Heinrich Lienkamp, Ashok Rastogi

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Experience with FC-Vehicles Hydrogen Infrastruct
ure in ZERO REGIO

• Heinrich Lienkamp, Ashok Rastogi
• Infraserv Höchst - Frankfurt
• Germany

www.zeroregio.com
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• Outline
• Brief presentation of Aims, activities
  highlights in
• Zero Regio
• Frankfurt, Germany
• Mantova, Italy
• Operational experience
• Some events
• Lessons learnt
• Collection and Assessment of Data
• Comparison with the state of the art
• Concluding Remarks Next steps

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Industrial Park Höchst
4.6 km2 area 72 km Streets 80 Companies Over
22000 Workforce 30 mil.Nm3/yr By-product H2
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Service Station Frankfurt
Area 4.062 m2 350 700 bar GH2 LH2
Dipensers. Photovoltaic 8 kW Opened on 17.11.2006
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• H2 - Infrastructure in Germany
• Hydrogen center in Industry park, Höchst
• Existing infrastructure
• By-product H2 is collected, conditioned,
  compressed (250 bar)
• Trailer station
• Ionic fluid compressor (900 bar) in Hydrogen
  center
• Agip station 1.7 km from H2-center
• Hydrogen transport to station via HP-pipeline
  (1000 bar)
• CGH2 dispensers, 350 bar and 700 bar one each
• LH2 dispenser (Truck supply of LH2)
• Agip station opened on Nov. 17, 2006

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Lay out HP Pipeline in Höchst
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Some Design Details
Overground
Hanging pipe system
Underground Tubing with PE sleeve in sandbed
1.4462 Material Din 18 mm Dout 33.7 mm Pmax
1000 bar Welded construction Leakproof by
definition HP-H2-Transport system is one of its
kind worldwide
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• Compression Scheme

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• Ionic Fluid Compressor working principle

PLC
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• Ionic Fluid Compressor

• Special Features
• Ionic liquid no vapor pr.
• Compressor capacity
• 900 Nm3/hr or
• 1.335 kg/min
• First time in Zero Regio for H2 - 900 bar

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Hydrogen-Dispensers Höchst
GH2 700 bar
GH2 350 bar
LH2
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Service Station Frankfurt
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• Experience with infrastructure in Germany
• High availability inspite of some problems
• Filters in the cooling system of the compressor
• Some valves failed on the compressor system
• Some loose fittings leading to system failure
• Ionic Compressor overhauled in 2nd year of
  operation
• Outage for 3 months
• Filter problems in the third year, regular
  maintenance reqd.
• Insufficient purging of the pipeline initially
• Control valves at dispenser minor electronic
  problems
• Incident reporting and management approach
  important
• One accident in the first year, no H2 discharge

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Operational Experience in Germany
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Operational Experience in Germany

• Damage of 700 bar Dispenser by accident
• Cause Passenger car runs into dispenser
• Effect major damage of dispenser and the
  installed technique No accidental escape of
  hydrogen
• Action Repair / replacement of dispenser

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Servicestation Mantova
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• H2 - Infrastructure in Mantova, Italy
• On-site production facility (CPO reformer)
• Small unit with 20 Nm3/hr
• Construction completed and in operation from July
  2008
• Truck transport from an industrial reformer
  (back-up)
• 350 bar GH2 dispenser (Cars homologated for 200
  bar)
• Delay partly due to approval formalities
• A mobile refueller initially (AP 100)
• Integration in multi-energy Agip service station
• 17.000 m2, Car Wash, Cafè Shop
• Opening ceremony took place on 21 Sept. 2007

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CPO Reformer by Eni
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On-site Hydrogen Production in Mantova

• Suitable for intermittent operation
• 3 Compaigns in 2009
• 20 kg. H2 in April 09
• 40 kg. H2 in July 09 (40 kg. Storage capacity)
• 40 kg. H2 in Oct. 09
• One day for plant start-up and shut down
• High quality achieved (COlt 0.1 ppm)
• Plant optimised for automatic operation
• 20 Nm3/hr. too high for 3 cars
• Other applications planned at the service station

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• Dedicated Fleets

Range 250 km (_at_350 bar)Maximum speed 135
km/hAcceleration 0-50 km/h within 7 sNuvera
PEM 70 kW 3 cars
Range 160 km (_at_350 bar)Maximum speed 140
km/hBallard PEM 72 kW 5 cars, one with 700 bar
storage
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Beauty and the Beast
F-Cell serving A-380 !!
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Some Demonstration Data

• Operational Performance of the vehicles in 2008

Mileage
Operating hours
F-Cell No. 29
F-Cell No. 49 (700 bar)
F-Cell No. 59, 60, 61
The operational performance 2008 was lower than
expected
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SOME INCIDENTS with Fleet

• In general all FCVs functioned better than
  expected
• Regular maintenance was performed
• Tank leak tests
• TÜV examinations
• Minor repairs could be done on site
• No road calls
• One accident due to drivers negligence
• One car was taken out of service
• in Sept. 2009 due to IPT defect
• (Integrated PowerTrain failure)

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Some other Customers

• Frankfurt station is used also by other customers
• For 350 bar dispenser
• Honda (FCX Clarity), 2 cars
• Mazda (Ice, RX 8 Hydrogen), 1 car
• Toyota Prius one visit
• For 700 bar dispenser
• Opel/GM Hydrogen 4, 1 car
• B-class F-Cell Daimler, extensive testing with a
  few cars
• IR Communication, SAE Release A Standard
• 3 min. for 4 kg, aiming at 100 fill rate

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• Assessment Framework

• INPUT DATA
• Data tables on
• Infrastructure
• Vehicles
• 2 Demo. sites
• OEMs and Operators

• Results
• Indicators on
• Infrastructure
• Vehicles
• 2 Demo. sites
• Indicator value (0 to 1)

Simple Data Processing

• Compare with Ref. Technology
• Technological aspects
• Performance, Environment, Safety
• Socio-Economy
• Project Organisation

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Data Assessment
Comparison of energy consumption Comparison of energy consumption
CNG CGH
Energy consumption for compression 0,035kWhel/kWh (200 mbar ? 300 bar) 0,124kWhel/kWh (70 mbar ? 700 bar)
Energy consumption of vehicle 73,75 kWh/100km (CNG-ICE) 35,66 kWh/100km (FC)
Total energy consumption 76,33 kWh/100km 40,08 kWh/100km
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Comparison F-Cell Vs. Diesel
Parameter FCV, A-Class 350 bar A-Class Diesel 160 cdi
Maximum speed, km /hr 140 162
Maximum range with a full tank, km 170 980
Tank volume capacity, l 78 54
Fuel consumption NEDC, eqiv. Diesel l/ 100 km 3.6 5.5
Acceleration time 0-100 km/hr, sec 14.3 16.8
Maximum Torque Nm 210 160
CO2 Emissions g/km 0 146
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Summary of 2 years

• 3-7 FCVs, 100 vehicle months of operation,
  over 45000 km driven (should have been more)
• over 510 kg. H2 consumed, 7.2 tons of CO2
  emission saved
• Vehicles showed high reliability and
  availablity (98)
• Availability 350 bar dispenser 95
• Availability 700 bar dispenser 55 (accident
  costed 11 months)
• Ionic compressor 77 (has been overhauled)
• By-product hydrogen should be exploited more
  initially
• Infrastructure problems experienced are not
  related to H2

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Some Lessons Learnt

• Serious problems with approval formalities in
  Italy
• Delay in infrastructure construction
• Fleet is still operated at 200 bar storage
• European Harmonisation, Integrate authorities in
  project
• Bottle neck for larger demonstrations
• Fleet availability (cost), not so much
  infrastructure
• Frankfurt station can fill 15 FCVs /hour
• By-product Hydrogen should be exploited much
  more

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• Concluding Remarks
• H2-infrastructure developed and FCV fleet used
  in Zero Regio Project
  have been briefly presented
• Operational experience has been encouraging at
  both sites
• FCV-Fleet has operated better than expected
• Fuel consumption of FCV is about half of NGV
• Fast refuelling of 700 bar FCVs has been
  realised
• Zero Regio high potentials HP-Pipeline
  transport,700 refuelling with IR communication.
  Thank You
• Final Conference at WHEC 2010, Essen, Germany.

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Service Station Mantova
Area 17.000 m2 350 bar GH2 Photovoltaic 16
kW Opened on 21.09.2007
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Hydrogen Dispenser - Mantova
GH2 350 bar
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Onsite H2 Production Plant
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• F-Cell A-Class

Vehicle type Mercedes-Benz A-Class Fuel-Cell
system PEM, 72 kW (97 PS)Electro-Asynchron-Motor
Motor rating 65 kW (87 PS)Max. Torque 210
NmFuel Hydrogen (350 bar)Range 160 kmMax.
Velocity 140 km/h Battery NiMh,
air-cooledPower (av./peak) 15 kW / 20 kW
Rating 6,5 Ah 1,4 kWh
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SOCIO-ECONOMIC STUDIES

• 1
• 2
• 3
• 4
• 5S