Conversion and testing of hydrogen-powered post office vehicle

A hydrogen-fueled post office jeep has been retrofitted for operation on hydrogen by the installation of a modified propane carburetor and by installation of an iron-titanium hydride storage vessel. The jeep was operated in the mail delivery system of the Independence, Missouri Post Office. Comparative data have been obtained by operating the jeep in tandem with a gasoline-fueled vehicle. Careful observation of fuel consumption for the two vehicles was closely monitored. Throughout the project, fuel consumption of the hydrogen vehicle was significantly less than the consumption of the gasoline version.     

The man hydrogen propulsion system for city buses

MAN Nutzfahrzeuge Aktiengesellschaft has developed a hydrogen-powered bus as part of the Euro-Quebec Hydro-Hydrogen Pilot Project. The project is being sponsored by the European Union.The MAN hydrogen bus is based on a model SL standard-production city bus. The bus is driven by an internal combustion engine. The engine will run on either hydrogen or gasoline, to which end it has two independently-operating injection systems. The engine's emission levels in both modes are well inside the applicable limits for commercial vehicles.The hydrogen is carried in the vehicle in liquid form at extremely low temperatures. The fuel tank system consists of three vacuum-insulated tanks, developed by Linde AG, who also developed the refueling system.A comprehensive safety concept has been compiled for the vehicle with the cooperation of TÜV Bayern-Sachsen to ensure that the highest possible levels of safety are met. The bus has been accepted by TÜV and has been in scheduled service since 1996. The vehicle has covered a distance of more than 10000 km in the city of Erlangen without any safety-relevant incident or fault.     

Safe,long range,inexpensive and rapidly refuelable hydrogen vehicles with cryogenic pressure vessels

Hydrogen storage is often cited as the greatest obstacle to achieving a hydrogen economy free of environmental pollution and dependence on foreign oil. A compact high-pressure cryogenic storage system has promising features to the storage challenge associated with hydrogen-powered vehicles. Cryogenic pressure vessels consist of an inner vessel designed for high pressure (350 bar) insulated with reflective sheets of metalized plastic and enclosed within an outer metallic vacuum jacket. When filled with pressurized liquid hydrogen, cryogenic pressure vessels become the most compact form of hydrogen storage available. A recent prototype is the only automotive hydrogen vessel meeting both Department of Energy's 2017 weight and volume targets. When installed onboard an experimental vehicle, a cryogenic pressure vessel demonstrated the longest driving distance with a single H₂ tank (1050 km). In a subsequent experiment, the vessel demonstrated unprecedented thermal endurance: 8 days parking with no evaporative losses, extending to a month if the vehicle is driven as little as 8 km per day. Calculations indicate that cryogenic vessels offer compelling safety advantages and the lowest total ownership cost of hydrogen storage technologies. Long-term (∼10 years) vacuum stability (necessary for high performance thermal insulation) is the key outstanding technical challenge. Testing continues to establish technical feasibility and safety.     

燃料电池车车载储氢系统的技术发展与应用现状

综述了燃料电池车车载储氢系统技术，包括高压氢、液氢、金属氢化物、低温吸附、纳米碳管高压吸附以及液体有机氢化物等的研究进展及其车载应用现状。参照燃料电池车对车载储氢系统单位重量储氢密度与体积储氢密度的目标要求，对目前已应用和处于研发阶段的一些储氢技术的性能指标和存在问题进行了分析讨论。同时对目前该领域的若干新的研究报道，如超高压轻质复合容器、混合储氢容器、b.c．c．储氢合金、超级活性碳和“浆液”双相储氢等，也作了简要介绍。     

Thermodynamic parametric analysis of refueling heavy-duty hydrogen fuel-cell electric vehicles

Reliable design and safe operation of heavy-duty hydrogen refueling stations are essential for the successful deployment of heavy-duty fuel cell electric vehicles (FCEVs). Fueling heavy-duty FCEVs is different from light-duty vehicles in terms of the dispensed hydrogen quantities and fueling rates, requiring tailored fueling station design for each vehicle class. In particular, the selection and design of the onboard hydrogen storage tank system and the fueling performance requirements influence the safe design of hydrogen fueling stations. A thermodynamic modeling and analysis are performed to evaluate the impact of various fueling parameters and boundary conditions on the fueling performance of heavy-duty FCEVs. We studied the effect of dispenser pressure ramp rate and precooling temperature, initial tank temperature and pressure, ambient temperature, and onboard storage design parameters, such as onboard storage pipe diameter and length, on the fueling rate and final vehicle state-of-charge, while observing prescribed tank pressure and temperature safety limits. An important finding was the sensitivity of the temporal fueling rate profile and the final tank state of charge to the design factors impacting pressure drop between the dispenser and vehicle tank, including onboard storage pipe diameter selection, and flow coefficients of nozzle, valves, and fittings. The fueling rate profile impacts the design and cost of the hydrogen precooling unit upstream of the dispenser.     

Affordable hydrogen supply pathways for fuel cell vehicles

Fuel cell vehicles can be powered directly by hydrogen stored on the vehicle, or indirectly by extracting hydrogen from onboard liquid fuels such as methanol or gasoline. The direct hydrogen fuel cell vehicle is preferred, since it would be less complex, have better fuel economy, lower greenhouse gas emissions, greater oil import reductions and would lead to a sustainable transportation system once renewable energy was used to produce hydrogen. The two oft-cited concerns with direct hydrogen fuel cell vehicles are onboard hydrogen storage and the lack of hydrogen supply options. Directed Technologies, Inc., working with the Ford Motor Company under a Department of Energy cost shared contract to develop direct hydrogen fuel cell vehicles, has addressed both perceived roadblocks to direct hydrogen fuel cell vehicles. We describe realistic, cost effective options for both onboard hydrogen storage and for economically viable hydrogen infrastructure development.     

An onboard hydrogen generator for hydrogen enhanced combustion with internal combustion engine

Hydrogen enhanced combustion (HEC) for internal combustion engine is known to be a simple mean for improving engine efficiency in fuel saving and cleaner exhaust. An onboard compact and high efficient methanol steam reformer is made and installed in the tailpipe of a vehicle to produce hydrogen continuously onboard by using the waste heat of the engine for heating up the reformer; this provides a practical device for the HEC to become a reality. This use of waste heat from engine enables an extremely high process efficiency of 113% to convert methanol (8.68 MJ) for 1.0 NM of hydrogen (9.83 MJ) and low cost of using hydrogen as an enhancer or as a fuel itself. The test results of HEC from the onboard hydrogen production are presented with 2 gasoline engine vehicles and 2 diesel engines; the results indicate a hike of engine efficiency in 15–25% fuel saving and a 40–50% pollutants reduction including 70% reduction of exhaust smoke. The use of hydrogen as an enhancer brings about 2–3 fold of net reductions in energy, carbon dioxide emission and fuel cost expense over the input of methanol feed for hydrogen production.     

Development of a Hydrogen Refueling Station Design Tool

In the last couple of decades, there has been a growing concern in what effects fossil fuels are having on the environment, resulting in governments and governing organizations issuing stringent emission standards in an effort to curve their environmental damage. To meet these new standards, the transportation industry has been conducting research into alternative fuels, such as hydrogen, but one critical problem utilizing hydrogen is that there is almost no infrastructure. A network of hydrogen refueling stations similar to modern gasoline stations will be required to be constructed to meet future demand. The hydrogen refueling station model was created to aid in designing hydrogen facilities, thus accelerating their development while reducing design cost. A model was created using Simulink consisting of an electrolyzer that generates hydrogen, a compressor, numerous storage tanks, a dispensing unit that transfers hydrogen, and a vehicle component that consumes hydrogen fuel. The model was validated using data from existing hydrogen refueling stations, and the data obtained from testing the previous version of the hydrogen refueling station model to determine model accuracy and if the model has improved. The model has demonstrated that it can produce reasonable results for a station's performance and has improved compared to the previous version.     

A thermodynamic analysis of refueling of a hydrogen tank

A thermodynamic analysis of refueling of a gaseous hydrogen fuel tank is described. This study may lend itself to the applications of refueling a hydrogen storage tank onboard a hydrogen fuel-cell vehicle. The gaseous hydrogen is treated as an ideal or a non-ideal gas. The refueling process is analyzed based on adiabatic, isothermal, or diathermal condition of the tank. A constant feed-rate is assumed in the analysis. The thermodynamic state of the feed stream also remains constant during refueling. Ideal-gas assumption results in simple closed-form expressions for tank temperature, pressure, and other parameters. The non-ideal behavior of high-pressure gaseous hydrogen is addressed using the newly developed equation of state for normal hydrogen, which is based on the reduced Helmholtz free energy formulation. Sample calculations are presented using initial tank and feed stream conditions commensurate to practical vehicular applications. Comparing to the non-ideal analysis, the ideal-gas assumption always results in under-prediction of the tank temperature and pressure irrespective of the filling condition. For a given target tank pressure, the refueling time is the shortest under adiabatic condition and is the longest under isothermal condition with the tank being maintained at the initial tank temperature. The adiabatic and isothermal conditions can be viewed, respectively, as the lower and upper bounds of the refueling time for a given final target tank pressure.     

Basic tuning of hydrogen powered car and artificial intelligent prediction of hydrogen engine characteristics

Many studies of renewable energy have shown hydrogen is one of the major green energy in the future. This has lead to the development of many automotive application of using hydrogen as a fuel especially in internal combustion engine. Nonetheless, there has been a slow growth and less knowledge details in building up the prototype and control methodology of the hydrogen internal combustion engine [1]. In this paper, The Toyota Corolla 4 cylinder, 1.8l engine running on petrol was systematically modified in such a way that it could be operated on either gasoline or hydrogen at the choice of the driver. Within the scope of this project, several ancillary instruments such as a new inlet manifold, hydrogen fuel injection, storage system and leak detection safety system were implemented. Attention is directed towards special characteristics related to the basic tuning of hydrogen engine such as: air to fuel ratio operating conditions, ignition timing and injection timing in terms of different engine speed and throttle position. Based on the experimental data, a suite of neural network models were tested to accurately predict the effect of different engine operating conditions (speed and throttle position) on the hydrogen powered car engine characteristics. Predictions were found to be ±3% to the experimental values for all of case studies. This work provided better understanding of the effect of hydrogen engine characteristic parameters on different engine operating conditions.     

Analysis of the behaviour of a 4-stroke Si engine fuelled with ammonia and hydrogen

The use of hydrogen as fuel represents a possible solution to reduce greenhouse gas emission from vehicles. Although proper engine running with hydrogen has been widely demonstrated, hydrogen storage onboard of the vehicle is a major problem.     

Turn of the century refueling: A review of innovations in early gasoline refueling methods and analogies for hydrogen

During the first decades of the 20th century, a variety of gasoline refueling methods supported early US gasoline vehicles and successfully alleviated consumer concerns over refueling availability. The refueling methods employed included cans, barrels, home refueling outfits, parking garage refueling facilities, mobile stations, hand carts and curb pumps. Only after robust markets for gasoline vehicles had been firmly established did the gasoline service station become the dominant refueling method. The present study reviews this history and draws analogies with current and future efforts to introduce hydrogen as a fuel for vehicles. These comparisons hold no predictive power; however, there is heuristic value in an historical review of the first successful and large-scale introduction of a vehicle fuel. From an energy policy perspective, these comparisons reinforce the importance of a long-term and portfolio approach to support for technology development and innovation.     

Hydrogen compatibility of austenitic stainless steel tubing and orbital tube welds

Refueling infrastructure for use in gaseous hydrogen powered vehicles requires extensive manifolding for delivering the hydrogen from the stationary fuel storage at the refueling station to the vehicle as well as from the mobile storage on the vehicle to the fuel cell or combustion engine. Manifolds for gas handling often use welded construction (as opposed to compression fittings) to minimize gas leaks. Therefore, it is important to understand the effects of hydrogen on tubing and tubing welds. This paper provides a brief overview of on-going studies on the effects of hydrogen precharging on the tensile properties of austenitic stainless tubing and orbital tube welds.     

Hydrogen refueling station compression and storage optimization with tube-trailer deliveries

Hydrogen refueling stations require high capital investment, with compression and storage comprising more than half of the installed cost of refueling equipment. Refueling station configurations and operation strategies can reduce capital investment while improving equipment utilization. Argonne National Laboratory developed a refueling model to evaluate the impact of various refueling compression and storage configurations and tube trailer operating strategies on the cost of hydrogen refueling. The modeling results revealed that a number of strategies can be employed to reduce fueling costs. Proper sizing of the high-pressure buffer storage reduces the compression requirement considerably, thus reducing refueling costs. Employing a tube trailer to initially fill the vehicle's tank also reduces the compression and storage requirements, further reducing refueling costs. Reducing the cut-off pressure of the tube trailer for initial vehicle fills can also significantly reduce the refueling costs. Finally, increasing the trailer's return pressure can cut refueling costs, especially for delivery distances less than 100 km, and in early markets, when refueling stations will be grossly underutilized.     

Comparison of well-to-wheels energy use and emissions of a hydrogen fuel cell electric vehicle relative to a conventional gasoline-powered internal combustion engine vehicle

The operation of hydrogen fuel cell electric vehicles (HFCEVs) is more efficient than that of gasoline conventional internal combustion engine vehicles (ICEVs), and produces zero tailpipe pollutant emissions. However, the production, transportation, and refueling of hydrogen are more energy- and emissions-intensive compared to gasoline. A well-to-wheels (WTW) energy use and emissions analysis was conducted to compare a HFCEV (Toyota Mirai) with a gasoline conventional ICEV (Mazda 3). Two sets of specific fuel consumption data were used for each vehicle: (1) fuel consumption derived from the U.S. Environmental Protection Agency's (EPA's) window-sticker fuel economy figure, and (2) weight-averaged fuel consumption based on physical vehicle testing with a chassis dynamometer on EPA's five standard driving cycles. The WTW results show that a HFCEV, even fueled by hydrogen from a fossil-based production pathway (via steam methane reforming of natural gas), uses 5%–33% less WTW fossil energy and has 15%–45% lower WTW greenhouse gas emissions compared to a gasoline conventional ICEV. The WTW results are sensitive to the source of electricity used for hydrogen compression or liquefaction.     

DIR-FCEV powered by different fuels – Part I: Well-to-wheel analysis for the Brazilian and Spanish contexts

This article describes the life cycle assessment of the Direct Internal Reforming Fuel Cell Electric Vehicle (DIR-FCEV) for the Brazilian and Spanish contexts. This recently proposed vehicle technology produces hydrogen onboard via heat recovery, while the Solid Oxide Fuel Cell (SOFC) and the gas turbine provide electricity to the electric motor with high overall efficiency. The exhaust gas emission was obtained via GASEQ software and the well-to-tank data were collected through literature search. These values were entered in the GREET Model software version v1.3.0.13656 to assess the negative environmental impacts of the DIR-FCEV in terms of global warming potential (GWP) and human toxicity potential (HTP). Using 1 km distance driven by a light-duty vehicle as the functional unit, the tank-to-wheel results indicate that regardless of the fuel, the DIR-FCEV achieved better than the internal combustion engine vehicle fuelled with gasoline A in both categories. Also, the DIR-FCEV powered by biomethane, gasoline A, gasoline C (73% gasoline A and 27% ethanol, in volume basis), glycerine, and ethanol attended all future tailpipe emissions standards stipulated by United States and European Union. Biomethane and gasoline-fuelled DIR-FCEV had more commendatory environmental performance in both countries. Thus, it is expected to obtain environmental indicators to stimulate the use of biofuels synergistically with the advancement of electromobility in Brazil and Spain.     

Impact of refueling parameters on storage density of compressed hydrogen storage Tank

Hydrogen fuel cell vehicle (HFCV) is one of the key contributors to sustainable development of the society. For commercial deployment and market acceptability of fuel cell vehicles, efficient storage of hydrogen with an optimum refueling is one of the important challenge. Compressed hydrogen storage in Type IV tanks is a mature and promising technology for on-board application. The fast refueling of the storage tank without overheating and overfilling is an essential requirement defined by SAE J2601. In this regard, station parameters such as hydrogen supply temperature, filling rate and vehicle tank parameters such as filling time strongly influences the storage capacity of the tank, affecting driving range of the fuel cell vehicle. This paper investigates the impact of these parameters on storage density of the tank defined in terms of state of charge. For this, refueling simulation based on SAE J2601 protocol has been performed using computational fluid dynamic approach to investigate the influence of station parameters on storage density of the tank. Further, the root cause analysis was carried out to investigate the contribution of station and vehicle tank parameters for enhancing the storage density of the tank. Finally, the regression model based on these refueling parameters was developed to predict the density attained at different filling conditions. The results confirmed the strong contribution of pressure, filling time, supply temperature and least contribution of temperature, filling rates in enhancing the storage density of the tank. The results can provide new insight into refueling behavior of the Type IV tank for fuel cell vehicle.     

A comparative analysis of the cryo-compression and cryo-adsorption hydrogen storage methods

While conventional low-pressure LH₂ dewars have existed for decades, advanced methods of cryogenic hydrogen storage have recently been developed. These advanced methods are cryo-compression and cryo-adsorption hydrogen storage, which operate best in the temperature range 30–100 K. We present a comparative analysis of both approaches for cryogenic hydrogen storage, examining how pressure and/or sorbent materials are used to effectively increase onboard H₂ density and dormancy. We start by reviewing some basic aspects of LH₂ properties and conventional means of storing it. From there we describe the cryo-compression and cryo-adsorption hydrogen storage methods, and then explore the relationship between them, clarifying the materials science and physics of the two approaches in trying to solve the same hydrogen storage task (∼5–8 kg H₂, typical of light duty vehicles). Assuming that the balance of plant and the available volume for the storage system in the vehicle are identical for both approaches, the comparison focuses on how the respective storage capacities, vessel weight and dormancy vary as a function of temperature, pressure and type of cryo-adsorption material (especially, powder MOF-5 and MIL-101). By performing a comparative analysis, we clarify the science of each approach individually, identify the regimes where the attributes of each can be maximized, elucidate the properties of these systems during refueling, and probe the possible benefits of a combined “hybrid” system with both cryo-adsorption and cryo-compression phenomena operating at the same time. In addition the relationships found between onboard H₂ capacity, pressure vessel and/or sorbent mass and dormancy as a function of rated pressure, type of sorbent material and fueling conditions are useful as general designing guidelines in future engineering efforts using these two hydrogen storage approaches.     

Onboard fuel processor for PEM fuel cell vehicles

To lower vehicle greenhouse gas emissions, many automotive companies are exploring fuel cell technologies, which combine hydrogen and oxygen to produce electricity and water. While hydrogen storage and infrastructure remain issues, Renault and Nuvera Fuel Cells are developing an onboard fuel processor, which can convert a variety of fuels into hydrogen to power these fuel cell vehicles.The fuel processor is now small enough and powerful enough for use on a vehicle. The catalysts and heat exchangers occupy 80 l and can be packaged with balance of plant controls components in a 150-l volume designed to fit under the vehicle. Recent systems can operate on gasoline, ethanol, and methanol with fuel inputs up to 200 kWth and hydrogen efficiencies above 77%. The startup time is now less than 4 min to lower the CO in the hydrogen stream to the target value for the fuel cell.