Session 3.1: Cryogenic Storage Systems. Dr. G. Bartlok. 25 th 29 th September 2006 Ingolstadt. Session 1.2: Introductory Lectures. K.

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1 Session 3.1: Cryogenic Storage Systems Dr. G. Bartlok 25 th 29 th September 2006 Ingolstadt Session 1.2: Introductory Lectures K. Hall

3.1 Cryogenic Storage Systems CV Dr. G. Bartlok Address: MAGNA STEYR Engineering Liebenauer Hauptstraße 317 8041 Graz, Austria Email: guido.bartlok@magnasteyr.

esden. The Ph.D. work was done at the cryogenic institute of the TU Dresden. He joined the MAGNA STEYR Fahrzeugtechnik AG & Co KG in 2003. Mr.

2 3.1 Cryogenic Storage Systems CV Dr. G. Bartlok Address: MAGNA STEYR Engineering Liebenauer Hauptstraße Graz, Austria Guido Bartlok, born 1970 in Frankfurt (Oder) in Germany, received his diploma in mechanical engineering at the Technical University Dresden. The Ph.D. work was done at the cryogenic institute of the TU Dresden. He joined the MAGNA STEYR Fahrzeugtechnik AG & Co KG in Mr. Bartlok is jointly responsibly for development and production of automotive liquid hydrogen storage systems and research activities (e.g. Project Management of the Subproject Cryogenic Storage within the EU 6th Framework Program IP StorHy ). Session 3.1 Cryogenic Storage Systems G. Bartlok 2

3 3.1 Cryogenic Storage Systems Lectures on Liquid H2 Storage Technology Dr. G. Bartlok Abstract: Within this session an overview about liquid H2 storage technology is given. This includes state of the art design, materials, challenges, characterisation techniques, laboratory tools, simulation methods, up-scaling, production process and testing. Session 3.1 Cryogenic Storage Systems G. Bartlok 3

4 L-H2 Storage System State of the Art Source: MAGNA STEYR Source: Air Liquide Source: Linde Session 3.1 Cryogenic Storage Systems G. Bartlok 4

5 Design Process according to IEC Maintenance Maintenance Specification Specification Validation Validation Verification Verification & Validation Validation Requirements Concept Concept Prototype Prototype Design Design Verification Prototype Prototype Validation Validation Documentation Documentation Integration Integration Tests Tests Realization Prototype Prototype Implementation Implementation Session 3.1 Cryogenic Storage Systems G. Bartlok 5

6 Risk Management Specific Components L-H2 storage vessel and pipes Safety devices 1st shut-off valve (downstream) Sensors Safety related electronics Risk analysis Safety Integrity Level (SIL) Failure Mode and Effect Analysis (FMEA) A fault of a specific component can lead to death of some people. Failure Tree Analysis (FTA) < (EN ISO or IEC ) Session 3.1 Cryogenic Storage Systems G. Bartlok 6

7 Manufacturing Production Welding process WIG automatic and manual welding of stainless steel parts Source: MAGNA STEYR Session 3.1 Cryogenic Storage Systems G. Bartlok 7

8 Manufacturing Quality Inspection Dye penetration inspection of valve housings and welding seams Source: MAGNA STEYR Source: MAGNA STEYR Session 3.1 Cryogenic Storage Systems G. Bartlok 8

the inner tank, vacuum chamber and auxiliary system box Cleaning process of inner tank shell and outer

9 Manufacturing Cleaning Process Hydrogen Quality Guideline SAE J2719 max. Particle size: < 10 µm Particulate concentration: 1 µg/liter Cleaning of hydrogen containing pipes in the inner tank, vacuum chamber and auxiliary system box Cleaning process of inner tank shell and outer jacket shell in a washing machine Use of special cleaning solutions Source: MAGNA STEYR Session 3.1 Cryogenic Storage Systems G. Bartlok 9

10 Manufacturing Assembly Assembly Mechanical and electrical installation of the liquid hydrogen level sensor in the inner tank Source: MAGNA STEYR Session 3.1 Cryogenic Storage Systems G. Bartlok 10

cleanroom Sewing process for fixing the foils and spacer on the inner tank

11 Manufacturing Thermal Insulation Multi-Layer Insulation Installation of layers of high reflecting aluminum foils and spacer of glass fiber in a cleanroom Sewing process for fixing the foils and spacer on the inner tank Source: MAGNA STEYR Source: MAGNA STEYR Session 3.1 Cryogenic Storage Systems G. Bartlok 11

12 Manufacturing Thermal Insulation Vacuum and Getter Evacuating the thermal insulation space down to 10-2 Pa within a heating chamber by use of turbomolecular pumps Activating the getter material Source: MAGNA STEYR Session 3.1 Cryogenic Storage Systems G. Bartlok 12

13 Manufacturing Quality Inspection Leak test Leak detection of components in the auxiliary system box Source: MAGNA STEYR Session 3.1 Cryogenic Storage Systems G. Bartlok 13

Manufacturing End of Line Mechanical inspections Visual inspections of joints Penetration and X-ray tests of welding seems Inner tank pressure test System tightness

14 Manufacturing End of Line Mechanical inspections Visual inspections of joints Penetration and X-ray tests of welding seems Inner tank pressure test System tightness tests Positioning of interfaces Electrical checks Operation of sensors (p, T) Operation of valves Source: MAGNA STEYR Session 3.1 Cryogenic Storage Systems G. Bartlok 14

Manufacturing Performance Test Functional tests Verification of valves and sensors at operating conditions System leak-rate measurement Verification of refueling time

15 Manufacturing Performance Test Functional tests Verification of valves and sensors at operating conditions System leak-rate measurement Verification of refueling time Validation of autonomy time Validation of boil-off rate Validation of specified hydrogen extraction rates Source: HyCentA Session 3.1 Cryogenic Storage Systems G. Bartlok 15

Design Rules Regulation & Standards TRANS/WP.29/GRPE/2003/14/Add.1 Proposal for draft amendments to the new draft regulation on uniform provisions concerning the approval of: I.

16 Design Rules Regulation & Standards TRANS/WP.29/GRPE/2003/14/Add.1 Proposal for draft amendments to the new draft regulation on uniform provisions concerning the approval of: I. Specific components of motor vehicles using L-H 2 II. Vehicle with regard to the installation of specific components for the use of L-H 2 Specific Components - Container -Pipes - Manual and automatic valves - Refuelling connection or receptacle - Heat exchanger - Pressure regulator -Sensors Validation tests - Pressure cycling tests - Temperature cycling tests - Leakage tests - Hydrogen tests - Bonfire tests - Functional tests - Durability tests Session 3.1 Cryogenic Storage Systems G. Bartlok 16

time Source: BAM The average temperature in the space 10 mm below the fuel tank shall be at least 863 K Thermal autonomy of the liquid

17 Destructive Tests Vacuum loss test Bonfire test Source: Energie Technologie Proves the design of the pressure relief devices in case of a degraded thermal insulation Following behaviours are observed: tank pressure and temperatures hydrogen blow-off behaviour hydrogen blow-off time Source: BAM The average temperature in the space 10 mm below the fuel tank shall be at least 863 K Thermal autonomy of the liquid hydrogen fuel tank shall be at least 5 minutes Verification of the design of the pressure relief devices Session 3.1 Cryogenic Storage Systems G. Bartlok 17

liquid hydrogen) Source: BMW Group In order to examine the: connection between body and liquid hydrogen

18 Destructive Tests Dynamic vibration test Crash and skid test Source: MAGNA STEYR Statistic values for estimating the lifetime behaviour Inner tank: at ambient temperature at cryogenic temperature (filled with liquid hydrogen) Source: BMW Group In order to examine the: connection between body and liquid hydrogen fuel tank the suspension of the inner tank at high external loads Session 3.1 Cryogenic Storage Systems G. Bartlok 18

19 Cost Reduction Degree of Automation vs. Costs (Prospects)( xx 50% Degree of Automation ~3% Factor 10 to 50 Prototypes Mass Production ,000 10, ,000 Costs per Tank Units per Year Session 3.1 Cryogenic Storage Systems G. Bartlok 19

20 Prospects for Hydrogen Storage Systems Price/quantity effects thanks to modular design strategy (flat tank geometry) 160 kg gasoline tank equivalent 80 kg common lightweight concepts and materials new materials + concepts 2008 on-board power supply Price/quantity effects thanks to number of units (lightweight free form geometry) price increase of gasoline legal environmental requirements 3 Mio. 2 Mio. prototype flat storage tanks 2010: units 2015: units 1 Mio Quantities are estimated Session 3.1 Cryogenic Storage Systems G. Bartlok 20

L-H 2 Tanks Next Steps Next Steps State of the art

materials increase road capability reduce system

21 L-H 2 Tanks Next Steps Next Steps State of the art Series BMW geometry / package increase capacity increase autonomy time reduce and use boil-off losses reduce system weight while using new materials increase road capability reduce system costs Future System Session 3.1 Cryogenic Storage Systems G. Bartlok 21

22 Requirements and Goals Parameter Unit State of the Art System Future System Hydrogen Storage Mass kg 9 10 System Volume (shrink wrap) l System Mass (without Hydrogen) kg Gravimetric Energy Density kwh/kg Volumetric Energy Density kwh/l State of the Art Hydrogen Storage Capacity wt% Operating Temperature C till till + 85 Operating Pressure MPa 0 till till 0.7 Refuelling Rate kg/min Boil-off Rate System Autonomy Time %/day days > 1 Future System Session 3.1 Cryogenic Storage Systems G. Bartlok 22

23 Needs and Opportunities for Future R&D Activities Requirement Approach of a Solution Integration Complex Free-form Geometrie Lightweight e.g. Composite Materials Mass production Processes for High Volume Production Costs Modular Design, Economic Processes and Materials Development of an free-form lightweight tank system manufactured from e.g. CFRP as well as adequate production technologies Session 3.1 Cryogenic Storage Systems G. Bartlok 23

24 Needs and Opportunities for Future R&D Activities Industrialisation concepts for mass production capability, cost reduction, quality, e.g. applying transition strategies from nonhydrogen technologies (e.g. CNG storage) toward hydrogen System validation of newly developed storage systems Integration into vehicle, including safety aspects, total thermal management, etc. Interaction with fuelling stations, hydrogen infrastructure Component development: e.g. filling devices, valves, temperature and pressure sensors, active cooling, hydrogen gas detectors, safety-related electrics/electronics Probabilistic safety approach for design and approval - improvement of standards and regulations Session 3.1 Cryogenic Storage Systems G. Bartlok 24

25 Conclusions Evolving the hydrogen economy will take time, strong partners and financial commitment Acceptance of industry and public required There is an enormous potential for design improvements without a decrease of safety level The first series Hydrogen Storage System will be engineered and produced by MAGNA STEYR by 2007 Session 3.1 Cryogenic Storage Systems G. Bartlok 25

26 Session 3.1: Cryogenic Storage Systems Dr. G. Bartlok 25 th 29 th September 2006 Ingolstadt Session 1.2: Introductory Lectures K. Hall

STORHY. Hydrogen Storage Systems for Automotive Application Integrated Project n Volker Strubel. Josef Zieger. Sitra Colom.

STORHY. Hydrogen Storage Systems for Automotive Application Integrated Project n Volker Strubel. Josef Zieger. Sitra Colom. STORHY Hydrogen Storage Systems for Automotive Application Integrated Project n 502667 Volker Strubel Josef Zieger Sitra Colom Guido Bartlok Jiri Muller Georg Mair Florent Montignac Angelika Bertalanic