Recent challenges of hydrogen storage technologies for fuel cell vehicles

Fuel cell vehicles have a high potential to reduce both energy consumption and carbon dioxide emissions. However, due to the low density, hydrogen gas limits the amount of hydrogen stored on board. This restriction also prevents wide penetration of fuel cells. Hydrogen storage is the key technology towards the hydrogen society. Currently high-pressure tanks and liquid hydrogen tanks are used for road tests, but both technologies do not meet all the requirements of future fuel cell vehicles. This paper briefly explains the current status of conventional technologies (simple containment) such as high-pressure tank systems and cryogenic storage. Another method, hydrogen-absorbing alloy has been long investigated but it has several difficulties for the vehicle applications such as low temperature discharge characteristics and quick charge capability due to its reaction heat. We tested a new idea of combining metal hydride and high pressure. It will solve some difficulties and improve performance such as gravimetric density. This paper describes the latest material and system development.     

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.     

Biogas as hydrogen source for fuel cell applications

In the last decade, production of biogas from biomass degradation has attracted the attention of several research groups. The interest on this hydrogen source is focused on the potential use of this gas as raw material to supply high temperature fuel cells (HTFC). This paper reports a wide research investigation carried out at CNR-ITAE on biogas reforming processes (steam reforming, autothermal reforming and partial oxidation). A mathematical model was developed, in Aspen Plus, and an experimental validation was made in order to confirm model results. Simulations were performed to determine the reformed gas composition and the system energy balance as a function of process temperature and pressure. The value of Gas Hour Space Velocity (GHSV) was selected for calculating compositions at full equilibrium, as it is expected in operative large scale plant. To obtain a realistic evaluation of the reforming processes efficiency, the energy balance for each examined process was developed as available energy of outlet syngas on inlet required energy ratio. The comparison between values of efficiency process gives useful indication about their reliability to be integrate with fuel cell systems.     

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.     

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.     

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%.     

Development of a hydrogen dual sensor for fuel cell applications

The development and application of a hydrogen dual sensor (HDS) for the application in the fuel cell (FC) field, is reported. The dual sensing device is based on a ceramic platform head with a semiconducting metal oxide layer (MOx) printed on Pt interdigitated contacts on one side and a Pt serpentine resistance on the back side. MOx layer acts as a conductometric (resistive) gas sensor, allowing to detect low H₂ concentrations in air with high sensitivity and fast response, making it suitable as a leak hydrogen sensor. The proposed Co-doped SnO₂ layer shows high sensitivity to hydrogen (R₀/R = 90, for 2000 ppm of H₂) at 250 °C in air, and with fast response (<3 s). Pt resistance serves as a thermal conductivity sensor, and can used to monitor the whole range of hydrogen concentration (0–100%) in the fuel cell feed line with short response-recovery times, lower than 13 s and 14 s, respectively. The effect of the main functional parameters on the sensor response have been evaluated by bench tests. The results demonstrate that the dual sensor, in spite of its simplicity and cheapness, is promising for application in safety and efficiency control systems for FC power source.     

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.     

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.     

Analysis of the control strategies for fuel saving in the hydrogen fuel cell vehicles

A hydrogen fuel cell vehicle requires fuel cells, batteries, supercapacitors, controllers and smart control units with their control strategies. The controller ensures that a control strategy predicated on the data taken from the traction motor and energy storage systems is created. The smart control unit compares the fuel cell nominal output power with the vehicle power demand, calculates the parameters and continually adjusts the variables. The control strategies that can be developed for these units will enable us to overcome the technological challenges for hydrogen fuel cell vehicles in the near future. This study presents the best hydrogen fuel cell vehicle configurations and control strategies for safe, low cost and high efficiency by comparing control strategies in the literature for fuel economy.     

A techno-economic analysis of decentralized electrolytic hydrogen production for fuel cell vehicles

Hydrogen from decentralized water electrolysis is one of the main fuelling options considered for future fuel cell vehicles. In this study, a model is developed to determine the key technical and economic parameters influencing the competitive position of decentralized electrolytic hydrogen. This model incorporates the capital, maintenance and energy costs of water electrolysis, as well as a monetary valuation of the associated greenhouse gas (GHG) emissions. It is used to analyze the competitive position of electrolytic hydrogen in three specific locations with distinct electricity mix: Vancouver, Los Angeles and Paris. Using local electricity prices and fuel taxes, electrolytic hydrogen is found to be commercially viable in Vancouver and Paris. Hydrogen storage comes out as the most important technical issue. But more than any technical issue, electricity prices and fuel taxes emerge as the two dominant issues affecting the competitive position of electrolytic hydrogen. The monetary valuation of GHG emissions, based on a price of $20/ton of CO₂, is found to be generally insufficient to tilt the balance in favor of electrolytic hydrogen.     

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).     

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.     

UNIDO-ICHET support to hydrogen and fuel cell technologies in Turkey

The International Centre for Hydrogen Energy Technologies (ICHET) has been implementing measures to demonstrate potential benefits of “hydrogen and fuel cell systems” in developing countries. ICHET is a United Nations Industrial Development Organization (UNIDO) project funded by the Turkish Ministry of Energy and Natural Resources. To achieve its mission, ICHET implements pilot demonstration projects, provides applied research and development funding, and organizes workshops, education and training activities. Long term objective of the centre are to show implementation of hydrogen energy technologies with renewable energy systems and encourage local industries to manufacture similar systems for commercial applications. Support has been provided to select industrial partners in Turkey for developing prototypes including a fuel cell forklift, a fuel cell boat, a fuel cell passenger cart, renewable energy systems integrated mobile house, fuel cell based Uninterrupted Power Supply (UPS) installations. As more and more systems are demonstrated, public awareness of applications of hydrogen and fuel cell technologies will increase. ICHET has polymer electrolyte membrane (PEM) fuel cell testing capabilities together with analytical equipment to conduct fuel cell, hydrogen production and storage research. These facilities are being used for educational purposes with hundreds of engineers trained to date.     

Modeling and dynamics of an autothermal JP5 fuel reformer for marine fuel cell applications

In this work, a dynamic model of an integrated autothermal reformer (ATR) and proton exchange membrane fuel cell (PEM FC) system and model-based evaluation of its dynamic characteristics are presented. The ATR reforms JP5 fuel into a hydrogen rich flow. The hydrogen is extracted from the reformate flow by a separator membrane (SEP), then supplied to the PEM FC for power generation. A catalytic burner (CB) and a turbine are also incorporated to recuperate energy from the remaining SEP flow that would otherwise be wasted. A dynamic model of this system, based on the ideal gas law and energy balance principles, is developed and used to explore the effects of the operating setpoint selection of the SEP on the overall system efficiency. The analysis reveals that a trade-off exists between the SEP efficiency and the overall system efficiency. Finally the open loop system simulation results are presented and conclusions are drawn on the SEP operation.     

Analysis of ammonia decomposition reactor to generate hydrogen for fuel cell applications

In this paper, reaction engineering principles are utilized to analyze process conditions for producing sufficient hydrogen in an ammonia decomposition reactor for generating net power of 100 W in a fuel cell. It is shown that operating the reactor adiabatically results in a sharp decrease in temperature due to endothermic reaction, which results in low conversion of ammonia. For this reason, the reactor is heated electrically to provide heat for the endothermic reactions. It is observed that when the reactor is operated non-adiabatically, it is possible to get over 99.5% conversion of ammonia. The weight of absorbent to reduce ammonia to ppb levels is calculated. An energy balance on the reactor exit gas indicates that there is sufficient heat available to vaporize enough water to achieve 100% relative humidity in the fuel cell. A suitable fuel cell stack is designed and it is shown that this stack is able to provide the necessary power to electrically heat the reactor and produce net power of 100 W.     

Method to release hydrogen from ammonia borane for portable fuel cell applications

Ammonia borane (AB, NH₃BH₃) is considered to be a promising hydrogen storage material as it contains 19.6 wt% hydrogen. It is difficult, however, to release hydrogen from AB. Thermolysis, catalytic hydrolysis and heat generated by additional reactive mixtures are usually employed, but these methods have disadvantages that limit their use for portable applications. In this paper, we demonstrate a new approach to release hydrogen, which does not require any catalyst and produces relatively high hydrogen yield and environmentally benign byproducts. It involves nano-aluminum (nAl)/water combustion reaction, which provides heat for AB dehydrogenation and releases additional hydrogen from water. To facilitate higher H₂ yield from thermolysis, as compared to hydrolysis, AB is spatially separated from the nAl/water mixture using a concentric cylindrical container. The effect of the container design on hydrogen generation is studied and optimized. This study also includes transient temperature and pressure measurements, and product characterization using mass spectrometer and ¹¹B NMR. This approach provides H₂ yield up to 9.5 wt% on material basis. Our experimental results and analysis show that a proposed power source based on this method is promising for portable electronic devices.     

System-level comparison of ammonia,compressed and liquid hydrogen as fuels for polymer electrolyte fuel cell powered shipping

With the aim to reduce emissions from marine transport, electric propulsion systems for a water taxi and container ship powered by a hydrogen polymer electrolyte membrane fuel cell system are designed and analyzed compared to the current fuel-oil engine systems in terms of system energy and exergy efficiency, fuel consumption, mass and volume, environmental impacts and cost. Hydrogen is stored either as a compressed gas (GH₂), cryogenic liquid (LH₂) or produced from liquid ammonia (LNH₃) and can deliver 91%,91% and 88% greenhouse gas reductions, respectively. All hydrogen sources fit within ship volume and mass constraints apart from GH₂ in the cargo ship. In the absence of carbon policy measures, the costs over a 25-year system life are 108% (GH₂), 112% (LH₂), 116% (LNH₃) greater for the container ship and 43% (GH₂), 105% (LNH₃) greater for the water taxi. A carbon tax of £75-191/tonne CO₂eq would allow the low carbon options to become cost competitive.     

Prospects and impediments for hydrogen and fuel cell vehicles in the transport sector

Hydrogen and fuel cell vehicles are often discussed as crucial elements in the decarbonisation of the transport systems. However, in spite of the fact that hydrogen and fuel cell vehicles have a long history, they are still seen only as a long-term mobility option. The major objective of this paper is to analyse key barriers to the increasing use of hydrogen and fuel cell vehicles. A special focus is put on their economic performance, because this will be most crucial for their future deployment. Mobility costs are calculated based on the total cost of ownership, and future developments are analysed based on technological learning. The major conclusion is that to achieve full benefits of hydrogen and fuel cells in the transport sector, it is necessary to provide stabile, long-term policy framework conditions, as well as to harmonize actions across regions to be able to take advantage of economies of scale.