Transcript Experience with FC-Vehicles & Hydrogen Infrastructure in ZERO REGIO www.zeroregio.com

Project Co-financed by the
European Commission
FCHJU-SGA09
Experience with FC-Vehicles & Hydrogen
Infrastructure in ZERO REGIO
Heinrich Lienkamp, Ashok Rastogi
Infraserv Höchst - Frankfurt
Germany
www.zeroregio.com
26-27.10.2009, Brussels
Rastogi / Lienkamp
1
Project Co-financed by the
European Commission
FCHJU-SGA09
Outline
• Brief presentation of Aims, activities & highlights in
Zero Regio (2004-2010)
– 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
26-27.10.2009, Brussels
Rastogi / Lienkamp
2
Project Co-financed by the
European Commission
FCHJU-SGA09
Zero Regio Objectives
• Development and demonstration of H2 infrastructure and
FCV‘s in European Cities
• Different hydrogen sources – By-product, industrial, Onsite production
• 700 bar refuelling technology
• Integration of hydrogen in public service stations
• Socio-economic impact
 Project implementation: 11. 2004 –11. 2006 Construction
11.2006 -11. 2009 Demonstration; End May 2010
26-27.10.2009, Brussels
Rastogi / Lienkamp
3
FCHJU-SGA09
Industrial Park Höchst
Project Co-financed by the
European Commission
4.6 km2 area
72 km Streets
80 Companies
Over 22000
Workforce
&
30 mil.Nm3/yr
By-product H
26-27.10.2009, Brussels
Rastogi / Lienkamp
2
4
Project Co-financed by the
European Commission
FCHJU-SGA09
H2 - 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
26-27.10.2009, Brussels
Rastogi / Lienkamp
5
Project Co-financed by the
European Commission
FCHJU-SGA09
Lay out HP Pipeline in Höchst
H2-High-Pressurepipeline
PN 1000 bar
H2-Centre
over ground
under ground
Fillingstation
26-27.10.2009, Brussels
Rastogi / Lienkamp
6
FCHJU-SGA09
26-27.10.2009, Brussels
Hydrogen-Dispensers – Höchst
Project Co-financed by the
European Commission
GH2 700 bar
LH2
GH2 350 bar
Rastogi / Lienkamp
7
Project Co-financed by the
European Commission
FCHJU-SGA09
Experience 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
26-27.10.2009, Brussels
Rastogi / Lienkamp
8
Project Co-financed by the
European Commission
FCHJU-SGA09
Operational Experience in Germany
26-27.10.2009, Brussels
Rastogi / Lienkamp
9
FCHJU-SGA09
Operational Experience in Germany
Project Co-financed by the
European Commission
• Damage of 700 bar Dispenser by accident
– Cause:
Passenger car runs into dispenser
– Effect:
major damage of dispenser and the installed technique
No accidental escape of hydrogen
– Action:
Repair / replacement of dispenser
26-27.10.2009, Brussels
Rastogi / Lienkamp
10
FCHJU-SGA09
26-27.10.2009, Brussels
Servicestation Mantova
Rastogi / Lienkamp
Project Co-financed by the
European Commission
11
Project Co-financed by the
European Commission
FCHJU-SGA09
H2 - 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
26-27.10.2009, Brussels
Rastogi / Lienkamp
12
FCHJU-SGA09
26-27.10.2009, Brussels
CPO Reformer by Eni
Rastogi / Lienkamp
Project Co-financed by the
European Commission
13
Project Co-financed by the
European Commission
FCHJU-SGA09
On-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
26-27.10.2009, Brussels
Rastogi / Lienkamp
14
Project Co-financed by the
European Commission
FCHJU-SGA09
Dedicated Fleets
Range: 250 km (@350 bar)
Maximum speed: 135 km/h
Acceleration: 0-50 km/h within 7 s
Nuvera PEM 70 kW
Range: 160 km (@350 bar)
Maximum speed: 140 km/h
Ballard PEM 72 kW
5 cars, one with 700 bar storage
26-27.10.2009, Brussels
3 cars
Rastogi / Lienkamp
15
FCHJU-SGA09
Beauty and the Beast
Project Co-financed by the
European Commission
F-Cell
serving
A-380 !!
26-27.10.2009, Brussels
Rastogi / Lienkamp
16
Project Co-financed by the
European Commission
Some Demonstration Data
FCHJU-SGA09
Operational Performance of the vehicles in 2008
8000
[km]
250
5906
6000
[h]
195
200
5084
Mileage
150
Operating
hours
100
4000
2481
2125
2491
2000
102
87
75
85
50
0
0
FC No. 29 FC No. 49 FC No. 59 FC No. 60 FC No. 61
F-Cell No. 29
FC No. 29 FC No. 49 FC No. 59 FC No. 60 FC No. 61
F-Cell No. 49 (700 bar)
F-Cell No. 59, 60, 61
The operational performance 2008 was lower than expected
26-27.10.2009, Brussels
Rastogi / Lienkamp
17
FCHJU-SGA09
SOME INCIDENTS with Fleet
Project Co-financed by the
European Commission
• 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)
26-27.10.2009, Brussels
Rastogi / Lienkamp
18
FCHJU-SGA09
H2 Dispenser Deployment
Project Co-financed by the
European Commission
• 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
26-27.10.2009, Brussels
Rastogi / Lienkamp
19
Project Co-financed by the
European Commission
FCHJU-SGA09
Some 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 15-20 FCV‘s /hour
• By-product Hydrogen should be exploited much more
26-27.10.2009, Brussels
Rastogi / Lienkamp
20
FCHJU-SGA09
Summary of 2 years
• 3-7
Project Co-financed by the
European Commission
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
26-27.10.2009, Brussels
Rastogi / Lienkamp
21
FCHJU-SGA09
Concluding Remarks
Project Co-financed by the
European Commission
•
H2-infrastructure developed and FCV fleet used in Zero Regio Project
have been briefly presented
•
Operational experience has been encouraging at both sites
•
FCV-Fleets have 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, Ionic liquid
compression,700 bar refuelling with IR communication.
Thank You
•
Final Conference at WHEC 2010, Essen, Germany.
26-27.10.2009, Brussels
Rastogi / Lienkamp
22