Regenerative energy control system for plug-in hydrogen fuel cell scooter

An intelligent control system was developed using simple control methodologies for an H₂-powered fuel cell scooter with the aid of a built-in microprocessor. This system increases the power input to drive a hydrogen fuel cell scooter, particularly during uphill conditions by running both the batteries and the fuel cell source in parallel. This system also improves the energy management of the scooter by recharging the battery using the fuel cell as well as automatic switching to the battery source when the hydrogen fuel cell is running low on hydrogen. This system was tested on a bench set simulating a 254 W hydrogen fuel cell stack equipped on a 200 W scooter. The test rig set-up depicts a practical scooter running on various load conditions. These results reflect the efficiencies of actual running conditions. The entire operation was embedded in a PICAXE-18 microcontroller for automatic switching between the batteries and the fuel cell source. An increase in the DC motor efficiency by 6 % has been shown. The uphill angle of the scooter has been increased by 19.3 %, which means the scooter would be able to travel on steeper hills. Copyright © 2007 John Wiley & Sons, Ltd.     

Hybrid fuel cell-based energy system with metal hydride hydrogen storage for small mobile applications

This paper describes the general architecture of a hybrid energy system, whose main components are a proton exchange membrane fuel cell, a battery pack and an ultracapacitor pack as power sources, and metal hydride canisters as energy storage devices, suitable for supplying power to small mobile non-automotive devices in a flexible and variable way. The first experimental results carried out on a system prototype are described, showing that the extra components, required in order to manage the hybrid system, do not remarkably affect the overall system efficiency, which is always higher than 36% in all the test configurations examined. In fact, the system allows the fuel cell to work most often at quasi-optimal conditions, near its maximum efficiency (i.e. at low/medium loads), because high external loads are met by the combined effort of the fuel cell and the ultracapacitors. For the same reason, the metal hydride storage system can be used also under highly dynamic operating conditions, notwithstanding its usually poor kinetic performance.     

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.     

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.     

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).     

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.     

Tests on a metal hydride based thermal energy storage system

In this paper, the performance tests on Mg + 30% MmNi₄ based thermal energy storage device is presented. Experiments were carried out at different supply pressures (10–30 bar) and absorption temperatures (120–150 °C). The effects of hydrogen supply pressure and absorption temperature on the amount of hydrogen/heat stored and thermal energy storage coefficient are presented. The maximum hydrogen storage capacity of 2.5wt% is reported at the operating conditions of 20 bar supply pressure and 150 °C absorption temperature. For a given absorption temperature of 150 °C, the thermal energy storage coefficient is found to increase from 0.5 at 10 bar to 0.74 at 30 bar supply pressure. For the given operating conditions of 20 bar supply pressure and 150 °C absorption temperature, the maximum amount of heat stored is about 0.714 MJ/kg and the corresponding thermal energy storage coefficient is 0.74.     

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.     

Enhancement of hydrogen storage performance in shell and tube metal hydride tank for fuel cell electric forklift

Novel metal hydride (MH) hydrogen storage tanks for fuel cell electric forklifts have been presented in this paper. The tanks comprise a shell side equipped with 6 baffles and a tube side filled with 120 kg AB₅ alloy and 10 copper fins. The alloy manufactured by vacuum induction melting has good hydrogen storage performance, with high storage capacity of 1.6 wt% and low equilibrium pressure of 4 MPa at ambient temperature. Two types of copper fins, including disk fins and corrugated fins, and three kinds of baffles, including segmental baffles, diagonal baffles and hole baffles, were applied to enhance the heat transfer in metal hydride tanks. We used the finite element method to simulate the hydrogen refueling process in MH tanks. It was found that the optimized tank with corrugated fins only took 630 s to reach 1.5 wt% saturation level. The intensification on the tube side of tanks is an effective method to improve hydrogen storage performance. Moreover, the shell side flow field and hydrogen refueling time in MH tanks with different baffles were compared, and the simulated refueling time is in good agreement with the experimental data. The metal hydride tank with diagonal baffles shows the shortest hydrogen refueling time because of the highest velocity of cooling water. Finally, correlations regarding the effect of cooling water flow rate on the refueling time in metal hydride tanks were proposed for future industrial design.     

Review of metal hydride hydrogen storage thermal management for use in the fuel cell systems

Thermal management of metal hydride (MH) hydrogen storage systems is critically important to maintain the hydrogen absorption and release rates at desired levels. Implementing thermal management arrangements introduces challenges at system level mostly related to system's overall mass, volume, energy efficiency, complexity and maintenance, long-term durability, and cost. Low effective thermal conductivity (ETC) of the MH bed (~0.1–0.3 W/mK) is a well-known challenge for effective implementation of different thermal management techniques. This paper comprehensively reviews thermal management solutions for the MH hydrogen storage used in fuel cell systems by also focusing on heat transfer enhancement techniques and assessment of heat sources used for this purpose. The literature recommended that the ETC of the MH bed should be greater than 2 W/mK, and heat transfer coefficient with heating/cooling media should be in the range of 1000–1200 W/m²K to achieve desired MH's performance. Furthermore, alternative heat sources such as fuel cell heat recovery or capturing MH heat during charging and releasing it back during discharging have also been thoroughly reviewed here. Finally, this review paper highlights the gaps and suggests directions accordingly for future research on thermal management for MH systems.     

Effects of tank heating on hydrogen release from metal hydride system in VoltaFCEV Fuel Cell Electric Vehicle

Metal hydride (MH) storage is known as a safe storage method because it does not require complex processes like high pressure or very low temperature. However, it is necessary to use a heat exchanger due to the endothermic and exothermic reactions occurring during the charging and discharging processes of the MH tanks. The performance of the MH is adversely affected by the lack of a heat exchanger or a suitable temperature range and it causes non-stable hydrogen supply to the fuel cell systems. In this study, effect of the tank surface temperature on hydrogen flow and hydrogen consumption performance were investigated for the MH hydrogen storage system of a hydrogen Fuel Cell Electric Vehicle (FCEV). Different temperature values were arranged using an external heat circulator device and a heat exchanger inside the MH tank. The fuel cell (FC) was operated at three different power levels (200 W, 400 W, and 600 W) and its performance was determined depending on the temperature and discharge flow rate of the MH tank. When the heat exchanger temperature (HET) was set to 40 °C, the discharge performance of the MH tank increased compared to lower temperatures. For example, when the FC power was set to 200 W and the HET of the system was at 40 °C, 1600 L hydrogen was supplied to the FC and 2000 Wh electrical energy was obtained. The results show that the amount of hydrogen supplied from the MH tank decreases significantly by increasing the flow rate in the system and rapid temperature changes occur in the MH tank.     

Experimental investigation on the online fuzzy energy management of hybrid fuel cell/battery power system for UAVs

The hybrid powerplant combining a fuel cell and a battery has become one of the most promising alternative power systems for electric unmanned aerial vehicles (UAVs). To enhance the fuel efficiency and battery service life, highly effective and robust online energy management strategies are needed in real applications.In this work, an energy management system is designed to control the hybrid fuel cell and battery power system for electric UAVs. To reduce the weight, only one programmable direct-current to direct-current (dcdc) converter is used as the critical power split component to implement the power management strategy. The output voltage and current of the dcdc is controlled by an independent energy management controller. An executable process of online fuzzy energy management strategy is proposed and established. According to the demand power and battery state of charge, the online fuzzy energy management strategy produces the current command for the dcdc to directly control the output current of the fuel cell and to indirectly control the charge/discharge current of the battery based on the power balance principle.Another two online strategies, the passive control strategy and the state machine strategy, are also employed to compare with the proposed online fuzzy strategy in terms of the battery management and fuel efficiency. To evaluate and compare the feasibility of the online energy management strategies in application, experiments with three types of missions are carried out using the hybrid power system test-bench, which consists of a commercial fuel cell EOS600, a Lipo battery, a programmable dcdc converter, an energy management controller, and an electric load. The experimental investigation shows that the proposed online fuzzy strategy prefers to use the most power from the battery and consumes the least amount of hydrogen fuel compared with the other two online energy management strategies.     

Thermally integrated energy storage system for hybrid fuel cell electric bike: An experimental study

The hybrid fuel cell/battery technology is an attractive option for a sustainable mobility with zero emissions. In fact, this solution owns system scalability features and high efficiency and, compared to battery electric solutions, it offers advantages in terms of flexibility of use and fast charging times. However, the thermal management for the battery in this type of powertrain is a crucial issue, since operating temperatures can significantly affect safety and performance. In this study, an innovative system aimed at providing high storage energy density and improving the battery pack performance of hybrid fuel cell/battery vehicles is investigated for use on-board of a plug-in fuel cell electric bike. The proposed system, developed by the authors in previous studies, integrates the battery pack with a hydrogen storage based on metal hydrides. The idea behind this solution is to exploit the endothermic desorption processes of hydrogen in metal hydrides to cool down the battery pack during operation. An experimental analysis is conducted to assess the thermal management capabilities of this system: by considering a typical duty cycle designed on the base of road test measurements, battery pack temperature profiles are evaluated and compared against those from a control experiment where no battery thermal management is enabled (i.e. no hydrogen desorption from the metal hydride tank). The results show that, beside enhancing the on-board stored energy capacity, the proposed system represents an effective solution to provide an efficient thermal management for the battery pack, with significant advantages in terms of attainable riding range.     

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.     

Dynamic modeling and simulation of hydrogen supply capacity from a metal hydride tank

The current study presents a modeling of a LaNi₅ metal hydride-based hydrogen storage tank to simulate and control the dynamic processes of hydrogen discharge from a metal hydride tank in various operating conditions. The metal hydride takes a partial volume in the tank and, therefore, hydrogen discharge through the exit of the tank was driven by two factors; one factor is compressibility of pressurized gaseous hydrogen in the tank, i.e. the pressure difference between the interior and the exit of the tank makes hydrogen released. The other factor is desorption of hydrogen from the metal hydride, which is subsequently released through the tank exit. The duration of a supposed full load supply is evaluated, which depends on the initial tank pressure, the circulation water temperature, and the metal hydride volume fraction in the tank. In the high pressure regime, the duration of full load supply is increased with increasing circulation water temperature while, in the low pressure regime where the initial amount of hydrogen absorbed in the metal hydride varies sensitively with the metal hydride temperature, the duration of full load supply is increased and then decreased with increasing circulation water temperature. PID control logic was implemented in the hydrogen supply system to simulate a representative scenario of hydrogen consumption demand for a fuel cell system. The demanded hydrogen consumption rate was controlled adequately by manipulating the discharge valve of the tank at a circulation water temperature not less than a certain limit, which is increased with an increase in the tank exit pressure.     

Performance prediction of a coupled metal hydride based thermal energy storage system

The present study discusses the thermodynamic compatibility criteria for the selection of metal hydride pairs for the application in coupled metal hydride based thermal energy storage systems. These are closed systems comprising of two metal hydride beds – a primary bed for energy storage and a secondary bed for hydrogen storage. The performance of a coupled system is analyzed considering Mg₂Ni material for energy storage and LaNi₅ material for hydrogen storage. A 3-D model is developed and simulated using COMSOL Multiphysics® at charging and discharging temperatures of 300 °C and 230 °C, respectively. The LaNi₅ bed used for hydrogen storage is operated close to ambient temperature of 25 °C. The results of the first three consecutive cycles are presented. The thermal storage system achieved a volumetric energy storage density of 156 kWh m⁻³ at energy storage efficiency of 89.4% during third cycle.     

Numerical simulation of the hydrogen storage with reaction heat recovery using metal hydride in the totalized hydrogen energy utilization system

Numerical simulation of a hydrogen storage tank of a Totalized Hydrogen Energy Utilization System (THEUS) for application to commercial buildings was done to verify the practicality of THEUS. THEUS consists of a fuel cell, water electrolyzer, hydrogen storage tank and their auxiliary machinery. The hydrogen storage tanks with metal hydrides for load leveling have been previously experimentally investigated as an important element of THEUS. A hydrogen storage tank with 50 kg AB5 type metal hydride was assembled to investigate the hydrogen-absorbing/desorbing process, which is exothermic/endothermic process. The goal of this tank is to recover the cold heat of the endothermic process for air conditioning, and thus improve the efficiency of THEUS. To verify the practical effectiveness of this improved system, we developed a numerical simulation code of hydrogen storage tank with metal hydride. The code was validated by comparing its results with experimental results. In this code the specific heat value of the upper and lower flanges of the hydrogen storage tank was adjusted to be equal to the thermal capacity of the entire tank. The simulation results reproduce well the experimental results.     

Thermal management and power saving operations for improved energy efficiency within a renewable hydrogen energy system utilizing metal hydride hydrogen storage

To ensure the energy efficiency of renewable hydrogen energy systems, power conservation and thermal management are necessary. This study applies these principals to the operation of metal hydride tanks (MHTs) in a bench-scale hydrogen system, named Hydro Q-BiC?, comprising photovoltaic panels (20 kW), an electrolyzer (5 Nm³/h), MHTs containing a TiFe-based MH (40 Nm³), fuel cells (FC; 3.5 kW(power)/2.5 kW(heat)), and Li-ion batteries (20 kW/20 kWh). Here, we show that in a modified hydrogen production operation, with limited use of auxiliaries for cooling the MHTs, the power consumption of the MHTs was reduced by more than 99% compared to a typical operation. The thermal requirements for the MHTs were reduced by ceasing production in a pressurized state. During the hydrogen use operation, the power consumption was reduced to 1/4 and the FC heat output could be fully used; hence, the overall energy efficiency (power-to-hydrogen-to-power/heat) was as high as ~ 60% (43% for the typical operation).     

An innovative optimal power allocation strategy for fuel cell, battery and supercapacitor hybrid electric vehicle

An optimal design of a three-component hybrid fuel cell electric vehicle comprised of fuel cells, battery, and supercapacitors is presented. First, the benefits of using this hybrid combination are analyzed, and then the article describes an active power-flow control strategy from each energy source based on optimal control theory to meet the demand of different vehicle loads while optimizing total energy cost, battery life and other possible objectives at the same time. A cost function that minimizes the square error between the desired variable settings and the current sensed values is developed. A gain sequence developed compels the choice of power drawn from all devices to follow an optimal path, which makes trade-offs among different targets and minimizes the total energy spent. A new method is introduced to make the global optimization into a real-time based control. A model is also presented to simulate the individual energy storage systems and compare this invention to existing control strategies, the simulation results show that the total energy spent is well saved over the long driving cycles, also the fuel cell and batteries are kept operating in a healthy way.     

A robust online energy management strategy for fuel cell/battery hybrid electric vehicles

Traditional optimization-based energy management strategies (EMSs) do not consider the uncertainty of driving cycle induced by the change of traffic conditions, this paper proposes a robust online EMS (ROEMS) for fuel cell hybrid electric vehicles (FCHEV) to handle the uncertain driving cycles. The energy consumption model of the FCHEV is built by considering the power loss of fuel cell, battery, electric motor, and brake. An offline linear programming-based method is proposed to produce the benchmark solution. The ROEMS instantaneously minimizes the equivalent power of fuel cell and battery, where an equivalent efficiency of battery is defined as the efficiency of hydrogen energy transforming to battery energy. To control the state of charge of battery, two control coefficients are introduced to adjust the power of battery in objective function. Another penalty coefficient is used to amend the power of fuel cell, which reduces the load change of fuel cell so as to slow the degradation of fuel cell. The simulation results indicate that ROEMS has good performance in both fuel economy and load change control of fuel cell. The most important advantage of ROEMS is its robustness and adaptivity, because it almost produces the optimal solution without changing the control parameters when driving cycles are changed.