Heinrich Lienkamp , Ashok Rastogi Infraserv Höchst - Frankfurt Germany

26-27.10.2009, Brussels Rastogi / Lienkamp 1

Project Co-financed by the European Commission FCHJU-SGA09

Experience with FC-Vehicles & HydrogenExperience with FC-Vehicles & Hydrogen

Infrastructure in ZERO REGIOInfrastructure in ZERO REGIO

Heinrich Lienkamp, Ashok RastogiInfraserv Höchst - Frankfurt

Germany

www.zeroregio.com



OutlineOutline• Brief presentation of Aims, activities & highlights in Zero Regio

– Frankfurt, Germany– Mantova, Italy

• Operational experience– Some events – Lessons learnt

• Collection and Assessment of Data– Comparison with the state of the art

• Concluding Remarks; Next steps



Industrial Park HöchstIndustrial Park Höchst

4.6 km2 area

72 km Streets

80 Companies

Over 22000

Workforce

&

30 mil.Nm3/yr

By-product H2


Project Co-financed by the European Commission FCHJU-SGA09 Service Station FrankfurtService Station Frankfurt

Area = 4.062 m2

350 & 700 bar GH2

LH2 Dipensers.

Photovoltaic 8 kW

Opened on 17.11.2006



HH22 - Infrastructure in Germany - Infrastructure in Germany• Hydrogen center in Industry park, Höchst

– Existing infrastructure– By-product H2 is collected, conditioned, compressed (250 bar) – Trailer station

• Ionic fluid compressor (900 bar) in Hydrogen center• Agip station 1.7 km from H2-center• Hydrogen transport to station via HP-pipeline (1000 bar)• CGH2 dispensers, 350 bar and 700 bar one each • LH2 dispenser (Truck supply of LH2)• Agip station opened on Nov. 17, 2006



H2-Centre

Fillingstation

H2-High-Pressure-pipeline

PN 1000 bar

over ground

under ground

H2-Centre

Fillingstation

H2-High-Pressure-pipeline

PN 1000 bar

over ground

under ground

Lay out HP Pipeline in HöchstLay out HP Pipeline in Höchst



Some Design DetailsSome Design Details

1.4462 Material

Din = 18 mm

Dout = 33.7 mm

Pmax =1000 bar

Welded construction

Leakproof by definition

HP-H2-Transport system is one of its kind

worldwide

Underground: Tubing with PE sleeve in sandbed

Overground: Hanging pipe system



Compression SchemeCompression Scheme

Particle- filter Hydrogen-

Refuelling Station

G 265

F

HP Pipeline- System

2.4 m3

Buffer

225 bar H2 storage

300 bar

Cold-Fill(-40°C)

25 m³

900 bar Compressor

Hg -filter(Option)

H2 Disp 350 bar

H2 Disp.700bar

PICF



Ionic Fluid Compressor – working principleIonic Fluid Compressor – working principle

PLC



Ionic Fluid Compressor

Special Features:

• Ionic liquid no vapor pr.

• Compressor capacity =900 Nm3/hr or1.335 kg/min

First time in Zero Regio for H2 - 900 bar


Project Co-financed by the European Commission FCHJU-SGA09 Hydrogen-Dispensers – Höchst

GH2 700 bar GH2 350 bar LH2


Project Co-financed by the European Commission FCHJU-SGA09 Service Station FrankfurtService Station Frankfurt



Experience with infrastructure in GermanyExperience with infrastructure in Germany• High availability inspite of some problems:

– Filters in the cooling system of the compressor– Some valves failed on the compressor system– Some loose fittings leading to system failure– Ionic Compressor overhauled in 2nd year of operation

• Outage for 3 months

– Filter problems in the third year, regular maintenance reqd.– Insufficient purging of the pipeline initially– Control valves at dispenser & minor electronic problems– Incident reporting and management approach important

• One accident in the first year, no H2 discharge


Project Co-financed by the European Commission FCHJU-SGA09 Operational Experience in Germany



• Damage of 700 bar Dispenser by accident – Cause: Passenger car runs into dispenser

– Effect: major damage of dispenser and the installed techniqueNo accidental escape of hydrogen

– Action: Repair / replacement of dispenser

Operational Experience in Germany


Project Co-financed by the European Commission FCHJU-SGA09 Servicestation Mantova



H2 - Infrastructure in Mantova, ItalyH2 - Infrastructure in Mantova, Italy• On-site production facility (CPO – reformer)

– Small unit with 20 Nm3/hr– Construction completed and in operation from July 2008

• Truck transport from an industrial reformer (back-up)• 350 bar GH2 dispenser (Cars homologated for 200 bar)• Delay partly due to approval formalities• A mobile refueller initially (AP 100)• Integration in multi-energy Agip service station

– 17.000 m2, Car Wash, Cafè Shop– Opening ceremony took place on 21 Sept. 2007


Project Co-financed by the European Commission FCHJU-SGA09 CPO Reformer by EniCPO Reformer by Eni



On-site Hydrogen Production in MantovaOn-site Hydrogen Production in Mantova

• Suitable for intermittent operation• 3 Compaigns in 2009

– 20 kg. H2 in April 09– 40 kg. H2 in July 09 (40 kg. Storage capacity)– 40 kg. H2 in Oct. 09

• One day for plant start-up and shut down• High quality achieved (CO< 0.1 ppm)• Plant optimised for automatic operation• 20 Nm3/hr. too high for 3 cars• Other applications planned at the service station



Dedicated Fleets Dedicated Fleets

Range: 160 km (@350 bar)Maximum speed: 140 km/h

Ballard PEM 72 kW

5 cars, one with 700 bar storage

Range: 250 km (@350 bar)Maximum speed: 135 km/h

Acceleration: 0-50 km/h within 7 sNuvera PEM 70 kW

3 cars



Beauty and the BeastBeauty and the Beast

F-Cell serving A-380 !!



8775

195

85102

0

50

100

150

200

250

FC No. 29 FC No. 49 FC No. 59 FC No. 60 FC No. 61

[h]

Operational Performance of the vehicles in 2008

F-Cell No. 29 F-Cell No. 49 (700 bar) F-Cell No. 59, 60, 61

2481

5084

2125

5906

2491

0

2000

4000

6000

8000

FC No. 29 FC No. 49 FC No. 59 FC No. 60 FC No. 61

[km]

Mileage

Operating hours

The operational performance 2008 was lower than expected

Some Demonstration DataSome Demonstration Data



SOME INCIDENTS with FleetSOME INCIDENTS with Fleet

• In general all FCV‘s functioned better than expected

• Regular maintenance was performed– Tank leak tests

– TÜV examinations

– Minor repairs could be done on site

• No road calls

• One accident due to drivers negligence

• One car was taken out of service

in Sept. 2009 due to IPT defect

(Integrated PowerTrain failure)



Some other Customers Some other Customers

• Frankfurt station is used also by other customers• For 350 bar dispenser

– Honda (FCX Clarity), 2 cars– Mazda (Ice, RX 8 Hydrogen), 1 car– Toyota Prius one visit

• For 700 bar dispenser – Opel/GM Hydrogen 4, 1 car– B-class F-Cell Daimler, extensive testing with a few cars – IR Communication, SAE Release A Standard – 3 min. for 4 kg, aiming at 100% fill rate



Assessment FrameworkAssessment Framework

INPUT DATA

• Data tables on

-Infrastructure

-Vehicles

• 2 Demo. sites

• OEM‘s and Operators

Simple Data Processing

Compare with Ref. Technology

•Technological aspects:

Performance, Environment, Safety

•Socio-Economy

•Project Organisation

Results

• Indicators on

-Infrastructure

-Vehicles

• 2 Demo. sites

• Indicator value (0 to 1)


Project Co-financed by the European Commission FCHJU-SGA09 Data Assessment Data Assessment

Comparison of energy consumption

CNG CGH

Energy consumption

for compression0,035kWhel/kWh

(200 mbar 300 bar)

0,124kWhel/kWh

(70 mbar 700 bar)

Energy consumption of vehicle

73,75 kWh/100km (CNG-ICE)

35,66 kWh/100km (FC)

Total energy consumption

76,33 kWh/100km 40,08 kWh/100km


Project Co-financed by the European Commission FCHJU-SGA09 Comparison F-Cell Vs. Diesel Comparison F-Cell Vs. Diesel

Parameter FCV, A-Class 350 bar

A-Class Diesel 160 cdi

Maximum speed, km /hr 140 162

Maximum range with a full tank, km 170 980

Tank volume capacity, l 78 54

Fuel consumption NEDC, eqiv. Diesel l/ 100 km 3.6 5.5

Acceleration time 0-100 km/hr, sec 14.3 16.8

Maximum Torque Nm 210 160

CO2 Emissions g/km 0 146



Summary of 2 yearsSummary of 2 years

• 3-7 FCV‘s, 100 vehicle months of operation, over 45000 km driven (should have been more)

• over 510 kg. H2 consumed, 7.2 tons of CO2 emission saved

• Vehicles showed high reliability and availablity (98%)

• Availability 350 bar dispenser 95%

• Availability 700 bar dispenser 55% (accident costed 11 months)

• Ionic compressor 77% (has been overhauled)

• By-product hydrogen should be exploited more initially

• Infrastructure problems experienced are not related to H2



Some Lessons LearntSome Lessons Learnt

• Serious problems with approval formalities in Italy

• Delay in infrastructure construction

• Fleet is still operated at 200 bar storage

• European Harmonisation, Integrate authorities in project

• Bottle neck for larger demonstrations

• Fleet availability (cost), not so much infrastructure

• Frankfurt station can fill 15 FCV‘s /hour

• By-product Hydrogen should be exploited much more



Concluding RemarksConcluding Remarks • H2-infrastructure developed and FCV fleet used in Zero Regio Project

have been briefly presented

• Operational experience has been encouraging at both sites

• FCV-Fleet has operated better than expected

• Fuel consumption of FCV is about half of NGV

• Fast refuelling of 700 bar FCV‘s has been realised

• Zero Regio high potentials: HP-Pipeline transport,700 refuelling with IR

communication.

Thank You Thank You

• Final Conference at WHEC 2010, Essen, Germany.Final Conference at WHEC 2010, Essen, Germany.


Project Co-financed by the European Commission FCHJU-SGA09 Service Station MantovaService Station Mantova

HH22

Area = 17.000 m2

350 bar GH2

Photovoltaic 16 kW

Opened on 21.09.2007


Project Co-financed by the European Commission FCHJU-SGA09 Hydrogen Dispenser - Mantova

GH2 350 bar



Onsite H2 Production PlantOnsite H2 Production Plant



F-Cell A-Class F-Cell A-Class

Vehicle type: Mercedes-Benz A-Class Fuel-Cell system: PEM, 72 kW (97 PS)Electro-Asynchron-MotorMotor rating: 65 kW (87 PS)Max. Torque: 210 NmFuel: Hydrogen (350 bar)Range: 160 kmMax. Velocity: 140 km/h Battery: NiMh, air-cooledPower (av./peak): 15 kW / 20 kW Rating: 6,5 Ah; 1,4 kWh



SOCIO-ECONOMIC STUDIES SOCIO-ECONOMIC STUDIES

• 1• 2• 3• 4• 5S

Heinrich Lienkamp , Ashok Rastogi Infraserv Höchst - Frankfurt Germany

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