender for EV Revolve has developed Fuel Cell Range Extender power module with Innovate UK, Bramble, HSSMI and STi to address the range anxiety and charging time concerns associated with modern battery powered electric vehicles Hydrogen fuel cells provide vehicle operators with a practical, carbonzero solution to these market limiting concerns, can be packaged for aftermarket fit, and with limited impact on load carrying capability IDP13 Project The use of the Fuel Cell Range Extender can almost double the effective range The flexibility of the fuel cell installation enabled mounting of the complete system on the roof of the vehicle meaning that there is no impact of the loading space ULEMCo FC Rx 7

8 Integrated Whole Energy Storage with Hydrogen (iwesh) Innovate UK funded project To test an innovative whole system energy renewable storage technology, including a novel control system & a low cost hydrogen refueller design The control system balances energy generation and use on site Real time cost data, grid balancing and peak shaving capability 48kWp Solar PV system 20kW Wind Turbine 5kW Hydrogen Boiler 20kW Electrolyser 350 bar Hydrogen Refueller 40 kwh Battery Ford Ranger Hydrogen Dual Fuel 8

9 Integrated Whole Energy Storage with Hydrogen (iwesh) On-site renewables are utilised in 4 distinct ways: Reducing the amount of electricity imported from the grid to meet the site load Excess energy generated on-site can be used to charge battery storage Excess energy generated on-site can be used to produce hydrogen via the electrolyser Excess energy generated on-site can be exported back onto the National Grid Cheaper, off-peak grid electricity can also be used to produce hydrogen via the electrolyser The hydrogen can be utilised to meet the on-site heating loads or compressed to fuel hydrogen vehicles 9

10 Hydrogen Refueling Infrastructure Revolve has worked with Fuel Cell Systems to design develop & build the FCS Mobile refuelling Station The first of its kind in the world, this mobile Refueller is capable of supplying 65kg of hydrogen to vehicles at both 350 and 700 bar. The mobile capabilities mean that it can fill in the gaps in the existing static hydrogen refuelling station network across the UK Revolve has also worked with Hydra, Canadian chemical company to develop and implement a system to recover, store and reuse waste hydrogen to power its fleet of heavy goods vehicles 10

11 Revolve Experience in Funded Programme Revolve has an impressive and successful record of sourcing and securing external research and development funding from local, national and international funding agencies We have helped our customers in assembling, leading and/or participating in consortia delivering funded R&D projects, European Regional Growth Fund, Department for Business, Energy and Industrial Strategy, Innovate UK, Advanced Propulsion Centre, Local Enterprise Boards etc Ford PHEV 11

12 For more details: Engineering Director +44(0) **Visit stand 68B**