“Hydrogen Storage Systems for Automotive Application ... Review Days 2007_Final.pdf ·...

Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October

STORHY“Hydrogen Storage Systems for Automotive Application”

Integrated Project n° 502667

Volker Strubel

Josef Zieger

Sitra Colom

Guido Bartlok

Jiri Muller

Georg Mair

Florent Montignac

Angelika Bertalanic


1. Project ObjectivesStorHy – General Project Information

“Hydrogen Storage Systems for Automotive Application”Integrated Project n° 502667 within the EU FP6

Co-ordinator: MAGNA STEYR Fahrzeugtechnik AG & Co KGTime frame: 2004 – 2008 (4,5 years)Official project start: March 1st, 2004Budget: € 18.7 mEU contribution: € 10.7 mWebsite: www.storhy.net

34 partners from 13 European countries (5 OEMs, 14 research institutes and 15 supplier companies)


Gas:700 bar Technologies

Source: Dynetek

Liquid:LightweightFree-form Tank

Solid:Advanced Alanates

Source: IFE

1. Project ObjectivesStorHy – Overall Structure

Users:Vehicle Requirements

Source: BMWSource: PSA Source: Daimler ChryslerSource: Daimler Chrysler

Safety Aspects and Requirements

Multi-Criteria Evaluation

Source: SP Cryo


1. Project ObjectivesHydrogen Storage: Consumer Expectations

Public Acceptance of Hydrogen Applications –Study by DC

Main conditions for consumer acceptance of FC vehicles*

Driving range

Refuelling process

High safety level

Vehicle costs

Communication / education

*Excerpt only!


Consumer Expectations

TechnicalRequirements

Unit StorHyTargets 2010

Driving range > 400 km – 600 km

Driving performance

Usable space

Refuellingconvenient and safe

Safety

Filling cycles 3*5,000

Vehicle costs Costs of storage system €/ kg H2 Not defined

Hydrogen storage mass kg 6 - 10

System grav. energy density kWh/kgwt.%

2.06

System vol. energy density kWh/lkg H2/100l

1.54.5

Refuelling rate kg H2/min 1.2

Burst pressure 700 bar bar 1,645

Permeation rate H2 Ncm3/h *l EHIP II1

Loss of usable H2 (boil-off) g/h *stored kg H2

1

1. Project ObjectivesStorHy:Hydrogen Storage Requirements


International technology watchIncrease of service pressure from 350 bar – 700 bar

700 bar Type III fully wrapped aluminum liner

700 bar Type IV fully wrapped non-load carrying plastic liner

700 bar system prototypes or small series announced inUSA, Japan and Europe

Source: Dynetek

2. Alignment to SRA/DSCompressed Hydrogen Storage:

State-of-the-Art


Material & microstructure– Modified CrMo steels

Liner material characterization– 5 steels assessed concerning H2

embrittlement700 bar design & calculation– Analytical + FE calculations for

composite thickness + optimized modulus (fibre type) + winding path

Vessel testing– Ambient T cycling < 15,000 cycles– Burst factor: > 2.35– Other EIHP-II tests were performed

successfully

Technical data:• Mass of vessel: 40 kg• Internal volume: 39 l• H2 storage capacity: 3.85 wt.%• Operating pressure: 700 bar• H2 mass stored: 1.6 kg

700 bar Type III vessel with metallic liner made by deep drawing

Source: Faber

Source: FaberSource: AL

2. Alignment to SRA/DSStorHy: 700 bar C-H2 Vessels


Polymeric material & microstructure– Development of specific PA6 formation

(permeation / mechanical elasticity / processability)

Liner material characterization:Permeation of PA polymer liner assessedat 700 bar f (T, p):– Material level: Pe ∼1*10-16mol/(Pa.s.m) – Vessel level: ongoing

700 bar vessel design & calculation– Analytical + FE calculations

for composite thicknessVessel testing– Ambient T cycling > 15,000 cycles– Burst factor: 2.2

Technical data:• Mass of vessel: 29 kg• Internal volume: 37 l• H2 storage capacity: 5.2 wt.%• Operating pressure: 700 bar• H2 mass stored: 1.6kg

Source: CEA

Source: CEA/Ullit

700 bar Type IV vessel with rotomoulded plastic liner

2. Alignment to SRA/DSStorHy: 700 bar C-H2 Vessels


2. Alignment to SRA/DSStorHy: Test Results of C-H2 Vessels

Type III (steel liner)

Type IV (PA liner)

Thermoplastic modular system

Burst test Passed Close to target Feasibility GF/PP

Cycling test Not passed Passed Not tested yet

Status Cycling behaviour to be improved

Burst behaviour to be improved

Feasibility at 300 bar

Typical failure mechanisms for C-H2 vessels identifiedMeasured proposed for further improvements steps:

R&D activities required for a fundamental understanding of aging & failure behaviour composite and liner materials, advanced modelling and simulation concepts


StorHy contribution (excerpt)

Steel liner

Production

Polymer liner

Production:

Rotomolding

Autofrettage

Process

Vessel testing

CF raw materials Impregnation bath

Filament winding Curing

Liner fabrication Composite manufacturing Post processing

Recycling

Polymer liner

Production:

Blowforming

Alu liner

Production

Shreddering

CF Recycling

Dismantling

2. Alignment to SRA/DSC-H2 Storage: Production Steps


Ring winding head with modular siphon impregnation units and suitable advancement of the path generationIncrease of the lay-down rate (> factor 3)Better exploitation of the fibre performance, which entails weight reduction potentials for pressure vesselsClean work station due to an almost closed systemReduction of resin consumption Almost no hazardous waste

Winner of two Innovation Awards!

Source: IVW

2. Alignment to SRA/DSStorHy: C-H2 Vessel Production –

Improved Winding and Impregnation


Development of pre-treatment technology– Hybrid shredder (Kema) selected

Development of recycling processes– Fluidised bed process selected– Good quality fibre (similar stiffness

and 50% strength) has been recycledR&D to increase material recycling rate:

– Microwave pyrolysis process in a fluidised bed

– 86% total material recovery achieved (increase from 63% for fluidised bed)

Recycling of a thermoplastic compositevessel by granulation and injection moulding demonstrated (GF/PP COMAT system)

Cyclone

Air Inlet

Electric Pre-heatersFibre

Scrap CFRP

Recovered FluidisedBed

Air distributorplate

300 mmAfterburner

Clean flue gas To energy recovery

Fan

Fluidised Bed RecyclingTwin screw shredder

Recovered CF fibreSource: UNOTT

2. Alignment to SRA/DSStorHy: C-H2 Composite Vessel

Recycling Concepts


Booster Cooler

High pressure H2

V2

For fast filling, gaseous hydrogen needs to be cooled down to prevent excessive pressure and temperature levelsHydrogen cooler required in the refuelling station!

Source: Linde / Aral

700 bar filling nozzle

Source: Weh

V1

2. Alignment to SRA/DSRefuelling C-H2: State-of-the-Art


Fast filling demonstrated on vessel levelFilling temperature down to -100°C demonstrated100% filling rate easy to reachGentle cylinder treatment compared to warm filling – but thermal stress for storage components, esp. sealingCooling down to -40 °C seems to be good compromiseDeeper cooling still needs to be evaluated with regard to costs and material exposure

700 bar cold (–40°C) filling test in F-Cell vehicleSafe and optimized filling demonstrated Source: ET, AL, Dynetek, DC, Weh

Technical data:• Filling T: -85°C• Filling time: <2min• Filling rate: 103%• Min. material T: -14°C

Technical data:• Filling T: -40°C• Filling time: 3 min.• Filling rate: 101%• Gas T: 65°C

2. Alignment to SRA/DSStorHy: C-H2 Cold Filling


Filling nozzle with/without infrared communication interface

Start of commercialization

Break-away device with infrared communications interface

Linear shut-off valve

Advanced C-H2 700 bar filling devicesdeveloped and tested:

Filling nozzle with infrared communication interfaceLinear shut-off valveBreak-away device

Sources: WEH Source: Weh

2. Alignment to SRA/DSStorHy: C-H2 700 bar Filling Devices


Source: MAGNA STEYR

2. Alignment to SRA/DSCryogenic Liquid Storage System

International technology watchSmall series, automotive, approved L-H2 storage systems with double-walled stainless cylinders

First cylindrical prototypes with lightweight aluminum tank shells

First flat-shaped prototypes with lightweight steel tank shells

Source: Air LiquideSource: Linde


Moisture, air, oil, etc

Outgassing

Outer Jacket Composite

Hydrogen

Outgassing

Inner Tank Composite

High Vacuum: 10-5 – 10-6mBar

Hydrogen

Liner

Aluminium sheet (outer jacket)

Liner

Liner

Structure and coating concepts for linerGalvanic copper coating

(inner tank)

Lightweight cylindrical tankCarbon fibre composite structure of inner tank and outer jacket

Source: SP Cryo

2. Alignment to SRA/DSStorHy: L-H2 Lightweight Design


Concept calculation(e.g. showing deformation at 10.8 bar)

Free-form tank system with auxiliary system boxFree-form design

Source: SP Cryo

Free-form tank demonstrator

Vehicle integrationconcepts

Risk analysis (FMEA and FTA)

2. Alignment to SRA/DSStorHy: L-H2 Free-form Design


Mass comparison of gasoline and L-H2 tank systemsEnergy content equivalent to 10 kg hydrogen

3010 10 10

10 kg

100 kg

40 kg25 kg

65

25

203

0

25

50

75

100

125

150

175

200

Gasoline 38 dm³ LH2 SteelE 68

cylindrical shape

LH2 LightweightStorHy

cylindrical shape

LH2 Lightweight2010

complex shape

Wei

ght [

kg]

Auxiliary System

Tank

Fuel

Source: SP Cryo

2. Alignment to SRA/DSStorHy: L-H2 Weight Reduction Potential


CFRP inner tank manufacturing

Inner tank - coating of liner

Post-processing

CFRP outer jacket manufacturing

StorHy contribution (excerpt SP Cryo)

Tensionsheet

Dome &pipes

Source: SP Cryo

Prepreg (e.g. knitting)

Piping

Pre-processing

Insulation

Component production

Valves, Sensor

Alu liner

Assembly

Evacuation of insulation gap

Testing

Welding

CuringImpregnation

2. Alignment to SRA/DSManufacturing process CFRP tank


International technology watchIntensive international R&D efforts focus on different types of materials and storage systems

But:None of these materials fulfills automotive targets (storage density, operation temperature etc.) yet!

Source: DoE 2007

• Metal and complex hydrides

• Chemical hydrides

• Nanoporousstructures

2. Alignment to SRA/DSSolid Storage


Automotive ChallengesScale-up strategies promising, but reversibility not sufficient!

Scale-up strategies promising, but material storage density of 3 wt. % not sufficient

Storage MaterialMagnesium Alanate

• Mg(AlH4)2: Solvent-free and fast synthesis• Deuterised Mg(AlD4)2 for neutron diffraction• Structure of Mg(AlH4)2: Neutron and

synchrotron X-ray diffraction• Details of thermal and isothermal

decomposition of Mg(AlH4 )2

Sodium Alanate• Purification of NaAlH4 and synthesis of

NaAlD4

Catalyst• Improved synthesis of catalyst: Ti13*6THF

First step: Magnesium and Sodium Alanates

Source: FZKSource: IFE

Source: IFE, FZK

2. Alignment to SRA/DSStorHy: Characterisation of Alanates


Storage MaterialScreening experiments for synthesis and

characterization for new mixed alanates:• Mg-Al-Li-H, Mg-Al-Ca-H, Ca-Al-Li-H, Ca-Al-Na-H• Mg-Al-Li-H, Mg-Al-Ca-H, Mg-Al-Na-H, Mg-Al-K-H• Mg-Al-Li-H, Mg-Al-Ca-H, Ca-Al-K-H

Synthesis and stabilisation of aluminium hydride AlH3 (Alane) – basic research purpose

2. Alignment to SRA/DSStorHy: Screening for new Alanates

Automotive ChallengesNo new reversiblehydrogen storage compound found

No break-through up to now

High material storage density 10.1%, but not reversible!

Simplified method to synthesize AlH3 by milling at liquid nitrogen temperature, compared to wet chemistry

Work in progress to change the stability of AlH3

Second step: Adaptation of work programme

liquid nitrogen

stainless steel

impactorvial

Spex 6750 freezer mill for cryomilling

2000

4000

6000

8000 α'-AlD3 and α-AlD3PND, Kjeller

INT

EN

SIT

Y (a

rb. u

nits

)

2θ(º)

10 20 30 40 50 60 70 80 90 100 110 120 130-800

0

800

Source: IFE, FZK, GKSS


Concept for upscaling of material production processes

Source: GKSS/TUHH

8 kg alanate Pilot tank (currently manufactured)

Length: 120 cm, Diameter: 22 cmCapacity: 0.4 kg H2,

Design and development of operational prototype solid storage tanksLaboratory tank for 0.5 kg of alanate

Length: 40 cm / Diameter: 6 cm Capacity: 20 g H2

0 10 20 30 40 50 600

1

2

3

4

5

simple preparation from NaH/Alwith TiCl4, 125°C100 bar (STORHY)

preparation from NaAlH4

with Ti-nanoclusters, 100°C, 100 bar(Fichtner et al.)

H2-c

once

ntra

tion

[wt.%

]

Time [min.]

preparation from NaAlH4 with TiCl3, 125°C, 79-88 bar(Sandrock et al.)

2nd absorption

Up-scaling to kg amounts demonstrated at GKSS mechanical processing facility

Evaluation of low cost production routes for complex hydrides using catalysed NaAlH4 as model material

2. Alignment to SRA/DSStorHy: Upscaling of Solid Storage Tank


Calculated performance of tanks based on lab-scale data (NaAlH4)

5

89

10

1 432

Oil

1236

Ø 10

Ø 6

625

273

2345678

0

50

100

150

200

250

300

350

400

0 200 400 600 800 1000

t in s

310 g

290 s 540 s458 s

5

89

10

1 432

Oil

1236

Ø 10

Ø 6

625

273

2345678

0

50

100

150

200

250

300

350

400

0 200 400 600 800 1000

t in s

310 g

290 s 540 s458 sHyd

roge

n ab

sorb

ed in

g

Less than 10 min. chargingtime expected even in cost-effective design (pilot tank)

Alpha version 100°C

130°C

Simulation based on kinetic data obtained from optimized StorHy material produced in kg scale

HydrideTank

Fuel cell

HydrogenExternal Heat Consumer

Vehicle

Heattransfer medium

Quick coupling

Internal heatexchanger

Concept for fillingHydride tank is cooled by external heat consumer working at approx. 100°C Coupling of hydrogen and heat transfer medium prior to filling

Concept for drivingFuel cell is cooled to 80°C by hydride tank and internal heat exchanger

Source: NCSRD/GKSS/TUHH

2. Alignment to SRA/DSStorHy: Solid Filling


Bonfire

Assessment of test procedures for C-H2 vessels

Interlaboratory tests at various European test facilitiesValidation of hydrogen sensors

3. Cross-cutting Issues:StorHy: Safety Assessment


Development of test procedures for C-H2 vessels: Impact test

Polarplot Crashenergy [KJ]

0

50

100

150

200

250

3000 °

30°

60°

90 °

120°

150°

180°

-150°

-120°

-90°

-60°

-3 0°

10%

50%

90%

99%

Source: BAM, Cidaut

Estimation of statistical crash energies

Estimation of energy impacting on storage system in crash models

Vessel impact tests

Assessment of theresidual burst strength

3. Cross-cutting Issues:StorHy: Safety Assessment of C-H2 Storage


Alanate powder release experiments

560 ms

Ignition by water droplets

30 ms 60 ms

240 msFlame 240 ms 560 msreproduction2005

Spark ignition

Water mist

Pure hydrogen

opening of burst disc

Source: FZK

1. Disk bursts at p = 10 bar

4. Assessment of sound levels

2. Material is released into various environments3. High speed images

3. Cross-cutting Issues:StorHy: Chemical Safety Experiments

of Solid Storage Materials


Technical performanceTechnical performance

CostsCosts SafetySafety

Social acceptanceSocial acceptanceEnvironmental impactEnvironmental impact

Multi-criteria evaluationFive different evaluation domains addressed Focus on technical and environmental parameters

Source: CEA

3. Cross-cutting Issues:StorHy: Evaluation


0.00

1.00

2.00

3.00

4.00

5.00

0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00 20.00Gravimetric energy density [wt.%]

Volu

met

ricen

ergy

dens

ity[k

g H

2/100

l]

StorHy target 6 wt.%

C-H2 Reference System Typ III H2 350 bar

L-H2 Reference System Stainless SteelC-H2 StorHy System Type IV 700

bar (extrap.)

StorHy Target 4.5 kg H2/100 l

L-H2 StorHy System Lightweight Free-form (extrap.)

Solid StorageSystem Reference

C-H2 StorHy 700 bar Swap Rack

Comparison of system storage densities

Solid Storage StorHySystem NaAlH4 (Not yet optimised)

? L-H2 StorHy System Lightweight Cylindrical

C-H2 Referenc 350 bar Swap Rack

4. Future Perspectives StorHy: Evaluation


Medium-class Car: Fuel cell vehicle with C-H2 storage

Systemmodule

Battery

CoolingSystem

Power el.: 72 kWHydrogen mass: 1.9 kgC-H2 storage: 350 barMax. speed: 150 km/hRange: 150 km

Today:Driving range lower than 400 kme.g. F-Cell 2002

Power: 60/85 kWHydrogen mass: 4 kgC-H2 storage: 700 barMax. speed: 174 km/hRange: >400 km

Tomorrow:Driving range of 400 km to 500 km by 700 bar C-H2 storage systemse.g. F600 Hygenius Concept Car

Source: DCSource: DC

Source: DC

4. Future Perspectives Hydrogen Storage in different

Vehicle Concepts


Delivery van: FC City Car with range extender

Power el. 28 kWMax. speed: 95 km/hFC power 5 kWBattery: 15 kWh Hydrogen C-H2@350bar: 1,6 kg Range H2: 70 km Range Battery: 80 km

Today: Tomorrow:

Power 28 kWMax. speed: 95 km/hFC power: 10 kWBattery: 15 kWh Hydrogen C-H2@700bar: 2,7 kgRange H2: 170 kmRange Battery: 80 km

Source: PSA

Source: PSA


Vehicle Concepts


Power: 191 kW (260 bhp)Hydrogen mass: > 8 kg L-H2 storage: Stainless steel

Cylindrical Range H2: > 200 km + Range Gasoline: > 500 km

Today: Tomorrow:

Monofuel (L-H2)

- Highly efficient hydrogen ICE - Lightweight cryogenic storage

+

Power: > 100 kW (136 bhp)Hydrogen mass: > 7 kgL-H2 storage: Lightweight

Free-form shapeRange H2: > 500 km

Source: BMWSource: MAGNA STEYR

Bi-Fuel (L-H2 + Gasoline)

Hydrogen ICE with L-H2 Storage


Vehicle Concepts


C-H2 storageStorage densities of ~4.5 wt.% and ~2.4 kg H2/100 l are achievable on system levelStorHy results regarding C-H2 vessels close up to worldwide R&DFurther optimisation requires fundamental understanding of ageing and failure behaviour of composite and liner materials, modelling and simulation concepts StorHy results on filling components and production conceptsshow promising advanced solutions Further cost reduction requires new industrialisation concepts for mass production and new CF fibresHigher storage densities and further cost reduction require change of Regulations, Codes & Standards as well as new vehicle platforms (e.g. compatible with single cylinder storage concepts)New advanced safety approach necessary in the future, e.g. basedon Probabilistic Safety Assessment

4. Future Perspectives StorHy: Preliminary Conclusions


L-H2 storageStorage densities up to 14 wt.% and 4 kg H2/100 l are achievable on system level for metal design, even up to 18 wt.% using advanced composite materialsStorHy results demonstrate a free form tank design with improved conformability to better enable vehicle integration StorHy results show promising advanced solutions beyond worldwide R&D, but still further R&D efforts are required for industrialisation and system validation Substantial cost reduction is indispensableLightweight L-H2 storage systems show considerable potential in combination with new H2 ICE Further L-H2 specific challenges, such as boil-off and permeation, have to be addressed



Solid Storage (1)Up to now, storage densities of ~2 wt.% are achieveable on system level with complex hydrides on alanate basisAt present, no solid storage material fulfils the major targets for automotive applicationsStorHy tank development demonstrates feasibility of a fast heat removal using lightweight complex hydridesStorHy safety study shows minimised explosion in case of hydrogen releaseStorHy up-scaling results show high potential for mass productionof complex light weight hydrides at low costs



Solid Storage (2)Further research for novel storage materials with improved storage densities, kinetics and thermodynamic behaviour as well as for advanced system components, e.g. heat exchanger, is still requiredAutomotive solutions are not realistic in the medium termStationary or marine applications have more potentials for a market entry in the near future



General conclusionsBeyond StorHy, further R&D activities are proposed for:

In-depth system/vehicle validation in demonstration projectsIndustrialisation and cost reduction conceptsSafety assessment and new advanced safety approachesOptimisation of Regulations, Codes & Standards (e.g design requirements for pressure vessels)New storage concepts, such as pressure tanks with new high performance tensile fibres, hybrid tanks (pressure / cryogenic /solid storage), etc.User-oriented fundamental research on solid storage materials, their safety and technical development of solid storage tanks



4. Future Perspectives StorHy Dissemination

More information?Join the

StorHy Dissemination Event:“Hydrogen Storage Perspectives of the Future”

Date: June 2008

Further information shortly on www.storhy.net!Or contact: [email protected]

http://www.storhy.net/

mailto:[email protected]


Backup only!Backup only!


Inner tank- Inner vessel- Level measurement- Pipework- Cryogenic shut-off valves- Inner tank support

Outer jacket- Outer vessel- Thermal insulation- Refueling interface- Outer support

Auxiliary System Box- Shut-off valves- Control valve- Safety relief valves- Sensors (p, T, H2)- Heat exchanger

Back upL-H2 Storage System

Source: MAGNA STEYR


Back upC-H2 Storage System

Source: Dynetek

Low pressure

connection

High pressure

connection

Pressure regulator

High pressure vessel

Electrical connections

SensorsValves,FittingsSolenoid

valve

Venting pipe

Fixing

Fully wrappedcylinder &

metallic liner

Type 3

Fully wrappedcylinder &

non-load carrying(plastic) liner

Type 4


Back upC-H2 Storage Reference System

Source: SP Users

Source: Dynetek


Back upL-H2 Storage Reference System

Source: SP Users

Source: Magna Steyr


Back upSolid Storage Reference System

Source: SP UsersSource: DC


Material & microstructure– Extruded multi-layer based PA

Liner material characterization– 8 multilayer polymers assessed: f (p,T)– Permeation: 2*10-18mol/(Pa.s.m) -> OK

700 bar vessel design & calculation– Optimized end cap design– CF/PA 700 bar system– GF/PP 200 bar system

CF for this thermoplastic composite not available yet!Vessel testing (GF/PP)– Burst pressure = 460 bar

Technical data (CF/PA design):• Mass of vessel: 10.9 kg• Internal volume: 9 l• H2 storage capacity: 3.5 wt.%• Design pressure: 700 bar• H2 mass stored: 0.4 kg

Back upStorHy: 700 bar C-H2 Vessels

700 bar modular system with extruded plastic liner and thermoplastic composite

Source: COMAT


Type Measure Effort ContributionIV

IV

IV

III

III/IV

III/IV

III/IV

III/IV

III/IV

Improve burst behavior (design, process)

Low 100% burst

Temperature cycling + burst Low Reliability of Type IV

Evaluate tightness after thermal & mechanical ageing (=> depending on permeation results)

Low Improved permeationreliability of Type IV

Low / high temperature exposure risk Medium Safety

Innovative manufacturing concepts High Weight, costs

Improve cycling behaviour Medium Cycling feasibility

Long term behavior (creep…) Medium Safety

Improve design requirements (safety factors) High Weight, costs

New innovative fibers High Weight, costs

Reliable and low cost components Medium Weight, costs, reliability

Back upStorHy: Recommendations for C-H2


Back upStorHy: C-H2 Vessel Production -

Quality Survey during Autofrettage

0

0,2

0,4

0,6

0,8

1

0 0,2 0,4 0,6 0,8 1

Normalized strain

Nor

mal

ized

inte

rnal

pre

ssur

e

autofrettage pressure (yileding of metal liner)

test pressure

nominal working pressure (15°C)

Example:Typ III (CNG) cylinder = metal liner with full CF/Epoxy wrapping

burst pressure

fibre

bre

ak

residual strain of wrapping after autofrettage

0,0 0,2 0,4 0,6 0,8 1,00,0

0,2

0,4

0,6

0,8

1,0

Nor

mal

ised

val

ues

Normalised autofrettage pressure

AE accumulation

strain intensity

10987654321

“Defect”type III

(cylinder 5)

Defect type II

(cylinder 4)

Defect type II

(cylinder 3)

Defect type I

(cylinder 2)

Defect type I

(cylinder 1)

AE criterion

10987654321

“Defect”type III

(cylinder 5)

Defect type II

(cylinder 4)

Defect type II

(cylinder 3)

Defect type I

(cylinder 2)

Defect type I

(cylinder 1)

AE criterion

Source: BAM

AE Quality Survey Concepts:

Successful in detecting every manufacturing defect by at least 2 of 10 developed AE-criteria!see:

Acoustic Emission (AE)


Development of test procedures for C-H2 vessels: Bonfire test

Source: BAM

Concept of modular testing

Bonfire tests ofcylinders

Test ofPressure Relief Devices (PRD)

pBurst

p0

Time t in [sec]

Pres

sure

or b

urst

pre

ssur

e p

in [M

Pa]

tBurst 0

pBurst

tIgnition

Burst pressure line as a function of the filling

tBurst max

insufficient PRD

well adjusted PRD

Rupture

Rupture

m << m0

Evolution of pressure in a gas receptacle with PRD

m0

m < m0

m > m0

Validation of combination

Back upStorHy: Safety Assessment of C-H2 Storage


Interlaboratory tests to evaluate C-H2 testing facilities

Source: BAM

BAM

WUT

Faber

ALTests performed at BAM, WUT, Faber and ALTests show relevance of influence of testing facilities on life-time of C-H2 vessels

ParisWroclaw

Udine

ParisWroclaw

Udine

Test cylinder

Adapter

Tool kit

MeasuringDevice

Sensors

Back upStorHy: Safety Assessment of C-H2 Storage


Tests of optical fibre sensors for detecting defects of C-H2 vesselsSensor technologies

– Fibre Bragg gratings– Microbending optical fibres

Cycling tests– Type III: detectable increase in local deformation– Type IV: correlation of optical signals and CF fibre

fatigue level to be demonstratedBurst test (for type IV)

– Linear deformation of vessel– Detection depends on sensor localization

Source: WUT

Back upStorHy: On-board Monitoring System


Training Course ‘StorHy TRAIN-IN 2006’One week full time training course on hydrogen storage technologies

Date: September 25th - 29th, 2006

Location: University of Applied Sciences, Ingolstadt, GermanyOver 80 participants from 20 countries(students, PhD students, scientists, researchers and company representatives)

25 theoretical and practical lectures, hardware exhibitions and excursions

Very good feedback by participants

All lecture handouts and results onlineon www.storhy.net

Back-upStorHy Training Course


Cost reduction of C-H2 storage systems

Source: DC

Back upStorHy: Cost Estimation


Magnesium Alanate:Fundamental work on synthesis, structural and thermal propertiesallowed a complete characterization of this promising complex hydride. However, the unfavourable thermodynamic properties of this material made the Mg-Alanate not suitable for hydrogen storage.

Sodium Alanate:Fundamental work carried out with this material in order to improve the kinetics allowed gaining insight into the reaction upon cycling under hydrogen. Indeed, XAS studies explained why the capacity decreases after some dehydrogenation / hydrogenation cycles and why the kinetics slow down at the same time. This knowledge in turn allowed a cost-effective production method of Al-based hydrogen storage material.

Back upStorHy: Work on Alanates


Complex mixed Alanates:The following systems {[MgH2 + Al + LiH] and [MgH2 + LiAlH4]} are extremely lightweight compounds, with a potential to achieve high gravimetric storage densities for hydrogen. (MgH2 + LiAlH4) appear as the most promising systems in terms of the formation of a newphase and the subsequent decomposition kinetics. However, further work is necessary to identify and isolate this new phase in order to conclude on the suitability of the material for hydrogen storage.

Back upStorHy: Work on mixed Alanates

“Hydrogen Storage Systems for Automotive Application ... Review Days 2007_Final.pdf ·...

Documents

Transcript of “Hydrogen Storage Systems for Automotive Application ... Review Days 2007_Final.pdf ·...