Session 1.4: Automotive Design Aspects and Requirements Requirements and Design Aspects for Automotive Liquid Hydrogen Storage M. Stoecklin 25 th 29 th September 2006 Ingolstadt Session 1.2: Introductory Lectures K. Hall
1.4 Automotive Design Aspects and Requirements CV Michael Stoecklin Address: BMW Group Research and Technology 80788 München Following my studies for mechanical engineering, I entered BMW Group in 1997. After 3 years as project engineer passive safety in the series development, I joined the hydrogen research and technology department in 2001, developing car safety concepts. From end of 2003 until early 2006 I worked in Tokyo/ Japan as technology scout hydrogen. Since my return I am responsible again for hydrogen safety and are the BMW project leader of HySafe, a European network of excellence. Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 2
1.4 Automotive Design Aspects and Requirements Internal Combustion Engine and Liquid Hydrogen,the BMW Approach, Michael Stoecklin (BMW) Abstract: BMW Group has been continuously working on hydrogen vehicles and their infrastructure for over 25 years. Having demonstrated the technical feasibility with a small fleet during the BMW CleanEnergy world tour in 2001, the development of the 6th generation, which will be launched in the near future, was shifted from the research into the series development departments. All BMW hydrogen vehicles have been powered by a bifuel internal combustion engine being able to use either gasoline or hydrogen, which is stored in its liquid form at -253 C offering the highest energy density. BMW is also working on fuel cells but as an auxiliary power unit (APU) e.g. to run the air-condition system during standstill of the engine. The presentation will give detailed background information and explain BMW s hydrogen strategy. Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 3
Requirements and Design Aspects for Automotive Liquid Hydrogen Storage M. Stoecklin Table of Content Hydrogen Vehicles at BMW Automotive Energy Storage System Liquid Hydrogen Powertrain Infrastructure Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 4
Potential of Hydrogen ICE BMW Record Drive, September 2004 Length: 5,60 m Width: 2,00 m Weight: 1560 kg c x : 0,21 Engine: V12, 6 litre Power: monovalent H 2 > 200KW Acceleration: : 0-100km/h 0 in 6 s Vmax = 302,4 km/h Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 5
Hydrogen Research Vehicles Five Gerneration from 1979-2002 Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 6
Commitment CleanEnergy CleanEnergy WorldTour 2001 + 2002 Dubai Brussels Milan Tokyo Los Angeles Berlin Sacramento London Johannesburg Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 7
Series Development of 6th Generation Bi Fuel Concept for First Market Introduction Internal Combustion Engine Liquid Hydrogen Tank Gasoline Tank Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 8
The Optimal Automotive Fuel System Requirements High energy density for broad driving range Freedom of shaping for package Low weight Minimal energy loss during standstill of car Highly dynamic for changing energy demand Easy and quick refueling Functional and passive safety Durability Low cost Infrastructure available Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 9
StorHy Targets 2010 Requirements for LH 2 / ICE-System StorHy DOE DOE 2005 2010 Storage System Gravimetric Density kwh/kg 2.0 1.5 2.0 wt% 6.0 4.5 6.0 Volumetric Density kwh/l 1.5 1.2 1.5 kgh 2 /100l 4.5 3.6 4.5 Operating Temperature C -40 / +85-20 / +85-30 / +85 Minimium Pressure bar 1.5 10 35 Delivery Rate kg H2/min 5.5 Purity % 99 98 98 Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 10
Alternative Fuels Energy Equivalent Gasoline / Hydrogen Gasoline 43 MJ/kg Gaseous Hydrogen 120 MJ/kg Liquid Hydrogen 120 MJ/kg 35 l =^ CGH 2 350 bar CGH 2 700 bar LH 2-253 C, 3-5bar 430 l 256 l 160 l 700km range 5l-car =^ 27 kg 10 kg 10 kg 3xCFRP-Tank (Quantum Typ IV) 2xCFRP-Tank (Lincoln) Steel (H 2 R) CFRP (StorHy) Any shape 15 kg 165 kg < 40 kg 170 kg 126 kg Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 11
H2-Storage in the Vehicle Volumetric energy density of LH 2 and GH 2 Volumetric Energy Density[kWh/l] 2,5 2,0 1,5 1,0 0,5 Working Point Liquid Hydrogen (Equilibrium) Critical Point Gaseous Hydrogen (280K) 0 1 5 10 100 1000 Pressure [bar] Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 12
Mobile Hydrogen Storage DOE Targets volumetric storage density [kg / m 3 ] 80 70 60 50 40 30 20 DOE LH2 (today) LH2 (future) CGH2 (today) CGH2 (future) Chem.Hyd. (today) MH (today) MH (future) Physics CGH2 Physics LH2 2005 2010 2015 1 bar 4 bar 1000bar 700 bar 350 bar Gasoline (7 series): 8 kwh/kg (-> 24mass% H 2 ) 9 kwh/l (270kg/m³) 10 0 5 10 gravimetric storage density [mass%] Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 13
Hydrogen Storage in the Vehicle Liquid Hydrogen Filling Line Outer Vessel Inner Vessel Level Probe Suspension Heater cooling water heat exchanger Coupling System Box Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 14
Hydrogen Storage State of the art / Future Tank System Challenges: State of the Art Vacuum stability Material properties Thermal shock Recycling Stainless steel Cylindrical vessels Plant specific design Session 1.4 Automotive Design Aspects and Requirements Future System Michael Stoecklin Lightweight materials Free form geometry Automotive design Reduced heat entry 15
StorHy: EU Funded Project at BMW H 2 Storage for automotive applications Cryogenic bei -253 C Highpressure bei 700 bar Solid storage Duration: 4,5 Years Budget: ~ 20 Mio. Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 16
Automotive Hydrogen Coupling Joint Development with GM Development of a standardised LH 2 -filling system for autocars. Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 17
Hydrogen Combustion Engine Clean and Powerful Ø Ø Ø Ø Ø Ø Power density Power characteristic Efficiency Reliability Cost Well Known Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 18
Hydrogen Combustion Engine Research Activities Cryogenic mixture formation (~ 200 C) High-pressure direct injection (~ 200 bar) Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 19
Fuel Cells Auxiliary Power Unit Unlimited supply of electricity independent of engine operation Air-conditioning during stand-still Immediate heating/warm-up Communication Lights. Potential: Replacement of alternator and lead acid battery Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 20
Hydrogen Fuelled Vehicles Challenges to be Resolved Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 21
Munich Airport Hydrogen Project First Public Hydrogen Filling Station Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 22
CleanEnergy Partnership Berlin Introduction of H 2 as Fuel for Road Transport ΛΗ 2 ΧΓΗ 2 Testing and Demonstration of: Production, transport and distribution of H 2 Storage and refuelling of H 2 Operation and maintenance of H 2 -Vehicles (FC+ICE) Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 23
BMW Hydrogen Cars Summary Internal Combustion Engine Proven technology at moderate costs Still high potential for improvements Liquid Hydrogen Tank Highest energy density Further potential for weight reduction Small Fuel Cell Supplement for electric board net Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 24
Session 1.4: Automotive Design Aspects and Requirements Requirements and Design Aspects for Automotive Liquid Hydrogen Storage M. Stoecklin 25 th 29 th September 2006 Ingolstadt Session 1.2: Introductory Lectures K. Hall