Systematic planning to optimize investments in hydrogen infrastructure deployment

The introduction of hydrogen infrastructure and fuel cell vehicles (FCVs) to gradually replace gasoline internal combustion engine vehicles can provide environment and energy security benefits. The deployment of hydrogen fueling infrastructure to support the demonstration and commercialization of FCVs remains a critical barrier to transitioning to hydrogen as a transportation fuel. This study utilizes an engineering methodology referred to as the Spatially and Temporally Resolved Energy and Environment Tool (STREET) to demonstrate how systematic planning can optimize early investments in hydrogen infrastructure in a way that supports and encourages growth in the deployment of FCVs while ensuring that the associated environment and energy security benefits are fully realized. Specifically, a case study is performed for the City of Irvine, California – a target area for FCV deployment – to determine the optimized number and location of hydrogen fueling stations required to provide a bridge to FCV commercialization, the preferred rollout strategy for those stations, and the environmental impact associated with three near-term scenarios for hydrogen production and distribution associated with local and regional sources of hydrogen available to the City. Furthermore, because the State of California has adopted legislation imposing environmental standards for hydrogen production, results of the environmental impact assessment for hydrogen production and distribution scenarios are measured against the California standards. The results show that significantly fewer hydrogen fueling stations are required to provide comparable service to the existing gasoline infrastructure, and that key community statistics are needed to inform the preferred rollout strategy for the stations. Well-to-wheel (WTW) greenhouse gas (GHG) emissions, urban criteria pollutants, energy use, and water use associated with hydrogen and FCVs can be significantly reduced in comparison to the average parc of gasoline vehicles regardless of whether hydrogen is produced and distributed with an emphasis on conventional resources (e.g., natural gas), or on local, renewable resources. An emphasis on local renewable resources to produce hydrogen further reduces emissions, energy use, and water use associated with hydrogen and FCVs compared to an emphasis on conventional resources. All three hydrogen production and distribution scenarios considered in the study meet California's standards for well-to-wheel GHG emissions, and well-to-tank emissions of urban ROG and NO_X. Two of the three scenarios also meet California's standard that 33% of hydrogen must be produced from renewable feedstocks. Overall, systematic planning optimizes both the economic and environmental impact associated with the deployment of hydrogen infrastructure and FCVs.     

Risk assessment for liquid hydrogen fueling stations

In recent years, consumers calling for the protection of the environment on a regional and global scale are demanding the use of vehicles that do not emit harmful exhaust. It is anticipated that one response to this demand is the widespread use of fuel cell vehicles (FCVs). In order to achieve this, it is necessary to provide hydrogen fueling stations where FCVs can refuel.     

Development of efficient hydrogen refueling station by process optimization and control

Development of efficient hydrogen refueling station (HRS) is highly desirable to reduce the hydrogen cost and hence the life cycle expense of fuel cell vehicles (FCVs), which is hindering the large scale application of hydrogen mobility. In this work, we demonstrate the optimization of gaseous HRS process and control method to perform fast and efficient refueling, with reduced energy consumption and increased daily fueling capacity. The HRS was modeled with thermodynamics using a numerical integration method and the accuracy for hydrogen refueling simulation was confirmed by experimental data, showing only 2 °C of temperature rise deviation. The refueling protocols for heavy duty FCVs were first optimized, demonstrating an average fueling rate of 2 kg/min and pre-cooling demand of less than 7 kW for 35 MPa type III tanks. Fast refueling of type IV tanks results in more significant temperature rise, and the required pre-cooling temperature is lowered by 20 K to achieve comparable fueling rate. The station process was also optimized to improve the daily fueling capacity. It is revealed that the hydrogen storage amount is cost-effective to be 25–30% that of the nominal daily refueling capacity, to enhance the refueling performance at peak time and minimize the start and stop cycles of compressor. A novel control method for cascade replenishment was developed by switching among the three banks in the order of decreased pressure, and results show that the daily refueling capacity of HRS is increased by 5%. Therefore, the refueling and station process optimization is effective to promote the efficiency of gaseous HRS.     

Generation of high-pressure hydrogen for fuel cell electric vehicles using photovoltaic-powered water electrolysis

Increasing the utilization of electric drive systems including hybrid, battery, and fuel cell electric vehicles (FCEV) will reduce the usage of petroleum and the emission of air pollution by vehicles. The eventual production of electricity and hydrogen in a renewable fashion, such as using solar energy, can achieve the long-term vision of having no tailpipe emissions, as well as eliminating the dependence of the transportation sector on dwindling supplies of petroleum for its energy. Before FCEVs can be introduced in large numbers, a hydrogen-fueling infrastructure is needed. This report describes an early proof-of-concept for a distributed hydrogen fueling option in which renewably generated, high-pressure hydrogen is dispensed at an FCEV owner’s home. In an earlier report we described the design and initial characterization of a solar photovoltaic (PV) powered electrolyzer/storage/dispensing (ESD) system that was a proof-of-concept for a single FCEV home fueling system. In the present report we determined the efficiency and other operational characteristics of that PV-ESD system during testing over a 109-day period at the GM Proving Ground in Milford, MI, at a hydrogen output pressure of approximately 2000 psi (13.8 MPa). The high pressure was achieved without any mechanical compression via electrolysis. Over the study period the photovoltaic solar to electrical efficiency averaged 13.7%, the electrolyzer efficiency averaged 59%, and the system solar to hydrogen efficiency averaged 8.2% based on the hydrogen lower heating value. A well-documented model used to evaluate solar photovoltaic power systems was used to calculate the maximum power point values of the voltage, current, and power of our PV system in order to derive the coupling factor between the PV and ESD systems and to determine its behavior over the range of environmental conditions experienced during the study. The average coupling factor was near unity, indicating that the two systems remained coupled in an optimal fashion. Also, the system operated well over a wide range of meteorological conditions, and in particular it responded quickly to instantaneous changes in the solar irradiance (caused by clouds) with negligible effect on the overall efficiency. During the study up to 0.67 kg of high-pressure hydrogen was generated on a sunny day for fueling FCEV. Future generations of high-pressure electrolyzers, properly combined with solar PV systems, can offer a compact, efficient, and environmentally acceptable system for FCEV home fueling.     

Consequence analysis and safety verification of hydrogen fueling stations using CFD simulation

Now that environmental awareness is enhanced on a global basis, great hopes are placed on the expanded use of hydrogen stations and fuel-cell vehicles (FCVs) that economize hydrogen energy. Hydrogen stations must be safe and secure because they store large quantities of hydrogen under higher pressure than the hydrogen actually consumed by FCVs. Thus, multiple safety measures are taken to ensure that hydrogen does not leak from the stations. Furthermore, in the unlikely event of leakage, the damage needs to be kept on an allowable level. For this reason, it is necessary to understand the behavior of hydrogen gas leaking from the stations.     

Less is more: Robust prediction for fueling processes on hydrogen refueling stations

The monitoring of hydrogen refueling stations (HRSs) ensures the safety of their operations as well as optimal fueling performance. For a H70-T40 dispenser, a fueling process is required to control the temperature to be below 85 °C; the pressure to be under 70 MPa; and the final state-of-charge (SOC) to be between 95% and 100%. Table-based or MC (total heat capacity) formula-based fueling protocols are traditionally used to achieve such control. In this paper, we propose using a machine learning model to predict the key parameters of fueling processes: the final SOC, the final temperature, and the final pressure in the vehicle tank. To handle outliers and noise in real operation, we adopt a two-stage method. In the first stage, after clustering fueling processes using soft dynamic time warping, a small number of fueling processes are selected from a large amount of historical data. In the second stage, based on initial and current operating conditions, the final SOC, temperature, and pressure of fueling processes are predicted using three models: least absolute shrinkage and selection operator (LASSO), Gaussian process regression (GPR), and robust regression. The experiments on real operational data collected from four hydrogen refueling stations show that the robust regression model achieves better performance than LASSO and GPR for three out of the four stations, and that the robust regression model captures the normal states of regular operation. The computational time of the robust regression model is also scalable for real-time operation. Our study provides a feasible machine learning model for predicting the key fueling parameters, which facilitates the optimization of HRS operation.     

Behavioral response to hydrogen fuel cell vehicles and refueling: Results of California drive clinics

Over the last several decades, hydrogen fuel cell vehicles (FCVs) have emerged as a zero tailpipe-emission alternative to the battery electric vehicle (EV). To address questions about consumer reaction to FCVs, this report presents the results of a “ride-and-drive” clinic series (N = 182) held in 2007 with a Mercedes-Benz A-Class “F-Cell” hydrogen FCV. The clinic evaluated participant reactions to driving and riding in an FCV, as well as vehicle refueling. Pre-and post-clinic surveys assessed consumer response. More than 80% left with a positive overall impression of hydrogen. The majority expressed a willingness to travel 5–10 min to find a hydrogen station. More than 90% of participants would consider an FCV driving range of 300 miles (480 km) to be acceptable. Stated willingness-to-pay preferences were explored. The results show that short-term exposure can improve consumer perceptions of hydrogen performance and safety among people who are the more likely early adopters.     

Simulation of hydrogen leak and explosion for the safety design of hydrogen fueling station in Korea

Hydrogen has been used as chemicals and fuels in industries for last decades. Recently, it has become attractive as one of promising green energy candidates in the era of facing with two critical energy issues such as accelerating deterioration of global environment (e.g. carbon dioxide emissions) as well as concerns on the depletion of limited fossil sources. A number of hydrogen fueling stations are under construction to fuel hydrogen-driven vehicles. It would be indispensable to ensure the safety of hydrogen station equipment and operating procedure in order to prevent any leak and explosions of hydrogen: safe design of facilities at hydrogen fueling stations e.g. pressurized hydrogen leak from storage tanks. Several researches have centered on the behaviors of hydrogen ejecting out of a set of holes of pressurized storage tanks or pipes. This work focuses on the 3D simulation of hydrogen leak scenario cases at a hydrogen fueling station, given conditions of a set of pressures, 100, 200, 300, 400 bar and a set of hydrogen ejecting hole sizes, 0.5, 0.7, 1.0 mm, using a commercial computational fluid dynamics (CFD) tool, FLACS. The simulation is based on real 3D geometrical configuration of a hydrogen fueling station that is being commercially operated in Korea. The simulation results are validated with hydrogen jet experimental data to examine the diffusion behavior of leak hydrogen jet stream. Finally, a set of marginal safe configurations of fueling facility system are presented, together with an analysis of distribution characteristics of blast pressure, directionality of explosion. This work can contribute to marginal hydrogen safety design for hydrogen fueling stations and a foundation on establishing a safety distance standard required to protect from hydrogen explosion in Korea being in the absence of such an official requirement.     

Modeling operating modes,energy consumptions,and infrastructure requirements of fuel cell plug in hybrid electric vehicles using longitudinal geographical transportation data

The fuel cell plug in hybrid electric vehicle (FCPHEV) is a near-term realizable concept to commercialize hydrogen fuel cell vehicles (FCV). Relative to conventional FCVs, FCPHEVs seek to achieve fuel economy benefits through the displacement of hydrogen energy with grid-sourced electrical energy, and they may have less dependence on a sparse hydrogen fueling infrastructure. Through the simulation of almost 690,000 FCPHEV trips using geographic information system (GIS) data surveyed from a fleet of private vehicles in the Puget Sound area of Washington State, USA, this study derives the electrical and hydrogen energy consumption of various design and control variants of FCPHEVs. Results demonstrate that FCPHEVs can realize hydrogen fuel consumption reductions relative to conventional FCV technologies, and that the fuel consumption reductions increase with increased charge depleting range. In addition, this study quantifies the degree to which FCPHEVs are less dependent on hydrogen fueling infrastructure, as FCPHEVs can refuel with hydrogen at a lower rate than FCVs. Reductions in hydrogen refueling infrastructure dependence vary with control strategies and vehicle charge depleting range, but reductions in fleet-level refueling events of 93% can be realized for FCPHEVs with 40 miles (60 km) of charge depleting range. These fueling events occur on or near the network of highways at approximately 4% of the rate (refuelings per year) of that for conventional FCVs. These results demonstrate that FCPHEVs are a type of FCV that can enable an effective and concentrated hydrogen refueling network.     

A solar-powered,high-efficiency hydrogen fueling system using high-pressure electrolysis of water: Design and initial results

Hydrogen for fuel-cell electric vehicles (FCEVs) was produced using clean, renewable solar energy to electrolyze water. This report describes the design, construction, and initial performance testing of a solar hydrogen fueler at the GM Proving Ground in Milford, MI. The system used high-efficiency photovoltaic (PV) modules, a high-pressure (6500 psi, 44.8 MPa) electrolyzer, and an optimized direct connection between the PV and electrolyzer systems. This resulted in world-class solar to hydrogen efficiencies as high as 9.3% (based on H₂ lower heating value, LHV). The system could potentially supply approximately 0.5 kg of hydrogen per day from solar power for the average solar insolation in Detroit; more hydrogen would be produced in locations with more abundant sunshine. This is sufficient hydrogen to operate an FCEV for an average daily urban commute. Thus, the solar hydrogen fueler testing served as a “proof of concept” for clean, renewable hydrogen with potential applications including convenient, clean, quiet, small-scale home fueling of FCEVs (that can contribute to the growth of a future FCEV fleet) and fueling in remote locations where grid electricity is not available.     

Market penetration analysis of fuel cell vehicles in Japan by using the energy system model MARKAL

The objective of the present work is to validate the hydrogen energy roadmap of Japan by analyzing the market penetration of fuel cell vehicles (FCVs) and the effects of a carbon tax using an energy system model of Japan based on MARKAL. The results of the analysis show that a hydrogen FCV would not be cost competitive until 2050 without a more severe carbon tax than the government's planned 2400 JPY/t-C carbon tax. However, as the carbon tax rate increases, instead of conventional vehicles including the gasoline hybrid electric vehicle, hydrogen FCVs gain market penetration earlier and more. By assuming a more severe carbon tax rate, such as 10 000 JPY/t-C, the market share of hydrogen FCVs approaches the governmental goal. This suggests that cheaper vehicle cost and hydrogen cost than those targeted in the roadmap should be attained or subsidies to hydrogen FCV and hydrogen refueling station will be necessary for achieving the goal of earlier market penetration.     

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.     

Liquid pump-enabled hydrogen refueling system for medium and heavy duty fuel cell vehicles: Station design and technoeconomic assessment

Recent progress in submerged liquid hydrogen (LH₂) cryopump technology development offers improved hydrogen fueling performance at a reduced cost in medium- and heavy-duty (MDV and HDV) fuel cell vehicle refueling applications at 35 MPa pressure, compared to fueling via gas compression. In this paper, we evaluate the fueling cost associated with cryopump-based refueling stations for different MDV and HDV hydrogen demand profiles. We adapt the Heavy Duty Refueling Station Analysis Model (HDRSAM) tool to analyze the submerged cryopump case, and compare the estimated fuel dispensing costs of stations supplied with LH₂ for fueling Class 4 delivery van (MDV), public transit bus (HDV), and Class 8 truck (HDV) fleets using cryopumps relative to station designs. A sensitivity analysis around upstream costs illustrates the trade-offs associated with H₂ production from onsite electrolysis versus central LH₂ production and delivery. Our results indicate that LH₂ cryopump-based stations become more economically attractive as the total station capacity (kg dispensed per day) and hourly demand (vehicles per hour) increase. Depending on the use case, savings relative to next best options range from about 5% up to 44% in dispensed costs, with more favorable economics at larger stations with high utilization.     

Dynamic simulation of the effect of vehicle-side pressure loss of hydrogen fueling process

This study explains the fundamental mathematical equations used for the main component models that are implemented in freely available library for hydrogen fueling station. The paper provides a background to the model formulation and theory, useful for the further investigations of hydrogen fueling stations. The model was verified against a specific manufacturer model, and it was validated by using test data from an actual fueling station. The study works as documentation and validation of the model formulation. The simulation library is used to make a model for investigating how the pressure loss in the vehicle affects the fueling process. Keeping the temperature out of the station constant and fueling to 80 MPa in the compressed hydrogen storage system, the pressure loss in the compressed hydrogen storage system directly correlates to the final temperature. The final temperature increases with increasing pressure losses. It is also shown that with no pressure loss in the vehicle the fueling has no limit in fueling speed as the heat of compression depends on the mass filled and the enthalpy of the mass, and not the filling time.     

Quantitative analysis of a successful public hydrogen station

Reliable hydrogen fueling stations will be required for the successful commercialization of fuel cell vehicles. An evolving hydrogen fueling station has been in operation in Irvine, California since 2003, with nearly five years of operation in its current form. The usage of the station has increased from just 1000 kg dispensed in 2007 to over 8000 kg dispensed in 2011 due to greater numbers of fuel cell vehicles in the area. The station regularly operates beyond its design capacity of 25 kg/day and enables fuel cell vehicles to exceed future carbon reduction goals today. Current limitations include a cost of hydrogen of $15 per kg, net electrical consumption of 5 kWh per kg dispensed, and a need for faster back-to-back vehicle refueling.     

TiCrVMo alloys with high dissociation pressure for high-pressure MH tank

High-pressure metal hydride (MH) tank is a possible hydrogen storage system for fuel cell vehicles. The merit of the high-pressure MH tank system is improved by the use of a metal hydride with high dissociation pressure. In this study, TiCrV and TiCrVMo alloys with BCC structure has been developed for the high-pressure MH tank system. The developed TiCrVMo alloy shows 2.4 mass% of effective hydrogen capacity between 0.1 MPa and 33 MPa at 298 K, which has a dissociation pressure of 2.3 MPa at 298 K. By investigating the dissociation pressures of the synthesized metal hydrides, it is found that Mo has a special effect to increase dissociation pressure of the metal hydrides. This effect is probably attributed to the large bulk modulus of Mo compared to other elements.     

Hydrogen as a transportation fuel produced from thermal gasification of municipal solid waste: an examination of two integrated technologies

Innovative technologies are required to offset increasing consumption and declining stocks of non-renewable resources. This study examines a possible enhancement of waste management and transportation by integrating two emerging technologies: municipal solid waste (MSW) gasification and fuel cell vehicles (FCVs), by fueling FCVs with hydrogen produced from gasified MSW. Material and energy flows were modeled in four MSW management scenarios (incineration, landfill, gasification, gasification with recycling) and four transportation scenarios (hybrid gasoline-electric, methanol FCVs, hydrogen FCVs using hydrogen from natural gas or municipal solid waste). Technological performance deemed feasible within 2010–2020 was assumed. Greenhouse gas emissions and non-renewable energy use were used to assess overall system performance. Gasification with hydrogen production performs as efficiently as incineration, but is advantageous compared to landfilling. Taking into account additional environmental criteria, the model suggests that hydrogen from MSW gasification for FCVs may provide benefits over conventional MSW treatment and transportation systems.     

Energetic evaluation of hydrogen refueling stations with liquid or gaseous stored hydrogen

The future success of fuel cell electric vehicles requires a corresponding infrastructure. In this study, two different refueling station concepts for fuel cell passenger cars with 70 MPa technology were evaluated energetically. In the first option, the input of the refueling station is gaseous hydrogen which is compressed to final pressure, remaining in gaseous state. In the second option, the input is liquid hydrogen which is cryo-compressed directly from the liquid phase to the target pressure. In the first case, the target temperature of −33 °C to −40 °C [1] is achieved by cooling down. In the second option, gaseous deep-cold hydrogen coming from the pump is heated up to target temperature. A dynamic simulation model considering real gas behavior to evaluate both types of fueling stations from an energetic perspective was created. The dynamic model allows the simulation of boil-off losses (liquid stations) and standby energy losses caused by the precooling system (gaseous station) dependent on fueling profiles. The functionality of the model was demonstrated with a sequence of three refueling processes within a short time period (high station utilization). The liquid station consumed 0.37 kWh/kg compared to 2.43 kWh/kg of the gaseous station. Rough estimations indicated that the energy consumption of the entire pathway is higher for liquid hydrogen. The analysis showed the high influence of the high-pressure storage system design on the energy consumption of the station. For future research work the refueling station model can be applied to analyze the energy consumption dependent on factors like utilization, component sizing and ambient temperature.     

Design of a hydrogen community

This paper discusses the conceptual design of a scalable and reproducible hydrogen fueling station at Santa Monica, California. Hydrogen production using renewable energy sources such as biogas, which accounts for 100% of the total production, has been discussed. The fueling station consists of a direct fuel cell (DFC) 300 fuel cell for on-site generation of 136 kg/day of hydrogen and 300 kW of electric power, five hydrogen storage tanks (storage capacity of 198 kg of H₂ at 350 and 700 bar), four compressors which assist in dispensing 400 kg of hydrogen in 14 h, two hydrogen dispensers operating at 350 bar and 700 bar independently and a SAE J2600 compliant hydrogen nozzle. Potential early market customers for hydrogen fuel cells and their daily fuel requirements have been computed. The safety codes, potential failure modes and the methods to mitigate risks have been explained. A well-to-wheel analysis is performed to compare the emissions and the total energy requirements of conventional gasoline and fuel cell vehicles.