Upload
others
View
3
Download
0
Embed Size (px)
Citation preview
Donald L Anton Director
Theodore Motyka Assistant Director
Savannah River National Laboratory
May 15 2012
P r o j e c t I D ST0 0 4 This presentation does not contain any proprietary
confidential or otherwise restricted information
2 2
Overview Timeline
bullStart February 1 2009 bullEnd July 31 2014 bull55 Complete (as of 33112)
Budget bullTotal Center Funding
DOE Share $ 36232765 Contractor Share $ 3591709 FY rsquo11 Funding $ 5144156 FY rsquo12 Funding $ 5930000
bullProg Mgmt Funding FY rsquo11 $ 400000 FY rsquo12 $ 400000
Barriers
Partners
A System Weight and Volume B System Cost C Efficiency D Durability E ChargingDischarging Rates G Materials of Construction
H Balance of Plant (BOP) Components J Thermal Management K System Life-Cycle Assessment O Hydrogen Boil-Off P Understanding PhysiChemi-sorption S By-ProductSpent Material Removal
3 3
Why Perform Materials Development and System Engineering in Parallel
Materials rarr Thermal rarr H2 Storage rarr Fuel Cell rarr Vehicle rarr Wheels Management BoP
Engineered Heat Transfer BoP What is Needed Materials Designs Component of the Hydrogen Storage Properties Requirements Media amp System
continuous feedback with system design indicating materials requirements
Approach
4 4
HSECoE Objectives Develop materials based hydrogen storage systems for On-Board Hydrogen Storage for Light Duty Vehicles
Develop system models that lend insight into overall fuel cycle efficiency
Compile all relevant materials data for candidate storage media and define future data requirements
Using systems engineering concepts design innovative system architectures for metal hydride chemical and sorption materials-based storage technologies with the potential to meet DOE performance and cost targets
Design components and experimental test fixtures to evaluate the innovative storage devices and subsystem design concepts validate model predictions and improve both component design and predictive capability
Design fabricate test and decommission subscale prototype systems of selected materials-based technologies
Approach
Phase I System
Requirements amp Novel
Concepts
Phase II Novel Concept
Modeling Design amp Evaluation
Phase III Sub-Scale Prototype
Construction Test and
Evaluation
bull Where are we and where can we get to
bull Model development
bull Benchmarking bull Gap Identification bull Projecting
advances
bull How do we get there (closing the gaps) and how much further can we go
bull Component development bull Concept validation bull Integration testing bull System design
bull Put it all together and confirm claims
bull System integration bull System assessments bull Model validation bull Gap analysis bull Performance projections
Phased Approach
5
Approach
6
Important Dates Duration 55 years
Phase 1 Start Feb 1 2009
Phase 1-2 Transition March 31 2011
Phase 1 End June 30 2011
Phase 2 Start July 1 2011
Phase 3 GoNo-Go Determination March 312013 Phase 2 End June 30 2013 Phase 3 Start July 1 2013 Completion Date June 30 2014 123114
6 Phase 1-2 Transition
Materials Selection
System Selection
Design Subscale
Prototypes
GoNoGo Decision
Building Subscale Prototypes
Approach
7
Phase 1-2 Transition
Overviewed Integrated System Model and its Role in Target Achievement
Prepared Summaries of Status for Metal Hydride Chemical Hydride and Adsorbent Systems
Current status vs targets
Identification of critical technical barriers
Identification of potential solutions to barriers
Summary of projected system performance vs targets
7
8
Outcomes of Phase 1-2 Transition Continued Work
Adsorbent-Based Hydrogen Storage Systems Increasing compaction of the sorbent materials
Demonstration of improved thermal conduction within the sorbent
Thermal isolation of the inner storage bed
Flow through cooling designs must be accompanied with total cooling requirements
Liquid-Phase Chemical Hydrogen Storage Materials (including liquids solutions andor slurries)
Development and validation of the critical components for baseline ammonia borane solutions
Thermal management within the reaction chamber
Gas-liquid phase separations and the
Hydrogen purification train be emphasized for the baseline ammonia borane solutions
Endothermic release material (eg AlH3 alane) must be modeled
8
9
Outcomes of Phase 1-2 Transition
Discontinued Work Solid-Phase Chemical Hydrogen Storage Materials
Material transport becomes a major challenge for this class of material
A reliable process for loadingunloading solids from the onboard storage vessel nor transporting it through an onboard reactor have been identified
Work on Reversible Metal Hydrides Analyses for highly optimized vessel configurations that could adequately
manage thermal and mass flow rates needed for reversible onboard hydrogen storage to meet the DOE performance targets imposed requirements substantially exceeding the properties and behavior of any single currently existing candidate hydride
The necessary combination of gravimetric and volumetric capacities reaction kinetics thermodynamics properties and reversibility have not been found simultaneously in any hydride investigated to date
Novel engineering solutions that will allow any currently known hydride when incorporated into a complete system have not been identified
9
10
HSECoE Phase 3 GoNoGo Milestones
10
Approach
11
Phase 2 Gantt Chart Approach
P12 Metal Hydride System Projection 2017 Targets
1 Gravimetric Density 2 System Cost 3 Onboard Efficiency 4 Volumetric Density 5 Fill Time 6 Fuel Cost
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
12
Buffer Tank P 5-150 bar V 10 L T ambient Q 0-16 gs
Fuel Cell
Storage Tank P 5-150 bar V 176 Ltank T 25-200degC Q 0-16 gs
Fuel Cell Delivery P 5 bar T lt 80degC Q 16 gs Max
H2 Combustor P 5 bar T lt 80degC Q 0-16 gs 12 kW
H2 Delivery Loop
Heat Transfer Fluid Loop
Fuel Cell Coolant Loop
Fuel CellCombustor Air Loop Heat Transfer Fluid Tank
Dual Vessel Sodium Alanate Design (w 4 molTiCl3 amp 5 wt ENG)
GM1 Design fin and tube heat exchanger optimized to meet 105 min refueling time at the expense of wt
2 Type 3 composite tanks with SS liners
System includes a 10 l buffer tank and a 12 kW H2 combustor
Accomplishment
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
2 2
Overview Timeline
bullStart February 1 2009 bullEnd July 31 2014 bull55 Complete (as of 33112)
Budget bullTotal Center Funding
DOE Share $ 36232765 Contractor Share $ 3591709 FY rsquo11 Funding $ 5144156 FY rsquo12 Funding $ 5930000
bullProg Mgmt Funding FY rsquo11 $ 400000 FY rsquo12 $ 400000
Barriers
Partners
A System Weight and Volume B System Cost C Efficiency D Durability E ChargingDischarging Rates G Materials of Construction
H Balance of Plant (BOP) Components J Thermal Management K System Life-Cycle Assessment O Hydrogen Boil-Off P Understanding PhysiChemi-sorption S By-ProductSpent Material Removal
3 3
Why Perform Materials Development and System Engineering in Parallel
Materials rarr Thermal rarr H2 Storage rarr Fuel Cell rarr Vehicle rarr Wheels Management BoP
Engineered Heat Transfer BoP What is Needed Materials Designs Component of the Hydrogen Storage Properties Requirements Media amp System
continuous feedback with system design indicating materials requirements
Approach
4 4
HSECoE Objectives Develop materials based hydrogen storage systems for On-Board Hydrogen Storage for Light Duty Vehicles
Develop system models that lend insight into overall fuel cycle efficiency
Compile all relevant materials data for candidate storage media and define future data requirements
Using systems engineering concepts design innovative system architectures for metal hydride chemical and sorption materials-based storage technologies with the potential to meet DOE performance and cost targets
Design components and experimental test fixtures to evaluate the innovative storage devices and subsystem design concepts validate model predictions and improve both component design and predictive capability
Design fabricate test and decommission subscale prototype systems of selected materials-based technologies
Approach
Phase I System
Requirements amp Novel
Concepts
Phase II Novel Concept
Modeling Design amp Evaluation
Phase III Sub-Scale Prototype
Construction Test and
Evaluation
bull Where are we and where can we get to
bull Model development
bull Benchmarking bull Gap Identification bull Projecting
advances
bull How do we get there (closing the gaps) and how much further can we go
bull Component development bull Concept validation bull Integration testing bull System design
bull Put it all together and confirm claims
bull System integration bull System assessments bull Model validation bull Gap analysis bull Performance projections
Phased Approach
5
Approach
6
Important Dates Duration 55 years
Phase 1 Start Feb 1 2009
Phase 1-2 Transition March 31 2011
Phase 1 End June 30 2011
Phase 2 Start July 1 2011
Phase 3 GoNo-Go Determination March 312013 Phase 2 End June 30 2013 Phase 3 Start July 1 2013 Completion Date June 30 2014 123114
6 Phase 1-2 Transition
Materials Selection
System Selection
Design Subscale
Prototypes
GoNoGo Decision
Building Subscale Prototypes
Approach
7
Phase 1-2 Transition
Overviewed Integrated System Model and its Role in Target Achievement
Prepared Summaries of Status for Metal Hydride Chemical Hydride and Adsorbent Systems
Current status vs targets
Identification of critical technical barriers
Identification of potential solutions to barriers
Summary of projected system performance vs targets
7
8
Outcomes of Phase 1-2 Transition Continued Work
Adsorbent-Based Hydrogen Storage Systems Increasing compaction of the sorbent materials
Demonstration of improved thermal conduction within the sorbent
Thermal isolation of the inner storage bed
Flow through cooling designs must be accompanied with total cooling requirements
Liquid-Phase Chemical Hydrogen Storage Materials (including liquids solutions andor slurries)
Development and validation of the critical components for baseline ammonia borane solutions
Thermal management within the reaction chamber
Gas-liquid phase separations and the
Hydrogen purification train be emphasized for the baseline ammonia borane solutions
Endothermic release material (eg AlH3 alane) must be modeled
8
9
Outcomes of Phase 1-2 Transition
Discontinued Work Solid-Phase Chemical Hydrogen Storage Materials
Material transport becomes a major challenge for this class of material
A reliable process for loadingunloading solids from the onboard storage vessel nor transporting it through an onboard reactor have been identified
Work on Reversible Metal Hydrides Analyses for highly optimized vessel configurations that could adequately
manage thermal and mass flow rates needed for reversible onboard hydrogen storage to meet the DOE performance targets imposed requirements substantially exceeding the properties and behavior of any single currently existing candidate hydride
The necessary combination of gravimetric and volumetric capacities reaction kinetics thermodynamics properties and reversibility have not been found simultaneously in any hydride investigated to date
Novel engineering solutions that will allow any currently known hydride when incorporated into a complete system have not been identified
9
10
HSECoE Phase 3 GoNoGo Milestones
10
Approach
11
Phase 2 Gantt Chart Approach
P12 Metal Hydride System Projection 2017 Targets
1 Gravimetric Density 2 System Cost 3 Onboard Efficiency 4 Volumetric Density 5 Fill Time 6 Fuel Cost
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
12
Buffer Tank P 5-150 bar V 10 L T ambient Q 0-16 gs
Fuel Cell
Storage Tank P 5-150 bar V 176 Ltank T 25-200degC Q 0-16 gs
Fuel Cell Delivery P 5 bar T lt 80degC Q 16 gs Max
H2 Combustor P 5 bar T lt 80degC Q 0-16 gs 12 kW
H2 Delivery Loop
Heat Transfer Fluid Loop
Fuel Cell Coolant Loop
Fuel CellCombustor Air Loop Heat Transfer Fluid Tank
Dual Vessel Sodium Alanate Design (w 4 molTiCl3 amp 5 wt ENG)
GM1 Design fin and tube heat exchanger optimized to meet 105 min refueling time at the expense of wt
2 Type 3 composite tanks with SS liners
System includes a 10 l buffer tank and a 12 kW H2 combustor
Accomplishment
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
3 3
Why Perform Materials Development and System Engineering in Parallel
Materials rarr Thermal rarr H2 Storage rarr Fuel Cell rarr Vehicle rarr Wheels Management BoP
Engineered Heat Transfer BoP What is Needed Materials Designs Component of the Hydrogen Storage Properties Requirements Media amp System
continuous feedback with system design indicating materials requirements
Approach
4 4
HSECoE Objectives Develop materials based hydrogen storage systems for On-Board Hydrogen Storage for Light Duty Vehicles
Develop system models that lend insight into overall fuel cycle efficiency
Compile all relevant materials data for candidate storage media and define future data requirements
Using systems engineering concepts design innovative system architectures for metal hydride chemical and sorption materials-based storage technologies with the potential to meet DOE performance and cost targets
Design components and experimental test fixtures to evaluate the innovative storage devices and subsystem design concepts validate model predictions and improve both component design and predictive capability
Design fabricate test and decommission subscale prototype systems of selected materials-based technologies
Approach
Phase I System
Requirements amp Novel
Concepts
Phase II Novel Concept
Modeling Design amp Evaluation
Phase III Sub-Scale Prototype
Construction Test and
Evaluation
bull Where are we and where can we get to
bull Model development
bull Benchmarking bull Gap Identification bull Projecting
advances
bull How do we get there (closing the gaps) and how much further can we go
bull Component development bull Concept validation bull Integration testing bull System design
bull Put it all together and confirm claims
bull System integration bull System assessments bull Model validation bull Gap analysis bull Performance projections
Phased Approach
5
Approach
6
Important Dates Duration 55 years
Phase 1 Start Feb 1 2009
Phase 1-2 Transition March 31 2011
Phase 1 End June 30 2011
Phase 2 Start July 1 2011
Phase 3 GoNo-Go Determination March 312013 Phase 2 End June 30 2013 Phase 3 Start July 1 2013 Completion Date June 30 2014 123114
6 Phase 1-2 Transition
Materials Selection
System Selection
Design Subscale
Prototypes
GoNoGo Decision
Building Subscale Prototypes
Approach
7
Phase 1-2 Transition
Overviewed Integrated System Model and its Role in Target Achievement
Prepared Summaries of Status for Metal Hydride Chemical Hydride and Adsorbent Systems
Current status vs targets
Identification of critical technical barriers
Identification of potential solutions to barriers
Summary of projected system performance vs targets
7
8
Outcomes of Phase 1-2 Transition Continued Work
Adsorbent-Based Hydrogen Storage Systems Increasing compaction of the sorbent materials
Demonstration of improved thermal conduction within the sorbent
Thermal isolation of the inner storage bed
Flow through cooling designs must be accompanied with total cooling requirements
Liquid-Phase Chemical Hydrogen Storage Materials (including liquids solutions andor slurries)
Development and validation of the critical components for baseline ammonia borane solutions
Thermal management within the reaction chamber
Gas-liquid phase separations and the
Hydrogen purification train be emphasized for the baseline ammonia borane solutions
Endothermic release material (eg AlH3 alane) must be modeled
8
9
Outcomes of Phase 1-2 Transition
Discontinued Work Solid-Phase Chemical Hydrogen Storage Materials
Material transport becomes a major challenge for this class of material
A reliable process for loadingunloading solids from the onboard storage vessel nor transporting it through an onboard reactor have been identified
Work on Reversible Metal Hydrides Analyses for highly optimized vessel configurations that could adequately
manage thermal and mass flow rates needed for reversible onboard hydrogen storage to meet the DOE performance targets imposed requirements substantially exceeding the properties and behavior of any single currently existing candidate hydride
The necessary combination of gravimetric and volumetric capacities reaction kinetics thermodynamics properties and reversibility have not been found simultaneously in any hydride investigated to date
Novel engineering solutions that will allow any currently known hydride when incorporated into a complete system have not been identified
9
10
HSECoE Phase 3 GoNoGo Milestones
10
Approach
11
Phase 2 Gantt Chart Approach
P12 Metal Hydride System Projection 2017 Targets
1 Gravimetric Density 2 System Cost 3 Onboard Efficiency 4 Volumetric Density 5 Fill Time 6 Fuel Cost
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
12
Buffer Tank P 5-150 bar V 10 L T ambient Q 0-16 gs
Fuel Cell
Storage Tank P 5-150 bar V 176 Ltank T 25-200degC Q 0-16 gs
Fuel Cell Delivery P 5 bar T lt 80degC Q 16 gs Max
H2 Combustor P 5 bar T lt 80degC Q 0-16 gs 12 kW
H2 Delivery Loop
Heat Transfer Fluid Loop
Fuel Cell Coolant Loop
Fuel CellCombustor Air Loop Heat Transfer Fluid Tank
Dual Vessel Sodium Alanate Design (w 4 molTiCl3 amp 5 wt ENG)
GM1 Design fin and tube heat exchanger optimized to meet 105 min refueling time at the expense of wt
2 Type 3 composite tanks with SS liners
System includes a 10 l buffer tank and a 12 kW H2 combustor
Accomplishment
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
4 4
HSECoE Objectives Develop materials based hydrogen storage systems for On-Board Hydrogen Storage for Light Duty Vehicles
Develop system models that lend insight into overall fuel cycle efficiency
Compile all relevant materials data for candidate storage media and define future data requirements
Using systems engineering concepts design innovative system architectures for metal hydride chemical and sorption materials-based storage technologies with the potential to meet DOE performance and cost targets
Design components and experimental test fixtures to evaluate the innovative storage devices and subsystem design concepts validate model predictions and improve both component design and predictive capability
Design fabricate test and decommission subscale prototype systems of selected materials-based technologies
Approach
Phase I System
Requirements amp Novel
Concepts
Phase II Novel Concept
Modeling Design amp Evaluation
Phase III Sub-Scale Prototype
Construction Test and
Evaluation
bull Where are we and where can we get to
bull Model development
bull Benchmarking bull Gap Identification bull Projecting
advances
bull How do we get there (closing the gaps) and how much further can we go
bull Component development bull Concept validation bull Integration testing bull System design
bull Put it all together and confirm claims
bull System integration bull System assessments bull Model validation bull Gap analysis bull Performance projections
Phased Approach
5
Approach
6
Important Dates Duration 55 years
Phase 1 Start Feb 1 2009
Phase 1-2 Transition March 31 2011
Phase 1 End June 30 2011
Phase 2 Start July 1 2011
Phase 3 GoNo-Go Determination March 312013 Phase 2 End June 30 2013 Phase 3 Start July 1 2013 Completion Date June 30 2014 123114
6 Phase 1-2 Transition
Materials Selection
System Selection
Design Subscale
Prototypes
GoNoGo Decision
Building Subscale Prototypes
Approach
7
Phase 1-2 Transition
Overviewed Integrated System Model and its Role in Target Achievement
Prepared Summaries of Status for Metal Hydride Chemical Hydride and Adsorbent Systems
Current status vs targets
Identification of critical technical barriers
Identification of potential solutions to barriers
Summary of projected system performance vs targets
7
8
Outcomes of Phase 1-2 Transition Continued Work
Adsorbent-Based Hydrogen Storage Systems Increasing compaction of the sorbent materials
Demonstration of improved thermal conduction within the sorbent
Thermal isolation of the inner storage bed
Flow through cooling designs must be accompanied with total cooling requirements
Liquid-Phase Chemical Hydrogen Storage Materials (including liquids solutions andor slurries)
Development and validation of the critical components for baseline ammonia borane solutions
Thermal management within the reaction chamber
Gas-liquid phase separations and the
Hydrogen purification train be emphasized for the baseline ammonia borane solutions
Endothermic release material (eg AlH3 alane) must be modeled
8
9
Outcomes of Phase 1-2 Transition
Discontinued Work Solid-Phase Chemical Hydrogen Storage Materials
Material transport becomes a major challenge for this class of material
A reliable process for loadingunloading solids from the onboard storage vessel nor transporting it through an onboard reactor have been identified
Work on Reversible Metal Hydrides Analyses for highly optimized vessel configurations that could adequately
manage thermal and mass flow rates needed for reversible onboard hydrogen storage to meet the DOE performance targets imposed requirements substantially exceeding the properties and behavior of any single currently existing candidate hydride
The necessary combination of gravimetric and volumetric capacities reaction kinetics thermodynamics properties and reversibility have not been found simultaneously in any hydride investigated to date
Novel engineering solutions that will allow any currently known hydride when incorporated into a complete system have not been identified
9
10
HSECoE Phase 3 GoNoGo Milestones
10
Approach
11
Phase 2 Gantt Chart Approach
P12 Metal Hydride System Projection 2017 Targets
1 Gravimetric Density 2 System Cost 3 Onboard Efficiency 4 Volumetric Density 5 Fill Time 6 Fuel Cost
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
12
Buffer Tank P 5-150 bar V 10 L T ambient Q 0-16 gs
Fuel Cell
Storage Tank P 5-150 bar V 176 Ltank T 25-200degC Q 0-16 gs
Fuel Cell Delivery P 5 bar T lt 80degC Q 16 gs Max
H2 Combustor P 5 bar T lt 80degC Q 0-16 gs 12 kW
H2 Delivery Loop
Heat Transfer Fluid Loop
Fuel Cell Coolant Loop
Fuel CellCombustor Air Loop Heat Transfer Fluid Tank
Dual Vessel Sodium Alanate Design (w 4 molTiCl3 amp 5 wt ENG)
GM1 Design fin and tube heat exchanger optimized to meet 105 min refueling time at the expense of wt
2 Type 3 composite tanks with SS liners
System includes a 10 l buffer tank and a 12 kW H2 combustor
Accomplishment
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
Phase I System
Requirements amp Novel
Concepts
Phase II Novel Concept
Modeling Design amp Evaluation
Phase III Sub-Scale Prototype
Construction Test and
Evaluation
bull Where are we and where can we get to
bull Model development
bull Benchmarking bull Gap Identification bull Projecting
advances
bull How do we get there (closing the gaps) and how much further can we go
bull Component development bull Concept validation bull Integration testing bull System design
bull Put it all together and confirm claims
bull System integration bull System assessments bull Model validation bull Gap analysis bull Performance projections
Phased Approach
5
Approach
6
Important Dates Duration 55 years
Phase 1 Start Feb 1 2009
Phase 1-2 Transition March 31 2011
Phase 1 End June 30 2011
Phase 2 Start July 1 2011
Phase 3 GoNo-Go Determination March 312013 Phase 2 End June 30 2013 Phase 3 Start July 1 2013 Completion Date June 30 2014 123114
6 Phase 1-2 Transition
Materials Selection
System Selection
Design Subscale
Prototypes
GoNoGo Decision
Building Subscale Prototypes
Approach
7
Phase 1-2 Transition
Overviewed Integrated System Model and its Role in Target Achievement
Prepared Summaries of Status for Metal Hydride Chemical Hydride and Adsorbent Systems
Current status vs targets
Identification of critical technical barriers
Identification of potential solutions to barriers
Summary of projected system performance vs targets
7
8
Outcomes of Phase 1-2 Transition Continued Work
Adsorbent-Based Hydrogen Storage Systems Increasing compaction of the sorbent materials
Demonstration of improved thermal conduction within the sorbent
Thermal isolation of the inner storage bed
Flow through cooling designs must be accompanied with total cooling requirements
Liquid-Phase Chemical Hydrogen Storage Materials (including liquids solutions andor slurries)
Development and validation of the critical components for baseline ammonia borane solutions
Thermal management within the reaction chamber
Gas-liquid phase separations and the
Hydrogen purification train be emphasized for the baseline ammonia borane solutions
Endothermic release material (eg AlH3 alane) must be modeled
8
9
Outcomes of Phase 1-2 Transition
Discontinued Work Solid-Phase Chemical Hydrogen Storage Materials
Material transport becomes a major challenge for this class of material
A reliable process for loadingunloading solids from the onboard storage vessel nor transporting it through an onboard reactor have been identified
Work on Reversible Metal Hydrides Analyses for highly optimized vessel configurations that could adequately
manage thermal and mass flow rates needed for reversible onboard hydrogen storage to meet the DOE performance targets imposed requirements substantially exceeding the properties and behavior of any single currently existing candidate hydride
The necessary combination of gravimetric and volumetric capacities reaction kinetics thermodynamics properties and reversibility have not been found simultaneously in any hydride investigated to date
Novel engineering solutions that will allow any currently known hydride when incorporated into a complete system have not been identified
9
10
HSECoE Phase 3 GoNoGo Milestones
10
Approach
11
Phase 2 Gantt Chart Approach
P12 Metal Hydride System Projection 2017 Targets
1 Gravimetric Density 2 System Cost 3 Onboard Efficiency 4 Volumetric Density 5 Fill Time 6 Fuel Cost
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
12
Buffer Tank P 5-150 bar V 10 L T ambient Q 0-16 gs
Fuel Cell
Storage Tank P 5-150 bar V 176 Ltank T 25-200degC Q 0-16 gs
Fuel Cell Delivery P 5 bar T lt 80degC Q 16 gs Max
H2 Combustor P 5 bar T lt 80degC Q 0-16 gs 12 kW
H2 Delivery Loop
Heat Transfer Fluid Loop
Fuel Cell Coolant Loop
Fuel CellCombustor Air Loop Heat Transfer Fluid Tank
Dual Vessel Sodium Alanate Design (w 4 molTiCl3 amp 5 wt ENG)
GM1 Design fin and tube heat exchanger optimized to meet 105 min refueling time at the expense of wt
2 Type 3 composite tanks with SS liners
System includes a 10 l buffer tank and a 12 kW H2 combustor
Accomplishment
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
6
Important Dates Duration 55 years
Phase 1 Start Feb 1 2009
Phase 1-2 Transition March 31 2011
Phase 1 End June 30 2011
Phase 2 Start July 1 2011
Phase 3 GoNo-Go Determination March 312013 Phase 2 End June 30 2013 Phase 3 Start July 1 2013 Completion Date June 30 2014 123114
6 Phase 1-2 Transition
Materials Selection
System Selection
Design Subscale
Prototypes
GoNoGo Decision
Building Subscale Prototypes
Approach
7
Phase 1-2 Transition
Overviewed Integrated System Model and its Role in Target Achievement
Prepared Summaries of Status for Metal Hydride Chemical Hydride and Adsorbent Systems
Current status vs targets
Identification of critical technical barriers
Identification of potential solutions to barriers
Summary of projected system performance vs targets
7
8
Outcomes of Phase 1-2 Transition Continued Work
Adsorbent-Based Hydrogen Storage Systems Increasing compaction of the sorbent materials
Demonstration of improved thermal conduction within the sorbent
Thermal isolation of the inner storage bed
Flow through cooling designs must be accompanied with total cooling requirements
Liquid-Phase Chemical Hydrogen Storage Materials (including liquids solutions andor slurries)
Development and validation of the critical components for baseline ammonia borane solutions
Thermal management within the reaction chamber
Gas-liquid phase separations and the
Hydrogen purification train be emphasized for the baseline ammonia borane solutions
Endothermic release material (eg AlH3 alane) must be modeled
8
9
Outcomes of Phase 1-2 Transition
Discontinued Work Solid-Phase Chemical Hydrogen Storage Materials
Material transport becomes a major challenge for this class of material
A reliable process for loadingunloading solids from the onboard storage vessel nor transporting it through an onboard reactor have been identified
Work on Reversible Metal Hydrides Analyses for highly optimized vessel configurations that could adequately
manage thermal and mass flow rates needed for reversible onboard hydrogen storage to meet the DOE performance targets imposed requirements substantially exceeding the properties and behavior of any single currently existing candidate hydride
The necessary combination of gravimetric and volumetric capacities reaction kinetics thermodynamics properties and reversibility have not been found simultaneously in any hydride investigated to date
Novel engineering solutions that will allow any currently known hydride when incorporated into a complete system have not been identified
9
10
HSECoE Phase 3 GoNoGo Milestones
10
Approach
11
Phase 2 Gantt Chart Approach
P12 Metal Hydride System Projection 2017 Targets
1 Gravimetric Density 2 System Cost 3 Onboard Efficiency 4 Volumetric Density 5 Fill Time 6 Fuel Cost
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
12
Buffer Tank P 5-150 bar V 10 L T ambient Q 0-16 gs
Fuel Cell
Storage Tank P 5-150 bar V 176 Ltank T 25-200degC Q 0-16 gs
Fuel Cell Delivery P 5 bar T lt 80degC Q 16 gs Max
H2 Combustor P 5 bar T lt 80degC Q 0-16 gs 12 kW
H2 Delivery Loop
Heat Transfer Fluid Loop
Fuel Cell Coolant Loop
Fuel CellCombustor Air Loop Heat Transfer Fluid Tank
Dual Vessel Sodium Alanate Design (w 4 molTiCl3 amp 5 wt ENG)
GM1 Design fin and tube heat exchanger optimized to meet 105 min refueling time at the expense of wt
2 Type 3 composite tanks with SS liners
System includes a 10 l buffer tank and a 12 kW H2 combustor
Accomplishment
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
7
Phase 1-2 Transition
Overviewed Integrated System Model and its Role in Target Achievement
Prepared Summaries of Status for Metal Hydride Chemical Hydride and Adsorbent Systems
Current status vs targets
Identification of critical technical barriers
Identification of potential solutions to barriers
Summary of projected system performance vs targets
7
8
Outcomes of Phase 1-2 Transition Continued Work
Adsorbent-Based Hydrogen Storage Systems Increasing compaction of the sorbent materials
Demonstration of improved thermal conduction within the sorbent
Thermal isolation of the inner storage bed
Flow through cooling designs must be accompanied with total cooling requirements
Liquid-Phase Chemical Hydrogen Storage Materials (including liquids solutions andor slurries)
Development and validation of the critical components for baseline ammonia borane solutions
Thermal management within the reaction chamber
Gas-liquid phase separations and the
Hydrogen purification train be emphasized for the baseline ammonia borane solutions
Endothermic release material (eg AlH3 alane) must be modeled
8
9
Outcomes of Phase 1-2 Transition
Discontinued Work Solid-Phase Chemical Hydrogen Storage Materials
Material transport becomes a major challenge for this class of material
A reliable process for loadingunloading solids from the onboard storage vessel nor transporting it through an onboard reactor have been identified
Work on Reversible Metal Hydrides Analyses for highly optimized vessel configurations that could adequately
manage thermal and mass flow rates needed for reversible onboard hydrogen storage to meet the DOE performance targets imposed requirements substantially exceeding the properties and behavior of any single currently existing candidate hydride
The necessary combination of gravimetric and volumetric capacities reaction kinetics thermodynamics properties and reversibility have not been found simultaneously in any hydride investigated to date
Novel engineering solutions that will allow any currently known hydride when incorporated into a complete system have not been identified
9
10
HSECoE Phase 3 GoNoGo Milestones
10
Approach
11
Phase 2 Gantt Chart Approach
P12 Metal Hydride System Projection 2017 Targets
1 Gravimetric Density 2 System Cost 3 Onboard Efficiency 4 Volumetric Density 5 Fill Time 6 Fuel Cost
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
12
Buffer Tank P 5-150 bar V 10 L T ambient Q 0-16 gs
Fuel Cell
Storage Tank P 5-150 bar V 176 Ltank T 25-200degC Q 0-16 gs
Fuel Cell Delivery P 5 bar T lt 80degC Q 16 gs Max
H2 Combustor P 5 bar T lt 80degC Q 0-16 gs 12 kW
H2 Delivery Loop
Heat Transfer Fluid Loop
Fuel Cell Coolant Loop
Fuel CellCombustor Air Loop Heat Transfer Fluid Tank
Dual Vessel Sodium Alanate Design (w 4 molTiCl3 amp 5 wt ENG)
GM1 Design fin and tube heat exchanger optimized to meet 105 min refueling time at the expense of wt
2 Type 3 composite tanks with SS liners
System includes a 10 l buffer tank and a 12 kW H2 combustor
Accomplishment
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
8
Outcomes of Phase 1-2 Transition Continued Work
Adsorbent-Based Hydrogen Storage Systems Increasing compaction of the sorbent materials
Demonstration of improved thermal conduction within the sorbent
Thermal isolation of the inner storage bed
Flow through cooling designs must be accompanied with total cooling requirements
Liquid-Phase Chemical Hydrogen Storage Materials (including liquids solutions andor slurries)
Development and validation of the critical components for baseline ammonia borane solutions
Thermal management within the reaction chamber
Gas-liquid phase separations and the
Hydrogen purification train be emphasized for the baseline ammonia borane solutions
Endothermic release material (eg AlH3 alane) must be modeled
8
9
Outcomes of Phase 1-2 Transition
Discontinued Work Solid-Phase Chemical Hydrogen Storage Materials
Material transport becomes a major challenge for this class of material
A reliable process for loadingunloading solids from the onboard storage vessel nor transporting it through an onboard reactor have been identified
Work on Reversible Metal Hydrides Analyses for highly optimized vessel configurations that could adequately
manage thermal and mass flow rates needed for reversible onboard hydrogen storage to meet the DOE performance targets imposed requirements substantially exceeding the properties and behavior of any single currently existing candidate hydride
The necessary combination of gravimetric and volumetric capacities reaction kinetics thermodynamics properties and reversibility have not been found simultaneously in any hydride investigated to date
Novel engineering solutions that will allow any currently known hydride when incorporated into a complete system have not been identified
9
10
HSECoE Phase 3 GoNoGo Milestones
10
Approach
11
Phase 2 Gantt Chart Approach
P12 Metal Hydride System Projection 2017 Targets
1 Gravimetric Density 2 System Cost 3 Onboard Efficiency 4 Volumetric Density 5 Fill Time 6 Fuel Cost
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
12
Buffer Tank P 5-150 bar V 10 L T ambient Q 0-16 gs
Fuel Cell
Storage Tank P 5-150 bar V 176 Ltank T 25-200degC Q 0-16 gs
Fuel Cell Delivery P 5 bar T lt 80degC Q 16 gs Max
H2 Combustor P 5 bar T lt 80degC Q 0-16 gs 12 kW
H2 Delivery Loop
Heat Transfer Fluid Loop
Fuel Cell Coolant Loop
Fuel CellCombustor Air Loop Heat Transfer Fluid Tank
Dual Vessel Sodium Alanate Design (w 4 molTiCl3 amp 5 wt ENG)
GM1 Design fin and tube heat exchanger optimized to meet 105 min refueling time at the expense of wt
2 Type 3 composite tanks with SS liners
System includes a 10 l buffer tank and a 12 kW H2 combustor
Accomplishment
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
9
Outcomes of Phase 1-2 Transition
Discontinued Work Solid-Phase Chemical Hydrogen Storage Materials
Material transport becomes a major challenge for this class of material
A reliable process for loadingunloading solids from the onboard storage vessel nor transporting it through an onboard reactor have been identified
Work on Reversible Metal Hydrides Analyses for highly optimized vessel configurations that could adequately
manage thermal and mass flow rates needed for reversible onboard hydrogen storage to meet the DOE performance targets imposed requirements substantially exceeding the properties and behavior of any single currently existing candidate hydride
The necessary combination of gravimetric and volumetric capacities reaction kinetics thermodynamics properties and reversibility have not been found simultaneously in any hydride investigated to date
Novel engineering solutions that will allow any currently known hydride when incorporated into a complete system have not been identified
9
10
HSECoE Phase 3 GoNoGo Milestones
10
Approach
11
Phase 2 Gantt Chart Approach
P12 Metal Hydride System Projection 2017 Targets
1 Gravimetric Density 2 System Cost 3 Onboard Efficiency 4 Volumetric Density 5 Fill Time 6 Fuel Cost
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
12
Buffer Tank P 5-150 bar V 10 L T ambient Q 0-16 gs
Fuel Cell
Storage Tank P 5-150 bar V 176 Ltank T 25-200degC Q 0-16 gs
Fuel Cell Delivery P 5 bar T lt 80degC Q 16 gs Max
H2 Combustor P 5 bar T lt 80degC Q 0-16 gs 12 kW
H2 Delivery Loop
Heat Transfer Fluid Loop
Fuel Cell Coolant Loop
Fuel CellCombustor Air Loop Heat Transfer Fluid Tank
Dual Vessel Sodium Alanate Design (w 4 molTiCl3 amp 5 wt ENG)
GM1 Design fin and tube heat exchanger optimized to meet 105 min refueling time at the expense of wt
2 Type 3 composite tanks with SS liners
System includes a 10 l buffer tank and a 12 kW H2 combustor
Accomplishment
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
10
HSECoE Phase 3 GoNoGo Milestones
10
Approach
11
Phase 2 Gantt Chart Approach
P12 Metal Hydride System Projection 2017 Targets
1 Gravimetric Density 2 System Cost 3 Onboard Efficiency 4 Volumetric Density 5 Fill Time 6 Fuel Cost
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
12
Buffer Tank P 5-150 bar V 10 L T ambient Q 0-16 gs
Fuel Cell
Storage Tank P 5-150 bar V 176 Ltank T 25-200degC Q 0-16 gs
Fuel Cell Delivery P 5 bar T lt 80degC Q 16 gs Max
H2 Combustor P 5 bar T lt 80degC Q 0-16 gs 12 kW
H2 Delivery Loop
Heat Transfer Fluid Loop
Fuel Cell Coolant Loop
Fuel CellCombustor Air Loop Heat Transfer Fluid Tank
Dual Vessel Sodium Alanate Design (w 4 molTiCl3 amp 5 wt ENG)
GM1 Design fin and tube heat exchanger optimized to meet 105 min refueling time at the expense of wt
2 Type 3 composite tanks with SS liners
System includes a 10 l buffer tank and a 12 kW H2 combustor
Accomplishment
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
11
Phase 2 Gantt Chart Approach
P12 Metal Hydride System Projection 2017 Targets
1 Gravimetric Density 2 System Cost 3 Onboard Efficiency 4 Volumetric Density 5 Fill Time 6 Fuel Cost
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
12
Buffer Tank P 5-150 bar V 10 L T ambient Q 0-16 gs
Fuel Cell
Storage Tank P 5-150 bar V 176 Ltank T 25-200degC Q 0-16 gs
Fuel Cell Delivery P 5 bar T lt 80degC Q 16 gs Max
H2 Combustor P 5 bar T lt 80degC Q 0-16 gs 12 kW
H2 Delivery Loop
Heat Transfer Fluid Loop
Fuel Cell Coolant Loop
Fuel CellCombustor Air Loop Heat Transfer Fluid Tank
Dual Vessel Sodium Alanate Design (w 4 molTiCl3 amp 5 wt ENG)
GM1 Design fin and tube heat exchanger optimized to meet 105 min refueling time at the expense of wt
2 Type 3 composite tanks with SS liners
System includes a 10 l buffer tank and a 12 kW H2 combustor
Accomplishment
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
P12 Metal Hydride System Projection 2017 Targets
1 Gravimetric Density 2 System Cost 3 Onboard Efficiency 4 Volumetric Density 5 Fill Time 6 Fuel Cost
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
12
Buffer Tank P 5-150 bar V 10 L T ambient Q 0-16 gs
Fuel Cell
Storage Tank P 5-150 bar V 176 Ltank T 25-200degC Q 0-16 gs
Fuel Cell Delivery P 5 bar T lt 80degC Q 16 gs Max
H2 Combustor P 5 bar T lt 80degC Q 0-16 gs 12 kW
H2 Delivery Loop
Heat Transfer Fluid Loop
Fuel Cell Coolant Loop
Fuel CellCombustor Air Loop Heat Transfer Fluid Tank
Dual Vessel Sodium Alanate Design (w 4 molTiCl3 amp 5 wt ENG)
GM1 Design fin and tube heat exchanger optimized to meet 105 min refueling time at the expense of wt
2 Type 3 composite tanks with SS liners
System includes a 10 l buffer tank and a 12 kW H2 combustor
Accomplishment
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
13
MH Barriers and Approaches
13
Gravimetric amp Volumetric Density New materials discovery Improved Tank Design Low mass BoP Components Improved Internal HX
Media Thermal Conductivity Internal HX Design
System mass 4575 kg
Improved Internal HX Concept discharged as-milled
NaAlH4 systems
Compacted Media
Accomplishment
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
14
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
15
MH Barriers and Approach
15
On Board Efficiency Improved Catalytic Combustor
Microchannel Catalytic Combustor gt96Efficency
Exploded View of Combustor
Assembled Experimental Facility
Wet Deposited Pt Catalyst
V Narayanan D Haley M Ghazvini amp K Drost
Accomplishment
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
Metal Hydride System 1 Use Waste Heat Only Attributes
Very simple system Fuel cell waste heat stream used No separate buffer tank use H2 in pores
Media Characteristics ∆H = 27 kJmol-H2 (T5 bar = 207 oC)
11 wt material capacity Results
Satisfies all targets On-board efficiency ~100 System 101 kg 124 liters
BOP
fittings regulators 145 14
BOP combustor
loop 0 0
Hydride 6588 65
HX 238 3
Pressure vessel
183 18
Weight distributionusing waste heat
BOP fittings
regulators 48 4
BOP combustor loop 0 0
Hydride 1046 84
HX 17 1
Pressure vessel
134 11
Volume distributionusing waste heat
Accomplishment
16
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
Metal Hydride System 2 Combust Some H2
Attributes Mix of fuel cell coolant and
recycled fluid used for warm-up and to maintain Ttank
No separate buffer tank use H2 in pores
Media Characteristics ∆H = -40 kJmol-H2 (T5 bar =
1228 oC) 17 wt pure material
capacity Results
Satisfies all targets except on-board system efficiency
On-board efficiency ~81 System 103 kg 126 liters Operating at 130oC delivers
54 kg-H2 (delivered + combusted 66 kg-H2)
BOP fittings
regulators 145 15
BOP combustor loop 160
17
Hydride 465 48
Expanded Natural
Graphite 47 5
HX 31 3
Pressure vessel
115 12
Weight distributionwith combustor
BOP fittings
regulator 48 4BOP
combustor loop 141
11
Hydride 613 50
Void space 272 22
Expanded Natural
Graphite 22 2
HX 22 2
Pressure vessel
115 9
Volume distributionwith combustor
Accomplishment
17
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
Gravimetric Capacity vs Enthalpy Accomplishment
18
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
MH System Conclusions
bull A material will need reasonably fast charging kinetics (3-8X better than SAH) at moderate pressures (lt 100 bar)
bull Any additional hydrogen capacity (1 to 15 wt) gained by using higher pressure hybrid tanks would be negated by the additional weight associated with the additional carbon fiber needed to reinforce the tank walls
bull For many material densities (gt800 kgm3) ndash the volumetric target can be easily met if the gravimetric target is met
bull A minimum material H2 capacity to meet the DOE 2017 Targets is 10 to 11 wo (with no hydrogen combusted ie ΔH lt 27 kJmol-H2)
bull For materials with a higher ΔH (some H2 combustion required ie ΔH gt30 kJmol-H2) a minimum material capacity would need to be 15 to 16 wo 19
Accomplishment
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
20
1 Gravimetric Density 2 On-Board Efficiency
3 Min Op Temperature 4 Fuel Cost 5 System Cost 6 H2 Purity
20
Media Type Fluid Phase Ammonia Borane
Composition 50wt AB in BMIMCl (1-n-butyl-3-methylimidazolium chloride)
Products Similar rheological properties to reactants
Chemical Hydride System Projection 2017 Targets
Accomplishment
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
21
Chemical Hydride Barriers and Approaches Gravimetric Density
Improved SolventSlurry to Achieve Higher Density Loading
Minimum Operating Temperature Identify Viscosity vs Temperature
System Cost Low Cost SolventSlurry
21
Slurry AB Development
20wtAB silicone oil sonicated
10wtAB silicone oil
as-is
30wtAB silicone oil sonicated
40wtAB silicone oil sonicated
TC
Oil bath
Heat stirrer
Water condenser
AB slurry
N2 feeder
H2 outlet
Slurry AB Kinetics Measurement
Slurry AB Viscosity
Measurement
Accomplishment
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
22
Chemical Hydride Barriers and Approaches
22
Hydrogen Purity Improved SolventSlurry Improved Chemical Trapping Good Thermal Control
Impurities Trap Development
Metal Chloride on Porous Supports
Activated Carbon Vermiculite
Accomplishment
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
23
Chemical Hydride Barriers and Approaches
23
On-Board Efficiency Endothermic vs Exothermic Daily Utilization
T Semelsberger K Brooks
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
24 24
Chemical Hydride Component Flow Through Reactor Validation Experiments
Fluid AB Flow Through Reactors amp Test Facility
H2 Purification
Gas-Liquid Separator
Heat Exchanger
Reactor
Accomplishment
GasLiquid Separator Test Facility
Drain
Pump
Mass Flow Controller
Static Mixer GLS
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
25
CH Projections of Progress
25
Step Description
A Phase 1 Baseline 5050 Fluid composition
B Change from steel shell ballast tank to aluminum
C Reduce HX from 76 kW to 38 kW D Reduce H2 Wetted Tubing E Low Mass Borazine Scrubber F Low Mass Ammonia Scrubber
G Increase AB loading from 50 to 65 wt
H Increase AB loading from 65 to 80 wt
Accomplishment
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
26 26
Adsorbent System Projection 2017 Targets
1 Gravimetric Density 2 Volumetric Density 3 System Cost 4 Loss of Usable H2 5 On-Board Efficiency
Accomplishment
2000 bar AX-21 no thermal enhancement 80 K initial fill
Type 3 CFAl lined pressure vessel 6 mm liner 200 bar
Double-wall 60-layer MLVI jacket design 5W heat leak 80 K
Porous-bed ldquoflow-throughrdquo coolingfueling design for adsorption
Desorption heat via tank-integral electrical resistance elementsHX
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
27
Adsorbent Barriers and Approaches
27
Accomplishment
Gravimetric Density Media Media Compaction Type 3 amp 4 Tank Development Advanced HX Design
Modular Tank Insert Flow
MOF-5 Activated Carbon
Type IV Cryogenic Pressure Vessel Manufacturing
Cryogenic Materials Testing
Cryogenic Tank Burst Facility
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
28
Adsorbent Barriers and Approaches
28
Compacted Media Incorporating ENG
Flow Through Cooling
Accomplishment
Volumetric Density Media Compaction Advanced HX Design
Modular Tank Insert Flow Through Cooling Hexagonal Pellet Array
Modular Tank Insert Cryogenic Adsorbent Component Test System
Pellet Thermal Modeling
Stacked Pellet Array
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
29
Adsorbent Materials Characterization
29
MOF-5 Thermal Conductivity Measurements MOF-5 Excess Adsorption Measurements
MOF-5 Cryogenic Permeability Measurements
25oC
Accomplishment
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
30
Adsorbent Barriers and Approaches
30
Loss of Usable H2 Reducing Parasitic Load
Improved thermal isolation Utilizing Vented Hydrogen
KevlarTM-suspended tank Vacuum shell
Heat Leak Evaluations
MLVI Development
Cryogenic Vacuum Outgassing
Accomplishment
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
31
Adsorbent Barriers and Approaches
31
On-Board Efficiency Low Pressure Design
Flow-through cooling for refueling Resistance heater for desorption 40K lt Toperating lt 120K
Aluminum Type I Tank Composite Type III Tank
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
32
Adsorbent Barriers and Approaches
32
System Cost Low Pressure Type I Tank Low cost BoP component identification
MOF-5 Cost Analysis Oct 2011
=
Accomplishment
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
33
Adsorbent System Projection of Progress
33
Step Description
A Phase 1 Baseline ndash Activated Carbon in a Composite Tank Flow-Through Cooling with a Resistance Heater Full Conditions of 80 K 200 bar
B Change Material to Powdered MOF-5
C Change Full Tank Conditions to 40 K 60 bar
D Change Tank to Type I Aluminum (lower cost)
E Change to Compacted MOF-5 (032 gcc)
F Increase Compacted MOF-5 thermal conductivity by an order of magnitude
G Change from Flow-Through Cooling with a Resistance Heater to the MATI
H Reduce mass and volume of BOP components by 25
I Improve material capacity by 10
J Improve material capacity by 20
Compromises in Gravimetric Density need to be made to make advancements
in Volumetric Density and Cost
Accomplishment
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
34
HSECoEHSECoE System Comparison ($System)System Comparison ($System)
-
1000
2000
3000
4000
5000
6000
7000
8000
AB MH MOF-5
Assembly
Balance of Plant
Valves
Hydrogen Cleanup
Media
Tanks
SA
500k Units
$2871
$7982
$4193
$23kWh $43kWh $15kWh
Initial System Cost Projections
MOF System Cost ComparisonMOF System Cost Comparison
TIAX higher cost
HSECoEhigher cost
1
1
2
3
3
4
55
5
Comments Observations1 Further analysis is required to evaluate pressure vessel cost (fiber and liner)2 MOF media difference is expected (MOF-177 with Tiax vs MOF-5 with HSECoE3 The insulation criteria for the fill tube and MLVI needs confirmation4 Heat exchanger details needs to be expanded into individual items5 The main difference is related to the number of parts assumed in the system
bull Developing bill-of-materials for various storage systems bull Assessed industry available parts with appropriate capabilities for system conditions bull Reviewed quotes from distributors and manufactures for different quantity levels bull Evaluated progress ratio models based on production level and volume bull Compared costs with direct material models and other benchmarks
34
Accomplishment
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
35
FMEA (Failure Modes and Effects Analysis) FMEA Completed for both Adsorbent and
Chemical Hydride Systems
Considered for deployed system Severity
Probability of Occurrence
Probability of Detection
Risk Priority Number
35
Accomplishment
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
36
FMEA Results
36
High RPN values due to insufficient controls
Potential Cause
Failure Mode (RPN) Actions
Material release rate insufficient due to inhomogeneous materials at end of life
Hydrogen supply unable to achieve full flow rate (720) Storage system only accepts partial fill (630) Storage system on-board efficiency lt 90 (560) System only supplies partial capacity (560) Storage system fills in gt 33 minutes (450)
Consider a vibration test Need to evaluate bed packing Use system models to evaluate sensitivity of contact resistance
Type IV tank liner incompatible with adsorbent or in-service activation
System unable to contain hydrogen due to component rupture (700) System exceeds allowable external leak rate limit (700)
Consider in-service process and evaluate the HDPE out-gassing
Material release rate insufficient due to impurities
Hydrogen supply unable to achieve full flow rate (640) Storage system only accepts partial fill (560) Storage system fills in gt 33 minutes (400)
Add a cycle test with spec hydrogen at the limits of J2719
Fuel cell system requires higher delivery pressure
System only supplies partial capacity (560)
Need to confirm with the fuel cell tech team regarding the probability of the min pressure increase
High RPN values due to insufficient material properties
Potential Cause Failure Mode (RPN) Actions
Not able to charge supply fuel due to the plugged plumbing (8)
System unable to supply hydrogen (320) Hydrogen supply unable to achieve full flow rate (320) Storage system only accepts partial fill (280) Storage system does not accept fuel (280)
Need to evaluate low temperature properties of the media Add settlingflocculation test for evaluating clogging
Incomplete phase separation (8)
Hydrogen supply pressure below 5 bar (320) System only supplies partial capacity (280) Storage system on-board efficiency lt 90 (280) System only supplies partial capacity (245)
Assess the separator effectiveness and quantify the hydrogen in spent fuel
Volume displacement from solids build-up in bladder tank (7)
Storage system only accepts partial fill (294) Lab scale test of pressurizing the slurry
Filling receptacle allows air exposure to fuel (7)
System exceeds allowable external leak rate limit (280)
Need to evaluate the system effects to air exposure
Incomplete reaction of the media (7)
Hydrogen supply pressure below 5 bar (320) Storage system on-board efficiency lt 90 (245)
Evaluate if material build-up within the reactor can still provide heat transfer
BOP components fail to close (7)
System exceeds allowable internal leak rate limit (280)
Include BOP components in bench tests and evaluate cycles
Adsorbent System Chemical Hydride System
Accomplishment
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
37
New Updated WEB Site Launched
wwwHSECoEorg
37
Description of Model
List of Models Available
Outline of Analysis
Model Download
Identification of User
WEB Czar responsible for updating Load models on site for public dissemination
Accomplishment
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
38
Future Work
Chemical Hydride System Improved SlurrySolvent CompositionsProperties Improved Chemical Trap Properties Flow Through Reactor Design and Evaluation GasLiquid Separator Evaluation
Adsorbent System Media CompactionCharacterization Advanced HX System Evaluation Advanced Insulation Evaluation Cryogenic Materials Evaluation
Phase 3 Preparations Construct Phase 3 Test Facilities Design Phase 3 Test Protocols
38
Cryogenic Adsorbent System
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
39
Conclusion bull None of the media considered to
date will allow systems to meet all of the DoE technical targets simultaneously but most can be met
bull Chemical Hydrides and Adsorbent Systems hold the highest near term promise of approaching the DoE 2017 Technical Targets
bull Chemical Hydride transport is facilitated by incorporation into a liquid via slurry or dissolution
39
0
100Gravimetric Density
Min Delivery Temperature
Max Delivery Temperature
Min Delivery Pressure (PEMFC)
Max Delivery Pressure
Minimum Operating Temperature
Maximum Operating Temperature
Minimum Full Flow Rate
System Cost
On Board Efficiency
Volumetric Density
Cycle Life (14 - full)
Fuel Cost
Loss of Useable H2
Wells to Power Plan Efficency
Fuel Purity
Transient Response
Start Time to Full Flow (-20oC)
Fill Time (5Kg H2)
Start Time to Full Flow (20oC)
Metal Hydride System
Chemical Hydride System
Adsorbent System
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
40 40
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
Technical Back-Up Slides
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
42 42
Materials Properties
120C60bar15hrs Abs70C1bar Desorption 100C1bar Desorption 110C1bar Desorption 120C1bar Desorption 80C1bar Desorption
t h t h wt t h t h wt t h t h wt t h t h wt t h t h wt1728076 00000 -11485 1778116 00000 -26114 1592968 00000 -24216 1584628 00000 -23089 1664692 00000 -105791729744 00167 -11022 1779784 00167 -25425 1594636 00167 -23095 1586296 00167 -21174 166636 00167 -100121731412 00334 -10592 1781452 00334 -24875 1596304 00334 -22010 1587964 00334 -19457 1668028 00334 -10004173308 00500 -10580 178312 00500 -24404 1597972 00500 -21145 1589632 00500 -18102 1669696 00500 -09551
1734748 00667 -10409 1784788 00667 -23994 159964 00667 -20181 15913 00667 -16388 1671364 00667 -095001736416 00834 -10438 1786456 00834 -23523 1601308 00834 -19218 1592968 00834 -14835 1673032 00834 -093891738084 01001 -10306 1788124 01001 -23093 1602976 01001 -18296 1594636 01001 -13325 16747 01001 -090981739752 01168 -10117 1789792 01168 -22926 1604644 01168 -17475 1596304 01168 -11777 1676368 01168 -09048174142 01334 -10286 179146 01334 -22319 1606312 01334 -16595 1597972 01334 -10350 1678036 01334 -09000
1743088 01501 -10139 1793128 01501 -21993 160798 01501 -15796 159964 01501 -08886 1679704 01501 -090721744756 01668 -10050 1794796 01668 -21489 1609648 01668 -14939 1601308 01668 -07562 1681372 01668 -088441746424 01835 -10123 1796464 01835 -21144 1611316 01835 -13983 1602976 01835 -06140 168304 01835 -087581748092 02002 -10076 1798132 02002 -20521 1612984 02002 -13028 1604644 02002 -04979 1684708 02002 -08632174976 02168 -10031 17998 02168 -20059 1614652 02168 -12332 1606312 02168 -03939 1686376 02168 -08586
1751428 02335 -10065 1801468 02335 -19735 161632 02335 -11418 160798 02335 -03059 1688044 02335 -083821753096 02502 -10100 1803136 02502 -19354 1617988 02502 -10544 1609648 02502 -02360 1689712 02502 -084971754764 02669 -09975 1804804 02669 -18973 1619656 02669 -09632 1611316 02669 -01860 169138 02669 -084121756432 02836 -09769 1806472 02836 -18353 1621324 02836 -08898 1612984 02836 -01681 1693048 02836 -08108
17581 03002 -09965 180814 03002 -17892 1622992 03002 -08283 1614652 03002 -01322 1694716 03002 -082251759768 03169 -09662 1809808 03169 -17472 162466 03169 -07530 161632 03169 -01363 1696384 03169 -080621761436 03336 -09797 1811476 03336 -17272 1626328 03336 -06837 1617988 03336 -01363 1698052 03336 -078991763104 03503 -09715 1813144 03503 -16773 1627996 03503 -06084 1619656 03503 -01324 169972 03503 -078561764772 03670 -09751 1814812 03670 -16433 1629664 03670 -05609 1621324 03670 -01145 1701388 03670 -07752176644 03836 -09569 181648 03836 -15775 1631332 03836 -05055 1622992 03836 -01065 1703056 03836 -07710
1768108 04003 -09705 1818148 04003 -15317 1633 04003 -04699 162466 04003 -00986 1704724 04003 -077491769776 04170 -09523 1819816 04170 -14978 1634668 04170 -04244 1626328 04170 -01106 1706392 04170 -076261771444 04337 -09600 1821484 04337 -14659 1636336 04337 -03750 1627996 04337 -01026 170806 04337 -073841773112 04504 -09438 1823152 04504 -14161 1638004 04504 -03453 1629664 04504 -00947 1709728 04504 -07422177478 04670 -09476 182482 04670 -13703 1639672 04670 -03216 1631332 04670 -01067 1711396 04670 -07300
1776448 04837 -09553 1826488 04837 -13166 164134 04837 -02920 1633 04837 -01207 1714009 04932 -071601778116 05004 -09689 1828156 05004 -12906 1643008 05004 -02802 1634668 05004 -00988 1714732 05004 -071981779784 05171 -09429 1829824 05171 -12410 1644676 05171 -02604 1636336 05171 -01028 17164 05171 -070371781452 05338 -09348 1831492 05338 -12012 1646344 05338 -02467 1638004 05338 -01029 1718068 05338 -07035178312 05504 -09305 183316 05504 -11674 1648012 05504 -02467 1639672 05504 -00989 1719736 05504 -06914
1784788 05671 -09542 1834828 05671 -11216 164968 05671 -02349 164134 05671 -00909 1721404 05671 -067941786456 05838 -09460 1836496 05838 -10839 1651348 05838 -02270 1643008 05838 -01209 1723072 05838 -066531788124 06005 -09260 1838164 06005 -10560 1653016 06005 -02152 1644676 06005 -01029 172474 06005 -067311789792 06172 -09259 1839832 06172 -10143 1654684 06172 -02192 1646344 06172 -01069 1726408 06172 -06690179146 06338 -09256 18415 06338 -09726 1656352 06338 -02192 1648012 06338 -00910 1728076 06338 -06529
1793128 06505 -09374 1843168 06505 -09567 165802 06505 -02192 164968 06505 -01070 1729744 06505 -065691794796 06672 -09372 1844836 06672 -09150 1659688 06672 -02153 1651348 06672 -01030 1731412 06672 -06369
agex VPP
TRTnn ρβα
minus
+
minus= 022
max lnexpAdsorbents
( )χCP
PPRTEA
dtdC
e
e
minus
minus=
expMetal Hydrides
( )χCRTEA
dtdC
minus=
expChemical Hydrides
Materials Performance Models
bull Materials Data bull Kinetics in the entire P amp T
space anticipated bull Thermodynamic Properties
bull ∆H cp bull Physical Properties
bull ρc ρp κp
Materials Catalogue Developed And Deployed on SharePointreg
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
43
Storage System Modeling
Adiabatic Wall
Detailed FEM ThermalMass Analysis Lumped Parameter Models
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
44
System Concepts
44
Flow through reactor
Gas
Liq
uid
Sepa
rato
r
Purif
ier
Fuel Cell
Radi
ator
RecyclePump
TransferPump
FeedPump
Fresh Fuel
Spent Fuel
BladderTank
FreshFuel
SpentFuel
H2
SpentFuel
Fluid Chemical Hydride System
Cryo-Adsorbent System
Metal Hydride System
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
45 45 45
BoP Catalogue Developed BoP Catalogue on SharePoint
Pressure Relief Device Metal Hydride System Operating Pressure
Burst Pressure Operating Temperature
Volume Weigh Cost
Specific System Design
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through
46 46
Integrated Model Framework
Vehicle level model
Fuel cell system H2 storage system
SRNL 200 bar AX-21 Flow-Through