Metal hydride hydrogen storage tank for fuel cell utility vehicles

The “low-temperature” intermetallic hydrides with hydrogen storage capacities below 2 wt% can provide compact H₂ storage simultaneously serving as a ballast. Thus, their low weight capacity, which is usually considered as a major disadvantage to their use in vehicular H₂ storage applications, is an advantage for the heavy duty utility vehicles. Here, we present new engineering solutions of a MH hydrogen storage tank for fuel cell utility vehicles which combines compactness, adjustable high weight, as well as good dynamics of hydrogen charge/discharge. The tank is an assembly of several MH cassettes each comprising several MH containers made of stainless steel tube with embedded (pressed-in) perforated copper fins and filled with a powder of a composite MH material which contains AB₂- and AB₅-type hydride forming alloys and expanded natural graphite. The assembly of the MH containers staggered together with heating/cooling tubes in the cassette is encased in molten lead followed by the solidification of the latter. The tank can provide >2 h long H₂ supply to the fuel cell stack operated at 11 kWe (H₂ flow rate of 120 NL/min). The refuelling time of the MH tank (T = 15–20 °C, P(H₂) = 100–150 bar) is about 15–20 min.     

Comments on solid state hydrogen storage systems design for fuel cell vehicles

In recent years, significant research and development efforts were spent on hydrogen storage technologies with the goal of realizing a breakthrough for fuel cell vehicle applications. This article scrutinizes design targets and material screening criteria for solid state hydrogen storage. Adopting an automotive engineering point of view, four important, but often neglected, issues are discussed: 1) volumetric storage capacity, 2) heat transfer for desorption, 3) recharging at low temperatures and 4) cold start of the vehicle. The article shall help to understand the requirements and support the research community when screening new materials.     

Design tool for estimating metal hydride storage system characteristics for light-duty hydrogen fuel cell vehicles

The U.S. Department of Energy (DOE) has developed the Framework model to simulate fuel cell-based light-duty vehicle operation for various hydrogen storage systems. This transient model simulates the performance of the storage system, fuel cell, and vehicle for comparison to DOE's Technical Targets using four drive cycles. Metal hydride hydrogen storage models have been developed for the Framework model. Despite the utility of this model, it requires that material researchers input system design specifications that cannot be easily estimated. To address this challenge, a design tool has been developed that allows researchers to directly enter physical and thermodynamic metal hydride properties into a simple sizing module that then estimates the systems parameters required to run the storage system model. This design tool can also be used as a standalone MS Excel model to estimate the storage system mass and volume outside of Framework and compare it to the DOE Technical Targets. This model will be explained and exercised with existing hydrogen storage materials.     

Efficiencies of hydrogen storage systems onboard fuel cell vehicles

Energy efficiency, vehicle weight, driving range, and fuel economy are compared among fuel cell vehicles (FCV) with different types of fuel storage and battery-powered electric vehicles. Three options for onboard fuel storage are examined and compared in order to evaluate the most energy efficient option of storing fuel in fuel cell vehicles: compressed hydrogen gas storage, metal hydride storage, and onboard reformer of methanol. Solar energy is considered the primary source for fair comparison of efficiencies for true zero emission vehicles. Component efficiencies are from the literature. The battery powered electric vehicle has the highest efficiency of conversion from solar energy for a driving range of 300 miles. Among the fuel cell vehicles, the most efficient is the vehicle with onboard compressed hydrogen storage. The compressed gas FCV is also the leader in four other categories: vehicle weight for a given range, driving range for a given weight, efficiency starting with fossil fuels, and miles per gallon equivalent (about equal to a hybrid electric) on urban and highway driving cycles.     

Advancements and current technologies on hydrogen fuel cell applications for marine vehicles

Maritime industry has led renewable energy sources for the greener environment and efficient vehicles that effect by increasing population and energy demands. Hydrogen is one of the most popular of these renewable energy sources and one of the most favourable research area, worldwide. In this study, authors reported the usage of hydrogen fuel cells in marine transport as main power forwarder, their advantages and challenges under the lights on state of art and furthermore new technologies perspective. The latest research activities, hydrogen production and storage methods with challenges are analyzed and the developments of fuel cell based marine vehicles are discussed. In detailed, newly approachment of electrolyses from seawater for sustainable fuel necessity is discussed. As a result, this forseen study is important in terms of handling energy from seawater and compiling the latest technology for marine transport.     

Refuelling scenarios of a light urban fuel cell vehicle with metal hydride hydrogen storage. Comparison with compressed hydrogen storage counterpart

The high price of hydrogen fuel in the fuel cell vehicle refuelling market is highly dependent on the one hand from the production costs of hydrogen and on the other from the capital cost of a hydrogen refuelling station's components to support a safe and adequate refuelling process of contemporary fuel cell vehicles. The hydrogen storage technology dominated in the vehicle sector is currently based on high-pressure compressed hydrogen tanks to extend as much as possible the driving range of the vehicles. However, this technology mandates the use of large hydrogen compression and cooling systems as part of the refuelling infrastructure that consequently increase the final cost of the fuel. This study investigated the prospects of lowering the refuelling cost of small urban hydrogen vehicles through the utilisation of metal hydride hydrogen storage. The results showed that for low compression hydrogen storage, metal hydride storage is in favour in terms of the dispensed hydrogen fuel price, while its weight is highly comparable to the one of a compressed hydrogen tank. The final refuelling cost from the consumer's perspective however was found to be higher than the compressed gas due to the increased hydrogen quantity required to be stored in fully empty metal hydride tanks to meet the same demand.     

Metal hydride hydrogen storage tank for light fuel cell vehicle

We describe a metal hydride (MH) hydrogen storage tank for light fuel cell vehicle application developed at HySA Systems. A multi-component AB₂-type hydrogen storage alloy was produced by vacuum induction melting (10 kg per a load) at our industrial-scale facility. The MH alloy has acceptable H sorption performance, including reversible H storage capacity up to ∼170 NL/kg (1.5 wt% H). The cassette-type MH tank was made up of 2 cylindrical aluminium canisters with transversal internal copper fins and external aluminium fins for improving the heat exchange between the heating medium and the MH tank. Heat supply and removal was provided from the outside using air at T = 15–25 °C. The MH tank was tested at the conditions of natural or forced (velocity ∼2 m/s) air convection. The tests included H₂ charge of the tank at P = 15–40 bar and its discharge at P = 1 bar. The tank in the H₂ discharge mode was also tested together with open cathode low-temperature proton exchange membrane fuel cell (LT PEMFC).     

Fuel economy of hydrogen fuel cell vehicles

On the basis of on-road energy consumption, fuel economy (FE) of hydrogen fuel cell light-duty vehicles is projected to be 2.5–2.7 times the fuel economy of the conventional gasoline internal combustion engine vehicles (ICEV) on the same platforms. Even with a less efficient but higher power density 0.6 V per cell than the base case 0.7 V per cell at the rated power point, the hydrogen fuel cell vehicles are projected to offer essentially the same fuel economy multiplier. The key to obtaining high fuel economy as measured on standardized urban and highway drive schedules lies in maintaining high efficiency of the fuel cell (FC) system at low loads. To achieve this, besides a high performance fuel cell stack, low parasitic losses in the air management system (i.e., turndown and part load efficiencies of the compressor–expander module) are critical.     

HYDRIDE4MOBILITY: An EU HORIZON 2020 project on hydrogen powered fuel cell utility vehicles using metal hydrides in hydrogen storage and refuelling systems

The goal of the EU Horizon 2020 RISE project 778307 “Hydrogen fuelled utility vehicles and their support systems utilising metal hydrides” (HYDRIDE4MOBILITY), is in addressing critical issues towards a commercial implementation of hydrogen powered forklifts using metal hydride (MH) based hydrogen storage and PEM fuel cells, together with the systems for their refuelling at industrial customers facilities. For these applications, high specific weight of the metallic hydrides has an added value, as it allows counterbalancing of a vehicle with no extra cost. Improving the rates of H₂ charge/discharge in MH on the materials and system level, simplification of the design and reducing the system cost, together with improvement of the efficiency of system “MH store-FC”, is in the focus of this work as a joint effort of consortium uniting academic teams and industrial partners from two EU and associated countries Member States (Norway, Germany, Croatia), and two partner countries (South Africa and Indonesia).The work within the project is focused on the validation of various efficient and cost-competitive solutions including (i) advanced MH materials for hydrogen storage and compression, (ii) advanced MH containers characterised by improved charge-discharge dynamic performance and ability to be mass produced, (iii) integrated hydrogen storage and compression/refuelling systems which are developed and tested together with PEM fuel cells during the collaborative efforts of the consortium.This article gives an overview of HYDRIDE4MOBILITY project focused on the results generated during its first phase (2017–2019).     

Off-grid solar powered charging station for electric and hydrogen vehicles including fuel cell and hydrogen storage

This paper designs an off-grid charging station for electric and hydrogen vehicles. Both the electric and hydrogen vehicles are charged at the same time. They appear as two electrical and hydrogen load demand on the charging station and the charging station is powered by solar panels. The output power of solar system is separated into two parts. On part of solar power is used to supply the electrical load demand (to charge the electric vehicles) and rest runs water electrolyzer and it will be converted to the hydrogen. The hydrogen is stored and it supplies the hydrogen load demand (to charge the hydrogen-burning vehicles). The uncertainty of parameters (solar energy, consumed power by electrical vehicles, and consumed power by hydrogen vehicles) is included and modeled. The fuel cell is added to the charging station to deal with such uncertainty. The fuel cell runs on hydrogen and produces electrical energy to supply electrical loading under uncertainties. The diesel generator is also added to the charging station as a supplementary generation. The problem is modeled as stochastic optimization programming and minimizes the investment and operational costs of solar and diesel systems. The introduced planning finds optimal rated powers of solar system and diesel generator, operation pattern for diesel generator and fuel cell, and the stored hydrogen. The results confirm that the cost of changing station is covered by investment cost of solar system (95%), operational cost of diesel generator (4.5%), and investment cost of diesel generator (0.5%). The fuel cell and diesel generator supply the load demand when the solar energy is zero. About 97% of solar energy will be converted to hydrogen and stored. The optimal operation of diesel generator reduces the cost approximately 15%.     

The fuel cell electric vehicles: The highlight review

Transportation sector is the important sector and consumed the most fossil fuel in the world. Since COVID-19 started in 2019, this sector had become the world connector because every country relies on logistics. The transportation sector does not only deal with the human transportation but also relates to logistics. Research in every country has searched for alternative transportation to replace internal combustion engines using fossil fuel, one of the most prominent choices is fuel cells. Fuel cells can use hydrogen as fuel. Hydrogen can be fed to the fuel cells to provide electric power to drive vehicles, no greenhouse gas emission and no direct combustion required. The fuel cells have been developed widely as the 21st century energy-conservation devices for mobile, stationary, and especially vehicles. The fuel cell electric vehicles using hydrogen as fuel were also called hydrogen fuel cell vehicles or hydrogen electric vehicles. The fuel cells were misconceived by several people that they were batteries, but the fuel cells could provide electric power continuously if their fuel was provided continuously. The batteries could provide electric power as their only capacities, when all ions are released, no power could be provided. Because the fuel cell vehicles play important roles for our future transportation, the overall review for these vehicles is significantly interesting. This overall review can provide general and technical information, variety of readers; vehicle users, manufacturers, and scientists, can perceive and understand the fuel cell vehicles within this review. The readers can realize how important the fuel cell technologies are and support research around the world to drive the fuel cell vehicles to be the leading vehicles in our sustainable developing world.     

Model-based design of an automotive-scale,metal hydride hydrogen storage system

Sandia and General Motors have successfully designed, fabricated, and experimentally operated a vehicle-scale hydrogen storage demonstration system using sodium alanates. The demonstration system module design and the system control strategies were enabled by experiment-based, computational simulations that included heat and mass transfer coupled with chemical kinetics. Module heat exchange systems were optimized using multi-dimensional models of coupled fluid dynamics and heat transfer. Chemical kinetics models were coupled with both heat and mass transfer calculations to design the sodium alanate vessels. Fluid flow distribution was a key aspect of the design for the hydrogen storage modules and computational simulations were used to balance heat transfer with fluid pressure requirements.     

Metal hydride material requirements for automotive hydrogen storage systems

The United States Department of Energy (DOE) has published a progression of technical targets to be satisfied by on-board rechargeable hydrogen storage systems in light-duty vehicles. By combining simplified storage system and vehicle models with interpolated data from metal hydride databases, we obtain material-level requirements for metal hydrides that can be assembled into systems that satisfy the DOE targets for 2017. We assume minimal balance-of-plant components for systems with and without a hydrogen combustion loop for supplemental heating. Tank weight and volume are driven by the stringent requirements for refueling time. The resulting requirements suggest that, at least for this specific application, no current on-board rechargeable metal hydride satisfies these requirements.     

System simulation model for high-pressure metal hydride hydrogen storage systems

On-board hydrogen storage systems employing high-pressure metal hydrides promise advantages including high volumetric capacities and cold start capability. In this paper, we discuss the development of a system simulation model in Matlab/Simulink platform. Transient equations for mass balance and energy balance are presented. Appropriate kinetic expressions are used for the absorption/desorption reactions for the Ti_1.1CrMn metal hydride. During refueling, the bed is cooled by passing a coolant through tubes embedded within the bed while during driving, the bed is heated by pumping the radiator fluid through same set of tubes. The feasibility of using a high-pressure metal hydride storage system for automotive applications is discussed. Drive cycle simulations for a fuel cell vehicle are performed and detailed results are presented.     

Numerical simulation of heat and mass transfer in metal hydride hydrogen storage tanks for fuel cell vehicles

This paper presents a two-dimensional mathematical model to optimized heat and mass transfer in metal hydride storage tanks (hereinafter MHSTs) for fuel cell vehicles, equipped with finned spiral tube heat exchangers. This model which considers complex heat and mass transfer was numerically solved and validated by comparison with experimental data and a good agreement is obtained.     

System modeling methodology and analyses for materials-based hydrogen storage

In the global efforts to develop advanced materials-based hydrogen storage, the various on-board reversible hydrides, adsorbents and chemical storage candidate materials and systems each have their individual strengths and weaknesses. An overarching challenge in associated research and development is to devise material/system architectures which satisfy all requirements for viability in a particular application area, such as light-duty vehicular transportation. System modeling at the level which encompasses not only the storage material and vessel/reactor, but also integration with a fuel cell and balance-of-plant components, provides a more complete assessment of viability and guides options for improvement. The current work covers the methodology developed for conducting such system modeling consistently across multiple organizations and will present performance results from studies focused on reversible hydride systems. Connecting this high level modeling to more detailed finite element design simulations will be one aspect of our framework approach. The complex hydride NaAlH₄ is representative of novel materials under development and will be used as the basis for properties, such as temperature dependent kinetics, which influence the integrated system configurations and component sizing. While system charging is included through the sizing of certain components, emphasis is placed on hydrogen discharge by the storage system, interrogated through drive cycle transients. Comparisons of performance relative to requirements, including effective gravimetric capacity, effective volumetric density and energy utilization, are given for the baseline material and for a sensitivity study on material density.     

Parametric investigations on LCC1 based hydrogen storage system intended for fuel cell applications

Considering the necessity for compact hydrogen storage system for fuel cell stacks, 41 embedded cooling tube (ECT) reactor with an outer cooling jacket (OCJ) is designed, fabricated and tested with 3.75 kg of LCC1® alloy. To analyse the sensitivity of the system performance at various operating conditions and the applicability of this prototype as storage system, an extensive parametric investigation was carried out at varying supply pressure (P_s), absorption temperature (T_a) and desorption temperature (T_d). LCC1® alloy achieved maximum hydrogen storage capacity (HSC) of 1.6 wt% within 420 s at P_s of 25 bar, T_a of 25 °C and heat transfer fluid (HTF) flow rate (HTF_a) of 6 LPM. Supply pressure is found to have greater influence than absorption temperature over absorption performance and heating output. With T_a of 25 °C, HTF_a of 6 LPM, HSC of 1.58 wt% and 1.6 wt% were achieved at P_s of 20 bar and 30 bar, respectively, resulting in corresponding specific heating power (SHP) of 497.7 W/kg and 544.9 W/kg. Varying T_a from 25 °C to 35 °C at P_s of 20 bar and HTF_a of 6 LPM resulted in 3% reduction in HSC. During desorption, desorption temperature of above 20 °C is found to be favourable with more than 95% of stored hydrogen being desorbed. It is further observed that the dehydriding rate of LCC1® was nearly steady which is potentially suitable for fuel cell applications, as the average dehydriding rate is estimated to be about 15.75 NLPM and 22.91 NLPM at T_d of 20 °C and 25 °C, respectively, with 6 LPM of HTF flow rate. The analysed module is proposed as a potential hydrogen supply unit for a 1 kW fuel cell reported in literature.     

On-board and Off-board performance of hydrogen storage options for light-duty vehicles

Leading physical and materials-based hydrogen storage options are evaluated for their potential to meet the vehicular targets for gravimetric and volumetric capacity, cost, efficiency, durability and operability, fuel purity, and environmental health and safety. Our analyses show that hydrogen stored as a compressed gas at 350–700 bar in Type III or Type IV tanks cannot meet the near-term volumetric target of 28 g/L. The problems of dormancy and hydrogen loss with conventional liquid H₂ storage can be mitigated by deploying pressure-bearing insulated tanks. Alane (AlH₃) is an attractive hydrogen carrier if it can be prepared and used as a slurry with >50% solids loading and an appropriate volume-exchange tank is developed. Regenerating AlH₃ is a major problem, however, since it is metastable and it cannot be directly formed by reacting the spent Al with H₂. We have evaluated two sorption-based hydrogen storage systems, one using AX-21, a high surface-area superactivated carbon, and the other using MOF-177, a metal-organic framework material. Releasing hydrogen by hydrolysis of sodium borohydride presents difficult chemical, thermal and water management issues, and regenerating NaBH₄ by converting B–O bonds is energy intensive. We have evaluated the option of using organic liquid carriers, such as n-ethylcarbazole, which can be dehydrogenated thermolytically on-board a vehicle and rehydrogenated efficiently in a central plant by established methods and processes. While ammonia borane has a high hydrogen content, a solvent that keeps it in a liquid state needs to be found, and developing an AB regeneration scheme that is practical, economical and efficient remains a major challenge.     

Hydrogen storage systems for fuel cells: Comparison between high and low-temperature metal hydrides

The need for the enhancement of alternative energy sources is increasingly recognised and, in this perspective, the achievement of hydrogen economy seems to be fundamental. In this regard, fuel cells represent an interesting option for small and medium scale distributed renewable generation; however, these systems are inextricably linked with the concept of hydrogen storage. Research on metal hydrides revealed the opportunity to use these materials as basic elements in hydrogen storage devices, called MH systems. This means that interest exists in investigating the behaviour of metal hydrides: in fact, MH system operation is based on the hydriding/dehydriding reactions hydrides undergo, and, with the aim of evaluating the performance of such devices, these processes must be discussed and modelled.In the light of this, a simple numerical model to study hydride-based storage systems and their integration with fuel cells was developed: two low-temperature hydrides (LaNi₅, LaNi_4·8Al_0.2) and two high-temperature hydrides (Mg, Mg₂Ni) were selected and their behaviours in a MH system were simulated and compared with the help of such a model. This is an essential step in identifying the hydrides more suited to the application in question. Results showed that the choice is the trade off between encumbrance and reaction times; this implies that low-temperature hydrides are preferable because their encumbrance is limited and their reaction temperature range grants a greater versatility in small scale generation.     

Dynamic simulation and lifecycle assessment of hydrogen fuel cell electric vehicles considering various hydrogen production methods

In this research study, a real model of a hydrogen fuel cell vehicle is simulated using Simcenter Amesim software. The software used for vehicle simulation enabled dynamic simulation, resulting in more precise simulation. Furthermore, considering that fuel cell degradation is one of the significant challenges confronting fuel cell vehicle manufacturers, we examined the impact of fuel cell degradation on the performance of hydrogen vehicles. According to the findings, a hydrogen vehicle with a degraded fuel cell consumes 14.3% more fuel than a fresh fuel cell hydrogen vehicle. A comprehensive life cycle assessment (LCA) is also performed for the designed hydrogen vehicle. The results of the hydrogen vehicle life cycle assessment are compared with a gasoline vehicle to fully understand the effect of hydrogen vehicles in reducing air emissions. The methods considered for hydrogen production included natural gas reforming, electrolysis, and thermochemical water splitting method. Furthermore, because the source of electricity used for electrolysis has a significant impact on the life cycle emission of a hydrogen vehicle, three different power sources were considered in this assessment. Finally, while a hydrogen vehicle with a degraded fuel cell emits lower carbon dioxide (CO₂) than a gasoline vehicle, the emitted CO₂ from this vehicle using hydrogen from electrolysis is approximately 25% higher than that of a new hydrogen vehicle.