SMALL-SCALE HYDROGEN FUELLING 6APPLIANCE FOR FCEV CASE STUDY 06

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1 SMALL-SCALE HYDROGEN FUELLING 6APPLIANCE FOR FCEV CASE STUDY 06

2 Case Study 06 Small-Scale Hydrogen Fuelling Appliance for FCEV Background ITM Power is a developer of hydrogen generation systems based on electrolysis. There are numerous applications for such systems in energy storage, clean fuel production and vehicle refuelling. One specific focus is that of an appliance for refuelling a fuel cell car at home. This case study describes a design project undertaken for the Next Energy Center in Detroit to develop a prototype Small-scale Hydrogen Fuelling Appliance (SHFA) for refuelling fuel cell vehicles that utilise 70MPa hydrogen storage tanks. This was part of a wider study into the deployment of an infrastructure in the US for dispensing hydrogen to fuel cell vehicles. The functional objectives of the feasibility study were the design of a system capable of: Hydrogen Generation 1kg/day over a 12 hour period Compression 70MPa Storage 70MPa bulk hydrogen storage Location Indoors or outdoors, must be frost and weatherproof and capable of functioning in a variety of weather conditions Fuelling Combination of initial fast fill followed by slow direct fill via 70MPa nozzle, hose and break-away coupling Safety Must be built with regard for current legislative environment

3 Case Study 06 Small-Scale Hydrogen Fuelling Appliance for FCEV SHFA DESIGN APPROACH To specify the key SHFA components a modularised concept was adopted for designing the electrolyser, compressor, high pressure storage and dispenser. This enabled the overall system to be configured either as separate components, or should legislation allow, assembled as an integrated stand-alone unit for use in all weather conditions. A balance was sought in the design of an integrated system between capital costs and energy costs for operation. With this in mind, ITM conducted an analysis of the system energetics and the costs of high and low pressure electrolysis in order to make an informed choice of electrolyser operating pressure. The outcome was the selection of 20MPa as the electrolyser hydrogen generation pressure. Special consideration was given to the residential environment in which the integrated system would operate. ITM addressed these challenges with a design which fully met the following criteria: Frost protection of the electrolyser during extended periods of power outages Capability of functioning through heavy snow storms and significant accumulations Compressor noise minimised using acoustic isolation and insulation Internal leakage dilution by forced air flow through all elements of the system to avoid the need for costly explosion-proof technologies within the enclosure Assembly view of storage compartment High pressure refuelling of ITM Ford Focus

4 Case Study 06 Small-Scale Hydrogen Fuelling Appliance for FCEV SHFA System Overview The SHFA concept comprised the following modular components integrated into a single system: Air Management System for temperature control and regulatory compliance protected against 3 feet of snow accumulation An ITM Power 20MPa self-pressurising PEM (Proton Exchange Membrane) electrolyser with an output expandable to 5kg/day fitted with trace heating frost protection in an insulated enclosure Hydrogen compression and buffer system designed around a Hydropac compressor and a 20MPa close-coupled buffer store, fitted with: manual isolation valves, frost protection, forced air leak dilution and soundproof enclosure Gas storage comprising composite cylinders with integral distribution and shut-off valves, solenoid valves for cascade filling and instrumentation in a naturally aspirated enclosure ITM Power s HFuel refuelling station hydrogen dispensing and user interface/integrated control system, comprising a breakaway coupling and fuelling nozzle, HMI touch screen and incorporating a fuelling control algorithm The SHFA design study confirmed that a domestic hydrogen generation, storage and dispensing unit suitable for the refuelling of hydrogen powered vehicles to 70MPa pressure is technologically viable. An associated market assessment identified the possibility of early FCEV purchasers also buying an SHFA, and estimated that the global SHFA market could exceed $2billion by the early 2020 s. Hydrogen fuel cell vehicles, for either on-road or off-road use, represent one of the clearest options available for zero or near zero emissions vehicles... A limiting factor that remains in the deployment and acceptance of such vehicles, though, is a lack of infrastructure for dispensing hydrogen. 70MPa SHFA Feasibility Study Final Report July 2009

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