Riga Exhibition and Conference October, 2013 Environment and Energy",

Transcription

1 Riga Exhibition and Conference October, 2013 Environment and Energy", Safety of Hydrogen Refueling and Hydrogen Vevicles Dr. Johannes Töpler German Hydrogen and Fuel Cells Association (DWV) and European Hydrogen Association (EHA)

2 Hydrogen as secondary energy carrier Electricity Hydrogen or:

3 Actual Situation of Energy Supply The availiability of fossil primary energies is limited to aproximately years (with respect to probable annual growing rates even less!) Fossil energy carriers are raw materials for organic chemistry - > to valuable for burning. The damage of climate due to CO 2 -emissions is obvious right now and will increase further on (in spite of Kyoto-protocol). The energy demand world-wide will increase (especially by the developing countries) and will aggravate the situation. The introduction of a new energy-system will need in principal about 50 years for the first 10% of market penetration. (Marcetti 1980) Consequence: It s very high time to introduce CO 2 -free renewable energies (if necessary via primary energies with less CO 2 ), with hydrogen as secondary energy carrier which can be stored, transported and used in manifold applications.

4 Fuel Cell vehicle Mercedes-Benz B-Class Electric motor Air module Essential Facts Lithium-Ion battery Hydrogen tank Fuel Cell Hydrogen module 1) Vehicle is constructed, fabricated and approved under serial condititions. 2) It was tested by a turn of 125 days around the world with km 3) Start of serial production in 2017

5 Daimler, FCell Packaging Fuel Cell Stack Power Distribution Unit (PDU) Battery Hydrogen Storage Cooling System Electric Drive System Module

6 Progress Fuel Cell Technology Next Generation FCVs Next generation of the fuel cell-power train: A-Class F-Cell Higher stack lifetime (>2000h) Increased power Higher reliability Freeze start ability Li-Ion Battery B-Class F-Cell Technical Data Vehicle Type Mercedes-Benz A-Class (Long) Fuel Cell System PEM, 72 kw (97 hp) Engine Output (Continuous / Peak): Engine 45 kw / 65 kw (87hp) Max. Torque: 210 Nm Fuel Hydrogen (35 MPa / 5,000 psi) [km] Range +135% Size - 40% [l/100km Consumption - 16% Power +30% Technical Data Vehicle Type Mercedes-Benz B-Class Fuel Cell PEM, 90 kw (122 hp) System IPT Engine Output (Continuous/ Peak) 70kW / Engine 100kW (136hp) Max. Torque: 290 Nm Compressed Hydrogen (70 Fuel MPa / 10,000 psi) Range 105 miles (170 km / NEDC) Top Speed 88 mph (140 km/h) Range ca. 250 miles (400 km) Top Speed 106 mph (170 km/h) Battery NiMh, Output (Continuous / Peak): 15 kw / 20 kw (27hp); Capacity: 6 Ah, 1.2 kwh [kw] Battery Li-Ion, Output (Continuous/ Peak): 24 kw / 30 kw (40hp); Capacity 6.8 Ah, 1.4 kwh

7 Compressed H 2 -container Different types

8 Wrapping of a composite liner α = : pic-up of radial forces α = : pic-up of radial and axial forces α = :pic-up of axial forces Quelle: Funck, Handbook of Fuel Cells Vol 3, S. 83 (2003)

9 BV351 Hydrogen Valve Temperature Sensor Withdrawal filter Port for Optional Pressure Sensor Solenoid valve Inlet / Outlet UN-2A Threading PRD Outlet Bleed Port Temperature Sensor connector PRD Inlet / Outlet With 40 Micron Filter Solenoid Connector Manual Valve Source: Dynetek

10 Pessure relief device Source: VTI, Dynetek

11 Tank System of H 2 -Busses (CUTE) Vehicle Model: Citaro City-bus H2 Storage Capacity: 43 kg Service Pressure: 350 Bar Approx. Range: 300km Number of Vehicles: 30 Location: Europe, North America, Australia ADVANCED LIGHTWEIGHT FUEL STORAGE SYSTEMS TM

12 Safety & Testing: tests of raw material corrosion test hydraulic pressure test burst test cycle test (ambient temperature) cycle test (extreme temperature) leak before break test chemical exposure test bonfire test penetration (bullet) test composite flaw tolerance test accelerated stress rupture test impact damage (drop) test leak test permeation test boss torque test hydrogen cycle test Safety: Testing of CH 2 Cylinders Test Requirements: > minimum burst pressure 1645 bar > specified burst pressure Only Type 4 Cylinders ADVANCED LIGHTWEIGHT FUEL STORAGE SYSTEMS TM

13 700 bar Composite Container Burst test: Cylinder with cryoformed steel liner burst pressure: 1954 bar internal pressure in bar ,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 Volumetric Expansion in Liter MFI-FP

14 Safety: Testing of CH 2 Cylinders Safety & Testing: tests of raw material corrosion test hydraulic pressure test burst test cycle test (ambient temperature) cycle test (extreme temperature) leak before break test chemical exposure test bonfire test penetration (bullet) test composite flaw tolerance test accelerated stress rupture test impact damage (drop) test leak test permeation test boss torque test hydrogen cycle test Only Type 4 Cylinders J.Töpler Test Requirements: Pressurised with liquid from 2 MPa to 1.25 x working pressure 3 x number of filling cycles NO leak Test Requirements: preconditioned by impact exposure to five chemicals 5000 cycles to 1.25 x working pressure x working pressure >1.8 x working pressure ADVANCED LIGHTWEIGHT FUEL STORAGE SYSTEMS TM

15 Safety: Chemical Exposure Test Impact Pendulum J.Töpler ADVANCED LIGHTWEIGHT FUEL STORAGE SYSTEMS TM

16 Safety: Chemical Exposure Test Exposure to five chemicals: 1.Sulphuric acid - 19% solution by volume in water 2.Sodium hydroxide - 25% solution by weight in water 3.Methanol/gasoline - 5/95 % concentration 4.Ammonium nitrate - 28% solution by weight in water 5.Windshield washer fluid (50% by volume solution of methyl alcohol and water) Testing: 5000 cycles to 1.25 x working pressure x working pressure >1.8 x working pressure J.Töpler ADVANCED LIGHTWEIGHT FUEL STORAGE SYSTEMS TM

17 Safety: Bonfire test on 700 bar Cylinder, 32 L Testing acc. to ISO and EIHP tests of raw material corrosion test hydraulic pressure test burst test cycle test (ambient temperature) cycle test (extreme temperature) leak before break test chemical exposure test bonfire test penetration (bullet) test composite flaw tolerance test accelerated stress rupture test impact damage (drop) test leak test permeation test boss torque test hydrogen cycle test Test Requirements: Pressurised with H 2 to working pressure Fire source length: 1.65 m NO burst but venting through the temperature triggered pressure relief device (TPRD) Only Type 4 Cylinders J.Töpler ADVANCED LIGHTWEIGHT FUEL STORAGE SYSTEMS TM

18 Hydrogen safety J.Töpler

19 Safety: Testing of CH 2 Cylinders Safety & Testing: tests of raw material corrosion test hydraulic pressure test burst test cycle test (ambient temperature) cycle test (extreme temperature) leak before break test chemical exposure test bonfire test penetration (bullet) test composite flaw tolerance test accelerated stress rupture test impact damage (drop) test leak test permeation test boss torque test hydrogen cycle test Test Requirements: Pressurised with gas to working pressure Armour Piercing Bullet 7.62 mm Impact at an angle of 45 NO burst but venting through the entrance (and exit) opening Only Type 4 Cylinders ADVANCED LIGHTWEIGHT FUEL STORAGE SYSTEMS TM

20 H 2 -nozzle with infrared-data exchange

21 Filling Procedure

22 Refueling ov vehicles with compressed H 2 Start of filling Coupling to fuel station Pressure surge Determination of filling pressure Calculation of SoC init Calculation of final pressure p final Filling till p final Remark: SoC (State of Charge)= r( pt, )- r( p0,15 C) Ч100% r( p,15 C)- r( p,15 C) typical: p 0 = 1,5 MPa (empty Tank) p 100 = 70 MPa (full Tank) End of filling Source: Maus, Daimler, Diss. TUHH 2007

23 Refueling ov vehicles with compressed H 2 Presure [MPa] Under temperature Overfilling Excess Pressure Operation range Excess temperature Temperature [ C] The filling occurs to a final density of 40,22 g/l (corresponding 70 MPa at 15 C) Der maximum pressure will than be reached at a maxilmum temperature of 85 C. Source: Maus, Daimler, Diss. TUHH 2007

24 CFD-Model of H2-Tank Spatial Distribution of Temperature During filling (p = 37 MPa) 57 C 52 C Cold incoming gas 47 C Highest temperature at the end of vessel Temperature-layers 2 min after filling (p = 80 MPa) Cooling near to the wall T 0 = 20 C p 0 = 1,5 MPa T e = -15 C Filling in 3 min. m = const. Quelle: Maus, Daimler, Diss. TUHH 2007

25 Breakaway Coupling for H 2 -Filling Stations

26 Crash of CNG-Vehicle Source:Powertech

27 Thank you very much for your attention! And see us occasionally at Which are the questions I can answer at first?

28 The sixth Kondratjew: Energy productivity (after Charlie Hargroves, Brisbane, Australia) Electricity, chemicals,cars Biotech IT TV, aviation, computers, Energy productivity, renew. energy Steel & railroads Mechanization Source: E.U.v.Weizsäcker

29 The laws of nature and the laws of mankind (especially those of a completely free economy) are not in harmony. It is not to be expected, that the laws of nature will adapt to those of mankind. Mankind can only survive, when it fits in with the laws of nature and does not affect the oecological system as a whole or in any of its parts The future will be ethic or it will not be!