CRYO-COMPRESSED HYDROGEN STORAGE - … HYDROGEN STORAGE CRYOGENIC CLUSTER DAY, OXFORD, SEPTEMBER 28, 2012 Dr. Klaas Kunze, Dr. Oliver …

CRYO-COMPRESSED HYDROGEN STORAGE CRYOGENIC CLUSTER DAY, OXFORD, SEPTEMBER 28, 2012

Dr. Klaas Kunze, Dr. Oliver Kircher

BMW EfficientDynamics Less emissions. More driving pleasure.

BMW HYDROGEN STORAGE DEVELOPMENT. AGENDA.

BMW Hydrogen Storage Strategy

Cryocompressed Hydrogen Storage Development

Refueling technology

Compatibility with infrastructure

Conclusion

Page 2 BMW Hydrogen Storage, September 28th, 2012






Conclusion


BMW EfficientDynamics Less emissions. More Driving Pleasure.

Hydrogen

Long Range ZEV Mobility

Optimizing:

• Efficiency • Aerodynamics • Lightweight • Energy Management • Road Resistance

BMW Hydrogen Storage, September 28th, 2012 Page 4

BMW EFFICIENT DYNAMICS. 4 STEPS TOWARDS EMISSION-FREE MOBILITY.

ActiveHybrid

ActiveHybrid X6 and Active Hybrid7

BMW i

Battery Electric and Plug-In Hybrid


BMW HYDROGEN TECHNOLOGY STRATEGY. ADVANCEMENT OF KEY COMPONENTS.

Source: BMW

Advanced key components Next vehicle & infrastructure Hydrogen 7 small series

LH2 Storage

Capacity

Safety

Boil-off loss

Pressure supply

Complexity

Infrastructure

Technology leap storage & drive train

Efficient long-range mobility:

Zero Emission.

Focus on medium & large vehicles with high energy demand.

Range > 500 km (6-8 kg H2)

Fast refueling (< 4 min / 6 kg)

Optimized safety oriented vehicle package & component integration

Loss-free operation for all relevant use cases

Compatibility to upcoming infrastructure standard

V12 PFI engine

Power density

Dynamics

Durability & cost

Efficiency

H2 Drive train

H2-Storage

Electrification

H2ICE H2HEV EREV FCHV FC-EREV

Advancement Storage & Drive train

CGH2

Source: Quantum

LH2

Source: BMW

CcH2

BMW HYDROGEN STORAGE. 5 SERIES GT CCH2-FC-HYBRID CONCEPT CAR.

Customer benefits of

CcH2-storage in

Fuel Cell Hybrid Vehicle

Range 500 km customer real life,

> 800 km test cycle

Refueling Refueling time < 5 min

for 500 km possible

Operating

costs

Potentially lower fuel cost due

to lower investment and

operating costs at the station.

Performance

Additional cooling from CcH2-

storage enables better fuel cell

power train performance in

critical driving situations.

PEM Fuel Cell

~90 kW electrical power

H2 Cryo-compressed central

tunnel storage

max. 7,2 kg usable

High voltage

battery

~1KWh usable

Electrical rear wheel

drive

~200/ 80 kW


Adsorption Liquid Hydrides Compressed

Physical Storage Solid storage

Single or multi- pressure

vessel 700 (350) bar

„activated

carbon“

„MOFs“

„chemical“

„Zeolith“

„organic“

„metallic“ CGH2

* LH2*

Source: BMW

Super-insulated low-pressure

cryotank

Research level!

Demonstration

level Small Series level,

Mainstream

Source: Quantum

*) CGH2 := Compressed Gaseous Hydrogen (700bar) CcH2 := Cryo-compressed Hydrogen (10bar - 350bar) LH2 := Liquid/Liquefied Hydrogen (1 bar_a - ca. 10 bar_a)

Cryo-compressed

CcH2*

Source: BMW

Super-insulated cryogenic

pressure vessel 350 bar

Prototype level

BMW Hydrogen Storage, September 28th, 2012

HYDROGEN STORAGE TECHNOLOGIES. ONLY PHYSICAL STORAGE VALIDATED FOR USE IN PASSENGER VEHICLES.

Page 7


BMW HYDROGEN STORAGE . CCH2 – CRYOGENIC GAS DENSER THAN LH2.

0

10

20

30

40

50

60

70

80

90

100

20 40 60 80 100 120 140 160 180 200 220 240 260 280 300

Temperatur [K]

Dic

hte

[g

/l]

Temperature [K]

De

nsi

ty [

g/L

]

CGH2 – 700 bar / 288 K

CcH2 – 300 bar / 38 K

-40°C

LH2 – 1

bara

LH2 – 4 bara

CGH2 – 350 bar / 288 K

LH2

CcH2 CGH2

LH2 Liquid Hydrogen

CcH2 Cryo-compressed Hydrogen

CGH2 Compressed Gaseous Hydrogen

33 K

80 g/L

63 g/L +27%

x2

40g/L

Page 8

Page 9

BMW HYDROGEN STORAGE. CCH2 – OPERATING REGIME.

0

10

20

30

40

50

60

70

80

90

100

20 40 60 80 100 120 140 160 180 200 220 240 260 280 300

Temperatur [K]

Dic

hte

[g

/l]

Temperature [K]

De

nsi

ty [

g/L

]

-40°C

LH2

CcH2 CGH2

LH2 Liquid Hydrogen

CcH2 Cryo-compressed Hydrogen

CGH2 Compressed Gaseous Hydrogen

33 K

Highest possible storage

pressure at warm conditions

(in CGH2 mode)

Highest possible storage

pressure at cryo. conditions

Refueling (300K, 38K)

Extraction to lowest pressure







Conclusion


Modular Super-insulated Pressure Vessel (Type III)

Max. usable capacity

CcH2: 7.8 kg (260 kWh) CGH2: 2.5 kg (83 kWh)

Operating pressure

350 bar

Vent pressure ≥ 350 bar

Refueling pressure

CcH2: 300 bar CGH2: 320 bar

Refueling time < 5 min

System volume ~ 235 L

System weight (incl. H2)

~ 145 kg

H2-Loss (Leakage| max. loss rate | infr. driver)

<< 3 g/day | 3 – 7 g/h (CcH2) |

< 1% / year


CRYO-COMPRESSED HYDROGEN STORAGE. SYSTEM LAYOUT – BMW PROTOTYPE 2011.

+ Active tank pressure control

+ Load carrying vehicle body integration

+ Engine/fuel cell waste heat recovery

Vacuum enclosure

Aux. systems (control valve, regulator, sensors)

MLI insulation (in vacuum space) Refueling

line Shut-off valve

Intank heat exchanger

Suspension

Coolant heat exchanger

COPV (Type III)

Secondary vacuum module (shut-off / saftey valves)

Sto

rag

e s

yste

m v

olu

me

[L

]

250

500

750

1000

1250

5 10

0

15 20

70 MPa CGH2

35 MPa CGH2

35 MPa CcH2


BMW CRYO-COMPRESSED HYDROGEN STORAGE. STORAGE SYSTEM VOLUME COMPARISON.

Max. usable storage capacity [kg H2]

0.4

kWh/L

0.6

kWh/L

0.8

kWh/L

1.0

kWh/L


BMW CRYO-COMPRESSED HYDROGEN STORAGE. STORAGE SYSTEM WEIGHT COMPARISON.

Sto

rag

e s

yste

m w

eig

ht

[kg

]

100

200

300

400

500

5 10

0

15 20

1.0

kWh/kg

1.5

kWh/kg

2.0

kWh/kg

2.5

kWh/kg

70 MPa CGH2

35 MPa CGH2

35 MPa CcH2

Max. usable storage capacity [kg H2]

BMW Hydrogen Storage, September 28th, 2012 Seite 14

CRYO-COMPRESSED HYDROGEN STORAGE. MAIN FUNCTIONS PERFORMANCE.

Refueling densities up to 72 g/L.

High CcH2 density after 3-4 refuelings.

First cold refueling of ambient storage

features 30 g/L hydrogen density,

second cold refueling more than

50 g/L.

First warm CGH2 refueling of cold

storage to 32 MPa results in more than

40 g/L refueling density.

BMW CcH2 test refuelings confirm the

predicted values.

CRYO-COMPRESSED HYDROGEN STORAGE. EXTENDED CCH2 OPERATING REGIME - INCREASED PRESSURE VESSEL REQUIREMENTS.

1 Refueling (300 / 57 K)

2

Highest possible

storage pressure at

cryogenic conditions (subsequent to refueling)

3

Extraction to lowest

pressure (subsequent to refueling)

4

Highest possible

storage pressure at

warm conditions (in CGH2 mode)

5

Out-baking and

vacuum generation during production

pre

ssu

re [

ba

r]

1

2

3 5

0

200

400

600

800

1000

temperature [K]

0 40 240 280 320 360

4

80 120 160 200

350 bar CGH2

operating regime (extended) CcH2 operating regime

CGH2 350 bar refueling

out-baking and vacuum generation

CcH2 refueling

currently required burst pressure (2.25 x 350 bar)







Conclusion



H2 INFRASTRUCTURE – POTENTIAL ROLE OF CCH2. CRYO-PUMP PERFORMANCE.

BMW Linde CcH2 pump prototype:

80 g/L at 300 bar

100 kg H2/h (up to 120 kg/h)

< 1% LHV compression energy

In Operation since 04/2010

H2 delivered (09/2012): ~ 45,000 kg (> 7000 refuelings with subscale and full size tank systems)

Proof of Concept: Function, Durability and Efficiency.

H2-INFRASTRUCTURE. CRYO-COMPRESSED REFUELING.

CcH2-filling station in operation since 11/2011.

High performance CcH2-quick connector coupling for consecutive refuelings.

Direct single-flow refueling to 30 MPa via cryo-pump

(no buffers required).

100 – 120 kg/h continuous fill rate

( 3 – 3.5 minutes for up to 6 kg).

No need for communication between vehicle and dispenser.

Test tank-sytem

CcH2-dispenser

Cryopump

CcH2-coupling


H2-INFRASTRUCTURE COMPARISON OF HYDROGEN REFUELING COUPLINGS.

H2-fuel Vehicle side Filling station side

Liquid Hydrogen (LH2)

0,4 MPa

BMW/Linde/Opel/Walther

Cryo-compressed /

Compressed Gas

CcH2 30 MPa

~2 kg H2/min

BMW/Linde/Walther

Compressed Gas

(CGH2)

70 MPa

~2 kg H2/min

WEH

LH2-coupling:

Low pressure

Cryogenic temperatures

Double flow (back-gas to

station)

Ball valves

CcH2-coupling:

Moderate pressure

Cryogenic temperatures

Single flow

Checkvalve on vehicle

side

High filling performance.

Online leakage control

Easy to use handling

Fully automated non-com

filling procedure.

Comparable in size to

existing CGH2-couplings.

LH2

CcH2







Conclusion


0

2

4

6

8

10

12

14

16

18

20

70MPa CGH2 (max.) 70MPa CGH2 (min.) 70 Mpa CGH2 (LH2) 30 Mpa CcH2

Cryo compressed LH2 70MPa, 2010




Pre-cooling CGH2 (-40°C)

Ionic Compression CGH2 70MPa


H2-INFRASTRUCTURE. HYDROGEN COMPRESSION EFFICIENCY.

GH2 compression (from 20bar)

(ionic compressor)

LH2 compression (from 2bar)

(high-pressure cryo-pump)

2-3x

higher

energy

demand

Energy consumption for compression to CGH2 vs CcH2 at the hydrogen refueling station.

>10x

Higher

energy

demand Large amount of

high-pressure

buffers, increasing

with number of

vehicles

Co

mp

ress

ion

en

erg

y d

em

an

d

(no

rma

lize

d t

o 3

0 M

Pa

CcH

2)

H2-INFRASTRUCTURE. HYDROGEN COMPRESSION EFFICIENCY.

kWh/

kg H

2 d

isp

ense

d

80 kg/d (small) 200 kg/d (medium) 400 kg/d (large) >400 kg/d

70 MPa CGH2

30 MPa CcH2

Source: CGH2 Source: LH2

0

2

4

6

8

10

12

min. max. min. max. min. max. min. max.

Aftercooling, idle

Aftercooling H2 (-40°C)

Compression LH2 70MPa

Compression LH2 30MPa

Compression CGH2 70MPa

Delivery

Liquefaction

Energy demand for liquefaction is nearly being compensated by less effort for compression, aftercooling

and logistics necessary for CGH2-based filling stations. Increasing station size reduces idle time losses.

25MPa 50MPa



BMW CRYO-COMPRESSED HYDROGEN STORAGE. HYDROGEN DISTRIBUTION – ROLE OF LH2.

H2-Infrastructure forecast:

„Cost-effectiveness, station footprint and safety issues will decide on delivery method and

station layout“:

Liquid hydrogen distribution at larger stations (> 400 kg/day).

LH2 distribution & station storage eases integration in existing infrastructure.

Gaseous hydrogen distribution via pipelines might face economic and social challenges even in the

long term.

Compressed gas trailers and onsite electrolysis in ramp-up phase, only.

Liquid delivery and station storage will play an important role in a future infrastructure.

1500 kg H2 / day

3500 kg LH2 /

trailer: 3

times a week

500 kg GH2 /

trailer: 3

times a day


H2-INFRASTRUCTURE. OPERATION OF LARGE STATIONS WITH LIQUID SUPPLY ECONOMICALLY ADVANTAGEOUS.

80 kg/d 200 kg/d 400 kg/d 1000 kg/d

€/kg H2 dispensed

* Fixed opex p.a. w/o electrictiy, incl SG&A (Selling, general and administrative Expenses)

** Currently under quantitative evaluation

80 kg/d 200 kg/d 400 kg/d 1000 kg/d

t€/station

Estimated Costs at Filling Station for 70MPa CGH2 outlet - Scenario 2020

*

*

**


H2-INFRASTRUCTURE. FUTURE FILLING STATION LAYOUT FOR CCH2 & CGH2.

Efficient compression and

high scalability.

Cryo-compressed fuel with highest density at

lower pressure.

LHLH22

CGH2

1,5 kg/min

(3 MW)

CGH2 40 g/L

69-65 g/L

1,5 – 3 bar

Heat

Exchanger

Partial warm

up

Aftercooler

70 MPa

LH2 Trailer

Filling station Distribution

LH2

Station storage

Production Source

cryogenic high

pressure pump

SMR

Elektrolysis

Natural gas

Carbon

Electricity mix

EU

Wind power

Hydropower

Solar energy

Geothermal

energy

Biomass

Liquefaction

GH2

2 kg/min

(4 MW)

CcH2

CcH2 80 g/L

30 MPa

High pressure buffer

up to 90 Mpa

for SAE J2601

Filling station with LH2-supply and cryogenic high pressure pump.

LH2

http://www.zebotec.de/upload/bilder-neu/wasserstoff/Img-Ely-12-1200.jpg

http://www.rabbarien.de/bild-braunkohlekraftwerk-4119.html






Conclusion


Page 27

BMW HYDROGEN STORAGE DEVELOPMENT. CONCLUSION.

LH2 is the solution for large stations (> 400 – 1000 kg/day).

Cryo-compressed H2-storage shows good performance and

interesting perspectives for the fueling station business case.

Technology risks of cryo-compressed are still high, but no show

stopper has been discovered until now.

BMW continues developing CGH2 700 bar and 350 bar CcH2 vehicle

storage in parallel.


Page 28

BMW HYDROGEN STORAGE DEVELOPMENT. ADDITIONAL SLIDES.


*) leakage at welded joint

Combined pressure and cryogenic temperature cycling does not lead to degradation in composite material properties

Combined pressure and cryogenic temperature cycling does not lead to degradation of vessel burst pressure & vessel pressure cycle life

Burst pressure of full scale COPV vessels after 600 CcH2 and 200 CGH2 refuelings stay within statistical spread of virgin vessel burst pressure

Initial virgin pressure cycle life of subscale COPV vessels (13.115 cycles 2 – 43.8 MPa at ambient temperatures) shows only minor degradation after 3.000 CcH2 and 1.000 CGH2 refuelings (1 – 32 MPa)

CRYO-COMPRESSED HYDROGEN STORAGE. VALIDATION OF STRUCTURAL DURABILITY.


Vacuum enclosure & safety release control Low adiabatic expansion energy

Vacuum enclosure design lowers risk of pressure vessel damage (mechanical and chemical intrusion, bonfire

damaging and aging) and enables leak monitoring.

Redundant safety devices for controlled hydrogen release in case of damage or vacuum failure.

Cryogenic hydrogen contains a fairly low adiabatic expansion energy and thus, can mitigate implications of a

sudden pressure vessel failure, in particular during refueling.

CcH2 storage eases vessel monitoring and mitigates failure impact. BMW Hydrogen Storage, September 28th, 2012 Seite 30

CRYO-COMPRESSED HYDROGEN STORAGE. SAFETY ASPECTS.

0

0,2

0,4

0,6

0,8

1

CcH2

Adi

abat

ic e

xpan

sion

ene

rgy

[kW

h/kg

]

6 – 15 times lower

expansion energy

Ambient CGH2 storage after

refueling

Full CcH2 storage

after cold refueling

Vacuum

Enclosure Redundant Safety

Devices

COPV in vacuum environment

Test Explanation Status

Vehicle crash

No additional implications compared to vehicle crash with CGH2 storage expected.

Tests will be done during vehicle qualification in 2012/2013.

Vehicle fire

Vacuum insulation & multiple safety devices (PRDs & TPRDs) lower risk of vessel failure.

Bonfire test validated in 2011, localized fire test in 2013.

Burst energy

Adiabatic expansion energy in case of sudden vessel failure is mitigated in cryogenic gas storage compared to warm gas storage:

Simulation: @ T < 100 K liquefaction during expansion supposable

Validation: burst test under warm & cryogenic conditions show significant differences

Sudden Vacuum Loss

Validation of safe H2-discharge via pressure relief devices (and optional vacuum-casing

burst disc) in case of Air- or H2- sided vacuum loss.

Implication of air-side vacuum-loss is mitigated compared to LH2.

Impact damage, penetration, chem.

exposure

Vacuum enclosure lowers risk of pressure vessel damage through external impacts.

Tests will be done during vehicle qualification in 2012/2013.

Permeation and Leakage

Type III pressure vessel with welded boss, joints & vacuum casing eliminates issue of

permeation & mitigates risk of leakage compared to CGH2 storage.

Leakage rate << 3g/day.

Page 31

CRYO-COMPRESSED HYDROGEN STORAGE. SAFETY – STATUS & SCHEDULED TESTS.

Air H2

Vacuum loss

Bonfire Local. fire

Crash


Page 32

BMW CRYO-COMPRESSED HYDROGEN STORAGE. USE CASE PROJECTIONS.

Auto-adaptive

density

minimizes vent

loss risk, still

leaves max.

capacity option.

Usa

ble

hyd

rog

en

de

nsi

ty [

g/L

]

long distance commuter infrequent driver

Long distance: continous driving

Frequent traveller: 15000 mls / year

Commuter: 10000 mls/year

Infrequent driver: 5000 mls/year

8kg reference CcH2 system, 8W heat leak (cost-efficient insulation), 65 mpkg vehicle fuel economy

Storage temperature [K]

frequent traveller


Page 33

BMW CRYO-COMPRESSED HYDROGEN STORAGE. USE CASE PROJECTIONS.

From warm

to cold

operation

with

consecutive

CcH2

refuelings. CGH2 70 MPa equiv.*

CGH2 35 MPa equiv.*

*) equivalent CGH2 storage density in identical package envelope

Usa

ble

hyd

rog

en

de

nsi

ty [

g/L

]

Storage temperature [K]

refill density (50mls range)

8kg reference CcH2 system, consecutive cold 30 MPa refuelings, constant discharge, ambient dispenser lines

max. density

max. extended density (cold dispenser lines)

Start with

ambient

storage

(steady state

35MPa

CGH2)


Documents

CRYO-COMPRESSED HYDROGEN STORAGE - … HYDROGEN STORAGE CRYOGENIC CLUSTER DAY, OXFORD, SEPTEMBER 28, 2012 Dr. Klaas Kunze, Dr. Oliver …