26-27.10.2009, Brussels Rastogi / Lienkamp 1
Project Co-financed by the European Commission FCHJU-SGA09
Experience with FC-Vehicles & HydrogenExperience with FC-Vehicles & Hydrogen
Infrastructure in ZERO REGIOInfrastructure in ZERO REGIO
Heinrich Lienkamp, Ashok RastogiInfraserv Höchst - Frankfurt
Germany
www.zeroregio.com
26-27.10.2009, Brussels Rastogi / Lienkamp 2
Project Co-financed by the European Commission FCHJU-SGA09
OutlineOutline• Brief presentation of Aims, activities & highlights in Zero Regio
– Frankfurt, Germany– Mantova, Italy
• Operational experience– Some events – Lessons learnt
• Collection and Assessment of Data– Comparison with the state of the art
• Concluding Remarks; Next steps
26-27.10.2009, Brussels Rastogi / Lienkamp 3
Project Co-financed by the European Commission FCHJU-SGA09
Industrial Park HöchstIndustrial Park Höchst
4.6 km2 area
72 km Streets
80 Companies
Over 22000
Workforce
&
30 mil.Nm3/yr
By-product H2
26-27.10.2009, Brussels Rastogi / Lienkamp 4
Project Co-financed by the European Commission FCHJU-SGA09 Service Station FrankfurtService Station Frankfurt
Area = 4.062 m2
350 & 700 bar GH2
LH2 Dipensers.
Photovoltaic 8 kW
Opened on 17.11.2006
26-27.10.2009, Brussels Rastogi / Lienkamp 5
Project Co-financed by the European Commission FCHJU-SGA09
HH22 - Infrastructure in Germany - Infrastructure in Germany• Hydrogen center in Industry park, Höchst
– Existing infrastructure– By-product H2 is collected, conditioned, compressed (250 bar) – Trailer station
• Ionic fluid compressor (900 bar) in Hydrogen center• Agip station 1.7 km from H2-center• Hydrogen transport to station via HP-pipeline (1000 bar)• CGH2 dispensers, 350 bar and 700 bar one each • LH2 dispenser (Truck supply of LH2)• Agip station opened on Nov. 17, 2006
26-27.10.2009, Brussels Rastogi / Lienkamp 6
Project Co-financed by the European Commission FCHJU-SGA09
H2-Centre
Fillingstation
H2-High-Pressure-pipeline
PN 1000 bar
over ground
under ground
H2-Centre
Fillingstation
H2-High-Pressure-pipeline
PN 1000 bar
over ground
under ground
Lay out HP Pipeline in HöchstLay out HP Pipeline in Höchst
26-27.10.2009, Brussels Rastogi / Lienkamp 7
Project Co-financed by the European Commission FCHJU-SGA09
Some Design DetailsSome Design Details
1.4462 Material
Din = 18 mm
Dout = 33.7 mm
Pmax =1000 bar
Welded construction
Leakproof by definition
HP-H2-Transport system is one of its kind
worldwide
Underground: Tubing with PE sleeve in sandbed
Overground: Hanging pipe system
26-27.10.2009, Brussels Rastogi / Lienkamp 8
Project Co-financed by the European Commission FCHJU-SGA09
Compression SchemeCompression Scheme
Particle- filter Hydrogen-
Refuelling Station
G 265
F
HP Pipeline- System
2.4 m3
Buffer
225 bar H2 storage
300 bar
Cold-Fill(-40°C)
25 m³
900 bar Compressor
Hg -filter(Option)
H2 Disp 350 bar
H2 Disp.700bar
PICF
26-27.10.2009, Brussels Rastogi / Lienkamp 9
Project Co-financed by the European Commission FCHJU-SGA09
Ionic Fluid Compressor – working principleIonic Fluid Compressor – working principle
PLC
26-27.10.2009, Brussels Rastogi / Lienkamp 10
Project Co-financed by the European Commission FCHJU-SGA09
Ionic Fluid Compressor
Special Features:
• Ionic liquid no vapor pr.
• Compressor capacity =900 Nm3/hr or1.335 kg/min
First time in Zero Regio for H2 - 900 bar
26-27.10.2009, Brussels Rastogi / Lienkamp 11
Project Co-financed by the European Commission FCHJU-SGA09 Hydrogen-Dispensers – Höchst
GH2 700 bar GH2 350 bar LH2
26-27.10.2009, Brussels Rastogi / Lienkamp 12
Project Co-financed by the European Commission FCHJU-SGA09 Service Station FrankfurtService Station Frankfurt
26-27.10.2009, Brussels Rastogi / Lienkamp 13
Project Co-financed by the European Commission FCHJU-SGA09
Experience with infrastructure in GermanyExperience with infrastructure in Germany• High availability inspite of some problems:
– Filters in the cooling system of the compressor– Some valves failed on the compressor system– Some loose fittings leading to system failure– Ionic Compressor overhauled in 2nd year of operation
• Outage for 3 months
– Filter problems in the third year, regular maintenance reqd.– Insufficient purging of the pipeline initially– Control valves at dispenser & minor electronic problems– Incident reporting and management approach important
• One accident in the first year, no H2 discharge
26-27.10.2009, Brussels Rastogi / Lienkamp 14
Project Co-financed by the European Commission FCHJU-SGA09 Operational Experience in Germany
26-27.10.2009, Brussels Rastogi / Lienkamp 15
Project Co-financed by the European Commission FCHJU-SGA09
• Damage of 700 bar Dispenser by accident – Cause: Passenger car runs into dispenser
– Effect: major damage of dispenser and the installed techniqueNo accidental escape of hydrogen
– Action: Repair / replacement of dispenser
Operational Experience in Germany
26-27.10.2009, Brussels Rastogi / Lienkamp 16
Project Co-financed by the European Commission FCHJU-SGA09 Servicestation Mantova
26-27.10.2009, Brussels Rastogi / Lienkamp 17
Project Co-financed by the European Commission FCHJU-SGA09
H2 - Infrastructure in Mantova, ItalyH2 - Infrastructure in Mantova, Italy• On-site production facility (CPO – reformer)
– Small unit with 20 Nm3/hr– Construction completed and in operation from July 2008
• Truck transport from an industrial reformer (back-up)• 350 bar GH2 dispenser (Cars homologated for 200 bar)• Delay partly due to approval formalities• A mobile refueller initially (AP 100)• Integration in multi-energy Agip service station
– 17.000 m2, Car Wash, Cafè Shop– Opening ceremony took place on 21 Sept. 2007
26-27.10.2009, Brussels Rastogi / Lienkamp 18
Project Co-financed by the European Commission FCHJU-SGA09 CPO Reformer by EniCPO Reformer by Eni
26-27.10.2009, Brussels Rastogi / Lienkamp 19
Project Co-financed by the European Commission FCHJU-SGA09
On-site Hydrogen Production in MantovaOn-site Hydrogen Production in Mantova
• Suitable for intermittent operation• 3 Compaigns in 2009
– 20 kg. H2 in April 09– 40 kg. H2 in July 09 (40 kg. Storage capacity)– 40 kg. H2 in Oct. 09
• One day for plant start-up and shut down• High quality achieved (CO< 0.1 ppm)• Plant optimised for automatic operation• 20 Nm3/hr. too high for 3 cars• Other applications planned at the service station
26-27.10.2009, Brussels Rastogi / Lienkamp 20
Project Co-financed by the European Commission FCHJU-SGA09
Dedicated Fleets Dedicated Fleets
Range: 160 km (@350 bar)Maximum speed: 140 km/h
Ballard PEM 72 kW
5 cars, one with 700 bar storage
Range: 250 km (@350 bar)Maximum speed: 135 km/h
Acceleration: 0-50 km/h within 7 sNuvera PEM 70 kW
3 cars
26-27.10.2009, Brussels Rastogi / Lienkamp 21
Project Co-financed by the European Commission FCHJU-SGA09
Beauty and the BeastBeauty and the Beast
F-Cell serving A-380 !!
26-27.10.2009, Brussels Rastogi / Lienkamp 22
Project Co-financed by the European Commission FCHJU-SGA09
8775
195
85102
0
50
100
150
200
250
FC No. 29 FC No. 49 FC No. 59 FC No. 60 FC No. 61
[h]
Operational Performance of the vehicles in 2008
F-Cell No. 29 F-Cell No. 49 (700 bar) F-Cell No. 59, 60, 61
2481
5084
2125
5906
2491
0
2000
4000
6000
8000
FC No. 29 FC No. 49 FC No. 59 FC No. 60 FC No. 61
[km]
Mileage
Operating hours
The operational performance 2008 was lower than expected
Some Demonstration DataSome Demonstration Data
26-27.10.2009, Brussels Rastogi / Lienkamp 23
Project Co-financed by the European Commission FCHJU-SGA09
SOME INCIDENTS with FleetSOME INCIDENTS with Fleet
• In general all FCV‘s functioned better than expected
• Regular maintenance was performed– Tank leak tests
– TÜV examinations
– Minor repairs could be done on site
• No road calls
• One accident due to drivers negligence
• One car was taken out of service
in Sept. 2009 due to IPT defect
(Integrated PowerTrain failure)
26-27.10.2009, Brussels Rastogi / Lienkamp 24
Project Co-financed by the European Commission FCHJU-SGA09
Some other Customers Some other Customers
• Frankfurt station is used also by other customers• For 350 bar dispenser
– Honda (FCX Clarity), 2 cars– Mazda (Ice, RX 8 Hydrogen), 1 car– Toyota Prius one visit
• For 700 bar dispenser – Opel/GM Hydrogen 4, 1 car– B-class F-Cell Daimler, extensive testing with a few cars – IR Communication, SAE Release A Standard – 3 min. for 4 kg, aiming at 100% fill rate
26-27.10.2009, Brussels Rastogi / Lienkamp 25
Project Co-financed by the European Commission FCHJU-SGA09
Assessment FrameworkAssessment Framework
INPUT DATA
• Data tables on
-Infrastructure
-Vehicles
• 2 Demo. sites
• OEM‘s and Operators
Simple Data Processing
Compare with Ref. Technology
•Technological aspects:
Performance, Environment, Safety
•Socio-Economy
•Project Organisation
Results
• Indicators on
-Infrastructure
-Vehicles
• 2 Demo. sites
• Indicator value (0 to 1)
26-27.10.2009, Brussels Rastogi / Lienkamp 26
Project Co-financed by the European Commission FCHJU-SGA09 Data Assessment Data Assessment
Comparison of energy consumption
CNG CGH
Energy consumption
for compression0,035kWhel/kWh
(200 mbar 300 bar)
0,124kWhel/kWh
(70 mbar 700 bar)
Energy consumption of vehicle
73,75 kWh/100km (CNG-ICE)
35,66 kWh/100km (FC)
Total energy consumption
76,33 kWh/100km 40,08 kWh/100km
26-27.10.2009, Brussels Rastogi / Lienkamp 27
Project Co-financed by the European Commission FCHJU-SGA09 Comparison F-Cell Vs. Diesel Comparison F-Cell Vs. Diesel
Parameter FCV, A-Class 350 bar
A-Class Diesel 160 cdi
Maximum speed, km /hr 140 162
Maximum range with a full tank, km 170 980
Tank volume capacity, l 78 54
Fuel consumption NEDC, eqiv. Diesel l/ 100 km 3.6 5.5
Acceleration time 0-100 km/hr, sec 14.3 16.8
Maximum Torque Nm 210 160
CO2 Emissions g/km 0 146
26-27.10.2009, Brussels Rastogi / Lienkamp 28
Project Co-financed by the European Commission FCHJU-SGA09
Summary of 2 yearsSummary of 2 years
• 3-7 FCV‘s, 100 vehicle months of operation, over 45000 km driven (should have been more)
• over 510 kg. H2 consumed, 7.2 tons of CO2 emission saved
• Vehicles showed high reliability and availablity (98%)
• Availability 350 bar dispenser 95%
• Availability 700 bar dispenser 55% (accident costed 11 months)
• Ionic compressor 77% (has been overhauled)
• By-product hydrogen should be exploited more initially
• Infrastructure problems experienced are not related to H2
26-27.10.2009, Brussels Rastogi / Lienkamp 29
Project Co-financed by the European Commission FCHJU-SGA09
Some Lessons LearntSome Lessons Learnt
• Serious problems with approval formalities in Italy
• Delay in infrastructure construction
• Fleet is still operated at 200 bar storage
• European Harmonisation, Integrate authorities in project
• Bottle neck for larger demonstrations
• Fleet availability (cost), not so much infrastructure
• Frankfurt station can fill 15 FCV‘s /hour
• By-product Hydrogen should be exploited much more
26-27.10.2009, Brussels Rastogi / Lienkamp 30
Project Co-financed by the European Commission FCHJU-SGA09
Concluding RemarksConcluding Remarks • H2-infrastructure developed and FCV fleet used in Zero Regio Project
have been briefly presented
• Operational experience has been encouraging at both sites
• FCV-Fleet has operated better than expected
• Fuel consumption of FCV is about half of NGV
• Fast refuelling of 700 bar FCV‘s has been realised
• Zero Regio high potentials: HP-Pipeline transport,700 refuelling with IR
communication.
Thank You Thank You
• Final Conference at WHEC 2010, Essen, Germany.Final Conference at WHEC 2010, Essen, Germany.
26-27.10.2009, Brussels Rastogi / Lienkamp 31
Project Co-financed by the European Commission FCHJU-SGA09 Service Station MantovaService Station Mantova
HH22
Area = 17.000 m2
350 bar GH2
Photovoltaic 16 kW
Opened on 21.09.2007
26-27.10.2009, Brussels Rastogi / Lienkamp 32
Project Co-financed by the European Commission FCHJU-SGA09 Hydrogen Dispenser - Mantova
GH2 350 bar
26-27.10.2009, Brussels Rastogi / Lienkamp 33
Project Co-financed by the European Commission FCHJU-SGA09
Onsite H2 Production PlantOnsite H2 Production Plant
26-27.10.2009, Brussels Rastogi / Lienkamp 34
Project Co-financed by the European Commission FCHJU-SGA09
F-Cell A-Class F-Cell A-Class
Vehicle type: Mercedes-Benz A-Class Fuel-Cell system: PEM, 72 kW (97 PS)Electro-Asynchron-MotorMotor rating: 65 kW (87 PS)Max. Torque: 210 NmFuel: Hydrogen (350 bar)Range: 160 kmMax. Velocity: 140 km/h Battery: NiMh, air-cooledPower (av./peak): 15 kW / 20 kW Rating: 6,5 Ah; 1,4 kWh
26-27.10.2009, Brussels Rastogi / Lienkamp 35
Project Co-financed by the European Commission FCHJU-SGA09
SOCIO-ECONOMIC STUDIES SOCIO-ECONOMIC STUDIES
• 1• 2• 3• 4• 5S