H2 refueling assessment of composite storage tank for fuel cell vehicle

Hydrogen as compressed gas is a promising option for zero-emission fuel cell vehicle. The fast and efficient refueling of high pressure hydrogen can provide a convenient platform for fuel cell vehicles to compete with conventional gasoline vehicles. This paper reports the finding of adiabatic simulation of the refueling process for Type IV tank at nominal working pressure of 70 MPa with considering the station refueling conditions. The overall heat transfer involved in refueling process was investigated by heat capacity model based on MC method defined by SAE J2601. The simulation results are validated against experimental data of European Commission's Gas Tank Testing Facility at Joint Research Centre (GasTef JRC), Netherlands. The results confirmed that end temperature and state of charge significantly depends on refueling parameters mainly supply hydrogen temperature and filling rate.     

On optimal investment strategies for a hydrogen refueling station

The uncertainty and cost of changing from a fossil-fuel-based society to a hydrogen-based society are considered to be extensive obstacles to the introduction of fuel cell vehicles (FCVs). The absence of existing profitable refueling stations has been shown to be one of the major barriers. This paper investigates methods for calculating an optimal transition from a gasoline refueling station to future methane and hydrogen combined use with an on site small-scale reformer for methane. In particular, we look into the problem of matching the hydrogen capacity of a single refueling station to an increasing demand. Based on an assumed future development scenario, optimal investment strategies are calculated. First, a constant utilization of the hydrogen reformer is assumed in order to find the minimum hydrogen production cost. Second, when considerations such as periodic maintenance are taken into account, optimal control is used to concurrently find both a short term equipment variable utilization for one week and a long term strategy. The result is a minimum hydrogen production cost of $4–6/kg, depending on the number of reinvestments during a 20 year period. The solution is shown to yield minimum hydrogen production cost for the individual refueling station, but the solution is sensitive to variations in the scenario parameters.     

Eliciting preferences on the design of hydrogen refueling infrastructure

Hydrogen vehicles are already a reality, However, consumers will be reluctant to purchase hydrogen vehicles (or any other alternative fuel vehicle) if they do not perceive the existence of adequate refueling infrastructure that reduces the risk of running out of fuel regularly while commuting to acceptable levels. This fact leads to the need to study the minimum requirements in terms of fuel availability required by drivers to achieve a demand for hydrogen vehicles beyond potential early-adopters.This paper studies consumer preferences in relation to the design of urban hydrogen refueling infrastructure. To this end, the paper analyzes the results of a survey carried out in Andalusia, a region in southern Spain, on drivers' current refueling tendencies, their willingness to use hydrogen vehicles and their minimum requirements (maximum distance to be traveled to refuel and number of stations in the city) when establishing a network of hydrogen refueling stations in a city. The results show that consumers consider the existence in cities of an infrastructure with a number of refueling stations ranging from approximately 10 to 20% of the total number of conventional service stations as a requisite to trigger the switch to the use of hydrogen vehicles. In addition, these stations should be distributed in response to the drivers’ preferences to refuel close to home.     

Operating experience with a liquid-hydrogen fueled buick and refueling system

An investigation of liquid-hydrogen storage and refueling systems for vehicular applications was made in a recently completed project. The vehicle used in the project was a 1979 Buick Century sedan with a 3.8.1, displacement turbocharged V6 engine and an automatic transmission. The vehicle had a fuel economy for driving in the high altitude Los Alamos area that was equivalent to 2.4 km/l of liquid hydrogen or 8.9 km/l of gasoline on an equivalent energy basis. About 22% less energy was required using hydrogen rather than gasoline to go a given distance based on the Environmental Protection Agency estimate of 7.2 km/l of gasoline for this vehicle. At the end of the project the engine had been operated for 138 h and the car driven 3633 km during the 17 months that the vehicle was operated on hydrogen. Two types of onboard liquid-hydrogen storage tanks were tested in the vehicle; the first was an aluminium Dewar with a liquid-hydrogen capacity of 1101.; the second was a Dewar with an aluminium outer vessel, two copper vapor-cooled thermal radiation shields, and a stainless steel inner vessel with a liquid-hydrogen capacity of 1551. The Buick had an unrefueled range of about 274 km with the first liquid-hydrogen tank and about 362 km with the second. The Buick was fueled at least 65 times involving a minimum of 8.1 kl of liquid hydrogen using various liquid-hydrogen storage Dewars at Los Alamos and a semiautomatic refueling station. A refueling time of 9 min was achieved, and liquid-hydrogen losses during refueling were measured. The project has demonstrated that liquid-hydrogen storage onboard a vehicle, and its refueling, can be accomplished over an extended period without any major difficulties; nevertheless, appropriate testing is still needed to quantitatively address the question of safety for liquid-hydrogen storage onboard a vehicle.     

Improving hydrogen refueling stations to achieve minimum refueling costs for small bus fleets

Fuel cell vehicles using green hydrogen as fuel can contribute to the mitigation of climate change. The increasing utilization of those vehicles creates the need for cost efficient hydrogen refueling stations. This study investigates how to build the most cost efficient refueling stations to fuel small fleet sizes of 2, 4, 8, 16 and 32 fuel cell busses. A detailed physical model of a hydrogen refueling station was built to determine the necessary hydrogen storage size as well as energy demand for compression and precooling of hydrogen. These results are used to determine the refueling costs for different station configurations that vary the number of storage banks, their volume and compressor capacity.It was found that increasing the number of storage banks will decrease the necessary total station storage volume as well as energy demand for compression and precooling. However, the benefit of adding storage banks decreases with each additional bank. Hence the cost for piping and instrumentation to add banks starts to outweigh the benefits when too many banks are used. Investigating the influence of the compressor mass flow found that when fueling fleets of 2 or 4 busses the lowest cost can be reached by using a compressor with the minimal mass flow necessary to refill all storage banks within 24 h. For fleets of 8, 16 and 32 busses, using the compressor with the maximum investigated mass flow of 54 kg/h leads to the lowest costs.     

Near-term location planning of hydrogen refueling stations in Yokohama City

Establishing hydrogen refueling stations is key to transition into a hydrogen economy. To achieve this, a near-term, city-level roll-out plan is required, as Japan is shifting from the demonstration to implementation stage of a hydrogen economy. The aim of this study was to devise a plan to identify near-term locations to build hydrogen refueling stations in Yokohama City, Japan. Our plan provides information on the potential location of hydrogen refueling stations for 2020–2030. We considered mobile and parallel-siting type refueling stations; the locations of these stations were determined by matching the supply and demand estimated from hybrid vehicle ownership data and the available space in existing gas stations based on a safety perspective. The results reaffirmed the importance of planning the locations of hydrogen refueling stations and highlighted the suitability of using mobile-type stations. This was based on the uncertainty in fuel demand for fuel cell vehicles during the implementation stage of the hydrogen economy.     

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

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

Developing an infrastructure for hydrogen vehicles: a Southern California case study

We have examined the technical feasibility and economics of developing a hydrogen vehicle refueling infrastructure for a specific area where zero emission vehicles are being considered, Southern California. Potential hydrogen demands for zero emission vehicles are estimated. We then assess in detail several near term possibilities for producing and delivering gaseous hydrogen transportation fuel including: (1) hydrogen produced from natural gas in a large, centralized steam reforming plant, and truck delivered as a liquid to refueling stations; (2) hydrogen produced in a large, centralized steam reforming plant, and delivered via small scale hydrogen gas pipeline to refueling stations; (3) by-product hydrogen from chemical industry sources; (4) hydrogen produced at the refueling station via small scale steam reforming of natural gas; and (5) hydrogen produced via small scale electrolysis at the refueling station. The capital cost of infrastructure and the delivered cost of hydrogen are estimated for each hydrogen supply option. Hydrogen is compared to other fuels for fuel cell vehicles (methanol, gasoline) in terms of vehicle cost, infrastructure cost and lifecycle cost of transportation. Finally, we discuss possible scenarios for introducing hydrogen as a fuel for fuel cell vehicles.     

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.     

Refueling hydrogen fuel cell vehicles with 68 proposed refueling stations in California: Measuring deviations from daily travel patterns

This paper examines the deviation of refueling a hydrogen fuel cell vehicle with limited opportunity provided by the 68 proposed stations in California. A refueling trip is inserted to reported travel patterns in early hydrogen adoption community clusters and the best and worst case insertions are analyzed. Based on these results, the 68 refueling stations provide an average of 2.5 and 9.6 min deviation for the best and the worst cases. These numbers are comparable to currently observed gasoline station deviation, and we conclude that these stations provide sufficient accessibility to residents in the target areas.     

Thermodynamic modeling of hydrogen refueling for heavy-duty fuel cell buses and comparison with aggregated real data

The foreseen uptake of hydrogen mobility is a fundamental step towards the decarbonization of the transport sector. Under such premises, both refueling infrastructure and vehicles should be deployed together with improved refueling protocols. Several studies focus on refueling the light-duty vehicles with 10 kg_H2 up to 700 bar, however less known effort is reported for refueling heavy-duty vehicles with 30–40 kg_H2 at 350 bar. The present study illustrates the application of a lumped model to a fuel cell bus tank-to-tank refueling event, tailored upon the real data acquired in the 3Emotion Project. The evolution of the main refueling quantities, such as pressure, temperature, and mass flow, are predicted dynamically throughout the refueling process, as a function of the operating parameters, within the safety limits imposed by SAE J2601/2 technical standard. The results show to refuel the vehicle tank from half to full capacity with an Average Pressure Ramp Rate (APRR) equal to 0.03 MPa/s are needed about 10 min. Furthermore, it is found that the effect of varying the initial vehicle tank pressure is more significant than changing the ambient temperature on the refueling performances. In conclusion, the analysis of the effect of different APRR, from 0.03 to 0.1 MPa/s, indicate that is possible to safely reduce the duration of half-to-full refueling by 62% increasing the APRR value from 0.03 to 0.08 MPa/s.     

Review on equipment configuration and operation process optimization of hydrogen refueling station

The construction of hydrogenation infrastructure is important to promote the large-scale development of hydrogen energy industry. The technical performance of hydrogen refueling station (HRS) largely determines the refueling efficiency and cost of hydrogen fuel cell vehicles. This paper systematically lists the hydrogen refueling process and the key equipment applicable in the HRS. It comprehensively reviews the key equipment configuration from the hydrogen supply, compression, storage and refueling of the HRS. On the basis of the parameter selection and quantity configuration method, the process optimization technology related to the equipment utilization efficiency and construction cost was quantitatively evaluated. Besides, the existing problems and prospects are put forward, which lays the foundation for further research on the technical economy of HRSs.     

Addition of hydrogen refueling for fuel cell bus fleet to existing natural gas stations: A case study in Wuhan,China

Hydrogen refueling is an essential infrastructure for fuel cell vehicles, and currently, it appears to be a critical service needed to initiate the highly anticipated hydrogen economy in China. A practical selecting procedure of adding hydrogen refueling service to existing natural gas (NG) stations is proposed in this study. A case study in Wuhan, China, is established to assess the feasibility and future planning. The demand for hydrogen fuel and initial supply chain of hydrogen in Wuhan are estimated based on the deployment objective of fuel cell buses. The existing NG stations are evaluated based on 300 kg/day to determine whether they meet the hydrogen safety requirement using Google map or field investigation. The safety space requirement of the hydrogen refueling area on existing NG station is determined as 25.9 × 27.1 m². The optimal hydrogen refueling plan for fuel cell buses is calculated with multi‐objective analysis in economic, environmental, and safety aspects from the view of the hydrogen refueling supply chain. It is shown that adding hydrogen refueling stations to existing NG stations is feasible in technology, economics, regulation, and operation considerations. This study provides guidelines for building the hydrogen infrastructure for fuel cell buses at their early stage of commercial operation.     

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.     

Optimal siting and sizing of hydrogen refueling stations considering distributed hydrogen production and cost reduction for regional consumers

Hydrogen fuel cell vehicles are currently facing two difficulties in achieving their general use: the lack of hydrogen refueling stations and high hydrogen prices. Hydrogen refueling stations are the middle stage for delivering hydrogen from its sources to consumers, and their location could be affected by the distributed locations of hydrogen sources and consumers. The reasonable siting and sizing of hydrogen refueling stations could both improve the hydrogen infrastructure and reduce regional consumers' cost of using hydrogen. By considering the hydrogen life cycle cost and using a commercial volume forecasting model, this paper creates a relatively thorough and comprehensive model for hydrogen station siting and sizing with the objective of achieving the optimal costs for consumers using hydrogen. The cost‐based model includes the selection of the hydrogen sources, transportation methods, and storage methods, and thus, the hydrogen supply chain can also be optimized. A numerical example is established in Section 4 with the solution algorithm and results.     

Manufacturing competitiveness analysis for hydrogen refueling stations

Fuel cell electric vehicles (FCEVs) have now entered the market as zero-emission vehicles. Original equipment manufacturers such as Toyota, Honda, and Hyundai have released commercial cars in parallel with efforts focusing on the development of hydrogen refueling infrastructure to support new FCEV fleets. Persistent challenges for FCEVs include high initial vehicle cost and the availability of hydrogen stations to support FCEV fleets. This study sheds light on the factors that drive manufacturing competitiveness of the principal systems in hydrogen refueling stations, including compressors, storage tanks, precoolers, and dispensers. To explore major cost drivers and investigate possible cost reduction areas, bottom-up manufacturing cost models were developed for these systems. Results from these manufacturing cost models show there is substantial room for cost reductions through economies of scale, as fixed costs can be spread over more units. Results also show that purchasing larger quantities of commodity and purchased parts can drive significant cost reductions. Intuitively, these cost reductions will be reflected in lower hydrogen fuel prices. A simple cost analysis shows there is some room for cost reduction in the manufacturing cost of the hydrogen refueling station systems, which could reach 35% or more when achieving production rates of more than 100 units per year. We estimated the potential cost reduction in hydrogen compression, storage and dispensing as a result of capital cost reduction to reach 5% or more when hydrogen refueling station systems are produced at scale.     

Refueling availability for alternative fuel vehicle markets: Sufficient urban station coverage

Alternative fuel vehicles can play an important role in addressing the challenges of climate change, energy security, urban air pollution and the continued growth in demand for transportation services. The successful commercialization of alternative fuels for vehicles is contingent upon a number of factors, including vehicle cost and performance. Among fuel infrastructure issues, adequate refueling availability is one of the most fundamental to successful commercialization. A commonly cited source reports 164,300 refueling stations in operation nationwide. However, from the perspective of refueling availability, this nationwide count tends to overstate the number of stations required to support the widespread deployment of alternative fuel vehicles. In terms of spatial distribution, the existing gasoline station networks in many urban areas are more than sufficient. We characterize a sufficient level of urban coverage based upon a subset of cities served by relatively low-density station networks, and estimate that some 51,000 urban stations would be required to provide this sufficient level of coverage to all major urban areas, 33 percent less than our estimate of total urban stations. This improved characterization will be useful for engineering, economic and policy analyses.     

Estimation of final hydrogen temperature from refueling parameters

Compressed hydrogen storage is currently widely used in fuel cell vehicles due to its simplicity in tank structure and refueling process. For safety reason, the final gas temperature in the hydrogen tank during vehicle refueling must be maintained under a certain limit, e.g., 85 °C. Many experiments have been performed to find the relations between the final gas temperature in the hydrogen tank and refueling conditions. The analytical solution of the hydrogen temperature in the tank can be obtained from the simplified thermodynamic model of a compressed hydrogen storage tank, and it serves as function formula to fit experimental temperatures. From the analytical solution, the final hydrogen temperature can be expressed as a weighted average form of initial temperature, inflow temperature and ambient temperature inspired by the rule of mixtures. The weighted factors are related to other refueling parameters, such as initial mass, initial pressure, refueling time, refueling mass rate, average pressure ramp rate (APRR), final mass, final pressure, etc. The function formula coming from the analytical solution of the thermodynamic model is more meaningful physically and more efficient mathematically in fitting experimental temperatures. The simple uniform formula, inspired by the concept of the rule of mixture and its weighted factors obtained from the analytical solution of lumped parameter thermodynamics model, is representatively used to fit the experimental and simulated results in publication. Estimation of final hydrogen temperature from refueling parameters based on the rule of mixtures is simple and practical for controlling the maximum temperature and for ensuring hydrogen safety during fast filling process.     

Node-based vs. path-based location models for urban hydrogen refueling stations: Comparing convenience and coverage abilities

For optimizing locations of hydrogen refueling stations, two popular approaches represent fuel demands as either nodes or paths, which imply different refueling behavior and definitions of convenience. This paper compares path-based vs. node-based models from the perspective of minimizing total additional travel time and feasibly covering all demands with the same number of stations. For this comparison, two new station location models are introduced that extend the Flow Capturing Location Model (FCLM) and p-Median Problem (PMP) by consistently defining upper limits on vehicle driving range and maximum inconvenience on refueling trips. Results for an idealized metropolitan area and Orlando, Florida show that path-based refueling substantially reduces wasteful travel time for refueling and covers more demand feasibly and more equitably in most scenarios. Path-based models incorporate the fact that residents of a zone regularly interact with other zones; therefore, individual stations can cover flows originating both near and far from their locations. This study suggests that path-based approaches to planning hydrogen refueling infrastructure enable more people in more neighborhoods to refuel fuel-cell vehicles without wasting excessive time or running out of fuel.     

Multi-objective and multi-period hydrogen refueling station location problem

Creating a distribution network and establishing refueling stations arises as an important problem in order to meet the refueling needs of hydrogen fuel cell vehicles. In this study, a multi-objective and multi-period hydrogen refueling station location problem that can take into account long-term planning decisions is proposed. Firstly, single objective mathematical models are proposed for the problem by addressing the cost, risk and population convergence objectives. Afterwards, a goal programming model is proposed and the results that will arise when three objectives are taken into consideration at the same time are examined. A risk analysis approach applied for each location alternative is considered in order to handle risk concerns about the hydrogen refueling station settlement. A case study is conducted in Adana, one of the crowded cities in Turkey, to determine the long-term location network plan. Covered population, operational risk and earthquake risks are used as input of the risk analysis method. The case study results show that the goal programming model covers the area with 77 hydrogen refueling stations by different types and capacities during the years from 2020 to 2030. In addition, a computational study is carried out with different alternative scenarios (different number of consumption nodes and all parameters in the model). The computational study results show that the highest deviations from the optimal solution on the model are observed in the distances between consumption nodes and targeted service area parameters which affect about 50% of absolute deviations on average. According to results, the proposed approach selects the station location suitable for the expected changes over the years.